Clark 50BZ3 Wheel Loader Shop Manual SN 4236B - PDF DOWNLOAD

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Record Your Machine SerialNumber Here

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TABLEOFCONTENTS 1 2

D［MENS（ONAしDRAWFNGOF50BZ3WHEELLOADER．．‥．．‥‥，，．‥． SPECIFICAT！ONS‥‥‥‥‥‥‥‥．‥‥‥‥．．．‥‥‥‥‥‥‥．．．‥． 7 7 7 8 2 2 00 5 1暮 3 3

1，ENGINEANDALuEDPARTS ‥‥‥．．‥‥‥‥‥‥‥い‥‥‥‥．． 11．ENGIN∈‥‥‥‥‥‥‥‥‥．‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥． 11，l SPECjF…CAT卜ONS‥‥．．‥‥‥‥．‥．‥‥‥‥‥‥‥‥‥‥ 11．2 REMOVALOFSUB・ASSEMBLY ‥‥‥‥‥‥‥．‥．．‥‥．‥ 11．3 DiSASSEMBLY，iNSPECTJONAND REASSEMBi．Y nF EACH PART ‥‥‥‥‥‥‥‥‥．．‥‥‥．‥．‥‥‥‥ 11．4 iNSTALLATiONOFSUB−ASSEMBLY‥‥‥＿‥‥‥‥‥‥‥． 11．5 MA削TENAN（こESERVECEDATAONLI6BDl ENGfNE ‥．．．‥

11．6 MAJOR BOLTTORQUECHART‥‥‥‥‥‥‥‥．．‥．＿‥．． 4

2．POWERTRAIN‥‥‥‥‥‥‥．‥‥‥‥‥．‥‥‥‥‥‥‥．‥‥‥ 47 21．D鋸VEUN汀‥．‥‥．‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥．．47

21．1 DぎSASSEMBLY，lNSPECT妻ON．AND REASSEMBLY OFTORQUECONVERTER‥‥．‖…………．‥‥‥‥‥ 47 21．2 ［1jSASSEMBLYOFて RANSル‖SS！ON‥‥‥‥‥．‥‥‥．‥‥．54

21．3 DISASSEMBLY．…NSPECT10N ANn REASSEMBLY OFCLUTCHGROUPS ‥‥．‥‥‥‥‥‥‥‥‥‥．．‥‥‥．57 21．4 1NSPECTぎONAND REASSEMBLYOFTRANSMISS旧N ‥．．‥．64 21．5 TROUBLESrlOOTJNGGUIDE‥‥‥‥‥‥‥‥．‥‥‥‥＿‥ 69 21．6 MA！NTENANCESERVICEDATA‥‥‥‥．．‥‥‥．．‥‥‥．72 2l．7 MAJOR BOLTTORQUECHART．．‥‥‥‥‥‥‥‥‥‥‥‥ 74 22．OFLC［RCULATIONCIRCUfT‥‥，‥‥‥‥‥‥．．．．‥‥‥‥‥．75 2：．1！NSPEC●円ONOF OぎLCIRCしJLATJONC！RCUIT‥‥‥‥‥‥‥ 75 22．2 ！NSPECT…ONOF HYDRAUuCPRESSURE ‥．．．

23．DRIVEAXLES（FRONTAND REAR）‥‥‥‥‥‥‥ 23．1 D；SASSEMBLY，rNSPECTJONAND REASSEMBl＿Y OFAXl＿E110し！引NG‥‥‥‥‥‥‥‥‥‥‥‥．

0 9

23．2 DISASSEMBLY，rNSPECTJONAN「）REASSEMBLY OFDFFFERENTIAL‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥ 81 23．3 DJSASSEMBLYAND REASSEMBLYOF F！NAL RE［）UCT（ONGEAR‥‥．．‥‥‥‥‥‥‥‥‥‥．．‥‥‥‥ 23．4 TROUBLESHO（〕TINGGし＝DE ．‥‥‥‥‥‥‥．‥．．．．‥‥ 23．5 MAINTENANCESERVICEDATA‥‥‥‥‥‥‥‥‥‥‥‥．

3 9 4 9 5 9

23．6 MAJOR BOLTTORQUECHART‥‥‥‥‥‥‥＿‥＿．．‥．．．

31BRAKESYSTEM‥‥．．．‥‥‥‥‥‥． ‥‥‥‥‥．‥‥‥‥．．‥．96 31．BRAKELIN∈．‥‥‥‥‥‥‥‥‥．‥‥‥‥‥‥‥‥‥‥‥‥96 3l，1 SERViCEBRAKE uNE‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥．96

31．2 BRAKE VALVE．．．．．‥．．．‥‥‥‥‥‥．‥‥‥‥．‥．． 3l．3 DISCBRAKE．．‥‥‥‥‥‥．‥‥‥‥‥．．‥‥‥‥‥‥．．．100 31．4 1NSPECT10N OFSERVICE BRAKE LINE．‥‥‥．‥．‥‥‥‥102 31．5 TROUBLESHOOTING GUIDE．．．．．‥‥‥‥‥．‥‥．‥‥．．． 31．6 MAINTENANCESERVICE DATA ‥‥．‥‥‥‥‥‥‥‥‥‥108 31．7 MAJOR BOLTTORQUE CHART‥．．‥‥‥‥‥‥．‥∴‥‥．109 32．PARKINGBRAKE ‥‥．‥．．‥‥‥．．．．．．．．‥‥‥‥．‥‥‥‥．1 32．1JNSPECTJONAND REPLACEMENTOF PADS‥‥．．．‥．．．．‥1 32．2 ADJUSTMENT，．‥‥．‥．．‥‥‥‥‥．．．‥‥．‥‥．‥‥‥110

4．STEERINGSYSTEM‥‥．．‥‥‥．‥‥．．．．．．．．．‥‥‥‥‥‥‥．．．112 41．STEERING SYSTEM‥‥‥ ‥‥‥‥‥‥‥‥‥‥‥‥．．‥．．‥112 41．1 01LCIRCULATrON SYSTEM‥‥‥‥‥．‥．‥．‥．．‥‥．，‥112 41．2 1NSPECT10N OF OLL PRESSURE．‥．．‥‥．．‥．‥‥．‥‥．．114 41．3 STEERINGWHEEL‥‥‥‥‥‥．‥．‥．‥．‖．．．．‥．‥‥．．115 4l．4 STEERING PUMP ‥．．．．‥‥．．‥‥‥‥．‥‥．．．．‥‥．．．‥123 41．5 STEERING CYL［NDER ‥‥‥‥‥‥‥‥‥．‥‥‥‥‥．‥．124 41．6 TROUBLESHOOTING GUIDE ‥‥‥‥‥．．‥‥‥．‥‥‥‥．127 4l．7 MAINTENANCESERVICE DATA．．‥‥‥‥‥‥‥‥‥．‥‥129 41．8 MAJOR BOLTTORQUE CHART‥‥‥‥‥‥‥‥‥‥‥．‥．130 5．FRAMEANDALLIED PARTS‥‥‥‥．．．‥‥‥‥‥．‥‥．‥‥‥‥131 51．FRAME ‥‥．‥．‥．．．‥‥‥‥‥．，‥．．‥．‥‥．．．‥‥‥‥‥．131 51．1 CENTER HINGE PLN ‥‥．．．．‥．．．．．‥．．．‥‥‥‥‥‥‥．131 51．2 MAINTENANCESERVICE DATA‥‥．‥．．‥‥．．‥‥‥‥．．133 51．3 MAJOR BOLTTORQUECHART‥‥‥‥‥‥‥．．．‥‥‥‥．135

6．HYDRAULICSYSTEM．‥‥‥‥‥‥‥‥‥．‥．．．．‥‥．．‥‥‥‥．136 61，MA（N PUMP ‥．‥‥‥‥‥‥．‥‥‥‥‥‥‥‥‥．．．．．‥‥．．．136 Gl盲．−！ 已−）星SASSEミM酎．．Y，lNSPECT；ONANごREAこ；SEi＼服i．Y．‥‥＿．．‥．13G 61．2 TROUBLESHOOTING GUIDE ‥‥‥‥‥，‥．‥‥‥‥‥‥．．142 62．CONTROLVALVE，‥‥‥‥‥‥‥‥‥．．‥．‥．‥．‥‥‥．‥．．143 6：〜．1 D皇SASSEMBLY．！NSPECTiONAN［1REASSE二M凱Y，．‥‥‥‥て43 62．2 TROUBLESHOOTING GUIDE．．，．．‥．．．．．‥．‥．．．‥‥

7．LOAD HANDLJNGSYSTEM ‥‥‥‥‥‥‥．‥．‥‥‥．‥‥‥‥‥．149 ■71．CYL．iNDE三RS、．．‥‥．‥‥．．．‥‥．‥．‥‥．．．‥．‥．‥‥‥．1 7l．1 BOOM CYLINDERS．‥‥‥‥．‥．．．‥．．‥‥．．．．‥‥ ．‥14 71．2 BUCKETCYLJNDERS ‥‥．．‥．‥．．‥．．．‥‥‥‥‥．‥．．．1 7l．3 1NSPECT10NOF LOAD HANDLINGSYSTEM．‥‥．．‥‥．．．． 71．4 TROUBLESHOOTING GUIDE．．‥‥‥．．‥‥‥．．‥‥．．‥‥155 71．5 MAINTENANCESERVICE DATA ‥‥‥‥‥．‥．．．‥‥‥‥．158 7l．6 MAJOR BOLTTORQUE CHART．．．‥‥‥‥‥‥‥‥‥‥‥．161

DI関ENS舞ONALTDRAWING OF50BZ3WHEEL LOADER Unit：mm

Bucketdumpingang豪e（α0き 48（Max） Dumpingclearance （hd） Dump暮ng柑8Ch

Ⅶ1−

如き

45

2740

2770

915

955

SPEC肝ICAT10NS 50BZ3

Model：

TYPe＝

3．42−tOnCaPaCitY．articulatedtypefrontend10aderwithdieselengine

Peげormance：

1．5m3 1．2m3 5190 kg 4470 kg 3970 kg 3420 kg 3100 kg 2700 kg

BucketCapacity（SAErated）： 〈Leveり：

Lifting Load （straight）： （fullturn）：

Maximum Load（straight）： （f山Iturn）：

ServiceLoad （straightI： 什ullturn）：

しiftingTime：

LoweringTime： BucketDumpingTime： TravelingSpeed：

Fwd

1st； 2nd； 3rd；

Rev

7．5km／h

8．5kmnl

13．5km／h

15．Okm／h

34．Okm／h

34．5km／h

Maximum Traction Force：

9100 kg

GradeabilitY： FuelConsumption Rate：

30 く！sisprJ＝い＝〕krll●ll〉 9．0史／h

Stopping Distance（servicebrake）：

ServiceBrakeBraking Force： MinimumTurningRadius（outermostpartofbody）： （outermostpartofbucket7：

3．1m，initialspeedat20km／h 6680kg 5500 mm 5940 mm

（centerofoutermostwheel）：

5300 mm

（innermostpartofbody）：

3250 mm

2．6払3〉kg／ぢm3 2．8（5．5きkg／cm3

GroundContactPressure（frontwheeL）： （rearwheeり：

Dimension5： 6125mm

OverallLength（bucketonground）： （st dunJoadedcondition．travelingposture）： OverallWidth（body）：

6165mm 2160 mm 2440 mm

（bucket）：

Overa11Height．bucketraised（maximum）：

2635 mm 4635 mm

Wheelbase：

2720 mm

OveralIHeight（bucketonground．mufflertaiLpipe）：

Tread（front＆rearwheels）：

1755mm

FrontOverhang： FrontOverhangAngle： RearOverhang： RearOverhangAngle： HoodHeight：

2055 mm

1390 mm

1985mm

ー2−

Oper∂モOrSeaモ‖eight：

1995mm

80d￥＝e盲g如ミrear∀iewmirrortop）：

2495 mm

Ground Clearance（rearaxlebottom）：

405 mm

BucketHingePinHeight：

3535 mm

DumpingC‡ear8nCe宅8rOund450forwardtilt）：

2770 mm 2740 mm

（f山Idump）：

Pump盲ngReach（∂rOund450forw8rdt廟：

955 mm

（fulIdump）：

915 mm

蜘mpingcすearance8t2100r門m∫即Ound450forw8rdti鮎

川15mm

Buck朗Ro篭l−backAng事e伽Cketonground〉：

那0

520 630

モsモ′dun‡oadedcondition′traVe‡ingposture）： 伽cketr∂ised）：

4SO

BuekeモDumpingAng章e（bucketraise曲 biggingDepth伽ck紆柚感ね潤椚頼椚：

210 mm 310 mm

紬uckeモモi‡t感forward160）：

CouplerHeight： Weight： MachineWeight： WeightDistribution：

850 mm

8300 kg Front axle

Rearaxle

（st d unIoadedcondition）

4000kg

4300 kg

（st′dloadedcondition）

10090kg

2180kg

Engine

1suzu L6BDl lDieselengine（JsuzuMotors）

Model：

Type： TotalDisplacement：

4・CYCle．vvater−COOJed，in−＝ne6−CYIinderdirectinjectiontype 5785 cc

Performance： 2350r

Ratedrpm；

Ratedoutput； Maximumtorque： Batterv： CoolingSYStem： Coolingmethod： Radiator； Totatradiatingarea；

37．プk9・m如1600rprれ） 12V，100Ah，2pcs．（HitachiKasei） WaterLCOOled，V−beltdrive．

Corrugatefin＆tubetype（Tokyo Radiator） 46．06mコ 0．456mヱ

Frontarea；

PushertYPe．550mmdia．，6blades．

Fan；

ExahustSystem： Muffler； Noise； ChargingGenerator＝ StartingMotor： PowerTrain： TorqueConverter：

Porousseparator，1pc．（KoritsuSangYO） Travelingnoise，79．5phon；Exhaustsystemnoise．72．5phon 24V．25A．AC 24V，4．5kW

Modelニ

TCM822・25

Type；

3・e董eme略One−Sモ喝e′Singl針PhasetYPefD∂ikinKogyoき

−3−−

Sta11torqueratio； Radiator；

3．20

Shett＆モube．water−CO8蔓edてyPe汀ok￥ORadia電Orき 0．901mユ

Tota［radiatingarea；

3．Okg／em2

Pressuresetting； Outputshaftreductionratio Transmission：

TCM822−25

Modelニ

Fu‡トpower−Shi普電COnSモan竜一閥繭噂鱒毎相川那加摘欄Ive〉 Gearratio；

Clutch（fortransmission）： Tung8㌻0￥声Weモ◆モyp◎mu蔓tip‡ed壱sk汀osh盲b竃き

TYPeニ

HYd「a山ic

Operationニ

Facing；

ー】エさ＝．竜．1いし心iこ：モさ、：：こ∴巨●＝ら∵：！il．ミいs≡〔！ご、iい．；∵ニ5：‥「汀：伸≡亡5く冨「已、ゝ）

1258m2竃ずwd＆revき5pcs．；1sモ＆3rdspeed，5pcs．；2ndspe感，6pcsせき 15．3・1B．Okg／cm2

しiningarea；

Pressuresetting； PropellerShaft： Universaljoint；

Crossjoint

Shaftdiameter；

90mm如電S盲dedi乱〉x83．6m閥パ摘融加代摘，きx550mm塁加gth）汀／誠一打鋸 90mm（ouモS盲ded盲乱〉x83，6m澗日柄粛鋏代鮎，きx6潟瑠mm紬ng痛き汀／M一打剰

Sh油diame電er；

90mm蔓ouモSide8盲a．拍蹴摘庸澗裾南海曲．拍卵ほ冊両如顧郎汀湖凋溝

Reduction Gear＆DifferentiaI： TCMWDBl−30

Model；

Ordinarytype2−Stagereduction Spiratbevelgear

Tvpe； Reductiongear； Reductionratio；

Banjo type Straightbevelgear

Dif†erentialcase；

Differentialgear； FinaIReduction Gear：

Planetarygeartype

TYPe； Reductionratio；

Totalreductionratio；

Fwd

Rev

81．665

72．334

2nd；

43．972

38．936

3rd；

15．042

13．320

1stニ

AxteandWheel： 4−WheeIdrive

DrivingMethod： Axle：

Frame・fixed，Semi−floating

Frontaxle；

Centerpinsupported，Semi・floating

Rearaxle； Wheel：

14．00x24・8PR．withtube（L−2） 如観描．8kg㌔cm2

Tires（tx）thfrontand rear）；

Tireinflationpressure；

−4−

Rim（bothfrontandrear）：

8．00TG x24

BrakeSYStem： Service Brake：

Wet−tyPedisk（TCM）

Name；

Frontandrearindependentbraking，Wet−tYPediskbrake（air−OVerhYdraulictype）

Operation； BrakevaIve；

E2brakevaJve（NABCO） 257mm（pistoninsidedia．）

Wheelcylinderdia．；

304mm（pistonoutsidedia．） Diskeffectivedia．； Pad；

280 mm

308mm如tside軸．きx240mm抽sidedi8，〉′2pcs．−292cm2in弧 Powercluster（Saitama Kiki）

Boosterニ

Maximumpressure； Aircompressor； Pressureregutator； Locationoftank； Capacityoftank； Airpressure； ParkingBrake： Name；

ー35kg／cm2

Reciprocating type D−2tYPegOVernOr．diaphra9mtyPetNABCO） Rearofrearframe，underradiator． 9セx2pcs．−18史

5。0−6．？kg／cm2 MechanicaIdiskbrake（Sumitomo Denko）

Transmissionoutputshaftbraking Diskdiameter； Padニ

312 mm

2−PCS．−40mm（length）x31mm（width）xll．5mm（thickness）

Ste即ingSystem：

Framearticulatingtype

TYPe：

Speed ReductionDevice： Name；

Orbitror（Sumitomo Eaton Kiki） LT−A，loadsensingsYStem

SteeringWheel： PowerSteering：

400mmdia．，4．2turnstmaximum）

Type； Pressuresetting；

Separatetype

Kindofoil；

Hvdra山icoil

SteeringCylinder：

ー30kg／cm2

2pcs．−63．5mm（insidedia．）x32mm（rodoutsidedia．）x420mm（stroke）

Framearモicu如ingARg8e：

350（さeft）′350（rightき

BodY： Frame： Typeanddimensions；

Steelplatewelding，16mmthick

Frameoverhang（front）

125mm 1390 mm

LoadHandlingSystem： TYPe： Buckettoothendshape：

JnverseZIink（withbucketauto−leveler）

Ishape

−5−

HYdrauticSYStem BoomCY［inder：

Double・aCtingpiston

Type： 2pcs・‖4．3mmく舟sidediat）x57．2mm如d

No．・Size

outsidedia．）x785mm（stroke）

BucketCylinder： Double・aCtingpiston

Type；

2pc＄．・89，5mm帥sidedia．きx44．3mm如doutsidedia．）x412mm匝oke）

No．−Size

Mainpump： Model；

Toshiba6PR170 Gearr】川叫＝￣rosllib8Kikni）

GeartYPe，reductionratio：1・02

52史如‡n如2304rpm．5kgゐm急き

Discharge；（url10aded）；

48史如in如2304rpm，175kg／cm2）

（10aded）；

SteeringPump： Model；

Toshiba 13PR190

Gearpump（ToshibaKikai） GeartYPe，reductionratio：1．02 γ‖史／min如2304rpm，柑kg／em2き 107史如in如2304rpm．】30kg加招

Type； Discharge（untoaded）； （l。aded）；

ChargingPump： Model；

ShimadzuSP20−27A2Hl−LJ131

Gearpump（Shimadzu）

TYPe；

Geartype．reductionratio：1．02

59受／min（at2304rpm，15．3−18kg／cm2き

Discharge； ControlVatve：

HUSCO4502（KayabaKogyo）

Modelニ

2・SPOOIslidingtype，Withreliefva］ve

Pressuresetting；

175k！ト川−ニ

−6−

1．ENGtNEANDALLtEDPARTS ll．ENGINE 11．1SPECIFICAT10NS Model：

6BDl−LB（lsuzu Motors）

TYPe：

4・CyC霊e，Water−COOled′in・‡ine，direcモinjection

typedieselengine 6−102mm）（118mm

No，OfcYlinders−dia．xstroke： Tota［Displacement：

5785 cc 17．5

Compression Ratio： EnginePerformance： Ratedoutput；

110PS（2350rpm）

Fuelconsumptionrate如r訳edspee郎；

180g／PSh

Maximumtorque；

37．7k計m宅1500rpm〉

about 450 kg

DryWeightofEngine： Dimensions（overa

lengthxoverallwidthx

1138．5mm x680mmx858mm

overa height）

l−5−3−6−2−4

Firing order Rotating Direction： VatveArrangement： FueISystem： lniectionpump；

C10Ckvviseasviewedfrom fan side overhead valve

NP・PE6A95C412 BoshtvpeA（Diese‡Kikり 9．5mm x8，Omm

Modelニ

Type； Plunger（diameterxIift）

Plungernozzle； Model； Type； Fuelfeed pump； Model； TYPe； Fuelfilter； FiItration； Gorvernor； Gorverningmethod；

NP−DLLA／54S324NP81 Poroustype（DieselKiki） NP−FP／KS221C47／3NP41 PlungerモYPe毒DieselKiki）

Filterpaper（TokYORoki） Centrifugal，a LSPeed

Forced−Circulation

しubrication；

Model； LubricationSYStem：

NP−EP／RSV（DieselKiki） Forced・Circulation

しUbric∂tionニ

Lubricatingoit pump； Tvpe；

Gearpump Camshaft．geardrive Pistonspringtype

Dl■iveニ

Oilpressureregulator； LubricatingoilfiIter； Filtration； Lubricatingoilcooler；

Fulトfbwpaperfilter汀okyoRoki〉 Water・COOled，built・intype

Coo）ingmethod；

CoolingSYStem： Coolingmethod；

Water pump circuiation type −7一

Coolingfan； Type； Drivingmethod； Waterpump； TYPe； Drivingmethod； VVatertemperatureregutator TYPe； AirCLeaner： Tvpe； Starter： Motor； Tvpe； Voltage； 0utout； EnginePreheatingDevice：

Pushertype．550mmdia．6blades Beltdrive

Centrifugal pump Beltdrive Waxモype痛ermosモ8琶竃Fuj毒To、mson）

Fi蔓terpaper＆Cyc‡ontype㈹潮那＝施欄l痴掛両

Engagem∂gneモモyPe毒NikkoDenk盲き

24 V 4．5kW lnstatled Fuelshut−Off

EngineShut−Of†Method： Ch∂ging（tig輔gener紬汀

ACモ∀Pe．W壷醸buiほ曾inre9u‡aモOr（N盲kkoDenk書き

TYPeニ

24 V 25 A Beltdrive

Voltage； 0utput； Drive； Batterv： Model； Voltage； Capacity； Number；

SD・11026（HitachiKasei）

Allowableti［tingAng［e：

12V lOO Ah 2pcs． 如e＆軌300；Sidew∂￥，300

Other Reference Data： Oilsump；

13史max；10史min 12紀（engineonlY）

Coo＝ngwater；

Valve claarance

Valve opening

Valve closing

lntakevalve

COld−0．4mm

Beず即eTDC′100

AfterBDC′420

Exhaustvatve

COld，0．4mm

Before払DC′500

糸摘rTDC′100

BeforeTDC20O 150kg／cm2

lnjectionTiming： lniectionStartPressure： CompressionPressure： Watertemperatureregulator

ふ＝い、昭二川r：丹illl opera血nsモa㌢tP㌻eSSure′76ぷ；菅u篭蔓叩en′900c

（strokeofmorethanlOmm） 2．Removalofstartermotor

、−i一 ：1≡： チ、・；ご：・＼／ミし．こ！き・一二ここ．Fリーニ＼らミ…斗‡ヒi：，

（D Remo∀eモhe琶appet chamber dueモhosec糎

1．Removatofgenerator

G）Remove醸e oi璽tevelgaugeand翰eexh8uSt

manifoId mounting nuts and then remove the 即納胤鹿鮒掛摘澗柚膵紳融狛触感・

∂nd p毒pe mounモIng S官ay aモ醸e蓼ower areao苦痛e ∈￥‡inderb60Ckandthenremove抽e∂盲rbre∂抽er・ ②Remo￥eモhesモarモermotor汀篭Ountingnu電Sand

removethestarter motor form thefIYWheelhous−

②Loosen 官he9ener8tOr mOunt裏門9 bo蔓ts an8

detachtheadjusting boltand thenremovethefan belts．

③Removeモhegenerator8tOngW墓tわ抽e∂8usモ毒ng Plate，

ー8−

ing．

3．RemovalofcYlinderheadcover

8．RemovaIofcrankshaftpulleY

①Remove抽e cylin8er head cover moun如g

nuts andloosen the breather hose clip．Remove thecylinderheadcoverfromthecYIinderhead，

F蔓g．瑠瑠．2径）Str∂盲gねモ帥モheEockw8Sher官an9SO菅

the crank pu［ley mounting nuts and remove the nutsfrom thecrank shaft， 、三 ≡．・：・∴・こ・ニー！ミてミニ；−！い＼・・い・l童：：ゴミ∴∴・ミミ！≡−…こ、・−し（i

■・‥F 婁リ1「ごこ：・：・ミ・、、〜ぐこ；11ミミ・、‡…り；ぎ、・、二；；ン、、いr・で

move the fueIpipe．（Feak−Off pipe．tarlk−feed pump，管ee8pump一触狛制札璃感鞘矧一画廃油鍾

remove the crank putLeY aSSembIY fTOm the Cranksh∂ft．

③Remove触ge8reaSeCOVermOu門号室ワgbo星モS

PUmP，OVerftowpipe）

and remove the case cover from the timing gear

③翫閤劉℃曾招乳感官招併翫Ⅶ耶津帽油脂＝湖面

CaSe．

fold，

9．RemovalofrockerarnlShaft

4．Removalofairpipe

①Re汀−OVe輌aircompressori痛ho§警・ （診Re円10Ve翰ea妄㌣評rVeFnOrun葛oade㌢P盲Pe． ③Re椚￠∀e乞わe∂ircompressoroi妻feedpipe． 5．RemovaJofinjectionpump

①Remo￥eてheinjecモ毒onpipe裾ghpressurep廟− 6pcs．）． （診Remove琶わe紬￠0盲雫触感8pipes￠管モhe毒njec如n PUmP．

③Re汀−Ve抽e細CO岬昏ingmoun号室ngbo董モSaモ

theiniectionpumpdrivingside． う ー、∴・二・ソ、、；トさ1・l…・・！！1j、ミl「ドさ：・・i、ミ・；−・；「‥こ1、、・：∴て；…；こ童

bolts and remove the injeetion pump from the 戸岳g．瑠瑠義3①Loose門theモわermosモa電b￥PaSSrubber bracket． hose c［ip and remove the rubber hose from the thermostathousing．

6．Removalofaircompressor ①Remove抽eモWO8毒rgorvenorbr∂Cketmou砧

ing boltsand removetheairgorvernoralongwith thebracket．

②Loosen∂nd remove食ゎe㌢8Cker a㌻m brackeモ mountingbolts，Startingfromtheoutside． ③Removethero￠ker∂rmSha翫∂SS昏mb毒∀ず㌢￠m thecy［inderhead．

②Remo∀ethe管our∂iざeOmPreSSOrmOunモ裏門g

bo．ts and remove the air compressor from the

④Remo∀e抽epush㌢Odずro汀1油ecy妻裏門derb月ock．

timinggearcase．

10．RemovaIofcYlinderhead

7．Removald oil川tel

and rernove the nozzle holder assembly Irom the

・；F‥こ・、、、ノー、1も・二；；1i・：トニさ、い毒バ、、；−i−1、・！■：・け1∵吊■tご−

：ミ・…雫0．「・、‥ご†ぎ、．・〜・：・、！ト・ト宇・∴・i：−；バ、‥tさ：−．小￣・【、、〜ll

CYlinderhead．

COOIerand theoilfilter．

干 しご、ト．ごべ、．、十、し！、；・‥：1：＼王墓 こ・∴∴trドミ竜1ミミ t・・、ミ盲S

②Remove帥e oil錯細r m凱酢加慣ゎ扉短∂涌

evenIyandremovethem，Startingfromtheoutside・

removetheoilfilterfromthecy［inderb暮ock．

③Remo∀et如cy箸盲門derhea8管㌢Omモhecy茎inder block．

ー9一

11．Removalofwatorpump ・i′ 恥汀10Velhe 手口…†anIll（1川1ii11q bo！ts and

② Remove the oi蔓pump由一ong轍はh納e oi‡ pIPe†rom theey蔓in8erb‡oek・Remo∀e alsothe Oilpumpdriveshaftcoupling・

③R母mOVe軌e o盲Ipumpか盲∀e g開r from the outsideofthecylinderblock． 15．R倶1仲V；iiofp享sto11811dcoilneCtin9I・Od

and remove theoilcoolerfromthecylinderb10Ck． tapplngi電箋ig如喜yw盲モhasoず電hamm弧

②Remo∀e the engine oi‡pressure senderun竜モ

fromthecylinderblock． ③Removeモわes毒xtapp尊号Chambercovermounモー

壬ng bolts∂nd㌢emOVe油e翻eeモappeモCh8mber COVerSfromthecYlinderblock．

Fig．瑠瑠，5①Removee8rbonorunevenwearon

13．Removalofoilpan

①put thec￥妻inderblock ona benchw托hthe flYWheelhousingsidedownl ②Removeモhe320ilp∂nmOun如gbo‡tsan8 removetheoilpanfromthecyFinderblock・

モhetopofモhecy暮inderbo柑W盲thasc㌻aPerOrOi‡ stone．ThisfacilitatesremovaIofthepiston．

②Loosen輔e connec血g rod eap bo悔and

removethebearingcapfromtheconnectingrodl ③R￠電aモe抽eGra門ksha管モSO thaモ抽e p毒stonis

PtaCedatthetopdeadcenterposition・ ④press the eonnec軸g rodlighモIY W盲th醸e

handleofa hammertoremovethe pistonandthe con門ee加grodfromthecy蔓盲nderb蔓oek．

（診Usethesam鳶PrOC感ureasabove∫remOVe81t pisモOnS and connect暮ng rOds誓rom醸eぢ￥linder block．

16．Removalofid］ergearandcamshaft （努Puモモわe c￥曇inder b‡ock uprig恒on a benじh

withtheoiIpanfittingsidedownl

野蚕g・瑠瑠・穏①Removethe柚00‖pumpOunモー ing bo萱ts and remo∀窟餓e two b摘s securlng抽e

oiLpipetothecYlinderblock．

−10−

、ふ

（診Remove the twoi抽r gearモhrust601妻ar

②Remove the cr∂nk sh油ず和m the cy嚢inder

mounting boltsand removetheidtergearand the

block．

thrustco ar．

③Remove thelower sideくb！ockside）b脚隻ng

③Remo∀e the two c8m Sh8fモ モhrust pl8te mounting botts and remove the cam sha†t atong

and mark thelocation number onits back with

afelt−tippedpenoraraceknife．

withthegearfromthecylinderblock． 20．Removalofcamshaftbushing 17．Removaloftiminggearcase

（D Remove軸einjec号室on pump gear∂nd shaft along vv盲モh抽ebearingco∀erfromthe柑a「Ofthe gear CaSe・

②Re汀10∀ethegenera官Orbrack軋

③Removethesix9earC8SemOun柚gbotts8nd removethegearcasefromthecylinderblock・ 18．RemovaLofftYWheethousing

①Removeモhesixfl￥Wheetmoun如gboほsand

removetheflywheelfromthecrankshaft．

【R〜も

（卦Remove翰層SeV守門恥Wheelhousing mounモー

詳竜9．椚．苫 ① Re†ⅥOVetheseating c∂P†ro汀Ithe

ing bolts and remove the flywheelhousing，by Cy＝nder b10Ck rearendand removethecamshaft

tappingittightlYWithaso†thammer．

bushings．

（診Us喜ngascrewd由erat醸ere8Ce∬edareaon

19．Removalofcrankshaft

theoilga

野毛g．1瑠．6 ￠）Loosen the bear盲ng cap bo篭モSin

turns，Startingat both sidesofthecrankshaftand remove the bearhg cap from the cy［inder bIock．

Remove thethrust bearingsfrombothsidesofthe No．4（center＝〕earingcap．

wl−−

eryseaLpIug．removetheidlershaft，

1†．3 DISASSEMBL．Y．INSPモ…Cr！0さVAh言l）

DistorsionofcYlinderheadfittingsurface

REASSEMBLY OF EACH PART

Assemblystandard＝0．05mmorless RepairLimit ＝0．2mmormore Usefu11imit ＝0．3mm

ll．3．1CYLINDER HEAD

l．DisassemblY

Note：USeSurfacegrinderforrepairing

①Loos研theexh乱離a糀＝両離汀蘭醐惣は汀旧㍍沖 ingboltsandremovebothmanifo（d． ②Remo∀e燈aChconne幽ro管theg篭owp璽ugand removetheg（owp（ug． ③牒顔料車軸漣劾輔他用撒如＝面相料鞘函 hangerfromthecY＝nderhead． ＠強練極り晦守桓郡酢蛸如適稲永由翻輌

⑧cheぢkfor8isモOrSionofthefiモ如9悉reaSOfモ短 inletand exhaustmanifolds．

DistorsionofmanifoIdfittingsurface AssembIystandard＝0．05mmorless

RepairJimit

＝0．4mmormore

⑤eh￠頭痛eglowp！喝如肘如単軌聯・

nutsandremovethethermostathousing．

⑤㈲如殖噂輿軸摘感涌鱒卿廟 a．Usinga vaJve＝fter，COmPreSSthevaIvespring （2）Valveguide ・三・・．一卜、：こ．至、‥…：・：；−．式ごSi汀・r′こ…トー：・．・i・−い；…−−い・；・い∫−、！；ミー盲！！！： and removethevalvecotter． inner surface andif the clearance between the

b．Remove the valvespringalongwiththesprin9

Seat．Then．removethevaLvefromthecylinder． ValveguideandthevalvestemisbeYOndtherepair limit，rePlacethevalveguide．

2．lnspectionandrepair

Ctearancebetweenvalveguideandstem

（1）Cylinderhead Remove carbon adhered tothebottom surface

Assemblystandard（intake）＝ 0．039−0．068mm （exhaust）＝

Of the cY＝nder head with care as notto damage

0．064−0．096mm

machined surfaces such as the valve seat．Check Repairlimit（intake）

the cylinder head for damage visually as well as Withaflawdetectororflawdetectingagent．

0．2mmor more

①Ap輌8hydrau蔓icpressureo†5kg7cm2如

（exhaust）

0．25mmor more

3minutes with a hydraulic tester to make sure thatthereisnoleakage．

Note：Replacevalveorguide．

②u紬喝 a紙面紳感絆窃仁輌＝新鹿鹿h矧

fittingsurface．measuretheclearanceatsixpoints in the axial，radiaL and diagonaldirectionsin relation to the crank shaft．If a thickness of O．2

mmormoreisfound，rePair． ③矧聯前哨が抽…画面即痛か佃擁膵離臓

②び礪机触感掛画ぬ鱒拍㈹摘髄如瀾勘 andifexcessivewearisfound．replace．

③職牒澗錮＝加Ⅷ納町画加パ購牒隠関柚離 blockwiththecyIinderfittingsurfaceupanddrive Withahammer，uSingavalveguidesettingtool．

iscarried outwithasurfacegrinder．1factearance Of O．3mmor moreisfound，rePlacethecylinder head．

Fi9．11．8 RemovingValv8Guide

−12−

④App‡yengi門eO言下即モhecircum紬reneeofモhe

Valve guide．lnsertan adapteron the vafveguide setting rool so as nol to damage the valve guide in the cYtinder head fitting sur†ace．Drive the

valve guide unlil the adapzer bottom contaels thetopoftheh由dtoadjusttheheight． Notel：Distance fromcYlinderheadtoptova［ve guidehead−14．1mm

Note2：Tighteninginterference of varve guide

（5）Repairingvalveseat ①Remove earぬn adheredモO the v∂‡ve se8モ

Surface and cIean awayscratches anddentsonthe Seat SUrface by machining at minimum with a Valveseatgrinderoravalveseatcutter． （診usi門g a V8星velapper′a叩亀vred電e量don触 Seat Surface of each valve．Check 汗the contact widthisl．75 mm and the contactis continous and found atthe middIeofthevalveseatsurface．

andcY＝nderhead−0，024mm くコ！；・てさき∵ぐこ丁；こ・ぎこが√ン・∴ニー、・＿；wこ⊂−：．＼て−−：ミニニ、r亡こ■●−J‥・●−さ； ofintetand exhaustvalves 一言 董；、∴、・i、；、・、こ卜′こ：；．∴．ド．三．−＼≡ぎ：1ミ：こ；・ぎ．？3ぐj；、．い1

measure the recess from thecY＝nder head fitting surface vvith a width gauge or a straightedgeand a scaIe．1f the recessis2．5mm or more，rePlace the valveinsert，

Fig．11．9A FittingofValv8

③き官theconモ∂CtWidモhor輔econモ∂eモPOSition

isimproper，rePair with a valve seat grinder or Valve seatcutter． （6）Valve

①蒼管モh￠Va‡ve sモem wears ouモ旨n diamete㌢

beyond the useful＝mit，rePIace the valve．An

EXるO

UneVenly worn stem end should be repaired with Oilstone or a valve refacer．Whenever a valveis

Fig．11．9 ValveandValveSeat

rep［aced，be sure to reprace the mating valve

②lf輔層岬掛抽0ぜ輔麿購−vese8モSurザace妄s2。5

guidewithanewoneaswelI．

mm Or mOre，rePalrl

V8lvestemdiameter 牲＝翫lく1こ・iミ1雪雲こ∫；り押；！ミ‥ミ：・‥−て

①Red hea電 モ700−8080cき the 盲nside of the

Valveinsert at tvvo points diagonaIly with a gas Weldingbu「ner．

②sモ8門8妄モforGOO妻ing3モ05minu髄胤Theval∀e

insert contracts due tolocalcontraction，SO that youcanremoveitwithascrewdriver． ③c篭e8n uPearぬnormeta糊cox盲de普rom触

insert bore of rhe cl/linder and make flat the insertandfititvvithapress．

−13−

Nominalsize（intake）＝9mmdia． （exhaust）＝9mmdia． Usefuttimit（illtake）＝8．88mmdia． （exhaust）＝8．85mmdia． ②閣easureモheモhick門eSS宅v翁Fvemarg墓n〉ofthe Valve head，andif the thicknessislmm orless， replacethevatvehead，

（7IValvespring ①visually check the general00感itionoずthe

t2）lnsta‖ationofnozzLeholderandgIowplu9 ①wi柚 new nozzle and corrugaモe W8Shers，

v扇ve spr暮ng for dam喝e′Or break喝ef and 盲f unsatisfactory，rePlace．

corrug8モ￠1washer pointing toward the englne

instaJlthenozzleholder．withthebentendofthe

combustionchamber． 受）Measure the freelength oず鮪e v油esprin9 w托h slide calipers，andif the measurementis ③tnsモa暮‡the nozz蔓e hold即aSSembly withthe flat side of the flange upand tightenthenutsat lessthantheusefullimit．repLacethespring． bothsidesuniform］y． ③Measuresquarenessofthevalvespring，名門diず the measureme州：ほ b叩Ond the useずu！lim蓋！′ ③擁舶附加柑‡0醐P‡ugandthent如connect肌 reptace． ′ヰ Me∂Sui・e†erlSion（）†

SPrhqとesミP−−．汀tlle nl usefu川mit，rePlacethespring．

spring vvith a （3）lnsta‖ationofinLetandexhaustmanifolds is below the lnstaIltheinLetandexhaustmanifoldassemblies on醸e c∀linderheadwithpaekings．Aぞterinstaト 廟頼短鱒ぬ戚澗離翫麟儲IkthenuモS．

Freelengthofvalvespring minalsize

＝51．1mm ＝48．4mm

（4）lnstalIationofthermostathousing ①A押転 封御噂 F献締喝 創巧 軌昏 納椚働舶

∪川mit（outer）＝48mm （inner）＝46mm Note：tX）thintakeand exhaustvaIves

housingandinstallitwithapacking・ ②！nstal‡the柏e毒用ter汀−Ountingbr8CkeモOnthe housing．

Valvespringtensiton

③lnstalleng毒neh8ngerSbe短eand behindthe

Settingloadiouter〉ニ20kg

Cytinderhead．

（inner）＝8．6kg Usefu川mit（outer）＝17kg （inner）＝7．3kg

unit．

④lnstal一紙e engine購ter穣mPera餌re send即

Note：（outer）settinglength−44．5mm （inner）settinglength−40．5mm

11．3．2 ROCKERARMAND SHAFT

Squarene550fvalvespring

l．DisassemblY

Us㍍ullimit如ter）＝1，000rless 軸ner〉た1．000r‡ess

Remove the split pins from both ends of the rocker arm shaft．Removethespring．rockerarm， bracketandrockerarmshaft．

3．AssemblY 2．lnspectionandrepair

（1）ln餌a仙tionofvaIve ①‡nst8＝anoi璽sealonthev8tVeguidehead・ ②Spread th守Vat￥eStemVぴiモh oiland盲nsモal…

（1）Rockerarmshaft ①support軸erocerarmsh透徹atboth帥ds8nd

Onthevafveguide．

measuredeflectionwithadialgauge．

③Appty a stand￠n the boモモom to prev釘沌

Loweringofthevalvel ④Puモモh…alv母 ．

co汀IP陀SSthesprl門g紺dsetitwi軸asp董itcol‡∂r・

ー14−

②Rockerarmdefさ￠Cモionisslight，rePair禅i翰a PreSSandifexcessive，（0．3mmormore），rePJace． ③馳8SreモherockerrmShaftoutsided緬eモer

With a micrometer atsix pointsinthe horizontat

Outsidediameteroftappet Nominalsize＝28．00mm Usefullimit ＝27．92mm

（診Visu81葦y check軌e呵叩etin t如CamShaft arm shaft．1f beYOnd the usefullimit．replace COntaCting area for pittings，CraCks or proper and verticaldirectionsin relation to the rocker therocerarmshaft．

COntaCt．

Rockerarmshaftoutsidediameter NominaIsize＝21mm Usefullimit ＝20．85mm

○◎

（2IRockerarm （むMeasure theinside diameter o†醸e rocker

arm bushing with slide caIipers or aninside micrometer．1ftheclearancebetweenthebushing

Cr8Ck

Pitting

Proper contact

and the rocker arm shaftis more than O．2mm．

replace the rocker arm bushing or the shaft de− Pending on the condition of the rocker arm Shaftoutsidecircumference． 川TS lmprop即COnt8Cて0†tapp飢

CLearance betweenrockerarm shaftand bush ing

Fig．11．10A ContactofTappot

AssemblYStaIldard＝0．01−0．05mm Repair＝mit 雲0，2mmormore

③S梅htstreaksorpiモボngsonthetappetinthe

O Visually check the rocker arm in the valve Stem COntaCting area forunevenwearorscratches． Stightunevenwear maY beTePairedwithoilstone or a va［ve refacer so that a correct curved surface is restored．1f the rocker arm has an excessive

UneVenWear，reP［acetherockerarm．

Cam COntaCting areashouLd be repairedwithgrind StOne．1f excessive cracks．streaksor pittingsare found，rePlacethetappet．

14）Pushrod Put the push rod on a stool and measure deflection with a thickness gauge．ro＝ngit．rf the defLectionis more than O．3mm or excessive

Wearatbothendsisfound，rePlacethepushrod．

3．ReassemblY （D Reassemb暮e therock即armandshaftin軌e

SeqUenCe OPPOSite to disassembly，Observing the followingrequirements． ③Thoroughlycleantheoilholesintherocker

arm and shaft．and blowair through the holes to besurethattheyarenotclogged． こ3．Jnst；1Slthc rockeri）rrn Wiihitsく？n（lpoin†ing towardtherockerarm bracketside． Fig．11．10 RoparingRo￠k即Arm く3〉Tapp醜

①Measuetheoutsidediameterofモhetappet

With a micrometer． rf the tappet wears out beyondtheusefu川mit．replace．

−15−

11．3．3 CYLINDER BLOCK

3．Reass￠mblY

l．DisassemblY

（1）Chromadetiner

（1）MeasurernentbeforedisassemblY Theinside of the cy＝nderlineris specia y

CareShouldbetakeninhandlingit．

chirome plated so that honing ar boring Gannot be performed．Before attempting to disassemble

酢蛸畷膵射か耶画極．Anerr即0ず8boutl￠〃eanbe

①The油romade暮in即isa裾nwa董象蔓iner，SO8ue ②lt c8n be easi垂y dam董g感￠r deformed by PrOducedin measuringtheinsidediameterwith a

the cylinderliner，meaSUre theinside diameter． CyIindergauge． 1f seizure− damage or excessive vvearis found，

③B如㌢e壷nser如g a 萱inerf turnit ov即and appIYit on the cyLinder bLock to makesurethat thefJangeoftheJinercanfitinthecYJinderbJc．ck．

replacetheliner． Cylinder‖nerinsidediameter Nominalsize＝102．00mm UsefuIlimit ＝102．20mm

綿岬如冊醐 circumference of theliner orinner surface ofthe

Note：Themeasuringpointis20mmupfrom theIinertopsurface

CYlinderboreincleanoil． 繊＝摘如馴動画馳ぬⅧ袖

t2）DisassemblY

①圃ぬ榔＝摘間紳痴＝ぬ地顔潤射通感触

′1Rr：言∫！刷：：直侶、…し13・・！．く∴てき！二車ト・fも・正伸申出由一−l●

an approprjateliner．CJean the＝ner and bore

fromthecyLinderblock． 僅）鮎閥㈹離ほ郁雄涌か融柁翫澗☆断頭摘ぬ

W圧hspindleoil．

and spread the outer circumference of theliner

block． ③Remov母tわe9ene㌢8モOr曾粍妄ngbr∂ek軋 0utsidedia．of tiner（after COPPerPlating）

④油粕‖糾明地肌汀㍍痴汀翰射線廟焼山お酌絹糀

removethecYLindertinerupward．

CYlinderbore mm

mm

105，011・105．020 105．001−105．010 2

105．021−105．030 105．011−105．020

3

105．03ト105．040

105．02ト105．030

The combination of a cy＝nder and a ‖ner

isdeterminedbYmatChingthenumberstampedon the cylinder block uppersurfacevvith thenumber on theinside face of theliner．Installwith a PrOPertighteninginterference． Fig．11．11R8mOVingCylind即しinor

2．lnspection Checkthecylinderblock forcracksordamage． Perform hydraulic test．AIso measure distorsion OfthecylinderbIockuppersurface． DistorsionofcyJinderbIockuppersurface Assemblystandard＝0．05mmor［ess

Repairlimit

＝0．2mmormore

−16−

ProjectingamoLJntOfJiner Assemblystandard＝0．03−0．10mm

Note：Differencebetweenprojectingamounts Ofadjacent＝ners−WithinO．03mm 11．3．4 PISTONAND CONNECTING ROD l．DisassemblY

①Remove輌p盲s師榔rom触piston ②Remo∀e抽esnapringfrom醸episモOnPln暮 ③us盲n98rOd aモ醸episモOn Pin′ti紳Iytapit Withahammertoremovethepistonpin．

Fig．11．12 MarksonCylinder

④when鮪℡bushing8モモhesma暮Ierend oずthe lnterferenceofcYlinderandliner：0−0．020mm

COnneCting rodisworn，aPPlya rodatthesmaIIer

endbushingandremovewithapress．

②pressf豆モモhe！雨両醜椚摘牒曲油狛流感瀾冊

a press so that the spindle forthepressisfound atthemiddleofthereplacer．

2．1nspection （1）Piston a．Ap匹aranCe

Visually check the general Gondition of rhe Piston for cracks．scratchesorwear，andifexces− Sive．replace． b．CJearancebetweenpistonand［iner

①Me塾Sre醸eouモSi8ed盲am紬ro＝he画On

With a micrometer at a right angIe of the piston PinhoIe，53mmdownfromthepistonhead．

F画．11．13 Preぉ−fittingofCylind訂しin即

③using aset如g柏0蓼．pressfitthelin即by∂

PreSSUre Of500kg and then fit completely bya PreSSureOf2500kg． Fig・11．14 Moaiurin90utsi由DiamotorofPi銃0∩

矧＝軸痛感ぬ削が軌酬

Put a straightedge across thelinersurfaceand②Measurethe m毒nimumworn∂朗如und

measure the cfearance between the cYJinder sur−

bottomortopofIiner，Whichpistonringcontacts

ずa8eandモhe妻in即Wiモhathieknessgauge★

融痛いが☆ほ行商弛0仁軌e柚餅肌柑＝Cylinder gaUge・

The clearance betvveenthepistonandlineristhe difference between this measurement and the maximumdiameterofthepiston．

ー17−

Clearancebetweenpistonandcylinder＝ner Nominalsize ＝102．00mm Assemblystandard＝0．182−0．200mm

②Measurethec‡椚Cebeモ棚nthepis加ring

groove andthepiston ringwith athicknessgauge at several points of the cirGumference of the Piston．

（2）Pistonring

Clearancebetweenpistonringgrooveand piston ring

①puモモhepistonringin柏thecylinderliner8nd

PuShitin with the piston head so thatitisata rightangleto thecylinderliner．Measurethejoint 汀けPringI gap of the piston ring with a thickness gauge atAssemblystandard＝0．085−0．110mm Usefu＝imit

theminimumareaoftheinsidediameter．

＝0．20mm

（Secondring）

AssembLystandard＝0．030−0．055mm Usefullimit

＝0．15mm

くGiいi！1g）

Assemblystandard＝0．03−0．07mm Usefullimit

＝0．15mm

Note：Replacepistonorpistonring

Fig．11．15 Me8Suri叩JointG叩OfPistonRing

Jointし；apofPis10nRing∬nsidcgi相即） （Topring）

AssembLystandard＝0．25−0．45mm Usefullimit ＝1．5mm Fig．11．16 M舶SUringRi咽Groovo

（Secondring）

Assemblystandard＝0．2−0．4mm Usefullimit ＝1．5mm

（OilringI

③Measu陀モension of醸e ptston ring雨h a tension meter，andif the readingisbelowtheuse・ ful＝mit．replacethepistonring．

AssemblYStandard＝0．2−0，4mm Usefullimil：

Pistonringtension

＝l．5mm

iTopi・iR笥〉

Assemblystandard＝2．15−2．85kg Usefullimit

＝1．Okg

〈Seこ（Iil〔iri11g）

Assemblystandard＝1．43・l．97kg Useful＝mit

＝0．5kg

くOi‡riRg〉

Assemblystandard＝6−8kg Useful＝mit

−18−

＝4kg

（3）Pistonpin

（5）Connectingrod

Measure the outside diameter of the piston Pin with a micrometer at both ends and mjddle

a．Defletionanddistorsion

areain the horizontaland vertica［directions，

six pointsin aIJ．1f the outside diameter of the

①lnsta】l軌e connecting rodin a connecモing

rodatigner and measuretheclearancebetweenthe COnneCting rod aligner stooland thelegs of a measuring instrument with a thickness gauga to

P毒sモOnP‡nisbe暮owtheusefu‡＝mitori守一hebush− ingcJearanceisbeyondtherepair＝mit．replace． Check for deflection（paralLelism）oftheconnect− ing「od．

②lnsta露‡theconnectingrodinaconnectingrod

aligner and measure the clearance between the COnneCting rod aFigner stooland thelegs of a measuring instrument with a thickness gauge to Checkfordistosionoftheconnectingrod．

Fi0．11．17 M●81uri叩Pi虞OnPinOutsidoDねm●tOr

PistonpinoLJtSidediameter Nominalsize＝35．00mm Usefullimit ＝34．95mm

C［earancebetweenpistonpinandbushingat COnneCtingrodsma end AssembJystandard＝0．012−0．025mm

Fig．11．18 M8aSUringConnoctingRod

Repair［imit ＝0、05mmormore Note：Replacebushingorpin

（診l管 de引ection or disモOrSionis beYOnd 軸e repairlimit．repairorreplace．

Deflectionofconnectingrod

（4）lnterferencebetweenpistonandpistonpin Theinterferenceis determined to be such a

distance rhat the pin can be pushed into a piston heateduptoabout600c．wheneverthepistonis replaced，besureto replacethepistonpinasvve［l．

Assemblystandard＝0．05mmorless （perlOOmm）

Repairlimkt

＝0．2mmormore

（perlOOmm）

Distorsionofconnectingrod Assemblystandard＝0．05mmorless （perlOOmm）

Repair［imit

＝0．2mmormore

（perlOOmm） b．Wear of connectin grodinlar9eendand sma endsidefa（：e

①Measurethecte那anCebeで鞘eenthe如geend

Of the connecting rod and the crank pin with a thicknessgauge．

−19−

piston and rhe piston pin in the wrong direction. lnsta

thepiston pinwiththenotchedpartinthe

Piston head pointing toward the enginefrontside and the Gylinder number mark on the connecting rodtoward thecamshaftside．

③wheninsモa＝ng a new p盲sモOn，me8Sure納e

inside diameter of the cYLinderliner and theout− side diameter of the piston at the grade position （at a point53mm down from piston head at a rightangleto piston pin），and makesurethatit Fig．11．19 Measurin9ClearanceBetweenLargBEnd ofConnectingRodandCrankPin

hasastandardpistonclearance． Note：Cylinder blockcarriesonitsuppersurface

③A画巨編牒廟鍾翰鰯場面蘭餅ぬが抽

theinsidediameters ofliners pressfitted（A，B，C and D）．Select appropriate pistons according to

COnneCtingrodandmeasurethecIearancebetween

thefollovvingtab［e．

the piston boss and thesma endoftheconnect−

ingrodwithathicknessgauge．

Gr8de

ln〜id￠dia．of＝n即

′

m8rk

Pr8SSfitt8d

Outさidedia、0†piston

mm

．

Standardvalue．rep［ace． 鞘叩L！Pl、・J責e…、ミニ・r占・ごモご盲、く…丁、；・こ⊂・iミ；な・・室卜！：・・・■どこi；rrミ

A

102，021−102．030

8

102．031◆102．040

101．840・101．849

C

102、04ト102．050

101、850−101，859

D

102．051−102．060

101．860−101、869

Crankpininaxialdirection Assemblystandard＝0．17−0．30mm

③Enst∂‖theconnecting rodsma肇蓼e門dbush盲ng

Repairlimit

With a pressand finish theinsidediameterofthe

＝0．35mmormore

Note：RepIaceconnectingrod，

bushingwithareamer．

⑥Aモモachas桐Pringn醸episモOnPin・ ⑧摘ぬ…瑚画廊油断洲加画触．

鞘柑旗蘭鱒消御感机瀾拍動矧醐蘭臨海掩射的 pis町≦・…蔓r、3㌧≡‥1−、ンイ・と；l〜．トミ王子†（弓；ミビt；−ト．、r≧巨10軋

Note：The piston rings，OrCOmPreSSion ring and

side）

Oilring，ShouLd beinstalledin the piston ring

Assenlblystandard＝l．5mm

grooveswithmarks（NPRorTOP）up． ⑥A穐er裏門st∂毒蚕8電蓋on7SPread醸e who‡e pisモOn

3．ReassemblY

with engine oil and slide the rings along their groovestomakesureeachringsmoothlyrotates・

⑦勒瀬…鹿画触＝聞醜蝮酬a臓舶綱 make sure that the differencein vveight between eachassemblyisbelow20g．

Fig．11．20 Reas鎚mbIingPiston

、1し−・：．「〜1、・ミ：・ミ・ミート…・．・！●いミ、・‥ 叫‥！−…一−．十ぐ両用1＝㍉￣i

w8terOrOi蔓0管around600cand蔓nse代官hepi＄モOn Pin．Care should be taken not toinstallthe

−20−

11．3．5 CRANt（SHAFT

Crankshaftjournaloutsidediameter

l．DisassemblY

Nominalsize＝80．00mm Repairlimit＝0．05mmormore Usefullimit ＝78．75mm Note：Repairorreplace．

①us毒閂g a9ear Pu蓼‡erタremOVeモheerankshaず電 gear・

②Rernovingf‡y脚hee星ringg鴇「：

The ring gearis shrinkage fitted to the f［y−

Crankshaftpinoutsidediameter

Wheel．Apply a brass barand driveitoutwith a

Nomlnat size＝64．00mm Repair［imit＝0．05mmormore Usefu＝imit ＝62．75mm Note：Repairorreplace．

hammer．

2．lnspection tl）Cranksha†t

Finishingaccuracyofcrankshaftjournaland Crankshaftpin

a．Crankshaftjourna［andpindiameters ①Me∂Sure翰e ouモS妄de d妄∂meもer o音痛e cr8nk

Shaftjournalandlhat ofthecrankshaftpinwith

（taperande［lipse）

a micrometerin the fore−and・aft direction（I、11） andin thehorizontalandverticaldirections（A，B）

Assemblystandard＝0．007mm ⑥checkthe佃shedsurねceofthec∂nks柚

and check forwear orunevenwear．

journalorthecrankshaftpinforexcessiveuneven Wear，taPer Or elIipse′andif found．repairit by grindingand usean under−Sized bearing．1fwithin

the repair timit，rePair with oilstone or sand PaPe「．

b．Deviationofcrankshaft Support thecrank shaft atthe No．1andNo．7 journals with a crank shaft aligner or a V・bIock． Usea dia［gaugeatthe No．4journalofthecrank

Shaft and read thegaugewhile rotating theshaft． The deviation of the crank shaft is the maximum readingofthedialgauge．

Fi9．11．21MeasuringPointofCrankShaft

②星管醸e uneven wear oぞcrank sha鴇如rna！

Deviationofcrankshaft

diameteris beyond O．05mmorthat ofthecrank Shaft pirldiameterisbeYOndO．05mm，rePairwith

a crank shaft grinder and use an under−Sized bearing． Note：Therearetwotypesofunder−Sizedbearings： 0．25and O．50

③号音the crank sha翫journa篭8盲8和郎er orモ短

Crank shaft pin diameteris wornin the normal manner beYOnd the repairlimit．replacethe beaト

ing or repair bY grinding and use their respective under−Sizedbearings．

−21−

Assemblystandard＝0．05mmorless Repairlimit ＝0．040mmormore Note：Repairorreplace．

（2）lnsidediameterofmain bearingandconnect・

＠）暮fモheclearance betwe研theeonnec如9rOd

ingrodlargeendbearing

bearing and the erank shaft journal diameter or the main bearingand thecrankshaftpindiameter

①tnstattthemainbear妄ngonthecytind即b毒ock and tigh伽the b銅rin9C8PモO thetorqueof24 is beYOnd the r叩a暮rlimit due翰Wear Of the kg−m．Measuretheinsidediameterwithacy‡in由r bearing．useanunder−Sizedbearing．Whenusingan gaUge・ und絆Sized bearin臥 m8Chine 輔e cr8nk shaft JOurnalortheer∂nkshaftpinsothatthee‡earance betweenits diameter and the under−Sized bearing usedistheassemblystandardvalue． く3！Mr！aSUri盲1q‖1ethoiiw盲thPLAST（GAGE

（むStandthecytinderb暮ockw壷抽itsbo鴇OmS毒de （oilpan side）up and cIean the main bearing hole

and the back andinner faces of the bearing to removeo‖．

②賢nsモa暮1紬e b朗ring onモhe cyl盲nder bぬ虎

journalandputthecrankshafts10Wly・ ③Turn the crankshaftabout300sothaモモhe

crank shaft bottom closely contacts the bearing．

Fig．11．22 MeasuringMainBoaring

Put a PLASTIGAGE（PR−1）on the crank shaft

②Enst∂暮Ia bearin90nモheconnec柚grodl即ge

journa［．acrossthebearing．

end and tighten the connc?cting rod cap boits to the torque of12kg−m and measure theinside

TYPeOfPLASTIGAGE Measurableclearance

diameterwithacYlindergauge．

Fig．11．23 MeasuringPointofLargeEndBearing

TYPE PR−1（red）

0．051−0．152mm

TYPE PB−1（bJue）

0．102・0．299mm

TYPEPG−＝green）

0．025・0．076mm

Fig．11．24 PLASTIGAGE

③Judge the we∂r COndition by seeing the difference between the bearinginside diameter， crank shaft journal diameter and crank shaft pin

tightentheboltstothespecifiedtorque．

diameter．

width of the PLASTIGAGE pressed flat bY the

④‡nstallthe bearing on the be8r盲ng eap抑d （をRemove the bearin9CaP and measure the Crank shaft and the bearing cap・Compare the

Clearancebetweenmainbearingandcrank Shaftjournal

measurementwiththescaleprintedonthebag．

Assemblystandard＝0．025−0．076mm

Repairlimit ＝0．11mmormore Note：RepIacebearing C［earancebetweenconnectingrodbearingand crank pin AssemblYStandard＝0．030−0．073mm

Repairlimit ＝0．10mmormore Note：Replacebearing

…22−

（4）Crankshaftp）aYinaxialdirection

②Me8Sure翰ecrushoftheconnectin9rOdbear−

①‡nsモ8＝heだrankshafton抽ecy‡ind即block，

ingandthecapinthesamemanner．

install the bearing cap and then temporarily

Bearingcrush＝0．04−0．065rnm

tighten．

②抽摘沼モ如Ⅶ詫b矧由昭C椚both sides of the

No．4 bearing cap and measure the clearance between the thrust bearing and the crank shaft sidefacewithathicknessgauge．

CrankshaftplaYinaxialdjrection Assemblystandard＝0．15−0．33mm

Repairlimit

＝0．40mmormore

Fig．11．27 RodB8aringCrush

③Toeasilymeasuretheconnecモingrodbe∂rin9 CruSh，installthe cap and fit the bearing．Then

tighten the cap bolts to the specified torquel Loosen completeFY the boItsatonesideandinsert a thickness gauge into the connecting rod fitting SUrface．

Fig．11．25 Moasuring円8YinAxialDiroction

③電子thecranksha干tplay盲n∂Xi∂Id汗ect盲0ワ旨s

beYOndtherepairlimit，rePraCethethrustbearingL （5）Bearingcrush

①】nsta‡lbearings onモhemainbearingsection

and the cap of the cyLinder bIock．Make both bearings closelY COntaCt VVith eachothertomake Certain that each bearing has a crush from the fittingsurface． Fig．11．28 M8aSuringRod8t！8rhgCluSh

Bearingcrush＝0−0．04mm

④‡ぞ no be8ring crushis found．rep蓼aee the

bearing． 3．ReassemblY （1）ReassemblYO†crankshaft ①Pou川ghtoi‡inモ0輌c抑ksh8手書o…0‡e forcleaningandfina

YUSeenginecteaner．

②MaモCh 抽e crank sh涌ge即key way and

install the gear on the crank shaft with a gear Settingtoor．

Fig．11．26 MainBoaringCrush

③！nstal‡the stra盲ght p盲n on the erank sh8ft

rear sideandlocatethefrYWheelaccording to the Straightpinandthentightenthemountingbolts．

ー23−

ほIlnstallationofringgear

①職椚刷惇 離間涌朝鳩摘隠密れ由撒油！Y with∂9aSburnerandshrinkageず盲モモ￠モheずIy聯hee星・

②7heringge8r毒seham誓eredaてbo軸s竜ぬ・ぬ

itcan bereusedbyinversing，ifonesideiswornor dam∂ged．

③柚那加㌻壱nggear室CO￠‡e8down′eheckモO see軸aモthe ring gear −S Close‡Ⅴ普iモモed 電O the

絢爛桶鉦痴胴靭Ⅷ＝柑呵搾画一tWiモhahammer■ 11．3．6 CAMSHAFT Fig．11・30 MeasuringCarTIShaftDeflection

l．DisassemblY

Remove the cam shaft tightening bolts and

Be†ore8nd behind

帽mOVe痛ege8㌢聯盲醸apu曇璽erorapress8門d軸en

Bofor（）and behind

removethethrustplates．

2．1nspectionandrepair ・†ぐ：i−ミ・r・、け…！、；ミ！1「こ：こ；；汀；盲、・…ト；．武・、、：i− d、●！・：、盲： ドい昔・㍉∵、「：ノ、ミ…丁ごミ・−l一号＝・∵−ご；こモーご：、∩亡・ ラ M．＝廿眉？汗∴二・「…−．；！！トミこ．−こ′ト・∴い・・ミリー呵−、、t、∴

andif the measurementis belowtheusefullimit， orif the cam surfaceis excessively damaged， ；ぐ…二・いり、八r・ir舶ミ…、…！tlこ汀：r、り ∴ミ、・、・！・、・、こい・・−ト：

eam surface may be repaired with oil stone.

ER80 C8m

Fig．11・31Moas＝ringPointofCamShaft

Camshaftjournaloutsidediameter ＝56．Omm Nominalsize Usefullimit ＝55．6mm Note：Replacecamshaft Unevenwearofcamshal：tjournal Assemblystandard＝0．015mmorless Repairlimit ＝0．05mmormore

Note：Repairorreplacecamshaft Camshahlih Nominalsize ＝7．71mm Usefu＝imit ＝7．21mm Note：Replacecamshaft Cle8ranCebetweencamshaftjoLJrnaland bushing

Fig・11・2g Meas＝rem8ntOfCam

③閲e窃Sure醸￠CamSh議書tjourn8tぞor網窃r聯廟

a micrometer，andifwornoutbeyondtheuseful limit，rePlacethejournal． ト…−・−・、：；ご！川ミF卜・い−！！、−−一両㌣畑∵‥−

Assemblystandard＝0．03−0．09mm Repairlimit ＝0．15mmormore

Note：Replacebushing ・さ −イ−しこ・ここご ざ− こ！・、・て∵・．・い．エー ニミ幸！・・j‥・・．・…き−！伸さ

uneven wear，andif worn out beyond therepair ・・r：こ・；・1、・．・・こ・lミ‥；ミ；・；‥、ご：こ．′・・：㌣∵・星：・∴ミー り・−・・−い limit．repairorreplace．

■ニ・、・、・、…＼・．．・・；．∴；こ・．、・t．い・・；−・…、い−ミ、：亘、∴ご・ミ；・く・．、：・−！ Shaft．

ー24−

、1・n、隷甘骨ヤ

・（：ト㌔ぐ「ト：−こ‥≡．こ：：∫；至ご‥−ごご、バ∴車∴ こ・∴、1‥こ…コ幸ぐj雨ミ・

（むEns電a妻‡抽e翻u＄モP妻∂モe∂nd thec8m gear￠n

tion，andif the clearanceis beyond the repair

thecamshaft，andtightenthegearmountingbolts

limit，rePlacethe thrustco．larorthegear．Visual・

tothetorqueof16kg・m．

lycheck the thrust collar for unevenvvearandif

・一ニ ミぎこ∴、・ミ∴∴・ご；さ：：こ∴い・小‥：、；そ．∴∵・・、い」

unsatisfactory，rePLace．

measure the clearance between the thrust pl∂te

Clearancebetweenidtergearbushingand

and thejournalend face．JftheplaYin theaxial Shaft directionis beYOnd the repairlimit，rePFace the Assel¶blYSlandard＝0．025−0．085mm thrustplate．

Repairlimit ＝0．2mmormore Note：Replacebushingorshaft Unevenwearofidlershaftoutsidediameter ＝45．O mm Nominalsize Repair［imit ＝0．1mmormore Note：Replaceshaft

CamshaftpLaYinaxiatdirection Assemblystandard＝0．050・0．114mm Repa汀＝mit

＝0．2mmormore

Note：Replacethrustp［ate

】dlergearplaYinaxialdirection Assemblystandard＝0．058・0．115mm

RepairIimit ＝0．2mmormore Note：Replacethrustco11ar （2）Backlashoftiminggear ・；−、！・ゝ十、∴・．：・￣一．、：こ．・・へ、1・・、：ごしいc

fittingarea orthegearteeth，arldifunsatisfactory，

replace． ・J．：−トーバー：コ．ミ・；−i∴、・−こて・∴、ゞ…・し−・−1−：：、・・、．；：l享ぐ．P〇：−

thickness gauge．As an atternative method，yOu CarlUSe a fuse wire between thege∂rS and rotate them．Measurethethicknessofthecrashed fuse．

1f the backJash js morethan O．30mm，Check the

gearorthebushingandrepairorrepIace． Fig．11．32 PlaYinAxialDirection

∴、、、：・1＝：∴・・、；∵ ミ．、．トミ㍉・ニ・：．−：・こ†ト〉11

ll．3．7 TIMING GEAR

Assemblystandar d＝0．10−0．17mm Usefu＝imit ＝0．30mm

l．DisassembIY

Note：Replacegear

（》sモr∂盲g醸nモheモan9S Oずthe80Ck w∂Sher o管

（3）ln錘Ctionpumpdrivegear ①checkモheb8‡露be那豆門g紬㌻Pee6ぎSCO㌻eSOn輔e races or seizure，andif unsatisfactory，rePlace．

theinjection pump gear and remove the gear tockllUtSfromthedriveshaft．

（診び油射沌朋由馴頭痛ソ開削酎触減矧廟銅血

Lock theinner race of the ba［L bearing and set a dialgaugeonthecircumferenceoftheouter race and try to move the outer race．tfthelooseness

gearfromthedriveshaft． 2．lnspection

ismorethanO．2mm，rePface．

（1）ldlershahandgear

・ラ・・て∴ト：：こ・、、；−へ二：．、ミ・・・S主；ト・；、；・！∴ミニll汀k

①閣e8Sure触ouモSide diameter oず醸e壷d寧er

forlooseness．（f excessiveIoosenessis found，

Shaft with a micrometer．tf an uneven wear of

reptace．

more than O．1mmis found．repFace theidler（診Enserモ醸e dr妄ve shaft壷門モ0モhe crank sh8ft

SPline of the air compressor and fit a key．Seta dialgauge on the key and measuretheclearance

Shaft．

・●−ごここ卜・；−ミニ…・−…●汀雨■ハ；…

between the sp＝nesin the rotating direction．

．

meter，andif the clearance between the bushing

1ftheclearanceisbeyondtherepairFimit．repIace．

and the shaftis more than O．2mm，rePIace the

bush11g．

−25−

C）earanceofdriveshaftsplineinrotating direction AssemblYStandard＝0．08mm Repairlimit ＝0．20mmormore

3．Reassembly ①Insta＝the kev onthecけvesha管モand press

fit the gear on the drive shaft，matChingthekey WaYinthegear． だ澱章鋤

蔓）Pressfit抽ebag曹be8ringonぬ醸endsoずthe

Fig．11．33 MQaSuringOilPump

driveshaft．

③膏帽離t摘k血＝紛紬汀即＝伽＝狛㈹融瀦

b．Clearancebetweengearandcover Applya squareonthepumpcoverandmeasure the cLearance between the pump cover and the PumPgearVVithathicknessgauge．1fthecIearance

and tighten theJock nuts tothetorqueof13to

17kg−m．Bend thelockwashertangstolockthe nuts．

is beyond the standard va（ue′rePlacethegear or

1l．3．8 LUBRICAT］NG SYSTEM

thecover．

l．Oilpump （1）Disassembly

①‖0はい紬epumpbodyina∀ise∂ndremovethe

two oil pipe mounting bolts and remove the oil Pipefromthepumpbody． ②Straigh伽輌伽geoftheo‖sモr∂iner ，

fromthetopcase． ③Remove軌eねurpumpcovermoun如9bo蓼モS

and remove the top case and the pump cover fromthepumpbody． 倭）Removeモhe drive gear8SSemb毎from the PUmP body．1f hard to remove．use a pul［er or

Fig．11．34 ClearanceBetwoenGearandCover

P「eSS，

ClearancebetweenoiIpumpcoverandgear

⑤Remむ∀e軸edri￥engea㌢fromthepumpbody．

teeth

（2Ilnspection

Assemblystandard＝0．100−0．176mm

a．C］earancebetweengearteeth andinnerwa‖of

Clearancebetweenoilpumpcoverandgearin axialdirection

COVer

Measure the clearance between thepumpcover inner walland the gear teeth with a thickness gauge，andifthecJearanceisbeYOndthestandard

AssembIystandard＝0．050・0．114mm

C．Clearancebetweendriveshaftandbushing ①Measure輔e ouモSide8iam摘r of the drive

Value．replacethegearorthecover．

Shaftwith a micrometer，andiftheshaftdiameter isless than15．9mm，rePlacetheshaft．Measure

theinsidediameter ofthe bushingwithacyIinder gauge，andifthe clearancebetween theshaft and the bushingis beyond thestandard value．replace thebushingorthesh∂ft．

−26−

②Me∂Sure the elearance be紬een醸e d㌻墓ven shaftandthebushinginthesamemannerasabove．

2．Oil用ter

（1IDisassemblY

Outsidediameterofdriveshaftanddriven

①Remo∀e抽eか扇n ptugモOdrainoffoi沌om

Shaft Nominalsize

theoilfilter． ＝16．Omm

（訂Loosenモhecenモerbo‡電andremo∀eモhef侮r

UsefuL timit

＝15．9mm

bodY．

③Remove the e−eme鴫 PaCk畜ng′SPring seaモ

Note：Replaceshaft

andspringfromfilterbodY．

ClearancebetweendriveshaftandpumpbodY

④Remo∀eモhe over一号！ow va篭ve assembly from

Assemblystandard＝0．05mm

thecover．

Clearancebetweendrivenshaftandbushing Assemblystandard＝0．035・0．090mm

（2）Cleaningandinspection （3IReassembly

；・r二；・．：‖・lい・．こ≡：sこ！ト・、：；‥・・毒ミ丁！妄j：：喜・・ミ 恒i〔再持‥1毒．1！l

①pressぞ注油e8r旨vegearon抽℡drivesh油and

SOIvent．

instalt the drive shaft on the pump coverso that thedriveshaftend projects by163±1mm from the bodY end face．TheheightfromthecYlinder fittingsurfaceon the oilpumptothefrontendof

②check モhe over一勒w v∂妻Veねr va雲ve seaモ

COntaCt and deterioration of the spring．and ifunsatisfactorY．rePIace．

③vまsu8曹妻y cheGk油層0抽er p∂F篭S如da椚喝e′ andifunsatisfactory，rePIace．

theshaftshould be65mm．

（封 ReassemblY （むF廟痛憤＝測 闇−−「盲n9Sa門dpack盲ngswithnew OneS．

．？雨吊巨 洋一・：…・；：、；…．丁：い−…・；ミ守、＼叶；・：ⅧS両・・！J

Seat，gaSket and element on the center boltin thatorder． ③1nst8嚢t an′′0−′−㌢富nginモわe柚erbodygroo∀e

SeCUretY andinsta＝the fitter bodY Onthecover．

F軌11．35 0ilPump

Tightenthecenterbolt．

②抽朗融It如か妄ven9ear￠n抽epumpeover．

④lnst8自‡曾帽OVer−ず憂0榊Va！∀e aSSemb‡￥Onモhe

③琶門Sモ∂香色tわe pumpGO皆erandモわetopc∂Se On

COVer．

the pump body and tighten with the top case mountingboLts．

・チ F√：、、、：、・硬・∴ い：≡こ∴・−・＝：・；くこ川・−・；：−こ！…；…こ、l）…：；1「l、

3．、Oil亡00ler

rotatesproperIy． （診さnst∂‡巨柚eぬ竜t￠m eaSe8門8醸esモraineron

‖IDisas8embtY

Remove the four stud bolts oC the element in thecooLer bodYand removetheeLementfromthe COOlerbody．

thetopcase andlock thebottomcasebybending thetopcasetangs．

・、こ；；i・−1し：ミ！：・已ミニ：トト・Pつ：1；！！ぐ、；−・し！∴「；．iい丁：・．・

−27−

（2）C】eaningandinspection

（2Ilnspection

a．Cleaning

①ch昏ぢk翰ebe8rin9毎w朗rOrdam喝eandねr abnormalnoisebyturningitbYhand．

ご1）Poし！i（）i：c等鞘■−−i†1g S（−1vent しil；0瑚巾 th110i！

POrt Of the element andleaveit for aboutlO

②‡ずthe！00S帥eSSis be∀Ond廟e useずu箋廟iモタ

hours．

repl∂Ce．

②Drainl／30ずthe e露ea円蓋n9SO暮榔電in the 81ement and blow cornpressed∂ir of2k9プcm2

Ba‖bearinglooseness（radialdire￠tion）

Usefu＝imit＝0．2mm

through the oilportwith air compressortodrain

③Gheck抽e盲mpe雷電er an8sわる穐紬r excessive dama9e Or Wear，andif unsatisfactory，rePlace．

CLeaningsoIvent．

③R叩母at抽母above procedure se∀er∂蓄電盲me写

dependingonthecontaminationoftheelement．

PaY SPeCiaL attention to errosion on theimpelLer andwearordamageon thecontactingareaofthe

b．lnspection

Sealunit．

①牒紬泳廟狛涌∝磁極欄廟川野鞘感む品狛

lnterferencewithfancenterand shaft

unsatisfactory，rePIace．

Assemblystandard＝0．07−0．11mm

②Check油ebypassvalvep妄s電Onand納e￥8篭皆e

lnterferencewithshaftandimpeller

Seatfordefect．andifunsatisfactory．replace．

Assemblystandard＝0．020−0．060mrn Clearancebetweenpu eyandfancenter AssembIystandard＝0．14mmorless

（3）ReassemblY Reassemble the oilcoo［erin the sequence

OPPOSitetodisassembly． （3IReassemblY 11．3．9 COOuNG SYSTEM

：、ミ峯‥、・ゝ、モ、∴ざ−−ざ‥・ ，

l．Waterpump

requirements．

川 Disas5embly

‥もぎ喜・い‥・こ「巨＝、ト・しミ；！・．・・・・・し、・・ミ、：：：ご．い！車こi！． thebearing．

①Removethewa髄汀Pu閏Pbodyeo￥er． ②Usingapulier，remOVethepu‡廟Ⅷm鰍． ③u柚馴紺細卵油m開削吼柑撒M凋料輌画

③凱腑昭脚融胤柚陽呵画朋輔酎削れ雨川棚 aneWOne．

Lerassembly．

④using∂PreSSg PreSS管毒モモh￠壷mpe！‡ers￠醸8モ

the clearance between theimpe．Jerand the bodY isO．3toO．8mm．

Fig．11．36 R8mOVi咽Imp8110r

（秒RerⅥ0∀e the sn叩雨9ずrom醸eぬdy a門8

Fig．11．37 Moasuring CloarancoBotw00nlmp011er

removetheshaftfromthebodywithapress．

and Body

⑥usin9∂PreSS．remOye軌ebe∂r裏門gfro椚抽e

りご／＼・！こ；こi・ご：、・こ、こ‥ト：．「‥；∴・・こ：．「、、：二、！．：ト∴ご・「・‥JT…：・ご・㌣皇、

shaft．

ShouldbeperformedeverY1000hours．

⑥Remo￥e餓esea妻u門i号音romモhebodv． 丁子′ニIi、、ド；ミミミ、；…：ミ、・ミ柑1・：叫、・j：ニ○；・．、盲；い・ミe∴i、毒ドミ√・ミ！．

AmountofseaIdgrea5e：55g

−28−

2．Lnspectionofthermostat ①checkモわe pe靂昏eモ宅sm8董董vesse竪ずor㈹X〉8nd SPringfordamage．

：；：・−・・−「ビ∴・・・：二・・、：・−・・；・・・−・∴；・・ぎ・：−ぐ…≡言…1巨吋貴と○・・「、、・

5minutes．Forthisprocedure．putpiecesofwood On the bottomDfavesselorsuspend thethermo− q！；1iミ、「ミ■・ミ‥：・≡ニゴ・‥．・ド・‥・・こ・・・こ・・・・・：l＼吊∴ii）、：∴；！

heated directJY．Make certain that the va［velift

islO mm or more at the standard temperature （ぎ）−ミ∴ −…−ト・‥i∴．・．‥、こ、．．．．．・．・ミ ー．、．・ measuringthebottomendfaceofthepelletbefore andafterheating． Openingstarttemperatureofvalve 卜い・：・！；い・∵∴・・ン・‥・ −1

・、：こ：、′三…ミ：≡∴、・∴：；・・・− て−・．・＿l Note：Rep［acethermostat

Fullopentemperature（atatmospheric PreSSureI ‥・．ト、∴−：−㌧、‥− い！ ・−、、こ− 、・・さ∴ Note：ValveliftMlOmmormore 11．3．10 FUEL SYSTEM

l．Nozzleand nozzleholder ∴＼− ミ、．．・−・

乱 Remova】ofnozzlespring ・二 …−・…、さ・．‥、；、・．・、：−．・．∵㌧、、 ・、＝−・・‥・・・−∴‡．亡＼●：‥− −・・：・：−：・ミ′、：−：こ：・、・・；・・！ remOVe．

1 Nozzle holder 2 DovvoIpin 4 Push rod 与 NozzIespring 寧 Adjustingsc長押 10 C8P nリー ll G8Sket 12 ＼〃asher 20 Nozzle nuT 21 G∈lSket 22 ln18t COnn8CtOr inてbo■t

Fig．11．38 AdjustingScrow Fig．11．39 ComponontPartsofNo王Zleand No三三l￠Holder

・●、−・・・′ミ・；、・・−：・丁・∴二・い；ニ・・∴へ・ r・：；−こ：≡．．・ −：．い・・∴−．‥…．．．‥；こ：ご、 −・；＼！−・ト＼ご：・…：「：：・∴・ご、・ミ、

−29−

③lmmersetheneedtev8雪ve8nd油e円OZZ蔓￠bod￥ 盲nfi篭teredl篭ghモOit andmak母Surethattheyslide

SmOOthtv． b．Inspビ山iリー川fl沌市由＝−0：dく甘 ．う Check［h（！nO7之ie h一両er ho（lYfoH！efect，an（l ifunsatisfactory，rePlace． ②check the nozz‡母SP㌢‡ng如d離㌻毒oration，

rustorcorrosion，andifunsatisfactorY，rePlacel ③checkthesc柑WS如dam聯∫8nd蓄funsaモis− factory，rePlace．

④Donoモreuseth￠gaSkets・Re紳eew廟n翻 OneS．

（3）lnstallation

Fig．11・40 RomovingNo王封oSpring

Due care should be exercised in reassembling the nozzle and the nozzLehoLder．ReassembLyis

b．Remova10fno三三le ①紬涌肩幅洞捕鯨如Iderin8Vise w鮎醸e

pe涌那閥酎椚摘闇鞘脚臓ほ桝触雨拍鋸摘矧都油Iy・

nozz．esideup．

②Loosenモhe nozzle nuモWi納adou純一ended

彿＝偏耶感触柑感腐擁離酬離婚触椚髄臓澗坤

SPanner・

乱軌如如椚髄射閥制帽画趣輌紳 ①抽細‡‡抽e nozzleho妻deron anozz‡e電ester． w肋thea（jjus如9SCreW‡00梵ne8離

②Mo∀e 抽e nozzle tester h∂ndle vigorous璽y

tvvo or three timesto removedustfrom the pipe andthenozzlebyinjection． ③Tight印篭he adjus雨g screw wi痛∂SCre騨− driver．

穫＝馳相打軌e娠冊摘＝鍾a n油 0†60一雨鳩SP酎

minuteandchecktheinjectionpressure． 闊0電e… Thepoin穣rofモhepressu柑gaugetrembies duringtheinjectionof紬e董．Read軸em盲dd董eof

theampiitudeasthe盲njec電蓄on sモarモPreSSureand Performadjustment． ⑤Aecor8盲ngtotheread盲n9・呼号eno㌻！QOヲen the adjus油gserewso乞わ8モ抽espeeiず毒虚妄njectton

Fig．11．41RomovingNo王王】oNut

③Removeで短nozz‡e，andimmerseitinc蔓ean 璽毒ghモOil，Removethedowelp軋 ④Removethe毒n露eモごOnn∝tOr・Donotぞorg飢to

StartPreSSureisassured． ⑥A触radjustme略号盲g触nthee叩閂ut・ ⑦納erモighten盲ng軸C藁嘲makesure醸離 モhe盲njection sta托PreSSu柑iS PrOPer璽￥SeモモOthe SPeCified value．

removethegasket．

！nje（：†…し）nさ千責rtP−・e‡Slj■e01−nIM2拍

（2）lnspection

Assemb−YSモan88rd芸−85k9／Gm2

a．lnspectionofno三三Ie

①Check 翰e nozzle如wear′COrrOSion or damage，andifuns8tisずa鵬ry′reP璽aceasanozz8e assemblY・

②lf油層n郎感e相暮∀eendof触nozz篭eisco？￣

taminated with carbon or theinjection portis doggedw托hcarbon，C蔓e8n輔盲thanozz‡ecleantng tool．

−30−

b．Oi＝jghtnessofneedlevalve ①璧nsモa蔓⊆the nozz圭e ho‡der assemb‡Y adjusted

SOthatitstartstoinjectatthespecifiedpressure， On a nOZZ］etester．

③p㌻eSSurize upto軸eモest pressu柑（165kg／ em2〉gr8dua事ty．

③Keepモhe tesモPr郎SUre and check for九蘭 Ieakage from the valve seat．1fIeakageisfound，

replacethenozzLeassembly． C．1nsp桝汁ionofinjectionpattern

Using a nozzle tester，Check theinjection Pattern Of fuelfrom the nozzlein the same

manner as for the adjustment ofinjection start PreSSure．1funsatisfactorY，rePIace．

F画．11．42lnjodionP8¶ornofno王之l0

2．hjectionpump Using aninjection pump tester，Check the injection pump forinjectingintervaI，amOUnt， uniformity of fuelinjected andinjection st∂rt timing．andifunsatjsfactory，Perform adiustment OrOVerha山，

−31−

11．4］NSTALLAT10N OF SUB−ASSEM−

BLY ll．4．1CAUT10NININSTALLAT10N

①cl鰯n a‖p訂鴇Sが執飯野嗅．巨悪peciaf‡y，Oi†

PaSSageSShouldbecleanedbybLowingair． ②App要yn窃Weng盲neo盲‡onthe由omade加即 inner surfaces，Pistons and bearingsin the sliding androtatingareasandinstallthem．

③鮎画皿＝沼騨融瀦＝椚霊鱒漁輌鰐融痛打帥 OneS．Where necessary，uSeliquid packing to Fig．11．441nst雨IingThrust80aring

PreVentOiIleakage． ④Careshou霊d beexer8壷s感電O main電8i閂PrOPer

②App璽yengineoi曹Vo円モわebe藁㌢蔓ngsurずaee抑d instaIlthe crank shaft．lnstallthe bearing cap． lnsta the No．4bearing capon thedowelonthe

Oilclearancesandgaps．

⑤80触 and nuモS紬r8篭um蓋num 8整lo￥P∂rモS

Should be tightened to the specified torque，Do block surface． Caution：Thebearingcapshoutdbeinsta

notovertighten．

edwith

theJocation mark on thecappointingtowardthe 11．4．2 1NSTALLATtON OF ENGINE COM− frontside． PONENTS l．lnsta‖ationofcamshaftbushin9

①usi喝a bushing pu‡暮e㌢蒼fit廟e e∂m Sha管t

bushing．

Fi払11．45ln式a＝ingBoさringC8P

③＝飯融璃申劇痛

0‖ and tighten them，Starting with one at the Center（No．4）and moving toward both ends a．ternateJY．TheboItsshouId betightened to the

Fi9．11．43 FittingCarnShaftBushin9

SPeCified torque，rOtating the crank shaft after tighteningeveryoneboIt．

②㈲1en盲nsモal萱毒ng鰊e bush裏門g′C8reShou18be

takentoaligntheoiIfil＝10les． ③抽潮劇‡鴎esea‡蓄ngeupon抽ebackoftheNo．

MainbearingcapboLttorque＝25−27kg・m

7bearing．

④TryモOrO官員te紬eeranksねaず電byhan8モ0和議ke

Surethatitrotateswithoutanyinterference．

2．1nstallationofcranksha巾

①は腐はI＝嚇由耶併用鹿印加繭＝肌綾踊か鹿

CaP Side．lnsta thrust bearingsonthe both ends OfNo．4bearing．

3．Install8tionoftiminggearc8Se lnstall a peeking an the timing gear ease and instaltthegearcaseontheknock−OUtPin．

Caution： Make sure that the bottom edge of the gearis aLigned with the bottom edge of the body．

−32−

4．lnsta ationofcamshaft ①摘鳳＝摘再摘り脚汀ぬ痛感如唱劇㌣血惜 CO ar mounting boIt，With the oilhole pointing

5．1nst8舶tionofflYWheel

①using8Seモtingto8いnsta蔓t8nOiise8lonモhe flyweel．

toward the middle betweenthecrankgearandthe

（塾Insta＝抽e椚ywheethousing∂書ongtheknock・

Camgear．

Out Pin of the cylinder block and tighten the housingmountingbolts．

Flywhee＝10USingmountingbolttorque くMて4‡1517kg−tll

佃一拍ト：＝−3．＝旬珊 ③薯nsta靂Itheず‡y揮hee暮a‡on9輔eknock・皿tPin． Lubricate the mounting boltswith engineoi［and installtheboltswithwashers．Tightenthem．

FtYWeelmountingbolttorque＝ 21．ト24．5kg−m

6．Jnstall8tionofpistonandconnectingrod Fig．11．46lnstallingIdlorGo訂Shさh

①puモ モhe cyl妄nd即 bloek uprightl〝i抽 the

flYWheelsidedown．

②さnsモa妻l抽eモ叩PeモOn鮪ecy璽in8erbloek．

③Apがy oiきon the cam sh涌journ8‡surf∂Ce

②きnsモa蓼璽thecrank＄h拍子rontnutssothaモモhe

andinstallthe cam shaft assembry．rnstallthe thrust plate mounting bolt through the cam

Crankshaftcan rotate．

gear removaIhole and tighten．Make sure the

acYIinderisatthetopdeadcenter．

③Roモ∂tethecranksh8ftsothatthepistonof ④Lubric∂穣theeonnec雨grodbear蔓ngsuげace

CamShaftrotates＝ghtly．

and the outer circumference of the piston with

CamshaftthrustplatemountingboItl：Orque

engine oil．Turnthepiston ringsothat thecom−

＝2．1kg−m

PreSSion ringleaves the combustion chamberand

モheき0抽tsofther毒n9Sare§P8C感1200叩a托†柑m each other．

（診‡nstalト軌e画紬脚＝With connec如g rodき豪n the cYlinder with the notchinits head pointing

towardthefrontsideoftheengine． ⑥using8PisモOnSeモモi咽短0臣or愈ri咽COmPr銭SOr，

PUShin the piston with a wooden bar unti［the COnneCtingrodbearingcontactsthecrankpin．

（∋Farth即PuShing w托h a woode閂bar，rOtate

the crank shafttopJacethepiston at the bottom dead center position．lnsta the connecting Fig．11．47 TighteningCarnShaftThrustCoHar

④蓼nst∂ilモheidさ餅gear8nd妄nstai蔓モhe由ust

rod cap on the connecting rod，matChing the marks on them，and tighten the cap boltstothe SPeCifiedtorque．

COllar．Wheninsta＝ng theidler gear，aJign the Connccti咽rOdcapbolttorque＝12kg−m timingrnarks（A，B）ofthegears． （診Tigh電en抽e軸ust∞l重点r mOu門如g boltsto thespecifiedtorque．

Thrustco arrnountingbolttorque ＝4．3・6．3kg・m

Caution：Overtightening of the bolts wi elimi− nate playofthegearin thefore−and−aftdirection．

therebycausingseizing．

−33−

Fig．11．48lnstallingDir郎tionotPiston

Note：ltis recommended toinstaltl：he connect−

ingrodsassetsof Nos．1and6，Nos．2and5．and Nos．3and4．ThisfaciJitatesinsta‖ationiob． Oit pan mounting bolts．using caution to keep

theminpLace． 7．lnsta＝ationofoilpumpandoilpan ①F室！i輌＝痛舶藩＝毎α両融叩湖贈再卸商

Oilpanmountingbolttorque＝2．6kg−m

OilandrotatethegearsbYhandtoIubricatethem． ②嚢nsta篭Ithecoup蔓ing8ntheserr∂如nofモheoil

Note：BeforeinstaLling the oilpan，aPPly＝quid PaCking（Belco Bond No．402）aboutlO mmin

PUmP end andinstaIJthe oiJpump assemblY On

Width on the frontand rear casesofthecYlinder

thecylinderblock．

btockandontheretainerfittingsurface． 8．InstalLationofinjectionpumpgear

… 上品烏・；1：喜二・、ミ「：3・−！ミ〜＝ −−1「q；・一室き−・；− ぐ…■1こ汀．（：t●こ1！、篭く gearandcamgear．

（診Matehthema沌璽C）onthepump9earW廟 the mark on theidler gear．andinsta．1theinje−

tion pumpdrivegearassemblyon thetiminggear CaSe．

③⑯ぬ摘如研繭摘扁亜麻紬庖弼血喝摘 bearingcovertothetiminggearcase．

9．lnsta‖ationoftiminggearcasecover F短．11．49lnsta＝ingOilPump

①hぬ南部乱射鳩C南蛮嶽＝纏C舟曾ほ宥加廟闇痴脚

CaSeCOVerVVithengineoit．

③七飯鯨油愉！沖e（cyぎ壷nderbody−0妄蓼pumpき

②牒離酢油滴l甑ov脚On輔eer毒液sh蛸．

andtightentheftange．

（卦Ⅶ冊＝＝憾相関承喚㌃癖融肛紬＝溺eぬ脚

④lnsモ81iaco粕ron軸eoi‡pans盲deo苦痛eか盲ve Pinion gear andinstalltheserrationofthecoup卜

along the knock−Out Pin and tighten the timing

ing from the b10Ck surface．rnsta11an

gearcasecovermountingbolts．

0

−ring

Timinggearcasecovermountingbolttorque

Onthecoverandtighten．

＝2．6kg−m

At the same time，tighten the bearing cover of the injeetion pump gear along vvilh the liming gear CaSeCOVer・

−34−

②馴飢融vp畑‖熱e勘Iinderheadonモhecylinder

10・lnsta ationofcrankpu ey Lnstallthe pulLey on the crank shaft so that

blockalongthedowel．

thekeywayinthepu＝eyengagesthekeyonthe ③Lubricaてe輌cy憂inderheadぬlモS噂i痛engine Crank shaft，andinstalla taper bushing andarock Oil．Of the26cylinder head bolts．six bolts to WaSher．Tightenthecrankshaftnuts．

beinstaIled at the nozzle side are shorterin

IengthlBecarefu［whenjnstaHingthebolts．

Crankshaftnuttorque＝60kg−m

④The tightenin90rder oずモhe bo‡モSis shown in theillustration belovv．

11．lnstallationofo‖cooler

①痛感は‖1抽e waモer dr8in cock∂ndtheengine OilpressuresenderunitonthecYlinderblock．

②油紙涌い柄e o‡re蔓iefva‡veon痛eoi暮∞0ぎer．

（3） （【り （事9） ヰ吊J−3）ヰ5 す す す

With a new packing．installthe oilcoo）eron the CYlinder b10Ck and tighten the oilcoolermount−

（23）

ヰ（Z5）ヰ（−7）ヰ（9）ヰ（−）ヰ（7）サ〈t5〉皐 ・二∴＝∴＝

ingbolts．

一−−Front

雷二

12．lnsta‖ationofwaterpump ①w妄th a new packingfinsモa妻Ithe朋terPumP

ER98

On thecYlinder block and tightenthewaterpump mountingbolts．

Fig111・51TighteningOrdorofCYlinderHBadBolts

Caution： The cylinder head bolts should be

②巨nstaF‡thebypasshoseonthevvaterpump，

栂hモened ∂S fol‡ows：∂t紬st′tighten扇＝おlモS

to the torque of6kg−m andloosen themto the

131［nsta ation of oiJfilter and tappet chamber COVer

①wiモh8neW PaCkin凱insta！馨theo‖fi‡teron 痛e函Ifi‡ter mounting section of the eY＝nder block．

torque of O kg−m．Then tighten again to the torqueofll．5kg−m．

CYlinderheadbolttorque： 6kg−m→Ok針mヰ11．5kg−m

②With n裡PaCkings′insモal‡the oi‡pipe bet

tweentheoilfilterand theoilcooler，andtighten （2）lnsta＝ationofrockerarm itsbothendsuniformly． ①lnsertthepushrodfromthetappetch8mber． ③withanewpackin臥instal＝新etappetcわamber On the cy豪inder b蔓ock anc‡tighてen 抽e鴇PPet

②加商‡モherockerarmshaftassembiyonモhe CYlinderheadandtightentheshaftbracketmount−

ChambercovermountingboJts．

ingboLtsand nuts．

Rockerarmshaftbracketmountingbolt

Tappetchambercovermountingbolttorque ＝2．1kg・m

andnuttorque＝3．1kg・m

14．lnsta‖atjonofcylinderhead

用 量嘲繭摘開扉印加舶㈹郷 ①cle∂n the top oぞthe cy暮inder b！ock and install a cylinder head gasket on the top of the CYlinder block with the 一丁OP

mark on the

て汚．VaivごLie8rミ：lぐe画ItS†：・1Crゝモ ①A！ignモhe markJ′0′′onモhe put暮eydamp即

With the pointer′ and judge by observlng柏e rocker arm which of the No．lor the No．6 Cylinderpistonisatthetopdeadcenter．

gasketup．

Fig・11・52 MarkonPulloyDamp即 −35−

No†t！・川e Nい．1cYli11（jel・11isl川1kご＝t11【さ†oP

Note：lf the adjusting scale mark on the pump

dead center position when the rocker arm at the

COUPting points upward，itindicatethattheNo．1

e）くhaust side of the No．6cYlinder begins to be

cylinder pisron is at the rop dead center on the

PUShed upwhiletherockerarm attheintakeside

COmPreSSionstroke．

begins to be pushed dovvn．The No．6cvlinder ②Tighモen軸einjecモion pump moun加g b油s Pistonis，Ontheotherhand，atthetopdeadcenter alongwiththebracket．

position when the rocker arm al the intake side OftheNo．1cYlinderbeginstobepusheddown． ⑦Proceedw廟￥8lveeie8r窃neadiustmenton

the No．lor6cYlinderwhose pistonisatthetop dead center position on the compression stroke． lnsert a thickness g∂uge（0．4mmJbetween the

lnjectionpumprnountingbolttorque ＝2．1−3．1kg−m

③A暮ignthenotchontheinjecモionpumpbod￥ With the notch on the timer，and tighten the COUPljngbolts．

lnjectionpumpcouplingbolttorque

inIet and exhaust valve rocker arms and the valve

Stem end faceand adjustwith theadjustingscrevv accordingtohardness． Valveclearance（hcoldI

三3．0−3．5kg−m

喀）曇nsta‡‡oilfe感p盲pes beモWeen theinjectぬn PumPand thecylinderblockandtheoilfitterand

AssembIystandard＝0．4mm（bothintakeandtheinjectionpump．

exhaustvalves）

18．lnstallation of cYlinder head cover ard air

・3・11−a両l」Sけ†1日＝†is sl、汀†点（51へ′三相iき1P帖）．1cYl盲il−

der，PrOCeed to the valves marked with circ（es in the table below andif started with the No．6

bre8ther

①Apply engine o盲‡on醸e rocker arm盲n軸e

CyIinder．proceed tothevalvesmarkedwithdoub［eValve contact area，and with an Circles． cvl．No． V8h嶋

②−nst∂一筆書hebreatherhosebe細eなn醸ec∀璽墓nder head coverand theinletmanifold．

1 2 3 4 6 in ￠X in 母X in ￠X in ￠X in ￠X in eX

No．1cy暮．pis− toninTDCon COn「P「￠§〜ion

○ ○

③tnsta‡ltheairbrea翰erand痛母0妄1璽eve‡gauge

○

guidetubingandthenoillevelgauge．

●￣

④払nneet翰ew∂terbypasshoseモOthewater

No．6cvI．pis† toninTDCon COmPr郎Sion

0′′・ringinsta

the cylinder head cover on the cylinder head． TightentheheadcovermountingboltsevenlY．

◎ ◎

◎ ◎

◎ ◎

PUmP・

StrOke in：int8ke valve ex：eXhaust v8lv8

19．InstalIation ofinjection pipe，fuelfi］ter and

④A魚ertighteningthetocknuモS，makesuretねaモ

塗〉憂nsta‡‡納e nozz‡e hoIder盲n free sta略a門8

eachvalvehasthepropervalveclearance．

temporarilytightentheinjectionpipe（airpressure

fual pipe Pipe）． After that，tighten the nozzIe holder

mountingnutsuniformly，

16．lnsta他tionofaircompressor ①with8neWPaCkin9′inst811thea盲「ぢOmPre笈SOr

NozzJehoJdermountjngnuttorque

Onthepumpgearshaftandinsta＝thetiminggear

＝2．1・3．1kg−m

CaSe．

Caution：Wheninstalling the air compressor，be SUre tO align the mark LO′′on the compressor Shaftwiththemark ・′ onthepumpgearshaft． ②lnst∂lIthe o‖毎ed pipe be栖母守門モhe air COmPreSSOrandthecy［inderblock． 17．lnsta‖ationofinje￠tionpipe

①剣如輔附加め銅価り溺吋ぬ叩即納 the pinter so that the No．1cylhlder pistonis ∂t a POSitionofげbe如e瞭柁モOPdea8cent即 Onthecompressionstroke（fueLin5ectionshaft）．

−36−

②Tig机enthein如tion画enozzleho‡derand thepumpsi8esleevenuモStOthespec盲†盲edモOrque．

lnjectionpipesleevenuttorque ＝2．9・3．2kg−m ③ぎns電at‡抽efue豪fi触ontheinl飢汀矧雨ね‡d鴨 ④加拇沼1血∋ 始融・Ofず va‡∀eS On モhe nozz‡e holders．

⑤A熊研・油層感！inge∂eh音uet pipe毛細ed pump−

fiIter，fiIter−injection pump，tank−feed pump， returnl′SeCureWithclips．

20．lnstallationofgeneratorandstartermotor ①Enstal疇 抽僧g即er8tOr mOunting br8CkeモOn

the cYlinder block and temporarilY tighten the adiustingplate． ②‡nsta＝hegenr8tOrgandadjusモモhef∂nb摘 for a correct tension（about15nlm）and then

tightentheadjustingboltl FAN PULLEY

CRANK PULLEY 印】02

Fig．11．53 FanBeltT8nSion ③！nstallthefanonモhegeneraぬrpulley響 ④‡nsモ窃豪富the f憂ywhee‡housing on the st8r如

motor and tighten the starter motor mounting nuts．Atthistime′thebondingcable（forearth− ing）shou［d besecured withtheoutermostmount・

ingnutofthestartermotor．

＿37−

111．5 ぎ札郎NTENANCF‡SERVICE DATA（コN

E6BDlりENGINF

CYlhderbody

Nominal Size

ttem

mm

Unevenwea「：「ePai「

102．20

102

1nnerdia，Of＝ner

Projectionofliner Distorsion on Gylinder body top surf∂Ce

Remarks

St′dmm

OrrePlace

0．03・0．100

Differenceこbelow 0．03mm

beloⅥ10．05 overO．2

g「inde「

Repairwithsurface しe8kage：Repairor

W8樋rpressuretestく3minきkg／cm2

replace．

5

Cylinder head ttem

Nominat Si之e

mm over2．5

RepJaceinsert

1．5

OVer2．5

SeatCUtter

Surface川atness）

belowO，05

overO．2

grinde「

Distorsioninm8nifoldfittinga「e∂

belowO．05 OVerO．4

1．0

Sink of valve Vatves朗tWidth

DistorsiononcYlinderheadbottom

Wat由「短t（3min）kg／cm2

Repair with surface Repair

5

Nominal ltem

S盲ze

mm

Assembly

st′dmm

Repair

Remarks

mm

Clearance

CJear∂nCebetweenpistonandcylin− der（atgradepo＄ition53mmdown

相ai耶tlong di8mete「

fromtopsurface）

0．182・0．200

Outerdia．ofpistonpin

35

34．95 Replace．

Nominal Size

ltem

Remarks mm

mm

toP 「ing

Pistonrlngjointgap （insidegauge）

Repairwithvalve

0．250．45

1．5 Replace

second ring

0，2−0．4

Oit ring

0．2−0．4

St dgaugeinnerdia∴

102mm

−38−

1．5

1．5

Pislon ring Nominat Size AssemblY mm St−dmm

1tem top

‑ Referenee data

SeCOnd ring

8bout13

Oil ring

about12．5

tOP

Tension（kg）

Remarks mm

about14

「ing

PistonrlngJOlntg8P †infreestate）

Repair

「ing

2．15−2−85

1．0

SeCOnd ring

1．43−1．97

Replace

6−8

翳霊響

0．085−0．110

0．20

0．030−0．055

0．15

0．03−0．07

0．15

Oil 「ing

toP 「ing

Clearancebetweenrlng

SeCOhd

9rOOVeandpistonnng inwidthdirection

rlng Oil ring

0．5

ReplacepIStOnrlng

OrPIStOn

叩那暦＝200

Spacingofjointgaps

aPa「t

eonneGting rod Item

Nominal Size

mm

Repalr

Assembly

Remarks

St′dmm

P‡aybetweensm81暮endandpiston bossinfore−and−aftdirection（atone

書

1．5

Side）

C‡e即aneebe輌eenconnectlngrOd

Referencedata

0．030−0．073 0Ve「 0．10

bearingandcrankpin

Replace RepIacebushing

CtearancebetweensmaJJendbush−

†ngandpistonpin

OrPln

Und即Sizeofeonnectingrodbearin9

0，25，0．50

Playbetwe帥COnneCtingro（j8nd

0．17−0．30 0Ver

crank pin in axial direction Tc．rsionofconnectingrod （perlOOmm）

Bendofconnectingrod （perlOOmm）

RepJaceconnectlng 「od．

betowO．05

OVerO．2

Repa什OrrePl8Ce

belowO．05

OVerO．2

Repair or replaee

Crank shaft

Repair

Nominal −暮

Remarks

Siヱe

mm

St

dmm

mm

Repairwithcrank

Outerdi8．Of引ankjourn∂‡

80

OVe「 0．05 78．75 g「inde「or「ept8Ce

Outerdia，Ofcrankpin

64

OVer 0．05 62．75 RepairorrepJace

−39−

Crankshaft Nominal size

ltem

Assembly 0．007

Taper

0．007

Clearancebet

Remarks

St′dmm

E＝pse

Finishingaccu flankjournal

Rep8ir

0．025−0．076 OVer 0．11

andbearing

Undersiヱeofj ing

0．25′0．50

P阜苔Yい†cト州kさhJ†十in声＼盲点両岬C−

0．15・0．33 OVer

tion

Replaαbearing

Replacethrustbear− 隻

Deflectionofcrankshaft CheckfordYnamic

Balanceofcrankshaft（g・Cm）

ltem

Nominal Size

mm

AssemblY

St

dmm

Repai「

Remarks mm

Unevenwearofjournal

betowO．015 OVer 0，05

RepairorrepIace

CJearancebetweenJOurnatand bushing

0．03・0．09 OVer 暮遍

Repairorrepほce

Outerdia．ofjournal

56

55．6 Replacecamshaft

C8mtift

7．71

6．21 Replacecamshaft

Pはyofcamsh油壷門紬re−a閂8−aずモ direction

0．050・0．114 overO．2

Replaee thrusr Plate

Timingg軸r ltem

Nominal Size

Repair

Remarks

mm

Backla‡hoftimingge即

lnterferencebetweencrankgear andcrankshaft 1nterferencebetweencamgear andcamshaft Clearancebetweenidlergearbush− 1ngandshaft Unevenwearofidlergearshaftin diamete「

P‡a∀．0ずid星erge∂rinfがe−and−aずt

0．3 Repta￠egear

0．10−0．17

（innormaldirection）

betowO．025 belowO．021

Replaee bushing or 0．025・0．085 overO．2

overO．1

45

0．058−0．＝5 overO．2

−40−

shaft

Replaee gear shaft ReplaGe thrust Gollar

Nominal Size

1tem

mm

Repair St′dmm

Remarks

mm

9

蔓蔓‡

9

8．85

Valve stem diameter

Replacevalve exhaust

Clearancebetweenvdlve Stemandvalveguide

intake

0．039・0．068 OVerO．2

exhaust

0．064−0．096 OVer 0．25

1nterferencebetweenvatveguide andcyJinderhead

Applyoiltoguide

0．024 1．5

Valveheadthickness（margin）

Replacevalveor VaIveguide

義 Replacevalve

Referencedata Valve spring Nom inal ltem

S盲ze

mm

Assembly St−dmm

Repa汀 Remarks 蔓

OUte「

20

17 44．5mm

inne「

8．6

7．3

Tension（kg† 40．5mm

48

Oute「

Freeheight inner

48．4

46 below

0Uter

Squarenes！

肇・

inner

RoGker arm ltem

Nominal Size mm

Repair A‡Sembly

St†dmm

ValvecIearance（co刷

Rockerarmshaftdiameter

Bothexhaustand intakevatves

0．4

CIearancebetweenrockerarm Shaftandbushing

Remarks

mm

0．01・0，05 OVerO．2 21

Replacebushingor 0「Shaft

20．85 Replace

Bendofpushrod

overO．3

−41−

Reptace

Tappet Nomin∂1 Size

1tem

mm

Ctearancebetweentappetandcylin・

AssembtY

Repair Remarks

St−dmm

0．02・0．054 overO．1

derbodY Tappetdiameter

Replaee tappc?t 27．92 Replacetappet

二路

Oilpump Nominat ▲

Item

mm

Assembly

Repair

は痛座職椚梅癖碕

over3．0

Clearancebetweenpumpcover

bc?law

2．0

訳2000rpm

Replacebushing，gear or pump body Replaca gear or

0．10・0，176

W訓andgearleeth

elttarance bezween pump cover andgearinaxiatdirection Clearancedriveshaftandpump bocIY Clearancebetweendrivenshaftand bushing Outsidediameterofdriveshaft and driven shafl

Remarks

St′dmm

0．05−0．114

COVer

0．035−0．09

betoⅥ／ 15．9 Replac

16

Relief valve Repai「

Nominat Size

Item

Remarks St′d

mm

4．5 Referencedata

sモartpressure抽g〆cm2〉 Oil 8

PUmP

ltem Loosenessofwaterpumpbatlbear− 山g†radialdirection）

Repair

Nominal

Remarks

蔓

0．2 Reptace

草6204V

Ctearancebetweenpumpimpeller andpumpbody

0．3−0．8

Fanbelttension

abut15

Operationstartpressureofthermo−

82

st∂t（0）gaモa電mospheriepressureき

82±2

Malfunction：RepIace

950

Temperatureatwhich fiftamountreaches

￣

10mmo「mo「e

lnterferencebetweenfancenterand 加aringshaft

0．07−0．11

−42−

Water pump Rep∂ir

Nominal Size

ltem

lnterferencebetweenbearingshaft andimpeller ClearancebetweenpulleYandfan

Remarks

0．020−0．060 betowO，14

Center

Rep8i「

Nominat Size

iltem

Remarks Suctionstarts

鮎溺加雨糾明那加パ融紬娠㈹ PUmPOPeratedatarateof60・

Within30up・

100／minリhe∂dニ1m）

and†down motlOnS

Oilfeedingrate（cc．＝pumpseed， 1000rpm；15min；SUCtionhead， 1m；discharge．0．3m）

0Ver300

60 motions 200

Repair or replace

beIow

Repair or replace

lnjectjonpump Repaけ

Nominal

ltem

Remarks

Size

app‖edpress．；1OOkg OittightnessofdetiveryvaJve（sec）

5

10

cm2パimenecessary toか叩b￥5kg／em2

SquarenessofdeJiveryspn

belowO．50

t肇◆

200

125

0毒害モ盲師nessoぞpEunger胱g／cm2）

ね鞘輔edpress∴て00kg／cm2，摘er

5strokes） PJaYOfcamshaftinaxiatdirec−

0−＋0．03

tion ‡n如tionst∂rモ蓋nt即V∂‡抑g‡egO〉

（PumPrOtatingangle）

60

CIearancebetweentappetandpump body

士0．5 0．02−0．07

Dento＝owersp「1ngSeathead

Rep8i「

Adjust or replace shaft or tappet

OVe「

±2

0．2 RepIace

0．2

8acklashbetweencontrolrackand Pin SIiding resistance of control

睾l妄

SPrlngSeat

Reptace PUmPnOtrO拍ting

betow150

rack（g）

tension

彙

Replaee lower

22．3 21．1−23，5

葦要 Reptace（44mm）

50．5

48．5

（kg）

PIungersprIng

菅ree

height

SqUa「e− neSS

49．5−51．5

Replace belowl．00

●

tnjedionnozzle ttem

Oilti9htnessofneedlevalveseat 針印1165kg／cm÷）

Repair Nominat Size

Remarks

Noleakagefromseat

Oiltightnessofneedlevalveshaft area（secJ（initialnozzIepressure： 300kgノCl廿‥柏200k9／‖n予）

Rep18Ce Repl∂Ce．Vis￠OSitY

over5．0

Oflightoit：37・40

sec．at1200c

①visuaI暮YCheckforproperatmi之a・ ln］ectionpatternandcondition

（needlevalveopeningpressure adjuster＝0185kg∵em÷†

tion こむCh（凍†0「・PrOP針川reいionn† injectedfuel

③checkねrun侮rm托yoずinjeごt母d fuelfrome8ChnoヱヱIe

→44−

lfunsatisfactorY′ repねce

11．6 MAJORBOLTTORQUECHART l．Engineanda＝由p8rtS 箪

Torque（kg−mI

Cylinderhead・tighteningboJt（OHapplied）．newboJtsandcyHnderheadused 藍6k9−m→Okg・m→11．5k9−mき

一＝．5

GtowpIu9

2．5

tnjectionthighpressure）pipesIeevenut

2．9−3．2

NozzJeholdertighteningnut

2，1−3．1

Crankbearingcapbo［t（oilappIied）

25−27

1dlegearthrustcoHarmountingboLt

4．3−6．3

CamshaftgeartighteningboIt

12．5・15．5

FJYWheeJtighteningbolt（oilappJied）

21．1・24．5

F輌he轟ousin9モ輌n輌boiモぞoil8PP侮dき

M14 MlO

15−17 2．1−3．1

Connectingrodcapbolt Crank shaft nut

60

TirTlnggearCaSetighteningbolt

2．6

Timinggearcasecovertighteningbolt

2．6

Rockerarmbrackettighteningbolt

3．1

Tappetchambercovertightenin9bott

2.1

CamshaftthTUStPlate

2．1

Oilpumptighteningbolt

5．3

WaterpumptighteningboJt

4．3

Oilpanti9hteningbolt

2．6

Starter tightening bolt

8．6

Jnjectionpumpmountingbolt

2．1−3．1

hjectionpumpcoupJingbolt

3，0−3．5

Other standerd bolts Torque（kg・m）

Nominalsize 4T（softsteeり

7丁仙ardsteel）

9T（5PeCial‡teeり

M 6xl．0

0．4・0．8

0．5・1．0

M 8xl．25

0．8・1．8

1．2・2．3

1．7・3．1

MlOxl．25

2．1−3．5

2．8・4．7

3．8・6．4

M12xl．25

5．0−7．5

6．2・9．3

7．7・11．6

M14xl．5

7．8・11．7

9．5・14．2

11．6・17．4

M16xl．5

10ふ16．0

13．8・20．8

16．3−24．5

M18xl．5

15．4−23．0

19．9−29，9

23．4・35．2

M20xl．5

21．0・31．6

27．5・41．3

32．3−48，5

M22xl．5

25．6−42．2

37．0・55．5

43．3・64．9

M24x2．0

36．6−55．0

43．9−72．5

56ふ84．7

2．BodY ltem

Torque（k9−m）

∈nginemountin9bo軋ねnsi呵ー母arfr∂me一轡函南感画

44

Rad融or汀10untin9bo‡モ，UPPer如diatorgri⊆事−rad如orラ

13

Radiatormountingbolt，lower（radiator−radiatorgr叫

13

Flywheeトto−inputpIatemountingbolt（LOCTITEap川ed）

4．3・4．9

FIYWheelhousing−tO・COnVerterhousingmountin9boIt

4．3・4．9

Note：Theatlowablerangeoftighteningtorqueiswithin±5％．

−46−

2，POWERTRAIN 21．DRIVE UN‡T

2111niSASSEMBLY．！NSPECT10N．ANnREASSFMELYOFTORQUECONVE

∝山＞OU仁山﹂﹂山d≡−

∝＜山口m⊃エ∝山﹂﹂山d≡−

u﹂﹈﹂＜∞﹂一〇

∝＜山じ山＞一正凸d≡⊃d

ト∝Odd⊃SUN一∝＜山岳

UZ一S⊃○エ仁山ト∝﹈＞ZOU

ィ．．．．−．1

Lく山じ山＞一∝□d≡⊃d

Fig121・1TorqueConvBrtOrComponentParts

ー47＿

21．1．1REMOVAL OF TORQUE CONVERTER2．Removalofchargin9PumP ASSEMBLY

When disassembIing the drive unit，Observe thefollowingrequirements： 川丁如閥明圃セd錯n廟か蛸餞涙roftheunitand snlecIilCl（さこI11＼V（1tki11q コl・e；i（oll∂（1心ss111雨）lY

stand）anduseappropriatetooIs． （フ）しIs蔦C飢両o11iほ11nti（＝】；！lnと仰山e一骨−ィi11！jS il■1（1（）ilゝeillsllVlll（！SCl・mVS（〉t●ih ！S郎ratioll・

（31EacIICO汀11）Pnご11【Pal・lis pt−（！（：iselv machi11e（】

in size and finish．Due care should beexercised as not to d8m歳ge軸em by hiモモing喝ainst8aeh other．

l．RemovaIofmainandsteeringpumps Fi9．21．3・†、Re汀−0Ve汁ほこh3■・g竜ngpしJr叩Sし貯再川 tubingnutsaモ納叩umPPOrモe‡bo軋 12、、RelT！OVe t音1（、tし血；1grlutSatthesuc†ionscrccn

ptugdbow．andremo∀e軸esuc如ntubing・ ③Removeモhe勧08h8r9妄ng pump rnounting

bolts and remove the charging pump from the COnVerterhousing． ⑥Remov母theかi∀eSt脚￠触mモhepumpdr墓ve gear・

3．ReIⅥOVa！0！torqlieCq‖Vet・tl汀3SSe1111封Y

Fig．21．2 十 Pしj＝ilパIDCk t；1e−1rive u■−i【0■1a

work bench and remove the four main pump mountingbo‡tsand removethema盲npumpfrom theconverterhousing．

せRen10Vethedrivesieevefrom†hepumpdrive gear・

③Remo￥e輔e短ursteerng pumPmOunting

nuts and remove the steering pump from the PumPadapter．

④Remo∀ethepumpadapterfromthe∞nVert即 housing and remove the dri￥e S‡eeve from the PumPdrivegear．

Fig、21、4・i＼R・：111r）V＝ll（さ星一叩iミSS和hi−1q r−し−is∂l the converterinlet side elbow of the converter housing and8t醸eぢOnVerter POrtelbowoず軸e controLvalve．RemovethebYPaSStubing． ②Remov8軸e−480nV母㌻モer housing moun扇ng

bolts and remove the torque converter assemtby from the transmission case bylightlY taPPingit withasofthammer． −48−

21．1．2 DtSASSEMBLY OF CONVERTER（See（う、Remove†he piston ri11g from［he stator Fig．21．1I

SUPPO「t．

l．Removalofimpせ舶rcover ①cuto汗theth帽e璽ock融resoずtheinputpl8te

5．Rernovalofturbineshaft

①Remove痛eモurbine shがt a暮ong with the

mountingbolts．

O Remove the six input plate mounting bolts bearing from the converter housing bY taPPing

and remove theinput plate from theimpe er eOVer．

③Removethe24impe嚢暮ercovernlOuntingbo血 andremovetheimpeLIercoverfromtheimpe er． ④Remove the snap ring什om納eimpel暮er

COVerand removethepilotbearingoftheturbine Shaft．

theturbineshaftendwithasofthammer．

②Remove the piston ring from軸eモurbine shaft． （卦Rcmove the t＼＼10SnaP rin！」S Of the tL・rhine

shaftand removetheballbearingfromtheturbine Shafiw＝hi＝JreSSOr：llJearingpuller．

6．Removalofpumpdri叩gear 甘Remove the bearirl！JSuPPOrlmount毒ng盲）0皇Is

2．RemovaJofturbineand stator

（j）Removelhcsnaprin‡】fromthet川−hincshafl

from the rear side of the converter housing．and

②Removethesn叩ring如mthestatorsupport

thedrivegearwithapress・

and remove theturbineassemblyfromtheturbine removethedrive9ear，bearingandsuppDrtaSaSet・ shaft．Remove the snap ring from the turbine 且 RemcNClhe snapring fromthe（lrivegearand remove the bearingsupportandthebearingfrom Shaft． andremovethestatorfromthestatorsupport．

（？）Using a press．removc the baH hcai−ing from

③Removethespa亡母rfromthestatorsupport．

thebearingsupport．

3．RemovaIofimpell即

manner asabove．

④Remove∂l‡pump drive gearsin the same

（育三・RerTIOVC theihrce oi＝コafflL！mOUnt壷叩ho11s attheoutsideoftheconverterhousing．

（？；Remove theimtleJiel ，OilbEl‖Ie andimpeller

2l．1．3 CLEANINGANDINSPECT10N

hubgearasasetfromthestatorsuppoT t・ や、Removcthesnapringof［heinlPellprhub；m（J remove theimpelIer hub gear from theimpe er

l．Cleaning

hub．

SOIvent or cleaningoilandleavethem untillubri− Cant and foreign materiaIs sticking to them disL lodgeandthenshakeeachpartsIowIY．

川 Cleaningofgeneralparts ①1mnlし汀Se disこ1SS〔HTll）1ed parLsin cIcaning

嘩）Removetheoi‡baf楠fromtheimpeI‡erhub and removetheoilseaJfromtheoilbaffle．

「う Remove thc snap rinfiFronltheinsideofthe impe erhuband removetheba bearingfromthe

恩Caslirr川PartSShouldbecleul（）dinc！朋nirlq Oilorsteamc（eaner．

impe＝erhub．

Q）When usingweakalka！isoIulionforcIeaninf！，

4．Removalofstatorsuppo

itisrequired to puteach partinatankfiHedwith heated sorvent until enough cleaning and heating

： t．Rcmove Lhc scven st∂Ior sLJPPOrt m仙nting

is assured．Then．taking out the part from the

bo（ts from the transmission case fitting areatank on and rinse with running or ctean waterunti［ theconverterhousing．

鑑、RemovethestaiorsuPPOrl†romtheconverter ho＝Sing・

−49−

alkaticontentisthoroughtYremOVed．

N（）te：ト帖atiilg ‥11ile Snlvc111ta11k w＝ G！！ow

・4 C†1eCk ＝le Pisto11l・i叫l†（汀bl朋kコ即㍉d81¶a！le

watcrlL）eVaPOrこ！1明し！ickly［ilnmneSU雨L：（‥C＞†the

ors馴Z暮ng′andiずuns8tisf8C！ory．reP垂88臥

Partafterrinsing．

⑧‡nst8暮‡thep毒stonringins盲dethesモatorsuP鱒rモ

Caution：When using soIvent base detergent or an8measure紬e50intgapofthepi＄tOnr−ngWほh v（）油川e（】e†e−・ロー汀＝二 SUCllaSl（汀Clen†0■・Cleani■1乱

keepbare粕m母aWay，ぬno電allowthe8離r9ent

a th盲cknes＄g8喝e抑diず軸e g叩−S eXCeSSiv如 Wide．replacethering．

to contact with the skin，and do notinhale the Pistonrin9jointgap VaPOrOfsoIvent．

Standardsize＝0．05−0．30mm

⑥Measurethew盲dthand納盲ckn￠SSOf擁episton rlng With8miGrOm飢即and盲fexcessivなWearis

（2）Cleaningofbearings

紛飯南流融ゆ壷融髄庸ebe8而g盲sずoundタ 妄mmerse翰ebearinginde憮rgentSOlut如and軸en

found，rePIace．

lig輔v−叩i【VJ帽13SO†−llarn−−1e−・n■＝＝血潮1〜l（州：l

Pistonringwidth

tabletoremovecrustedIubricant．

Standardsize＝3．12−3．15mm Usefu＝imit ＝2．80mmorless

②Blow drY air電0輔e bぬ雨感触油日ぬ繭掬 録画雨針圧働か汀登！ntng蓼and a梅rdrying，aPP書y

Pistonringthickness

greasetopre∀en電舶￥澄‡oplng￠誓rusモ・

Standardsize＝2．54−2．79mm Usefu＝imit ＝2．45mmorless

2．lnspe￠tion MeasurIng毒n§trume離：鬱Thicknessgauge ●Sii（iec3！童l油：i●…：1S抽一1血nlⅥeほ！−●Micro・

meter（0−25mm）

（l）Turbineshaft （筆Checkthe p妄iotb￠翁㌻毒閂ginthero＝ngsurf8ee forseほ暮ngOrWear，andifuns∂モisf8eモOrygr叩‡ace・

12Ilmp甜er ①checkモheimpet暮erhubintheo盲暮sea‡conモ8et・

箋ng area如scratchesぞorrned to sueh an extent r雨t†llぐ＝l一号打rila‖c∂…√‥いl三S．抑【！−√し…S∂てis†8C10叩．

replace． ③check theモurbine sh納sp霊ine for d8mageク ②Che洩血st抽rSuPPO托inthepistonl妄ng モOrSion−OrV㈹∂r，andifexcessive，reP‡a8e．Cheek sl盲d妄ng ar◎a fordam8geOrW脚−andifexce＄S暮∀eJ atso fit of the turbine wheet hub spline and the replace．

turbineshaftspIine． ③check the piston油ggroo∀密書or8amageor Se暮Z−n払andi誓unsatisfactory．r叩l8ぢe・篭nstallthe

pis短n r‡喝inモhe ring groove and measure抽e thickness with a thicknessgauge′andifexcessive

lnsidediameterofimpellerinpistonring sliding area Standardsize＝79．38−79．40mm Usefullimit ＝79．60mm ormore

Wearisfound，rePlace． ③㌫heck the妄mpe‡ler hub sp！ine紬rexごeSS蚕ve Pislo−−ri−一日grOOVeWidtho†tu由inesぎI油

d8m8ge一号OrS套0門Or We8r′8nd盲管uns8モ盲sずaetory′

Standardsize＝3．25−3．33mm UsefulIimit ＝3．55mmormore

rep‡aぢe．Ch母Ck a蔓sofiモOf翰e壷mpe11erhubgear

SPlineandthespline． ⑥check the vanes∂nd t幅circumference oず

C）earancebetweenpistonringandringgroove

納e緬pe璽！erずor8am8geOrCraCks′and毒ずumsat盲s−

Standardsize＝0．10・0．21mm Useful＝mit ＝0．75mmormore

factorY，rePJace．

−50−

（3）Turbine

⑤check the pisモOn ringforbre∂k聯′d∂mage

（むCheckモhe turb毒ne hub splineねr excessIve

OrSeizing，andifunsatisfactory．rep［ace，

damage′ tOrSion or wear，andif unsatisfactory，

⑥摘琉滅巨由episモOnringinsideモheimpel自erhub

reptace．Check atsofitoftheturbineshaftsptine and measure the jointgapo†thepiston ringvvith a thickness gauge．1f the joint gapisexcessively ②cheekthevanes∂ndthec…rcumfe榔CeOf鮪e Wide，rePlacethepistonring． turbinefordamageorcracks，andifunsatisfactorY，

andtheturbinehubspline．

replace．

③checkthereve鵬dareaofモhewhee璽∂門d翰e

Pistonrjngjointgap Slandard size＝0．05−0．30mm

hub forlooseness or breakage of the revets，and（》Me∂SUre the width∂nd theth墓cknessof抽e ifunsatisfactorY，rePlace．

Piston ringwithamicrometerandifexcessivewear

isfound，rePlacethepistonring．

t41Stator

Pistonringwidth Standard size＝3．12−3．15mm torsion or wear，andifexcessive，rePLace．Check Usefu＝imit ＝2．80mm or（ess also fitofthestatorsupportspIine and thestator hubspline． Pistonringthickness

（D check 抽e sモator hub spIine for darn8ge．

②ch∝kthev8neSandモhecircumf即enCeOfthe StatOrfordamageor cracks−andifunsatisfactorY，

Standard size＝3．33−3．58mm Useful】imit ＝3．25mm orless

replace． （引 Statorsupport

は）Gears

①checkthesモatorsuPPOrモintheb脚ing書出ing area for seizing or sLip．andif unsatisfactorY．

①check each gearね「＼Ⅳe∂r．d∂m∂geOrmissing

in theteeth andif unsatisfactory．reptace．Check

replacethestatorsupportarongwiththebearing． alsoforcrackswith a magneticfrawdetector．and ②ch妊kthesplineforexcessived8m聯，tOrSion iffound，rePLace． Or Wear，andif unsatisfactory．replace．Check （診Checkモhe盲mpe蔓！er hub9e∂rSP柚e8ndthe

also fitofthestator supportsplineand thestatorPUmP drive gear sp＝ne for damage．torsion or SP＝ne．

Wear，andif excessive，rePlace．Check alsofitof

③check the turbine shaずtin痛e pisモOn ring

theimpeller hubgearspline and theimpellerhub

Sliding area for excessive damage or wear，andif SPline and the pump drive gear spIine and the unsatisfactory，rePlace．

SreeVeSPline．

1nsidediameterofstatorsupportinpiston ringslidingarea

③checkthemPdri∀egearinモhebearlng fittingareaforseizingorslip．andifunsatisfactorY，

Standardsize＝60．33−60．35mm Usefullimit ＝60．55mm or more

repLacethegearaIongwiththebearing．

（7）Converterhousing

④G廃油痛e肉細＝廟

eheck the eonverter housing in rhe pump fitting area and in the baaring fitting area for

．

factorY，rePlace．Insta11a new piston ringin the groove in the stator support and measure zhe

Clearancewithathicknessgauge．tfexcessivewear isfound．replace． Pistonringgroovewidthofstatorsupport Standardsize＝3．23−3．28mm UsefulLimit ＝3．50mm ormore Clearancebetweenpistonringandringgroove Standardsize＝0．08・0．16mm Usefullimit ＝0．65mm ormore

−51一

damage or burrs．andif unsatisfactory，rePlace． BurrsmaYberepairedwithsandpaper．

3．lnsta‖ationofstatorsupport ′1、ノUsi叩Cこ州t血一之ーS！−0−10ぐ1am3ge†he pis†0n

は）8e8rings

①check朗ぢhbearingforar∫d8mageタruSt

n＝山il叩illミ】裾d for proper spi−1．紺d墓f一川Sat−S−

l・i11q（111†加l川・！Ii11eSぎ1細い雨庖Il†hestatorsuppol●t

factorY．rePlace．

on軸eeon㈹rter housingfromthefronts盲8℡Of

②check納eouterand盲nnerperipheriesof輔e

theturbineshaft．

beari咽raCe for se−Z暮ng Or Slip−andiずunsat妄s・ factory，rePlace．

fromthetransmissioncasefittingsurface．

F T軸亜11Lhc sLator SuPPOrt mOu・lti叩ilOLrs

Statorsupportmountingbolttorque

2l．1．4 REASSEMBLYOFCONVERTER

＝8．4kg−m±5％

l．lnstall8tionofpumpdrivegear ①Pressfiモモhebearingonthebearingsuppo軋 ②p陀SSfit輔eb朗ringsupportunti蔓it∽nt藁CtS

＼ぎCoGlてIle口iston ri11g With co−1Vぐ「し（汀（｝ilal−tll

毒nstal葦軸e p蚕ston r暮ngin the statorsupport ring grOOVe・

モhe dri∀e9ear end fac鳶Of the charging pump′

andiミ††∂Cl−こ】S11：ミl一三・i叩i＝＝−1川（‥；l−・印・く）∩∨しさi（〉：ock

4．ReassemblYOfimpeller

thebearinginplace．

r言、、P！・eSS†iてthトト即！一両】（川血さi111世Ile！一血tl訓1〔l insta‡Iasn叩「箋ng毒nthegroo∀ein抽eimp甜餅hub

③l隅繍‖☆憺d由昭砂矧「紬矧血‡y on the con・

verter housing andinstaIlthe bearing support tolockthebearinginpJace． r．1〇Unlミil喜！）O：hl11r叩小雨（lrivく？ge（W・Tighten

（ざ・AIJPIYilthir ｛ iOFPEFIMATEKSNo120n

themtothespecifiedtorque．

the circumference of an oilsealand press fitit

PLlmP血vege即SuP騨）rtnlOUnt両津戚t torque＝4．6kg−m±5％

ontheoi］baffle．

：3・A川IIY＜）Hli！l（：（、ミ！‡｛一f gr（：aSe Onlhelipofan

oilsealandinsta the oilbaffle on theimpe er

④lnstalt the pump dri￥窃gearS On the m8in

hub．

PumP＄id￠andthesteer‡ngPumPS盲8e妄nモわes藁me

⑥i門Sモ8‖抽e竜mpe‖erhubgear

mannerasabove． ．

intheimpellerhubtolockthegearinplace． 2．lnstallationofturbineshaft

（むInstal暮a−snapringintheturbineshaftgroove ∂nd press管妄モモhe bearing unti一 汗contacモS納e SnaP「lng．

③毒nsてa‡暮asnaprnginモheturbinesh油groove

tolockthebearinginplace．

5，tnSta‖ationo†impetler （D coat anew′′Of′−ringwithconvert即Oiland instatlthe 0 −ringin the groovein the circum− ferenceoftheoilbaffle．

②UsingcautぬnasnotモOd∂mageth叩isモOnring on the stator support．installtheimpel）er，Oil ontheconverterhousing，drivingtheturbineshaft ba用eandimpetleFhubgear8＄aSeモOnthestaモOr ③‡nsta暮‡モheturbinesha無血n9Withthebearing

endwith a soft hammer．

SuPIX）rt．

④払aモモhe piston ring withconve徹roiland

③軸弼e 輌＝叩蘭野 郎那 髄融＝涌い輌

insta暮‡抽eか離別＝lnginモhegroove毒ntheturbine

PumPdrivegearモee鮪8門d壷n芳一a‡l軌eimpe暮Ierhub

shaft．

しm相！h巳卜IW小r】【：n！1tこl（：tSl王1（−S叫）Pe〔一口■闇O一山e

stator support byかiv妄n9輔eimpeller hubwith asofthammer．

−52−

⑧lnstaIl軸e oi暮ba矧e on the bottom ofthe

21．1．5 1NSTALLAT10N OF TORQUE CON−

COnVerter housing with one mounting bolt and

VERTER ASSEMBLY

a newsealwasher．

l．lnsta‖ationoftorqueconverterassembIY

⑨Ti9htenでheoilbが刊emountingbo鹿ず和mモhe

①‡nsta暮l翫〟O dowe8pins on the t柑nSmission

transmissionmountingarea．

CaSeandinstallgaskets．

Oilbaff［emountingbolttorque

②A廟モheholes両hecovrterhous盲ngwi抽

＝4．6kg−m±5％

thedowelpins on thetransmission case′and turn the turbine shaft so that the forward／reverse

①Instal】a spacer on翰e stator supporモand

CIutch shaft sp＝ne engages the turbine shaft SPline．

insta‖ the stator on the spline of the stator SuPPOrt．

missioncasebydrivingitwithasofthammer．

6．Insta＝atjonofstatorandturbine

②‡nst811thesnapringinthegrooveinモhestator

SUPPOrttOlockthestator．

③‡楠‡lth母COn∀er即housingonthetrans− ④T廟如entheconverterhousingmounti咽bo蔓ts． ConverterhousingmountingboIttorque

③‡nsモ∂暮‡asnapringinthegrooveintheturbine

＝4．6kg−m±5％

Shaftandinstalltheturbineassembryonthespline Oftheturbineshaft．

⑥‡nsta11apiee￠Ofbypassモubingbetw雛nthe COnVerterhousinginIet side elbowandthecontroI Va［veconverterportelbowand tightenthetubing

④抽醸‡‡8SnaPringinthegrooveintheturbine ShafttoJocktheturbineassernbly．

nuts．

7．1nsta仙tionofimpellercover ①Press fit the pi如be8ring on theim卵暮Ier

2．lnstallationofchalgingpump

COVer andinsta‖a snap ringin thegrooveinthe

①‡nst81lsn8P rings on the盲nsideand outside Of the three drive sleeves，Sixin all．JnstaIlthe

impellercovertolockthebearing． ②Coat8n飢財〃8㌧抽喝＝感曾＝∽脚柁柏餅（l8nd insta the 0′ −ringin the grooveinthecercum−

three drive sleeves on thethree pumpdrivegears intheirsplineareas．

ferenceoftheimpellercover．rnstalJtheimpeller

②‡nst8‖the ch即ging purmp on the con∀ert即

COVer On theimpeller and tighten theimpeL［er housing with a gasket and tighten the mounting COVermOuntingboltsuniformly．

lrnpe

bolts．

ercovernountingbolttorque

Chargingpumpmounthlgbolttorque

＝2．Okgィ¶

＝4．6kg−m±5％

③Drive the dowelpininto輔eimpe暮‡ercover ④Tighten theinput p！atemountingboEtsand

（卦Installapieceofsue血ntubingbeモW令enthe SuCtion screen pIug elbowand thecharging pump

attachlock wirestoIockthe bolts．

POrte［bovv，andtightenthetubingnuts．

andinstaIttheinputptateonthedowetpin．

lnputplatemoLJntingbolttorque 3．1nsta

＝6．2kg・m

ationofmainandsteeringpumps

①触感＝he main pump on the80n∀erter housingwithagasketandtightenthebolts．

Majnpumpmountingbo［ttorque ＝8．4kg−m±5％

②暮nst∂t暮the st脚ing pump adapter on the StUd bolt on the converter housing along with a gasket． ③汗圃ほ‡Ithesteeringpumponthepumpadapモer andtightenthemountingnuts．

SteeringpumprTlOuntingnuttorque ＝6．4kg−m±5％

−53−

21．2 DISASSEMBLYOFTRANSMISSION

Fig．21．5 ClutchGroup8ndOutputShaft

酬54−

The transmissionisone ofthe mostimportant

2．Removalo†pa†kingblake

COmPOnentSinthedriveunit．Whendisassemb＝ng ①Remove the two c良一iper moun如g bo‡モS Oず thedriveunit，disassemblYOfthetorqueconverter the park盲ng brake．Remove the parking br∂ke is attempted at first．However．whendisassembト assemblyfromthebrakecarrier．

ing the transmission onlv．remove the torque （参Removeモhe six moun柚g bolモSO管モhed竜sk COnVerter first（see para．21．1．1l，then proceed Plate and remove the disk plate from the brake WithdisassembLyofthetransmission．

flange．

1．RemovaIoffrontbearingcap

ftange nuts from the output shaft．Remove the

（1）3rdspeedclutchside ①Re汀10Ve軸e†ourbearingc8PmOun血gboits

ring．

③Lock 抽e output shaずt′ ∂nd remove the brake f‡8nge∂lo稲With抽e辞aSherand醸e

Of′−

at the 3rd speed clutch side and remove the

⑧Remov￠鮪eずourbrake00rriermoun柚gbo触

transmissioncasefromthebearingcap．

and remove the brake carrierfromthebearingcap Oftheoutputshaft．

②Removeモhesn8Pringず柑mモhelst／3rdspeed CIutchshaftbearing．

t2I2ndspedclutchside

3．Removalo†−earbea†ingcap

①Removethe山bric8tingoi蔓tubingnuts∂モthe frontbearingcapnippleo†the2ndspeedcIutch．

（l）Outputshaftside

①Loosen thespeedometerdrivengearbushing

and removeitfromtheoutputshaftbearingcap． bearing capetbovvofthereverse cIutch，and then②Rer閏OVe the speedome脚dri∀en gear from （診Removethe‡ubric8tingoi蔓モubi咽nutSaモモ短

removethetubing．

theoutputshaftbearingcap．

③Removetheねurbearingc叩mOun扇ngbolモS

③Remov￠モheずourbe∂ringcapmoun如gbo蔓モS

of the 2nd speed ciutch and remove the bearingOf the output shaft and remove the bearing cap CaPfromthetransmissioncase．

from thetransmissloncase．

④Removeモhe snap rin9ずrom the2nd speed

④Rer閏0￥e電hespeedomeモerdrivegearfromthe

CtutChshaftbearing．

OutPUtShaftalongwiththelockball．

（310utputshaftside

（2き 2nd叩￠8de鰹u電Cねs裏de

①bcktheouモPutSh油and柑mOVethe引ange （D Remove軸ethreebearin9CaP汀10un加gbolts nuts from the output shaft．Remove the com− Of the2nd speed clutch and remove the bearing

Panion fIange atong with the washer and the

CaPfromthetransmissioncase．

0‖−ring．

②RerⅥOVeモhe two piston ringsfromt触2nd

②Removethefourbearingcapmounti喝ぬぬ

SPeedctutchshaft．

Of the output shaft and remove the bearing cap fromthetransmissioncase．

（3IIst5Peeddutchside

③Remo∀e紬e snap由ginモhe front bearing

①Removeモhethreebe8rl咽eaPmOunt盲n9boモモS

grOOVe・

Ofthelstspeedclutchandremovethebearingcap from thetransmissioncase．

−55−

2 Rcmovcih（、Ihl・ee PisTOn［hl（JS［rc、m rhc

′ら Sh州」the fwし川IeV L：iutch assem川y ut）V相＝1

Ist／3rdspeedcIutchshaft．

and remove thelst／3rd speed clutch assembly fromthetransmissioncase．

（4）ReversecIutchside

⑥Rem∀eモhefw紳￠∀荘重此hassemblyヂrom紬

①Rernov母擁ethreebearingcapmoun如gbo‡モS

transmissioncase．

of the reverse clutch and remove the bearing cap fromthetransmissioncase．

8．Removalofbackgear

③Remove 痛e three pis柏n rings from モhe

（むDr妄ve細密backgearshaftfromtheins妄deof

fwd／revcIutchshaft．

the transmission Gase with a soft: hammer to removeittoward the rearsideofthetransmission

③Remove the snap rin9かom the fwd／㌻郡 Clutchshaftbearing．

CaSe．

②Remove抽elock batlbeずore痛e backgear

①RemovethelOcontro蔓∀al㈹m別冊柄沼感触 ②RemVeモhecontroIv由eassemb腑om摘

shaftcomesoutcompletelyfromthecase． ③Remoye抽ebackge∂randthethrustw8納er

from thetransmissioncase． transmission case cover using caution as not to （彰Remo￥e醸e ne感Ie ro‡蔓er be∂r盲ng frorn輔e

‡ose 抽e p‡unger8nd痛e sprin90f醸e safety

backgear．

valve．

5．Removatoftransmissioncasecover ①Removethe28mount墓ng bo触0ず篭heモrans− mlSS10nCaSeCOVer．

⑦＝輔酬＝奴汀阿曲汀奴！tsonthet柑nSmission CaSeCOVer．

③T屏鹿n醸e河曲好ぬ極溌桝感擾那適用澗糾

the transmission case cover onlY from the trans− m盲ssion case，モ∂PP壷ng the抽曲e∀duモCh sh8食・ Donotremovetheshaft．

6．Removatofoutputshaft ①usinga bearingpu蔓‡er′remOVethe盲nnerrace fromtheoutputshaftrearbearing・ ②Remove the output sha無 gearずrom輔e OUtPutShafta10ngWiththespacer・ ③Remove the front sp8Cer計om醸e ouモPuモ Shaft．

⑧Drive醸eouモPuモSh拍子romtherearsi如to

removeittowardthefrontsideofthetransmission CaSe．

7．RemovalofclutchassemblY ①Remo∀e抽e snap ring oず輔els電／3r8speed Clutchshaftbearing．

②Us毒ng∂be8ringput‡er′remOVe軸e納nerrace of輔e r脚bea㌻ing onモhelsモノ3rd speed c！utch Shaft．

③Remove 抽e ge8r 〈3STき ずromモhelsモプ3r8

SPeedcLutchshaft．

④Remoe触2ndspeedclutchassemb輌Om

thetransmissioncase．

−56−

2l．3 DFSASSEMBLY，iNSPE二CTIONAND

REASSEMBしY OF CLUTC＝

GROUPS

21．3．●t［＝SASSEMBしY．ぎ卜！SPEC7−！∩汽！へ卜lロF澤＿ ASSEMBLY OF FORWARD AND RE＿ VERSECLUTCHES l．Dis8SSembly

Note：Theaeモua璽8PPe8柑neeOずtheunitissome＿ What dif如enモfromモhe pictures g押en be‡ow，

Howev餅，thedis∂SSemb璽yproc感ureisthesame． （1IReversec山tch

F岳g．21．8（D using a gear pul‡er．remove the re∀erSeぬモCh hub ge8r and ou官er b矧雨g軌澗 theclutch shaft．

（参Removeモhespacerずror門翰ec暮utchsha軋

F毒g−2瑠・6 Removethesnaprin9ず柑m柏ere8r bearing．

芦毒g轟21．9 Usingabe∂ringpuF！er，rernOVeモheinner be∂ring of the reverse c葦uteh hubgear計om the C［utch shaft．

F羞g・2瑠．7①using∂b脚ingpu暮Ier．removethe rearbearingfromthecIutchshaft．

②Removethesp∝erかomthec璽uモChsh紙

声音g■21義一O Usingascrewdr盲v即7remO∀e翰eend Platesnaprhlgfromtheclutchdrum．

−57−

l−一時∴汀−「！き1n；∵：ごミヾい‡：一県い圧ト一山「−hバ＝抽−、r・恒T・−・トニ

F；ミl．鉦1′ざこトトc■−・…ミ、Vr、晶・一口し長いご…r・盲‥1ile∴・ルとC：1

drum．

disksfromthecIutchdrum．

③り知Ⅵ￠ゆ巨細寧紬澗効a涌琶耶＝飯＝弛攣

dium with a wooden hammer to remove the ぬ鹿恒細面津御厨無感鱒鱒如潤・ （2）FonⅣardclutch

Disassemble theforward clutch usingthesame mannerasforthereversecIutch． 2．lnspection 眺那涌璃凍融南海涙＝机ぬ繭澗ぬ脚洞触 診Th壷eknessg為u9e魯Cyl墓nderg∂喝e魯S毒毒8e

感廟消極庸涌如輝脚聯い緋瓶那加紺即 断蝕摘凋紬紺油断矧酢＝緋酢沼澗融酢膵−25

mm） 11）Cleaning

勘洩∴那．昭 一触頑断面率ぬ＝沼輔er離urnSPring

Referモ0抽esec抽n ∫c妻ean富ngoぞd盲s8SSemb暮感 野鶴が庵明騰Ⅸ抑御触′−forcle8n曇n9PrOCe8ure■

retainer with aiig and remove the snap ring直 納ec‡u電ぢhsh涌groo∀eモhrough紬ehoteinモhej軌

（2）Beari叩

①check the bearing普orwe警r′8ama汎ruSt 駅頭廟廟＝痛感純綿離托画開脚叩紳・宴ず ∴・ミ：ミsr、‥∫い‥・、一．iい一；、い！…・出いい∬1巨：廿−；Si−しし 茎竜一il（−・〜 replace．

③Checkモhe壷nne㌻andou脚Per幅her竜esoず抽e b朗r毒ng for seほ嚢ngOrS蔓盲p′a閂di管un§題号盲sfacモOr￥∫

replace．

㌻FG∴二ご、ご，ニー∴；点こざ．ミ・、．トこ∴・・：：ミざし・．さ こ）：・：i；くさlて：童こ・盲ilご三ミ gra8ua‡⊆y8nd remove醸e spr響ng ret8盲nerandthe returnspringfromthec［utchshaft．

−58−

（4IPistonring

（3）Clutchshaft

①ch∝k抽epist。。rin9如ふreak89e′由m聯

a．Shah

OrSeizing，andifunsatisfactory．replacethepiston・ （診Measureモhe w妄離h and theモh妄ckness ofthe Piston ring，andifexcessivewearisfound，rePlace

①甜融…転地滑津蘭璃＝徹納加′We∂rOr bend，andifunsatisfactory，rePtaCe． ②Cわeck輌c‡uモCh sh∂ずモinthebearingず盲モモ旨ng

area for stip，主eizing or excessive wear．andif

thepistonring．

unsatisfactorY，rePlace the shaft afong with thePistonringwidth bearing．

Standard size＝3．12−3．15mm

③cheek t如shaずt spEi門e f￠＝ors妄0門f dam聯 or wear andif excessive defectis found，rePlace．

Usefullimit ＝2．80mm orless

Check aJso fit of theclutch shaft splinewith the

Pistonringthickness Standard size＝l．60−1．85mm Usefu＝imit ＝1．50mm orless

turbineshaftsp＝ne． ④using8m∂gn離毒e侮wd摘GtO㌢Or侮w8eモeeモー e門g∂ge鴫Checkず0用aw．8n8椚ou門d，reP臣8Ce． ・う′ コ心＼‥、●・・い、、ミ・コー．−！一己Oミ：；−、こゞゞ：・：・：ミ・巨、こ…1eこ・‥く−∴−

CIogging，andifunsatisfactory，C［eanwithvvire・ ⑥eheckthe盲関門erSea毛㌻亘nggrooveandモhepis−

③fnsモalt thepisモOn由gon頼ed勧ibuモOrC叩 and measurethejointgapofthepiston ringwith athicknessgauge．1fthegapistoowide．replace・

ton ring groovein the cIutch shaft for damage， Pistonringjointgap

Standard size＝0．10−0．35mm

WearOrSeizing，andifunsatisfactory，rePlacel

⑦閣easureモわe wi8th ofモ輸inner sea‡㌻ing grooveintheshaft．andifexcessivevvearisfound，t5）Clutchpiston ①Checktheoutersea8ring replacetheshaft． lnnerseaJringgroovewidth

．

factorY，rePlacethepiston． （塾緋e8Suretheouモerse8‡ringgroovewid軋and

Standardsize＝3．25−3．33mm Usefullimit ＝3．55mmormore

ifexcessivewearisfound，rePlace．

Widthofoutersealringgrooveinclutch Piston

Pistonringgroovewidth Standardsize＝3．25−3．33mm

Standard size＝3．33−3．43mm Usefu＝imit ＝3．65mm or more

Usefurlimit ＝3．55mm or more

b．Clutchdrum

（診B雪ow∂irモ0モ摘c‡uモCh p旨sモOn b豪eed v∂‡veto

①check痛e裏門n「ぬm如enceofthedrum Check foroperation oftheva［ve（balり．1fIeakage in the outer seal ring sliding area for damage or Of oilor malfunction of the va［veis found，rePair

Wear，andifexcessivedefectisfound，rePlace．

OrrePIace．

lnsidedjameterofdruminoutersealring sliding area

④checkthec蔓utch p妄stonsplineforwe∂r′and ifunsatisfactorY．rePlace．CheckaIsotheclearance

Standardsize＝149．23・149．28mm Usefu＝imit ＝149．50mm ormore

drumspline．

between the clしJtCh piston spline and the crutch （診Checkモ如毒nnerc毒rcumferenceofthec‡桐油

②cheek輌かum

Pistonintheinnersealringslidingareafordamage Or eXCeSSive wear，andif unsatisfactorY，rePJace

．

Check also the cIearance betweenthecIutchdrum

thectutchpiston．

SP．ine and the outer disk，CIutch piston，and

endplaterespectiveLyintherotationaLdirection．

lnsidediameterofclutchpistonininnerseat ringslidingarea Standardsize＝63，50−63．55mm Usefu＝imit ＝63．75mm ormore

一59−

′2、・Ch（：CkthecIutchhLll】！JCarSPlinefortorsio110r

（6IOuterandinnerseal一山gs

uneven wear．andif excessive defectis found， replace．Check a（so the clearance between the

8．Outer雉alrhg J●t；Check thl）OLJtCr Seall・i叩 丁川・hreakage． rlamagcors（3iz両・，JndifurlStliiゝrLjL：i川Y．・eP！acel

inner disk spIine and the c］utch hub gear spline in therotationaldirection．

（参Measur母the widthand輔ethicknessoモモh￠

Outer Sealring andif excessive wearis found， ③check the cluteh hub gearin班e bearin9

fittingareaforstip，Seizingorexcessivewear，and

replace．

ifunsatisfactory，rePlacetheclutchhubgearalong Withthebearing．

OuterseaJringwidth Standard size＝3．12−3．15mm Usefullimit ＝2．80mmorless

（8）lnnerandoutercIutchdisks

Out即Sealringthicknes5 Standardsize＝5．94mm Usefu‖油日：＝5．60mmorIess

a．1nnerclut亡hdisks

①cheごk軸einner c蔓uteh disks触se蚕z篭ng or 組織繭馴楯狛開抽油滴廊聯短軸鮒細浦叩いぬ ifunsatisfactory，rePlace．

・3 いsとaLltheoし＝rtr里用IrillSjOnlhc（：！utr：h（1rLjm

lnnercIutchdiskthickness Standard size＝2．52−2．67mm

and measurethejointgapwithathicknessgauge． 1fthegapistoowide．replace．

Usefu＝imit ＝2．30mmorless

Outersealringjointgap Standardsize＝0．15−0．35mm

F書く：inpthickness（別1倶血届

Standard size＝0．4mm UsefuLlimit ＝0．25mmorless

b．tnnersealring ①checkth松innersea！ringforbre8k8ge．dam8ge ②checktheinnerだIutchdiskspl套neぬrwear． OrSeizing．andifunsatisfactory．replace・

andifworn，rePlace．

②払旭∂Sure納ewi離わ8nd輔iekne＄SOf抽einner Sealring．andifexcessivewearisfound，rePlace・

b．OutercLutchdisks

①check the out餅Clutch disks盲n the f∂Cing COntaCt area for seizing，andif unsatisfactorY．

lnnersea】ringwidth Standardsize＝3．12−3．15mm Usefullimit ＝2．80mmorLess

replace．

（参Measu㌢eモhe thiぢkness of油e outer cIutch lnn即Sea＝jngthickn朗S Standardsize＝2．69mm−2．95mm

disk，andifexcessivewearisfound，rePlace． OutercLutchdiskthickness Standardsize＝1．76−1．80mm

Usefu＝imit ＝2．60mm orless

Usefullimit ＝1．60mmorless

・3！11Sta‖the汗m＝S心裏ト11F】Oil由c如けき一両沌川

and measurethejointgapwithathicknessgauge．

③ch母Ck軸eouモer8lutehdisksp‡盲neねrw朗r， andifworn，rePlace． ④put軸e ou如C蔓uモ8h disk on a sモ00！and

1fthegapistoowide．rep（acethering． lnnersealringiointgap Standardsize＝0．05・0．30mm

measure the clearance between the outer cIutch

disk and the stooIwith athicknessgauge．1fthe distorsionofthedisksurfaceisexcessive．replace．

（7）CIutchhubgear

①cheek納e cIutch hub伊那樋融hぬ＝鱒鞘 damage，Chipping．cracks or missing．andif

unsatisfactory，rePlace the gear．Aslightdamage mayberepairedbYOilstone．

−60−

ミ9〉iこミe†urr．！・言ンi・…星咽

①check the return spr壷ng forde如mat竜￠nOr breakage，andifunsatisfactory，rePlace．

②Me8Surethe柄e8eng痛ofモhereturnsprin臥 andifexcessivelYdeteriorated，rePlace．

3．ReassemblY （1IReversec山tch 晦署瑠・瑠す①妾nsモ8‡‡翰ereモurnspringandspri咽 retainerontheclutchshaft．

②Ap幽PreSSu〔eOn抽eret8緬w軌apress andinsta11asnapringonthecLutchshaft．

Fig■㌢打ほ①Lubricaモe抽eoutersea彗㌻旨ngw廟 torqueconverteroilandinsta1lonthecIutchpiston．

②Lubric8モe輌re￥erSe C蓋u℃ch壷nner sealring With torqueconverteroilandinsta1lontheclutch Shaft． Fig．21．18lnstalIan outer cLutch disk on the C．UtCh drum．

トご ご1、一持汗藍ムー＝ぐこ巨甘言㌧ 二・i：・し（、．・‥、．・：卜lこ（：山鳥． drum．

e凋uモ蓋0閃＝ Usecau如n∂SnOモモOdam∂gethein閂er

Fig．21．19lnsta

andoutersealrings．

aninner cIutch disk．Then

afternateouterclutchdisksandinnerclutchdisks．

−61−

声量g。2瑠．21油粕胴a甜噸＝雨g紬「he即痛F南髄 ontheclutch drum．

詳姦g−2瑠．2尋①‡nsモ∂竜篭8SnaPringon抽ereverse

cLutchhubgearouterbearingl ②馨りSta＝輔ebearingon輌ぢ箋utc㌫sh班w裾he

SnaPringsideup． Note：ThecIutch shaft pistonringistobeinstat− ‡esduringthereass℡mb章yo音痴etransm盲ssi肌 （2）ForwardcIutch

①Reassemb警e抽e紬rw穏rd cluteh盲n thesame manneraswiththereverseclutch．

②pr密SSず托廟e普orw8rd c蔓uモChhubgearouさer bearingontheご肇uモChshaずモ，8ndinsモalt8SnaPrlng

OnthecIutchshaftto10Ckthebearing． 芦象g．訊腰（む け蛸‡‡a sn叩㌢盲ngontheinneF

bearingoずthereverseclutchhub9ear† ②暮ns電a‖the ．

③辱nsモaら蔓aspaceronthec‡uモehshaft・

−62−

21．3．2 DISASSEMBLY，JNSPECT10NAND RE− ③裏門st8‖輌returnspr盲ngandモhesprigre・

tainerontheclutchshaftandinstaIlasnapringon

ASSEMBLY OFIST AND 3RD SPEED CLUTCHES

the clutch shaft tolock the return spring．apply−

ingpressureontheretainerwithapress．

The reassembly procedure of thelst and3rd SPeed clutchesis thesameaswiththeforwardand

④柚拍沼8椚8刷er c董utch d墓sk on the c‡utch

reverse clutches．This paragraph covers the dis− drum and then aninner clutch disk．Alternate Outerandinnerctutchdisks． assemblyandreassemblyproceduresofthelstand 3rd speed cIutches only．Fortheinspection pro−

Cedure，refer to that of the forward and reverse CtutChes．

⑤‡nsta‖theendp璽aモeonthec妻uモehdrumand insta‖asnapringtolocktheendplate． ⑥尋nst扉‡8SnaPrin90ntheinnerb朗ringofthe

3rd speed clutch hub gear and press fitthe bear− ingontheclutchshaft．

1．DisassemblY （113rdspeedcLutch ①Removethegear〈52TきfromthecIutchshaft，

and using a gear pulfer，remOVe the3rd speed clutch hub gear and its outer bearing from the Clutchshaft．

②usingthes∂ePrOC∝幅removethespacer

andthehubgearinnerbearing． ③withascrewdr盲ver，remOVetheen8p‡摘SnaP

（∋Al盲gn thehubge8rSPl毒newiththeinnerdisk teeth andinsta the3rdspeedhubgearbydriving itwithasofthammer，Wh‖eturningthegear． ⑧貞nstal！8SPaCerOnモhecluモめsha吾andinsモal‡ a snapringontheouter bearing ofthe3rd speed

CJutch hubgear．lnsta［lthe bearingonthecIutch sh∂ft．

⑨lnst∂蓼＝かege8r汚2T）onthecIutchshaft．

ring from the clutch drum and then remove the endplatefromthecfutchdrum．

④AppEvpressureonthereturnsring舶iner 櫛り廟叩矧拍如油

With a press and remove the snap ring from the

Clutch shaft．Then，remOVethe snap ring retainer

andthereturnspringfromtheclutchshaft．

Reassemblethelstspeedcfutchusingthesame PrOCedureaswiththe3rdspeedcIutch．

⑧Remove the outer andinner c蔓u紙h disks

N￠モ◎：Thege8ri38T〉；stobeinstalledduringthe

fromthecJutchdrum．

reassemblyofthetransmission．

⑥Turn over the c‡utch shaft and removethe

CtutCh piston bY taPPing the ctutch drumwitha SOft hammer．

21．3．3 DISASSEMBLY，lNSPECT10N AND RE−

ASSEMBLY OF2ND SPEED CLUTCH

ほ！1st叩坪dc恒†dl

Disassemble thelstspeedclutchusingthesame PrOCedureaswiththe3rdspeedcIutch．

Sincetheinternalpartsofthe2ndspeedcIutch are simiIar to those of thelst and the3rd speed

2．ReassemblY

CIutches，the disassembly，inspection and re− assembly procedures pertain to them．Fordetails， referto thoseoftheforward and reversec（utches．

（1I3rdspeedclutch ①Lubric8te抽e 行脚訂Sea− ringⅥ州翰rque COnVerter O‖andinstallonthecfutch shaft．

②Lubrica樋the ou脚Sea‡㌻in9Wiモh torque COnVerter OiJandinsta‖ on the clutch piston．

Using caution as not to dama9e the sealring， instaIItheclutchpistononthecIutchdrum．

ー63一

1．DisassemblY ①Remo￥eモhモSnaPringfro■Ⅵtheelutch sh摘

④け繭酢瀦牒摘畑如油…臨0汀1翫e七眈抽療 drum and theninsta aninnerclutch disk．Then

frontbear盲ng・u＄壷ngab￠a㌻妄ngpuller∫remOVethe 軌鮒沌矧雨献納澗牒紗醜腐れ油滴

alternateoutercTutchdisksandinnerctutchdisks．

②Remove納e sp∂eerf gearミ2尋Tき量nd spaeer inthatorderfromtheclutchshaft． ③us盲ng8ge8r Pu璽机remove油e2n8speed clutch hub9穏ar andtheou如bearingずrom醸e

tocktheendp］atewithasnapringl ⑥pressf毒tthe2ndspeedc肇utchhubge議rinner

CIutchshaft．

加須弼沼減雨聯．A妻妾gn抽ehubg◎arSP‡妄newith

④u緬那沌矧両川溺軌閥冊則雄espacerand 頗廟吋脚摘佃両脚廟紳闇醐隠ぬ融ゆ融−

sp矧ゴ 沈庇h 奴ぬ那鱒byか廟咽埴冊＝＝が

⑥！nst∂‖theendp嚢窃電eon醸ec暮uモehdrumand

bearingonthectuモGhshaft．

⑦症醸‡‡篭WOSnaPringson軸e2ndspeedc電utch

theinner clutch disk teeth，andinstallthe2nd

r5・Usi！1！！；lSC−・e＼〃（油ミ：：．；−i｝・−1て珊＝…−e Cぎ1くjいl刷上

hammer．

snaprtngfromtheclutchdrum靡 Remoぜe電わ凛e閂8 PlatedromthecLutchdrum・

⑧璽nst8賽Isp8Cer On the c‡uモCh＄h摘and press ぞ毒モ柚援2R8speed cluモCh hubge斎rOuterbea㌻妄門g

⑥App‡∀PreSSureOnthereturnsp雨gre篭る盲ne㌢ wiモhapre鑓，㌻母mO∀援抽esnapr盲ngfromthec‡uモCh

ontheclutchshaft．

⑨馨nsモa‡‡asp∂eerOn翰eelu篭めshがtand盲nstalt

shaft．Then remove the spring retainer and thethegear（24T）． 痛踊川油阻翫㈹軌拍加療油紙． ⑦Rernove抽eouterand壷nnereluモChd盲sks触m

press管it the front b路面闇併＝煽情‡漬油パ雨滴・

thec］utchdrum．

Lockthefrontbearingwithasnapringl

⑧Turnモh￠e璽utch sha無ups蓋8e80Wn′「emO￥e thec篭uモChpisモ￠nbyモapp壷ngthe雨音Gh8rumw篭モh

⑬油滴！輔憺ge8r宅36Tきontherearsid誓0管モhe cIutchshaftandlockthegearwithasnapring・

⑲凍細Il∂SPaCerOn翰eetuモChsha穐andモhe門

asofthammer．

⑨Remove油e§n8PringfromモheGluteh shaft andremove！わege∂r看36Tき誓㌢8閃電わee蔓ut￠hsh納・

2．ReassembtY 2・童．4 …NSI叩し、＝L情主A凧県IFほAドS已三MBLY

①Lubr壷caモe theinner s￠a簑 ring w托h torque

converteroilandinstallonthecIutchshaft．

Oド‥≧−をIANSⅣ盲事SSlnN

②Lubriea電eモhe outer sea‡r壷ng with torque converter oilandinsta‖ on the clutch piston．

21．4．11NSPECT10NANDCLEANING

Using caution as noモモ08ama9eモhe sea要㌻蓋ngタ

l．Cleaning

installthecLutchpistononthecIutchdrum・ C‡eanモhe disassemb篭e（j par鴨re勧㌻抽gモ0翰e ③抽醸‡用削融胴咽涌那加柑那画幅相加w secモ盲0門一きご毛e抑IngOfd妄s∂SSemb‡edparモSOftorque on the cIutch shaft．Pressing the retainer，insta converter ． ∂S閂aPr璽ngOnthecluモehshafモモoho【dthereturn SPrlng・

−64−

2．lnspection

く3IOutplil他nqe

①check醸e eorれPanion and brake f如gesin

Measuringinstrument：●Flawdetectoror fIawdetectingagent●Cy＝ndergauge

the oilseal＝p contact area for wear formed to SuCh an extent that the finger nailcatches．1f

●Micrometer（50−75mm）

unsatisfactory．replace． （1）Bearings

Outerdiameterofoutputflan9einoilseal ①checkthebearin9Sforwear．dam喝e．ruStOr 摘曲喝訂鴇律ぬ離射通陀料 Chipping．andif unsatisfactorY，rePlace．Check Standard size ＝54．93−55．00mnl

also spiningconditiontomakecertaintheYCanbe

②Ch∝kthef暮anges抑nefortorsion．damageor ②Check納einnerandoutercircumf即enCeSOf wear，andif excessive defectis found，reP［ace． the bearing raceforseizin90rSlip，andif unsatis− Checkalsofitoftheflangesplinewiththemating reused．

factory，rePlace．

Shaftspline．

（2）Shaftsandgears

formationordamageandifunsatisfactorY．rePlace．

（謬Checkモhe bolt hoI8Sin the fl8喝e for de−

a．Outputshaft

（むCheck the sh8ftfordistorsion orbend，and （4）Transmissionc85e ①checkthecont8CtSurねcesoモモhetransmission

ifunsatisfactorY，rePlace．

CaSe COVer，COnVerterhousingand bearingcap for

②ch鰐ktheshaftinthebe∂ringfit加gareaずor Chippingor burrs．Check atso thatthereis nooil Slip，Seizing or excessive wear．andif found，re− 暮eakage of pressure oiIafter reassembling．Jf Placetheshaftatongwiththebearing． iき、一Che（：kt…1eSP＝川1fo！・tOi・Sion，（hrnaf！COrWL）ar．

UnSatisfactorY′rePairorreplace．

andif excessjve defectis found，rePlace．Check 「ぎ Che・：k thetransm王ssio‖CaSC訓一d hearirlgCaP in the bearingfitting areaforsIip，Seizingorwear， atso fit ofits spline with the mating gear spline，

andif excessive defectis found，rePlacethecase COmPanion flange spline and brake flange spline aLong with the bearing．tf burrs present at the respectivetY． （ji）Checkthcshilftforf！れl一＼Vi抽ilf；aul雨tecIcl・

bearingfittingarea，rePair．

Or flaw detecting agent．andif unsatisfactorY，③checkthedistributorcapinthepistonrng

Sliding area for damage or wear，andifexcessive

replace．

defectisfound．rep［ace．

b．Backgear5haft Check thebackgear shaftinthebearingsIiding area for excessive wear，andif unsatisfactory， rep（ace．

lnsidediameterofdistributorcapinpiston ringslidingarea St8ndard size＝40．13−40．16mm UsefuHimit ＝40．35mm ormore

C．Gears

①check∂憂さgears for wear，dam8ge，e輌叩i咽

21．4．2 R［ASSEMBLY

Or CraCks on the teeth，andif excessivedefectis l．lnsta

ationofsuctionscreen

found，rePlace．Aslightchippingmayberepaired ①豪nsta＝the oi憂ba用epI摘a＝heboモモomoず byoilstone．

thetransmissioncase．

②checkthegeasp柚efortorsれd8m聯Or ②tnsta＝th∬uCモionscreen Wear，and excessive defectis found，reP［ace．

Check also fit of the gearsplinewith the mating ShaftspIine．

−65−

．

③with a new g8S抽′蓋nsモ8暮l鮪e plug on軸e

③tn醜allthe output shafモSet On醸e柄ns−

transmissioncasetolockthesuctionscreen．

missioncasefromtherearside．

2．lnsta‖ationofclutchassembly

5．lnstallationoftransmissioncasecover ①ロ㌢盲vethedowe廟摘モhetranmSSioncase Press fit the rear bearing onthecIutch shaftand （》璽nsモal璽a§P8CerOn軸efwd如vc‡uモCh sh紙

andinst8‡‡anewgaskeモOn軸eモr∂パsmlSS暮OnCaSe． ②Ai毒g門鮪e80梯etP竜nw盲モh納eho‡e汗＝軌ec8Se cover andinsta the case cover on the trans−

10Ckwithasnapring． ②Eng昭e痛か幡癖鹿戊触漁＝柚須細評庭冊＝加

1st／3rd speedぬt￠h shaftgeる㌻ミ52Tきandinstat‡

missioncasebYtaPPingthecover．

both the fwd／rev andlst／3rd speed clutch as−

③T盲帥モenthemoun加gboほs．

sembliesonthetransmissioncase．

（診P柑SS f盲モモhe柑ar beaF盲nginner㌢aCeOnモhe

Transmissioncasecovermountingbolttorque

2nd speedc蒼ut￡h納a管モ8門8璽0ぢkwith∂SnaPr毒ng徽

＝4．6kg−m±5％

Instal［the 2nd speed cIutch assembly on the transmission case．

④暮nstal蔓thelsモ／3rd spee8e萱uモeh sh8無ge8r （38T）．

⑤pressずit翰e re那bearinginner raceonthe

6．lnsta

ationofcontroJvalve

lst／3rd speed cIutch shaft andlock with a snap ①柏細l肇モhes8触￥∀a‡ve8nd翰espr毒門gOnthe l−i岬．

transmlSS10nCaSeCOVer． （診W毒thag8Sk鴫墓nstalt抽econモro要va‡∀e∂SSem−

blyonthetransmissioncasecover．

3．lns也帖tionofba（：kgear

③¶紳那輌潤舶掛油断欄踊輌ぬぬ

①lnsta＝theneedlero箋‡erbe8ringon醸eb8ek gear・

ControIvaIvemountingbolttorque

②Put醸ebaだkge遜randthe抽usモWaSherin§盲de the transmission case andinsta the back gear

＝4．6kg−m±5％

shaftfromtherearsidebytappingit． ③A暮ignthesha官モ9rOOVeWi輔抽ecasegroo∀ef andinsta theLockbalItokeepthebackgearshaft inposition．

7．lnsta ationofrearbearingcap

（1IReverseclutchside ①拍醸‡‡asnapringon抽e知的evc蓼uモChsh油

4．InstaItationofoutputshaft （診劇邪S翻†he触nt beari咽On醸e ouモPuモ

bearing． （診Lubr盲cate three p盲sモOn ㌢妄門gS Wほh モ即que

shaft．

converter oilandinstallthem on the fwd／rev

②憂nsta箋l軸e璽ongerspaeerタinputsh8fモgearand short spacer on the output shaずt．Pressずiモモhe

c［utch shaft． ③lnsta‡1anew ∫0′ ィ盲ngon抽eo裏書ho露e裏門醸e

rearbearinginnerrace．

rearbearingcap．

雀h矧廊卜軌e扇＝憮施行1抽e佃椚紺廠涙甲αは

COVer With the oilhotein the rear bearing cap andinstalt the rear bearing cap on the trans− missioncasewithagasket．

−66−

⑤Tighモen抽erearbearingc叩mOun柚gbo‡モS。

8．lnsta ationofparkingbrake ①−nsモ∂＝he b柑ke carr毒er￠n鮪ere8rbearing

Rearbearingcapmountingbolttorque

CaP On the output shaft．Tighten the brake

＝4．6kg−m±5％

Carriermountingbotls．

Parkingbrakecarriermountingbolttorque

ミニー ●こ：・ミミPeeて．：・二：；J†J．㍉ナ車：・ ①桝ess fiモモhe rear be∂rin90uモerr∂CeOn痛e

＝8．4kg−m±5％

transmissioncase．

②Lubr盲caモe three pisモOn r盲ngs w傭1加叩e COnVerterOilandinsta＝themonthelst／3rdspeed CIutch shaft．

②壷nst∂‡看官hebr∂kef‡angeontheoutpuモSha吾． ③油紙鮒＝＝闇WV臓腑er抑8′∫0′′−㌻盲ngon抽eout・

PUt Shaft andlocktheshaft．Tightentheoutput Shaftfrangenuts．

③董nsモa‡章there8rbe∂ringcapin抽es8mem∂関門er

Outputshaftflangenut（rear）torque

aswith thereverseclutch side．

＝35−37kg・m

潮パ知摘抑掛血蘭柄励 ①press fiモモhe r朗r b錮「盲ng outer柑CeOn醸e

④Fnsモa‖モhediskp露aモeonthebrake侮nge∂nd tightenthediskplatemountingboLts．

transmission case．

DiskpJatemountingbolttorque

②Lubric8モe餓e摘O P盲sモOn rings w価torque

＝4．6kg−m±5％

COnVerter O‖ andinsta［lthem on the2nd speed C［utchshaft．

⑤−nst8−！抽e parking brake assemb蓄y onモhe

③や甜冊erearbearingcapin触samem8閂neF

brakecarrierandtightenthebrakecalipermount−

asvvith thereverse cIutch side．

ingbo圧s．

（4）Oijlリリこニ：．が・：頭喪

①press fiモモhe rear bearing outer㌢8CeOn翰e

91rnStaI］ationoffrontbearingcap

transmission case．

川Outputshaftside

③喜nsta‡蔓 摘speedometer drive9e8r On the OUtPut Shaft．Align the groovein thedrivegear

tolockthebearing．

①lnst∂‖asnPr壷ng盲nthefron拍earing9rOOVe ②油紙甜∵輌e手相耐be訂妄ng cap on痛eモ「緋S−

VVith the groovein the shaft andinstallthe Lock

missioncasewithagasket． ③Tighモe円the曾ontbearingcapmountingbo眈

balltolockthedrivegear． ③抽蘭は＝・汁e re8r bearing c叩On the trans−

Frontbearingcapmountingbolttorque

missioncasewithagasket．

④T輌ntheearbearingeapmountingぬ蓄電S・

＝4．6kg−m±5％

Coat the outer circumference of the oilsealwith

④ coaモ納ecircum短enceoftheoiisea‡with PERMATECS No．2andiモS＝pwiモh grease and

PERMATECS No．2anditsIip with grease and insta［lthesealontherearbearingcap． ⑤！nsta蔓5the speedometerかiven gear on the

instaJ［thesea（onthefrontbearingcap．

rear bearing cap and tighten the speedometer drivengearbushingtotherearbearingcap．

Shaft．

⑥拍銘甜卜軌e companion f彗ange ontheoutpuモ

−67−

⑧−nsta暮暮thewasheran8anew′ 0

・r毒ngonthe

OutPut Shaft．Lock theoutputshaftand tighten theoutputshaftfIangenuts． Ou†putshaftflangenut（tlOnt）torqut！ ＝35−37kg・m

（2）2ndspeedclutchside ①lnstattasnapringinモhefrontbe忍由ggroove tolockthebearing．

②抽細‡l翰e front bearing e∂P On the trans・

missioncasewithagasket． ③T短htenthefrontbe8r盲ngcapm￠unti喝bo触・ lnsta a piece oflubricatingtubingto the nippte

of the front bearing cap and tighten the tubing nuts．

④抽細Ila pieee of蔓ubricating tubing to廟e

bearing cap elbow at the reverse c［utch side and tightenthetubingnuts．

ほ131d叩eedcIutchside 庄）lnsta暮暮a snap ringon thefronモb朗ringand PreSSずiモモhebearingonモhetr紺Smission8aSeWiモh thesnapringsideout．

暖＝座頭l8SnaPringonthelst／3r8speedc‡u㍑h Shafttolockthefrontbearing． ⑨l−−Sld＝ 抽e†l・0州 ぃく融l咽（一利⊃（）11the t■●卸S−

missioncasewithagasket． ④Ti如enthe計ontbearingc8P汀10untingbo竃モS■

−68−

2l．5 TROUBLESHOOTING GUJDE 10rqueCOnVert

Probtem

Cheeking Wlethod

PossibleCause しowoiltevel

Coolertinedefective

Checkoillevelwithviewgauge CheckcooJantforcont3mi− nation Checkdrainingamountbe− tweentorqueconverterand

Pistonringdefective

tranSmlSS10∩

RemedY Addoiltospecト fiedlevel Ctean

Disassemble and replaceparts

Checkforoilb10W−0†ffrom Disassembteand

SafetYVafvemalfunctionlng Oveトheat一 lngOrtOW OutPut Brokenbearing

Jnsufficientdischargeofcharg− lngPUmP

breather

replacepa「ts

Checkoilpress．attorque COnVerterinlet

Disassemblecon− trol valve and re‑ Placeparts

Checkforelgnmatterinoil drained from transmission

Disassembleand replaceparts

CheckinIinef‖teroroilfor Disassembleand COntaminat10∩

replaceparts

CheckforclogglngOftrans− missionstrainer

Ctean

CheckforoiJpress．attorque COnVerterinlet

RepJacepump

CheckoiJpress．oftrans・ missiondutch

Replacepump

lmproperuse

Recheckusingconditionand Re−readmanual OPeratingprocedure anduseproperJy

Defectivetransmission

Seepara．IITRANSMISSlON

Engineoverheatingorlowoutput Seepar8．′ ∈NGIN［り

Oil leaks frombreath−

Pistonringdefective

Checkforoilblow−Offfrom DisassembIeand replaceparts breather

鎚fetYV古山em8tfunctioning

CheckoiJpress．attorque COnVerterinlet

Checkforelgnmatterinoil

er

drained from transmission

Disassernblecon− troIvalve8nd replaceparts Disassembte∂nd replaceparts

Brokenbea「ing CheckinJinefilterandoil

Disassembleand

forcontamination

replaceparts

rorqueGonverter CheckingMethod

RemedY

Problem

PossibteCau覚

Oil leaks

Defectiveoilsealofoilbaffle

RemovedrainpIugand Check

Repla00Part＄

Defective IO

Removedrainplugand Check

Replacepa「ts

fromflY・

wheel

・rin90foiJbaffJ

CheckforeignmatterinoiI drained from transmission B「okenbearing

NoisY OPeration

Brokengear

Disassembleand 「eptacep8「tS

CheckinJinefoIterandoilfor Disassembleand replacep8rt COntamination Usenoisedetector

Defectivepumpofpumpdrive Usenoisedetector

Disassembie and replacepart Replacepump Retighten pipe

Aeration

Dravvoutsomeoilandcheck

jointso「rept8Ce PartS

Useofimproperoil

Check for quality

Use proper oil

Transmission Problem

CheckingMethod

PossibIeCause Torqueconverteroverheating

RemedY

Seepara．＋JTorqueCon・ verter−−

しowoillevet

1mproperqualitYOfoil 0verheating 0rIowout一

CheckforoilIevelwith

Addoiltospeci−

Viewgauge

fiedtevel

Checkoil

Changeoilwith P「OPe「One

MeasurecIutchoilpress． oftransmission

DisassembJeand Changepa「ts

Measureoilpress．attorque COnVerterOutIet

Cleanoilcooler

Put Lowlevelofc［utchIubeoil

Checkforforei9nmatter inoitdrainedfromtrans− 8rokenbe∂ring

mlSS10∩

Disassemble and Changepart

Checkinlinefilterandoil Low馴吻雨鋸元噸鮎＝y叩澗

CheckforstaIIspeed

−70−

Adjust clngine

Transmission Problem

CheckingMethod

PossibleC8USe

RemedY

Checkwithanoisedetector

B「okenbearing

Checkforforelgnmatterin oildrainedfromtrans− mlSSlOn．

Disassemble or Changeparts

Checkiniinefilteroroil Checkwithanoisedetector Noise is Checkforforeignmatterin

heard BrokengearortooIargebacklash

mtSStOn

Dis∂SSembleor Changeparts

Checkinlinefitteroroil Burnedclutch

Measureollpress．oftrans一 missionc山tch

Disassembleand Changepart

SlippingfwdcIutch

CheckfwdctutchoiIpress． Oftransmission

Disassembteand Changeparts

w∂rdinneutraI

Changeparts

Machine Can−trun forward but runback− Ward Machine Can′tnJn

BurnedrevcILJtCh

DecIutchvalvekeptinoperation CheckdecIutchvalve

S＝ppingrevclutch

CheckrevcIutchoiIpress． oftransmission

backward VVardjnneutral Lowlevelofoil

CheckoilIevelwithviewgauge CheckcIutchoilpress．of

Chargingpumpma［functionLn9

transmission（1cIⅥ／ineach range）

Machine Can−trun Regulatorvalvestickingopen

Torqueconverterinputplate mountingboltsbroken

Certain「∂nge

Disassembleand Changeparts Disassembteand

butrun†or− Ward

Machine Can trunlna

Disassemble and Changeparts

Correspondingrange scIutch Slipplng

CheckcIutchoilpress．of transmission（lowineach range） Actuateloadhandling SYStemandcheckfor

AddoiJtospecト fiedlevel Change charging PumP

Disassemble and Changeparts

Changeparts

OPe「ation CheckcIutchoilpress．of t「anSmlS引On

−71一

Disassembleand Changeparts

21．6 MA！N−l−ENANじESEFIVICE DA■TA Torque￠0巾V即t即

Standardsize（mmI UsefutLimittmm）

Checkingltem

★

99．913−100．000

Outerdiametero＝mpellerinoilsealslidingarea

lnnerdiameterofimpe‖erinpistonringslidingarea

79．38−79．40

79．600rmOre

WidthofpistonrlnggrOOVeinstatorsupport

3．23−3．28

3，500rmOre

Piston ring width

3．12−3．15

2．800rless

Clearancebetweenpistonringandringgroove

0．08−0，16

0．650rmOre

Pistonrin9thickness

3．33−3．58

3．250rless

PisモOnr裏門gjointg叩くwheninsモalleか即油町野梢汀軋ぬ

0．05−0，30

1nnerdiameterofstatorsupportinp†StOnrin9

60．33−60．35

Slidingarea

60．550rmOre

Widthofpistonr■nggrOOVeinturbineshaft

3．25−3．33

3．55

Piston ring width

3、12−3．15

2．800rless

Clearancebetweenpistonringandringgroove

0．10−0．21

0．750rmOre

Thickness of piston ring

2，5412．79

2．450rless

P毒sモOnringjoinモgapくwheninsta】暮edonstaモOrSuPPOrモき

0．05−0．30

Transmission

Checkingltem

Standardsi王e（mm）＋ UsefulLim7t（mm）

wi8…画nr妄nggroo∀einc‡utehshaft

3．25・3．33

3．550rmOre

Pistonringwidth（dutchshaft）

3．12−3．15

2．800rless

CLe∂ranCebetweenpJStOnrlngandringgroove

0，10−0．21

0．750rmOre

Pistonring抽ickness（c璽utchsha柑

1．60−1．85

1．500rless

Noてe：Asterisksmeanthatifthep即t盲swornuneven毒yorhas∂ny管圭∂WモOSuChanextenlthat☆ほぞ盲nger nailcatches．itisrequiredtoreplacewithanewone・ −72−

Transmission Standardsize（mmI UsefuILimittmmI

Checkin91tem Pistonringjoint9aP（wheninsta‖edondistributor

CaP） lnnerdiameterofdistributorcaplnPistonslidin

0．10−0．35 40．13・40．16

40．350rmOre

WidthofoutersealringgrooveincIutchpiston

3．33−3．43

3．650rmOre

OutersealringwidthofcIutchpiston

3．12−3．15

2．800r‡ess

Clearancebetweenclutchpistonoutersealring and ring grooVe

0、18−0．31

0．850rmOre

CIutchpistonoutersealringthickness

5、69−5．94

5．600rless

ClutchpistonoutersealringlOintgap

0．15・0．35

area

lnnerdiameterofc山tchdruminouterseal

149．23−149．28

149．500rmOre

Widthofinnersea†ringgrooveinctutchshaft

3．25−3．33

3．550rmOre

Lnnersealringvvidthofclutchsha†t

3．12−3．15

2．800rless

0．10・0．21

0．750rmOre

Ctutchshaftinnersealrlngthickness

2．69・2．95

2．600rless

CIutchshaftinnerseaIrlngJOlntgaP

0、05−0．30

1nnerdiameterofcIutchpistonininnerseaLrtng 輔dinga「ea

63．50・63．55

63．750rmOre

tnnercIutchdiskthickness

2．52−2．67

2．300r‡ess

0．40

0．250rless

1．76−1．80

1．600r卓ess

ring sliding area

ClearancebetweencIutchshaftinnersea川ngand rlngg「00Ve

Jnnerdutchdiskfacingthickness OutercJutchdiskthickness Outerdiameterofoutputshaftcompanionflangein Oilsealslidnga「ea

53．93−54．03

Outerdiameterofoutputsha†tbrake†lan9einoil seal sliding area

53．93−54．03

瀞 碁

Others

CheckingJtem

Standardsize（mm） Usefulしimit（mm）

Torqueconverterou鵬tporてPreSSureくkg／cm2き Transmissionclutchpressure（kg／cm2〉

3．1

OVer3．6． betow2．6

16．9−19．7

16．90rle〜S

Note：AsterisksmeanthatifthepartiswornuneventYOrhasanYftawtosuchanextentthatthefinger nailcatches．itisrequiredtoreplacewith anewone．

−73−

2l．7 MAJOR BOLTTORQUE CHART

ttem

Torque（kg−m）

Pumpdrivegearsupportmountingbolt

4．6

Stator＄UPPOrtmOuntingboIt

8，4

Oi＝）afflemountingbolt

4．6

（mpeltercovermountingbo！t

2．0

Chargingpumpmountlngbolt

4．6

SteerlngPUmPmOUntingstudnut

6．4

Mainpumpmountin9bolt

8．4

Di‡kpEatemountingboJ

4．6

Outputshaftbea「ingcapmountingbolt

4，6

Companionflangelocknut

35−37

Parkingbrakecarriermountingbolt

8．4

Br∂kefI∂ngeIocknリー

35−37

TransmiiSioncasecovermountingbolt

4．6

CIutchshaftbearlngCaPmOUntingbo［t

4，6

ControIvalvemountlngbolt

軋6

lnput plare mounting bolt

藻

Converterhousingmountlngbolt

4，6

Note：Theal10WabIerangeoftighteningtorqueiswithin±5？ム．

−74−

ごき．●〜i．亡、き毒も．．ミこ：§F言草：ニ己．5LA■モ、一事（七弼仁！門（TU！1Ⅰ− 22．11NSPECTLON OF OIL CIRCULA− 22．1．2 INSPECT］ON OF STALL SPEED AND

T10N CIRCUIT

RELIEFSPEED

22．1．1PRECAUT10NIN［NSPECT10N

l．Measuringmethod Measuringinstrument：●Oilpressuregauge

Before attempting to proceed withinspection． Checkthefollowingrequirements．

electrictachograph ●Thermisterthermo−

（1qkg／cm2）◎Hus鵬rtachographorPho随一 me電er￠rrOd−Shaped鮪ermom飢er（1500c）

1．Checkingoiltemperature Check whether the oiltemperatureis between

川 Lowidlingspeed ①check油e d＝酌頑拍∵軌かか勧＝澗托抄㌢紬 rミミ・− ご．−：．三．も．「：ハ・∴・い∴、：1・；1卜．・…い・．‡；1√ニ：・ミニ：ゞ、． thetemperatureofoilusingthefo

owingmanner． ViewgaugeandifleveIislow，addoil．

②Ke叩モheoi‡temperaモureofthedriveuni官員モ ∴いr・ミミご∴．・i…1山一−S…こ・……：ミ…・jミ、：10コ：・叩hⅣ膏−e叩い〇 ③sta代抽e℡ng盲ne a門8check抽en伊董oadm盲ni−

Procedureforincreasjngoiltemperature Travelthe machine or place the machinein

mum speed of the engint? with the accelerator PedaInotpressed．

Sta‖stateandusethefollovvingprocedure．

∴、・こ：、・・．萱？：…、こ√卜こ…・…ミミ・；1ぐ室、：：；・：、′＝：∴・？：；・；∴‥トlロ…：手 SeCUrelY．

④when輔ere8di喝盲souモ0ぞtherangeoず600

三・ミ：・、！i！：、1ご−∴い：室・；．・；「し．∵．．・、、：ミ．㍗ 喜∴．㌧・＼吋・！；こ；

to700rpm，Check to seeifthepeda［rodcontacts

andthespeedchangeleverin3rdspeedposition．

the floor board or the governor controlleveris inthelowidlingposition．

③‡nerease engine spee8to abouモ瑠500rpm andpLacethetorqueconverterinstalLstate．

Note：The［owidling position of the governor

Caution： Do not continue the sta［lstate for morethan30secondsatatime．

co醐0嚢Iever壷s∂ta POS墓モio門190モiIt感ぞ㌢Omthe Verticallinetoward thefan side．

⑤憂ず鮪eco醐0‡‡eveposi血isimprop即∫

④Repeaモ油壷s procedu帽untie抽eo＝empe㌻8−

remove the axle rod clevisyokefrom the controI

turereachesabout70Oc．

IeverandtightenorloosentheclevisYOkedepend・ ingupontheconditionoftheleverforadjustment．

2．OjlIevelinspectionofdriveunit Run the engine atid＝ng speed（600to 700 いよ．．1〉†こ；：・：バ、：∴こ・．≡！・r・：‥〜．・．や∴・㌃l・トさ．，二、一宇ニー・十．

郁 卜堀摘猟隙聯感

Cheek the oil level by observing the view gauge①check the oi＝即et and temper紬re毒n翰e Same VVaY aS above．Installa tachograph on the

∴ ニ・、ご・：1ミ ：？ぎミ・；−・い●ご：；、・い．・；−し −：−−こ．ご．：・ごて汀…ご、1；；「 UnSatisfactory，addconverteroil．

en馴ne．

②pressモhe∂CCe月er∂tOr Pe蛮勇to劇恒仁毎‖u酢蛸

itcontactsthestopperandkeepingthiscondition， 3．Oilleakinspection Checktheno−Ioadmaximumspeedoftheengine． Run the engine for a while to make certain that there occurs no oilleak from the charging ③when廟ereadingisnoモW肋intherangeof PumP，drive unit．oilcooler，OiJfilter．or piping 謡300モ02400rpm，Check wheモher納egovernor COntrOlleverisfしJ YOPenedornot．

and joints，and retighten vvhere necessary and replacepartifneeded．

−75−

Note：The highid＝ng position of the governor controE蔓everis窃鱒Siぬnabou電50登竜墾モedず㌻Om軸e

Vertica川netowardtheflywheelside． 喀＝揉扇庵∴馴鹿藤 一ever pos音容onisimpr叩erタ tighten or［00Sen the stopperboltoftheacceJer−

atorpedalforproperadjustment．

Clogged exhaust systemem ●lnjectionpumpornozzledefective ●lncorrectlyadjustedfuelsystem ● Lowcompression pressure ● Machine operated at a higher altitude than SPeCified

ln genera［，a（ow staIIspeedisderived from a ほ）Stattandreliefspeed defective engine．Beforeattemptingtocheck the ①舟触用融輌用紙由廟漁価拍噛細雨珊 torque converter and transmission circuits and aproperhighid＝ngspeed，Checkthesta［lspeed． hYdr∂uIic circuit，inspect the engine for any ②usingthe＄amem抑ne㌢aS如椚eaSu㌻蓄ngh毒gh defect． idling speed，Check theoiltemperatureandlevel，

andinstallatachographontheengine． 1き：長州・：ロ＼・ぐ−；！C、・ざ…、：、．ミ、！・・、！ミ；・ト、上：lこ吉；こ！・ソいJ∴こ．、 tubing eIbow oftheconverterhousingandinsta

anoilpressuregaugetocheckthetorqueconverter h】etojlpressure．

t2IHighst州speed Possiblecauses：

● Transmissionctutchslipping ● Cavitationoftorqueconverter

frameandthe rearframe．

ln general，a high stallspeedis derived from a defective torque converter or transmission

⑧阿ぬ摘肘曲紺油川紳輔摘淵血醸紺掴閤

Circuit．

POSition and the speed controIleverin the3rd SPeed position．Start the engine and press the brake pedalto the fulItoIock atlthe wheels

22．2 JNSPECT10N OF HYDRAULIC PRESSURE

唾）伽閻紺＝摘烏旅糎＝涌溌敵購緋粛鳩紬狛

COmP（ete（Y． 、さト＝こ、ゝ、；汗・、・・バ し…5；し−・；一卜∴！†・ニ・T…こど．；！：毒！：．：1十さ萱

it contaGts the stopper se that engine speed is raised to maximum．Check the engine speed at

22．2．11NSPECT10NOFTORQUECONVERTER Measuringinstrument：●Oilpressure（10kg／ cm2）⑳Therm盲ster鮪ermome電e㌢0管㌻感一

Whichthetorqueconvertersta s．（stallspeed）

＄hape8thermometer竜1500c）◎‖us鵬r

Caution：Do not allow the torque converter to

tachographorPhotoelectrictachograph

bein sta‖condition for more than30seconds at

a time with the engine at fuIlthrottle．since an OVerheatedtorqueconverterwillresult．

l．Torqueconverterinletoilpres5ur8

⑦place油ebucket‡￠脚盲nモhero！沌ぬ机淵踊酬 and press the accelerator peda．to thefu＝toget a fu

throttle．Relieve themaincontroIvalveand

Check the engine speed at which the torque COnVerterStaIIs（stal［＆reliefspeeds）

2．Judgementofresultsofsta‖speedtest （1）Lowst州speモd Possiblecauses：

卜iミ；．よ∴1 ミ ∴：ミSiこ1＼こ・・・ト；・￣料」：二．1．＝l「1こ：V01；1r、 P［ug（1／8r PT）from the bypass tubing elbowat the converter housing andinsta‖an oilpressure 、・こ！・；ミ≡eミミミ、5：、ミ‥・川−ミ．

Ciogged air Glaanerer Defective acGelerator linkagege ● Contaminated fuelf‖ter

−76−

馳

②p蓼ace鮪ed盲rectわncontrol‡ever妄nモhene洪ra‡

POSition and check that the torque converter oil 電emperaモureis聯査翰in抽erangeof75to850c． ③sモart輌en9ine ．

id8ingspee8，Cbeckモheoi‡pressure8モモhetorque COnVerterinletport． Torqueconverterinletpor（OiLpressure

＝4．7−6．7kg／cm2 2・Torqueconverteroutletoilpressure

声音g．22．3②p璽acethespee8c￠nモro‡豪鮒erinthe lstspee8pos盲如nandcheckモhaモモheo盲lモempera一 号ure妄sw妄油in翰erangeof75to850c． ③st8rモモheen9妄neandkeepitaモid暮套n9rP軋 ④p蔓∂Ce the8套rec扇on con甘0貞一ever毒n食ゎefor−

Ward position and check thelength of time re− quired for the moduIation valve to operate from beginningtoend．

ModulationvaIveoperatingtime＝l．1−1．5sec

⑤check a‡so the cきutch oi‡pressurea触Fthe modulationis finished to seeifitis within the Stand∂rdpressurerange．

賢妻g．22．2①Remove納ea8∂錘rp‡ugく7／8ダーPTき fiモモedモ0鮪econ∀e托er hous旨ng and8モモachanoi蔓

pres§uregaugeflOkg／cm2）． ②ptace抽ed毒rectぬnco醸Og妻everin醸eneuモrat

Transmissioncl山Choilpressure

Sモandardpressure＝隠3−18．Ok9∠cm2

POSition and check that the torque converter oil

⑥糸ctu8モe thespeedcontro‡蔓everin thes∂me

PreSSu㌢eisw酬nモherangeof75モ0850c． ③usingモhe same m∂nner8Sぬrcheck査ngthe inlet pressure．check theoutIetoilpressureofthe

mannerandchecktheclutchoilpressureswiththe

torqueconverter．

ranges．Make surethatthedifferencebetweenthe readingsiswithinthestandardvalue．

Torqueconverteroutletoilpressure

＝2，6−3．6kg／cm2

始ve㌻ 妄n鮪eず0杓Vard2nd spee（j抑d3rd spe∝5

Pressuredifferencebetweentransmission Clutch

Standardvalue＝0．4kg／cm20r‡ess

22．2．21NSPECTlONOF TRANSMISS10N

Measuringinstrument‥●Oilpressuregauge （25kg／cm2〉◎SモOPWaモCh⑳Thermisモer

2．Reverseclutchoilpressure

thermomerer or rod‑shaped thermometer

Using納e same manner as for checking the

f1500c〉◎削s鵬rtachographorPわ0モ0−

f研形ard clutch oi‡pressure，PtaCe the cEirec血n

electrictachograph

COntrOJleverin the reverse positionandcheckthe 仁一uモCh o妄璽pres会uresfr￠m鮪elstthru3rd speed

l．ForwardcIutchoilpressure

ranges and thelength of time required for the

①Remov針軌＝血喝‖躇〃椚1訳譲渡油頭幼扇 PreSSure Check port，aS Shownin the Fig．22．3， a門daモモachanoi‡pressuregague（25k9／cm2き．

−77−

OPerationofthemodulation valve．

3．Judgement of results of clutch oiIpressure in申∝tion

（1）LowcILJtChoilpressureataIIspeedranges （thclll・eSSUr（！differencc betwee11eaCilC）utch

isO．ヰkg烏nlニor−ess・） ● Lowoillevel

● Suctionlhle）eakingorclogged ● Chdrqingpumt）WO‖lOrbrokcn（insuffi（：ic‖tdis−

Charge） ● Pr（！SSure r柑ulator valve（11汗ective（sprinq

brokenorspooIsticking） （2）しowclutchoi！pressureatacertainclutch （at10WSPeedrangectutch）

● Oilleaksfromclutchdrumshaftsealingring ● C＝tchIlisto11ri叩WOrn nr！っrok町バ汀柚血 Valvestickingopen Control valve defecriveve

−78−

23．DRNEAXLES（FRONTANDREAR） 23．1DFSASSEMBしY．

［NSPECTION

AND REASSEMBLY OF AXLE HOUSING

りN−∽⊃○ ∝く山ロ

F画．23．1Construction ofAxl8

t79−

23．l．1D［SASSEMBLY（seeFi9，2：字，1）

23．1．21NSPECT10N

Before attempting to overhau［or repair the axle．thorougMy clean the exterior of the unit to preventtheentranceofforeignmaterialordust tothe mechanism．1tisagoodpracticetoputthe disassembled partsintheorferfortheconvenience OfreassemblY．

Measuringinstrument：●Flawdetectoror flaw detecting aIlent l．Axteshaft

①checktheax‡母Sha魚fordisモOrSionorb帥d， andifunsatisfactory，rePlace． ②che洩モhe sh油splineぬr tors廊，damage Or Wear，andif excessive defectis found，re・

1．Removaloffina［reductiongearandbrake

PIacetheshaft．CheckaJsofitoftheshaftspline

し亨′恥…110V已Ille山・3i11叶咽（一千＝1ebrakく】ll（）…ii叩

Withthesidegearsp＝neandthesungearspline． ③usingaflawd離ectororぞa‡wd離ee如g8g帥tぎ Checkforflaw，andiffound，rePlacetheshaft．

to thoroughlydrainoffoi］fromthegearhousing andbrakehousing．

②Loos翻thebrakef暮uidtubingnutsat抽ebr8ke

housing nipple and remove the tubing from the 2．Axlehousing． ①check the ax【e housing for deわrma需on or CraCks，andif excessive defectis found，rePlace the brake housing to ensure correct reassemblythehousing．Aslightdefectmayberepaired． brakehousing．

③puモmarkson翰母aXtehousingen（羞恥ngeand

andremovethe16brakehousingmountingbolts．

②check the brake hou富豪n9inthef妄モモ盲ngare童

⑥Remove the fin8‡reductぬn9母ar∂n8brake

Or differentialcarrier fitting area for burrs，and

assemblyfromtheaxlehousing．

iffound，rePair．

⑥Remo∀eモheax暮eshaftfrol耶the8Xlehous盲ng徽

⑧Remove the柚a璽reduc軸n gear and brake 23．1．3 REASSEMBLY

assembly attheoppositesideinthesamemanner．

l．lnsta＝ationofdifIerentialcarrier 2．Removalofdifferenti8lcarrier

（Dcoaモモhe dげferentia‡c∂rr如fit加g surface

（むRemoveモhedrainplug管romtheaxlehousi閂g

With LOCTtTE No．504uniformly． ②董nsta‡箋鮪ed妄f管erenモia暮carr如assemb暮yon鮪e

todrainoffoilfromtheaxlehousing． ②Remo∀ethe＝dif如entia暮carriermoun扇ng bolts．

③Remove モhe three d蔓ず短ent盲a！mounting nuts and remove the three dowels drom the stud bolts．

④＝ぬ＝摘d酢潤痛離ふ醸＝表面由協冊

axlehousing．

③‡nsモa‡】納e如ee stud boE恕On the dowe！s

andlocate the differentialcarrier by Light［Y tighteningthe nutsevenly． ④T璽ghtenモhemountingbo‡モSO管翰ediずずerenモia‡ Carrler．

Chainsandremoveitfromtheaxlehousing．

DjfferentjalcarrierrTmuntingboltandnut torque＝6．5kg−m±5％

⑤Attach a snap ringinモheax暮eshaデモ9rO8Ve andinsert theaxleshaftin the axlehousingwith

the snap ring side out．Engage the shaft spline Withthesidegearsplinecorrectly，tUrningit．

ー80−

2．lnstalJatjon of finat reduction gear and brake as5emblY

①抽醸侶＝脚けW頒料摘抽鋸卿帥油＝e brakehousing．

②A‡ign軌emaモCh m∂洩onthebrakehous盲ng With the mark ontheaxle housingendflangeand instaL［thefinalreduction gearandbrakeassembIy Ontheaxlehousing．

③Lubriぢate電he brakehous盲ngmount盲ngbo妻電S With LOCTITENo．262andtightenthem．

BrakehousingmountingboLttorque ＝21kg−m±5％

声量鬱。23．3①putmarkonthed汗ferenti∂蔓carr妄er andthecarriercaptoinsurecorrectreassembly．

④lnsta‡i意Piece of brake o盲∃琶ubin90n軌e brakehousing． ⑤Enst∂‡lモheo☆帽rSideぞina象F感ucモ盲on∂ndbrake assemlbyinthesamemanner．

（診Removethe‡ock andc8Pbolts管romthead−

justing nuts and remove the carriercapfrom the differentialcarriel・．

23．2 DESASSヒM削Y，‡NSPE（ごミ￣篭く）NAND

REASSEMBLYOF DIFFERENTJAL 23．2．1DISASSEMBLY Note：The actualappearance of YOur unitis SOmeWhatdifferentfromthepicturesgivenbelow，

butthedisassemb］ingprocedureisthesame．

F毒9．23．4①蓼nserモabarモhrou9hthedifずerent盲a‡ and＝ft thedifferentialvvith hoistchains．Remove

the adjusting nuts and the bearing cups at both Side．

②Removeモhedif勧en鵬Ifrom翰ecarr如．

Fig．23．2 Lockthedifferentialonastablestand

and set a dialgauge on the ringgear．Check the backLashoftheringgear． F墓守嘉23■5①Remove thefEangenuモ ，

②us妄ng a ge∂r Pu巨竜er，remO∀e幼e companion flangefromthedrivepinion．

−81−

ing bolts，and take off the oilsealretainerfrom Fi9．23．8 Dismount the drive pinion，bearing thebearingcage． Cage．andpilotbearingfromthedifferentialcarrier inassemblv．

Fミg、23．ミミ、1ぎ）川1l・！−r：ロし⊆ぎ1t（ドn−∂直し−…・11篭1（：r廟1日ミコ OfdifferentialcaseandplainhaIfcase．

②Tighten軸epu‡‡即bo‡モSe∀母nty′anddrawout

thebearingcagefromdifferentialcarrier．

②翫潤郡針鮪折柄瞑油壷打触椰割線感服紺紳ぬ ③Atthisモ盲me，ino雨erモOP㌻e￥ent細密shimof bearing cag＝血…油増加咽絶滅榔輔憺 瑞新曲中鱒⑯痢酢晦やか攣攣攣抽

heill・ii−g Cageis s＝由！童∨；氾＝J、10こ！いく、r−Sし‥■＝i−、、rheF加印、i…こ−＝川棚・ PuHer bolts．andinsert a patch plate beneath the PUller boIts，and tighten the pu er boLts again，

thenremovethebearingcase． Caution： Tighten the puller boIts uniformly．

Otherwisedifferentialcarrier，drivepinionshaftor bearingmaybedamaged．

声量g．23．瑠O T∂keoぞ管翰eモhrusモW竃Sh療rfS套degear，

SPiderandpiniongearfromthef［angehaLfcase．

−82−

F毒g．23．瑠瑠 G）when removingモhe ring ge∂r．

Fig．23．14 When replacing the pilog bearing，re−

apply pressure on the flange half case to fixit， remove12nuts of ring gear mounting bolts．and

movethe flange partfromtheendofdrivepinion， and detaeh from the drive pinion by means of a

detachtheringgearfromtheflangehaIfcase．

PreSS．

（診When rep葺ac妄ngモhebearing，remOVethebear− ingconebyusingbearingpuller．

Fig．23．15 When rep［acing the outer bearing or

inner bearing，remOVe the bearing cup from the Fjg．23．12 Push the shaft end ofdrive pinionby bearingcagebyusingdriftpinorthelike． using a press，and dismount thedrive pinionfrom bearingcase． 23．2．21NSPECT10N l．Cle8ning Clearlthe disassembled parts according to the

Cleaning procedure of torque converter parts （21．1．3）

2．lnspectionofdrivepinion ①check油層drive pinionず即8eforma需on of ShaftortwistofspIine．Replaceifdefective． ②check the sp董ine 杵陀ing w柚 companion flange．ReplaceifabnormalIywornand暮00Sened．

Fig．23．13 Using a press．detach theinner bear−

ingconefromthedrivepinion．

ー83−

3．1nspectionofringgear ①check紬e r裏門9gear勧モ0￠thsuげaeewear，

②Fitfourp墓円加ge∂rSand管our☆汀uSモWaShers tothespider．andputthemonflangehatfcase．

CraCk．cutorotherdefects．Replaceifdefective．

③using8mOun加9jigasshown毒nF盲g．23義16 0rSPaCerand boLt．fasten thespiderto thefIange

②R叩Iaceif bo‡モho‡eisdefo㌻me8雲脚斎den母乳

Caution：Whenreplacingringgearordrivepinion， halfcase．

repIacetheminassembIy． 4．1nsp∝tionofbe8ring ①㌫heektheb朗ringforwe8r，ずさaw，ぬ鴫甜磯料 defect，Or heavy rotation to judgeifitis usabIe．

Replace defectivi ②瑠細密塞

ing raceinside and out．and

repIaceifseizureorslippin9isfound． Caution：When replacing the cone or cup of

bearing．replacetheminassembly．

5．lnspectionofpiniongearandsidegear ミlき 八神とこ1；一利lニュl：

（Dcheck電わeモ00鮪sur官aceず餅Wear′C㌢肛k．cuモ

声名g。23．瑠7④Asshow門i門油esketchfSeモthedial

OrOtherdefects．Replaceifdefective． ②che夜モhe翻ustwashe㌢．R叩Iaceif worn

gaugetotheouterendoftoothprofile． ⑨円x萬場Sぬe卵馴．Turn触p細盲ongearright

excessivelY，OrSeized．

andIeft，and measure the backlash between side gearandpiniongear．

（2）Backlash

Backlashbetweensidegoar8ndpi山ongear Standard size＝0．15toO．25mm

Measuringinstrument：●Dialgauge PINlON GEAR

⑥暮ず電heback‡ashisexcessive．㌻eP蔓aeeモhe納rusモ

F［TT［NGJIG

W∂Sher．

⑦嚢普モhe bac摘shis st＝largeⅥ／hen伽us電 WaSherisreplaced，rePLacethesidegearandpinion ge∂r．

⑧さn鮪esameprocedure∂SOnthef如geh∂け CaSe Side，Check the backlash between the side gearandpiniongearontheplainhalfcaseside．

F壷g．23．瑠6（お琴nse沌翻ust騨aSherands墓degear intofIangehalfcase．

−84−

23．2．3 REASSEMBLY

ミー：．・i‥ニ■．二】

許毒g．23覆瑠＄①pressずiモ醸epi‡0モbear壷ngonモhe

Pre】oadcheck

drivepinionend．

①App住y∂P㌻eSSure∈aぬu琶280kgきwi抽apress

②us室ng∂ehis鈍st8ke∂モぬurpo裏門モS∂電r盲ght

SO thatthedrivepinion on the pirotbearingdoes

angIeswitheachothertolockthepiIotbearing．

notturn．

（診W査nd騨ire or cord around抽e be8r旨ngcage SeVeralturns as shownin Fig．23．2land attach

aspringbalancer． ③pu露豪触sp雨gb8童ance㌻hor妄zonモ∂E‡￥モOCheck

forrotatingresistancebyreadingtheindication． ④眺掘画仁輌＝閻茹昭和仁輌＝感触目頭鮎 bearing cage．The product shows the pre10ad． ぼほパs w桐油上納蔦閂町野（抒0−5！00攣26kg−m．

thepreloadisnormal．1fnot，Shimadjust． Note：This preload checkis a preliminarY One．

The fina）preload check and adjustment should be performed afterthedrive pinion and the bear− き＝；ミ1モーき．デーご 享 …丁．、・ヾ‡−i．・ir：こ・：いぃこい…：！・；い‥トミ：∴l、

ingcageareinstalled onthedifferentialcarrier．

thedrivepinion．

（参加感は聯㈹Ⅶ離柚掛紺地油紙

Fi9．23．22 Press fitthe bearingconeontheplain

half． 声音g．細腰狛診・酢蛸欄車輌油Ⅵ酢訓練凱髄‖淵絨関

CuPSOnthebearingcage． ②摘鵬…摘録融稲闘卵即納巌柚町画廊

andtheouterbearingconeonthedrivepinion．

−85−

Fig，23．23Clean the fIange ha［finthe ringgear fitting surface．］f any burrs are found，make

theflangehaIf．

SmOOthwith a f‖e．

②Engageモhe s盲8e gears w盲翰翰epin；ong銅rS andinstalT them．

rニ！p．こミ3、ユキ！重きさ・；、・！＝：1t、ii！−、！ゝ1し・‥＝≠＝h＝−⊆こ珊【、 halfandtightenwithboLtsandnuts． ②A触摘輌臨画緋鰯郵舶瀾ぬ

F・i貞、ヱ3、コ了！！…こIiiい川〜い−ノ．−ゞき1いi−Sい＝tll（川l・両1き1再†． ②加舶‖翰思か油＝触げ餅＝甑＝血母脾臓用靴

RinggearmountingboJtandnuttorque ＝16．5−18．2kg・m

then align the matchmark on the plain halfwith the matchmark on the fJange halfandinstaIlthe mountingboltswithnuts．Tightenthem．

DjfFerentiaLcasemountingboltandnut torque＝16．5・18．2kg−m

Fig．23．25lnstaIlthesidegearaLong with thrust

WaShersontheflangehalf． ‡・亙：−P．ごご圭！…・−：く；、．1＝；1：‥！l卜し、！−‥−il＝こ−！1こt！；く1こ1竜一盲il！】 CageSetOnthedifferentiaIcarrier．

−86−

③＝and軸hten the oi隻sea！reモa盲n即mOun抽g bolts，

．

丁−こ、 ニ・十両・ミ・ Fig。23義29①鮎極相加泡肋確醸eo妄藍sealr摘iner

．．

On the bearing cage．installthecompanion flange Onthedrivepinion．

tighten the cap botts coated with LOCTtTE No．271．

②Te汀1POrari‡yモightenモhe compan盲on f董ange

DifferentiaIcarriercapboJttorque

CaStled nutstoabout55kg・mtOrque．

＝32．5kg−m±5％

Checkingpreloadofbearingcage ③Aモモ∂Ch aモOrque WrenCh as shownin Fig． 23．29，and check the preload ofthe bearingcage．

8ealingcagepreload Standardtorque＝0．15−0．26kg−m ④萱fモhe pre蔓0∂8蓋s not w毒裾n抽e standar8

torque．disassemble and shim adjust toinsure a PrOPerPre10ad．

Bearingcageshimthickness t＝0．10mm，t＝0．20mm

（診A穐erpre‡oadadjustme鴫remOVethetempo− Fig．23．32 Tighten the adjusting nuts untilno

rariIy tightened castled nuts and retainer mount− ingbolts．

PIaYispresent．

卜 ：jjつ3；．＼；；ごミ√：i！・」i＝・・、・こ！：t、・、バ ート ミ；トニ

end of the ring gear teeth and iack the drive

F姦g．23．3￠①露nserモ∂b∂rthrough翰ediffe帽n雨8

Pinion．Turn the ring gear to the right and Feft to check forbackJash．

CaSeandliftthecase with hoistchains， ②抽醸‡−thedi梅rent妄∂璽caseon富he8椚eren亀吉∂‡ Ca「rler．

：；：・・＝・−ニー：、．∴・、：∴ ‥・…．・・・ト、… い車．・r・…∴；＝ぐ・く justingnutandtightentheother、

−87−

Backlashbetweenringgear8nddrivepinion Standard value＝0，20−0．33mm Ringg銅radjustment 鈎沖瀬上凝縁∵癖釦牒ぬ班巨や画凝頑∴⑭仁研降パ加 gear and the drive pinionin the fo owing pro− cedure．

Fig．23．37 ContactofToetsmallend） Fig．23．34 NameofGearPa代S・

Aninsufficientcontactoftoeisshownin Fig． 23．37．

To adjustit，loosen the adjusting nut at the flange half side．and tighten the adjusting nut at the plain haLf side．and move the ring gear awayfromthedrivepinionside． Then reduce the thickness of shim of bearing Cage，and move thedrive pinion closertothering ge∂r．

、

ド gear． ・：ご −1：・・ミし！・−・−‥・●い ．

・、さ・り・＼−‥：‥・−．く− −・・−−：・−−・・；：、・●∴−ミ い、さ・・ l

andcheckthetoothcontactoftheringgear． ．

facein normalcontactstate． ・き −＼！1・、．：・し、、・．‥・：−、：ニ‥・，てこ一三こ ∴ミ、・ミニ「−・∴1．′∴′：十‡・ミ‥

backlashagain． Caution： The tooth contactis required to be about80％ofthetoothlength starting fromthe

Fig．23．38 ContactofHeeIllar9eend）

AninsufficientcontactofheelisshowninFig．

toetotheheeIdirection．

23．38．

To adjustit，loosen the adiusting nut at the PLain haLf case side．and tighten theadjusting nut atthe flange halfcaseside，andmovetheringgear Closertothedrivepinionside． Then add to the thickness of shim ofbearing Cage．and move the drive pillion away from the 川1g gear．

Fig．23．36 NormalToothContact ー88−

F竜g．23，名瑠①checkthe軸h電en竜噂！0昭ueOぞcap boltsofdifferentialcarrier．

（診Check乞わeback篭ashbeモWeenモheFin9ge∂rand drivepinionagain．

Fig．23．39 ContzICtOfFace（toothsurfaceupperpart）

Aninsufficient contact of ftankis shownin Fig．23．39．

To adjustit．reduce the thickness of shim of bearing cage．and movethe drive pinion cIoserto theringgear． ThenloosentheadiustingnutattheftangehaLf Side．and tighten the adjusting nut at the plain hatf side，and move the ring gear away from thedrivepinionside．

、ご．ご ∴．ここ・・1・、∴：；：：ニ・！：ご・：＝、章√巨・：・klいiいこ一 gea「・

②Roモate翰e rin9ge∂r One reVO警uモ盲on，and measuretherunoutofringgear． Runoutofringgear Standard size＝0．13mmor tess

③邑督therunQuモisexcess廟☆ほmOun柚gsur−

faceis defective orstainedwithdust．Disassemble and correct．

Fig．23．40 ContactofFlank（toothsurfaceLowerpart）

AninsufficientcontactoffaceisshowninFig． 23．40．

To adjustit，add to the thickness of shim of bearingcage．andmovethedrivepinionavvayfrom さ−−；：丁ごこ．ヰ∴ 盲．−i■・両・・ニ1．iFl！】い…∴トこ：トい・、・：；・：巨・；・ご汀， theringgear． Thenloosen theadjustingnutatthe pIain half Side，and tighten the adjusting nut at the flan9e ha［fside，andmovetheringgearclosertothedrive

Pinionside． −89一

②L油壷ぬ＝輌＝嘲血油汗血仁加東加鱒雨噛 boltswith LOCT［TENo．27landtightenthem． 箱師面昭触御朋舶矧涌輌浄血呼鱒 jllSl叫〉niよ−こミく）川 ご・∠−3・b！く口111

フ33口【SASSER郎甘．、ヾ q軋！DREASSこMらミ．Y りF Fけ直症．！：i㌔FニーりCT毒ONく二言F．AR ？1：き1「蔓S九戸六I：！ⅥHi、′くぎeゃぎ喜丁．ココ．d汽‡

1．Removalofbrakehousingassembly ①Rernove紬ediskhubfrom萬場8盲skpl摘・ ②putma！chmarkonthe9earhousing∂ndthe b㌻ake hous篭ng an8removeモhe瑠2gear hous盲ng mountingbolts． ③Remo∀e鮪eぞ壱n∂豪㌻感ueモ盲0門gear aSSernb‡∀

fromthebrakinghousing． ④Removethesungearず㌻Omモねe管in竃l撒か躍痛澗

gearhousing．

2．Remova10fplanetcarrier ①円emo∀e鮪e r宅急盲閂er纏emoun加gbo‡電S

and removethe retainer pLate and shims fromthe ㌻・iq．23．歪・ミ；き1刷・・−ゾミ・・：：・．‥rこ−；「、‥、J：：、い＝∴：＝∴・、巨℃−1−；

thedrivepinion． （診Coaモモhe亡妻rcum勧enee oず8n O盲isea箋w喜醸

PARMATEKS No．2and pressfitonthe retainer 感納廟糾掛摘斬搾雨擁紺帥脚か摘牒湖南ぬ

③軸幽牒鰊而∽離が鮮閻針師鮪＝沼緋 【盲ト ミゾ盲こト‥ ■、＼：ニー、：、ごこ・∴：∴J喜・●・！・：こ・こ、い−ニー：・！！1・さ Onthebearingcage．

④禰腑裾加瀬摘仙風緬狛郡幽輌頼弛・ 〔ミ；；Fし‥d至・・ミ・t、、汗悍・汀Ilこlミ，−1・…i二さ妄皇∫．持＝一望膏卜甘木ポ ＝4．6kg−m±5％ ∫＿甘い．．涙．（・1子；．．3「…茎・こ・フき．ミ・さぎ…！、：：；一石」付−ぎニ；†帖、ごてjご ＝2．9kg−m±5％ ⑨一門st∂】lモhe comp8n盲on管星8ngean8号hewasher Onthedrivepinion．

⑥Tighモen輔ecas鵬dnuモSandtockw妄モheo！翫汀 Phs．

Companionflangecastlednuttorque ＝55kg−m±5％

hub．

②Removethept8netCar㌻盲erasse汀！姉川閻酎輌 hub．

3．DisassembIYOfhub ①Removeモhegea『hous盲ng8SSemblyずromthe hub．

・・さ；：、・れ1∴・・：‥・t・：、：ミl巨∴ ＝・√〉・・；「‥、…し；、∴さ・こ：・ぐミー

fromthegearhousing． ③when柑P毒ac裏門g軸e hubbear毒ng，remOVe醸e 巨・・・・い：「ぐ！・・し…い；・し、！・・、ミ：i：、い、・−・・卜ゞ−■・さ：盲喜…り−i‥・：：：・：ミ≡i…て毒；1 ④us盲門gabe竃㌢毒ngpu一業erタremOVe抽esle糾eand

thebe訂盲門gCOneずromthehuban8removeモheo竜自 sealfrom the hub．

4．DisassemblYOfplanetcarrier ①翫潤購軌相即血綱聞相即軸融脚繭・ さ・、、・・、こ；バ・・しこ−：：・こ・∵∵・＝、ミ・い・、（、仁一汀ハト浩一i・‥一ミ・−・−！ミ●！

boss sidewith a press and removethe planetgear Shaft．

∵‥ r−∴：．！：く、V．、・．；1さ・竜：t；こバ1、．しご・・−・∴、・1くjい○、．＼●∂こ…汀∴

1…；、：・；！r、＼・、∴；！…ぎ：！；ミし−・．い：バ：＼、盲・■：ぎ：、・・、「！￣∴r！1i‥！トl、−・

一部トー

LNERIG 、

PARALLEL PIN

Fig．23．45 ConstructionofFinalReductionGo3randBrakoHousing 23．3．2 REASSEMBLY

2．ReassemblYOfhub

①Press fit on！y the如er r盲n90ず∂門Oi‡seal

l．Reassemblyofplanetcarrier

On thehub．

（》lnst81‡asp紀erOnモhecenモeroずeachptaneモ

gear．Coat roHers with grease andinstallin two②1門Sモ81暮∂nOiさse∂‡onモhes臣ee∀eand盲nsta‡＝納e rowssothatthespacerissandwichedvvithro

Note：Eachgearhas58rollers．

ers． sleeveon thehub． ③App璽y∂裾門CO8モ0テ鬱reaSeOnaneW一′0′′−ring

andinstal＝tinthegrooveinthesleeve．

（診Press号室t the bushing蔓n短the蔓nsideo青the

④pressず托軸eouterbe8r盲門gCOnein油層hub．

Planetcarrier．

③蓼nsモal‡軌e planeモgearsonthepianeモCarrier． 3．Reassemblyofgearhousing．

lnstallwashers above and under each p［anet gear

SO that the proiection of the washeris fittedin①pressぞ享モモheinner and outer bearing cups thegrooveintheplanetcarrier．

Onthegearhousing．

④puモaba‡lin翰eho暮einth￠P‡an￠tg￠arSh納 and声‡ign the planet carriergroovewith軌e b8靂董

metrically．

②ori∀e tWO P蓄nsinモ0鮪e gear housi門g S∀m偶

andinsta pIanetgearshaftontheplanetcarrier． ③Lubricaモethec妄rcu汀Iferenceof班e r盲ngg￠8r ⑥如tach a snap r盲n90n thep加etca㌻㌻盲即モ0

With LOCT（TE No．515 and press fit the gear housing，USingthetvvopinsasguides．

locktheplanetgearshaft． ⑥きnst8曇‡therestofthepeanetgearsin納es∂me

④Dr蔓veモhe rem∂in盲ng加O P毒nsinto抽e9ear

manner．

housing．

⑦pressず托theinnerbearingconeof抽ehubon theplanetcarrier．

−91−

4．lnstalLationofptanetcarrier

Caution：Wheninsta川ng the brake housing．use ①putthehubassemb璽yonastandandinsert caution asnotto嚢os母thepar抽蔓pinsoり醸e ∂＄em盲circu加jigミ官記7mmきbeモWe即輔ehuband br8kehou如g．

thesJeeve．

⑥油滴相即徹血融格納画面中鳳輌潮

②puモモhe g銅r housin9aSSembiy on軸ehub・ Spline擁eplanetcarrierassemb‡yモ0モhehub塾n8

thediskpIateteeth．

theninstalItheplanetcarrieronthegearhousing． ③Pu＝hereta竜nerplateon抽ehub官㌻脚モend andモ毒ghモen the ret8iner plate mounモi咽boiモS短

the torqueofabout20kg−m．Pressfitthesleeve Onthegearhousing．

Caution：The mounting boltsshouldbetightened until no elearance is found between rhe gear housingandthesleeve． ④糸悔沌紺ゆ融炉触輌津酢ieeve柏鮪e9ear housing，remOVe the bolts．Remove the retainer p璽酎冶a門dモh◎ji9．だheぢk鮪盈モ翰e9e∂rhous納gcan

beturnedlightlybyhand． ：こ ミ＼彗ハ；：、し；；、．∴し．こ毒＝卜！・、・いし：：i：l し5eバト1；jenVぐ〇＝

the hubend and the planetcarrierbushingwitha depthgauge．

⑥se−ecモSわims so油∂モ触8i悔㌻en澤bec￠meS O．2toO．4mmlessthanthereading．

（∋榊軌凱血相柚喝抽醸沼翫紺摘油町画商即 the hub end．Appty LOCTITE No．2620n the

mounting bolts of the retainer plate and tighten the bolts．

Retainerplaternountingbolttorque ＝31kg・m±5％

5．lnstalLationofbrakehousingassembly ①抽感＝摘鋸町野射卸鮎川如離郷廠 納画幅湖融Ⅷ融狛涌か輌膵如融即断触融 ②山繭ぬ臨翻り弼＝痛加増 桐油狛那加 with LOCTJTE No．515．

Caution：LOCTLTE shou［d be coated uniformlY withoutbead breaks．

（卦鋸幽庵痴紺欄油闇夜那鮪朋問欄M擁 with the matchmark on the brakehousing．insta［雷 thebrakehousing．

：車＝・・…：‡ミ・呈！こ：ミ！−ご：∫・t：・−い；：・二・しiドミlミぐ；11し、し：け鈷￣哨卜小心

With LOCTITE No．262andtightenthem． Gearhousingmountingbolttorque ＝21kg・m±5％

−92−

23．4 TROUBLESHOOTING GUIDE Problem

PossibleCause Gasketofdifferentialcarrierisbroken．

Oilleakfrom Boltandnutloosened． differentialcarrier

Noisv differential

Noisy reduction gear

Oirleaksfrom

RemedY

Rep輌抽 Ret紳

OHsealisvvornordamaged．

Reptace．

Gearisvvorn，dama9edorbroken．

Re癖

BearinglSWOrn．damagedorbroken．

Splinefittin90fsidegearandaxLeshaft is100Se．

Replace．

Gearoitisinsufficient．

Addoil．

Gearisworn，damagedorbroken．

Replace．

BearinglSWOrn．damagedorbroken．

Re極

Gearoilisinsu冊cienし

A相

Loosemountingbolts．

Re紳

Damaged IO ′−ring，

Rep触

Housln9fittingsurfacedamaged．

Re画

Oilsealwornordamaged．

Replaceoits的し

ge8「housing

ー93一

23．5 MAJNTENANCE SERV［CE DATA

Differential

Standard Size

Checkin91te

UsefuILimit

（mm）

OuterdiameterofcompanionftangeinoiJseaJsHdingarea （frontandrearI

60．28・60．37

BacklashofdriveplnIOnandringgear

0．20・0．33

Preloadofdrivepinion（kg・m）

0．15・0．26

Run−OutOfringgea

beIowO」3

BacklashofdifferentiaJpiniongearandsidegear

0．1ら−0．25

Sidegearthrustwasherthickne＄S

2．32−2．36

Piniongearthrustwasherthickness

1．56−1．61

Bearingcage∫himtHckness

0．10，0．20

f

寧

Adjust with spacer

Drive axle

Checkingltem

Srandard Size

UsefuIしimit

（mm）

（mm）

0．50rmOre

DefJectionofaxJeshaftlentireshaft） BackIashofsungea「andpJanetpiniongear

0．16−0．30

BackIashofplanetpiniongearandinternalgear

0．16・0．30

Planetpinionthrustwasherthickness

2．3・2．5

轡部轡繭整理轡潤轡攣飯野楠讐抑㈹脚恒離別鞘触沌瀾廊椚！昏n電翰轟音触

fingernailcatches，itisrequiredtoreplacewithanewone．

叫1錮卜鵬

23．6 MAJOR BOLTTORQUECHART

ltem

Torque（kg−m）

Cradle pin lock bolt

13

Brake housing mounting bolt

21

闘閤Iredu離盲ongearre電ainerplaモemount盲ngb8亜 tcoatedwithLOCTITENo．262）

31

GearhousingmountingboIt（coatedwithLOCTITENo．262）

21

DifferentialcarriermountingboLtandnut

6．5

Adjustin9nUt（ockmountingbolt

3，2−3，5

Ring gear mounting bolt

16．5−18t2

DifferentialcasemountingboJt

16．5−18．2

DifferenaitlcarriercapmountingboJt

32．5

OilseaJretainermountingboJt DrivepinioncompanionfJ8ngeCaStJednut

M14

4．6

M12

2．9 55

Note：Theallowablerangeoftighteningtorqueiswithin±5％．

−95−

3．BRAKESY−STEM 31【BRAKE L覧NE 31．1 SERVICE BRAKE LINE

F桓．31．1Sch8maticDiagramo†S￠ⅣicoBrakoしino

−96−

Which are connected to the front and rear side SafetycYlindersrespectivelY． The service brakeis a wet−disk type．consist− Thefrontsafetycylinderisconnectedthrough ing primarilY Of theinner ring．disk plate，disk the brake hose and tubing to the brake housing hub．outerringand brake piston，anditishoused piston port at the final reduction gear and brake inthefinat reductiongearand brakeassemblYOn assemblYOnthefrontaxleshaftateachside． thedriveax［e．Theadoptionofair・OVer−hYdrauric Likewise．the rearsafetYCylinderisconnected OPeration system has broughtabouta compound to the brake housing piston port at the fina［ brake sYStem Which hastherichnessofoperating reduction gear and brake assembly on the rear materia［of the pneumatic brake and the good 31．1．1GENERALDESCRIPTION

axle．

response of the hYdraulic brake，PrOducing a SUfficientbrakingforce． The brake system has a power cIuster from

The air hose fitted to the double check vaLve adapter at thetopchamberoftheleftside brake Valveis connected to the transmission contror Whichtwo brakeoi＝inesare branched to the front Valveslavepiston． andrearareasofthemachine．Eachlineisequip− Ped withasafetycY＝nderandtubingsothateven if oneline becomes defective，the whole brake

2．Whenbrakepedalispressed

SyStemremainsstilleffective．

The brake line consists primarily of the air （1Ilnnormal￠Ondition COmPreSSOr．air tank，brake valve，POWer CIutster． When the brake pedaJispressed，thecompres− andwet−tyPediskbrake． Sedairflowsfromthe brake valvebottomchamber and the top chamber to the double check valve． Wheretheshuttleisactuated sothatthecompres− Sedairissenttothepowerc）uster．

31．1．2 0PERAT10N

The compressed air sent to the power cluster

l．Brakeline

The compressed air for braking operation is Sent from theaircompressor byoperationofthe enginethroughthecheckvalvetotheairtank． The check valve prevents the release of the COmPreSSed airin the airtank whenthe air com− PreSSOrin the unload condition according tothe PreSSUreintheairline． ［f the pressurein the air tank exceeds the SPeCified value because of a defective governor， thesafetYValveopensandre［ievesthecompressed

is there converted蚕nモ0翰e brake甑盲d pressure

air什om the air tank to preventdamage to the

force．

depending on the compressed air supplied．By this，f［uid pressureoperatesthefrontandtherear

SafetY CYlinder piston whichin turn send the brake fluid under pressure to the brake housing Pistonports． The brake fluid directed to the piston port Of each brake forces out the brake pistoninthe br8ke housing∂nd‡ocks upモhe盲nner rlng′disk

Plates and outer ringtogether，PrOducing braking When the brake pedalis not being pressed， the brake valve does not operate so that the PaSSage between the top chamber of the brake Valve and the bottom chamberisclosed，thereby no compressed air f10Wing to the power cluster．

releventequipment． When the compressed air pressure lowers to モhe m妄n盲mu汀書 PreSSure neCeSS∂ry ぞor br∂king

OPeration．the10W PreSSure SWitch operates to Warntheoperatorwith buzzersound． The compressedairsentfromtheaircompres−

Thereforethebrakedoes notactuate．

SOr tO the air tank enters the bottom chamber of

the rightside brake vatveand then flowsintothe bottomchamberoftheleftsidebrakevaJve． The top chambers of tnth brake valves are COnneCted to the power cIuster air chamber through the double check va］ve．The master

Cylinder of the power c．uster hasanoilreservoir Onits top area．The brakelinQCOnneCted tothe discharge port of themastercYlinderisbranched to the front and rear areas with brake tubings

−97−

（2）Whenoilleaksoccur lf fluid．eaks occurin either the front or the

rear side line due to a damaged brake tubing Or brake hose，the safetY Cylinder at thesideon Which fluidleakageis produced operates due to the brake fIuid pressure from the power cIuster master cylinder，Cutting off the f10W Of brake fluidleadingtotheleakingarea．

As a飽nSequ帥eeパhe brake凝モ軸e＄盲de on

which no fluidleakageis produced operates rl（汀111ai！v．！fthdil・G！1［si（重点＝11e、咄l−eleak汀Ig．the

rear side brake would operate norma y．while if the rear side＝ne wereleaking，the front side l汀akLIWr）ii；d r）ぎ1（汀atei10i●・llal！v．u（herL Ony fiしIid

te奴叩OCCur＄．PumP鮪e br液￠Pedat柑P毒d暮y

forassuringapositivebrakingeffect． 3．WhenIefth8ndsidebrakepedalispressed Theleft hand side brake pedalis providedfor Performinginchingoperation． 酵hen 鮪e p昏d∂‡is pre∬ed during forwar8 trave伽g，モhe compre＄Se8塾盲㌢恥w＄伽0喝h電he

bottom and top Ghambers of the brake valvct to the double check valve wherethe shuttleis actu− ated．Then the compressed air passes from the doubLe check valveinLet adapter through the air hose to the decIutch vaIve of the transmission controIvalve．Thislets the decIutch valve slave PisモOnOPerate SO抽atthe cuモ・0脛v8‡ve盲sぞorced

in to cut off the flow of clutch operating oil． Placi咽thetran＄mission套n軌eneuモra‡・

一98−

②check輔e va‡∀eand theva暮ves開モf那椚ow

31．2 BRAKE VALVE

andifunsatisfactory，rePlaceasanassembly．

③check the spring for bre8kage or de如…0隅

31．2．1 DISASSEMBLY

rationandreplaceanYeXCeSSivelydefectivepart．

④check the dねph柑gm for侮worf8exib捕ty andifunsatisfactory，rePlace．

31．2．3 REASSEMBLY RepIace an

0一′−ring and apply a thin filmof

REMAX 20r barium−based grease（NA−141M） On the 10′′−ring，the ring grooveand slidingarea

EXHAUST

in the valve bodY，then reassemble the brake Valveinthesequenceoppositetodisassembly． SNAPRING

Fig．31．2 Const川CtionofBrakoValv0

1．RemovalofpistonassemblY ①push downモhe va‡ve seat and remove the

retainerfromthebody． （参Re汀10∀e抽e pistonassembIy andモhe return SP「lng・

2．RemovaIofinlet＆exhaustvalveassembty

①Remove thesnapring8モモheぬt翰mofthe Valvebodyandremovethewasher．

②RemovetheinletandexhausモVa賽veassembly fromthevalvebodY． Note：Whenreplacing theinletand exhaustvalve assemblyonly．usethesameprocedureasabove．

③Remo㈹翰e8iaphr喝m mOunモing bolts8nd removethewasher，diaphragmandspring．

3l．2．21NSPECT10N ANDCLEANING

l．Cleaning Clean alldiassembled meta

ic parts with

Cleaning oiland drv with compressed air．Clean updustordirtoftherubberpartswith cleandry C10th．

2．tnspection

①chedく∂llpartsforexcess盲veweaタordamage andifunsatisfactory，rePlace．

−99−

31．3 DJSCBRAKE

lNNER ′0 ′−RING

BRAKE HOUSING

Fig．31．3 DiskBrakやComponontPans 31．3．1 DISASSEMBLY

②Removetheinnerd盲skfromthebrakehousing

l．Removatofbrakeassembly

andremovethe12pins．

removethewheelboIts．thetireandthewheel．

③円ernove抽e brakehousingpl噂＝mdb始職局由 throughtheplugopeningtoremovethepiston．

③Remo機the br∂ke housing d帽盲n pE喝and

⑨Remo￥e抽einnerandouterp盲sモOnS．

①suppo托ing軸e axIe転購納9融痛∂訂鰍鴎

drain off oilfrom the fhlalreduction gear and brakehousingassemblY．

31．3．2 REASSEMBLY

③軋ほ汀離恵閉脚庵s即＝加莞加商婚h飢感稲＝椚

l．lnsta ationofdisk brake

theendflangeofthealxehousing．

①AppEyath盲nず毒蔓mofgre8SeOnneWinn即and

嘩）Remo∀eモhe18brakehousingmountingbolts

Outer

and remove the final reduGrion gear and brake

inthepiston．

housingassemblyfromtheaxlehousing．

0′ −rings andinstalF themin the grooves

②us盲ng00u号室on8S nO登竜08am聯the 0，∫−

⑤puモma琶Chmarksonモheb㌢akehousingandモhe

rings，instaIlthepistononthebrakehousing．

gearhousing．

噂）Remov￠輔e12ge∂r hous妄n9m￠un如gぬほs and remove the brake assembJy 什om the gear

さ …妻・…Sl砧＝2汗・−Ⅷ油；・卜・：こitく！、雨情両川・00VC．

housing．

alongthe pinswith thesmoothsurface（machined Surface）oftheinnerringpointingtowardthedisk

2．DisassembLYOfdiskbrake

Plateside．

④抽細‡lモ如盲nner ring on電he brake hous盲ng

（D、Removeモheouterringfrom抽ebr8kehousi門9

⑥け敵酢紬渦紋画摘OVer抽e盲nnerring．

andthenremovethediskplate．

⑥usingモhep毒nsasgu盲des．instat‡輔eou翫汀由g Onthebrakehousing．

ー100−

2．1nsta

ationofbrakeassembly

①Apply LOCT汀E No＃515uniform嚢∀脚輔e ず翫ingsurずaceof抽eb㌻轟kehous妄ngso食ゎatnobeat breaksare found．

②は輌膵涌加郎糀椚極細呵由糾痛鉦輌

gearhousingonthebrakehousingl ③App雲y LOGT8TENo．2620n鰊ege8rhous妄ng mountingboltsandtightenthem． Gearhousingmountingbolttorque ＝21kg・m±5％

④tn如l巨細憺d鹿khubonthediskp‡細い勒画厘 theirteeth with each other．

⑤w柚a new g∫0ターーrin9in輔e brake housing

groove，installthe brake housing on the axle housing，aligningthematchmarkswitheachother・ ⑥Lubr墓毘モe t如brakehousing moun如g boEモS With LOCT［TENo．262andtightenthem．

Brakehousingmountingborttorque ＝21kg・m±5％

⑦摘摘附加庸eand抽ewhee−on柚ehuban8 thentightenthewheelboIts・

−101一

31．4INSPECTION OFSERVICEBRAKE

3l．4．3 0PERATlONCHECKOFBRAKE LINE

しINE

Measuringinstrument：●Airpressuregauge く10k9′ぐ！¶こ〉●Oil！−1むSSしIi−egFし；耶＝50！くロ／

31．4．1AIR TIGHTNESSOFAIR uNE

l：l†盲、）

l．Airtightnessinunloadedcondition

①Aモモ∂Ch an air pressurega喝eO督10kg㌔em2

①駄art輌engineandra盲sethecomresse8a…r pressurein the brakeltneto抽e maxlmum要6，巧 kgたm2き．Shuモdowntheengineandcheck如air leakage．

（the one attached to the dashboard can be used） on the line between the brake valve and the

POWerC暮usモer and anoi蔓pressuFeOnthe＝nebe− tweenthepowerclusterandthediskplate． ・軍′Stdr＝舟＝叩小出針d−■a壷st：さ‖1ミ、亡く）叩！−ミ1SSed3il●

（多野aint犯aP Sがution on軌e connecting簑in郎

andfittingstodetectleakage．IfairbubbLesoccur pressu柑モ06kg／cm2．p相客S輔ebr鼻kepe88‡電O the fuIIso that the brake vaIve opens fully and check to seeif the oilpressure gaugeindicates anpre最澄ureoザabout130kg／cm2．霊＝ower触n

from a part，itindicates that the partisleaking・

Replacedefectivepartsorretightenthejoint・ ③p8inモSO叩SO暮u血n on the d盲sch8rg穏P8沌S

Of both the right andleft brake valves．1f airthis va［ue．check the fo owing points andif unsatisfactory，rePairorrepIace． bubbles become more than25mmin5seconds， itindicates that the valveis notseatingcarrectIy ● mastercYlinderpistoncuporvalveforIeaks・ Onthevalveseat．Repairorreplace．

● hYdrau．icbrakelineforaeration．

2．Airtightnessinloadedcondition

③Re‡ease the brake peda‡柏Cheekiぞ翰eo盲葺 pre＄＄ure g8uge鱒i㈹r return＄tO O kg／ごm2料

t

0

b

V′

①翫8rモモhe eng盲ne and raise the∞mPreSSed mediateLy． airpressurein柚ebr8kelineto6kg／cm2．shut down the engine and press the brake pedal Check for airleaks．You canlearnleakage 10Weredairpressureinthebrakepeda川ne．

31．4．4 AIR BLEEDING OF HYDRAULIC LINE

②wh帥the air pressrelowers bぬw翰e

VVhenever the hYdraulicline has aeration，any initialoperating pressure，inspect the brake valve PartOfthehydrauliclineisreplaced，Orthebrake fluidisdrained，itisrequiredtobleedairfromthe

andrepairorreplaceasnecessary．

31．4．2 AIR TIGHTNESS OF HYDRAULIC LtNE hyc警rau事盲cline専 璽fair盲smixe8inthebrakef山id，

the brake wi produce no braking force evenif

①飢a代theenginean8r8ise毛細8irpressureo手 the brake pedalispressed．（Checkalsofluidlevel 書he8ir＝ne紬6kg／cm2。Shuモぬwnモheen9盲ne inthebrakefluidreservoirtank）． andpressthebrakepedalandholdforoneminute・ BleedairfromthehYdraulic＝neinthefollow・ （参A触r one minute．if theindica細r o背痛e lng manne「：

POWerCIustercomesforward，itindicatesthatthe At firststart the engineto put the aircompressor master eyiinder conneeting lines or joints of inope「ation． the POWerClusterareleaking．

①Theair b‡e感両川桐油藩画撒油川摘凍矧血

③Rep‡ace a defec電i∀e Piping．Ret盲ghten or

replace the joint．Check the disk brake or thebestartedwith the pointfarthestfromthepower cIuster．

POWerClusterandrepairorreplaceasnecessary・

③Loos帥モheairb暮ee鮎rscrewof醸e触ntside SafetycylinderuntilitsLightlYtOuChesthestopper・

−102−

③w釣摘 the br窃ke pedaipre＄＄ed，OPen the

31．4．51NSPECT10N OF BRAKE SYSTEM COM−

bIeeder screw on topofthe brake housingatthe

PONENTS

ri9柄s盲deofthe管和ntaX‡eモ0か∂墓no桝brake鮎紋

Then tighten the screw and release the brake

l．Airtank

Peda［．Repeat this procedure untiIno bubbJes

川 Operationcheckofgovernor

areshovvninthefluid fromthe bleederscrew．

①A机ach an∂套r pressure g∂uge（10kg／cm2〉

Note：Jtisagood practiceto attachavinylpipe

betweentheairtank andthe brake valve．

to the bleeder screw and receive fLuid with an

（診Sモarttheengineandcheek輌毒n篭eモPreSSure

appropiratepan．

（5．0±0．3kg／cm2き∂n8モhe8i§Chagepressure〈6蠣1

④puring8ir b‡eed盲ng′ Pay aモモen血nモ0油e

±0．3kg7cm2きb∀OP即a如g sound o手痛e∂盲r

fluidIeveIin the fluid reservoir tank．1fleve1 ］owers，addfluid．

COmPreSSOr．

③鰹ずthemeasurementisoutof鮪erangeoぞ抽e Standard valvue，adiust with the adjusting screw．

⑥A触rのmPle竜ionoぞモhehydrau藍ic‡盲neatthe

right side ofthe front axIe．proceedwiththeair bleeding of the hydraulicline at theleft side of

One revoIution ofthe adjustingscrewwi［lchange

bleeder valve untilitlightly touches the stopper and proceed with the air bleeding of both side hYdrauliclines of the rear side，uSing the same

leaks．

apressureoデー．2モ01．4kg／cm2． thefrontaxle．Afterthat，tightentheair bleeder④seモモhe∂ir‡ine pressure∂モ6kg／em2，and ValveofthesafetYCY）inderofthefrontside． Paht soap solution over the piping and jointsat ⑥Loosen 翰e rear s豪如 s∂勧y ey‡盲nder a妄r theinlet and discharge positions forcheckingair

⑨匿f軸e height of bubb自es reachesmorethan 25mm，rePairorrepLace．

PrOCedureasabove．

Cautionl：Be sure to tighten the air bleeding Valvesecurelyaftercompletionoftheairbleeding；

∈2き Opera如gehe￠ko管sa菅etyv金一ve

Otherwise，thesafetYValvewiH malfunction．

the air tank and attach an airpressuregauge（15

Caution2：Do notovertighten the bleederscrew，

butit shouLd be tightened to the extent thatit may notbeloosenedbyvibrationsofthemachine． Anovertightened screwwilLthrustintothemating Wallofthe brake housing．resultingin brakefluid

（D Removetheou引ets旨dehighpressurehoseof kg／cm2きand8djust翰e adjus引n9SCreW Of the gOVernOr・

②sモ∂代the engine toincrease毛細pres＄urein the air tank to thespecified pressure（10．5±0．4 kg／cm2き。

③withtheprSSurekeptaモモhespec硝edpres−

leaks．

Sure．Check forairleaksatthe fittingareas，Valves and seats．

④check紬Seeif醸e saずety vaEve operates

PrOPerLYWhen the pressureintheairtankexceeds the specified one．andif unsatisfactory，rePairor replace．

2．Operationcheckofpowercluster ①RemわVe the high pressure hose from鮪e mastercylinderdischargeport．

②B暮ov∀airofabout7kgメcm2甑oughthe笥nlet POrtOfthepowercYlinderandpaintsoapso［ution

OVer the connection between the power cYlinder andthecylinderbodytocheckforleaks．

−103−

③GheckモOSeeiぞ鰊epu納㌢Odactu8モesat托s 3．Functioncheckofsafetycylinder fuIIstroke bY Observing theindicator，browing ①舶佃8irbleedingthehyか8ul妄e雪盲nes，輌輌廊 00mPreSSedairofaboutlkg／cm2ずromモhepowe㌢

the air b［eeding valve．Press the brake peda［to

CyIinderinret port．Check a［so whetheritreturns

Seeif thereis any differencein operation when

Withoutanyinterferencewhen thecompressedair

the screwis mounted．1f satisfactory，a brake

isdischarged．

assemb（iesonthewheelsareoperatingproperly．

④closethereservoir電ankpo沌Of輔e￠y‡壷n8er ②ぎfanyabnorma‡掬isぬun8when軌ebrake bodyand b．ocking upthedischarge portwiththe Pedalis pressed，Check again forfluid teaksfrom finger，PreSSin the piston．Atthistime，Checkto thepipingorforaeration． Seeiftheairinthe mastercy［inderisforced out．③openthebEeeぬse柑WO誓翰eb㌻akeh￠u霊室閂g With the discharge porlb［ocked by the finger， Checkifthepiston returnswhenreleased．

⑥淘触恒酢蘭卿海沼紗噂牒ぬ細面硝ふ

at the front side to pIace the frontsidelineata leaky condition，and pump the brake pedaltwo times．1f any stepping allowanceis found，the

Safety cylinder of the front sideis operating PrOPerlv．

thedischargeportofthemastercylinder．Jncrease 輔e disぢha㌻ge PreSSureモ￠一駅＝囁ぬが㌧緋感摘洩

forlO seconds to checkif a pressure drop of5

⑧ぴs盲門g醜e開me PrOeedure′Check琶he rear

至√ニーJ・・・・／ト∵−．ミこ・ご ≡．

SidesafetycY＝nder． Note：This safety cylinder check should be per−

formedwheneverthebrakesYStemisinspected． 3l．4．6 MAINTENANCEOFSAFETYCYuNDER l．Whenftuidleaksoccur

①whenthes∂勧yc￥弓inぬ盲＄Pu電墓n叩er8如n

and Ihe maehine is braked by only the front or therearwheels′Checkforleaks．

（熟苅酢加相場漁感＝納鋸狛輌爛廟断頭擁臓 attheleakingside（frontorrearside）alItheway

toshutoffthefluidlineafterthesafetycYlinder． Caution：Nevertightenthecheckvalveattheside notleaking． 2．Afterrepairingofleakage

①風鮎川鹿呵画廊附か鳳廟勘ぬ瀾か如脚 to reset the check valve to open the brake fluid PaSSagefromthemastercylinder． ②whenre＄eモ加g輔￠Cheekv∂廟モu㌻n醸eぢわeek

Valvebackandtightenthesamewithapacking． ・写 ぺ；：：・：：−・、ミごごしこ川上1卜iニ・、：：−…、l‥…、、・・小こ．いl、・：い！〔！

brake pedaIto checkifthereoccur no fluid feaks Whentheoperatingpressureisachieved． ●

−104−

31．5 TROUBLESHOOTING GUIDE Air line Problem

CheckingMethod Measure pressure ar dis‑ Chargeport．

PossibleCause

DeliverYSPrlngOfcompressor isbroken．

UnJoadervalveofcompressor

Measurepressureatdis−

isdefective．

CrackincyJinderheadofcom− P「eSSOr・

Remedy Replacespr［n9．

Cha「gepo「t．

Replacevalve．

Checkwithsoapsolution．

Reptaceasassembly．

CheGk valve at inlet of air tank Measure prassure of inlet PIPlngOfvalve． isfroヱenOrSticking．

CJeanorrepJace， Disassemble，Clean

AirgovernormaJfunctioning． Brakeisnot

MeasureunloaderinJet PreSSUre． Or「ePtaCeaSaSSem一 bly ．

effective（air PreSSUredoes defective． notrlSeト Springofsafetvvatvejs

Safetyvalveseatsurfaceis Disassemble′Clean， Checkwithsoapsolution．

OrrePlace∂SaS−

SemblY．

broken．

Ad5ustmentofsetpressureof Safetyvalveisimproper．

Measuresetpressure．

Seatofdraincockisdefective．

Checkwithsoapsolution．

Adjust． Disassemble．clean OrrePlaceinassem− 響

Exhaustsideofbrakevalveis defective．

Disassemble，Ctean＋

OrrePlaceinassem・ VatVeisbroken．

airleakwithsoapsotu−

Pipingiscracked，broken，Or

tion

blY．

loose．

PistonrlngOfcompressoris

Measurepressureof

WOrn．

COmP「eSSion．

DisassembIe′Clean，

AirgovernormaIfunctions． PipinglSSlightlYIoosenedor Brakeisnot effective

ReplacerlngOr CVlinder．

Checkvvithsoapsofution． Checkwith＄OaPSOIution，

①わefecモiveseaモOrSe8月of

（chargingtakes Safety．brakevalve． disassemble′OrCheck Visualty． time, or air ②sp㌢ingiswornorbroken． teaks†． Pistonofbrakeandseatofbrake Checkexhaustportforair

Replaceseatvalve．

Cuporseatof＋powercluster damagedorbroken． Pipingbetweenbrakevalve andpowerdusteristoosened′ CraCked．orbroken，

−105−

OrrePlace． Retightenorre− Disassemble，CJean，

OrrePlace−

VaLvedefective．

Listenforairle8k．

RepIace．

ListenforairIeak；With SOaPSOIution；Check Visua11v．

Replace．

Air line

CheckingMethod

RemedY

Operateandcheck；Or Checkvisualty，

OrrePlaceparts，

PossibIeCause

Problem

Pedalpinofbrakevalveis 「UStY．

Br∂kedrags．

Forei9nma恍eriscau9htbe−

hindpedalofbrakevalve． PJungerofbrakevalveand Pistonarestuck．

Ai「gauge

Clo＄eUnloadercircuit，

needkswin9S

andmeasurewithpres＄Ure

excessi㈹1Y．

gauge・

Checkforairteakby 1isteningorwithsoap

Pipingisbroken，CraCked，Or

Pressure drops quicklYafter StOPPlngenglne．

loosened．

soIution，

Retightenorre− PtaCe．

Checkforairleakby

Defectiveseator＄ealofgover− nor

Correctorreplace．

．checkvalve−Safetyvalve， draincock，brakevaJve．

SOtUtion；OrmeaSUre Withpressuregauge．

Cupor＄eatOfpowercIuster isbroken．

Checkforairleakby listenhg．

replace．

Oit（pistonringorcYlinde「

CheckforoHvisua11y．

「ePa汀・

Oilispresent inairtank．

Dis8SSembte．clean，

i‡WOrnト

Disassembleor Disassemble and

Oil line

CheckinqMethod

Possible由use

Probtem

Lackoffluidinbrakereservoir tank，

Tubelineis100Sened，CraCked，Or Brakeisnot

effective（oil ressuredoes notrise）．

broken， defective．

Cupofpowerclusterisdeterio− ratedordamaged．

Remedv

Supplementbrake

CheckfluidleveL．

fluid．

Checkforleak．

Retightenorre− Place．

reservoirtankoradvanc・

DisassembJe，rePaIr，

8rakepistonseaLsdeteriorated， ChecktoseeifsafetYDisassembJe．repalr．

Cylinderoperate＄PrO− Pe「1y．

surfaceisdefective．

OrrePIace．

Onesideofbrakepistonis rustY． Uneven

Raisethewheetandturn Disassemble′re叩け，

braking．

Pl8te 1nnerandouterplatesordisk Plateunevenwearordeformed．

−106−

Foreignmatteriscaughtindisk

itforchecking．

OrrePlace．

Oil line Problem

CheckingMethod LiftwheeJs，tLJrnbyhand forchecking． Loosenbleeder．turn Wheelbyhandforckeck−

PossibleCause

BrakepistonrustY．

Remedy Disas＄embIe，rePair

andreptacepart．

…

SpringofhYdraulicpistonof B「akedra9S．

POWerdu＄terisbroken． Pistonofpowe「clusterissticking．

Disassembleandcheck．

伽「rector「eptace，

CheckvalveofpowercIusteris Clogged． Checkgradeofbrake fluid；disassembleand

PistoncupofpowercLusteris expanded．

Check．

Loosenbteederandcheck． Bleedairfrom SYStem．

Airpresentinoi川ne． Unstable

Check9radeofbrake

VaportockofoHIine．

brakeeffect．

AfterfIu＄hing，

Changebrakefluid andcup．

Changebrakefluid．

fluid．

Discptaterunsoutorunevenly

WearS．

Disass曲dch奴

Replace．

町融軌ぬ Alarm unil: Problem Wrongindicat tionofpres−

PossibJeCause

CheckingMethod Comparewithtestgau9e．

Remedy Replace．

Sure．

Malfunction Of8larm lamp and buzzer．

Lampbulbisbtowoutorcircuit i〜disconnected． FauttYCOntaCtOfbuzzeror Circuitisdi＄COnneCted．

Checkwithtester，

Malfunctionoflowpressure SWitch．

−107−

Correctorreplace．

31．6 MAINTENANCESERVICE DATA Checkingltem

翫andardSiヱe（mm） UsefuILimit（mmI

1nnerdiameterofpowerclustermastercYlinder

44．85

lnnerdiameterofsafetYCylinder（rearsidel

40．0

1nnerdiameterofsafetycYlinderlfrontside）

45．0

Ai叩rOSSU川S抽叩Ofhr∂ke＝no悔／cmJ）

5．0−6．1

1nletドreSS廿eOfgorvernorくk油正）

4．7−5．3

D幸吉亡卜a耶PreさSUreOfgⅣVernOr（kg在mこI

5，8−6．4

Operath19PrC＄SurぐOfsafctyvaIvcikg／cm＝）

10．1−10．9

Opera柚gpre∬ureOflowpressureswitch（kg／cm2）

3．7−4．7

Operatingpressu柁O平成OP暮8mPSWitch純9／cm2）

0．50rk∬

Thicknessofbrakediskplate

6．0−6，4

lnnerdiameterofpi＄tOngrOOVeOfbrakehousing

256，9・257．0

Outerdiameterofpistongrooveofbrakehousing

3駒．0・3囲，1

tnnerdiameterofbrakepiston

257．2・257．3

Outerdiameterofbrakepi＄tOn

303．7−303．8

−108−

31．7 MAJOR BOLTTORQUECHART ltem

Torque（kg−rnl

Gearhousingmountingbolt（coatedvvithLOCTITENo．262）

21

Brakehousingmountingbolt（coatedwithLOCTITENo，262

21

PowercJustermountingbolt

5．4

AirgorvernormountingboIt

4，6

Safetycylindermountingblt

4．6

MastercYlinder＄tOPPerbott

0．9−1．3

Air bleeder screw

0．7−1．2

AircYfindercapmountingbo（t

1．3−1．5

SafetYCYIindercap（Frontside†

36−38

SafetYCyLindercap（RearsideI

30−32

Note：Theal［owablerangeoftighteningtorqueiswithin±5％．

−109−

32．PARKING BRAKE 32．1JNSPECTJONAND REPLACEMENT OF PADS

OnJYisrep）aced．theotheroneshoutdbereplaced Shortly，Whichisnotveryuneconomical．Whenever

32．1．11NSPECT10N

the padisreplaced，besureto replacethe retract Plate．

Measuringinstrument：●Slidecalipers う Actuate thei）rakc kver t（さChく）Ci（t！lrL C証v！S

P毒n forwear andtheleverねrloosen郎＄紳dop・ erationandifunsatisfactory，rePairorrepLace．

2．lnstaltation ①Re竃汀旺aき蔓毒nthesequence￠PPOSite電Or￠mOV姉

ObservingthefoLJowingpoints．

3 Checkね一●b：￣akinsl浦（一（：1．1r！（川…Sこlヒis−iiiilい；、ヾl adjustorreplacethepart．

②γ廟観相鳩矧雨＝Ⅷ洒加糾如飢融欄猟

thetabJockandthenJockthemountingboIts．

③scre鞘汀＝加＝場面＝椚忽＝ぬ鶴相即町軌か鹿倒 蕗晦∽涌＝触＝豚狛無闇蝮鱒鱒鱒鱒り噂凋腐りl離e at severaIpoints with slide caIipers andif anY measurementis belowthe useful＝mit．replacetheand then turn back the hand brake tx）ltl／3

③柚脚購劇場裾如闇…＝摘開か捌面的

revolutiontoadjusttheclearancebetweenthepad andthedisk plate．

Padassembly． ThicknessofpadassemblY

り．．へくモjしミF！．いこi！ミー、由、い●・、ミ＼、∫ii：−；いr・こ・r・11：；・1！

Standardthickness＝13．7mm

1inkage．

Usefullimit＝7mmorless Note：incIudingthicknessofbackingplate

32．2 ADJUSTMENT

（2mm）

lf the friction materialof thepadassemblYis

Caution：If this check were neglected，theinner Or OuterPlate would contactthedisk pIate，CaUS・

ingseizing．ThisresuJtsinamaJfunctioningbrake OruneVenlyworndiskplate．

WOrn．theJeverstrokechanges．Adjusttheparking

brakeaccordingtothechange． 32．2．1 ADJUSTMENTOF PAD

32．1．2 REPLACEMENTOF PADASSEMBLY

When the padisworn beyondthe usefu＝imit （totalthickness，7mm；frictionmateriaIthickness， 5mm）．rep［aceasapadkit． 1．Remov81

①Aぬ細川鹿如舶用醐＝料地射伽牒油輌 brakeinthe releasecondition． ②suずず盲cie閂七重￥箋00Senモhe han8brake b8雨モO

Widen the space between theinner and outer Plates． ③Loos守門the門u電S兄CuFing the pa8asser油Iy and remove the nuts and toothed washers from

theinnerandouterp（ates． ④s電ra輌en紬§8P㌻盲n90苦痛eモ哉b！oekb⑳重電S

and remove the carrier mounting bolts．Remove theretractpLateaIongwiththetablock．

F−：ぎさ．てご．−ト■jトくr、ト釦＝叫、、1；−：∴1′！：侶吾、．

③隅闘胴相場柚廟隅＝㍍鮎川感約磯加

materialIandif thepadiswornby2mmatone Side，thatis．the pad thickness becomes9．7mm．

⑥Loosen輔e specia蔓ぬIt＄0ずthepadan8re−

7．7mm or5．7mm，SCreWin the hand brake bolt

move the pad asst?mbly along the pad guide oF thepIate．

from thelever side untilthe padc（osetycontacts

thediskplate．

Note：The padis available as a pad kit．When ③鬼無即電hepadc者oseさyconモ∂CtSthed壷skp著離e， turn back the hand brake boltl／3revolution to replacement of one padisin need，besureto re・

PLace both pads as a set．Tf the padatoneside

adjust the elearance betVveen the pad and the diskplate．

ー110−

Caution：lf the adjustmentis neglected andthe Padis worn by2．4mm or more，the pivot seat

OftheinnerplatewiIlbebroken． 32．2．2 ADJUSTMENTOF CONTROL LINKAGE

F壷g−32．2 ① 納er the adjus佃ent of the pad

Clearance．remove the cotter pin connecting the inner p［ate sidelever and the clevis at the brake cabIeend．

（診Remove theconnec如g pinand screwin or

OUttheclevis YOketoadjustthedistancebetween the clevispinhoIesofthecablesothattheparking brakeleverisplacedinthespecifiedposition．

③Turn醸eknobontopoftheparking brake lever or Ghange the bracket mounting position of the parking brake lever ro readjust the parking brake】everpositionprecisely．

−111一

4．STEERING SYSTEM 41．STEERING SYSTEM 41．101LCLRCULATLONSYSTEM

Fig．41．1LoadSonsingSystomCircuit

flowsthroughthesteeringport（CF）totheorbitrol lN port（P）．On the other hand，the oilforthe main circuitflowsthroughthe main port（EF）to

41．1．1GENERAL DESCRIPT10N

This machine has aload sensingsysteminthe Steeringsystem．TheIoadsensingsYStemPrimarily

thelNportofthecontroIvalve． COnSistsofasteeringwheel，anOrbitro（，aSteering When the engineis started，thesteering pump PUmP，a PrioritY Valve．steering cYlinders，hy− draulichosesandtubing． The oilflowin the oilcirculation circuitis

asfo

ows：the operatingoilisdrawnupfromthe

Oiltankbythesteeringpumpattachedtothedrive unit and is directed under pressure to the pump POrt（P）ofthe priority valve where the oilflow

isdividedintotwocircuits，thesteeringcircuitand the main circuit．The oilforthesteeringcircuit

−112−

draws up oilfrom the oiL tank and sendstheoil Under pressure to the priority vatve where the Steering circuit haspriorityoverthe maincircuit． SO that oilflowsintothesteeringcircuit byonly thequantitYrequiredforsteeringandtheremaining Oilflowsinto the main circuit．The pressureoil from the steering pumpis regulated for130kg／

cm2．モhep柑SSureS離tingofthes触汀ingcircuit．

The oilthat enters the rotor setis pressurized．

The oilflowirlE！throuqh thc sle（汀ing circuぎt

is pressure regulatedforthespecified pressurebY Thus，theoilissentunderpressuretothesteering the spooland the controIspringin the priority CYlinder，turningthemachine． Valveand flowsthrough thecheck valvetothelN POrtOftheorbitrol．

41．1．2 PR10RITYVALVE

When the orbitrolis placedin the neutral

POSition，the oiJflows from thelN portthrough theoilpassageinthehousing，PaSSingthroughthe neutralholesin the sleeve，tO the cavitYin the SPOOl．Thenitflowsthroughthenotchedgrooves in tlle S叩0‡a11〔＝由e扇eeveaildoilpassagein【he

housing to the OUT port（T）and then back to theoiltank．

When the steering wheeIis turned totheleft． t！1C O‖†：ows f！−Om theJN port through thc oil

PaSSagein thehousing，Oi＝10lesin thesleeve．the groovein the spoo［and then the other oilholes

in thL）SIL，tlVt，iH）doi＝）ilSSこ）！Jt！inthe housingtothe

Orbitrolrotor set（metering device），and passes througheachportlLsidLさOrRsidc）toThcstccring Cylinder，Thatis，When the steering wheelis turned counterclockwise．the o‖flows from the

Fi9．41．2 0poI電tionofPrioritYValv8

The priorityva］ve hasfive ports；P，CF，EF，LS

and T．The port Pis connected to the steering

POrt LtotherodsideoftheIeftsteeringcylinder

PumP discharge port，theportCFtotheorbitro［ lN port，POrt LStotheorbitrolloadsensingport，

and to thelai！sideo†thlモri！Jhlsu！Cr・i！1日（：y；in（Jcr，

SOthatthe［eftsteering cylinderiscontractedand andtheportEFtothemaincircuitblock． The port Tis a］so connected to the return thefrontframetotheleft． Circuit of the orbitroJ．so that when the oil When the steering whee［is turned clockwise， PreSSureinthepriorityvalveexceedsthespecified theo‖flowsfromtheportRtothetailsideofthe PreSSure，the relief valve opensandoilisrelieved left steering cy［inder and to the rod side of the fromthisporttotheoiltank． right onesothatthefrontframeisturned tothe The spool in the priority valve moVes to the the righ†side one享s extendeしき，lherchy turning

right．

right orleft bY the differentialpressureヒ把tWeen

The oildischarged from the steering cy［inder 伽町e凱reChambers＠るnd⑧andthesprng opposite to the cylinder into which pressure oil forccoflhl‥Cミ）ntrOIsprirlq，COiltrOllingtheopening

f；owsFlaSS【！Sミhroi）小1Ehく：Oilpassage盲nthchousing．

Ofthe ports CFand EF．When nooilflowsfrom the portPoftheprioritYValve，thespoolisforced

Oilholesinthecenterofthes］eeve．grooveinthe

SPOOl．notched groovein top of the sleeve and to theIeft bythecontro暮spring．sothatport EF again the oilpassagein the housing to the OUT isc［osedand portCFisopened．Whentheengine POrtand backtotheoi［tank．Iftheenginestalls is startcd，the oH dis（：h叩（！d rrom the stecring

foranYreaSOnOrthesteeringpumpbreaksdown，

Stee…−ing pしnli）C；1nl10†s（，n（loilt（一†h（！Steering Cylinders．hlSuCha cnsc，Whe＝thest【）（！ringvvhccl is turncd，this stce油1g SySt（！rn dCtS aS a manUa！

PumPf］owsfromthepriorityvaJveportPthrough the port CFtothelNportoftheorbitroいncreas−

ing the pressurein the steering circuit．This incIleaSeS thc pressurcillthc pressurc chanlbcrミA）

Steering system． Thatis．the rotor setin the in the priority vaIve．shifting the spoolto the

Orbitrolacts as an oilpump to pressurize the rightsothatthecontro［springiscontracted． OPerating oiland sendit under pressure to the B（！CaUSe the pressurechamber・B］is conrlCCtCd Steering cylinders．SothelN portsideoftheoiI throughtheorbitroJloadsensingporttotheport PaSSagein the housinggoesnegative，OPeningthe LS．there occurs a pressure difference between Check valvein the housing so that the oi［dis−

Charged from the steering cy＝nders to the OUT POrtflowsthroughthecheckvalvetothelNport．

−113−

th（？Prt！SSUn！l：！1コ！油（汀ゝ・A3！1d B．When this dif−

Outputinspectionprocedure：

・F（照11tiilil）「（さSS川・t！PXこ：eeds し；1eio8d se【ti11g（10．3 k！由11・、‡い†輔心e即沌・0！sp！・iilg，thespoo！i！1tlle

CllJl・耶Si【je（！F由（さSl（：l：i●廟lつしド11Pa…1⊂！conIleCtthe

（1ミR胴OV（さttl（！hiミjh pr（2SSl汀e hose at th（：dis・

Priorityvalveisshiftedfromthelefttothe right，inletsideofahYdraulictester． l〕lこ盲（：iil！＝）Ol−1EF11eariv fしき童萱叩en an〔jぎ）伸 CF

・2 C川1nC（：Litsく）Ut！Lさ1：Side to the retu童・ぎ1S壷de of

theprioritYValve． Oildischarged from the steering pump flows to ③S鐙毛細e恥w rate and thespeedoずthehy・ S璽igllliYCPm．SOthdモロlOSt！）Ort盲ぐ；10†血I汀（さSSl●iで

draulic tester to the measuring range and open When the steering wheelis turned clockwise theIoadingvalveofthetester． Or COunterC10Ckwise．the sleeve and the spoolin ㊨s勧＝摘剖頑㈹那隠如南蛮highi8加grpn− theorbitrolrotatesothattheoilpassageischanged and measurethedischargeratewhenthe pressure OVer by the combination of the notchedgrooves isatO．

the maincircuit．

and the oilhoIesin them．Thisletsthe pressure

・ら Closi叩tlle毒0コく！i11q Valv【−ぴ・l＝−5＝州v．■川リS＝一口

oildirectedto the［N portoftheorbitroIpassthe the discharge rate untilthe pressureraisestothe 瞭漕澤イ餅巨鯨南海仁毎り触＝両脚柁行＝鮎＝鹿郡

SPeCifiedone．

and the oilhoLein the spool，CaUSing a pressure difference across theorifice．Asaresult．thespool

is placed in a position where the pressure differ‑ 41．2．3INSPECT10N OF RELIEF PRESSURE enceぬ勧e愈n軸e pre§Sureぢhambers㊨and⑧

柚…騨雨叩函1ゝTr＝√＝〔−1し●m＝−；−i：SSljl−〔さ（200

isbalancedbythecontroIspringtension， At this point，POrt CFisopened to theextent that the flow rate necessary for the steering

lく∫I／ミ1ぎ11・、l●￣什肝・川南両1ミ・い誹・＝Mn＝1r汀el一口葛・i−0〔ト sh叩ed輌rmomeモer宅15￠0ぢき

Circuitisassured．

41．21NSPECTLONOFOILPRESSURE 41．2．1AIR BLEEDING

Lf airis mixedin the steering circuit．the response of the steering cylinder to the motion Of the steering wheelbecomes s10W Or dull．ln SOme CaSeS．aerationis producedin the steering PumP．PreVentingits norma10Peration，and

damagingthepump． （む鱒離ゆ郎欄油柑感知凝離恕椚卿．

炉毒g．穏瑠．3（むRemo∀eモheptug∂電醸ep㌻融和V扇ve check por電and a鴇題Ch竃nO毒筆pressure9augeミ200 kg／em2抽曾掩Checkp8代．

③バ加納隠離離幅画地狛108kw盲se量n8count絆

②隠滅冶引∬e軒㈲＝加狛扉＝酌頑パn☆掩0‡モankis

Airbleedingprocedurc：

Clockwise unti［the steering cylinder actuatesasupspecified，then raise the oiltemperature to tothestrokeendtorelievethepriorityvalve． 55to650c． ③馳紆細面糎澗離繭腐輌輌紬扁叩

③難関紙軌卵鹿洞膵矧鱒地相押測掛軸閥．

嘩）Tur円価e s篭eer盲ng wh穏e雷電0モher毒9htor‡e吾 4l．2．21NSPECT10N OFSTEERING PUMPOUT− ＝n川iい：こ＝tこl（汁S1日i、ボ（）ドドM−Jn（モモilei一汗毒訓●盲tY、′∂卜∫〔、 PUT

！fthesteeringpumpmalfun戊…ons一紙esモeer富ng Sy5モem00n nOt OPera穣S PrOPer憂y′a侮c如gモhe

OPerationofthewholeloadhand［ingsystem．

relieves oiI． Take the reading on the pressure gaUge・

⑥葦f柚e reading盲s not w竜th壷n輔e＄PeC消ed range′adjustwiththeadjustingscrew．

ー114−

4l．3 STEERINGWHEEL 41．3．1 STEERING UN‖■

Fig．41．4 St00ringWh001Construction

ー115−

41．3．2 0R81TROL

CheckValveSection Crosssectiona］viewB・B

CrosssectionalviewA・A

Fig．41．5 0rbitr01Con虞ru亡tion

−116−

41．3．3 DISASSEMBLY，lNSPECT10NANDRE−

ASSEMBLYOFORB＝￣ROL T

Clealiness cannot be overemphasizedin repair− ing軸e orbitrot，Select a cleanworking8rea†or r8P∂書㌢蔓ng．Beずore墨書モemP如gto（ヨisassemb‡ethe

unit．cLeanupdustordirtfromtheexterioTWith awirebrushandawastecloth． 1．DisassemblY （1IDisassemblYOfrotorside Fig．41．8 や R亡mOVethL：SPaCr汀PkltC fronlthe housing and鮪e drive sha吾from the housing・ Removethel 0

−ringfromthehousing．

⑤Loosen軸evise抑d柁mOVethehousingfrom the vise．

（2）DisassemblYOfcontroIvalve

F蓋g．ヰ1．6 ① Aモモachcoppermou擁piecesora waste clothin a vise and hoId the orbitrolinit

withtherotorsideup，C）ampingthefIange＝ghtlY． ②Put matchmarks on the housin駄StatOrand end cap．Remove the7endcapmountingtx）ttS and removetheend capfromthe housing．Then， removethe

0 ′−ringfromtheendcap．

Fig．41．9、乍一 Pl」t∂Clea11dot11aSnOttOd∂lnage the machined surface of the housing．pry upthe retainミng ring cLnd vvilh a sma‖screwdriver and

removetheretainingringfromthehousing．

Fi9．41．了・、3 Usミng cauticHl∂S nOlto（］rop the rotor，remOVe therotorsetfromthe housingand thespacerfromthedriveshaftend side．Remove the

0′ ・ringfromtherotorset．

F竜g．41．1D・皇 Tul・n the sI）00landtlleSleeveso

that the cross pinisin the horizontalposition．

−117−

Pressthespoolandsleeve bYthefingertoremove thesealglandbushingfromthehousing・

野蒜9．弧−1③Remove頼eX釦沌＝ゆ針糎叩＝血

SealgIand bushing． Using caution as not to damagethebushing，remOVethedustsealfromthe Fi豆．41．14・自 Pしiiき1汁帖叩GO巨n＝1i‡（：foi・＼Ⅵ＝て！i；1

Sealglandbushingwithascrewdriver・

the sIeeve to remove the6centeringspring from the spoolby hand．Then turn the spooIslowIY toremovethespooLtowardtherearside． （3）Disassemb吋Ofcheckv油e

鞘ぬノ射．12 ④ Removethebeari喝柑Ce′モhrusモ

needle rolrer bearing and bearing race in that order．

即臥41．15 ① Remo∀e the′∫Ogg曽ring from醸e

housing and remove the set screw of the check Valvefromthehousing． Note： The set screwislubricated with SCREW しOC．

②抽繭l憂8ぬ陀妄nモ0輔escrewhoIeinthecheck Seatandremovethecheckseatbypu‖ingthebolt from the housing．Remove two L 0′■−rings from thecheckseat．

F壷g．軋13⑥Turnin9thes蔓eeveandthespoo憂

to the rightandlefts10Wly，remOVethemfromthe housing toward theoppositesidetotheflangeas

③s如モモhehou如g∂nd電叩theendp肇ateside light］y to remove the balland the check ba

retainerfromthehousing．

Shownin Fig．41．13．Then removethe cross pin fromthespootandsLeeveassemblY．

−118−

2．lnspection

〈引 戸easse汀1的Cf叩り〔王ia！1ds言把V・ニ

①c‡ean81‡meta！董盲cp∂rtSin c‡eanso‡vent8nd

drywithcompressedair． ②cheek8‡‡parts盲n the…r join裏門gsurf8CeSねr SCratChes or burrs which would cause oilleaks．

1ffound，rePlacethepart．

Cautionl：When using a waster c10th or paper for wiping soIvent off the part．care should be exercised as nottoleavewastethreadorsoonthe

Surface sinceit c8nenterモhemechanisn】，CauS暮ng troubles．

Caution2：Do not useafileorroughsandpaper Onthepart．

杓い牲朋 ① pt8Ceモhe spr盲ng9rOOVe套n the

SPOOland the spring groovein thesleevetoward the same direction andinsert the spooIinto the

3．Reassembly （1）lnstallationofcheckvalve

Sleeve，turning the spool．Make certain that the

SPOOlis rotating smoothlY，hoFding the spline of thespool． ②A毒盲gn themaモehm8rkonthespoo‡w掴1輔e matchmark on thesleeve．

＠㌦SETSC円EW 、

‥○・・−RING O

‖○‥lRING O

ヂ

＼

cHECKSEAT

宝で ト

BALL CHECK BALL RETAJNER

F姦g．梯1．1＄ ① using紬eezers，盲nserモモheeheck

ba retainerinto the check valve holein the housing．After making certain that the check ba retainer restsin placeuprightinthehousing， inserlthe ball． （参加蘭‡new慮メ0〆ぎ・r妄咽SOnthe書argeandsmaE‡

F毒g．軋1窃③put亀he叩00妻∂nd抽es‡e糾eⅥ雨h

SeatOn the housingwith thedr‖ed section down

their matchmarksaligned with each other．onthe WOrk bench．Set six centering springs back to

and pushitin untiIit stops with care as not to

back each otherin aninsertion tooIwith the

damagethe 10

notchedsectionsdown，aSShowninFig．41．18． ④Ra盲sing翰e spoo暮a冊きe如mモhe s‡eeve．

diameter areas ofthecheckseat．Insta‡Ithecheck

・rings．

③Lubri00te醸e seモ＄CreW W圧h LOCT汀E No．

242and tightenit witha hexagonalwrenchkeY．

installthe centering springsin thegroovesin the

Make certain that thesetscrewhead recessesfrom

SPOOlandthesleeve．

theendfaceofthehousing．

⑨紙erモ鹿cenモ即in9SPr毒n9Shavebe帥Se鵬d

in the center of the spooland the sleeve．align

Checkvalveset＄CreWtOrque ＝1．2kg−m±5％

the end facesofthe spoolandthes［eevewiththe

frontendofthesprings．

−119−

Fig．4t19 ⑥ tnse托thecrosspin軸roughthe

holesinthespoolandthesleeveandfitevenly． （3IReassemblyofeontrotvatveside Fig．41．≡1 ヰ tilSt∂‖iil【さ！）（！：】I−i明l−aく：n．tll…Sl・

needle ro er bearing．and bearing racein that order，

野ig．軋20①Holdingモhecrosspi門h8r盲ヱOnt8‡声

installthe spooland sleeve assemblyinto the housing from the end plate side，turning alittle to the right and teft，untilthe end face of the assemblY a［igns with the rear end face of the鞘隠・那㍍招 ⑥ 抽融通＝1かe（uStSealonthese81 housing．

紬nd bushingwith the侮モSide po摘t妄ng toward

C8ution：lf the spooIand sleeve assembIy was

the bushing．Press fittheX sea］ringontheseal

instatledinto the housingfromthe rear end side． glandbushingbYthefinger． thecrosspincouIddrop．

②関akecertainth8t抽espoo‡andsIe帥e8SSem− blyrotatessmooth［y． ③puモモh母hou＄ingo円∂暮eve！work benchwith theendplatesideup．InstalIanew 0′′−ring．

Fi草．弧23 ⑥ Turningモhe se感g‡and bushing−

installitinto thespooL Driveituntilitcontacts thebearingracewithasofthammer・

⑦汀繭附加相加油gr盲nginthegroove盲n抽e housingtoIockthesealgIandbushing．

−120−

（4IReassemblyofrotol・side

Fig．41．27 ④lnstalE a neⅥ7′∫0′f−ring on the SPaCerPlatesideoftherotorset．

Fig．4も24①put抽ehousinginavisewiththe SOftjawsofcopper mouth piecesorwastecloths， ho）ding theflangesection．Cleantheend faceof thehousingbycleanhand．

Fig．那．25 ② w潜1∂n飢￥1y−ring，Putthe SPaCer Plate on the housing，aligning the match・ mark on the spacer plate with the matchmark Onthehousing．

芦蓑9暮軋2＄⑥poin血gthe一′0′′−ringfittingarea

Of the rotor set toward the spacer plate．instaIl the spacer plate on the rotorset．withthestator t−OttOnl（Ain Fig．4l．2と‡）al如血wiiき1thelint10n thedriveshaft．

Note：Rし・membcr！hatlinesA，B．C：andD，Which

representtheposition andthe plane ofeach part． areinpara‖elwitheachother．

⑥with the drivesh8無andtherotorfiモモe8to Fig．41．2ぢ ③ For positioning thed屑ve shaft．

each other，align the matchmark on therotorset Withthematchmarkonthehousing．

draw aline on the spline end face as shownin Fig．41．26．Turnthespoolandthesleevesothat

the ぽ0お Pin becomes para】lelwith the port Surface of the housing，andinsta tofittheyokeareatothecrosspin．

thedriveshaft

−121−

4l．3．4

JNSPECT10N OF STEERING WHEEL

Measuringinstrument：●steeItape

F毒g−4瑠．29（∋＝場面Ithespac即盲閂the㌢0モOrho！e Ofthe rotorset．Withanew 一0一′−ring，Puttheend CaPWiththematchmarkonthehousing． Fig．41．31

1．Checkingforplay 川 PIaywithengineshutdown Turn the steering wheelto measurethe ［ock− to−Iock′′distance at the periphery of the wheel

Orthemovingangleofthewheel， Note： Thel lock・1：0−lock distance means the

range from the contaGting of the spool and the CrOSSPintotheoperatingofthedriveshaft． t2）Playwithenginerunning ①sモ穏㌻モモheeng如摘感知油は拍摘戊駒場狩猟

F壷g。紙3￠⑧Lubぬ摘湖融甑擁膵潤購画廊扇

andinsertinto the end cap holes．Tighten the ②P‡8Ce醸e steer妄ng whee‡∂＝he cenモer poo

Sition and brake the machine．Apply the parking in the sequence as shownin Fig．41．30．to thebrakesecurely．

SCreWS tO aboutl．5kg・m．Then retighten them

③了融侶舶用細痴境南磯＝ぬ椚廟昏璃加齢・

torquespecified．

treme or vice versa to check the operating range

Endcapfittingscrewtorque

Of the steering cy＝nders bY meaSUring the pe− ＝2．75kg−m±5％

ripheraldistanceofthesteeringwheeL withatape

lnstallthesteering shaftandthesteeringwhee1 0n the spooland make certain thatthe spooland the sleeve are rotate smooth［y．When their rota・

meaSure，

Caution：Therangeinwhichthesteeringcylinders do not operateshould be checked bYthe motion

tionis hard，itindicatesthatthefittingscrewsare OVertightened． Check the screws for proper

Ofthe bucketandthetires，

torque．1f they do not rotate smoothly，itindi−

CateSthatdustismixedbetweenthespooIandthe Sleeve and the housing．Disassemb［e，CLean and

reassembleagain．

−122−

馳矧血射融朋頼砲両歯蘭欄吻ぬ欄澗油料 Standardplay＝10−20mm Usefullimit ＝20mm ormore

2．Loosenessinspection Move the steering wheelin a11directions to Check for tightinstaFlation of the wheel．Check also for tightinsta［lation of the wheelon the Orbitroland the coIumn jacket．looseness of the

41．4 STEERING PUMP

The steering pump has the sarne structure as themainpumpexceptforitstype． Fordisassembly and reassemblyofthesteering PUmP．refer to the corresponding section of the bearing，and wear of the hard rubber bushing．mahlPUmP． 1f unsatisfactory，rePair or replace． Move the

COIumn jacket up and down to check for tight installation of the steering post and100SeneSS Ofthe mounting bracket，and retighten orrepIace ifnecessary．

4l．5 STEERINGCYLJNDER

8ACK−UP RING

Fi9．41．32 St00ri叩CYlindorConstrtJCtionandConponontParts

−124−

41．5．21NSPECT10N

41．5．1 DISASSEMBLY

Measuringinstrument：●V・bIock●Dialgauge ◎Cy一室nderg8u9e◎Micrometer〈25−58mm〉

（む＝oE8醸este即ingcylinder室nav皇紀Wi鮪so寵

jawsofcoppermouthpiecesorwastercloths．

●F10Wdetectororflawdetectingagent

②鮎move the4画毒nder窃P mOuntin9bolts

and remove the cylinder cap assembly from the l．8ushing Steeringbody．

①Measure抽einner diame嶺汀Ofモhebush盲n9S Of the piston rod and the cYtinder tx）dy，andif bodY，With the piston and cylindercapassembly excessiveorunevenwearisfound，rePlace． Onit． ②cheekモhe bush摘gsintheinnersurfaceねr ③Rernove the pisモOn rOd打omモ摘c￥妻in8er

SCOreS，andifunsatisfactory，rePlace． 2．CYlind即bodY

①usin9員侮wdeモect吼Checkthewetdofthe Cy＝nder bodY for cracks，andif unsatisfactory， repairorreplace．

②checkモhe壷nnersur管a∈eO†モhecYl盲nderbo8y

for wear，damage or deformation，andifunsatis− factory．replace． 3．Pistonrod

F蓋g．41．33④＝otd輔epistonrodinav；sew妄th （むCheck the piston rodねrscratchesorwe∂r′ andif unsatisfactory，rePlace．The piston rod

so食言awsoずcoppermouthpiecesorwast即C‡0モhs．

and remove the cotter pin and then the Locknut fromthepistonrod．

havingslightscratchesmayberepairedorreplaced ifnecessary． （参S岬桝椚譲渡如踊椚相通感触℃−bEocksatboth ends on a stool．Measurethedeflectionoftherod

atitsmiddLeareawithadiatgauge，andifunsatis・ factorY，rePlace．A slight deflection may be repairedbYaPreSS（cotd）． 4．Pistonandpistonring

Check the piston，Wear ring and outer seal ring for wear or damage．andif unsatisfactory， replace． 5．Cylindercapandpacking

Fig．軋3梯⑤Remo∀e納epis紬nassemblyfrom the piston rod and remove the wear ring，inner

尊）checkモ如c塁earanceおt騨eenモhecyさindercap andthepistonrodandifunsatisfactory，rePlace．

②Checkthe′慮U ′・PaCkingof抽ecy肋8er毘Pand

Sea［ringandoutersealringfromthepiston・

⑥Remove抽ecylin8er儲PaSSemb墓yfromthe

the dust seat of the ftange for wear of thellp，

Pistonrod．

damage or deterioration，andif unsatisfactorY，

⑦Remove軸e4reモ扇nerp！8官emountin9bo竜ts and removethefJangeandtheretainerp［atefrom thecYlindercap．

replace．

⑧Remove翰e du§モ§ea暮fromthe侮nge．

⑨Remo∀e輌′ Ug′・PaCking from the吋inder CaP and remove the 0 −ring and back・uP ring fromthejointofthecY＝nderbody．

一125−

41．5．3 REASSEMBLY

ReassernbIY ShouJd be performedin the se− quence opposiモe to disassembly observing 抽e followln9requ盲ほm紺tS．Pr竜or to柑aSSemb肝吼 be sure to repIace alJ

0′ ・rings and dust seaJs

With newones． ①when 盲桐髄Iling the ∫′U′ ・PaCk盲n90n th昏

（‥Yぎi■−ぐIc！・C叩．riし｝ilO†llaリー）il−UW■・0■−q州t・ect吾0−10r th￠lip；thei盲p＄hould be po盲nモedモOWard the tailside．

②Thepis伽㌻盲nSShouldb8ins油80n鮪e Pistoninthefo［［owingorder＝Wearring，innerseal ring，OUterSealringandwearring． ③漱雨用融紬両津鹿画ぬか錮㈲町醸ぬ再感 the retainer plate．dust seaL，flange and cYlinder 00P如拙は秘結油粕‡led on抽ep毒sモOnrOd盲n醸aモ order．Then the pistonisinstal［ed with a new 一 0′ ・ring．

④‖oldthe p毒ston rodin8V篭sew托hso徹jaws

of copper mouth pieces or waster cloths and tightenthelocknut． Pistonrodlocknuttorque＝35kg・m±5％

⑧u戒軌痛感棚減廟㈹硝町画 ⑥with pis電On『盲ngs董ubri88電ed w軌hyd柑u‡‡c

Oil．installthe piston rod and piston assembly Onthecylinderbody． ⑦拍醸‡‡醸草 Cy璽inder c叩 On the cY曹ind即

body8nd醸en電ightenthemount摘gboltsofthe CaP・

Cylindercapmountingboltandnuttorque ＝6．5kg−m±5％

⑧加舶＝童n闇V軌戚S闇ほ研一抽e蝕脚絆教戒 tightenthe retainer platemountingboltstosecure theretainerandthefJangetothecY）indercap．

Retainerplatemountingbolttorque ＝1．5kg・m±5％

−126−

41．6 TROUBLESHOOTtNGGUtDE Problem

CheckingMethod

PossibleCause Underinf）atedtire

Measure with rire sause lnflate properly

AerationduetoIowoiHevel

Check oil level

1nsufficientdischargeofsteeringpump

Hard Steerlng

RemedY

Addoil

CheckfJowratesand COmParemeaSurementS inlowandhighspeeds Measureftowrateand

）nsufficientftowtosteeringfine

P「eSSU「eOfoil

andpump

Cloggedsteeringlinetubing

Measure flow rate

RepairorrepI

BrokenhYdraulichose

Checkvisually

Reptace

MeasurefJowrate

Replaceparts

Priorityvalvespringbroken PrioritYVa）vespootsticking OrbitrolrnaIfunctioning

Disassemble and check Rt?place

SteeringcYlindermountlooseness

Checkvisua）lY

LoosesteeringwheeJandcoIumnjacket

Replaceparts

SeeJJLoosenessofsteer− JngWheelandcoIumn jacket′′

Truck Wanders

AerationofprioritYVaLve

Extractoilandcheck Changeoit

0「Pulls

Check visually

toone

Repair

Side

Uneven tire pressure

Checkwithtiregauge Adjust

UnevenJYWOrnt汗es

Checkvi＄Ua‖y

OrbitroIm81functioning

Disassembleandcheck RepIaceassembIy

−127−

Replaceortire 「otation

Probtem

CheGking Wfethod

PossibJeCause

Checklevel

Addoil

Checkforsteeringforce

CheckfordefIection OrrePlace

PriorityvalvespoolmaLfunctioning

Measure flow rate

Replaceparts

Uneven tire pressure

Checkwithtire9auge Adjust

Unevenly worn tires

Checkvisua11y

Lowoilleveloraeration Hard

Steering In one

Side

RemedY

Replaceortire rotation

Steeringshaftbearingworn DisassembIeandcheck Replacepart Loose

Steering

Wheetor COIumn

Retighten

jacket Steerin9Shaft Loo＄eCOIumniacketmountingbolts

Check for looseness

Reptacepart

Steeringshaftbearingbroken Noise is fornoise

Retighten

TurnwheeJandcheck

Replacepart SteeringcyIinderplnOrbushingworn

heard Repair

SteeringcyJinderanchorbossholeworn Steeringcy＝nderpistonrod鵬ntor

Disassemble and eheck Repair or replace

broken

Orbitroldustsealdamaged

Disassemble and check Replace dust seal

SteeringcYlindercappacking．dustseal Oilleaks

Or JO

−ringdamaged

Steerin9Iineconnection＄）00Se．hYdraulic

hose or tubing damaged

−128−

CheckvisuaIty

Replacepart

Checkvisualty

Retighten，rePaIrOr replacepart

41．7 MAINTENANCE SERV（CE DATA

Checkin91tem

StandardSizelmml Usefulしimit（mm）

PlayofsteeringwheeHwithenghlerUnning）

10・20

20 or more

Lnnerdiameterofsteeringcylinder

64．14−64．23

Outerdiameterofpistonrod

31．975▼32．000

Jnnerdiameterofbushingofpistonrod

31．74・31．75

32．0

Outerdiameterofconnectingpins （steeringcYJinderpistonrodtofrontframel

31．59−31．62

31．4

Clearancebetweenconnectingpinandbu＄hing

0．12・0．16

0．6

Jointgapofpistonwearrin9

0．8・2．4

Thicknessofpistonwearnng

3．09−3．17

lnnerdiameterofbushin9OfsteeringcYlindertail

31，74−31．75

32．0

Outerdiameterofconnectingpin （steeringcYIindertailtorearframel

31．59・31．62

31．4

Clearancebetweenconnectingpinandbushing

0．12−0．16

0、6

Re‡iefpressureofpriorityva】ve（kg／cm2〉

130

−129−

41，8 MAJOR BOLTTORQUECHART

OrbitroLcheckvaIvesetscre

Note：TheallowabIerangeoftighteningtorqueiswithin±5％．

−130−

5．FRAMEANDAi上声EDPAR−てでS 5写．FRA師ヒ 51．1 CENTER HINGE PIN

Fig．51．1Upp即Hin卵 LOCKNUT

Fig．51．2 LoworHingo

−131−

51．1．1REMOVAL

③や極小＊頑姉掛軸拍輌葎流隷承upthe

l．Pr叩aration

frame and measure thelooseness between the

①Forthe∝〉nVenience of removing軌e柚ge

Pin，Park the machineonalevel front frame and rear frame in BlockaJIthewheels．

Surface with the

Plate of the rear frame at both sides，just behind thelower hinge POSitions justin USing the same

front of the10Wer hinge pin．

disassemble and shim adjust at the bearing cap．

a straightline． （shimthickness：0．2mm）

②support the bottom pivoモ

Pin，Witharigidstand． ③supporモモhefront育ameat

frontandrearframes．1flargeloosenessisfound，

manner．

④supportthe触nモaxiean8モherearframeend

byrigidstands． 2．Removaloflowerhingepin

①Remove納e8spiぬbe董r妄ngmountingbolts

Of the center propeller shaft and remove the CenterPrOPe ershaft．

②R￠mOVe抽e two‡oekp響a紬mounti咽bolts and remove theIock plate from thelower hinge Pin．

③Remo∀e電he nuモOfthe hinge pin bo‡t那涌

remove the hinge pin bo［t and the retaining Plate．

⑥Dri∀etheloⅥ柁rhingepinupw8rdwiモh∂bras＄ baranda hammerfromundertheframe．

3．Removalofupperhingepin ①Removethecoverptateず和m輔eず‡00rboard

Ofthecockpit． ②Remov母the紬0‡oekplaモemounモingbolモSand removethe10Ckplatefromtheupperhingepin．

③Drive out納e upper h盲nge pinw毒醸a brass baranda hammer． 51．1．2 RE［NSTALLATION

①Lubr言開電e 軌e hinge pin with grease and reinstallinthesequenceoppositetoremoval．

②Lubri闊teモhe h盲nge pinぬ蔓モWith SCREW− T］TEandtightenthenut．

HingepinboJtandnuttorque （lubricatedwithSCREWTITE） ＝＝Okg−m±5％

Lowerhingecaprnountingbolttorque （lubricatedwithSCREWT［TE） ＝12．5kg−m±5％

Hingepinlockplatemountingbolttorque ＝13kg−m±5％

−132−

Centerpinhingepinlooseness Standard100SeneSS＝0．5mm Usefullimit

＝1．2mmormore

5l．2 MAJNTENANCESERVICE DATA Fmntframe Checkingltem

St dsize（mm） UsefuILimit（mmI

1nnerdiameterofboommountin9bushing

63．50−63．55

64．4

Outerdiameterofboommountpin

63．17−63．20

62．6

Clearancebetweenboommountpinandbushing

0．30−0．38

1．5

1nnerdiameterofbushingatbucketcYlindertaiJside

50．88・50．90

51．7

Outerdiameterofbucketcylindermountpin

50．47−50．50

49．9

ClearaneebetweenbuckeモCylindermountp盲nandbushing

0．33−0．43

1．5

rnnerdiameterofbushingatboomcyJindertailside

76．20−76．25

77．1

Outerdiameterofboomcylinderpivotcasting

75．90−75．99

lnnerdiameterofanchorplatepinhoJeinsteerlng Cylinder

31．70−31．72

32．2

Outerdiameterofpistonrodsidepinofsteeringcylinder

31．59−31．62

31．4

Clearancebetweensteerin9Cylinderpistonrodsidepinand anchorplatepinhoJ

0．08−0．13

Rear frame

Checkingltem

St dsizefmm） Usefulしimit（mml

璽nnerdiameterofanchorp‡∂紬Pinholeinsモeerlng吋inder 31．70−31．72

32．2

Outerc量iame穣rofsteeringeylindert∂ilsi血pin

31．4

31．59−31．62

CJearancebetweensteeringcy仙dertailsidepinand

anchorplatepinhote

0．08−0．13

lnnerdiameterofpinholeinbosiSeCtionofrearaxle CradJesupport

37．90−37．95

38．5

Innerdiam飢erofcradIebushi咽

38．00・38．02

38．8

Outerdiamet6TOfcradlepin

37．77−37．80

37．2

CJearancebetweencradtepinandpinhoJeinrearaxIe SuPPOrtboss

0．10−0．18

Cle∂r∂nCebeモWeenCrad憂epinan88radlebushing

0．20−0．25

−133−

1．5

Upperhingepinsection St，dsize（mm） UsefuJLimit（mm）

Checkingltem 1nnerdiameterofupperhingepinbossbu＄hing

44．55−44．60

44．、8

lnnerdiameterofself−aligningbushin9InPinfittingarea

44．43・44．45

44，9

Outerdiameterofupperhingepln

44．40−44．42

44．0

Clearancebetweenupperhingepinandbossbushing

0．13−0．20

1．5

CJearancebetweenupperhin9ePinandieJf・ali9ningbushing

0．01・0．05

Checking ltem

StTd扇7＝m雨

OuterdiarneterofJowerhingepinhead

76．01・76．03

DiameterofLowerhingepinbosshole

76，20・76．22

（uppersideofrearframe）

CLearancebetweenlowerhin9ePinheadandbosshole

0．17・0．21

1nnerdiameteroflowerhingecoIIar

65．14・65．26

ClearancebetweenJowerhingepinandco‖ar

0．14−0．27

OuterdiameterofJowerhingepin

64．97・64，99

lnnerdiameterofseIf・aligningbushingp

64．99−65．00

Clearancebetweenlowerhingepinandseff−a‖gningbu！hing

ー134−

0・0，03

UsefuILimittmmI

51．3 MAJOR BOLTTORQUE CHART ltem

Torque（kg−m）

Boomey暮inderpivotcast毒ngretainingpt離emoun柚gb8蔓t

‖．5

UpperhingepinlockpJatemountingbolt

13

LowerhingeplnmOuntingbolt

110

Lowerhingec8PmOunt盲ngbo暮t（lubr毒catedw盲モhSCREWT汀Eき

12．5

Lowerhinge10CkplatemountingboJt

13

SteeringcYlinderconnectingpin10CkpJatemountingbolt

5．4

CradleconnectingpinJockboJt

13

BucketcytindertailsideconnectingpinJockbolt

13

Boomanchorconnectingplnretainermountingbolt

23

Note：Theatlowablerangeoftighteningtorqueiswithin±5％・

−135−

ー136−

61．1．1DISASSEMBLY Before attem郎in9モO dis8∬embIe醸e pump，

Cleantheexterioroftheunitwithacleanc10th． The procedures of the disassembly，inspection and re∂SSemb墓y of翰e main pump a耶巾r融和

tothatofthesteeringpump． Note：The appearance of the unit shownin the Photographs belowissomewhatdifferentfromthe actua10ne．but the maintenance procedureisin COmmOn．

Fig・6l・4WhenthewearpIateFishardtoremove． Placeモhe cov即housi咽hor盲zo机紬廟牒噸油汗＝如 wear plate F to thr? gear hole bortom and then

raiseits10Wly，keepingithorizontal．

F壷g蓼＄1．2① Remove burrsonthepor…さnge Surぬだ母and put marks on the housing forモhe COnVenienceofcorrectreassembly．

②Remove theadapte卜tO−COVerhous妄n9亡妻amp− 1ng boIts・U写ing cauモぬn as noモぬdam8geモhe faying8r朗Of the housing′remOVe the hous裏門g

芦i9・6瑠．5 W廟紬e9earSmeShedw盲モhe∂Chother′

bytappingthesamewithasofthammer．

Puモmarksonモhesha熊endsofモhedrivege8rand driven gear for the convenience of correct re− assembIv．

Fig・61・3 RennovctheミニOVi汀！1く）しほi●1g帥（j代n−わ、′くさ 柏針弼脚Ⅷ南柏F∴0 ′−ringandback−uPr蓼ng．

戸墓守・＄瑠16Re汀−OVe抽edrivegearanddrivengear，

ー137−

61．1．2 tNSPECT10N

Clean alIdisassembled partsin flushing oiL or CleaningsoIventanddrywithair． Caution：NeverusegasoIineforcleaning．

Fi卦61・7F；eiTO、′C抽‥・ごVrニa！ぎー！8te C，′一け‥高一！i・

SPaCerandseaJringfromtheadapterl

the adapter．At this time，uSe CaUtion as notto ぬ欄駆輔憺欄幽庵ぬ如鳩那感感坤erSea‡hole・

鞠い弧瀾＝触閥Ⅶ ぞ如擁い郡上ぬ南 of叫 adapterandthespacer，ifany，byoilstone・

rig．61．∋l＼・−l．1i−ミゝ：・「・汀芯・‥＝；−：、、…−、‥‥誹ニ：・こ細一言：−‥！5

unlessitis required to replace．When removing 二十 どキー∴−ilhぐ−11rVく；！；・iトこi；iヨ乙さ−・ミい畔；一S：・㌻［−1：、l二C叩盲●

theneedlebearing．useabearingpuller・

housingbyoilstone．

−138−

61．1．3 REASSEMBLY Reassemble the main pump in the sequenee OPPOSite to disassembly，uShlg theadapterasthe base．

Fig．61．12 Removef］akingand burrson theside Ofthegears bYOilstone．［fanYOfthe foIIowing

defects is found on the drive gear or the driven gear．replace．

Fig．61．14 Pointing the marked sidetowardthe ho．e bottom，PreSS fit the needle bearing．Make

a．Deepflaworcracksonthegear．

b．More than two and three dentson the bearing Certain thatthe bearing endfacerecessesfromthe journalasfound． 1f the journalis found defective，rePlace also machiningsurfaceoftheadapter． theneedlebearing．

㌻ごiミミ し、ぎ：ミ：・●！二 …・・1、：て∴；！；こ・・−し−・●∫ィ童ilこ毒ミ1ヽ；lり1；iご1日Vで Fig．61．131f the wear plateis found to have inthebackofthewearptateC．

deep flaws or excessive damagedueto cavitation in the gear contact area，rePlace aJIof oilseal′ dustseat，Sealring．L 0 Lringandback−UPring．

・チ：：！・●⊆ニニ、・てヾ‥：、…、こi．・：い：こ−妄√iふvjミ竜「ざW†「も！・函・ Oftheadapter．

−139−

and the back−uP

the grooves ln

鞠納轟浄①極秘‡鱒郎梵竹油㊥㊥暗御車軸球・uP ringasshowninFig．61．20． ②嘩画梅軒恥＝離奴㊦納金戸板噂ぬ痛紅や叫ヤ

thesametothebottomofthegearhoJe． Note：The wear plate F should beinsta ed so

that the back facebalancegroove havinga notch 勘錘塵融ぬぬ巌油壷明断摘巌甘油如鱒頑．

Fi9．61．18lnstallthe drive gear and the driven gear，a＝gningthematchmarksonthem・

Fi9．61．21lnstallthe wear plate F as fo ows：

Place the cover housing horozontally．Put the

−140−

longer endofthewear plate F totheextentthat the seaL hides from the opening of the cover housingand then puttheother end sealby press・

ingbYthefingerorascrewdriver．

Fig．61．24 Tighten the cover housing mounting bolts．

Coverhousingnountingbolttorque ＝16，6kg−m±5％ ′Fig．61．22 Press the wear plate F from the

SUCtion side and put the cover housing over the gear・

Fig．61．25 AppIy a thin film of grease on the

innerperipheryoftheoilsealandpressfititwith ahandpressorasofthammer． Note：llle］ip shouId be pointed toward the Fig．61．23lnsertthedowet pin untiIitcontacts PumPgearSide．

the pin holein the adapter． Press the cover housing untilthe cover housing faying area con− tactsthespacer．

Fig．61．26 lnsta

the dust seatin the same

manneraswith the oilseal．

−141−

馴．2 TROUBLESHOOTINGG川DE

Frohie＝

靴闇油脂e凱闇

CheckingMethod

Remedy

Measuref［owrateof

1u豆ged引＝雨0＝…半 H

Replacepart

PUrnP C血甘≠ oT：bunble＄inoii

Aerationinpump

Pl印n9那1∂rep訓r

td‖k

Cavitationinpu獅P

Cわecko‖細雨k加eath即 Replacebreathe酢

妻虻。W榊∂舶廟皇室

Cheekl即糟＝noiltank Addoil

Pumpshaftordrivingshaftsleeve

櫛鹿組陥Ⅷ駆rating

broken

‖OISe

rnnerwal［ofpumpwornor damaged

＝OISe

狩ipingorhydraui盲ehosedamaged

Checkoirleakinline

PIP＝〔

sure of pump

Repiace針椚噂牒r Part

閉脚波蝕机欄森組廟

Replacepu関野 RepaIrOrrePlace Part

Measuredischargepres− Cleanorreplace

臨席＝汀副「モmi米e〔貞insuctionline

闇触感U料㈹狛noiIモa醸

Lowieveiofわyc汗au毒icoil

Part 萱 斗ddいi十

Measuredischargerate

皇妻nsufficient離滴御難

0ヂpu捌駆

k紬㌢OPerating

義n。erW掴。umPW。m。rdamaged

repLacepump 触岬

l ・

Aerationinpump

0盲卓篭ank

Cavitationinpump

ヨPiP画紺靴抽坤繭

誓わeekoi章鷲a門kbreather Rep！acebre∂油er Checkforoperating

lnnerwaJlofpumpdamaged

noise

RepLacepump

勘椚叩凋rivingshaftsleevewornor ぎmpropercenモenng

Check for operating noise

Removeand recentering

lmpr明媚ず柳姻Iityofhydra

CheckqualityofoiJ

Changeoil

凱ぬbles Checklevelinoiltank Addoil

両hY− Jト∂ulic

Checksuctionside PIPJngandconnections Ofhydrau［ic‖ne

い（‡

Airmixedinoilc狛乱摘消化椚 SVStem

−142−

Airbleedor rep］acepart

62r CONTROLⅥlLVE 〔i2、盲 口重SASSヒⅣ旧し1−r【NSF一仁C■！汀沖、ト八一や≒こ二i・？EA占SヒⅣ墓臼LY

STAINLESS BALL

CAM

E）

BUCKET SP00L

CH∈CKVALVEPLUG

HECKVALVEPOPPET

Fig．L62．1ControIValveConstruction

−143−

62．1．1PRECAUT10NIN DISASSEMBLY

a．SinceallpartsofthecontroIvalveareprecisely machined，SO USe Caution as nottodamagethem andselectacteanworkingare． b．ThespooIsareselectfitforthehousinglWhen replacementis required，rePlaceasacontroIvaIve assemblv． C．Each poppet ofthe mainand port reliefvaIves

③snapoffさPr盲ng p首n抽mc叩−andpuI蔓out detentpinfromcap． Holding down the return spring．dismount Plunger end，and take off seat．return spring，

andseatsequentiallY． （2）Disassernblingofhousing

isalsoa selectfit．Replaceasareliefvalveassem−

blY． d．Whenthedetentareaofeach spoolis required to service．simply detachthe valve coverwiththe COntrOL valve on the machine．ln regard to the Piping，remOVe the air hose at the bucket side detent．

e．When servicing the contro（vaIvein on・the・

machine condition．be sure to place the control leverin the neutralposition andIockit．since hydraulic oiJ00n flow outif the spooIshifts． damagingtheseals． 勒62・3①Remove梱OmOun加gぬ毒tsアrom

62．1．2 SPOOL UNIT FOR BOOM

Sealplateatspooleyeside．and dismounttheseal

l．DisassemblY

PIatefromhousing． ②usin9∂Wirebarorthe‡妄ke，remOVe伽wiper

（1）Desassemblingofdetent

Sea［fromhousing．andthentakeofflipseal．

③Remo∀e SeaIplate and spacerfromhousing atthedetentside．

④Remo∀eWiper seat and‡ipseal如mspacer inthesameprocedureasonthespooleyeside． ⑨Drawouモモhespoots‡ow‡y†romthehousing．

Fig．62．2①T8keo曹細Ohexagon＄OCkethead

bolts for mounting spacer and cap，and pullthe CaPbyforcetodetachitfromthehousing． Note：When the capispulledbyforce，thedetent COmeSOff．

（診Removethree3〆16fgan80neフグ32−′sta盲n暮ess

Steelballs and detent spring from thedetent pin inthecap．

−144−

2．lnspection

②F托theseatoずspringモ0抽espooIend，and

（むClean a毛！me電a川cpartscare†ut！yincteaning fluid，anddrybyairblow．

align the spacer and sea］plate with housingbolt hores．then holdingdown the return spring attach

（診Checkthedeモentspr盲n98n8reモurnspringfor breakageandaging．Replacedefectiveones．

thepIungerendtothespool． ③Coa電the de価モSP由gw軌grease′8ndモhe

③checks琶a墓円蓋esss穣elba楓andr叩Iacedefee−

StainresssteeIba‖swith Never−Seizeorgrease．

tiveones．

Note：When overhauling renew allstainlesssteel balls．

④check㊨醸espooEouモ即Surface8nds璽idingparモ

OfthetDreOf housingfor scratches，UneVen Wear or burr．Correct minor defects by oilstone or lapping agent．Replacein assemblyif seriousIY damaged． 3．Reassembly

（1）Re8SSemblingofhousing ①紬闇離輌牒胱摘甜油滴胤Iic引u軋andput

itinto housing．andcoverthespooleYe PartWith Ce ophanetapetoprotecttheseal． ②R印さaee署ipsea‡andw壱perse8暮雨hnewones．

F毒9．62．卑唾）Asshownin抽edrawing，Seモdetent

and direct thelip part oflip seaJtoward the SPring and stainlessstee＝〕a］Isintothedetentpin inside 05 housing and the lip part of wiper seal byusingjigs．

towardits outside．then coat thelips with hy− draulic fluid and assemble them into the spool eyesidehousing．

③inser電Sea篭plate from spooIeye s竜de，an8

tightenit to the housing with bolts to hold the WiperseaL ④Renew摘′fO′′−rin90fspooしandco8モ妄tw柚

hYdraulic fluid，then fititinto the ring groove Of spacer．Temporarily tighten the spacer with hexagon socket head bolts byinserting from the Fig．62．5⑥Asshownaぬ∀e−COnneCtthedeモent endsideofspool． Pin，and hititlightlyto assembleintothepIunger

⑨Rep蔓ace油層＝p se8t and wiper se∂‡of the

SPOOlendsidewith newones，SPreadthelipswith hydraulic fIuid，and assembIe theminto the SPaCerinspecifiedliporientation． ⑥拍開招1翫e s朗Iplate柑om the end side of SPOOl．andfitittothespacer． （2）Reassemblin90fdetent ①Mo∀eモ如spooIs暮owtvtofixintheneuモra星

end（pIate the detentin thefirstorsecond stage groove）．

⑥円＝御細油粕明画パ！妙＝扉＝感es′Put SPring pin and fix the cap，and bY PreSSing the CaPtemPOrarilytightenthe boltintothehousing． （》M哉ke sure the de毛色n＝uncモ竜onis normal， andfirmlytightenthehexagonsocketheadbolt．

POSition，andinsert the seat ofspringand return SPringintothe end sideofspool，and removethe hexagon socket head boIts used for temporary tightening．

−145−

（2）Reassemblingofdetentwithairkick

62．1．3 SPOOLUNIT FOR BUCKET

rl・Mov【ミ 小口 叩00⊆ s亘ow；Y tぐ ■汀＼il一 口eUll−；−！

l．DisassemblY

阿痛恨即も甜閻＝nsertspr蓼n9Seal抑d相加軌牒威喝

（1）Disassemblingofdetentwithairkick

intotheendsideofspool．

②m牒画咽瀾融細牒加顧m幽む油翫咽軒軌 Sl：a！pld†e wililhclltSii！〔卓ho璽t喜1ロl㌦1両ml！1⊂＝りi11q

down thereturnspringfitthepIungerendtothe SPOOt．

③co8電醸edeモen電SP㌻蔓n9抑d儲mW勧9reaSe． andstainlesssteelba swithNever−Seizeorgrease． ⑧抽酬摘幽虹鱒廠牒勒訂か感繭針蜘‡ bal［ssequentiaHyintotheplungerend．

Fig．62，6①Remove琶W￠hexagonsock母the8d

bolts from the cap，and pullthecap by forceto detachitoffthehousing．

②翫澗那智緒由南∬蛮紺＝ぬ‡s′Cam and detent SPringfromthedetentsleeveinthecap・

F毒g．62．7 ⑥ 如shown aぬ∀e−鹿極目狛摘聞知

③Takeofずthep8ugof8e電enモSteeVeダan8ぞ托る bolt（5mm）to the pistonin detent sleeve，and

bar（jigB），PuShthecamandputthestainIesssteel

dismountthepiston．

Sleeve．Put cap on the detentsleeve．and fitthe

④Remove輔e§naP由go晋deモents‡別添昭，and

CaP tO the housing by tightening with hexagon

takeoffthecap．

sockethead bolts．

ぬ摘パ雨ヵpiun9er en8．and push盲n the c蓋e電ent

⑧‖olding80Wn the return spr盲ng．d盲smoun電

⑧＝憫鴎叩抑汀涙針軸細山‡㈹V￠′f盲tsnapring

P‡ungerend∫窃nd remo∀e Se軋r離urn sPrtng，and

to the detent sleeve．and fix the cap and detent

SeatSeqUentially．

Sleeve．

⑦R￠neW∫一0′′・r壷ngsofp盲s加。Coa電themwi翰 桓如融髄鞘庇摘涌引出ぬ翰町醸触．‡nse柁醸e （2IDisassemblingofhousing Disassemblein the same procedure for dis− Pistonintodetentsleeve． ⑧R鮒脚〃鮮−㌢盲n90管画g′窃nd f盲モモ08eモent

assemb＝1gSPOOlunitforboom．

SIeeve． 2．tnspection

⑨廃紙ach a套r hoseモO PEug′and m8ke sure触

①cheek鮪e ou如Sur短ce ofdeelutch p盲sモOn

detentfunctionsnormaHy．

andslidingsurfaceofdetentsleevebore．Replace ifunevenwear，StePPedwear，Orbruiseisfound． ③eheごk輔eotherpa托S盲n輔esameproぢedu㌻e forcheckingspoolunitforboom・ 3．ReassemblY

（1IReassemblingo†housing

ReassembleinthesameprocedureforreassembLL ingspoolunitforboom．

−146−

62．2 TROUBLESHOOTJNGGUIDE ProbIem

CheckingMethod

PossibteCau‡e

Operate．disassemble′

SpooIcLearanceistoonarro

andcheck

RepJaceinassembly

Operate．disas＄emble，

Spool action

isheavy

Remedy

andcheck

replaceinassemblY

Checkmountingsurface

Correctmounting： Deformationduetodefectivemount− fordistortion，boItsfor retightenぬtts ing of oontrol ValVe looseness

Controttinkageisdefective

Operateandcheck

Adjustorreplace Pa「tS

FauItyadjustmentofmainrelief

MeasurereIiefpressure Adiust

Valve

Slow Excessiveinternatteakofcontrol action Valve

Measurerateofflowintb

CVlinder Checkforexternaloil

Seatofcontroしvalveisdefective

ReplaceinassemblY Replaceparts

享．

LackofhYdrauIicftuid

Checklevetinoittank Replaceparts

HydrauticoitcontainsduitOrWater

Removefilterandcheck； dischargehYdrauficoil 8ndcheck

CheckbyseeIn9PumP troubleshootinghints

Lackofpumpde＝verY

Pressure

andctean

doesnot iseif

Measurereliefpressure Adjust

r

SPOOlis OPerated

Measureretiefpressure

Sticks

Springofmainreliefvalveisa9ed

DisassembIeand

Clean；OrrePJaceparts

Disassembleandcheck Replace

0rbroken

Spootstrokeisimperfect

Checkcontro川nkage Adjust；rePfaceparts

ExcessivespooIcIearance，CaUSing internaHeakofcontroIvafve

Measure natural drop

SpooJdoesnotreturncomp）etelyto

CheckcontroIJinka9e Adjust；rePJaceparts

CYlinder

descends With V∂lveat hold

RepIaceinassembly

MalfunctionofoverloadreIief

Measurereliefpressure Adiustorcorrect MeasurenaturaJdrop．

POSition

anddisassembJeand

causing internal leak of valve

RepIaceinassembly

CheckspooJ

SpoolisnotsetcompIeteIyin

Checkcontrollinkage Adiust；rePlaceparts

−147−

Problem

CheckingMethod

PossibleCause Overloadre＝efvaIvesticks．orse

Cylinder

Mea＄Urereliefpressure

＄Urlfaceほworn

descends With valve at tnternaLleakofhYdraulkcYIinder hold POSition Looseconnection，Orhydrautichose

RemedY Clean，OrrePJace

CheckbYSeeingcY＝nder SeecylindertroubLe− troubleshootin9hints ‡hooting

CheckhydrauIiclinefor oilleak

Place

Checkcircuitpiping， hose，Otherconnections forloosene＄SOrbreak− age

CheckoilIeveloil tank

Replenish

Checkpumpforaer− tion or eavilation

Seepumptrouble− Shootin9

CheckfHterforcIoggtng

Cleanorreplace element

1mproperqualityofhYdrauHcfluid

Checkgrade

Usespecifiedfluid

LackofhYdrauIicfluid

CIleCklevelinoiltank Replenish

Airismixedinoilcirculatingline

Checkoiltankfor bubbJing

Lackofhydraulicfluid

Check fevel in oil rank Replenish

NoisY OPe卜

ation． exGessive bubb＝ng OfhY− dr8utic 暮

Removefilterandcheck；

dischargehYdraulic fluidandcheck

Chan9efl山d

Deeline of pump function

Mea＄UreOilpressure andflowrate

Replace

Measurere＝efpressure

Cleanorreplace PartS

PreSSUre

rise

Replaceelement；

Hydraulicfluidcontainsdustorwater S飢

Of reIief doesnot

Deaerate，and COrreCt

MainreliefvaIvesticks．or＄eat

Surfaceisworn 0verloadretiefvalvestick‡．OrSeat surfacei‡WOrn

Measurereliefpressure

CleanorrepJace Part‡

−148−

7−．む，OA蛤HAN扮LきNG§YSてEM 、J●享．ミニ、‥￥き．．蔓草勺i〉藍RS 71．1．BOOMCYLINDERS

CYLINDER CAP

‖0■■−RING AND BACK−UP RING

OUTER SEAL RING

LOCKNUT

Fig．71．1BoomCYlinderConstT−uction 71．1．1 DISASSEMBLY

71．1．21NSPECT10N

Measuringinstrument‥●V−block●Dialgauge ●Cy＝ndergauge●Micrometer（50to75 mm）●FIawdetectororflawdetectingagent

！、：ゎし！；こ；1；−．てトー・‥圭一‥こ−ノ…！！、（；こ：‥−−‥い・巨l＼、誉−・、「；−ミ

jawsofcoppermouthpiecesorwastec10ths． （手・1こ−さ・−も・・、こ・、：：：‥ ぎ．−！・：・．＼・：・…≡ご．・・・・∴ごミ：・・∴∴・・言∴二t bolts and removethecylindercapassembly from thecylinderbody．

l．Cleaning

●、1Fてel・…・！ミ1＼鳩廿∴・・こ亡くlき．い・ミ ぎ：ご・・．・・；∴、、、・：：・：・ミ．．．

①c摘酢蛸m摘舶用納如M摘雨喝ぬ鹿沼紳

body withthe pistonand thecYlindercapassem−

drywithcompressedair．

blYOnit．

（診The rubber pa沌S Shou匿d be e萱eaned w旺わ8 CleanclothorwashedincIeanhydraulico軋

④‖0蓄d醸ep妄s柏nrodin8V盲sew妄モh so難題aw＄ Of copper n10Uth pieces or waste cloths and re− movethecotterpinandthenthelocknut．

：弓…￣…・、−ミ、01い…−ご

2．lnspection

．

（1IBushing

OuterSeatringfromthepiston．

（む補e8Sure the盲n門er diameter￠ぞ抽e bush盲n9S

⑥Remove電hec￥董裏門8er00P8SSem輌触mモhe

Ofthe piston rodandthecylinderbodyandcheck

Pistonrod．

for excessive wear or uneven wear．1f unsatis−

r−−ノ：…−ミ、、；；￣・（・りe ㌔…−、．丁、−i‥−「さtt：：・、．・一 汗H∵、1：！トー；ミ1ざ1 boItsand rernovetheftangeandtheretainerptate

factory，rePlace．

fromthecy）indercap． ⑧Rem￠Ve電he8usモSea星☆0澗モわe管亀a門ge an8 removethe U ，PaCkingfromthecylindercap． 再∴m・！…こソ、ご∴・こ…1：き∴・ミミ†・・い−：・二…・モ・：津！−1・−：ミミ．・、．車

ミ、ゞぐこ．、ミ．き＼・、・：こ（こミ…−！∴ニミーーミミし：−：！とぐ．；￣…Cニ√；：：：r≡；√−…！1ざ．：t富三戸㌫−、−−・ごi−V

③cわeekモhe毒nner suげ8Ce O干☆柑busゎーn9for

replace．

RemovethesleevefromthecyLindercap． や抽l一点′い一基ミミミ●−（−∴・；！・；ミご∴●：∴−・、・こ‥・●ミ・− い；・・rミ fromthejointingareaofthecylinderbodY．

ー149−

ほ〉 CY柚d引・body

Pistonrodlocknuttorque＝103．7kg−m±5％

すUs盲11g∂111aq11eticllこ】Wde加亡ロ「．ellnCktllCWRld

OfcYlinderbodyforcracks，andifunsatisfactory，⑨Lubrieate the p融on ringwi軸hydrau暮ぎcoi暮 repairorreplace．

andinsta

②Check the cylinder body言nner surfaceぬr WearOrdeformationandifunsatisfactory，rePlace．

body．

thepistonrodassemblyonthecy＝nder

⑥‡nstal蔓鮪e c∀linder c叩mOun幻ng bolts on

the cylinder body and tightenthem．Tightenthe （3ICapandsleeve

nutsfinallv．

ナぐ：；1eCkいぃ⊂叩i11tlle′′lj−′−P肛killg†沖両Ⅶal・eこI

for occurrence of rust or burrs．andif found．

CYlindercapmountingbo）tandnuttorque ＝17．7kg−m±5％

rePal「・

②Measu柑軌e妄nner8蔓8meモero管軌ec∂甲Ste鮒e

⑦Align盲門g theぬ托ho聖母sin翰erぬinerpl竃te

and check for wear or uneven wear，andif ex−

With the bolt holesin the fJange，instalJthe

CeSSivedefectisfound，rePlace．

柑臨如訂P極細訓戒＝i8咽eOnthecy暮indercap，抑d

tightentheretainerplatemountingboIts．

（4IPistonandpistonring Check the piston，Wear ring，and outer seal ring for excessive wear or damage，if unsatis・

factoryrepF8Ce． （引 Pistonrod

①check the p妄stonrod如seratぢhesorw脚， andif excessive defectis found，rePlace．Slight SCratChesmayberepairedbyoi［stone． ②suppo代官hepis電OnrOd斎電ぬモhendswi鮪V− blocks on a stooland check for deflection of the

piston rod by measuring its middle area with a dialgauge．Andifanydeflectionisfound，rePlace

thepistonrod．AsJightdeflectionmayberepaired byapress．

71．1．3 REASSEMBLY

′巨 Re11いi‥こ 雨： ○ −！−i−11i．（iliSt SごG！邦1〔j ′しドー・

PaCking with new ones．Reassemble the boom

Cylinderin thesequenceoppositetodisassembly， Observingthefoltowingrequirements．

③抽繭‡l☆ほご′U′ やaCk蓋ng ontheeyiinderc叩

Withitstippointingtowardthecylindertail． ③加商‡th母retain即P‡a隠．血統鍾姉督励関 こミilこ呈（：∨…盲：1由：●r∫二い訓11ilぐご！）i抽＝i一口し＝ll相鋸−し川くje幸一． Then with a new 0 l−ring，insta the piston on thepistonrod．

④Ho邑d廟ep盲s短n㌢Od盲n8V盲sewithso食言aws Of copper mouth pieces or waste c10ths，and tightenthe10Cknutandlockwithcotterpin．

−150−

Retainerplatemountingbolttorque ＝4．6kg−m±5％

71．2 BUCKET CYLINDERS

Fig．71．2 Buck8tCYlind8rConstruction

71．2．21NSPECT10N

71．2．1 DISASSEMBLY

①‖oldモhebuckeモCy‡盲nderin8Visewithsoft

For the inspeeting procedure of the buGket

jaws of copper mouth piecesorwaste clothsand Cylinder，See Para． remove the fourcylindercap mounting boltsand

lNSPECT10N

of the boom

CYlinde「．71．1．2．

remove thecYlindercap assemblyfrom thecy‖n・

derbodY． 71．2．3 REASSEMBLY

②Re†ⅥOVe軸￠Piston rod from the cy肋der

bodY With the piston and cylinder cap assemblY①R叩Iace∫ 0′′ィing．dustseaし′′U−′−PaCkingwith Onit．

newones．Reassemblethe bucketcYlinderin the

③Hold the pisぬn和d篭n a∀ise w盲th copper

SequenCe OPPOSite to disassembly，Observing the

mouth pieces or waste cloths and remove the

fo owingrequirements．

COtterPinand10Cknut．

②さnst穏‡la new′′U′′−PaCking on the cylinぬ

④Removethep盲sモOn8＄＄mb‡yずromthepis加

CaPWithits［ippointingtowardthecylindertail．

rod and removethewear ring，innersealringand ③けば摘朗1肋ereモainerp‡8晩dustseれflangeand OuterSealringfromthepiston．

Cylindercapinthatorderonthepistonrod．With

⑧鮎move軸ecy＝ndercapassemb‡yfromthe

a new′一0′′・ring，insta‖the piston on the piston

Pistonrod．

「od．

⑥Removeモhe four r細iner p蔓8te mOunting

④HoldthepisモOnrOdina油ew軌softね㈹

bolts and remove the flange and retainer plateOf copper mouth pieces or waste cloths，tighten fromthecyIindercap． thepistonrodlocknutandlockwithacotterpin． ⑦Remove the dust seal如m theず蓋ange and Pistonrodlocknuttorque＝69kg・m±5％

removetheLLU

・PaCkingfromthecY＝ndercap．

⑧Removethesn叩ringofth￠Cy＝ndercapand

「5・Lubric訂巨、1he pistoilrhlg With hy（lr∂uhc oil

remove thesleeve．

andinsta thepistonrodassemblYOnthecYlinder

⑨Removethe L，0′｛一盲・ぎIlg an（＝8Ck−UPr盲Il〔lfrom

body．

thejointareaofthecylinderbody．

−151−

71．31NSPECT10NOFLOADHANDLLNG SYSTEM

⑥‡童1SLai：訓1d瑚1【eilthecyii雨el・CaP・T代Y＝11†雨

boLtstothecylinderbodyandtightenthenuts． Cylindercapmountingboltandnuttorque

71．3．1 0PERAT［NG SPEED CHECKING OF SYST∈M

＝12kg−m±5％

Measuringinstrument：●Stopwatch

⑦Al輌ng the bo托ho蔓e＄inthe昭電竃妄nerpIate

With the boltholeintheflange．installtheretainer Plate andtheflangeonthecylindercap．Tighten

l．800mliftingtime

theretainerplatemountingtx）lts．

①餅槽淡裏鳩￠針橡紺＝わ輔痘戚＝融取捌通計帥師

Retainerp［atemountingbolttorque

addoil．

②Pu電in軸e bueket sand or鮪e！ike eorr℡−

＝4．5kg−m±5％

SPOndinginweighJtotheratedloadandparkthe machine at a［evelsurface．AppIY the parking brake．

③糸ぬ融巨編l￠∂d茎咽 Sy＄t鱒m モO r∂ise抽e

叩蛸漁場髄鞘問融酬いが0一書055t￠650c・

Actuate the boom cylinders to the fuIIstroke SeVeraItimes to b］eed air from the cylinders． ④p‡塾Ce醸e bucket on納e ground androEきiモ back．Keeptheenginespeedathighidlingrpm． ⑥Actuaモe廟ebo8m養母∀er短measure翰et盲me required for the bucket to raise from thelowest leveltothehighest． Liftingtimeofboom（load；3100kg） Standardtime＝6．4sec Usefullimit ＝8．Osecormore

⑥＝ず鮪e酵＝準猶＝は細0摘摘いheck触0毒l leaks from the hydraulic hose and piping con・ nections，main relief pressure，Priority valverelief

PreSSUre．Oilteaks of the boom cylinder and discharge rateof mainpump，andifunsatisfactory repairorrepIace．

2．Bucketdumpingtime ①汽油輔椚矧鮎閥離狛紺‡sur管aceandapp‡y the parking brake．Check the oiI［evelintheoiL

tank．Actuatetheloadingsystem to raisetheoil モemPeratureモ055to650c−

②R8盲se醸eぬom笈W綾h翰e bucke電un†oaded

andactuatethe bucketcyIinderstothefuIIstroke several times to bleed air from the buckez Cylinders．

−152−

③Ra盲setheboornsto油e鳩hest豪evelandroIE

Boomcy］indernaturaldrop（15min） Standard value＝110mmorless Usefullimit ＝165mmormore

backthebucket．

④Keep納eeng盲nespee88琶h毒gh盲d‡i咽rP汀篭．

⑤Actuatethebucketlevertomeasuretheモ妄me

⑧lfthesh削盲咽amOunモismore痛8n几鮪euse乳l璽

required for the bucket to move from the ro − backpositiontothedumpposition．

Iimit，Check foroilleaksfromthehYdrautic hose and pipingconnections，Oilleaksofboomcylinder

Bucketdumpingtime（un［oaded） Standardtime＝1．Osec

andthecontroIva［veinthatorder．1fanydefect isfound，rePairorreplace．

⑥げthedumpin9＄Peedistoostow．eheck如 oil leaks from the hydrauiic hose and piping

2．Bucketcylindernaturaltilt

COnneCtions，main reIief pressure．prioritY Valve

①using軸e s8me PrOCedure8S for check盲ng

relief pressure，Oilleaks of bucket cYlinder，and naturaldrop of the boom cylinders，raisetheoil

discharge rate of the main pump．1f unsatisq モemperatureモ055to650c．putin the bueket factorY，rePairorrepIace．

Sandorthelikecorrespondingtotheratedload．

②Aぬate the bueket cylin舶rsモO th母子u‡【 stroke severa［times to bleed air from the bucket 71．3．2 1NSPECT10N OF NATURAL DROP OF

Cy＝nders．

CYLINDERS

③Raiseth￠boomstothemax緬umreaeh抑d

Measuringinstrument：●Stopwatch●Steel

tiltthe bucketbackbYatX）ut20degreesandplace

tape

the controIvalvein the neutraland shut off the englne．

l．］nspectionofboorncYlindernaturaldrop ①check軌eoi書きevetintheoi＝遣nk抑dacモu細

the piston rod withfeIt−POinted penorpenciland

the［oadingsystemtoraisetheoiltemperatureto

measurethedistanceuptothecy＝ndercap．

④lmmediatetya触rtheenginei＄Shuto玖m8rk

55to650c．

せAfてer15nlinutes．measurethedistanccfronl

②put s∂円d or so correspond盲ngin w鴫ht to

the mark to the cYlinder cap and calcu［ate the Shiftingamountofthepistonrod．

the ratedloadinthebucketandparkthemachine

ataleversurfaceandapp］Ytheparkingbrake． BucketcYlirdernaturaltilt（15min） ③Ac餌aモeモheboomcy‡inderstothefu‡tstroke Standardvalue＝45mmorless tob［eedairfromthecylinders． Usefullimit ＝70mm ormore ④Rolきbackモhebuckeモ8ndraisetheboomsto the maximum reach．（Atthis time，the centerof⑥tf the sh漸咽amOuntis more th8n the the boom anchor pinis at the samelevelas the usefulIimit，Check the bucket cY］inder hydraulic 10ad scenterofgravity．） ⑨p‡ace軸econモro‡va蒼veintheneutraさ．．position

PreSSure Circuit using the same procedure as for

CheckingnaturaldropoftheboomcyJinders．

andshutofftheengine．

⑥如椚Iediatelv a触r the即gineis shuモ、down′

mark the piston rodsoftheboomcYlinderswith felt・POinted pen or penciL and measure the dis− tanceuptothecylindercap．

Caution：lfadhesivetapeis usedforthispurpose be sure to removeit after the measuring．1fthe

叫川盲sh†l．盲twliic2し」Sedaillagetく〉thel）．1【：k盲；1qS．

⑦Aft訂15m血恥meaSure翰el母n酢h付om

the mark to the cylinder cap and calcuLate the Shiftingamountofthepistonrod．

−153−

71．3．3 LOADINGSYSTEMSTOPPERS

3．Cautionsforfittingstoppers

l．Checkingatmaximumheight

①Low hydrogenelectrodesareus感ね㌻W母蔓d− ing．Dryth那bぬreh8nd8モ300紬3500cfor

①馳rk班emaGh納eona‡郡el餌掩頂摘涙ほ如頗

SOme60minutes，andmovetheboomandbucket，

the parking brake． Raise the booms to the maximum height，tilt the bucket alittleforward

andweldindumppositionasfaraspossible． L、盲、【ium oしItlh（！PailitS O11thcゝLopp（汀WC！di‖g

antishu†（）†fth・e11q盲111∴

PartS by using a gas burner−Or rub them off by

③Durnp the bucket488egFeeS短Che洩勧

Wirebrushorgrinder．

COntaCting condition between the bucket side StOPPer and boom side stopper and the bell and bell crank side crank support sid

Clearance against boom arm and other contact

・さ、財1ml‡拭kw柚曲1g†lln Sl叩Per．et血盲11踊

Surface．and avoid arc strike on the machine

StOPPer．

（al暮ow to spark by tapping the tip of electrode

敏雄牒叩頭閲卿阻凍凍岬軒凝嘲卿＝画

SO aS tOimprove depositing）．striking arcs onIy OnthetemporarYmetal．

StOPPer，remOVe the stopper andinstalla new StOPPer by welding．1f the bucket won t dump

ヰト正伸t11…・Ck＝泄1こ‖w叩SilqSh（汀■∂S！ヽいSSi仙

bY48degreesduetotoohighstoppers，SCraPethe

（about4mm），aVOidingsuddenarccut，andextend

StOPPerPrOPer．y． ④whentouch富ngto脚eStOPPe㌻On‡y−iずthere妄s

the arm somewhat and hold st＝and cutit off SlowtY．

⑧A触㌻Weld盲n9e8Ch‡a￥er，remOVe the sla9

a clearance of more than O．5 mm at the other

SUfficientlY，and producea smooth bead，COrreCt−

StOPPer，remOVe the stopper，and weId a new One．When touching unevenly on one stopper， ingundercutoroverIap． if thereis a clearance of more thanlmm both

］ateraIIyandlongitudinalIy，rePlacethestoppers．

2．lnspectionunderc8rryingposition 十Pa■・k仙emoclli！1C（Ml∂l（さVe！sし廿†ac＝11れl叩iY

the parking brake．Raise the booms so thatthe CenterOftheconnectingpinofthebucketandthe boomsis ata heightofabout470mm abvethe ground．（connecting pin centeris10Wer than thecenterofthewheelsbYaboutlOOmm．） つノS；ミ）＼VIY！−け＝ヒmdく廿1（さijUCトこl、1しmlilしhe huckel

StOPPer COntaCtS the booms and measure the reartiItingangle． ③章ず納ebuck朗ro‡暮b8Cka喝Ieは肝臓桐汀輔都 52degrees，SCraPe the bucket stopper properly．

1flarger than 52 degrees，remOVe the bucket StOPPerandinstaIlanewstopperbywelding． 喀）Whentheboomarm短uchesoniyo門e離OPPer， andif thereis a clearance of O．5 mm or more

On the other stopper，remOVe the stopper，and

Weld a new one．When touching unevenIy on One StOPPer，andif thereis a clearanceoflmm Or mOre bothlatera y and horizontal］y．repIace thestoppers．

一環54−

7l．4 TROUBLESHOOTJNG GULDE

Problem

CheckingMethod

PossibteG】uSe

CheckoillevelinoiI tank

Bucket 0「

boom＄

Checkdischargerateof

donot

function ataIl

PumP

DefectivereliefvaJveofcontroIvalve

Measure relief pressure

Remedy Addoit Reptace Adjustordisassemble andclean

lmproperqualityofoiJ Oper− ationof bucket Or

booms

PriorityvalvemaIfunctioning

isslow Mainpumpmalfunctionlng

Gheck oil quality

Changeoil

Checkoilpressureand flowrate

RepIace

＋Cavitationofmainpump

CheckoiJtankbreather Replacebreather

DefectivereliefvaJveofcontroIvalve

MeasurereLiefpressure

しowoitlevel

CheckoilJeveJintank Addoil

Bucket

8nd

booms donot have POWer

Check oil quality

Changeoil

Checkoilpre＄SUreand ftowrate

Reptace

CheckforbubbIesinoil tank LowreJiefpressureofre‖efvalveof

Adjustordisassemble and clean

PIPlngandrepair

Measurereliefpressure Adjust

COntrOIvatve Bucket has Boomcylinderpiston−10 ′・ring POWer

but 【氾OmS

Measurenaturaldrop

RepIacepart

Measure natural drop

Replacepa「t

donot h∂Ve

POWer

Booms have

BucketcY＝nderpiston

0′−ィing

POWer′

but bucket doesnot have

Measurereliefpressure

defective

POWer

ー155疇

Problem

Booms shimmy Orjerk vvhen rai‡ed

CheckingMethod

Po＄SibleCau＄e しowoitlevet

CheckoilleveIinoiI tank

Addoil

Cavitation in main pump

Checkoiltankbrea− ther

Replacebreather

CheckforbubbJesinoit t8nk

PIPlngandrepaLr

BoomcYlinderpistonroddefLected

Checkfordeflection

Replace

Torsionofboom

Checkfordeformation Ofeachboom

Repair or replace

Booms Shimmv Orierk When towered Booms Or

bucket drops naturaト

fy

Remedy

Checkforplayof linkage Defectiveportreliefvalveofcontrol Valve

Adjustorrepla￠e

pin or bushing

Measure relief pressure Adjust or repair

hternaHeakageofcontroJvalve

Replass as assembly

OiHeaksfrompi＄tOnrlngOfboom CV＝nder OilleaksfrompistonrlngOfbucket

MeasurenaturaJdrop

Reptacepart

CY‖nder

Noise：

Cavitationinmainpump

Noise

Gheck oil tank breather Replace breather CheckforbubbJesinoil Check‡UCtionside

Aerationinmainpump

tarlk

義

Checkforoperating

！

PUmP

Mainpumpinsidedamaged

noise

Checkforoperating noise

Main pump sleeve worn High− Pitched Toohighpressuresettingofrelief relief

Pipingandrepair Replace RepJacesJeeve

Measurereliefpressure Adiust

Va蔓ve

noise Loose pipe line Dueto Pipe Vibra− tions

Checkforloosness

AerationinpIPlngOfhYdraulic

Retighten

Checkfornoise，bubble Checksuctionside Pipingandrepair

in oil tank

Cavitationinpipingofhydraulic

ChecknoiseandoiI tankbreather

暮ine

RestrictioninpIPtngOfhydraulicJine OrChatteringvatve

RepJacebreather

Checkfornoise

Dueto reSO−

nanceof machine bodv

Check for noise

−156−

Repair

ProbJem

PossibleCause

CheckingMethod

Cracksofoittank

RemedY Wetd

DefectiveoilseaJofcontT・OIvalve SPOOt

VisuaJIYCheck

Replacepart

Oil DefectivedustseaI．1JU −PaCkingorI10′′− leaks rlngOfboomorbucketcYIindercap Loosepipingioints．brokenpIPlng

Retighten．repalrOr

OrhoseofhYdraulictine

replacepart

OveruseofmainreliefvaIveofcontrol Valve

Measureretiefpressure

Low oil level

CheckoillevelinoiJ tank

Addoil

MainpumpmaIfunctionlng

Measureoilpressure andflowrate

Replace

Too high Oil temper− ature

Cavitationinmainpump

Adjust．Usemachine PrOPe「1Y

Gheck oil tank breather Replace breather

Aerationinmainpump

Checkbubblesinoil tank

Checksuctionside piping and repair

Disassembleandcheck

ReptacereIiefvalve assembly

Booms Or bucket ‖

fadto

function

OCCa■

Sionatlv

−157−

71．5 MAJNTENANCE SERVICE DATA 感

Booms

Checkingltem

St dsize電m叩き UsefuILimittmm）

lnnerdiameterofboomanchorpinbushin9 （outerdiameterofpin：63．17to63．20mmI

63．50−63．55

64．4

50．65・50．70

51．2

1nnerdiameterofbossofpinconnectionboomandboom Cylinderpistonrod（outerdiamterofpin：50．55to50．58

mm） 1nnerdiameterofbossofpinconnectionboomandbeJJ Crank（outerdiameterofpin：56．82−56．85mml

lnnerdiameterofbushingofpinconnectionboomand bucket（outerdiameterofpin：63．17−63．20mm）

56．95−57．00

63．48−63．50

64，3

Bucket

Checkingltem

St dsize（mm） UsefuILimit（mm）

Innerdiameterofbucketboss（boomandbucket）

63．37−63．42

64．4

Outerdねmeterofpin（boomandbucket）

63．17−63．20

62．6

CIearancebetweenpinandboss（boomandbucketト

0．17−0．25

lnnerdiameterofbossofpinconnectingbucketandpush rod（outerdiameterofpin：44．13−44．15mm）

lnnerdiameterofbe

44．25・44．30

44．8

Checkingltem

St′dsiヱe（mm） ∪‡efulしimit（mmI

crankbushh19（boomandbelJcrankI

57．13−57．15

Outerdiameterofpin（boomandbe crank）

56．82−56．85

62．6

Clearancebetweenpinandbushing（boomandbeltcrankI

0．28−0．33

1．5

44．25−44．30

44．8

44．25−44．30

44．8

lnnerdiameterofbo＄SOfpinconnectingbelLcrankand bucketcyJinderpistonrod（outerdiameterofpinこ 44．13・44．15mmI 1nnerdiameterofbossofpinconnectingbe

crankand

岬紬関山h触＝柚冊terO†ド両‥叫．13一斗4．15汀−m）

Checkingltem

Sでds盲ze（mm） Usef山しimit（mm）

Distancebetweencenterrofpinholesinpushrod

875

1nnerdiameterofpushrodbushing（beJIcrankside）

−158一

44．35−44．37

45．2

Push rod Checkingltem

St dsize†mm） UsefuILimit（mmI

Outerdiameterofpin（beJJcranksideI

44．13−44．15

43．5

CJearancebetweenpinandbushing（beJJcrankside）

0．20−0．24

1．5

lnnerdiameterofpushrodbushing（bucketside）

44．32−44．34

45．1

Outerdiameterofpin（bucketside）

44．13−44．15

43．5

Clearancebetweenpinandbushingtbucketside）

0．17−0．20

1．5

Boom cylinders Checkingltem

St′dsiヱe（mm） UsefutLimit（mm）

1nnerdiameterofcYtinder

‖5．03−114．94

Outerdiameterofpistonrod

57．18−57．23

Jnnerdiameterofrodsleeve

57．29−57，31

ClearancebetweenpistonrodandsJeeve

0．06−0．13

lnnerdiameterofpistonrodsJeeve

50．87−50．90

51．7

50．55−50．58

49．9

Outerdiameterofpin（boomcYlinderpistonrodandboom） Clearancebetweenpinandbushing

0．29−0．35

Naturatdropofboom（15m両

1100rless

1650rmOre

BoomHftingtime（1oaded．sec）

6．4

8．00rmOre

1．5

BuGket cylinder Checkingltem

St dsize（mml UsefリーLimit（mm）

1nnerdiameterofcylinder

89．40・89．63

Outerdiameterofpistonrod

44．48←44．53

1nnerdねmeterofrodsleeve

44．59・44．61

CJearancebetweenpistonrodandsIeeve

0．06−0．13

ー159−

BuGket Gylinder St，dsize†mm） UsefuJLimit（mm）

Checkingttem

感 44．35−44，37

45．2

44．13I44．15

43．5

Clearancebetweenpinandbushing

0．20−0．24

1．5

Naturaldropofbucket‖5min）

450rless

70 or more

lnnerdiameterofpiitOnrOdbushing Outerdiameterofpin（bucketcylinderpistonrodand be11crank）

Dumpingtimeofbucket（unloaded．sec）

1，0

−160−

7l．6 MAJOR BOLTTORQUE CHART 1tem

Torque（kg−m）

ConnectingpinlockboJt（boomtoboomcylinderpistonrod）

5．4

ConnectingpinLockbolt（boomtobucket）

13

ConnectingpinlockptatemountingboJt（boomtobelLcrank）

8．5

Connectingpinlockbolt

26

Connectingpintockbolt（pushrodtobucket）

13

Connectingpin．ockplatemountingbolt（bucketcYlinderpiston

rodtobellcrank）

4．8

BoomcylinderpIStOnrOdlocknut

103．7

Boomcylindercapmountingbolt

17．7

BoomcYLinderretainerptaterTlOunthlgbolt

4．6

8ucketcylinderpistonrodIocknut

69

BucketcY‖ndercapmountingboJt

12

BucketcYlinderretainerplatemountingbolt

4．5

Noモe：Thea嚢蔓ow8b旨erangeoずモigh官印妄ngtorque妄sw廟妄n±5％．

義明

驚夢

Book No．823AE lSSUED：JULY，1983

T肝中野始恥群好学昏昏．：。＆晋捗モ TRADING OFF［CE： CABLE ADDRESS：

ALlrightsreserved．

15−5．1・Chome．Nishi−Shimbashi．Minato−ku，Tokyo，Japan TOYOUMPANKITOKYO J・5807010 PrintedinJapan

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