Professional Documents
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ElectraVan Service Manual
ElectraVan Service Manual
J Z T I N D U S T R I E S , INC.
AUSTIP; , TEXAS
CHAPTER 1: BODY
1- 3 . . . . . .
BODY PARTS . . . . . . . .. . . . . . . . 3
1- 4. DOORS . . . . . . . . . . . . . . .. . . . . . . . 4
1.5 . WINDSHIELDGLASS . . . . . . . . . .. . . . . . . . 18
1.6 . INSTRUMENTPANEL . . . . . . . . . .. . . . . . . . 20
1- 7 . SEAT . . . . . . . . . . . . . . .. . . . . . . . 27
1.8 . I N N E R T R I M . . . . . 5 . . . . . . . . . . . . . . 29
1- 9 . INNER ACCESSORIES . . . . . . . . . . . . . . . . . 31
1-10 . OUTER ACCESSORIES . . . . . . . . . . . . . . . . . 32
1- 1. COMPONENT PARTS OF BODY CONSTRUCTION
- . --
1. Front Bumper
REMOVAL AND INSTALLATION
2) Remove the two bolts under the right and left combina-
tion lights to disconnect bumbez.
3) Installation is the reverse order of .-remqval.
2. Rear Bumper - k
2) Remove the four bolts on bumber uider the right and left
combination light to disconnect bumper.
3) Installation is the reverse order of removal.
-*
1-4
1-4. DOORS
i
A. COMPONENT PARS OF DOORS
1
m%
D€TAIL 'C' DETAIL '0'
NOTE:
After adjustment of the door, confirm there
is no play around the door when the outer
handle is depressed with the door closed.
Play, if found, shall be removed according
to the following procedure.
1) Loosen four screws; Fig. .' 8 Adjusting door hinge
2 ) Turn the wedge around the pin with
the wedge centering on the wedge c. Small amount of adjustment in the door
receiver. transversal direction and vertical dircction
3) ,Loosen screws. can be performed by loosening the door side
4 ) Close the door to check play of the hinge.
door.
1 1
Fig. 7 Fig. . q : Adjusting door hirye
a *I-..
3. Door window regulator d . Turn the glass while rotating the regulator
tlandlc, remove the glass from the regulator
1) REMOVAL and hold the glass so that it doesn't iaII.
a. Remove the regulator handle, inner remote
k
.
: handle
.. ;Ad..door inner pull handle, and NOTE:
'remove.Ith;- .door trim.
-?
Fig. 13 RemovinggLzsj
Fig. . 4 Removing r e p l a i o r
2) INSTALLATION
Installation js the reverse of renioval. Pay
careful attention to the direction o f the puU
handlc, the regulator handle and remote handle
Fig. ) 1. Pemoving bolts installation angle.
4. Cab door glass
1) REPLACEMENT
a. Remove the glass assembly from t h e regula-
tor in t h e same manner as rcmoving the
regulator. ,
b. Installation is the reverse of removal.
NOTE:.
To hold the glass horizonatally and move up
and down without iildinalion, finely adjust
the rail of the regulztor sub arm up and
dcwn.
Fig. I b ' Removing rear quarter trim
5. Door lock
I ) REMOVAL AND REINSTALLATION b. Remove t h e stopper (sliding door) from tlie
a. Remove rhc d c o r trim, and t h e service hole lower rail.
cover, and raise t h e glass t o the top.
b. Remove t h e safety knob, and disconnect the
outer handle and inner remote wire con-
nec t ion,
c . Unscrew the door lock rnounting screws, and
remove the lock through the working hole.
d. Installation is the reverse of removal.
C. SLIDING DOOH
I. Sliding door
1) REMOVAL
a. Remove the rear quai-ter trim (refer t o trim
panel item). Fig. .I 8 Removing stopper (center a m )
)
=-%
--
clearance.
TZf 0 2 2
/
Stopper (sliding door 1
2) INSTALLATION
a. Fit the upper arm to the upper rail.
b. Fit the lower arm from the rear cnd of the
lower rail.
c. Slide the door to the front end and fit the /
center arm to the center rait, Stopper (center arm)
. d . InstaU the stopper (sliding door). At this
time, insert the flange of the stopper secure-
ly between the flanges of the rail, Fig. 13 Stopper (center a r m )
f. With the door closed (striker and ratchet
perfectly meshed), tighten the stopper
(center arm) securely.
g. Install the rear quarter trim.
NOTE:
Tightening torque:
Stopper (sliding door)
8 mm bolt:
1.2 to 1.4 kg-m 18.7 to 10.1 ft-lb)
5 m m bolt:
Fig.& Adjusting sliding d o o r
0.25 to 0.30 kg-m (1.8 to 1.0 ft-16)
Stopper (center arm)
8 mm bolts: When inequality has appeared between door
1.0 to 1.2 kg-rn (7.2 to 8.7 ft-lb) and pillar, adjust it by moving the upper arm or
striker to the left or right.
3)
-
Removing and installing the galss
The glass can be removed and installed
together with the rubber.
24
Fig.I.r Moving upper arm
Fig. 3 Rmtovinggh$
-
, broken.
d. Does rhe roller turn smoothly-?.-- Apply
grease on the roller axis.
NOTE:
Tightening torque:
28
Fig, Suspender
6) Door latch
Rubber
Difference of the
eech canter line should
Striker
I
Sliding door
721-023
29
Fig. r r Contact
~ between s t r i k e r
and suspender Fig. Component ports of door b t c k
a . Adjustment 4) Rcmove t h e mounting bolt and two
1 ) Fix t h e connector s o that there is n o mounting screws, then remove t h e latch.
looseness when the wire is stretched fully.
1 2) Adjust and install t h e outer handle so
1 that t h e push lever and adjusting screw
contact wheu thc safety rod is pushed
I
d o w n . Aftcr adjustment, push the push-
b u t t o n , and confirm moving of the pinion
by hand.
!
Adjusting
screw
1
Push lwer T3t 4 2 4
Fig. & Removing lorck
31
Fig. Adjustins screw
5) Raise t h e safety rod upward and remove
b. Removal t h e o u t e r handle. At tlus time, be careful
1) Remove t h e stopper bushing and inner not t o drop t h e mounting nut inside t h e
I
handle. door.
2) Rernovc the trim pancl (refer t o trim 6) Remove the safety rod knob while twist-
panel item). ing it.
3) Remove the connector screw. At this 7) Remove the remote by removing two
lime, b e careful not to d r o p t h e screw o r mounting bolts.
washer inside t h e door.
32 35
Fig. Removing connector sciew Fig. Rcrnoving rcmote
7) Sliding door inspection
Door 'closcs Striker (latch) position Is vertical direction good? Good if door is
poorly. incorrect. Is the door too far insidc? locked whcn
pltshcd by hand
~ & in
e arrow direction.
/ ;.,.-. ,
. ,
i
':stopper . .
(center arm)
.. .. -
j-:I,.;
I
. '
- ;:., .c...:;!.,*',..-'f.: ' .. . .
Symptom Cause Inspection and corrective action
Door closes Latch pinion cover and Insert the spacer under the striker as required for
poorly. striker mesh when the adjustment.
door opened and closed.
*
I
Striker
T ~ w s r
cww
T2 1-025
38
Fig. s&t
Rattles when
vchicle is
moving.
Striker protrudes too far. Install inside.
- r. ..
- _ ...
, --
.a-
+ .. ' .-. - ..
Fig. &
Symptom Cause Inspection and corrective action
Rattles when Roller is not moving. Apply grease between the rollcr and shaft.
the d o o r is slide,
Door doesn't Roller ecccn tric wear Replace the roller, coat the shaft with grease,
slide s m o o t h . znd inside and outside and confirm that rotation of the roller is
diameter wear. smooth. - -
Foreign matter such as Remove the foreign matter and keep clean inside
the sand, mud, etc. are of the rail.
fitted on the roller
surface.
Door doesn't Center arm spring pcrma Coat the spring with enough amount of grease.
open nently straincd or spring When the spring i s permanently strained, replace.
sufficiently. coils are rubbed each
(Door does n o t other.
fly open when
outer handle
push b u t ton
depressed.)
3. Stay
1) REMOVAL
2. Door hinge a. Remove t h e nuts mounting the stay upper
1) INSPECTION from the d o o r (hinge) with the door opened.
a. Whcn the door hinge rattles in t h e front and
rear. left a n d r i g h t , , or top and b o t t o m
directions, tighten the hinge bolts.
b. Whcn the hinge pin is loose, replace the
hinge assembly.
c. Adjust d o o r drooping, joggling and split line
as fouows.
2) ADJUSTMENT
a. Perform adjustment using a spanner or b o x
wrench.
b. Perform door vertical and longitudinal ad-
justn~cnt by loosening the door side hinge
bolts, Fig. * Rernovittg stay
b. Rctt~orcIwo stay lower mounting bolls from
the body.
nti
\
50
Fig. Installing door lock
Fig.
4% R ~ ~ n o v i yslay
g
2) INSTALLATION
Installation is t h e reverse of rernoval,
4. Door lock
I) REBIOVAL
a. Remove the door trirn.
b, Remove the d o o r lock mounting bolts and .I-5. WlNDSHlELD GLASS
remove the lock from the working hole.
REMOVAL AND INSTALLATION
1) Remove the wiper arms.
2) Bend the weather strip inwards and push
the dass, outw3:ds by foot from Ule inside of
thc passenger compartment. Then @ass is
removed.
2) lNSTALLATlON
lnstallalian is the reverse o f removal. Fig. Pushing w i n d s h i e l d g b r
3) When installing windshield glass to t h e 5) Pushing the glass from the outside, p~adual-
body, f i t t h e weather strip onto the windsllield lv pulling t h e work cord at a ri&t angle to the
glass and insert the work cord into t h e weather glass.
strip.
NOTE:
NOTE: a. Fitting is carried out from the upper center
a. Overlap the ends of the work cord at the top of the glass to the l e f t and right.
of the glass. b. Install the glass sufficiently to the body;
b. After the work cord is fitted to the weather gerhly pushing it with hands from the
+ strip, coat all around with clean gasoline, outside.
c. Fit the weather strip on the outside of the
body correctly.
d. Apply a sealing compound (Cernedine
8366E3 into the groove of the weather strip.
1 Work cord
5 A
Fig. M Fitting work cord
54
Fig. alw Appbing senling compound
A24-090 .
5s
Fig. a Sealing pbdtion
1. Component Parts
RIGHT-HAND DRIVE VEHICLE
I
Fig. bS'lb Componerlt parts of inrtrtrmmt porn1
21
a -33
2. Combination meter 3. Ash tray
Fig.
ss
P - P Removing combination meter
6.
Fig. 1-1Et3 Removing l ~ o f d e r
6'
Fig. a-S Removing lid
-0
Fig. a-%d
e Y
~ i r c o n n c c t i nvbing
~ harness
7. Instrument panel
REMOVAt-AND INSTALLATION
1) &or to removing the iristrurnent panel,
remove the steering wheel.
2) Remove the combination meter.
3) Pull out the ash tray and remove the ash
tray holder.
4) Remove the glove box lid by removing Lhc
installing screws.
b4
Fig. 4UOl Removing glove box lid
6. Fuse box lid 5 ) Remove the fuse box lid by removing the
installing screws.
REMOVAL A N D INSTALLATION
I ) Remove 5 nirn screw under the lid.
I 1
Fig. %- Removing control knob
T71-332
NOTE:
When pulling out the lever assembly, take
care the soldered portion where cables are
I d
connected to the heater fan switch is not
Fig. a - nDisconnecti~rgcontrol cable damaged by the body panel.
7) Installation the lever assernbly in the 4) Remove two screws fucing the v e i i l a t o r
reversc order of removal. duct to the lower part of the instrument panel.
I 1
NOTE:
a. When connecting control cables, confirm
all shutters and cock completes are entirely
closed.
b. After connection, confirm the operation of
each shutter and cock complete.
,
Removing wentihior duct installing
screw
3b
~ i gB-m
. Shutter closing position
i
7
screw
FRONT SEAT
I ) Remove the cushion by lifting the front
end of it while pushing it to the rear.
2 , .
Fig. &b. .Removing bcck rest
I I
81
Fig. S-= Removing back rest
1. Component parts
-.>J
. -. DETAIL "C'
DETAIL 'A" m .-.
P ~ p e( 12 10.47) dia.1
Unit: mrn linl
T 2 1.039
1 Clip
2 Trim pancl
I 3 Special tool
T2 1.042 I
Fig. a-HSRemoving t r i m
1 T r i m panel
2 Clip NOTE:
3 Special tool
T2 1 -040 If the removed resin clip is damaged, replace
it with new one.
Fig. Ronoving trim
2 Screwdriver
Fig. PY-rn Removing resin clip F 9 . S ' Removing back door trim
8& 30
rn -*
. 1-9. INNER ACCESORIES
1. Component parts
10
Fig. $F-= Component parts of outer accesories
Fig. a?-&
4. Splashboard
93
Fig. H a
CHAPTER 2 : BODY ELECTRICAL S Y S T E M
2- 1. WINDSHIELD WIPER . . . . . . . ., . . . . . . . . . . 2
2- 2. COhIBINATLON METER . . . . . . . . . . . . . . . . . . 5
2- 3. HORN . . . . . . . . . . . . . . . . . . . . . . . . 7
2 - 4 . TURNSIGNALANDHAZARDUNITS . . . . . . . . . . . . 10
2 - 5 . SWITCHES . . . . . . . . . . . . . . . . . . . . . . 12
2- 6. LIGHTS . . . . . . . . . . . . . . . . . . 14
1 W v r blade
2 wiperum
6 Wanher
7 Cushion A
8 Cushion B
9 W~pcrtink
10 Packing
11 Wtpcr motor bracket
12 Wiper motor
Fig. x-4
2) INSTALLATION
Fig. $2-3 R emotting nuts installation is h e reverse of removal,
Connection fault or Check the connections. Correct connections.
wiring error in S 1
(yellow) or B (blue)
circuit.
Incorrect - - .-
wiper Switch
Bad connection
stopping between terminals 1
and 2 of switch
continuity between
U-2. COMBINATION METER
1. Component parts
-.
1 Meter visor
2 Combinalion meter glass
3 Combination meter window plate
4 Combination mctcr
S Thermometer
6 Fuel meter 8
7 Printed plate 8
8 Bulb
9 Socket
10 Buzzer
11 Sgccdorneter TZZ-005
P-*5
4) installation is the reverse order ofremoval.
Fig. a - 1 1
Fig. s - 9
1 Thermometer terminals
2 Fuel meter termindl
3 Meter ilturninstion hght
4 High beam indicator light
5 Direct terminal
6 Meter illumination light
7 Buucr
8 Combination meter c u e
9 Specdomatar a b l e bou
10 Left turn signal light
1 I Right turn signal light
1 2 Charge indicator tight
13 Hand brake and brakc fluid level wuning light
=-R
722016
Fig. -9
I
1
42-3. HORN
1. Specifications
Current
, + 0.5 A
3.0 - 1 .o
Basic frequency 330-370 Hz
Sound pressure 100 - 110 dB
-
4. Checking combination meter NOTE:
With the drive shatt turning at 1,020 rpm,
1) Speedometer the nominal indication i s 60 MPH.
a, Indicated error as measured with a speed-
ometer tester is acceptable if il conforms to
values in the following table. With the drive b. When the pointer fluctuation is large, the
shaft turning at 637 rpm, the nominal cable may be defective or installation may
indication is 60 kmfh.. be incorrect.
- -
2) Fuel meter
a. Check for a grounding or open circuit
between fuel meter and unit. Check if each
conncction a n f c o n t a c t are insufficient.
b. When unit terminal connection is discon-
nected, the meter indicates "0" (empty). If
the meter pointer slowly shifts toward the
"1" (full) position when the disconnected
lead i s grounded through the pilot ljght
(12V-3W),the meter is functioning properly.
If the plot light does not light in this situa-
tion, the heat coil of the meter is open.
-- -- /
2. Operation
Sound energy is produced by a diaphragm Ignltion-ltsmr switch
set into motion by electric means. Pushing the
horn switch closes a circuit which allows
current t o flow through the horn coil and the Horn button
coil attracts the plunger. The diaphragm COU- --
-
pled directly with !he plunger is attracted -Bansry
rapidly pnd density of air ir! front of diaphragm
becomes low. At tlus time, one part of the -
plunger strikes the contact spring, opening the
coil circuit. The magnetic field collapses and 10V rrngs
the plunger returns t o its original slate by virtue T2241B
of spring force o f the diaphragm. This action
cornbresses air in front of the diaphragm. At
Fig. m-21Horn inspection
the same time t h e contacts reclose and the
sequence repeats itself. Repetition continues as
long as the horn button remains depressed.
Sound is generated by repeating change o f air
density.
?:., * 7.
3. Inspection , '.
72 - 98 tirnes/min.
frequency
122-021
2. Wiring diagrams
Fig. 20 Operation A
1) Turn signal unit
Ptlot
swltch
-
-
f Battery 4
4
.+
T22-019 Fig. 2 1 Operation B
1 2 v - 3.4W
Hazard unit Turn signal pilot light
(14V - 0.24A)
2. :darter switch
For Wt-hand drive, the stdrter
switch is Qtached by dress nut to the.dnstru-
ment panel. For !eft-hand drive, the rgnition-
starter switch is attached with stetring lock
system IocateC. under the instrument panel.
Connections are made by meanyof a junction
block.'
3 T22023
.
.
.'j -
f . .
Fig. s - 2 8 Lighting circuit diagram
T2242
Fig. fP-31 &nnedionr
Combination switch
3. Back-up light switch 1
REMOVAL AND REINSTALLATION
1) Open the trap door.
2) Take out the insulator.
3) Detach the back-up light switch attached
-on the left side of transmission.
4) Reinstallation is the reverse of removal.
5. Wiper s w i t c h
NOTE:
In reinstalling the knob, turn it so t h a t the
Pig. 3f-32 Back-up light sul'tch m e w is located a t the bottom. ,
Fig. 9 - 3 3 Stop light switch (Left-knnd drive)
Fig. a - 3 4 Wiper switch
92-6. LIGHTS
1. Specification
Front corr~binationlight
Turn signal light 12V - 23W
Clearance light I Z V - 5W
'.
1 Hcadllight assembly
2 Screw
3 Ring
4 Washer
5 Spring
6 Set plate B
7 Screw
6 Sealed bcarn unit
9 Set plate A TZZ-025
B. TRUCK-
1) Remove the lens by pushing the lens edge
with fingers.
2) Remove the light assembly by loosening
the screws.
3) Disconnect the wiring harness.
Fig. fP-48 Repkacing fuse
CHANGING BULB
Remove the lens and pull out the bulb.
- ..-
!
I
Fig. a - 4 9 Fure
2. Cautions for removing and
reinstalling the wiring harness
1) Before carrying out operation, be sure t o
i disconnect the battery (-1 tennirul.
1 2) When pulling out the wiring harness which
1 runs through inside of the front pillar, rear
) quarter and,qa& door, tie the wiring harness
i with the wire% string and pull it out
i 3) I f the &;ing harness is contacted with the
I: clamp or other parts, protect the harness
; contacting point with the vinyl tape.
: 4) When installing the parts, d o not put the
' harness between the parts and its fitting posi-
tion.
5 ) When connecting the connector, be sure to
confirm the color w r d of the connector with
the wiring diagram.
i 6 ) When connecting the battery cable, turn
I off each switch and confirm whether the wiring
harness is shorted or not by contacting the
: battery cable t o the battery terminal.
c2-'dP),7
6. Rear combination light I) Removal and reinstallation
8. Remove seven (Van) or k lens
- installing screws and remove the lens.
b. Discomcct the wiring harness.
c. Reinstallation is the reverse of removal.
2) Changing bulb
R'emovc the lens by removing the lens
installing screws and remove the bulb by
depressing it and turning t o the left.
3) Back-up light
\
.- When removing, remove two lens installing
screws and remove the lens, and disconnect the
i b
wiring harness. Reinstallation is the revtrsc of
removal.
When changing the bulb, remove the lens by
removing the lens installing screws and remove
the bulb by depressing i t and turning t o the
left.
7. Room light
Truck Van
3 . Bulb (I ZV-2115W)
7 Lens complete
8 Pan hm~dscrew 2 Room light .
3 Bulb
T22034
-
Fig. L1-45 Rear combimfion light (Truck) Fig. W-47 Room light
2- 7. FUSE AND WIRING HARNESS
In addition to the fuse box located on the instrument
: panel which contain the f.ises shown in box below.
m
2 5A Black Fan motor
Vent fan accessory cirpuit
(Radio)
(Cigarette lighter)
A d d i t i o n a l fuses a r e l o c a t e d a s f o l l o w s :
3- 1. DESCRIPTION ..................... 2
3- 3. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . 7
.3,.1. DESCR IPTlON The clutch control mechanism is a mccha.
nical type of simple construction as shown
1. Construction in figure. The clutch cover is a n overcover type
strap drive system. The spring is a diaphragm
- type which has an excellent characteristics such
1 Clutch disc
as less change o r installed spriqg setting load
2 Clutch cover
3 Clutch rckav bearing against the wear of the clutch disc and can be
4 Clutch r c k n w fork operated with light pedal pressure. Woven
5 Clutch cable asbestos i s used for the facing material of the
6 Clutch pedal d u t c h disc,. The clutch disc is provided with
torsion springs (coil springs) to absorb rota-
tional shock a t clutch engagement.
T 10-001
2. Specifications
l tern Value
Numbcr of facing 2
T 1c o o 2
,
..
r r
I) Removal
a. Remove the transmission. (Refer t o Chapter
11.) L
b. ~ e m o b ethe release bearing holder springs
8.
c. Remove the clutch release bearing @ and
release bearing holder @ together. Fig. llED Driving in straight pin
d. Using a special tool "Remover I1 (straight
pin)'', drive out straight pin (5 x 22) @ b. Apply grcase (equivalent to Unilube No. 2) .
until the clutch release lever compl. @ can t o groove of the clutch release bearing
be pulled out. holder a t the point indicated by an arrow in
Fig. b - 3 , and put it on the transmission case
guide along with the clutch release bearing.
39879 1600 Join the pawl of release fork and relcaw: '
Special tool
(Remover 11) bearing holder with the release bearing
holder sprinp.
6 I
. .
NOTE:
Be careful not t o let the'disc facing get
soaked with grease or oil.
Fk. Incpec:ing clutch
2) Inspection and adjustment c. Check disc plate for runout whenever the
Clutch'covet compl. old disc or a new one is installed.
a. Replace the clutch cover if the pawls of the d. If runout e::ceeds 0.5 mm (0.020 in) at the
diaphragm spring are excessively worn. outer circumference of facing [K = 75 mrn
b. Replace the clutch cover i T it makes any (2.95 in) from the hub center], replace or
abnormal sound when shaken up and down, repair disc. See Figure t0-9.
or if its riveted parts are in any way unusual. e. Put a special tool "Clutch disc guide" in thc
c. Replace i t if the contact surface of pressure clutch disc compl. and install t o the fly-
plate is worn, warped, or damaged. wheel.
Tighten it with six bolts (6x1 8x1 8 rnm).
499745400
Special toot
Guide (Clutch disc)
Tightening torque 1.0 L 0.075 kg-rn
3)
Fig. -
Installation
Measuring runout
3) Judder . .
The entire body vibrates uncomfortably when vchicle starts in half-clutch condition.
. .
1. Hardened facing. ~ e ~ r i r 9 t h emery cloth 'or re-
place.
2. Oil-soaked facing. Replam.
3. Broken o r fatigued torsion springs. Replace disc ycompl.
4. Improper contact of facing, or cxces- Replace disc cornpl.
sivt runout of disc.
5. Distorted pressure plate or flywheel. Rcpair,or replace.
I
6. Loose disc rivets: RepIaa.
7. Loose engine mounting or fatigued Tighten, o r replace rnounling'rubber.
mounting rubber.
. .
4) Noise or abnormal sound
Examine whether the noise is generated when clutch is disengaged (1.2) or engaged'(3,4,5).
5) Rabbit-jump ' . .
. . . :.
clutch engages suddenly in half-clutched s t a t c w h c n starting. Vehicle will. not accelerate
smoothly, but moves forward jerkily.
.................
GENERAL D E S C R I P T I O N 2
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . 2
DISASSEMBLY ..................... 6
INSPECTION . . . . . . . . . . . . . . . . . . . . . 11
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . 13
INSTALLATION. . . . . . . . . . . . . . . . . . . . . 21
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . 22
-,&I,GENJ&~L DESCRIPTION
...-- . ,-.,. . .
' 4- 2. SPECIFICATIONS
[
& 1
Model T23B I
I .
1
Gear ratio 3rd 1.809 (38121) i
4th 1.107 (31/28)., - *..
Reverse 4.272 (4711 1)
Final rcduclion gear ratio 5.733 (86/ 15)
Diilertntial Number of side gear teeth 18
gear Number of pinion gear tceth 13 !
Oil quantity 0.9 L (0.95 U.S. qt., 0.80 Imp.qt.)
----.
4-3. COMPONENT PARTS OF TRANSMISSION
.
.
... .
.
. .
1. Component parts of transmission case
37 Shirter fork 2
*39
40
Reverse shifter levcr
Shifrcr urn 2
-
-41 Shiftcr fork
42 Shifter fork rail
I
53
Back-up light switch
54
clutch u b l c c k m p
)Sluminu,lr gasket
55
I
Plug (14 x 9)
56
57
Plug (clutch hourinn
timinu hole).
58 Accent plun3e1 spring 2
59 Shifter fork spring
' Selectire puts
2. Transmission gear component parts ,- 1.
. -. .- - . .
. .
la - 4
3. Differential gear component parts
' \
. .
'5 .
$8 , e,
, 1 Oilseal(27x45x9] '$8 %'asher (53 x 65.5 x t)
2 Oil -1 retainer 9 Diffcrcntial caw
3 BaU bearing ( j 6 0 0 7 ) 10 Differential pinion shaft . ,
a - 5
4- 4. DISASSEMBLY
1) Clutch lever
Refer t o the paragraph "Clutch lever" for
1. Removal removal.
2 ) Transmlss~oncase
Pull out the 011 gauge near the differential
chamber of the upper case Place the transmis-
1. Jack vehicle rear wheel off sion case upside down, unscrew twenty fixing
floor,. bolts and disassemble the case into two sec-
2. piace jack under motor [for tions T h e twenty fixing bolts to be loosened
support only) . are 8 m m 18 pcs. and 6 mm 2 pcs.
3. Disconnect hose clamps and re-
move hoses from motor cooling fan. 8 m m Bolt.
4. Unplug red wire on fan and two L = 4 5 m m ( l 77111) : 1 3
red wires on transmission. L = 65 mm ( 2 56 in) . 3
5. Remove fan. L = 95 mm (3.74 in) 2 '
2. Disassembly NOTE:
When removing the lower case, be careful
Wipe the transmlss~on clean of grcasc and n o t t o lose the straight pin 8
on the reverse
dirt. loosen d r a ~ nplug ( 7 0 x 10) and drdln oil
Remove metal powder etc. attracted o n magnet
, idler shafta.
of the drain plug.
Retighten the plug after 011 1s d r a ~ n e d
3 5 + 0.4 kg-nl
T~ghtenlngtorque
( 2 5 3 + 2.9 ft-lb)
3) Main shaft, drive pinion and differential
assemblies
Main shaft
MSC.
5
"Expander" and remove ball bearing (#6204
NR), washer (20.2 x 29 x 0.2), ball bearing
(#6204) and washer (20 x 38 x 3).
. -Main
- shaft ass'y
Special tool
Expander
899474 100
'Fig. H - 9 Disassembling t r a ~ m k s i o n
thrust spacer II @, 3rd driven gear @ , Remove the synchronizer hub springs @
synchronizer ring @, gear thrust spacer I1 and pull out the synchronizer hub inserts@
0 ,hub assembly (3rd & 4th speeds) @ , Separate the reverse driven gear @ from the
synchronizer ring @, 4th driven gear @ , synchronizer hub 0 .
and gear thrust spacer I1 @ in that order.
7) Hub assembly (3rd & 4th speeds)
Fig. l - 1 3 Duassembled drive pinion assembly ~ & . @ - 1 5Hub assembly (3rd & 4th speeds)
r .
f-
d. Remove the needle bcaringi:@.,(34 x 50 x ~ e m o v cthe synchronizer hub springs @
20).
'y and pull out the synchronizer hub inserts @.
Separate synchronizer hub sleeve @ from the
synchronizer hub @.
8) Diifcrential assembly
.,. . .. -'.
->.;..-
,,. a,
* 7 - - " I ..>
. . -
.-
Fig. *-I8 Removing side gear
Fig. @ - I 6 Removing oilseal
d. Drive the straight pin (4 x 35) @ out from
the differential case @ sidc and then dif-
a. Wind vinyl tape on the spline of side gcar ferential pinion shaft @. Remove the dif-
shaft t o prevent damage l o oil seal lips. ferential pinion @, differential side gear @,
Remove the oil seal (27 x 62 x 9) from the and washer (27.1 x 42 x t).
differential case side first. Then remove the
oil seal (27 x 45 x 9) and retainer from the
final gear side.
special
tool :
I Straight pin remover 11:
398791'700
Fig. B-23 Removing shijter fork Fig..#-25 Removing reverse idler gear
switch (with aluminum gasket). Remove the Take out the straight pin (6 x 15) 0and
shifter forks a and 0 ,shifter arm I1 0 , remove the reverse idler gear compl. @ by
and reverse shifter lever @) from the trans- moving the reverse idler gear shaft @ to the
mission case. clutch side. The reverse idler gear shaft @
c. Four interlock balls (5.55 rnm dia.) are should be removed outside after the plug (1 3 x
provided in the interlock holes in the trans- 5) @ is driven out.
mission case, two balls tach between the
threc shifter fork rails. Remove these baUs NOTE:
carefully so as not to lose them. Take care Do not remove the reverse idler ear shaft
not t o lose the plunger installed on rail 11. unless necessary.
4- 5. INSPECTION
Thoroughly clean ail disassembled parts and
theninspect. *
2nd &-3rd
0.110 - 0.430 m m
,(0.0043- 0.0169 in) 0.2- 0.4 rnm
Standard clearance'
(0.0079- 0.0157 in)
0.1 10 - 0.480m m
4th
(0.0043- 0.0189 in)
2) ~ e ~ l a c the
e ' lock ball (6.350 .mrn dia.),
shifter rork rail spring, shifter rail plunger, and
interlock ball (5.55 mm dia.) if they are
excessively worn or deformed,
2. Synchronizer ring
' Inner
I
Needle bearing
Tll-011 I
- -
NOTE:
The washer (2b.2 x 29 x 0.2) is inPtalled t o
F*. 11 -32 Instolling g m r thrust spacer keep clearance between bearing outer races.
7) Select a snsp ring that will provide a 3. Differential assembly
clearance of 0 to 0.05 rnm (0 to 0.0020 in)
between the inner race end fact of ban bearing 1) Press fit the baU bearings (#6007) onto the
(#6204 NR) and the snap ring. Press fit the final gear and differential case i n a d v a n a .
snap ring in the groove using a special tool 2 ) Select a suitable adjusting washer t o adjust
"Prcss assembly" and make sure that the the differential backlash t o 0.05 t o 0.15 mm
snap ring isrccurely seated in the groove. (0.6020 t o 0.006Win) and install on the back o i
the side gear.
.
;
5-.
.
.-
.,-
-
, '
. - - A -.-.
. : - . . :
1 Adjusting washer
2 Pinion (Differential)
3 Adjusting washer
4 Gear (Dificrcntkl side) Tl1-016
A
NOTE: Fig. t&36 Adjusting washer
Always replace the snap ring once it has
been removed,
NOTE:
Guide (snap ring) Selective adjusting washers must be as-
Special tool: 899754121 sembled with t h e chamfered face of the
Press assembly washer toward the gear.
899754 100 Press (snap ring)
899754 102
J
Adjusting washer
Snap rings
- 2.63+0.01Smm
80S020026
+
(0.1035 0.0006in)
805020028 '
+
2.69 0.015 mni
(0.1059 2 0.0006 in)
3) Tighten bolts (10 x 21 x 13) to the 5) Reverse idler gear . :
specified lorque and bend the lock washers
(final gear).
Fig. XI-37 Bending lock wnrher Install the reverse idler gear shaft @ on the
case with the pin hole facing outside. Then. put
the reverse idler gear @ o n the shaft as the
groove i n . which .the lever is placed faces
Tightening lorque 6.3 + 0.5 kg-m outside, and lock with fhe straight pin (6
(10 mm Bolt) (45.6 + 3.6 Tt-lb) x 15). (Apply a small amount of grease lo the
pin head t o prevent i t from falling off when
assernblingthe-cast I.) Drive the plug (1 3 x 5)
into the case.
4) Apply gearoilbetween the l i p s o f t h e o i l
seals (27 x 45 x 9 , % 27 x 62 x 9). Wind tape
around the side gear spline and install the oil 4. Gear shif-t mechanism
seals carefully. Be sure to keep a gap of about 3
I) Transmission cover
m m between the oil seal (27 x 62 x 9) and the
end face of ball bearing (#6007). Keep the oil
seal (27 x 45 x 9) in close conlact with the oil
scal retainer.
. Fig.lP-40Tra~muJionc0verCOMPL
Coat the screw of plug (8 x 10.5) with liquid
packing (Fuji Bond "C" or equivalent). While
inserting the shifter'arm shafi into the cover as
Fig. S 3 8 Installing oil scal a guide of selector plunger and accent plunger
springs, screw in the plug with the selector +.
plunger pushed fully inward until the plug head , Identification
becomes flush with the cover surface. Makc Part No' Remarks
mark on lcver
sure that the selector plunger pushed ope:ates
smoothly. Approach to
2 ) Shifter forks and shifter fork rails 3A2772101 ,.. A ' the I st gear
., The shifter forks and rails should be installed side
in the following manner, beginning with the
reverk side. 342772 102 B Standard
Approach to
342772 103 C the 2nd gear
side
NOTE:
After having determined the lever, use wash-
ers of correct thickness t o provide 0.5 t o 1.0
mm (0.0197 to 0.0394 in) clearance be-
tween the lever and gear compl. (reverse
.idler).
. .
a. With the lock ball groove on the shifter fork Reverw! rhilter lever
Shifter fork
Identification
Part No. mark on Remarks
the fork
Approach to
342012101 A the 2nd gear
side
Fig. PI43 Installing sh$er fork
342012102; B Standard
Approach to
3420 I2 103 C the 1st gear
g.-.Selecting shifter fork and shifter fork 11 side
Shifter fork I1
. .
ldentificidon
Part No. mark i;n Remarks
the fork I1
Approch t o
3420221 1 I A the 3rd gear
side
Approach t o
3420221 13 C the 4th gear
side
Fig. a 4 4 Selecting shifter fork
81 - 1 8
h. Tighten the shifter rail spring pLtt and
shifter rail plate with two &mm bolts (L =
12 mm) tach. The shifter rail spring plate
should be installed with the flange for the
harness clamp placed outside.
803053013
+0
. .2.7 -0.03
Tightening torque
6 mrn Bolt
+
1 0.075 kg-rn
(7.23 2 0.54 ft-lb)
..2.
Secure the transmission t o the engine with
four 10-mrn bolts.
3.
Remove the oil level gauge and fiU the
transmission with gear oil (MP $80). Straighten
Fk. a - 5 1 Checking gear shift condition the bent tip of the oil level gauge.
6) Clutch lever 3
Refer t o Chapter m,"CLUTCH"
4- 8. TROUBLESHOOTING
Difficult gear shifting is usually caused by a change rod failure andlor a transmission failure.
At the same time, however, when the lever feels heavy and gear shifting is difficult, it may be
the result of sn improperly disengaged clutch. Therefore, first check that the clutch is
operating properly and then check the change rod and transmission.
3 Noisy transmission
'4
. If a noise is heard during idling but stops when the d u t c h is disengaged, the problem is
probably in the transmission.
NOTE:
High humming i s heard at high speeds
if the wear has progressed t o the
extent that the tooth surface is worn. a
I n case of breakage rotational knock-
ihg sounds are heard even a t low
speeds.
This causes an abnormal noise and a failure i n rotation, making it impossible for the vehicle to
run.
In the casc of a differential failure and finat gear failure, various distinctive sounds can be
heard and the source o f trouble can often be isolated by listening closely to these. Be careful
not to mistake a symptomatic sound for one coming from the engine, muffler, tires, bearings,
body, elc. Particularly, the sound o f final gear is often confused with other gcar sounds.
insufficient gear oil, improperly mesfing gears, or broken gears are the cause when the
noise increases as vehicle is accelerated.
(2) Bearing noise while acccleraling or coasting
Cracked or broken bcaring.
(3) Noisc produced mainly while turning
Abnormal noise of differential side gear. differential pinion, and differential pinion shaft.
SPECIFICATIONS . . . . . . . . . . .
O U T L I N E OF SUSPENSION .......
WHEEL ALIGNMENT ...........
COMPONENT PARTS OF FRONT SUSPENSION
FRONT SUSPENSION . . . . . . . . . .
REAR SUSPENSION . . . . . . . . . .
POSTURE ADJUSTMENT . . . . . . . .
ADJUSTMENT O F WHEEL ALIGNMENT . . .
TROUBLESHOOTING . . . . . . . . . .
5 - 1. SPECIFICATIONS
1. Front suspension
-
Lcngth 3 0 m m (1.18 in)
2. Rear suspension
item
527
I VAN (K87)
mm (20.75 in)
Total length
Effective length 483.5 rnm (19.04 in)
Torsion bar Effective diameter 22.5 rnm ( 0.89 in)
Inner end: 3 7 Outer end: 34
Number of serration teeth
-
Spring constant 6.7 1 kgm/dtg. (48.53 ft-lbldeg.)
-
hlaximum length 269 mrn (1 0.59 ir;)
7
Lsngrh
5- 2. OUTLINE OF SUSPENSION
?.. . e.,.
.Y
The front suspension employed is of a semi- The trailing arm swings up and down w i t h '
trailing arrn type. The front crossmember, the crossmember acting as the pivot.
which is integral with the chassis frame and Slidc occurs between the nylon bearing
located ahead of the front wheel center, houses press-fitted inside the trailing arm, which is
torsion bars that are the main springs for the adopted t o give a smooth slide, and the metal
front suspension. sleeve press-fitted on the crossmcmber.
Both ends of the torsion bar are provided The upper end of the shock abosrber is
with serrations; inner cnd is anchored a t the attached to a bracket on the chassis frame and
center of the crossmcmber and the outer end is the bottom end is installed on a pin welded on
connected to the trailing arrn. the trailing arm near to the center of the wheel.
The rear suspension is of a semi-trailing, The inner and outer t r d i n e anns rrc con-
independent type using outer and inner trailing nected to Lhe crossmember through rubber
arms. A crossmember, integral with the chassis bushings.
frame and located in front of the trailing arms, The upper end of the shock absorber is
houses torsion bars. T h e inner ends or the attached to a bracket on the chassis frame, and
torsion ban are connected to the center arm st the lower end to the pin on the inner arm,
the center of the crossmember, which serves as As an auxiliary mpring. a helper is installed
vehicle height adjuster, and the outer ends of on a bracket welded to thc chassis frame on
the torsion bars t o the outer trailing arms. each side.
+30'
Front 2010' -60' '
Camber**
+30*
Rear 3 O 15' -60.
Distance between ground and center of torsion bar outer end facc, with vehicle unloaded.
Difference between right and lcft should be less than 10 mm (0.39 in).
* * With vehicle unloade.
*++ With driver in vehicle.
**++Difference between right and lcft should be less than 3 O .
COMPONENT PARTS OF FRONT SUSPENSION ,
6E -5
5- 5. COMPONENT PARTS OF REAR SUSPENSION \
m-6
5- 6. FRONT SUSPENSION . Or
a. Turn the steering wheel l o the left (right)
1. Front suspension assembly fully to disconnect the right (left)-hand
brake hose from the wheel cylinder.
REMOVAL
1) Loosen the four w h t d nuts securing the
rim to the brake drum.
2) Raise the vehicle front and remove the
nuts-the detach the wheel.
&-8
10) Extract the suspension assembly from
the crossmember by hand.
NOTE:
INSPECTION
a. When installing the torsion bar into the
1) Check the bearings in t h e lrailing am for crossmember, align the lock bolt hole in the
wear and damage.
crossmember with the V-shaped groove a t
2) Chcck the sleeves on the crossmember for the torsion bar inner end and install the.lock
wear and damge.
bolt
3) Check threaded parts for wear and damage. Also align the lock bolt hole in the trailing
4) Chcck the oiJ scal lips for wear and
arm with the V-shaped groove a t the torsion
damage.
bar outer end and,install the lock b o l t
5) Check the torsion bar and lrailing arm for After completing the above job, adjust the
any evidence of deformation which may have
vehicle height and side slip.
decreased their strength. Also check the painted
b. The torsion bar lock bolts are of special
surface of these parts ior peeling, and repaint if
design. Always use genuine SUSARU b o l t s
necessary.
c. Tightening torque specifications are as
follows.
NOTE:
If the trailing arm coating has come off or if ' r
the trailing arm is rusted, carefully check the
Torsion bar lock bolt
3.0 - 4.4 kg-m
I
1- Plug
2 Lock bolt
3 Bolt
. .
.-.
.b.
I-
+
?, T 2 2-004
: : . q.L
, \'
ADJUSTMENT
After the front suspension assembly has
been installed, check the ground clearance and
wheel alignment. If necessary, adjust.
(Refer to "Posture adjustment" and "Adjust-
ment of wheel alignment".)
2. Torsion bar INSPECTION
. 1) Check (he torsion bar for damage and its
MMOVAL painted surface for peeling.
1) Remove the front suspension assembly. 2) Check the torsion bar serrations for wear.
(Refer to removal of front suspension assembly.)
2) Remove the torsion bar lock bolt at the INSTALLATION
center of crossmember underside. 1) Remove the upper lock nuts from the
upper end of the shock abosrber. and then
loosen the lower lock nuts. Set the shock
absorber so that three or four threads at its
-. upper end are engaged.
-
T- - v
\*.
-1
'
-.
F&. S - 1 9 I ~ t a l l i n gfiont suspension assembly
-!? , * .-
7) Tighten bolts and nuts in the following
621001381 (FRH)
order:
a. Torsion bar lock bolt a t lower center o f
crossmember. 621001391 (FLH)
torsion bar
b. Torsion bar at trailing arm end.
c. Trailing arm stopper bolt.
d. Two 'lock nuts 'at 'upper end of shock d. After t h e front suspension has been installed,
absorber. check the ground clearance and wheel
e. Nut a t lower end of hock absorber. alignment I f necessary, adjust
3. Bearing (Traiting arm inner and 2) Drive out thc bearing in h e following
outer) and Dust cover manner, using the special tool (Remover:
922290000).
REMOVAL a. Attach t h e hook @ to the inner side of the
I ) Remove the dust cover press-fitted to the trading arm.
inner end o f the trailing arm, by using a screw b. Open the hook @ until it catches the
driver. bearing end.
c. Insert t h e retainer @ from the serration
side of the trailing a m to prevent the from
coming off.
NOTE: . .
. d. Attach t h e cap @ to the location formerly
occupied by the dust cover.
Be careful not to damage the rubber surface e. Turn the screw @ to tighten the cap @
of dust cover. and drive out the bearing.
1 Retainer
2 Hook
3 Cap
4 Screw
5 Special tool:
(922290000)
6 Bearing
T 13-007
e-13
INSPECTION INSTALLATION
Check the followinp items for abnormalities. 1) With r clean cloth, wipe off dust from the
lr necessary, replace. surfaces of the trailing arm, bearing and dust
I ) Bearing surfaces for wear or damage. cover.
2) Resin and metallic areas for detachment. 2) lnstall the bearing onto the end (51.6 mm
3) Dust cover for deformation. diarn.) of the special tool (Lnstaller:
922350000), and k e n insert it into the trail-
ing arm.
3) T o d o this, drive the end of the tool with
a press or h y m e r until it comes into contact
with the end o f the-traiIing arm. Then press the
outer bearing into position.
NOTE:
Before removing the front suspension
assembly, check the trailing arm end play
with a dial gauge, using the following 1 Bearing (outer)
2 Special tool:
procedure. If the dial gauge pointer deflects Bearing installer
more than 1 mm, remove the front suspen-
sion assembly and replace the bearing.
Our1 cover
Fig. $2-26
Bearing (outer)
Bearing (inner)
Dust cover
Special tool:
Dust cover installer
(922360000)
a-15
INSPECTION
1) Check the inner and outer sleeves for wear
or damage. If necessary, replace.
NOTE:
Measure the outside diameters of the sleeves
at points D l and D2 shown in figure.
If the difference between D l and D2
exceeds 0.1 mm, replace w i t h a new one.
INSTALLATlON
1) Attach the oil seal to the crossmember.
2) Insert the inner sleeve into the special tool
(Installer: 922330000) and install it onto the
crossmember; drive the special tool with a
hammer until it comes into contact with the
crossmernber.
1 Oil sul
2 Inner sleeve T12-014
NOTE:
Check for proper fit of the inner sleeve
Fig. @28 Removing inner sleeve through the access h o l e in the special tool.
5. Shock absorber
REMOVAL
1) Remove the two 10 mm nuts securing the
shock absorber to the chassis frame bracket.
2) Pull off the washer and rubber bushing
from'thc rod.
Crass m e m b e r
Hole
Special tool:
Oil scal and sleeve inctallcr
(9 22330000)
lnncr slecvc
Oil scal
TI2416
m - 17
3) Loosen the lOmm nut securing the
lower end of the shock absorber t o t h e trailing
arm, and detach the shock absorber.
4) Remove the washer and rubber bushing
from t h e damper pin.
I
Fig. S - 3 4 Checking oil leakage
I INSPECTION
! Check the shock absorber for the following
Fig.- m-35
items, and replace it if any of the following
abnormalities is found.
1) Excessive oil leakage or damage.
.
.
5
7
-.
b.
,-
Fig. H-37
NOTE:
Attach* jack to the designated points
Torque 1.5 - 2.0 kg-rn (1 l - 14 it-lb)
lNSPECTlON
I ) Check the helper for fatigue or damage.
If necessary, replace.
2) Check the height of the helper and replace
if it is less than the specified value.
Truck: H =49 mm (1.93 in)
VAN: H = 5 l mm (2.0 in) Fig. a 3 8 Jacking up
3) Remove the bolts and nuts securing the
underside cover, and detach the covcr.
10 rnm bolt ............ 2 bolts
8 mm nut ............. 2 nuu
6 m m bolt ............. 6 bolts
6 mm tapping screw ..... 2 screws
- ,- - . . .... . .- ?.
,..
5) Pull the cable with the grommet off the
outer arm. Fig. &-43 Disconnecting brake hose
s - 20
8) Loosen the lock nut, then remove the 1 1 ) Remove the rear suspension assembly
outer bushing lock bolt. from the chassis frame by pulling it out.
NOTE:
T o avoid daniaging the back plab, place the
year suspension assembly on a soft surface,
such ar r a g or cardboard.
DISASSEMBLY
I ) Remove the flare nut securing the brake
pipe t o the brake asstrnbly.
NOTE:
Be careful not t o damage t h e head of t h e
Fig. m4.5Removing inner arm bracket nut
10) Remove the 10 rnm nut securing the
lower end of the shock absorber to the trailing
arm, separate the two.
Fig. tlD-46 Disconnecting Bock absorber Fig. S?-48 Disconnecting brake pipe
2) Remove the four 12 rnm bolts securing the ASSEMBLY AND 1NSTALLATlON
rear hub to the trailing arm. Assembly and installation arc in the reverse
order of disassembly and removal.
NOTE:
a. Tighten the outer and inner bushing lock
bolts only after ail assembling and installa-
tion work has been completed, with the
wheels on the ground and in an unloaded
condition.
b. The specified torque setting for bolts and
nuts is shown in the chart below.
.
Be careful not t o damage or deform t h e
brake pipe or the axle b o o t Shock absorber
attaching nut
1.8 - 2.6 kg-rn
(13 - 19 TI-lb)
Pren
-F
INSTALLATION
Press the outer rubber bushing into place
with the special tool (Installer: 92 1380000)
3 Trlilingarm
and a press. 4 Rubber bushing
N UTE: T12-030
Be sure t o center the boss i n the trailing arm
and rubber bushing when installing. Fig. &-54 Removing inner rubber bushing
3) Check the rubber bushing for cradrs or . 2 mrn
other damage. If necessary, replace. 49 mm (193 tnl (0.08 in)
INSTALLATION
With the special tool (Installer & Remover:
922340000) and a hand press, drive the inner
rubber bushing into the trail& inner arm as
follows:
1) Ptce soapy water on the inner facc of the
die 0 ,and install dic onto the trailing inner
arm bushing.
2) Apply r coatofsoapy watertotheouter
face of the inner rubber bushing, and install the Fig. EP-56
rubber bushing into the die. Then install the die
on the base @ (special toor) with a hand press.
3) Insert the push rod @ (special tool) into
the inner rubber bushing. Exert pressure on the NOTE:
inner rubber bushing liner with the press until a. When pressing the innei bushing, always
the end of t h e rubber bushing shows through rlign the center lines of the inner trailing
the access hole in the base @. arm of the rubber bushing, die 0 ,rubber
4) Make sure that the rubber bushing is
bushing and push rod aFailure to do so
pressed to the specified value.
may result in unusua! noise while driving. . I
b. After installing the bushing, a l l w the bush-
ing face t o dry for 48 houm If the trailing
arm is installed on the vehicle while the
rubber bushing is wet, the rubber bushing
may slip out of place while driving, as soapy
water acts as a lubricant I
4. T o r s i o n b a r and c e n t e r arm
REMOVAL
1) Before removing the torsion bar, detach
the rear suspcnsio? assembly from the vehicle.
Then pull off the !orsion bar, grasping the
serrated portion wit# your hand. If it is hard
to remove with han& lightly tap on the end of
the other torsion bar to push it out.
2) After the left and right torsion b a n have
been removed, remove the center arm from the
rear crossmember. - "
I @F'urhzod
2 Q Die INSPECTION
3 @Base Visually check the torsion b a n and center
4 Rubberbushing am to see if the coating is peeling or if rust is
5 Trailing m
TI2031 developing. If necessary, use a dyeing test t o
check for cracks or damage. Replace any parts
Fig. a - 5 5 Installing inner rubber bushing which are cracked.
F3-
INSTALLATION 5 ) l n s t d each tonlon bar on the side from
I ) Before installing parts, apply a coal of the which it was removed. If the torsion bar
same color paint t o any portion from which positions arc interchanged between the right
paint has peeled. and left, early breakage may result. T h e torsion
2) Apply a coat of grease to the serrated bars are marked as follows for identification. .
portions of the center arm and trailing outer
arm.
3) I n s ~ r t the center arm and torsion bars
into the crossmember.
4) Be sure t o align the toothless points at the
serration before assembling the center arm and
torsion bars.
Left-hand
torsion bar
I 621001910 RLH
.- ,-
c. * ,.- .-..
/
Shock absorber
.,
; ,.'
..
XZ - 25
:5- 8. POSTURE ADJUSTMENT .
t. Front p o s t u r e adjustment
NOTE:
a. Be careful not t o scratch or damage the
brake drum when jacking up.
b. Failure t o use a jack when removing the
torsion bar can result in damage t o the
brake hose.
. . .-. . . .,. .
a b.
*
I' Fig. L3-62 Jacking up brake drum
5
4) Engage t h ~ ? ~ a * n gbrake. Loosen (but do
not remove) tht<,fo;r nuts securing the front. 9 ) Remove the lock bolts securing the torsion
wheel. bar to the center of the crossmember and the
5 ) Raise the front end of the vehicle with' trailing arm.
a jack. 10) Remove the plug from the center of the
6) Remove the nuts securing the lower end of crossmember. Drive the torsion bar and the
the front shock absorber to the trailing arm, trailing arm cap, as an assembly, out of the
and detach the shock absorber to fret the crossmember by applying hammer blows t o
lrailing arm. a bent crosshead screwdriver or a bent bar
7) Mark the body fender and wheel center attached to the torsion bar end surface through
cap and measure distance "L" between the two. the hole in t h e crossmember.
OTE:
To prevent the tentry of water through the
threaded portions, be sure to apply a coat of
cemedine to the threads.
NOTE:
The turning direction is quite different for
each of the two lock nuts.
NOTE:
Turn the turnbuckle equally on each side
until tfie steering angle o f the left and rear
Pig. S 6 5 Vehicle height adjusting bolt wheels are within the specifications.
Inner wheel: 37" i 2"
Steering
Outer wheel: 33.5' * 2"
1 Lock nut
2 Turn buckle
.. .-
- :.-
Fig. S 6 7
t;.
:. . q,.
4) Measurc toe-in or side dip to see5f i t is NOTE:
within the specifications. Then tighten the a. Use two wrenches when tightening the lock
turnbuckle lock nuts in the following sequence: n u t Failure to do so can cause the tie rod to
a. Tighten tie rod end nut and turnbuckle. be dislocated from its end.
b, With the tie rod push all the way backward, b. Holding the turnbuckle with ' a wrench,
tighten the tie rod nut and turnbuckle. tighten tfie nut and then lock.
r
Torque 8 - 8.5 kg-m (58 - 6 1 ft-lb)
I
1 Tie rod
2 Turn buckle (19 rnm in
width rcmss flats) Fig. S 6 9 Tightening lock nut
3 Tic rod end
4 Nut (22 rnm in width across
flats)
5 Holding spanner (do not turn)
6 Tightening spanner
7 Nut (left-hand screw) c. After tightening the lock nut, move the tie
(22 mrn in width across flats)
. 712-036 rod to the front and back t o see that it
moves equally from side to side more than
Fig. S 6 8 35 rnrn (1 -38 in).
Fig. 63-70
tP - 30
2. Rear wheel alignment
Toe-in can be adjusted by changing the
number of shims at the inner trailing arm
bracket.
Check the following items and, if necessary,
adjust or replace parts. Then adjust toe-in.
a) Tire pressure
b) Height above ground (Ground clearance)
c) Be'aring play
d) Deformed trailing arm
NOTE:
Fig. B-71 Toe-in adjusting shim Use the same number of shims on both sides.
A. Unstable running
When the vehicle is driven along a flat surface at a constant speed and the hands arc released from the
steering wheel, it pulls t o one side.
The vehicle wanders immediately after a lane change, even though the steering wheel is held in the
straight-ahead position.
. .
.%
B. Incorrect vehicle posture or ground clearance
? '
I Probable cause
I Remedy
I
1 (I) incorrecr &ound clearmu. I Adjust.
. ,
1
(2) Insufficient shock absorber extension. Replace.
(3) Broken torsion bar. Replace.
1
(4) Insufficient swing angle of double offset joint
(D.O.J.).
(5) Excessively deformed trailing arm.
II Correct engine installation or replace.
Replace. I
E. Unusual noire
-
( 1 1) Deformed or dislocated rear suspension ann Replace.
bushing.
( 1 2) Play in rear suspension inner arm bracket. Replace.
(13) Incorrect shock absorber travel strokes. Replace.
(14) Helper is dislocated or has dropped off. Correct or install.
(1 5) Steering angle not properly adjusted. Adjust.
(16) Broken torsion bar. Replace.
.. CHAPTER 6: IJHEELS AND AXLES
6- 2 . REARMHEELSANDAXLES . . . . . . . . . . . . . . . 7
6- 3 . TIRES AND RIMS ................... 16
6- . I . FRONT WHEELS AND AXLES
1. General description
L d t side-
The tire is installed on a 3.50 D x 10 split king pin. T h e king pin connection is designed as
'type rim which is attached t o the brake drum. a maintenance-free type, consisting of an upper
The brake drum is provided with two taper and lower bushings made of resin, two thrust
roller bearings, which rest on the knuckle washers of high wear resistance, and four
spindle. Since these taper roller bearings are O-rings and two plugs. The oil seals prevent the
used with specified preload, special care should entry of foul water and consequent rusting, so
be taken during installation. T h e knuckle is that removal and installation are easily per-
connected to the trailing arm by m a n s of a formed.
2. Brake drum b. If the inner bearing remains attached on t h e
spindle when the drum is removed, install
1) Removal Special Tool (BEARING REMOVER:
a. With the wheel o n the ground, loosen the 922120000) as shown in Fig. a-3 and
four 10 rnm wheel nuts attaching the rim to remove the bearing by turning the handle.
the brake drum.
b. Raise the vehicle with a lift or jack and, in 2) Disassembly (bearings and oil seal)
either case, assure the safety by locking the a. Tap the inner bearing outer race out of the
lift or using safety stands. drum by using a brass rod etc.
c. Remove the wheel nuts and pull the wheel Remove the oil real a t this time. (Fig. B - 4 )
off. ' b. Tap the outer bearing outer race out of the I
d. Remove the three 5 mrn screws attachhg thc drum by using a brass rod etc. using care not
cap t o the drum and remove the cap. t o damage the race.
NOTE:
Since the left-side cap is provided with a pin
t o drive the speedometer cable, be careful
not to bend the pin when removing the cap.
3) Inspection
Wipe off the grease in the bearing mounting
bore in the brakc drum. Clean the bearing in
cleaning solvent.
Inspect the disassembled parts and replace
Fig. #-I Removing w h e r defective parts with new ones.
NOTE:
When it is necessary to replace one of the
bearings, always replace both the inner and .
outer bearings as a set.
a. Brake drum
I ) Check the drum bolts for damage.
2) check the innsr surface of the brake
'drum for wear and damage. .
. ;..
.-.
b.
. . L Fig. i U l O Removing king pin
F& S 8 Removing bcck pkztc
'i'
-
:-. +.
c. Remove *e trailing arm in accordance with
a - 1 in Chapter NOTE:
d. Remove the pin at t h e center of the knuckle For the removal and installation of the king
by tapping it from the spindle side. (Fig. pin bushing on the trailing arm, refer l a
b B-9) Chapter U&d
2) Reassembly e. Apply r thin coat of pease on theking pin
surface.
NOTE: f. Tap the king pin into the upper yoke
Be sure to keep the parts free from dust bushing from the tap of the yoke.
during this job. g. Hold the parts assembled in a. under the
upper yoke and press the king pin ,down
a. Put the cover, upper md lower h s t until its lower end becomes flush with the
washers and O-ring jogether as shown in thrust washer as shown in Fig. B-13.
Fig. m-11, with sufficient grease applied h. Place the knuckle fitted with O-rings be-
between the upper and lower thrust washers tween the thrust washer and lower yoke and
and on the O-ring. . . align the king pin with the king pin hole in
b. Coal the bushing inside surface with grease h e knuckle while pressing the king pin
and also fill the oil groove in the bushing down by hand to the position shown in
with weau. . Fig. H-14.
c. Cost the king pin hole in the knuckle with
grease. NOTE:
Be sure to press the king pin by hand when
aligning. Driving the king pin with a hammer
will break the 0-rinp on the yoke if tha king
pin and the hole in the knuckle are not lined
UP.
hrust washer(lower )
T 13-006
Fig. -12 Assembled components Fig. JZi4 Aligning king pin with knuckle
a - 6
i. Direct the cut in thc king pin SO that it will k. Apply sealant to *e knock pin and drivc it
fit on the knock pin, and tap the king pin into the knuckle.
with a plastic hammer down t o a position
slightly above the O-ring installed at &e NOTE:
bottom o f t h e knuckle as shown in Fig. Alwayr use a new knock pin for reessembly.
m-15.
' \
NOTE: .., . ,
NOTE:
Before applying sealant, wipe grease, oil, etc.
away with clean cloth.
pull the drum with r puller as shown in Tighten the cnrtle nut to tho above torque
Fig. 11-18. firrt and retighten further until a slot of the
... - castle nut is aligned to the hole in the axle
NOT€: shaft - . !.- . .
In place of the standard puller, Special Tool
(BRAKE ..DRUM ...PULLER: 921120000) . c. I ~ c kthe castle nut with a new cotter pin.
may also be used. (Fig. f3-19) d. Install the under cover and wheel.
. .
3. Hub and axle shaft assembly
Spacial twl: ATTACHMENT 1) Removal
"
921420000 a. Rcmove the brake drum in accordance with
Conventional 2.1).
puller
b. Disconnect the axle shaft assembly from the
engine b y driving out the spring pin with a
4.8 mm (0.1 9 in) diameter bar.
c. Rcmove the parking brake return spring and
the cotter pin and disconnect the parking
brake cable.
.?
~13012'
NOTE:
Do not uw a hammer since the threads at
the shsft end may be'crushed.
3) Inspection
Check t h e disassembled parts as follows.
a. Bearing
Wash the bearing in a cleaning solvent and
check the inner and outer races for cracking
and other damage, and also check if the
outer race rotates smoothly without noise
when the inner race is supported.
b. Spacer
Wash the spacer in a cleaning solvent and
check for damage and deformation.
Fig. #-21 Removing uxk shaft from hub c. Hub
Wipe the inside surface with clean cloth and
1 NOTE: check for cracking and other damage.
Do not reuse the oil seal. A damaged or 4) Reassembly
! worn oil seal will allow the entry of mud and a. Apply 9 g (0.33 oz) of grease to the inner
I
I
water into the hub, and shorten the life of bearing and position the bearing in t h e hub.
1 the bearing. With the 30 mrn (1.2 in) diameter end of
Special Tool (HUBBEARING INSTALLER:
921350000) inserted in the inner race of the
bearing, press the bearing into the hub.
Special twl:
H U B BEARING INSTALLER
921350000
II bearing Y6206C4
10
b. Coat the oil seal with grease and position it e. Apply a coat or'grease to the oil seal to be
in the hub. With the 30 mm (1.2 in) installed on the outer bearing side. Press the
diameter end of Special Tool (HWB BEAR- oil seal into the hub using a 65 mrn (2.56 in)
ING INSTALLER: 921 350000) inserted diameter bar or block as shown in Fig.
into the oil seal, press the oil seal against the 8-27.
bearing.
Special tool:
HUB BEARING INSTALLER
Cross rmion
of oil raal
713-016 Cross r a i o n
00 oil teal
Fig. 3Z25 lnrtalling oil surl T13-018
NOTE:
Press the oil seal fully u d i l it bonorns. If
clearance exists a t A, it will cause the oil seal
lip t o wear.
NOTE:
c. Invert the hub and apply 14 t o 18 g (0.51 t o Using more grease than specified may result
0.65 oz) of grease to the inside surface of i n grease leakage from the outer bearing into
the hub. the brake drum, causing brake failure.
d. Install the spacer in the hub. Apply 5 to 6 g
(0.18 to 0.21 oz) of grmse to the outer
bearing and position it over the bearing hole.
With the 25 mm (1.0 in) diameter end of
Special Tool (HUB BEARING INSTALLER:
921 3500G0) inserted into the inner race of f. Installing the axle shaft into hub
the bearing, press the bearing into the hub. Prepare Special Tool (HUB INSTALLER
CAP: 922320000) 0 ,and the lead scrcw
Special tool: HU8 BEARING INSTALLER @ and handle @ of Special Tool (HUB
921350000 INSTALLER: 921360000). Insert the axle
shaft into the hub by hand as far as possible
and secure the shafkin3 vise. Install the lead
8sll bearing 16305C4
scrcw @ I the &c ;haft end, and install
onto
the cap @ and handle @ J as shown in
Fig. 13-28 so that the cap @ presses the
bearing and n o load is applied to the oil seal.
Pull the axle shaft until it stops by turning
the handle while holding the lead screw with
TI3017
a wrench.
5) Installation
Install the hub and axle shaft assembly in
Fig. -26 ~nrtallingq c e r and outer bearing the reverse ordcr of the removal.
NOTE; Broom for identification. (Fig. S 2 9 )
a. When connecting the axle shaft to the 2) B e careful not to damage the boot,
engine. 3) U s r new spring pin.
1) Install each axle shaft on the correct side b. The two upper bolts attaching the back plate
as the lengths of the right-hand and . . are slse used to secure the parking brake
left-hand axle shafts are different. The bracket
right-hand axle shaft is provided with a
Axle shaft
Spacial 1001 921360000
Special tao1.922320000
Hub installer cap
<
TlJ-019
ing... . .
NOTE
a. To remove the cage from the inner race, turn
the-cage by a half pitch of the ball tracks
aftei,r$moving the balls and pull the cage.
h. Exeyke care not t o loss the balls.
I
!
1
FQ. -33 Removing s m p ring
NOTE:
Be careful not to damage the boot with the Fig. S 3 5 Installing circlip and cage
squaresection circlip on the shaft.
f
b. Place the cage on the shaft with its direction
as shown in Figure S 3 5 .
c. Install the inner race on the shaft and lock it
with the snap ring using special pliers.
NOTE:
Make sure that the map-ring is completely
inserted in the shaft groove.
e. Insert the six balls into the cage holes. (Fig. g. Install the outer race on the assembly of the
B - 37) inner race, cage and ball assembly.
h. Install the circlip in the groove in'the outer
race.
NOTE:
Be sure to place the jack straight. The
vehicle is provided with four jacking points,
one near each wheel. , .
-.
b
Fig. W 0 ~ ~ t d lboot
i h bond
~ c. Remove the wheel nuts and washers, and\
take off the whpel;...
2) Tighten the band by pulling the end of 2) Installation :k'
the band with pliers while hojding the Install the wheel in the reverse order of the
clip. removal.
T ~ r eand Rim Specifications
Valve TR244A
Front
h p h t Load 45 lbs. I
Full Load 45 lbs.
Tire inflation
pressure Light Load 45 lbs.
kg/cm2 (psi) Rear
Full Load 45 lbs.
Spare 45 lbs.
Tlre w ~ d t h mm (In) Approx. 136 (5.4) with inflation pressure of 2.4 kg/cm2 (34.1 psi)
Tire outer
diameter mm (in) Approx. 5 18 (20.4) w ~ t hinflation pressure of 2.4 kg/cm2(34.1 pd)
>
6-17
-%Lz_
CHAPTER 7 : BRAKE SYSTEM
7- 1 . ...............
GENERAL D E S C R I P T I O N 2
7- 2 . BRAKEASSEMBLY . . . . . . . . . . . . . . . . . . 4
7- 3 . MASTER C Y L I N D E R . . . . . . . . . . . . . . . . . 11
Service brakes
Item Parking brake
Front brakes Rear brakes
Brake drum inside diameter 180 mm (7.09 in) 170 mm (6.69 in) 170 mm (6.69 in)
DETAIL 'c'
DETAIL 'H'
Fig. m-1
a-3
7- 2. B R A K E ASSEMBLY
12
14
14
1) Disassembly
a. Raise the front o f the vehicle and install
safety stands.
b. Remove the center cap. (Fig. R-3)
c. Spread the lock washer and unscrew the
spindle nut. Remove the spindle nut, lock
washer, and washer. (Fig. B4)
d. Rcmovc the plug from the brake drum.
Using a'screwdriver, force the shoes in the
directions of the arrows shown in Figure
13-5 t o make the shoe clearances wider.
Cenle? cap - -
-- -,/? \
NOTE:
To make the work easier, remove both the
primary and secondary shoes from the wheel
cylinder adjuster wheel sides first and then
from the wheel cylinder piston sides.
NOTE:
NOTE: Do not disassemble t h e automatic adjuster
When removing the brake drum, be careful because its nut is staked.
that the wheel bearing will not fall off.
2) Inspection, repair and adjustment
a. Measure the Iining wcar. If the thickness of
the lining is less than 1.7 mrn (0.07 in),
replace the shoe assemblies. Always replace
the primary and secondary shoes on both
sides of the vehicle at the same time.
b. Replace the shoe return springs if they are
weak.
c: Replace the back plate if warp or wear is
evident.
d. In case the inside surface of the brake drum
is scored, correct with No. 60 sandpaper.
Also correct or replace the brake drum if
irregular wear or tapered scoring is evident,
or if the drum exterior is damaged.
Fig. m-5 Removing plug
3) Assembly
a. Apply a small amount o f brake grease to the
sliding surfaces between the back plate and
brake shoes, and contact points between t l ~ c
brake shoes and wheel cylinders.
b. Install the shoe springs on both primary and
secondary shoes, and install them onto the
wheel cylinder ends.
NOTE:
Be sure t o install the shoe return springs as
Fig.-#-6 Removing broke purrs shown in Fig. S3-7.
c. Hook the mid-point or the spring l o the approxirnalley 0.3 mm (0.012 in). Therefore,
wheel cylinder as shown in Fig. a4. pedal travel will not change even the linings
d. Install the shoe set pins. wear out.
e lnstall the brake drum o n t o the knuckle
Y!
spindle after wiping off the oil o n the brake
lining surface and brake drum inside surface.
Fklurn spring
Brake shoe
. -.
/
Fig. 13-7 Installing shoe return spring Fig. a - 9 Cross scction o ~ a u f o m o r i c
adjuster
/ .'
f. Install the washer, lock washer, and nut o n
the spindle and adjust the preload for the
When the clearance between the brake shce
bearings. (% R)See h p 6s and brake drum is more than t h e designed
g. Test drive the vehicle at about 10 km/h (6
mph) and' apply the brakes forcefully t w o o r clearance S, namely when the clearance is S +
three times. Check the pedal travel and make .AS,automatic clearance adjusting action takes
sure that there is n o abnormality in braking p!ace as fo!lows.
operation. As the brakes are applied, the brake shoes,
which have been stopped by A'of the adjusting
1 4) Automatic adjuster block, arc forced toward the brakc drum and at
1
t h e same time the adjuster bolts (4) installed o n
!I I- - I the shoe webs move away from A and coatact
B, travelling the distance S. As the pistons
further force t h e shoes outward overcoming the
frictional resistance produced b y the friction
springs (6), sliding occurs between the shoe web
(1) and the friction plate (5) to compensate the
surplus cleararlce A S and eventually the shoes
contact and press the brake drum.
When the b;akes a r t released the sI~ocsmove
off the drum and are retnrned inwards b y the
return springs until the aGjuster bolts (4) are
stopped by A. The shoes d o not move inward
more t11a.n that since the frictional resistance of
the friction spring is set greater t h a n the pulling
Fig. #i9 L.ocntion ojarrtomntic adjuster
force of the rcturr? spring, thus maintaining the
shoc ciearance S.
The front brakes are equipped with the 5) Front wheel cylinder
automatic adjuster that automalically keeps the The front wheel cylinder components are
I
clearance between the brake shoe and drum at shown in Fig. R-I0.
1
a. Rcasscrnbly 2. Rear brake assembly
I ) Thoroughly clean the wheel cylinder
body and install the bleeder screw, with a The components of the rear brake assembly
rubber cap o n it, into the cylinder body. are shown in Fig. U-1I .
2) Wash the piston and cup in alcohol, 1) Disassembly
carefully -wipe them with clean cloth and a. Raise the rear pf the vehicle and place it on
soak them in clean brake fluid. the stands.
3) 111staH the cup into the piston, being b. Rcmove the wheel and brake drum as
careful about the c u p direction. If the described in a - 2 , Chapter -5
cup i s damaged or deformed, replace it c. Release the parking brake and loosen the
with a new one. cable adjusting nut at the rear end of the
4) Insert the piston into the wheel cylinder. parking brake rod. Remove the cable return
Be careful not to damage the lip of the spring from the lever.
cup.
5) Install the rubber boot on the cylinder
body.
b. Torque specifications
d. Remove the shoe set springs. g. Remove the shoe return springs from the
e. Return the brake shoe adjuster wheel of the brake shoes.
anchor block so as to make the spring 2) Inspection, correction and replacement
tension smaller. a. Check the linings for wear. When the lining
-
Allowable 1.7 mm
lining thickness (0.07 in)
b. Replace the shoe return springs if the ten-
sion is insufficient.
Adjuster c. Replace the back plate, brake shoes, and
lcvcr if deformed or worn.
Fig. a - 1 2 R crnoving brake parts d. Rcplace the lever if excessively worn.
e. Correct the inside surface of the brake drum
with No. 60 sandpaper if scoring is evident.
f. Remove the brake shoes from the anchor Also correct or replace the brake drum if
block first, and then from the wlleel cyl- irregular wear, tapered scoring, or external
indcr. damage is found.
d. Install the brake shoes together with the
Drum Standard 170 m m (6.69 in) return springs, by fust instatling the upper
inside ends of the trailing shoe and leading shoe in
diameter Limit 172 mm (6.77 in) this order to the wheel cylinder and then the
lower ends of the trailing shoe and leading
f. Replace the boot (dust seal) and adapter if shoe in this order to the anchor block.
defective. e. Install the shoe s'et springs.
3) Assembly f. Check the brake drum Tor abnormality and
a. Install the lever t o the back plate. Check t o carefully install it over the brake assembly,
see if the lever is installed on the correct Refer to 5 2 , Chapter for the installing t
side, as the left-hand and right-hand levers procedure. S 1
Fig. Sf
4 D i r e c t i o n of spring Fig. m-f5Connectirrg parking brake cable
5)
.
Rear wheel cylinder and anchor block
"
Boo1 Piston Cylidcr body COMPL
1 I I . .
/ ?w
d ;$r o w + 8 .
Piston head Cup
" "r*;s'r'-
Adjuster
Reassembly
a. Rear wheel cylinder
I ) Clean the wheel cylindcr, attach the
\ rubber cap on the bleeder screw and
install the cap into the wheel cylinder.
2) Soak the piston and cup in clean brake
Fig. =I 7 Adjusting rhoc clearance
fluid.
3) Install the cup to the piston, being careful
c. Turn the adjusters on both sides in t h e about the cup direction. When inserting
direction that decreases the shoe clearances the piston into the cylinder, use care not
until the wheel cannot be rotaled with o n e to damage the lip of the cup.
hand. b. Anchor block
d. Then back off the adjuster b y 8 riotches. 1) One of the two supporters of the anchor
c. After centering the shoes in the brake drum block has right-handed screw threads and
by depressing the brake pedal 2 or 3 times, the other has left-handed ones. If warpage
turn the wheel t o see that it rotates easily or wear is evident on the threads, replace
and n o noticeable noise is made between the the supporter together with'the adjuster.
shoe and drum. 2) The adjusters arc expected t o be rotated
f. Perform the above adjustment for t h e lead- lightly with fmgers. Replace tht adjuster
ing and trailing shoes on both rear wheels. if its teeth are excessively deformed or
worn.
NOTE: 3) Replace the anchor block body if the
a. Before starting the brake adjustment, fully mounting bolt is defective.
release the parking brake. 4) Before assembling, clean the inside sur-
b. Be sure to back off t h e adjuster by 8 notches face of the anchor block, iht outside
otherwise the brakes may drag. surface and threaded hole of the adjuster,
c. When the wheel i s heavy t o turn or noise is and the threaded part of the supporter,
distinctly audible, readjust the shoe clear- and apply a generous amount of grease to
ance. these parts.
7- 3. MASTER CYLINDER 2) Operation when secondary (rear wheel)
brake Line leaks
1. Operation Since there is no pressure rise in the sccond-
ary chamber even if the push rod moves, the
1) Normal operation secondary piston reaches the inner end of the
When the brake pedal is depressed, the master cylinder. However the primary piston
primary and secondary pistons are maved i n by compresses-the fluid in the primary chamber,
the force transmitted from the pedal through thus keeping the front brake system operative.
the push rod. As soon as the return port is 3) Operation when primary (front wheel)
closed b y the secondary piston, the hydraulic brake line leaks
pressure begins to rise in [he secondary cham- Sincc there is no pressure rise in the primary
ber, consequently applyiag pressure t o the rear chamber even if the push rod moves, the
wheel cylinders, and then the pressure in the primary piston comes into contact with the
primary chamber also rises, applying pressure to secondary piston and pushes it, thus keeping
thr front wheel cylinders. (ReTcr to Fig. B-20.) the rear brake system operative. (Fig. U-22)
I P
SrC- 11
Secondary
Fronr our1.1
econdary piston
Return port
~ i g M-20
. S e c t i o m l view of master cylinder
/
I Standard
I 0.020
(0.0008
- 0.105 mm
- 0.004 1 in)
Limit 0.15 mrn (0.0059 in)
pin 5. Assembly
NOTE:
The brake fluid level drops as the brake
lining wear develops as well as when the
brake system leaks. When the vehicle jolts
along a rough road, the indicator light may
flicker because the float moves u p and d o w n
Fig. B - 2 5 Cornponenfs of brakc fluid with the waving fluid surface.
level warning syrtem
1 Rod assy (Hand brake) 1 1 Hand brake lever assy 21 Grommet (Hand brake)
2 Nut 12 Button (Hand brake lever) 22 Clamp
3 Washer 13 Spring (Hand brake Icvcr) 23 Bracket (Hand brake RH)
4 Pipe (Hand brake) 14 Screw (Pan head) 24 Bracket (Hand brake LH)
5 Joint (Hand brake) 15 Hand brake switch t s s y 25 Spring (Hand brake cable)
6 Cable u s y (Hand brake) 16 Cord assy (Hand brake switch) 26 Clevh pin
7 Spring washcr 17 Bolt (8x18) 27 Clamp (Hand brake cable)
8 Bushing 18 Spring washer 28 Bolt
9 Clamp (Hand brakc) 19 Clevis pin
10 Boltauy 20 Cotter pin
m- 15
d. Install the clip on t h i r o d and attach the clip
t o the bracket on the crossrncmbcr.
c. Adjust the cable in accordance with "2.
Parking brake cable".
Norchcs
Standard lever travel
[when pulled with approx. 3 notches
25 kg (55 Ib) of force]
Fig. st-30 Parking brake lever ratchet
Limitof travel
[when pulled with approx. 5 notches -
25 kg ( 5 5 lb) o f force]
Joint
Total notches provided 8 notches
Torque -
0.3 0.6 kg-m
(Joint lock nut) (2 - 4 ft-lb) Lock nut
1
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1
c. Make sure that the wheel rotates lightly alter i
adjusting the cable. Fig. m-31 Joint and lock nut3 iI
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CHAPTER 8: S T E E R I N G SYSTEM
GENERAL DESCRIPTION . . . . . . . . . . . . . . . 2
S T E E R I N G SYSTEM .
. . . . . . . . . . . . . . . . 3
STEERING WHEEL .
. . . . . . . . . . . . . . . . 4
S T E E R I N G SHAFT .
. . . . . . . . . . . . . . . 5
S T E E R I N G GEAR BOX . . . . . . . . . . . . . . . . 10
TIE-RODEND . . . . . . . . . . . . . . . . . . . 15
TROUBLESHOOTING . . . . . . . . . . . . . . . . . 16
8- 1. G E N E R A L DESCRIPTION to steer the vehicle. 'Th: tie rods are ball.jointed
to the knucklt am and l o the rack. The
1. Outline backlash between the rack and pinion is set to 0
using a spring installed in the slecve adjuster. In
The steering gcar box employed is of the this sleering system, t h e bevel gcar box is
rack and pinion type, which is simple and locaied in front of the sltering gear box;
rcliablc. As the pinion rotates, thc rack moves therefore, the iorquc from t h e steering wheel is
laterally. pulling or pustung the tic rods that reversed by the bevel gear and is transmitted
connects the rack and the knuckle a r m . Thus through the torque rod and rubber joint to the'
both the front whcels are turned right and left pinion on the steering gear box.
- -
I
-
2. Specifications
Inner 36O
Turning angle
Oulcr 3S0 .
Steering ratio 22.5
Pinion 7 teeth
Steering Scar assembly
Rack 28 tecth
Pinion 15 teeth
Gear 21 ~ c e ~ h
Since this stecring system cmploy s the bevel o r d e r of @ to @ as indicated in Fig. 14-1,
gcar assembly, it is very important to obtain ensuring that the c o m p o n e n t s are aligned cor-
correct alignment bctwcen the bevel gcar box. rectly with each other.
stccring gear box a n d steering wheel which are 1) Tighten t h e bolts attaching t h e stccring
installed a n the vchiclc. Whcn installing the shaft b r a c k e t t o thc instrument panel.
steering system c o m p o n e n t s , first temporarily 2) Secure t h e s ~ c c r i n ggear box b y tightenin?
tighten their attachi;;g bolts a n d nuts. Then t h e attaching bolts in t h c order o f @, @.@
fully tighten t h e m t o the specifications in thc artd @ .
3) Sccurc the bcvcl gcar box with the rubber
bushing and clamp by tigh~cningthc allaching
bolts to the specified torque. The construction of thc stccring wheel is
shown in Fig. fd-3.
m-4
2. Inspection 3) Install rhe cover o n t h e sleeting wheel by
tightening t h e t w o screws from t h e back of the
Check all the parts for damage a n d poor steering wheel.
operation, and if necessary replace defective
4) Check the horn operation by pushing the
parts with new ones.
horn key.
8-4. S T E E R I N G SHAFT
3. Reinstallation
The construction o f the steering shaft is
I) C l e m t h e horn contact points and slide shown in Fig. L-8.
plarc.
1. Removal
Clamp
1 Steering wheel
2 Cover (Column)
3 Combination swi~ch
4 Hazard warning switch knob
5 Brackt~complete
6 Shaft complete
7 Bearing
3. Inspection
1) Check t h e steering shaft for bend and
other damage.
2) Check the bcaring for wear, and for noise
and smoothness when thc steering shaft is
Fig. R-9 Removing steering bracket rotated in t h e bearing.
tighten with the clamp. At this time, adjust the
gap between the bottom of the steering wheel
and the t o p o f the shaft cover to 1 t o 3 rnm
(0.04 to 0.12 in). (Fig. m-1 1) '
3) Check t h e o t h e r p a r t s f o r d e f e c t .
( 9 ) Dust r u l
(10) Oil r u l
(11) Adjusler
(1 3) Grounding cord
(14) B u r i n g
1. Removal
1) Raise the vehicle or place i t on a pit. 4) Remove the two bolts at the rubber
2) Remove the clamp bolt connecting the coupling and disconnect the torque rod from
stccring shafi t o the bevel gear box and pull the the pinion shait of the steering gear box
steering shafr off the bcvcl gear box. ascmbly.
3) Remove the front bumper and under
cover. It is unnecessary t o remove the radiator
and protector.
Rubber bushing
i
wire t o t h e upper bolt.
Fig. *-I5 Renloving bevelgear box 4) Connect the torque rod ,to the rubber
coupling with the two bolts, spring washers and
nuts.
L
gear shaft and temporarily tighten the clamp
bolt.
3. Installatian 6) Fully tighten the clamp bolts attaching the
bevel gear b o x t o the chassis frame, after
1) Install t h e clamp .on the torque rod and establishing the bevel gear box position in
temporarily connect the torque rod to the bevel which the steering wheel turns rnost,lightly. TO
I
- -
Ei. S T E E R I N G G E A R BOX
The construction of the steering gear box is 5 ) Separate the tie rod and tie rod end by
shown in Fig. W-20. turning the turnbuckle.
1. Removal 6) Remove the iour 8 m m bolts attachjng the
steering gear b o x t o t h e crossmember ,and
I ) Raise the vehicle and place i t on safcty remove the stecring gear b o x by shifting it
stands. rearward. (Fig. M-21)
1 N U ~ ( I D X ~ )
2 Lock washer (Rnck)
3 Stopper (Rack)
4 Rack compl
5 Cap (Rack)
6 Snap pin
7 S p a a r ( G ubox)
8 Clip (Gear box)
9 Boot (Steering gcar box)
10 Scat ( G a r box spring)
I! Spring (Gear box ball)
12 Seat (Gear box ball)
13 Tic r o d end au'y
14 Nut
15 Turn buckle (Tie rod)
16 Nut (18 x 10)
17 Tic rod
18 Clip (Tic rod)
19 Boot (Gear box)
20 Gcar box unit
2 1 Bushing (Gear box)
22 Bushing (Gear box)
23 Bushing (Slcering pinion)
24 Bushing (Steering pinion)
25 Oil scal(l9 x 26 x 6 )
26 ' ~ o l t
27 Spring washer
28 Covcr (Pinion)
29 Packing ( G a r box)
30 Reraincr (Pinion)
3 1 Lock nut (Steeling gcar)
32 Adjuster (Gear box)
33 Spring (Ccar box)
34 Sleeve (Gcar box)
35 Boot (Gcar box)
36 Pinion tss'y (Gcar box)
2. Disassembly
B-11
6) Turn the pinion shaft clockwise t o pull the
rack out of the gear box. '
7) Take out the spacer, spring and ball
retaining seats from the rack.
NOTE:
Be careful not to damage the sliding surfaces
of the rack.
3. Assembly
tp-12
11) Adjust the rack-to-pinion backlash by
fully tightening t h e adjuster and then back off
about 1/15 turn.
Turn the pinion from lock t o lock to see its
rotating condition. If the rotation i s smooth,
back off the adjuster less.than 1/15 turn, ---.-.
12) Measure t h i rotating torque of the
pinion. The torque from the slraight-ahead
position should be 0.01 to 0.09 kg-m (0.07 t o
0.65 ft-lb), and the maximum torque through
the whole range o f travel should be less than
0.22 kg-m(1.59 ft-lb). (Fig. a - 2 8 )
Fig. tl-26 Knrtallinx pinion After the above condition is satisfied, lock
the adjuster with the lock nut.
Install the pinion cover with the gasket, 13) lnsert the two gear box ball seats, spring,
4) spring scat, spacer and rack cap into the rack
two 6 rnm bolts and spring washers.
holc in this order.
.- 14) Install the tie rods after applying grease
o n the ball scats and tie rod ball ends.
Torque 0.5 - 0.7 kg-m
(Bolt) (3.6 - 5.1 ft-lb) 15) Insert the tie rods into the holes in the
boot and install the rubber clips in position.
(Fig. Qr1-23)
5 ) Apply a sufficient amount o f grease lo the
rack.
6) Insert the rack into the gear box from the
side opposite t o thc pinion. Engage the tceth'of
the rack and pinion, and turn the pinion
counterctockwise.
Lever
7) Apply grease to the adjuster sleeve and thc
Gear box
inside o f the adjuster bore in the gear box, and
insert the sleeve into position.
8) Apply grease t o the adjuster spring and -
L
'
111 - 14
8- 7. TIE-ROD END 2) lnsert t h e ball stud of the l i e rod end into
the hole in the knuckle arm and inslatl the
1. Removal ' castle nut. Tighten the castle nut t o 2.5 t o 3.0
kg-rn (18 to 22 ft-lb) first, and then further
1) Raise the front of the vehicle and place tighten within 1 / 6 turn t o align a slot in the
it on the safety stand,-.- cotter pin with the hole in the baU stud.
2) Loosen the lock nuts of the turnbuckle
and remove the turnbuckle. - - -
3) Pull the cotter pin off the castle nut Castle nut 2 . 5 - 3.0 kg-m
connecting the tie rod end t o the knuckle arm, lightening torque (18 - 22 ft-lb)
and remove the castle nut.
4) Press the baU stud of the tic rod end o u t
of the knuckle arm, using Special Tool (BALL 3) Lock the castle nut with a new cotter pin.
STUD REMOVER: 921 240000). 4) Turn the stcering wheel; from lock t o lock
t o check its operation.
5) Adjust the toe-in t o the specification by
turning the turnbuckle, and tighten the 18 mm
lock nuts after aligning the mark on t h e tie rod
with the mold parting line o n the tie rod end.
(Fig. 1 - 3 0 )
1.
Trouble and possible cause
Raise the front of the vehicle until both front wheels clear the ground. Then turn the steering
wheel. If i l becomes lighter than the case that the front wheels arc on the ground, the tire
p r a s u r c or t h e suspension may be responsible and if it is still heavy the steering syslem may
have some trouble.
This condition is very dangerous t o vehicles, and often atlributable to defective front
. suspension.
r
1) Uneven tire pressure. Adjust to correct pressure.
2) Incorrect front wheel alignment. Correct.
3) Damaged or worn wheel align- Replace.
ment bearing.
4) Brake dragging, Adjust.
5. Abnormal noise.
Page
W I R I N G DIAGRAM . . . . . . . . . . . . . . . . 9-6
9- 1. DESCRIPTION
1
Beating C a p a c i t y
Fuel - Diesel o r C o m b i n a t i o n D i e s e l
Kerosene o r Gasoline
I Fuel Consumption + 5%
0.19 l/hr -
--
ESPAR MODEL -
B1L- P : C O Y ' f
Specifications--
Fue 1 - Gasoline
F u e l Consumption - -022 l/hr +- 10%
Chapter 4--CHARGER
4- 1. Description
4 - 2. Schematic Wiring Diagram
4- 3. Troubleshooting
50A FUSE MAIN
EV-1 CONTROL
COLOR CODE
I
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CHAPTER I: BATTERIES/ELECTRICAL W I R I N G SYSTEM
1- 2 . . . . . . . . . . . . .
SPECIFICATIONS AND DESCRIPTION 1
1 - 3 . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . 2
BATTERIES/ELECTRICAL WIRING SYSTEM -q,
d
w/
WARNING-- A l w a y s u s e c o m p l e t e l y i n s u l a t e d t o o l s when w o r k i n g o n b a t t e r i e s
o r t h e - - ~ l e c t r i c a lS y s t e m s . D r o p p i n g metal objects on top of t h e b a t t e r y
pack c o u l d c a u s e t h e b a t t e r i e s t o s h o r t , r e s u l t i n a n e x p l o s i o n , and c a u s e
i n j u r y t o body a n d p r o p e r t y .
T h e y a l s o h a v e t h e same p r o p e r t i e s a s any e x p o s e d e l e c t r i c a l a p p l i a n c e -
t h e y c a n s h o c k a n d i g n i t e . B a t t e r i e s c o n t a i n s u l f u r i c a c i d and can c a u s e
severe b u r n s . A v o i d c o n t a c t w i t h skin, e y e s , a n d c l o t h i n g . I n c a s e of
c o n t a c t with a c i d , i m m e d i a t e l y f l u s h s k i n o r e y e s w i t h w a t e r for f i f t e e n
minutes, for e y e s , i m m e d i a t e l y g e t m e d i c a l a t t e n t i o n . ALWAYS WEAR
P R O T E C T I O N WHEN WORKING NEAR B A T T E R I E S . D o n o t s m o k e when t h e B a t t e r y
Fewer P a c k l i d s a r e o p e n . Do n o t p u t tools on t h e b a t t e r y pack, even a
single light tool. S p a r k s a n d s h o c k s may r e s u l t w h e n i t i s p i c k e d u p o r
moved around on the batteries.
1- 1. s p e c i f i c a t i o n s o f B a t t e r i e s Used
b. 12 V o l t Auxiliary Battery
1- 2. Description
I n s t a l l a t i o n - - T h e b a t t e r y c o m p a r t m e n t a n d a l l h o l d - d o w n s s h o u l d be
f r e e of c o r r o s i o n a n d r u s t . C o r r o d e d , f r a y e d o r overheated c a b l e con-
n e c t i o n s must b e r e p l a c e d . C l e a n b a t t e r y t e r m i n a l s before cables a r e
tightened.
BATTERIES/ELECTRXCAL W I R I N G SYSTEM
1-1. S p e c i f i c a t i o n s of B a t t e r i e s Used
b. SGL -- Accessory B a t t e r y
Type: 24H - Lead Acid BCI Group: GC 24 Volts: 12
Length: 10 1/6" Width: 7 1/16" Height: 8 17/16''
Weight: 45 l b s . AH 2 Hours: 90
1-2. S p e c i f i c a t i o n s and D e s c r i p t i o n
S e v e n t e e n 6 v o l t and one 1 2 v o l t b a t t e r y c o m p r i s e t h e E l e c t r a
V a n ' s power p a c k f o r t h e various d r i v e trains and a u x i l i a r y
power systems. The b a t t e r i e s a r e under w a r r a n t y f o r 1 2 months.
A t t h e end of t h a t p e r i o d , s h o u l d t h e b a t t e r i e s start t o n e e d
replacement o n e by one, i t is recommended t h a t t h e t o t a l b a t t e r y
pack b e r e p l a c e d , i n o r d e r t o assure e v e n o p e r a t i o n o f t h e power
pack.
WARNING--Dropping m e t a l objects o n top o f the b a t t e r y pack
c o u l d c a u s e t h e b a t t e r i e s t o s h o r t , result i n a n e x p l o s i o n , a n d
c a u s e i n j u r y t o body and p r o p e r t y .
Batteries a r e toxic. They a l s o have t h e same p r o p e r t i e s a s
any exposed e l e c t r i c a l a p p l i a n c e - t h e y c a n shock and i g n i t e .
Wear s a f e t y g o g g l e s o r g l a s s e s when s e r v i c i n g t h e b a t t e r i e s .
D o n o t smoke when t h e b a t t e r y power p a c k h a t c h i s o f f .
Do n o t p u t t o o l s on t h e b a t t e r y pack, even a s i n g l e light t o o l .
Sparks a n d shocks may r e s u l t when it i s p i c k e d u p o r moved
a r o u n d on t h e b a t t e r i e s .
Controller
.gency Disconnect
Switch
D I S T I L L E D WATER o n l y s h o u l d b e u s e d t o s e r v i c e t h e b a t t e r i e s . One
by one, e a c h cap s h o u l d be removed a n d distilled water added. The
e l e c t r o l y t e level should be b r o u g h t u p t o 1 - 1 / 1 6 inch b e l o w the
l e v e l of t h e i n s i d e c a p , a t the bottom of t h e r i d g e . It should
n e v e r be so high t h a t when t h e c a p i s replaced i t forces t h e water
u p and o u t of t h e battery cell nor should it be allowed t o d r o p
below the top e d g e s of t h e p l a t e s .
\
I n case o f a c i d s p i l l a g e o r d i r t a c c u m u l a t i o n , b a t t e r y tops s h o u l d
be b r u s h s c r u b b e d w i t h a s o l u t i o n o f baking s o d a -- one-half pound
per pail of warm water -- a n d thoroughly r i n s e d .
1- 3 . Removal
To remove b a t t e r y p a c k , d i s c o n n e c t a l l cables a n d c o n n e c t o r s ,
l i f t o u t by h a n d . When r e p l a c i n g , b a t t e r i e s s h o u l d be torqued to
120 pounds.
BATTERY PACK b AUXILIARY
Controller
Disconnec
ch
1-3. Removal
To remove b a t t e r y p a c k , d i s c o n n e c t a l l cables a n d c o n n e c t o r s ,
5
lift o u t by h a n d . When r e p l a c i n g , b a t t e r i e s s h o u l d be t o r q u e d
t o 75 pounds.
1, EXAMINE BATTERIES, CABLES, ETC.
_t:
IVE (broken post, ( c h a r r e d , corroded,
broken case, brok- sulfated, etc. )
en cover)
Repair or replace,
Repair cr replace c l e a n terminals
Go to 4 . Go to 4 .
4 I
0m
-I CHARGING TEST
DESCRIPTIOi4 . . . . . . . . . . . . . . . . . 2-2
TROUBLESHOOTING . . . . . . . . . . . . . . . 2-6
2- 1. Description
CAlHODE (PIGrP
GATE
ANODE (51IUD')
PHOTOS OF CONTROL
T h e c o n t r o l card s u p p l i e s a q a t e p u l s e t o 2 R E C ,
turning it on
to a c a n d u c ' t i n g state, allowing current to flow from the battery
t h r o u q h lC, 2REC, lX, notor field, motor armature, current sensor,
and back to the battery. After 1 C charges, 2REC shuts OFF due to
lack of current. The control card c h e c k s that IC is charged and
u n l o c k s the gates to 1 WEC and 5 REC.
-
,oo/,- -.-- - - - -. -i
., AVERAGE
CURRENT
ON OFF O H OFF ON O F F
TIME
--
ON OFF ON OFF OM OfF
TIME
I q ON
5 50 95 TIME
CS SCR range TS
T h e p e r c e n t ON t i n e h a s a r a n q e o f a p p r o x i m a t e l y 5 t o 9 5 percent.
The center operating condition of the o s c i l l a t o r i s a t 5 0 p e r c e n t
O?l time w i t h a n o m i n a l 1 . 7 milliseconds ON time and 1.7 milli-
second OFF time. This corresponds to a maximum operating
frequency o f a b o u t 3 0 3 h e r t z . A t creep the 0 l J time will decrease
to a p p r o s i m a t e l y 0 . 8 milliseconds while OFF time will become i n
t h e o r d e r of 2 0 milliseconds. A t f u l l SC!? operation, t h i s
condition will be r e v e r s e d (short OFF time, long ON tine). T h i s
variatioc of ON a n d OFF time of t h e oscillator produces the
optixum frequencies t h r c u g h t h e SCR r a n q c . See F i g u r e 7.
C U R R E K T LIMIT--This circuit m o n i t o r s motor current by utilizing
a sensor in series with the armature. The information detected
<?cross the s e n s o r is f e d back to t h e c a r d s o current may be
l i n i ! - : d to a maxirnum safe v a l u e . If heavy Load currents a r e
#N
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!
d e t e c t e d , this c i r c u i t o v e r r i d e s t h e o s c i l l a t o r and l i m i t s t h e
t-
a v e r a g e c u r r e n t . An i n d e x e d t r i m p o t for t h e c u r r e n t l i m i t ( C / L )
a d j u s t m e n t i s p r o v i d e d t o m a i n t a i n t h e peak v o l t a g e o n t h e
I - capacitor within i t s r a t i n g when u s e d o n high source i n d u c t a n c e
i a n d / o r l o w motor r e s i s t a n c e a p p l i c a t i o n s . B e c a u s e o f t h e fly-
iI1l I
back c u r r e n t t h r o u g h 3 REC, t h e m o t o r c u r r e n t u s u a l l y r u n s 2 t o
3 times t h e b a t t e r y c u r r e n t .
2- 4. General Maintenance I n s t r u c t i o n s
M a l f u n c t i o n s of t h e SCR w i l l g e n e r a l l y f a l l i n t o o n e o f t w o
categories. They a r e either n o power ( T a b l e 1 ) o r f u l l power
(Table 2 1 , when operating i n the SCR c o n t r o l r a n g e .
These simple and e a s y - t o - f o l l o w t a b l e s outline t h e various symptoms
and t h e c o r r e c t i v e a c t i o n t o be t a k e n .
T h e same d e v i c e d e s i g n a t i o n s h a v e b e e n m a i n t a i n e d on d i f f e r e n t
c o n t r o l s but the w i r e n u m b e r s may v a r y . Refer t o the e l e m e n t a r y
and wiring diagrams f o r your s p e c i f i c c o n t r o l . The w i r e numbers
shown on the elementary diagram will have identical numbers on
the c o r r e s p o n d i n g wiring d i a g r a m s f o r a specific vehicle but
thcse numbers may be different from the numbers referenced in
this publication.
WARNING : BEFORE TROUBLES HOOTING, JACK UP WHEELS,
DI SCONNECT THE BATTERY AND DISCHARGE CAPACITOR 1 C .
RECONNECT THE BATTERY A S NEEDED FOR THE S P E C I F I C
CHECK.
R2 1 A thermal h o l d o f f Key o n , c o l d T / P 0
c o n t r o l jumper t o Key o n , t h e r m a l 0 . 6 6 o r more
R4 to disable 1 A cutback
thermal holdoff
Output to PMT Key off 0 Volts
Driver Key c l o s e d , 5-10 rnilliamps
accelerator depressed.
See Note 1.
R7 8 ON time o u t p u t . C r e e p speed
Top speed
TABLE 1
O Close B r a k e . V o l t s on L 3 , L S , L7
should be battery volts. V o l t s on L9
should b e n e a r z e r o . Wait f o r one
I second, t h e n depress a c c e l e r a t o r .
V o l t s a t L9 and L9 side of F c o i l
should be battery v o l t s . I f not,
check w i r i n g and s w i t c h e s .
1C. C o n t a c t o r s c l o s e . NO O Check v o l t s a t S C R p o s i t i v e .
power and NO S C R hum S h o u l d be b a t t e r y v o l t s . If n o t ,
w i t h a c c e l e r a t o r i n SCR c h e c k power f u s e .
range.
O Check v o l t s a t T 2 . Fhould be z e r o .
I f n o t , c h e c k v o l t s a t S 1 , 52, A l ,
a n d A 2 t o l o c a t e open circuit.
TABLE 2
O Replace c o n t r o l c a r d ( 4 A ) .
TABLE 3
TABLE 4
C H E C K I N G COMPONENT'S
Remove T B
Retarnrna Screws
Retarnrng
Card
T o check a n S C R ,
it i s n e c e s s a r y to have a 12-volt battery, a 1 2 -
volt lamp and 2 A - 1 4 diodes.
Gnre ,21
(Top V~e..v)
Fig. 13.
Anoae Cathode
Anode Cathode
Anode
Thick
End
?!>e c a p a c i t o r f i l t e r t e s t , a s i n 4 K , is v a l i d f o r 2 2 REC a n d 25
RCC only t o d e t e c t a n o p e n o r s h o r t e d f i l t e r . T f control h a s
s y m p t o m s a s in 16, interchange 22 REC and 2 5 RCC a n d t r y a g a i n .
I f problem is c o r r e c t e d the o l d 2 5 REC is mar4inal. If problem
is ~ o corrected,
t replace both f i l t e r s with k n o w n good filters.
4N. I X Choke--Transformer Secondary T3-T4
7%
RE4R V l EW WI TG
CWER R M W E D
-
WIRE TLBLC
:,{
ABWE
#8
*8
111
18
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Fig. 18. Model C wiring diagram
CHAPTER 3 : DC ELECTRIC MOTOR
Page
DESCRIPTION . . . . . . . . . . . . . . . . . . 3-2
BEARINGS . . . . . . . . . . . . . . . . . . . 3-2
INSULATION . . . . . . . . . . . . . . . . . . 3-3
BRUSHES . . . . . . . . . . . . . . . . . . . . 3-3
COMMUTATOR . . . . . . . . . . . . . . . . . . 3-3
CLEANING . . . . . . . . . . . . . . . . . . . 3-3
MECHANICAL . . . . . . . . . . . . . . . . . . 3-4
FAILURE . . . . . . . . . . . . . . . . . . . . 3-5
REPAIR . . . . . . . . . . . . . . . . . . . . 3-5
3- 1. Description
3- 2. Maintenance
S t a n d a r d B e a r i n g s a r e t h e s i n g l e row, d o u b l e d s h i e l d e d , C o n r a d
t y p e p r e - l u b r i c a t e d with h i g h t e m p e r a t u r e grease w i t h ABECl
t o l e r a n c e a n d AFMBA $ 3 i n t e r n a l r a d i a l c l e a r a n c e . Standard
b e a r i n g s do ' n o t r e q u i r e l u b r i c a t i o n . Under n o r m a l c o n d i t i o n s
the bearings f a i l after s e v e r a l years s e r v i c e d u e e i t h e r F r o m
d i r t y c o n t a m i n a n t i n the g r e a s e o r i n s u f f i c i e n t o i l in the yrease
New g r e a s e c o n s i s t s of a b o u t 8 0 % o i l , 2 0 % soap. When b l e e d i n g
r e s u l t s i n a r e d u c t i o n of oil t o a b o u t 6 0 8 , t h e bleed r a t e i s
r e d u c e d t o a l e v e l that may n o t s u p p l y s u f f i c i e n t l u b r i c a t i o n .
For t h i s r e a s o n when m a i n t e n a n c e o v e r h a u l s a r e performed a f t e r
s e v e r a l y e a r s of s e r v i c e , b e a r i n g s are a u t o m a t i c a l l y replaced a s
a routine practice. A b e a r i n g should b e r e p l a c e d with a n e s a c t
r e p l a c e m e n t c r o n e w i t h a l l interchangeable f e a t u r e s . It i s
especially i m p o r t a n t that t h e b e a r i n g h a v e high t e m p e r a t u r e
grease.
3- 2b. Insulation
I n s u l a t i o n r e s i s t a n c e s h o u l d be c h e c k e d d u r i n g e a c h m a i n t e n a n c e
inspection. Low r e s i s t a n c e m a y b e c a u s e d by e x c e s s i v e d i r t ,
x o i s t u r e o r impending f a i l u r e . A l t h o u g h motors c a n be s u c c e s s -
f u l l y r u n with i n s u l a t i o n r e s i s t a n c e a s l o w a s 1 / 4 megohm i t i s
well t o i n v e s t i g a t e t h e r e a s o n s f o r a n y i n s u l a t i o n r e s i s t a n c e
b e l o w 1 rnegohm. Low r e s i s t a n c e v a l u e s d u e t o d i r t c a n u s u a l l y
be c o r r e c t e d by c l e a n i n g f o l l o w e d by a v a r n i s h d i p a n d b a k e . Low
r e s i s t a n c e d u e t o m o i s t u r e c a n be c o r r e c t e d by b a k i n g t h e m o t o x
i n a 90°C o v e n u n t i l the i n s u l a t i o n r e s i s t a n c e r i s e s above t h i s
value a n d stabilizes t o a n e a r l y c o n s t a n t v a l v e . A new motor
s h o u l d withstand for o n e minute w i t h o u t b r e a k d o w n t h e a p p l i c a t i o n
of 6 0 Hertz potential 1 2 0 0 v o l t s . O l d motors s h o u l d be t e s t e d a t
7 5 % of t h e s e v a l u e s .
3- 2c. Brushes
B r u s h c o n d i t i o n a n d r e m a i n i n g b r u s h l i f e s h o u l d be c h e c k e d a t e a c h
maintenance inspection. i?hen i n s t a l l i n g new b r u s h e s , e a c h b r u s h
s h o u l d be s a n d e d i n t o t h e c u r v a t u r e o f the c o m m u t a t o r for m o s t
reliable performace. A m i n i m u m of 859- s u r f a c e c o n t a c t with 1 0 0 %
brush a r c i s recommended. R e p l a c e m e n t b r u s h e s s h o u l d be e x a c t l y
t h e same b r u s h grade a s o r i g i n a l .
3- 2d. Commutator
3- 2e. Cleanina
B o t h t h e i n t e r i o r a n d exterior o f t h e motor should be kept c l e a n
a n d f r e e of d i r t a n d g r e a s e . Loose d i r t may be removed by vacuum
c l e a n i n g o r b l o w i n g with compressed a i r . '2acuurn c l e a n i n g i s p r e f e r r e d
because compressed a i r m a y d r i v e d i r t d e e p e r i n t o cracks a n d
v o i d s i n the i n s u l a t i o n s y s t e m . L o o s e d i r t c a n be removed w i t h
a c l e a n i n g rag or a s o f t b r i s t l e b r u s h . Clogged a i r o p e n i n g s
should be c l e a n e d o u t u s i n g c a r e n o t t o damage i n s u l a t e d p a r t s .
O i l a n d g r e a s e may be removed by w i p i n u w i t h a c l e a n cloth
dampened s l i g h t l y w i t h FREON TF (a fluorinated h y d r o c a r b o n s o l v e n t
made by D u P o n t ) o r P e r c h l o r e t h y l e n e .
C A L I : 'FIE: CLOTF Si?OFLD NO'!' OF ::JET, PQR L I Q t ' I D
SOLVC?IT >!LAY CARRY E L E C T R I C ; I L C3?:LlXCTI>TC D I R T DEEP
INTO CRACKS A N D V O I D S I V T I E I N S U L A T T O S SVSTE.".I.
If insulation resistance is !ow a f t e r cleaninn it n a y be necessary
to either Sake the a r m a t u r e a t 3 0 ° C to remove moisture o r t c ,
varnish t r c a t a n d S a k e .
3- 3. -
3isassembly Instruction
3- 4. Repair
See \l1arranty .
3- 5. genewal P a r t s
3.1.1
--
Description
3.1.2 Maintenance
3.1.2~. Brushes
Brush condition and remaining brush life should be checked
at each maintenance inspection. Each brush should be checked
for length and each spring for proper pressure. When installing
new brushes, each brush should be sanded into the curvature of the
commutator for most reliable performance. A minimum of 85%
surface contact with 300% brush arc is recommended. Replacement
brushes should be exactly the same brush grade as original.
3.1.2d. Commutator
Commutator runout should not exceed .002" total indicated
runout with a bar-to-bar variation of .0002". The mica bar-to-bar
insulation should always be kept below the copper surface. When
commutator wear results in flush o r protruding mica, t h e mica
should be undercut to a depth equal ot the thickness of the mica
or about . 0 2 5 " . The undercut slot should be kept clean and
free of dirt.
3.1.2e. Cleanin9
3.1.5.
--
R e n e w a l Parts
T h e m o t o r serial n u m b e r c o m p l e t e 1 . y i d e n t i f i e s t h e motor
and every p a r t t h e r e i n . I t m u s t be g i v e n when ordering replacement
parts. Any order fox motor parts should give t h e number of parts
desired, the d e s c r i p t i o n of t h e p a r t , t h e serial number of t h e
motor, and e i t h e r t h e model n u m b e r o r t h e OEM-customer i d e n t i f i c a t i o n
number.
CHPATER 4 : CHARGER
4- 1 . DESCRIPTION . . . . . . . . . . . . . . . . . . . . 1
4- 2. SCHEMATIC WIRING DIAGRAM . . . . . . . . . . . . . I
4- 3 . TROUBLESHOOTING . . . . . . . . . . . . . . . . . . I
/ 1, -
4- 1. Description Ffl.
1'
L e s t r o n i c B a t t e r y C h a r g e r , Model 3 4 5 8 - 'I'ype ' , 2 / 1 0 2 L C R 2 5 - i E T
Input: 115/230 v o l t s A.C. 60HZ
Output: 1 2 & 1 0 2 volts D.C., L 0 / 2 5 amps
4- 2. Schematic Wiring D i a g r a m
See page 3 .
4- 3. Troubleshooting
The charge r a t e of t h e 1 2 v o l t b a t t e r y w i l l v a r y g r e a t l y d e p e n d i n g
on the s t a t e of d i s c h a r g e of b o t h the 1 2 a n d 1 0 2 v o l t b a t t e r y
system.
\" + > :4ALFUNCTION SYYPTOMS AND TIIETR REPIEDIES
?\
L s s t r o n i c Sat tery Chargers
Models 9 4 5 8 a n d 9575
I n t h e e v e n t n o hum i s d e t e c t e d f r o m t h e transformer, c h e c k t h e
AC. c o r d t o , b e s u r e I t i s s e c u r e l y p l u g g e d i n t o a live AC o u t l e t
( c h e c k line f u s e o r c i r c u i t b r e a k e r ) . Also c h e c k t o b e s u r e t h e
c h a r g e r DC o u t p u t l e a d s a r e c o n n e c t e d s e c u r e l y t o t h e i r r e s p e c t i v e
batteries.
XOTE: 9 e c a u s e t h e r e l a y , -dhlch c o n t r o l s the t u r n l n g
on and-61-f 'of-Ehe c h a r g e r , i s activat-eT%-$-the
_C__
< /.
terminals using a suitable DC v o l b m e t e r . Voltage s h o u l d b e t h e
same a s t h e 1 0 2 v o l t b a t t e r y s y s t e m . If voltage is c o r r e c t c h e c k
the r e l a y c o i l resistance.
----.L
IMPORTANT: D i s c o n n e c t c o n t r o l c a b l e from E l e c t r o n i c
'-- , . T i m e r Assembly b e f o r e checking r e l a y c o i l
resistance. Damage t o E l e c t r o n i c T L m e r o r
meter w i l l result If c o n t r o l c a b l e remains
connected.
E r 3 a y c o i l r r s j s t a r l c c should bc* : ~ l ) p r o Jxl r ~ : i t t ~ I y6 , 0 0 0 o l l r n s . If
c o i l r e s i s t a n c e i s n o t correct, relay I s d e f e c t i v e a n d m u s t b e
rep1 aced.
T h l s condition m a y b e c a u s e d by:
PIN P i n Voltage
6 C h a r g e r ON - I Vdc
Charger OFF- Same as 102 volt battery s y s t e m
7 Charger ON - 78 V a c
8 "START" b u t t o n c l o s e d ( d e p r e s s e d ) - 0 Vdc
"START" button open (released) - 10 Vdc
T r a n s f o r m e r Short o r B u r n - O u t
F a l l u r e o f t h e t r a n s f o r m e r nay b e c a u s e d b y n a t u r a l aging o r
p r e m ~ t u r e shorting of e d j a c e n t coil turns. The transformer may
hum when A C and DC l e a d s a r e c o n n e c t e d , however, a low or c o m p l e t e
lack of o u t p u t would b e observed on t h e ammeter. To test trans-
f o r m e r , f i r s t disconnect AC cord a n d DC o u t p u t l e a d s a n d perform
DC c i r c u i t test a s d e s c r i b e d in "Transformer Hums But No Ammeter
Indication". If c i r c u i t t e s t s good, r e c o n n e c t AC cord and m e a s u r e
t r z n s f o r m e r output voltages. C o r r e c t voltages are shown in t h e
following t a b l e . Voltages will vary sllghtly If AC Input voltage
Is other than 115 or 2 3 0 Vac. If measured v o l t a g e s a r e substantially
lower t h a n t h o s e shewn, t h e t r a n s f o r a e r I s shorted a n d ~ u s tb e r e p l a c e
T r a n s f o r n e r Ooen-Circui t Vol t a r e s
I~ Transforaer
I
with
C O L ~V o l t a g e tVac)
without
~ coil capacitors
connected
capacitors
connected
#6V Nom. Fully 25% 50% 75% 100% Max. Gasing 30min.
Bats Volt Disch. Float C.Taper CnstCur
cell
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