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FD1802 圃

FD200-2
FD230-2
 FOREWORD
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 SPECIFICATIONS

tem
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dei
FD160.2 FD180.2 FD200.2 FD230.2

Performance
R
at巴dl
oad kg[
lbs
] 16000{35280} 18000{39690} 20000{
441
00} 23000{50715}
Loadc
ent
er mm[
in
.] 900[
35.
4] ‘
ー一 モ
ーー モ
一一

L
ift
ingh
eig
ht mm[
in
.] 3000[
118
.1] モ
一一 モ
ー
白血 ‘
司一

Mastt
ilt
inga
ngl
e，f
ron
t/r
ear (
0) 6-1
2 モー モ
ー一 モ
ー一

Forkl
ift
ings
pee
d mm/s[
fee
t/m
in]
Unload巴d 400[
78.
7] 310[
61.0
] モ
目
ーー 260[
51.2
]
Loaded 330[
65.
0] 290[
57.
1] 285[
56.
1] 240[
47.
3]
T
rav
eli
ngs
pee
d km/h[
mph
]
fwd&rev 1
st 7
.5[
4.7
] 8
.0[
5.0
] モ
ー一 ‘
一一

2nd 1
4.5[
9.0
] 1
5.0[
9.3
] 1
5.5[
9.6
] 1
5.0[
9.3
]
3
rd 3
4.0[
21.
1] モ
ー一 モ
ーー 3
2.0[
19.
9]
Min.t
urn
ingr
adi
us mm[
in
.]A 5000[
196
.9] モ
一一 5150[
202
.8] 5350[
210
.6]
M
in.i
nte
rse
cti
ngt
urn
inga
isl
ewi
dth
mm[
in
.]B 4430[
174.
4] 4460[
175
.6] モ
ーー 4650[
183
.1]
Dimensions
O
ver
alll
eng
th
in
( cl
.fo
rkl
eng
th) mm[
in
.]C 7165[
282
.1] 7205[
283
.7] モ
ー
司司 7990[
314
.6]
O
ver
allw
idt
h mm[
in
.]D 2970[
116
.9] 2990[
117
.7] 3060[
120
.5] ←
一
O
ver
allh
eig
ht mm[
in
.]E 3290[
129
.5] 3540[
139.
4] 3570[
140
.6] 3580[14
0.9
]
O
ver
al1h
eig
ht，w
/fo
rksr
ais
ed mm[
in
.]F 4790[
188
.6] 5040[
198.
4] 5070[
199
.6] 5080[
200
]
Wheelbase m m[
in
.] 3650[
143
.7] そ
一一 モ
ー
ーー ‘
一一

T
rea
d mm[
in
.]
F
ron
t G 2195[
86.
4] モ
一一 2185[
86.
0] モ
ーー

Rear 日 2340[
92.
1] ‘
一ー 2300[
90.
6] ‘
一一

Fo
rks i
ze mm[i
n.
] 1830x250x90 1830x260xl00 モー 2440x310x98
le
( ng
thJxwi
dthK xt
hic
kne
ssL) [
72.0x
9.8x3.] [
5 72.0x10
.2x3.9
] [
96.
1x12.2x3
.9]
Forks
pac
ing m m[
in
.]M 790-2750 810-2750 モ
ーー 950-2750
[
31.1- 1
08.
3] [
31.9-108
.3] [
37.4-108
.3]
Forko
ver
han
g N 885[
38.
4] 925[
36.
4] モ
一一 945[
37.
2]
R巴a
rov
erh
ang P 800[
31.
5] モ
ー向 モ
ーー 955[
37.
6]
Groundc
lea
ran
ce 295[
11.6
] 270[
10.
6] 300[
11.8
] .4
290[11 ]
(
atf
ram
e) (
atm
ast
) (
atm
ast
) (
atm
ast
)
Towingp
inh
eig
ht 730[
28.
7] 760[
29.
9] 790[
31.1
] モ
ーー

Weight
T
arew
eig
ht kg[
lbs
] 22510[
496
35] 25040[
552
13] 27260[
601
08] 30760[
678
26]
 U
nit
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in
.]

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 CONTENTS

1
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3
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 3
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3
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1 REMOVINGANDREINSTALLINGWHEELASSEMBLY……...・ ・.....・ ・.....・ ・.....・ H H H H ・
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2 TROUBLESHOOTINGGUIDE…...・ H ・
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3
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3 SERVICEDATA.
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02
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6
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13

7
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il
te
r.

NOZZLEHOLDERASSEMBLY

OVERFLOWVALVE

ドUELFILTER

F
ig.1
.3 F
uelS
yst
em

-5-
1
. ENGINE

(
1)Fueltank
Figure1.4showsas ectio
nalviewofthefue
ltank.Itcanhold400lit
ers[
105.
7USg a
l]offuel
.
Thef uel
levelse
nderdetec
tstheremain
ingamountofthefue
linthetan
k.
Ont hes i
defac
eoft hetanki
saf u
elviewgaugewhichlet
stheoper
atorknowthefu
elleve
lofthe
tankinadditi
ont
ot h
ef u
elmeteronthedash
boa
rd.Whent hefue
lviewgaugere
adsthelow
erlimi
t(20
li
ter
so r5.3USga ，
)
l addfuel
.

C
apa
cit
y:400l
it
er
s[1
05.
7US.9a
目l)
CAP

VIEWGAUGE

LEVELSENDER

、¥

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F
ig.1
.4 F
uelTank

Thef ue
ll e
velsenderc on
v ert
st hef uel
leveli nthet a
nki n
toane l
ect
riccur
rentsigna.
lF igure1.6
showsi t
sc o
nstr
ucti
on.Forc o nver
s i
o noffuellevelint
oe l
ect
ricsig
nal，ava
ria
bleres
isto
rw it
hNichrome
wireisu sedwit
ラhas lid
inge lementli n
kedwit haf l
oat
.Ast h
ef l
oatmovesupanddown， th
er e
sist
a n
ce
variesaccordi
nglysot h
att h
eamounto fele
ctricc u
rrentpassi
nga c
rossther
esis
tancealsovar
ies. The
fue
lm e t
erisab imeta
lt ypewhosep oint
ers wingsdependingont heamountofelec
triccurre
ntpassing
throught h
eh e
atingunitofth ebimeta .
lWhent hefloa
tisatthehighes
tposit
ion，th
el ev
els en
derreads
are s
istanc
eo f9.5ohmst o11ohms.T hisa l
lo wsal a
rge
amountofe lec
triccur
renttop as
st hroughther e
s i
stanc
e ラ

thusc ausingbimetaltobendl argelys othatt hefuel

meterp oin
terindic
atesthe“ F"mar k.Ast hefuell e
vel
drops，thefloa
tg oesdownandt heresista
ncebecomes
greatertoreducetheamountofe l
ectriccurrentpassing ‘

throughitt
ラ hu
sc ausi
ngt hefuelme t
e rpointertoswing
towardt he“E"mar k.
Thef ue
lmeteri si nc
orpo ra
tedi nt hecombination
meterpane.l

F
ig.1
.5 CombinationMeterP
ane
l

-6 開
 1
. ENGINE

叫(〉
mく
〉
1
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FLOAT

F
loa
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ドυし
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1
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1
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9.5
EMPTY 80
F

L
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(2
) Fuelf ilt
er
Thefuelfil
terisins
tall
edonthee ng
inetoremoved us
tandd
ir
tfromt
hef
ueltobes uppli
edi
ntot
he
engme.
Thefue
ls entfromthef e
edpumpe nte
rsthejo
intbol
t
JOINTBOLT固
囚
， passingthroughtheelement， andflowsoutoft h
e
jo
intb o
lt圃 t ot h
ei nj
ecti
onpump. Whent hequantit
y
off u
elfedisgreate
rt h
anthequan
tityoffue
lconsumed ラ

excessfue
lopenst h
eo ver
flowvalveandflowsthrou
gh
thejoin
tb o
lt固ラ returningbackintothefu
eltank.

COVER

ELEMENT

F
ig.1
.7 F
uelF
ilt
er

開 7-
1
. ENGINE

1.1.2 COOL lNGSYST正M

Thec o
olingsys
temcons
ist
sofara
dia
to，r
r es
ervetak，
n w
aterpump f
anandt
ラ h
ermos
tat.Fig
ure1.
8
showsit
sc o
nstr
uct
ion.
Thew ate
rpumpandf a
naredr
ive
nbyt hecr
anks
haftthr
ought
heV-be
lttocir
cula
teth
ec oo
lin
g
waterwit
hintheeng
ine.

CAP(va
lveopeningpressure:
50kPa{05kgflcm2} [
. 7.1psi
]
RADIATOR
RESERVETANK

DRAINVALVE

F
ig.1
.8 C
ool
ingSystem

() Reservetank
1
Thereser
vet a
nkholdsthecoo
lingwaterove
rflown
fromtherad
iato
rwhent hetempe
ratureofthecoo
ling
wate
rbecomess ohigh，andre
turnsi
tintoth
eradiat
or
whenthecooli
ngw a
terintherad
iato
rc o
olsdown.
tillit--
塑
汁 11

時斡
旦
色

F
ig.1
.9 R
ese
rveTank

-8-
 1
. ENGINE

(2
) Thermostat
Thet hermo
st a
tisi n
stal
ledonthet h
ermostathousin g
t
oc on t
rolt h
ec oolingwatertempera
ture.
Whent hecoolingwatert emp
e r
aturee xceeds8 20C
[179.60P，]theprimaryv alveoft hethermostatopens .
RUBBER
Whent hecoolingwatertemperaturer ea
che s85 C
0 (
82Cor1
79.
6F)0 0

[185P
0
]，thes econd
aryv alv
eopenst oallowthec o
ol i
n g MAINVALVE
(85 C o
r185 F
0
) 0

waterw ith
int heenginetocirc
ula
tet hrou
g hth
er ad
iato r
.
I
ft het emperatureoft hecoolingwatere xceeds95 C
0

jluuuU1LF
平均J 刻d
刊以﹁パi凶1 E旧

コ
l
二
こCN
と

コ山川
[20
3P0
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ラ hethermosta
tv a
lvesful
lyopenanda tthesame
time， t
heb ypassvalveblocksupt h
eb ypassportsot hat
a
llt hec o
olingw atercircu
lateswithi
nt herad
iator
.

GO

Em
HωC

川m山

M川
F
ig.1
.10 Thermostat

(3
) Thermosenderu nit
Thethermosenderun
itisinstal
ledonthetherm
osta
thousingofth
een
ginet
od e
tec
tthet
emper
atur
e
oftheco
olingwate r
.
Theoutputofthethermosenderunitdr
ivesth
ethermometeronth
eme
terpan
elont h
edash
boardt
o
giv
eag ene
rali d
eaofthec ool
ingw at
e rte
mper
aturetotheope
rat
or.

THERMOMETER
ぽ
心一

直2
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b

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也、 ao 31
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l
l之
剛

胸sI

F
ig.1
.11

-
9ω
1
. ENGINE

1
.1.3 LUBRICATIONSYSTEM
Thelu
bri
cat
ions
yst
erns
erv
esb
otht
olu
bri
cat
eandc
oolt
hee
ngi
nec
orn
pon
ent
s.

O
ilpressure
ドu
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lowf
il
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r p
ilo
tlamp
「一一一一一ーー一、 S
tar
ter
J 土ごごごごご . s
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ry
.
.
..
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-
=-
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i

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r
11196.1kPaロ{ 弓
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a
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e
r
匂g
l 4p

d
2k cm' s
i]

以
化

-
q
.I

uy
M
v
(vari
abl
e)

Val
veo p
ening
pr
ess.
:7 84
.5
kPa(8kgl
'州
[1
13.8p
si]

、、一ー一一

F
ig.1
.12L
ubr
ica
tio
nSy
ste
rn

(
1)O
ilf
ilt
er
Theoilfil
terconsis
tsoft hepart
sshowni nFigure
1.
13.Itisins
talledont h
eleftsideoftheeng
ine.
Thefil
te
rbodyh asapressur
es wi
tchwhicht ur
nson
whentheoilp re
ss u
red rop
sbelowas p
ecif
iedl ev
el，
allo
win
gt hewarningl a
rnpont herne
terpan
elt ocorne
on
.

FILTER
CARTRIDGE

F
ig.1
.13O
ilF
ilt
er

嗣 1
0-
 1
. ENGINE

1
.1.4 ENGINECONTROLSYSTEM
Theengi
nec on
trolsystemcon
sis
tsofakeysw
itc
hst
art
ers
ole
noi
danda
ラcce
ler
ato
rpe
dal，and ラ

c
ontro
lsth
es t
art，s
top，andspe
edofthee
ngi
ne.

(
1)S tart
ing
① Keys witchinACCp os
ition

xz 一J 凶﹂∞一ωコ
Whent hekeyswitchisplace
dinthe“ ACC"p o
sitin，
o
t
heb at
teryrela
yisa ctiva
tedtoc onnectth
ec ir
cuitof
t
heb a
tter
yt oboththestart
erands a
fetyrela
yt erm
inal
圃
，t h
usmakingt heenginer ea
dytos t
art
.

hh
However u
ラ nles
st hef orward
/reversel e
verisi n
n
eutrlt
a ラheneut
ralrelaywon'tbea cti
vate
dtokeept he
c
ircu
itbetween固 a nd固 open，s ot川 y
l oucannotsta
rt R
ENGINESTOPPING
t
hee n
gine
. SOLENOID

② Keys witchi n“ST"p osition

Byt urn
ingt h
ekeys witc
ht othe“ST"p ositi
on，the
circuitoft heb att
eryt ot hestartert erminal酉 lS
completedtod riv
et heenginef lywheel
. Ast heengine
st
artsupa ndthegenerat
org e
neratespowerl argeenough
toi nc
reasethev o
ltageatt hesafetyrelayterminal圃，
thesafet
yr e
layreducesthevoltag
ea tthestar
terterm
inal
園t ozeroV， t
husb r
ingingthestar
tert ocomet oas t
op.
Asl o
nga sthevoltageatthesafetyrelayterminl圏
a
i
sm aintained，thestar
terwon'tbea ctiv
atedift h
ekey
switchisturnedtot e“ST p
h 円 o
sition.

(
2) Stopping
Whent hekeyswit
chistu
rnedfrom“ACC t o“OFF
円 ラ
'
，
t
hebatterycir
cui
ttoeachterm
i n
alisallopenedtocut
o
fftheb a
tter
yp o
wer.I nad
ditin，t
o heenginestopp
ing
s
olenoidplac
estheinje
cti
onpumpf uelcut
-offlev
erin
t
heshuto
側 ffpo
siti
on，th
usshut
tingofftheengin
e.

F
ig.1
.14

-1
1-
1
. ENGINE

(
3) Enginespeedcont
roI
Enginespeedisc
ont
rolle
dw it
ht heac
cel
eratorp
edalshowninFig.1
.15.
Themotionoft heac
celera
torpedalistra
nsmit
tedthroughlin
kagetothein
ject
ionpumps
pee
d
c
ontrollev
er.
Ast heacc
eler
ato
rpedalispress
ed，thespeedco
ntr
olleverismovedtowardth
e“FULL markt
o 刊

i
ncreaseengines
pee
d.

角リ

PEDAL
JY/
ヨ/￨問
Jl
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ー
一
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ENGINE

F
ig.1
.15A
cce
ler
ato
rPe
dal

幽 1
2
刷
 1
. ENGINE

1
.2 MAINTENANCE
1
.2. lNDERHEAD80し
1 TIGHTENINGCYL .TS
Applymolybdenumd
ofeachb
showni
① F ir
s
o
nF
t，
l
i
t
tandt
g
i
g
.1
ht
.1
e
6
ne
i
.
a
g

c
ht
e

hbo
i

l
s

tt
ul
f

o6
i
nthemi

8
d

.
eont
nth
h

7N-m{
ethreadeda
enumericalo

7kgf-m}[
r
d

5
r
e
e

0
.
a
r

6
⑨…
凶 A
仰
d仰
p
i
s附
p
柳
ull
fid
e

lbι
ft].
② Givethema dd
itiona
l8 8.3N-m{ 9kgf-m}[ 6
5.1
lbιf
t]torque. F
ro
nt
③ F inal
lyt
ラ u
rn900 clockw
ise.

N
ote
: Thec
yli
nde
rhe
adb
olt
smayb
ere
use
dupt
o2t
ime
s. F
ig.1
.16

1.
2.2 ADJU5TINGVALVECLEARANCE
(
1) Turnt hec ra
nkshaftt othelef
tt oa li
gnt he00
markingont hepulle
ydamperw iththepointer
.
(
2) Makes uretheNO.1o rNO.6cyli
nderisattheTDC
onthec o
mpressionstro
ke.Ifacylin
derattheTDC
onthecompressions tro
ket
ラ herock
erarmsoft he
int
akeande xhaustvalvescanbemoved.
(
3)P utat hi
cknessgaugebetweenther oc
kerarmand
valve stem and securewitht herockerarm
adjustme
nts cre
w. Makea djustm
enta ccordi
ngto F
ig.1
.17
Table1.1
.
Valveclear
ance:0.4m m[ 0.
016in.
]f o
ri nt
akeand
exhaus
tv al
ves( co
ld)

F
ig.1
.18
(
4)R
otateth
ecr
ank
sha
ftonef
ul
ltu
rni
nth
ecounte
rc1ock
wis
eandmakea
dju
stm
entont
her
ema
ini
ng
v
alv
es.
Table1.1
Cy.
lNo. 2 3 4 5 6
Val
vearra
nge
men
t I
N EX I
N EX I
N EX IN EX IN EX I
N EX
NO
.lcy
.la
tTDConco
mpr
ess
ions
tr
ok
e O O O O O O
N
O.6c
yla
.tTDCo
nco
mpr
ess
ions
tr
ok
e O O O O O O

同 1
3
削
1
. ENGINE

1.
2.3 INJECTIONTIMING
(
1)R otat
ethecranksh
aftc ou
nterc
1ock
wis
etoalignt
he
markingont h
ep ul
leydamperw it
hanappro
pria
te
timin
gm ar
k.
Inj
ectio
nt i
ming:1 60
(
2) Makes uretoa l
ignt hemarkingontheinje
cti
on
pumpbodyw i
tht h
emarkingont hec
oupl
ing.

F
ig.1
.19

1.
2.4 MEASURINGCOMPRESSIONPRESSURE
(
l) Removet heglowp lu
gsandi n
jectio
np i
pesfrom
al
lt h
ec y
linde
rs.
(
2)I n
stal
lac ompress
iongaugeononeo fthecyl
i n
der
s.
Rotatethecranksha
ftwiththestarte
rtomeasure
thecompressionpres
sure.(F
ig.1 .
20)
Compressionp ressuremeasurements hou ldbe
madea tlea
sttwiceoneachcylind
er.
Compressionpressu
re:3MPa{ 31kgf/cm2}
F
ig.1
.20
[
441ps
i]at200rpm
Limi
t: 2.6MPa{26kgf/cm} [
2
36
9.7psi]

1.
2.5ADJUSTINGINJECTIONSTARTPRESSURE
(
l)I ns
tal
lan ozzleassemblyont hen ozzlete
ste
r.
(
2)S lowlymovet hehandlet omeasurethep r
essureat
whichfuelinjec
tionsta
rts.
Inje
ctio
ns t
artpressu
re:1 8.1MPa{ 1
8 5kgf/cm2}
[2631psi
]
Checkalsothes pr
ayp a
tt er
noff uel
.
(
3)I fth
emeasuredi nj
ecti
ons ta
rtpres
s u
reisotherthan
18.1MPa{185kgf/cm} [2
261p
3 si]a
ラ dju
stw ith
thenozzlea djuster. I fthe spraypatterni s F
ig .2
.1 1
inap
prop
riate，repl
acethen ozzlewithanewo ne.
Good I
nap
pro
pri
ate
11ノ
e

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1
4

F
ig.1
.22
-1
4-
 1
. ENGINE

1
.2.
6 AIRCLEANER
I
ftheairc
1eanereler
nentisc10ggedbeyondt helir
nt，
i t
hes e
nsordete
ctsthecond
itio
nandthewaming
l
arn
pont hepanel
lightsup.Itisp re
ferabletoc1eantheairc1ean
eratperiodi
cinter
val
sinth
ef o
llowi
ng
r
nann
er:
(
l) Rernovethec1arn
pandd etachthecover.
(
2) Rernovetheboltandt a
k eoutthee l
ernent
.
(
3) Useal ow-pr
essureairhoset oc1eant h
ee le
rnent blowingf
ラ rornins
ideout
.
(
4) Checkt h
ee l
ernen
tf orruptureorpinh ole
s.I fanyd efec
tisfound， r
eplac
eitwithanewo ne
.
(
5) Cleanthecoverandb af
fle.
(
6)R ei
nstal
lt h
ee l
ernentandc overinasequenceo pp
o si
tet odis
asse
rnbly.

CLAMP

INDICATOR

F
ig.1
.23 AirC
lea
ner

-1
5-
1
. ENGINE

1.
2.7 FUELSYSTEM
(
1) Replacingfue
lfilte
r
JOINTBOLT闇
① Us in
gana ppropr
iatefi1
terwrench，removethe
fi
lt
er.
② I ns
tallanewf i
lt
er
.A fterth
ep a
ckingtouch
esthe
base，givet
hefil
teranot
her2/3ofatur
n.
③ B leeda i
routoft hesysteminthemannergiven
below.

F
ig.1
.24 F
uelF
ilt
er

(
2)Airbleeding
① Loosentheo ve
rflowpip
ejoi
ntbol
ts.
② Pushingintheprimin
gpumph a
ndle，tu
rnitcountercl
ockwi
se.
③ Pumpt hehandleupanddowntof ee
dfuelint
ot hefi
lt
er.
④ Repeatstep③ unt
ilnobubb
lesareobserve
di nfuelfromthejo
intbol
t.
⑤ Tighte
nt h
ejointbo
ltsandtu
rnthehand
lec lo
c k
wi sepu
ラshingi
nit.

宮
町。

F
ig.1
.25 A
irB
lee
din
gPr
oce
dur
e

制 1
6-
 1
. ENGINE

Table1
.2 L
istofBoltandNutTorquef
ort
he6BG1Engine

Torque
Name Remarks
Nm{
田k g
f-m}[lb
f-
ft
]
C
y1i
nde
rhe
adboI
t 1
12.
8土5{1l.5土0
.5}[
83.
2土3
.6] Newb o1
tsshou1
db e
tor
quedto93土5N-m
{9.
5土0 .
5kgf-m}
[6
8.7土3.61bff
“ t
].
Oi
1s hou1
dbea p
p1ie
dto
th
es e
atsurfa
ceand
thr
eadedare
aofeachbo
1t
.
Cy1inde
rh eadbol
t(w/tur
boch
arge
r) SeeNote2 .
G10wp 1ug 24.5{ 2
.5}[ 18
.1]
Inje
ctio
n( h
igh.
予 30土l.5{ 3.05土0 .15}[22.1土l.1]
Nozz1eho1dertig
hte
nin
gtorque 18.6{l.9}[3
.7]
Cranks
haftbearingc
apbo1t 236 2 45{
開 23幽2 5}[ 166 181] O i1s ho
u1
聞dbea pp
1iedt
o
b
oltseatsu
rfaceand
t
hreadedar
ea.
Id1
eg eartighten
ingb o1
t 44幽6 3.7{4.5 6 .5
}[ 32.6幽4
・ 7
.0] O i1s ho
u1dbea p
p1ie
d.
Camshaftg eartighten
ingb o
lt 1
42 1
・ 8
1{ 14
.5 1 8.5}[
開104 .
9-133.8
]O i1s h
ou1dbea p
p1ie
d.
F1ywhee1tightenin
gb olt 1
96 240{
“ 20.
02 4.5}[
聞144.7幽1 7
7.2]
F1ywhee1tightenin
gb olt(w/turboc
harger) SeeNote3 .
F1ywhee1h ousin
gt ighten
ingb o
1t 1
42-1 81{14.5幽1 8.5
}[ 104.9-133.8
]O i1s h
ou1dbeapp1ie
d.
Flywhee1h ousin
gt ighten
ingb o
lt 20.6 30.
開 4{2.
1 3 .
1}[ 15.2 22.
“ 4] atoilsea1r
eta
悶i
ner
Enginefoott ig
hteningbo1t(fron
t) 29.4
幽3 4
.3{ 3 3 .
5}[ 2l.7-2
・ 5.3]
Enginerearmountb ol
t 245{ 25}[ 1
80.9]
Connectingr o
db earingcapt igh
tenin
gb ol
t S
eeNote3 . O
i1s h
ou1dbeapp1ie
d.
Cranksh
a f
tf ron
tn uttighteni
ngn ut 588土 49{ 60土5}[ 4 34土36]
Timingg earcasetightenin
gb ol
t 20.6-30.4{ 2.
1 3 .1}[ 15.2-22.
・ 4]
Timingg earcasecov e
rb ol
t 20.6-30.4{ 2.
1幽3 .1}[ 15.2-22.4]
lnje
ctio
npumpg ea
rb earingnut 17土 1
4 9.
6{ 15土2}[ 109土 14]
Rockerarmb ra
ckett ig
hteningbolt 25.5 30.
・ 4{ 2.6-3.1}[ 18.8 22.4] ・

Tappetchamberc overt igh

teningbo1t 7
.9-9 .
8{ 0.8 1 .
0}[ 5.8 7.2
閉] 岨

Camshaftthrustp1atetighten
ingb o
lt 20.6 30.
開 4{ 2.
1 3 .1}[ 15.2 22.
国 4] 田

Oi1pumpt i g
htenin
gb olt 52{5.3}[ 38
.3]
Waterpumpt igh
teningb o
lt 42.2-6l.8{ 4.3-6.3}[ 3l.1-45.6]
Oi1pant ig
h t
eningbolt 2
5.5{ 2.6
}[ 8.
8]
Sta
rtertighten
ingbo1tn ut 74.5-9 5{7.6-9.7}[ 54.9-70.1]
Inje
ctio
npumpc ou
p 1in
gt igh
teningbolt 29.4-34{ 3-3 .5
}[ 2l.7 2 5
.3] 四

N
ote
s:1
.C y1ind
erh e
adb o1
tss hou 1dbetigh
tenedintwos tep
s:firsttor q
ueto58.
8N-m{ 6kgf-m}[43.
41bf “

ft
];thento93.2土 4.9N寸n{ 9.
5土0.5k gf
-m }[68.7土3.61 bf
-ft]fornewboI
tsorto112.
8N引 1{11
.5
kg手m}[ 83.
21 bf
-f
t].
2
. Torqueto68.7N m {
幽 7. 0kgf-m}[50.61bf
-ft
]f i
rs
t;andt hent o
rquet
o8 8
.3N-m{ 9.
0kgf-m}[65
.1
1b
f-f
t].Final
lyt u
rn90 0 • Be
foretigh
teningthebo1s，a
t pp 1ymo1ybdenumd i
su1
fid
etot h
rea
dedar
ea
andseati
ngs u
rface
.
3
.T orqueto39.2N-m{ 4kgf-m}[ 2
8.91bf
-ft
]a ndturn60 ・ 90 • 0

-17-
1
. ENGINE

Table1
.3 ISUZU-makeStandardBoltTorqueN-m{kgf-m}[
lι白
b ]

N
o
¥m
¥i
n
¥a
lS
s:
i
汀窓口¥
怠 g
¥t
h 4T(
so
fts
te
el
) 7T(
har
dst
ee
I) 9T(
sp
ec
ia
Ist
eel
)

M6x1.0 3.
9{ 0.4-0 .8}[29・5
. .8
] 4
.9{ 0
.5・1 .0
}[3.6幽7.2] *
M8x1.25 7.9幽17.7{0. 8-1.8}[5.8・13.
0] 1
.2・2. 3{1
.2・2勾 [ 8.
7-1 6.7
] 16
.7-30.
4{I.
7・ 3.I
}[ 12ふ 22.4
]
MIOx1.25 20.6・34.
3{ 2.1 3
司 .5}[15.2
・2 5.
3] 27.54 6.1{
姐 2.8-4 .
7}[ 2
0.3-34.0] 37.5・6
2.8{38-6.
. 4
}[ 2
7.5幽46.3
]
M12x1.25 4
97開3.6{ 5
. 0・7 .
5}[36.
I
同5 4.
3] 608幽91
. 2{
. 6
.2・9 .
3}[60
.8-6 7.3
] 75.5・11
3.8{7.
71
舗 1.6
}[ 7
5.5・1I3.8
]
M14x1.5 7
6.5・114
.7{ 7.81
働 1.7
}[ 6.
7 5-84
.6] 93.
2幽1 39.
3{9.5-14.2
}[932幽1
. 39.
3] 113
.8・1
706{
. I1
.6-17.
4}[83.
91
圃 7
0.6]
M16x1.5 10
4-1 57{IO.6・1 6.0
}[ 7
6.71凶16] I35.
3・2 04{I3.8幽20.8
}[ 9
9.8・1 5
0] 15
9.8-2
40.3{6.
1 3
幽2 4.5
}[ 11
8-1 7
7]
M18x1.5 15
12岨55.6{1 5.4-26.
1}[111幽189
] 1 5.
9 2-293
.2{ 1
9.9・29.9
}[ 1
44-2 3.
9 2 229.
5
“3 45
.2{3.
2 4
・3 5.
2}[ 1
69・255
]
M20x1.5 207幽310 {
21.1・ 31.6
}[ 1
5
岨32 29] 2 69.
7- 405
.0{27.5幽4I.
3}[1992開99] 316
.8・4
75.6{
323・4
. 8.5
}[316.
8-351
]
M22x1.5 251・4I3.9{25.6幽4 2.
2}[ 1
85・305] 362.9幽544.
3{ 37・55.5
}[ 28幽4
6 01] 4
24.6・6
36.5{3.
4 3-64.
9}[3I3
幽4 69]
M24x2.0 3
58.9-539.
4{ 36.6・5 5
.0}[265-398] 4
30.5・711{43.97 2.
舗5
}[ 3
18・5 24] 5
54.ト 8
30.6{6.
5 5
幽8 4.
7}[ 49-6I
0 3]

Signofbolt

。住ヨ
4T 7T 9T

Note:Theabovet
abl
eap
pli
est
oca
seswheret
igh
ten
ingt
orq
uei
sno
tsp
eci
fie
d.

開 1
8-
 1
. ENGINE

1.2
.8 TROUBLESHOOTINGGUIDE
(
1) Enginedoesnots
tar
t

Problem P
rob
abl
eca
useandremedy
S
tar
terd
oesn
otr
ota
te (
1) Checkw i
rin
gsf o
rl oo
sec o
nnec
tionsorimpr
opercont
act
.
(
2)D efe
ctivest
arte
rs w
itch.
(
3)D efe
ctiveengagemagnetics wit
ch，brok
eni n
ter
nalcols
i t
ick
ysh
iftl
eve
r，o
r ラ

maladju
stmentofengages w
itc
hc on
tac
tpoint
.
(
4)D ischa
rgedbatt
ery
b
an

u
hwmv
P3JU

pι
4tcd
4lrL
創氾

J山 由 し
町札刊

42t
久間勺

Checkrin
ggeara
ndp i
nio
ng ea
rendfo
rc u
rlandre
pai
rorr
epl
acei
fne
ede
d. Check
弘
は

engagem
agne
ticswi
tch.(pi
niond
oesnotpopout
.
)
v

St
arte
rp i
nio
ncomesin (
1) Measurebatte
rycapa
cityandele
ctrol
ytespec
ifi
cg r
avitybyate
ste
ran
dre
cha
rge
meshwithrin
ggear bat
teryifneede
d.
butengi
nedoesn
ot (
2) Checkforl o
oseconne
ction
sofb at
terycordter
minals
ro
tat
e. (
3) Roughc on
tactsur
faceofmagn
e t
ics wit
ch
(
4) Checkforworns t
art
erbrushordeter
iorat
edbrushspring
(
5)S eize
dp is
tonortrou
bleinmechanica
lp ar
tsinsi
dethee n
gin
e.

Enginero
tate
s，b
ut (
1)F uelisnoti n
ject
ed.
doesnotst
art @ Fueltankise m
pty.
a
v Cloggedf uelt a
nks t
rainerorf ue
lf il
terelement o
ラ rdamagedp ipeorl
oos
e
connec
tiono fpipin
g.
@ Stick
yf eedpumpp iston.
(
2)F uelisinject
edb
ラ ute ngineworγts t
art
.
Checkf o
rf ue
li nj
ectiontiming:
Makes urecamg earmarka lignswithpumpg earmarkbyp eepingthr
oug
hti
min
g
gearcasewindowwhenf ir
stcylinderisintopdeadcente
rp os
iti
on.
(
3) Lackofair.
③ Checki fthrott
lev a
l veisfull
yo pened.
⑥ Checka irc le
anerforc10ggingandc l
eanifneeded.
(
4) Toolowc o m
pressio npressur
e
@ I n
suffic
ienttappetc1earance
⑥ I mproperseatin
go fv alv
eduet os t
ickyvalvestemandg uid
e
@ Checkf o
rworno rstickypistonringorwornl i
ner
.
(payatte
ntiontoblow-backt oo i
ls ep
aratororbre
athe
r.)

Enginesta
rts，b
ut I
nsu
ffici
entfu
elfeed
stop
si m
mediate
ly. (
1) Checkforstic
kyf e
edpumpp i
sto
no rwat
ercont
entoffue1
.
(
2)A irmixedinsystem
③ F uel日It
erelement，fue
ltankstra
inerorf
uelf
ilt
ersc
1og
ge d
.
⑥ Damagedf u
elpipeo rloo
sec o
nnect
i o
nsofpi
pin
g.
@ Feedpumpp ist
onr odworn.
m
-
.msd

bm
s'nl
e w ・6
n
rESny

組問

n円dハ d
u b p主

U2
HU

ιEL4z-L

I
dli
nga
dju
stm
ent
:
o
旧山

はい附

rz
円
Unb

Adjustbyusingi
dli
ngadjustmentscrewo
fth
rot
tlev
alv
e.
M

﹂戸
沿
M

UV

-1
9 蜘
1
. ENGINE

(
2) 主nginedoesnots
tar
t

Problem P
rob
abl
eca
useandremedy
Unsmoothi
dli
ng (
1) Checkf oroi
1l e
aksfromi nje
ctio
np i
pe.Ifunsa
tisf
acto
ry，rep
lace.
(
2)D efecti
ven oz
zle:
Checks praypat
tern.Ifs t
ickynozzl
eisfoundrepl
ace
.S etinje
ctio
np r
ess
ureat
18.1MPa{ 185kg打cm} [
2
2631psi]andmakes u
renod r
ipisfound.
(
3)D efecti
vei nj
ect
ionpump:
Checkt h
ate a
chpumph asequalamountofin
ject
ionandcorr
ectinjec
tio
ntimi
ng.
(
4)T hr
ottlevalveshaftworn:
Ifgovernornegativepressur
ev a
riesduetolooseval
ves et
-upc aus
edbyworn
valveshat，r
f epla
cet h
rott
levalve
.

Tooh
ighi
dli
ng (
1)A
djustthr
ottl
ev al
veidl
ings
top
perbo
lt.
(
2)D
efe
ct i
vei n
tern
alpar
tsofgo
vern
or:

Hunchinga
tmedium (
1)D
efe
cti
veg
ove
rno
r

Unsmoothro
tat
iona
t (
1)F uelfeedisi ns
uffic
ient
:
hig
hs pe
ed @ Checkf ormixingofa irinsystemandrepa
ir.
⑤ Checkf o
rcl ogg
edf u
elfi
1tereleme
ntorotherclo
ggin
ginsyste
mandclen，
a replac
e
eleme
nt.
@ Defectiv
eo verflowvalve:
Checkf orc10ggingofv alveordeter
ior
ationofspri
ng，andrep
airorre
place，if
needed.
(
2)D efect
ivei nje
ctionpump:
③ D ete
riorate
dg overnors pr
ing
⑥ S tic
kyp lun
g erorn oz
zle
@ P lungerspringord e
liveryspri
ngb r
oken
.
(
3)I ns
uffici
entvalvec lea
rance
(
4) Checkf orbreakageord et
erio
ratio
nofv a
lves p
rig，
n andrepl
ace，i
fnec
essa
ry.

Enginero
tat
esathig
h (
1) Checkfors
ticki
ngbetweena
cce
ler
ato
r・p
eda
landt
hro
ttl
eva
lveandr
epa
ir，i
f
speedanddoesno
t nee
ded.
cometoas t
op. (
2)D ef
ecti
vegove
rnor.

同 20-
 1
. ENGINE

(
3) Lowoutput

Problem P
rob
abl
eca
useandremedy
Lowo utp
utdueto (
1)Improperinjec
tiontiming
def
ecti
vei n
jec
tio
n Checkf o
rl oosen
essofpumpc a
mshaftandt imer，loo
ses e
tboltofcamg e
arand
pumpo rit
saII
ied id
leg ea
roラrt o
ol arg
eb a
cklas
ho ftimi
n ggear，andrepa
ir.
pa
rts
. (
2)Defec
tiven o
zzle:
Checkf o
rs pra
yp att
ern，in
jec
tionpres
su r
eo rafter
-inj
ectio
nf u
eldri
p.
(
3)Ins
uffic
ientfuelfeed
:
Seethep re
cedingp a
ge.
(
4)Defec
tiveg o
vernor:
③ Cloggedaircleaner
⑥ Ift
hrot
tlevalvedoesn o
tc o
mplete
lyopenwhena ccele
ratorped
alisfuI
Iypres
sed，
adj
ustp e
dalo pera
tinganglebyu si
ngp edalstopp
er. AIsobyu sin
gc o
ntr
olr o
d
tu
rnb ack
le，adjustrela
tion
shipbetweenpedala ndthro
ttl
ev al
ve.
@ Defec
tiveg o
vernor.

Lowo ut
putdueto D
efe
ctivevalvemechanism
in
suff
icie
nt ③ I n
suf
fici
enttapptc
e Ieara
nce
comp
ressIOnpr
ess
ure ⑥ Br
・okenvalvesp
ring
@ S t
ickyvalvestemandguide

(
4) Overheatingofengine

Problem P
rob
abl
eca
useandremedy
O
verhe
at i
ngdueto (
1) Lowl eve
lofc oolan
t
d
efe
ctivecoo
lin
g (
2)I ns
uffic
ientrota
tionofwaterpumpduet oslipp
ingbeltorimpro
perb e
lttensi
on
s
ystem oradjus
tingbeltstic
kingtopuIIe
yg roo
ve.R eplacebelt
.
(
3) Deformedc ool
ingfan:
Checkf o
rp rop
ert e
nsionoffanbel
t.
(
4)M alfun
ctionoft her
mosta
t:
Checkthati
tbeginstoopenat820C[ 1
79. ]a
60P ndfin
ish
estoopenat900C[1940P]
.
(
5)D efe
ctiveradiato
rc apofpres
surizi
ngtype:
Checkp res
surevalveandn eg
ativepressurevalvesprin
gsfordete
riora
tio
nand
valv
es e
atr ubb
erf o
rdamage. Ifunsati
sfacto
ry，rep
lace
.
(
6)C ontaminantincoolingsys
tem:
Removec ontaminantinrad
iatororenginecoolantpas
sages
.
(
7)D efe
ctiveradia
tor:
Checkb endin
ga ndcIoggin
goff i
no rforpluggedradia
tortub
e.

O
verhe
atingduet
o (
1)I
nje
cti
o山
o
the
rd e
fec
ts (
2)I
nsu
ffi
cie
ntt
appetc
leara
nce. (
-re
fert
otepe;t~ini;g ite~s.
h
(
3)I
nsu
ffi
cie
ntcom
pressi
onp r
essu
re.

開 2
1-
1
. ENGINE

NOTE

-22-
 2
. DRIVEUNIT

2 DRIVEUNIT
聞

Model 90S-25
Name Torquec
onv
ertertyped
riv
eun
it
Torquec onve
rter
Type 3
-el
eme
nt，ト s
tage，l
-ph
aset
ype
Stal
lt o
rquerat
io 2
.3
Chargingpump
Type GearPump
Discha
rge 33.
3cc/r
e v
Pressu
res et
tin
g 706kPa{
7.2kgf/cm} [
2
1
02.
4ps
i]
Transmission
Type C
ons
tan
t-m
eshpowers
幽hif
t
Speeds 3fwd/
3rev
Gearr a
tio
Fwd1 st 2.
770
“ 2nd .392
1
“3 rd 0.
473
Rev 1st 2.
776
“ 2nd 1.3
95
“ 3rd 0.
475
Clutchdisksiz
e
(O.D .D
.X I .xT hi
ckn
ess
) 1
60m mx113mmx2.
2mm
[
6.3i
n.x4
.5in
.x0
.08
7in
.]
Co
ntrolvalv
e
Type S
oleno
idtype
Clutchpr
essu
res
ett
ing 2
.06-2
.35MPa{2
1-24k gf
/cm2} [
1.5
2-1.7
3ps
i]
O
ilcap
acity 25li
ter
s[6.6USgal]

2
.1 GENERALDESCRIPTION
Thed
riv
eun
iti
scomposedofacombinationofatorqueconverterandap
owe
r-s
hif
ttransmission
andconnectedt
oth
eenginea
sshowni
nFi
g.2
.1.

-23回
2
. DRIVEUNIT

TORQUECONVERTER CHARGINGPUMP

COUNTERGEAR

国国~

1ST/2ND
CLUTCHSHAFT

2NDCLUTCH
SHAFT

PARKINGBRAKE

STRAINER

F
ig.
2.1D
riv
eUn
it(
1/4
)

-24-
 2
. DRIVEυNIT

crosss
ect
ion
alview陪欄間

恒国出盟

fromOILCOOLER

Viewl
ook
ingfrom固

E
DGreen eBlack

Crosss
ect
ion
alview用
-fF
1

Viewl
ook
ingfrom聞

F
ig.
2.2D
riv
eUn
it(
2/4
)

側 25-
2
. DRIVEUNIT

-~四冨

TRANSMISSION
CONTROLVALVE
fromOIL
COOLER

Viewl
ook
ingfromf
i
l

開 26-
 2
. DRIVEUNIT

。@@

Viewl
ook
ingf
rom臨

Fig.2.
4 DriveU
nit(
4/4
)

-27-
2
. DRIVEUNIT

2.1.1 TORQUECONVERTER
Thetorqueconv
erterisa3-element，l-s
tage，sin
gle.p
剛 hasetypeconsi
stingofapumpwheel， t
urbine
wheel，ands ta
torwheelwitht heinsidefil
ledwitht orqueconvert
ero i
ls upp
liedfromt hecharging
pump.
Whent h
ee ngi
nes t
art
sandt hepumpwheelr o
tates，th
epoweri stransm
ittedtoth
et or
quec o
nverter
oi
li ns
idetheconver
terandt he
nt heoi
lf l
owsi n
tot h
et urb
inewheels otha
tt h
epowerist ran
smitte
dto
theturbi
newheel， p
assingthroughthetransmiss
ions ha
fttラothetransm
ission
.
Meanwhilet het
ヲ orqueco
nverteroi
lwhichf lowsintothesta
torfromtheturbin
e，chan
gesitsdire
ction
offlowwhenp assingthroughthesta
tor
.Att hesamet im
erラeacti
ont o
rqueisproducedanditisadded
totheturbi
newheel.
Ther eact
iontorqueismaximumwhent het u
rbineshaftisatres
tandr e
ducesasthet u
rbineshaf
t
rot
ates
.
Thet orq
ueconvert
er，asdesc
ribedabovei
ラsi nten
de dt
oa ut
omati
callychangeoutpu
ttorqueaccordin
g
tothemagnitudeofl o
ad.

1
. LOCKWASHER 6. INPUTPLATE 1
1. SEALRETAINER
2
. LOCKNUT 7. CASECOVER 1
2. OILSEAL
3
. TURBINESHAFT 8. TURBINEWHEEL 1
3. SEALRING
4
. STATORHUB 9. STATORWHEEL 1
4. STATORSUPPORT
5
. SPACER 1
0. PUMPWHEEL

F
ig.2
.5 TorqueC
onv
ert
er

聞 28-
 2
. DRIVEUNIT

2.
1.2 TRANSMISSION
Thetran
smiss
ionco
nsi
stsofth
reeclu
tchsh
aftas
sem
bli
es，eachofwhichc
onv
ert
sth
epowerfrom
t
hetorqu
ec on
verte
randsend
sittoth
edrivea
xle
.

(
1) Clutchs h
aftassembly
Therearethreetype
sofc l
utchshaftassemb
liesusedforthetru
ck:onef o
rforward
/rever
set ra
vel，
oneforlst
/3rdspeeds，andonef o
r2nds peed
. Theyhavet h
esameh ydra
ulicclu
tchpackdesi
gn. Each
c
lutchpackh asinne
rando u
terd i
sks，withtheinne
rd i
sksinmeshw iththegear
sandt h
eo uterdisks
w
it htheclu
tchdrumt eeth
.
Thep r
essureoilfromt hecontrolvalveflowsthroughtheoi
lh ol
esi nth
es h
aftandgetsi nt
ot h
e
p
istonofanyc lu
tchshaftassembly，whichinturnloc
ksupt h
ec l
utchpackt
ラ h
usaggre
gatingtheclutch
s
haftandc l
utchhubg eartogethe
rt otran
smitthepowertothedriveaxl
e.

WAVESPRING
OUTERDISK

INNERDISK

PISTON

"
"--
n"ー“円“一ー「ー寸 r
--r
F
ig.2
.6C
lut
chS
haf
tAssemblyI
nOp
era
tio
n

Withnopre
ssu
reoi
lfromtheco
ntro
lv al
ve，thepi
stoni
skep
tbackbyt
hewaves
pri
ng，
unl
ock
ing
th
ec l
utc
hpacksoth
atnopoweristra
nsmit
tedtothedr
ivea
xle
.

WAVESPRING
OUTERDISK

INNERDISK

PISTON

ι T。
一I
I 一
ー r
r-
--
[I
"-
"-
Ir
--
n-一一一一
F
ig.2
.7C
lut
chS
haf
tAssemblyNoti
nOp
era
tio
n

-29-
2
. DRIVEUNIT

SPACER
OUTERDISK
O"-RING
“

ENDPLATE
PISTON
BALL SNAPRING

DISKSPRING

FWDCLUTCH
OILPRESSURE
REVCLUTCH
OILPRESSURE

'-LUB.OIL

SEALRING

F
ig.2
.8 Fwd/RevC
lut
chS
haf
tAssembly

BALL

OUTERDISK

3RDSPEED
CLUTCHOIL
PRESSURE
1STSPEED
CLUTCHOIL
PRESSURE
_ LUB.OIL

F
ig.2
.9 1
st/
3rdSpeedC
lut
chS
haf
tAssembly

-30-
 2
. DRIVEUNIT

OUTERDISK
INNERDIS PISTON

WAVESPRING SEALRING

SNAPRING
BALL

SEALRING

2NDSPEED
CLUTCHOIL
PRESSURE

SEALRING

Fig.2.10 2ndSpeedC
lut
chS
haf
tAssembly

-3
1-
2
. DRIVEUNIT

2.1.
3 TRANSMISSIONCONTROLVALVE
Thec on
trolvalveser
vestos el
ectthetra
velin
gs pe
edrangeandthedire
ctio
noftrave
lofthet ruc
k
s
electi
velys e
ndingth
ec lu
tchoiltoeachclutc
hp ac
k.
Thec o
ntrolvalvec
onsis
tsofav alvebodyandf o
ursole
noidva
lveswhichareac
tivat
edbyu sin
gt h
e
tr
ansmissioncon
trolswi
t h(
c lever
).Thec lu
tchoilpres
surei
scontr
olle
dbymovingt hes po
olsinsid
e
t
hev a
lve.
Thec on
trolvalvei
se quip
pedw ithmodulat
ionmechanismswhosechara
cter
ist
icsarediffe
ren
tf o
r
d
iffer
entspeedr an
ges
.I naddit
ion，i
tcanbemanuallyo pera
tedifth
eelect
ricsyste
mf a
ilstoopera
te
n
ormally.

一
一
。一一
。。一
一一一
一ー

2 3 4

O@O 0

PLATE(FORMANUAL 11
. SPOOLA 21
. SPRING
OPERATION) 1
2. SELECTSPRING 22
. FしO WSENSING
2. COVER 1
3. SPOOLB SPOOL
3、. COVER 1
4. SELECTSPRING 23
. SPRING

…m)
4. COVER 1
5. ORIFICE<
>8
1 2. 円N
4
5. SOLENOIDVALVE (FORSOLENOIDVALVE) 25
. ROD
6. ADAPTER 1
6. 26
. SPRING，INNER
7. VALVEBODY(LOWER) 1
7. ORIFICE(
Z) ¥NOTE 27
. SPRING，CENTER
8. F/RSELECTORSPOOL 1
8. ORIFICE(
Y) 28
. SPRING，OUTER
9. ADAPTER 1
9. ORIFICE(
X) 29
. LOADPISTONH
1
0. SPRING 2
0. VALVEBODY(UPPER)

F
ig.
2.1
1 T
ran
smi
ssi
onC
ont
rolV
alv
e(1
)

-3
2ω
 2
. DRIVEUNIT

5
~/7
1
'"』l量 E

O O
O
8 O

9 ~o
O O
10
1
1
12
13
叶
。
14

6
S
ect
ionA-A
16 17 18 19
20、 /30 S
ect
ionB輔自

21、 ¥¥ / /
31 ~40
22、 下
.J.V¥.ゴ) 三ど止コY I
JI
zi /32
23 33
24 34
25 35
26 36
27 37 S
ect
ion0-0

28 38
29 39
S
ect
ionC C “

Note: O
rifi
cediameter O
rific
e(W) O
rifi
ce(X
) Ori
fice(Y) Or
ific
e(Z
)
m m[i
n.] (fo
rm ai
n) (
for1s
t/2n
dspee
ds) (
for2ndspee
d) (
for3
rd/4
thsp
eed
s)

。6
.0[
0.23
6] 。.
13[
0.0
51] 。0
.8[
0.0
31] 。
1
.6[
0.0
63]

30
. REGULATORSPOOL 3
4. MODULATIONSPOOL 3
8. SPRING
，OUTER
31
. PISTON 3
5. ROD 3
9. LOADPISTONし
32
. SPRING，OUTER 3
6. ，INNER
SPRING 4
0. MANUALSPOOL
J3
ぺ. SPRING，INNER 3
7. ，OUγER
SPRING (EMERGENCY
TRAVELSPOOL)

Fig.2.12 TransmissionControlValve(
2)
司
司、)
3
2
. DRIVEUNIT

①ー④， F，R
:Clutches

[
;
… 0-
与問仁元一三月 t
l
II-@J
l l
II=r'T
J..i 'l阻
t 山 !
dI伽ュ
i
IR SOL.r
n，. 庁
i d
III
JN
;
山
B SOl
.

ー
LF1却 し ;
』ー・ r-~
toTORQUE
CONVERTER
~~t*IÎtl*t 山

崎P
MANUAL
SPOOL Ii
』時一一ー一ーーー 1'-一一一一一ーー
令..-一一一一一ー・一一一一一一 一一ー....-~豆一-...-ー一一一一
r 噂

SPOOLA
L__
)~ (y)

z
，
，

)
ほ沼PE.
REGULATOR

、
r-一ー「

，
)
I(

×
(W)

、
，
、‘，，，
‘
s
fromPUMP

ACCUMULATOR
H
ydr
aul
icC
irc
uitDiagram 4J(LOADPISTON)

F
ig.
2.1
3Tr
ans
mis
sio
nCo
ntr
olV
alv
e(3
)

峨 34-
 2
. DRIVEUNIT

2.1
.4 POWERFLOW
(
1) Forwardt
rav
el

1
sts
pee
d
F
ig.
2.1
4

(
2) Reverset
rav
el

・
.
-
!

1
sts
pee
d
F
ig.
2.1
5

帥 3
5-
2
. DRIVEUNIT

2 .
1 5 HYDRAUL
. lC OILPIPING
Theoilusedf orthedriveuni
ti ss up
pliedfromt het ran
smissioncase
. Ast hee ngin
es tar
ts，the
chargingpumpp icksupoilfromt het r
ansmissio
nc asethroughthesuctio
nf i
lte
rands endsitthrough
thei n
lin
efilt
ertothecon
trolvalv
e . Thecontrolvalvedivid
est h
eoilintotwof10wsw ithth
er egul
ator
spool:oneforc1utchoper
ationandonef o
rt orqu
ec onve
rtero p
erat
ion.
Theoilsentintoth
ec onv
erter，af
t e
rl ea
vingthec onv
erter，f
10wsi nt
ot h
er ad
iatoroi
lc oole
rt oget
cooleddown.A fterleav
ingtheoilco o
leri
ラ tf10wst hroug
ht h
ed is
trib
utorcaptol u
bric
ateandc oolthe
c1utchdisk
sg
ラ earsandbearingsofe achc1utchshaf
ta ssembly，bef
orereturnin
gi nt
othet ra
n s
mission
case.
Theoilisdist
ribut
edt h
rought ub
i ng
so utsi
det h
et rans
missioncasetothec1utchshaftassemblie
s
andt orq
uec o
nvert
er.

ぽ凶ト﹂一斗 ω Z一
JZ一

F
ig.
2.6H
1 y
dra
uli
cOi
lPi
pin
g

-36-
 2
. DRIVEUNIT

2.1
.6 PARKINGBRAKE
Theparkin
gbrakehasadesig
nshowni nFi
gur
e2 .17andisin
sta
lledontheoutp
utshaf
tofth
e2nd
c
lutchsh
aftasse
mbly.
Whennoo ilpre
ssurea
ctsonthepi
ston，t
hepisto
nl o
cksupthediskswit
ht h
es pr
ingtoa
pplyt
he
p
arkingbra
ke.
Wheno i
lpress
ureisap
plie
dtラhep
isto
nmovest otherig
httounloc
kt h
edisk
s.

BRAKERELEASE
PRESSURE

BRAKERELEASEBOLT

HUB

SPRING
2NDSPEED
CLUTCH
PISTON

D
ISK

F
ig.2
.17P
ark
ingBrake

圃Pr
oceduref
orr
ele
asingparki
ngb r
akemanually
A DANGER: Don ott r
yt ore
l附 et heparkingbrakeonas l
ope.
. Loosent
1 h
ese
tplat
ef i
tti
ngboltoft
her e
leas
eboltandremovethese
tplat
e合omtherel
eas
ebo
lt
groo
ve.
2
. Pushinth
ere
lea
seboltandt u
rnitclo
ckwiseeve
nly.Pu
llthepis
tontow
ardth
eco
ver.

阻 Afterre
turn
ingth
epa
rkingb
rak
etot
heo
rig
ina
lpo
sit
ion，engaget
hes
etp
lat
eint
her
ele
aseb
olt
groovesec
urel
yandlo
ck.

-37 司
2
. DRIVEUNIT

2
.2 MAINTENANC在
2.21 HYDRAUL
. lC0 1しPRESSUREMEASUREMENT
(1
) Preparations
Prio
rt omeasuringt h
ehydr
auli
coi
lpres
sure，
makes uretheoi
ltemp
erat
ureiswith
inther an
gefrom
75-8 5C [
0
167-185P0
.I
] f
theoi
ltemp
eratu
reisno
tw ithi
nt h
erane，
g iti
sdi
ffic
ultt
oobt ai
nac o
rrec
t
measuremen t
. Makes uret
og e
tanoi
lpres
sureofa
tl e
ast2.5-5 .
0MPa{ 25-5 0kgf/c
m} [
2
356-711
ps
i]capacit
y.

(
2) Measurementprocedure
① S hutofftheengin
e.
i
nle
toilpressure
② Removet heplugfromtheportwhereyouaregoing
O
utietolpressure I343{
i 3.5
}[4
9.7
)
tomeasurei t
sp r
essure
.I nstal
lt heoi
lp res
sure
Inl
etoil
gauge
. pressure

③ S t
arttheengineandleti
tr unat2000to2200r pm
.
④ Readt h
eoilpressu
regaugeandr ec
ordit
.
⑤ L etthee n
g in
er unatidlin
grpmandt hens h
utit
o
u 五
⑥ Removet heoilpressureandr ei
nsta
llt h
ep lu
g
sec
urely
.

F
ig.1
.18
(
3) Measurementpoin
tsandstandardo
ilp
res
sur
e
① T orquecon
verte
r
② 耳y draul
icclu
tchpack
s
Pressures
ett
ing
: 2.06-2.35MPa{ 1-24kgf/cm2} [
2 298
.8-340.8p
si)
Measurepressureset
tin
gwi
ththeengineru
nninga
tidlerpm.

FWDCLUTCH
OILPRESSURE

REVCLUTCH
OILPRESSURE

1STSPEED
CLUTCHOIL
PRESSURE

3RDSPE巨D
CLUTCHOIL 2NDSPEED
PRESSURE CLUTCHOIL
PRESSURE

F
ig.
2.1
9

時 38-
 3
. DRIVEAXLE

3
. DRIVEAXLE

瓦¥寸竺 FD160-2 FD180-2 FD200-2 FD230-2

Type F
ull
-fl
oat
ingt
ype
T
ota
lre
duc
tio
nra
tio 2
5.0
70
D
iff
ere
nti
al
Type 4p
i
幽ni
ont
ype
R
edu
cti
onr
ati
o 4
.5
O
ilc
apa
cit
y 38l
it
er
s[1
0USg
al](SAE#90)
F
ina
lre
duc
tio
nge
ar
Type P
lan
eta
ryg
eart
ype
R
edu
cti
onr
ati
o 5
.57
1
OiIc
apa
cit
y 5l
it
er
s[.3USg
1 al]f
ore
achs
ide
Wheel
T
ires
ize 1
2.0
0-2
4-1
8PR
(ID) 1
3.0
0-2
4-2
0PR(
ID) 1
4.0
0-2
4-2
4PR
(ID
) 1
4.0
0-2
4-2
4PR(
ID)
設ims
ize 8.5Vx24 モ
ーー モ
ーー ‘
一切開
匂

I
nfl
ati
onp
res
sur
e 7
85k
Pa{ 8
.0k
gf/c
m2} 8
09k
Pa{8.
25kgf
/cm2 8
83k
Pa{9.
0kgf/
cm2} やー

[1
13.
8ps
i] [1
17.
3ps
i] [
128.
lps
i]

3
.1 GENERALDESCRIPTION
Thed
riveaxlecon
sistsofanaxlehousing d
ラ iff
eren
til，
a wheelbraks，
e wheelhubsandaf
ina
lre
duc
tio
n
gearandisins
talle
dont h
ef r
ontpar
toft heframe.SeeFigure3.1
.
Thea
xlehousingisroughlydiv
idedintotwosecti
ons
:t h
es p
indl
es ec
tio
ntowhichthef
ina
lre
duc
tio
n
geari
sins
tal
led
;andthehousingtowhicht
hedi
ffe
renti
ali
sins
tal
led
.Thesetwosec
tion
sareassembled
withbo
lts
. Thewheelhub f
ラ i
tte
dwithabrakedisk，i
sins
tal
ledonthespin
dlewithtwotape
rr ol
ler
b
ear
ing
s.

-39削
 ω O 刃一︿閉山﹀×﹁m

6
λ

f
m

j
G
M川
7'
AU寸

、
GJ
U
n-
:
門UOAU
仁1
12
﹃内ノ
#

刊匂伯
)

小T
山山代E
広

e dN 寸-
凶手間
tT}
T-
3rA
l
J
+tnv 戸U

リ1
h
7

明山間- M ・]戸

'
ロ

hc
ユ︿

↑'
O﹀
T
ighte
ningto
rqu
e: 765N-m{78kg手m}
[56
4.2I
bf
-f
t]

V向 日 。
(Ap
plyLOCTITE#262.) Tight
eni
ngt o
rque:
Ti
ghte
ningtor
que: Tig
hteni
ngt o
rque: 147Nィn{15k g
f-m}
98N刊 {10Iくgf
-m} 226N-m{23k g
f-m} [108.
4Ibf
-f
t]
[7
2.3Ib
f-
ft
] [166.
7Ibf
-f
t]

l
. INTERNALGEAR 7
. SPACER 1
3. BRAKECALIPER
2
. CARRIER 8
. TAPERROLLERBEARING 1
4. BRAKEDISK
3
. LOCKNUT 9
. HUB 1
5. SHAFT
4
. SUNGEAR 10
. SPINDLE 1
6. BREATHER
5
. SPACER . TAPERROLLERBEARING
1l 1
7. DIFFERENTIAL
6
. ADJUSTMENTNUT 12
. OILSEAL 1
8. AXLEHOUSING
 3
. DRIVEAXL定

3.1
.1 DIFFERENTIAL
Figu
re3 .2showst hecons
truct
ionoft h
ed if
fere
ntia
lwhichcompensatesf
orthediff
ere
nceint
he
numberofr o
tati
onsbetweent h
erightandlef
twheelswhent hetru
ckmakesatUf
ll
.
Thed i
ffere
nti
alc o
nsistsofas e
paratetypecrosscase，arin
ggear，dri
vepin
ions i
d
ラegeas，f
r o
ur
pin
iongears，andas p
ider
.
Thedrivepinion，supp
ortedbytwot ape
rrollerbea
rings，i
sinmeshwithth
eringgear
.

2
. DRIVEPINION
3
. FLANGEHALF
4
. PLAINHALF
5
. PIN
6
. PINIONGEAR
7
. SIDEGEAR
8
. THRUSTWASHER
9
. THRUSTWASHER
10
. SPIDER
11
. BEARING
12
. BEARINGCAGE
13
. BEARING
14
. BEARING
15
. “O九 RING
16
. NUT
17
. LOCK
18
. BEARING
19
. GASKET
18 2
0. OILSEAL
16 2
1. SHIM
2
2. NUT
2
3. WASHER
2
4. “0ヘ RING
2
5. SPACER
2
6. DUSTSEAL
2
7. CARRIER
2
8. CAP
2
9. RETAINER
3 3
0. FLANGE
T
igh
ten
ingt
orq
ue:
1
47N-m{
15k
gf-
m}[
108.
4Ib
f-
代]
(ApplyL
OCT
ITE
#26
2.)

F
ig.3
.2D
iff
ere
nti
al

-4
1 目
3
. DRIVEAXLE

3.1.2 FINALREDUCTIONGEAR
Thef i
nalreductio
ng earisap lane
tarytypeconsis
tingofani nte
rnalge
ar，sung
ear，andp laneta
ry
pi
niong e
ars，anditisins
talledont hewheelhuboft heaxl
e.
Thes ungeariss p
linedtot hedriveshaf
tandt heint
ernalg ears e
cure
dt oth
espin
dl ethroughthe
hu
b.Thep in
iong e
arsareinstalle
dont heshaf
tsp a
ssedintoth ecarr
ier
.
Thep r
incipl
eofpowert ransmi
ssionisasfollow
s: NEEDLE
BEARING
Whent hes ungearturs，t
n herotat
ionistrans
mitted T HRSUT
WASHER
NEEDLE
t
ot hepiniongearsandi nte
rnalg e
ar.However s
ラ inc
e BEARING

t
hei nt
ernalgeariss e
curedt othes pin
dle，thepinio
n BALL THRUST
WASHER
gea
rsr evolvearoundt hesung earwhilespinning
t
hemselves.
Thep i
niongearsareinst
alledont hecar
rie
rwhichis
CAP
i
nt u
rnfixedtothewheelhub andt
ラ husthepoweroft h
e
d
riveshaftcausesthewheeltot urn
. SNA，
P SPACER
RING
CAR只IER

F
ig.
3.3F
ina
lRe
duc
tio
nGear

3.1.
3 WHEEL
Asshowni
nF i
gur
e3.
4
， twow
hee
lsofthesames
izea
rei
nst
all
edont
hewheelhubw
ithawedge
bandan
daclam
p.

SPACER

WEDGEBAND

二Eコ

CLAMP

rrl
Tighteningto
rque:
686N-m{70k g
f-m}
[506I b
f-f
t]

Fig.3.
4 WheelsMountedonWheelHub

-42-
 3
. DRIVEAXLE

3
.2 MAINTENANCE
3
.2.1 REMOVINGANDREINSTAしSL lNGWHE在 し ASSEMBLY
(
1) Removingwheelassembly
① J ackupthedriv
ea x
leoffthefl
oor
.
② Loosent h
ewheeln utsinadiago
nalo r
derevenl
yandremovet h
enutswit
hthec
1amp.
③ Loosent h
ewedgebandremovalb ol
tl ockn
utsandtight
ensth
eb o
ltsi
ntobo
ltho
leseve
nlyi
na
diago
nalord
er. Removethewedgeb and.
④ Removet hei n
nerwheelai
rv a
lvebracket
.
⑤ Removet heo u
terwheel，sp
acerandi nn
erwheelintha
torde
r.

(
2)I ns
tallin
gwheelassembly
① Removed ustandd ir
tfromt hee xt
erio
roft hewheelhubandi n
sideoftherim.
② A ligntheinnerwheela i
rv a
lveandt heg r
o oveint hehubandi ns
tal
lt h
ewheelont heh u
b. Make
suretoalignthecente
roft heairvalvewitht heb r
acketinst
alla
tionhol
e.
③ I ns
tal
lt h
es pacerandouterwheel. Makes u
ret oa l
igntheairvalvewiththegrooveint h
eh ub
.
④ Loosent h
ewedgebandremovalb olt
sjustbefor ethei
re nd
sp r
ojectfromthetapb lo
cks ur
face
.
⑤ A lignthewedgebandn o
tchw iththegrooveint hehubandpushi nt h
ewedgebanbetweent hehub
andrim.
⑥ Pushi nt h
ewedgebandw it
ht hec1ampsandn uts.T ightenthenutsevenlyinad i
agonalorderto
thefin
altightenin
gtorque.
Fi
nalt i
ghteningtorq
ue:686N-m{ 70kgιm}[ 506l bιft
]
⑦ S ecuretheinnerwheela i
rv al
vew iththebracket.
③ T ightenth
ewedgebandremovalb olt
suntiltheirendst o
uchtheh u
b.S ecurethemw ithlocknut
s.

REMOVALBOLT

RIM

WEDGEBAND LOCKNUT
u--
g甘H
as

D
eta
ilo
fwedgeband
a
v
e
Jt

n
Hb
口市

HUBGROOVε
O

争L
川

F
ig.
3.5

側 4
3
伽
3
. DRIVEAXLE

3
.2.
2 TROUBLESHOOTINGGUIDE
Problem Cause Remedy
1
.O i
ll e
aksfrom Loosebol
torbrokeng
ask
etofd
iff
ere
nti
alc
arr
ier
. Replaceo
rre
tig
hte
n.
dif
fer
ent
ialca
rri
er. Breat
herisc
log
ged. C
lea
norr
epl
ace
.
O
ils
eali
sworno
rdamage. R
epl
ace
.
2
.Noisyd
iff
ere
nti
al sworn，damagedo
Geari rbr
oke
n. R
epl
ace
.
B
ear
in sworn，damagedo
gi rbr
oke
n. R
epl
ace
.
Improperb
ack
las
h. Adjust
.
Looses
pli
nef
itn
essofs
ideg
eart
opr
ope
lle
rsh
aft
. Replacep
art
s
I
nsu
ffi
cie
ntamountofg
ea i.
rol Adda
sne
ces
sar
y.

3
.2.
3 SERVICEDATA

m
n
n
4墨色
U
seful
I
tem S
tan
dar
dva
lue
lim
it
T
igh
ten
ingtor
queo
fbo
ltsa
sse
mbl
ings
pin
dle
b
cb
a
ndhou
sing N-m{
kgf
-m}
[lb
f-f
t] 765{
78}[
564勾

ロ
r
n 0
.0.ofs
pin
dlei
noi
lse
als
lid
inga
rea 1
17.
424-1
17.
551[
4.6
23-4
.62
8
。0.0.ofmastsupport
z 1
79.
96-1
80.
00[
7.0
85-7
.08
6]
T
igh
ten
ingt
orq
ueo
fax
lemountf
itt
ingb
olt N-m{
kgf
-m}
[lb
f-f
t] 2393{
244}
[17
65]
B
ack
las
hbetweens
ideg
earandp
ini
ong
ear 0.
23 0
開.33[
0.0
091-0
.01
30]
B
ack
las
hbetweenr
ingg
earandd
riv
epi
nio
n 25“ 0.
0. 36[
0.0
098“ 0
.01
42]
O
riv
epi
nio
npr
elo
ad N-m{
kgι
m}[
lbf
-町 .47 2
1 .
国55{
0.1
5 0.26
}
開

[
1.09 1.
8
開8]
T
igh
ten
ingt
orq
ueo
fbe
ari
ngc
apf
itt
ingb
olt N-m{
kgf
-m}
[lb
f-f
t] 539{
55}[
397
.6]
h
h
+
吋5
4

T
igh
ten
ingt
orq
ueofcompanionf
lan
gef
itt
ingn
ut N-m{
kgf
-m}[
Ib
f-
ft
] 353{
36}[
260.
4
]
凸 0
.0.ofcompanionf
lan
gei
noi
lse
als
lid
inga
rea 60.
33-60.
38[
2.3
75-2.
377
]
τ
igh
ten
ingt
orq
ueofr
ingg
earf
itt
ingb
olt Nィn{
kgf
-m}
[lb
f-仇
] 1
47{
15}[
108.
4
]
T
igh
ten
ingt
orq
ueofc
ros
sca
sea
sse
mbl
ingboI
t Nィn{
kgf
-m}
[lb
f-f
t] 1
47{
15}[
108.
4
]
T
ighten
ingto
rqu
eofd
iff
ere
nti
alassembly
f
itt
ingbo
lt N-m{
kgf
-m}
[lb
手先] 1
47{
15}[
108.
4
]
T
igh
ten
ingt
orq
ueofp
lan
etc
arr
ierf
itt
ingb
olt Nm{
kgf
-
幽m}
[I
bι食
] 98{
10}[
72.
3
b
与A
C
q白
司
同

0
.0.o
fpl
ane
tar
yge
ars
haf
t
。
c
:
:
B
ack
las
hbetweenp
lan
eta
ryg
earands
ung
ear
+
td
J
》

コ
'u
私A
q
鴫
T
igh
ten
ingt
orq
ueofwheeln
ut Nm {
幽kgf
-m}
[lb
f-f
t] 686{
70kgf-m}[
506
1bf
-ft
]
。
司 Braked
iskf
itt
ingb
olt N-m{
kgf
-m}
[lb
f-f
t] 226{
23}[
166
.7]
ロ
・同

μ吋 Brakec
ali
perf
itt
ingb
olt N-m{
kgf
-m}
[lb
f-f
t] 461{
47}[
340
.0]

-44-
 4
. B沢AKESYSTEM

4
. BRAKESYSTEM

i
I
「¥¥ご± F
D16
0-2 F
D18
0-2 F
D20
0-2 F
D23
0-2

T
ype Fr
ont-w
heelbrakin
gラ ‘
一一

d
iskb
raketyp
ewit hboo
ster
A
irp r
essur
e 8
14kPa{8.
3k gf
/cm} [
2
11
.8.1ps
i] モ
ー同

Bo
oster
Airc .b
yl ore 2
00mm[7
.9in
.] モ
一一

Aircyl
.strok
e 10
0mm[3
.9in
.] モ
ーー

Hydr
auliccyl
.b o
re 40mm[
1.6i
n.
] モ
ーー

8r
akev a
lve
Type S
ing
let
ype +
ーー

B
rakec a
lip
er
Type R
igi
dcal
iper モ
一一

ODo fbrakedisk 4
74mm[ 18.
7in.
] 490mm[ 19
.3i
n.
]
Brakepadthick
ness 14mm[ 0
.55in
.] ぐ
一一

Cyli
nderbore 7
3mm[ 2.
9in.
] モ
ーー

B
rakeoiltobeu s
ed TCMa ppr
ove
dbr
akeo
i
l(m
ine
ralo
il
)

A DANGER:Theboosterof伽 br 伽 system山 eshighp

聞 ressurecompres制 1ai
r.M蜘 s ure
theairi
scompletelydrainedfromt h
ea i
rtankb efo
r etry
ingtodisassembleormaintainthe
brakesyst
em.
AD 臥AN
悶GE昧R
恥 u
恥s 町C
鈍eT M-ap伊
叩 pE
brakeoilsuch制asDOT-3w i
llca
剖uset h
emalfunctionoft h
ebrakes y
s“
tem.

4
.1 GENERALDESC畏I
PTI
ON
Thebrak
esystemisad is
kb ra
ketypewit
hapneumaticbo
oste
rcons
i
ラstin
goftwobrak
eva
lvs，a
e
b
ooste
randab rakecal
ipe
runit
.
Theai
rcompressordri
venbyt hee
ngin
es t
ore
sai
rint h
etankt
oge
nerat
ea i
rpr
ess
ure
.

4
.1.
1 BRAKEVALVE
Twob ra
kev al
vesarelocate
dunder・thefloo
rboard
.
Thebrakev a
lvescontroltheboo
st e
rbyc on
vertingbrakep e
daleffo
rtin
toai
rpres
surew i
ththe
p
lsto
ns.
Thebrakevalveatth
er i
ghtsid
eisusedf ornormalb r
akingopera
tio
nandtheb
rakevalv
ea tth
ele
ft
s
ideisusedforcutt
ingoffpowertra
nsrniss
ionfror
nt hetra
nsrn
issio
naswella
sfo
rp e
rformin
gnormal
br
akingoper
ation
.

-45-
4
. BRAKESYSTEM

4.1.2 BRAKECAL lPER

Thed iskb ra
keisar i
gidcalip
ertypeconsi
stingofat orq
uep l
ateandpiston
s，andtwos et
sofdisk
bra
kesa reinsta
lledoneachwhee.l
Thet orq
u eplat
eh a
sas tr
uctu
reshowni nFi
gs.4.1and4 .
2.Ithasf o
urcyl
inders(FD160-2，FD1
80-2)
or6c yl
inders( FD2
00-2，FD230
-2)madei nitwherep i
stonsandp ac
kingsareincor
p o
rated.
Theb rakepadi sattac
hedtoeachp i
stonofthet o
rqueplate
.Whent h
eoilpressureisa p
pliedthe ラ

p
istonspressthepadstothebrakedis
kt
ラ husproduc
ingb r
akingforc
e.Whent heoi
lp ress
ureisreduc
ed ヲ

t
hep ist
onsr etur
nbyt hedefle
ctionofthepisto
np ackingtokeepana ppr
opriatec1eara
nce.Thepad
a
s s
embliesa resuppor
tedbyt orq
uepins
.

GROOVED
TORQUEPIN

LOCKBOLT

Crosss
ecl
ion
alview闇ー闇
PISTON

日LEEDER ヨ
宅F
VALVE

PAD

TORQUE
PLATE

TORQUEPIN PISTON

PISTONPLUG
COVERPLATE
LOCKBOLT
Crosss
ecl
ion
alview岡ー岡

F
ig.
4.1 BrakeC
ali
per(
FD1
602，
- F
D18
0-2
)

-46-
 4
. BRAKESYSTEM

GROOVED
TORQUEPIN

国
LOCKBOLT

Crosss
ecl
ion
alview悶柏田

PISTON

BLE医DER 舎
VALVE

TORQUEPIN PAD

TORQUE
PLATE

PISTON

PISTONPLUG
COVERPLATE
LOCKBOLT
Crosss
ecl
ion
alview岡ー岡

F
ig.
4.2 BrakeC
ali
per(
FD2
002，FD2302
- ) 幽

-47-
4
. BRAKESYSTEM

4.1.3 BOOSTER
Theb oo
sterincre
asestheoilp
ressu
rei nthehydra
uliccyli
nderbyi nt
roduc
ingth
eh ig
hpress
ureai
r
企omt hemaint ankint
ot hepowerpiston，uti
lizi
ngtheairpress
urecontro
lledbythebrak
ev alv
eas
p
ilotpres
sure.
Theboostercon
sis
tsprimar
ilyofanai
rc yl
inderandahyd
rauliccy
lind
er.Thea i
rcy
lind
erinc
orpor
ate
s
apowerp is
ton，whichissli
dbya i
rpressureinsid
et h
ecylin
der.
Theh y
drauliccyl
inde，t
r oo，hasapist
o nwhichmovesi nthecyli
nderbyb e
ingforc
edbythepower
pi
stonpushr o
d.

Tight
e n
ingto
rque:
58.8 73.6Nィn
司

{600・750kgf-cm}
SPRING ，[520.4-651.
4Ibふin.
]
PACKING

PISTON

PISTON
/

一
正一-
--~..:'ALlPER
¥
}OVER¥
Tigh
te ni
ngtorque:
34.3-41.2N-m
{350・ 420kgf-cm}
1111tKIll

¥ [303.6-364.7Ibf-
in.
]
R
O
D

CYL
lNDER “O"-RING
D'

MH
CU
UU

F
ig.4
.3B
oos
ter

-48-
 4
. BRAKESYSTEM

4.1.4 DOUBLECHECKVALVE
Thed oub
lec hec
kv a
lveisprovidedtoensuresmooth
opera
tionwhenbothbrakevalve
sa repres
sedatthesame
1m
t e.
Thed oub
lec hec
kv a
lveh a
sas truct
ureshowni nFi
g. fromLEFT
BRAKE
4.4andisfit
tedwithashut
tleinit，whichgiv
e spri
ori
ty VALVE
tothehighe
rp re
ssureai
r，blockingupt helowerone. +
Thedoublecheckv alveisl ocatedbetweent he
junc
tionofthetube
sfromb rakev a
lvesandthebooste
r.
SHUTTLE

oB
t
+
OOSTER

F
ig.4.
4 DoubleCheckV
alv
e

問 4
9
削
4
. BRAKESYSTEM

4.1.
5 AIRGOVERNOR
Theairgovernorcon
tro
lstheai
r
pr
essureintheai
rt a
nk.Itcon
sis
ts CAP ADJUSTING
SCREW
ofap i
ston，spr
ingsando th
ersas
showninF i
g.4.5
.
LOCKNUT

SPRING SPRING

EXHAUSTSTEM

PISTON EXHAUSTVALVE

F
ig.4
.5 AirGovernor

(
1) Whent h
ea i
rp r
essur ei
nthetankisl o
w:
Whentheai
rpressur
ei nth
eairtan
kislow ，t
hepi
stoni
spusheddownbyspri
ngfo
rce
. Thee xh
aus
t
v
alveismadei n
tocontactwiththepist
onbyt hespr
ingandtheexha
uststempa
ssingthroughth
e
c
ente
rofthepisto
nisf o
rcedagai
nstthepushrodbythesp
rin
g.

AIRGOVERNOR

TANK 圃 . .

t
oBRAKEVALVE

UNLOADERVALVE
CYL
lNDERHEAD

OUTLETVALVE

F
ig.
4.6

陶 50-
 4
. BRAKESYSTEM

(2) Whent heairpressureint h

ea irtankreachesthes p
ecifiedvalue:
Whent heairpressur
eintheairtankishighenought oovercomet hespri
ngforcet
ラ h
ep i
stonmoves
ups otha
tt heexhaustvalv
eisu nseat
edfromt hepist
onbyt heexhauststem.Thisallowstheairinthe
tanktop as
st hrought h
isopeningt otheco出 pres
soru n
loadervalve. Thepushrodoft heunloader
valveopenst hecompressori nl
etv alv
es othattheintakeairisdischargedthroughtheinle
tv alv
e
withoutbeingc omp
r e
ssed.
Whent heairpressurei
nt heairtankbecomeslowert hanthespecifi
edvalue，thepist
onispushed
downbys prin
gf or
ces oth
atthee xh
austvalveisseate
dont hepisto
n.T hisallow
st heexh
austs t
e mt
o
leavetheex haus
tv alve，sothattheairpressu
r eappli
edont heu nloaderval
veisd isch
argedtot h
e
atmospheret hroughtheinsi
deoft heexhauststem. Hence t
ラ hecompressorcompressesa i
ra ga
i nt
o
sendittothet a
nk.

AIRGOVERNOR.
TANK ーー+
t
oBRAKEVALVE

一i

UNLOADERVALVE

CYL
lNDERHEAD

OUTLETVALVE
¥ INLETVALVE

F
ig.
4.7

目 5
1-
4
. BRAKESYSTEM

4.1.6 AIRTANK
Thea irtankisinsta
lledont h
elef
tr earpartoftheframef orstori
ngcompressedairforthebra
ke
system.
A checkv al
veisi n
stall
edatthea
irt ankinl
etpor
tt opreventtheoccurr
enceofp r
essu
red r
opdueto
poorairtigh
tnessbetweent h
ecompressorandt heairtankorr up
turedtubingbetweenthem.
Thea irtankalsoh asas a
fetyva
lv etop rev
enttheairp re
ssureint h
et ankfromrisin
gabovet h
e
pres
su r
elimitofthet a
n kwhentheairgovernorfai
lstooperateproper
ly.
Moistureintheairmayc onden
seint h
et an
kduetoc ha
ng esinpress
ureandt e
mper
ature
.Tod isc
har
ge
water，adrai
nv alveisinst
alle
donthet ank.
Whent h
ed rai
nv alveleve
rispull
e d，waterinth
et an
ki sdrainedoffwithai
r.

一三三三三段=

日
AIRGOVERNOR

SAFETYVALVE
d
:=:
:!:
:l

二三」ι
二二工二3
DRAINVALVE
AIRTANK

F
ig.4
.8A
irTank

情 52-
 4
. BRAKESYSTEM

(
1) Checkv al
ve
Thecheckvalvei
sins
tall
edattheai
rtan
ki n
letpor
ttopre
venttheoc
currenceofairpre
ssuredr
o pi
n
t
heairtankduetoadefe
ctivecom
pr e
ssororruptu
redtub
ingbetweenthecompressorandtank.Ifth
e
a
irpres
sureintheta
nkd r
opstotheminimump res
surene
cessa
ryforbrakingthelowp r
ラess
ureswit
制c
h
f
uncti
onstogiveanalarmwithalampandb u
zzer.

「引証言言 I br-ti岡市
(宍月田￨ド思し耳
副
参 圃
争

Operatingpressure
kPa{kgf/cm2} [
psi
]
1
. VALVEBODY 5
. WASHER OFF ON
2
. SCREWCAP 6
. LABEL Brakevalves
ideI392{ 4}[56.
9] I294{ 3}[42.6]
3
. DISKVALVE 7
. DISKVALVE Booster I118{1.2}[17.1] I49{O.5}[7.1]
. S
4 PRING SHEE
γ

F
ig.4
.9 CheckV
alv
e F
ig.
4.1
0 LowP
res
sur
eSw
itc
h

(
2)S
afe
tyv
alv
e
Thes afet
yv alv
ep re
ventsthea
irpres
sureinthetankfromrisi
ngabovet h
epressu
relim
itof t
het an
k
orp lpe
.
Iftheairpressu
reint h
et a
nkincr
easeshig
hert h
anthespeci
fiedpre
ssure，th
eforcepre
ssingthebal
l
overcomest h espr
ingforce，t
huspush
ingtheballint
ot h
edirec
tionind
icat
e dbythearr
ow.T h
isa llo
ws
thea i
rtobed is
chargedthrought
hepart[A
]intotheatmosphe
reu n
tilthea
irp r
essur
einthetankd r
ops
toth espec
ifiedvalue
. Whent heai
rpressu
reint h
et a
nkd r
opsbelowthespecif
iedvale，
u thebal
la ga
in
getss eat
eda tthepat国-
r

. VALVEBODY
1
2
. BALL
3
. SPRING
4
. RELEASEPIN
5
. SPRINGCAGE
6
. ADJUSTINGNUT
7
. LOCKNUT

F
ig.
4.1
1 S
afe
tyV
alv
e

-5
3ω
4
. BRAKESYSTEM

(
3) Drainvalve
Thedrai
nv a
lveisins
tall
edatth
ebottor
noft hern
ainta
nkfo
rdrai
ningo
ffth
ew a
terinthetan
kw i
th
m
r.
Thepoppet③ isusual
lyk e
ptagai
nsttheva l
vebodybybothth
es p
rin
g② andt h
ep r
essu
reinthe
t
ank. Whent h
el e
ver⑤ pushesthepoppettip，th
ep a
rt⑧ ofth
ev al
vebodyisopenedtodrainoff
w
aterinthetankthrou
ght h
ep a
rt⑧ w i
thair
.

ι
丁
困

ア
司

1
. PLUG
2
. SPRING
3
. POPPET
4
. “O九 RING
5
. LEVEIえ

Crosss
ect
ion
alview国ー岡

F
ig.
4.1
2 DrainV
alv
e

時 54-
 4
. BRAKESYSTEM

4
.2 MAINTENANCE
4
.2.1 MAINTENANCEOFAIRGOVERNOR
*
" Disassembly
(
1)P riortoattern
ptingtodisas
sernb
let heairgovernor，clea
nt h
ee x
ter
ioroftheuni
t.
(
2) Rernovet hecoverands naprin
g. Rernovet hespringassern
blyandsprin
gseat
.
(
3) Rernovet helocknutfrorntheadjus
tings cre
w. Thenr erno
vet h
euppersprin
gs e
at，s
pri
ngl
owe
r ラ

s
pringseatands p
r i
ngguide.
(
4) Rernovet heexhaustste
rnands prin
gf rornthetopofthep i
ston
.
(
5)P utt h
ev alvebodyu ps
idedownandt a
pitt ole
tt h
ep is
toncorneou
t.
(
6) Rernovet hevalveandv alv
es p
ring，andtwo“0"- ring
sf r
ornthepi
ston
.
(
7) Rernovet hewasher，then“0"ィ ingfrorntheexhaustster
n.
(
8) Rernovet hevalvesprin
gf ro
rnthepiston. Rernovethevalve.

*
"Reassemblyandadjustment
(
1)C leanthernet
allicpart
sw it
hc lea
ningflui
dandr ubbe rpar
tswithd r
yc l
oth
.R eassern
blethernin
asequenceo p
positetod i
sasse
rnbly
.
(
2) Whenyouf in
dt ha
tt e“s
h e
parati
onp r
円essu
reish i
ghert han814kPa{ 8.
3k gf
/crn2} [
118psi
]o rthe
"int
akep円ressureislowerthan677kPa{ 6
.9k g
f/crn} [
2
98psi]rer
ラnovethecove乙l oosenthelock
nutanda dj
u s
tt hep r
essurebyt urni
ngt h
ea djus
tingscrewc loc
kwisetod ecreaset h
evalueo r
counter
clockwisetoi n
crea
se.A fteradj
ustrn
ent，bes uretotigh
tenthelocknut.
(
3) Tocheckf orairleaksaラp
plysoapyw ateront heexhaustp o
rtwiththeg ove
rnori n“intak
e"s t
ate
and“separ
ation"s t
atere
ラspe
ctiv
ely.Thea irbubblesh oul
db e25rnrn[0.9
8in.]orl e
ssindiarn
eter
5s ec
ondsafterthea p
plica
tionofsoapyw a
ter.

4.2.2 MAINTENANCEOFVALVES
(1
)S i nglecheckv a l
v e
Feedana i
rp r
essu eof687kPa{
r 7kgf /r
cn2} [
100p s
i]intothev a
l vetocheckt ha
tt h
ereisnoa irleak
fro
rnt hevalvebodyandc on
n ectionsoft h
ec ap.Ifairl e
akisn oticedr
ラ erno
vet hecapf ro
rnt hevalve
bodyandd isa
ssernblyt h
ei n
te r
nalpartstocheckf ord arna
geo runduew ea
r.
(2
)S a fetyvalve
Pullupt her e
leasep inendt orernoves prin
gl oadfror
nt heball
.I fthisactionfai
lstop utthes af
ety
valv
ei n“releas
e"statei
ラ ts u
ggeststhattheballisstick
ingtotheseat
.Rernovet hevalveandd is
assernb
le.
Applysoapyw ateront h
es pringcagee xhaustporttochecki fthereisairl eak
. Thea irb ubble
shouldnotbe70r nrn[ 2.
76in.]orr noreind i
arnet
erw ith
in3s e
conds. Makes uretha
tt h
es afetyvalve
i
sp ro
p erlyadjust
edf ora9 81kPa{ 10k g
f/crn} [
2
142psi]pressur
e.I fnotlラoosent h
el ocknutandt urn
theadju s
t i
ngscrewc lock
wi set oincreaset hepressureo rc oun
t ercl o
ckwi setod ecrease
.A fter
adj
ustrnent，besuret otightenthel ocknu t
.
(3
) Lowp ress
ures w
i t
ch
Sta
rtt heenginea ndle
titru nforaw h
ile. Measuret hepre
ssurewhent h
el ar
npg oesou. Thens
t hutoff
th
ee ngineandopent hedrai
nc ocktor educetheairpres
sure.Measuret h
ep re
ssurewhent hel a
rnpl i
gh
ts.
Theopeningandc losingp res
suresofthec on
tactors ho
ul dbet hoseasshowni nFig.4.10.I f
not，
rep
lacet helowp ressures wi
t chwithanewo ne.Af t
eri nc
reasingt h
eb rakeairp r
essuretor norethan
490kPa{ 5kgf/crn} [
2
71.1psi] checkf
ラ orairleakbetweent hevalvebodyandt hec o
ver.I fairleakis
noti
ced，r epl
acethes witchw ithanewo ne.

-5
5-
4
. BRAKESYSTEM

4
.2 .3 REPLACEINGBRAKEPADS
Makes uretogetthefoll
owingite
ms:
• Vinyltube(6-7m m[ 0.2
4-0 .
28in.
]ind
iam
ete
r，300 500m m[
11
醐 .8 1
9.7i
n.
]inl
e
幽ng
th，
tran
spare
ntands o
ft)
• Oilrecei
vingpan(200 500c c
)
・
欄

Minera
lb ra
keo i
l(500cc)
• Newb rakepads
• Pist
onp u
shing-
injig(se
eF i
g.4.21
.)
・
Stand

聞 Pre
parat
ions
• Parkthetru
ckonal e
velsur
faceandinap
lacewhereac
ran
ecanbeu
sed
.
• Jac
kupt hefro
ntaxl
eands upp
ortitw
ithast
and.
• Removet h
e丘o ntw
heels.

• Replacement
• Connectoneendo fav iny
lt ubetot hebleedervalveandp u
tt h
eo the
rendi nt
heoi
lrec ei
ving
pan
.
• Loosent h ebleedervalveandp utthep ist
onp ush
欄inginjig(SeeFig.4.21
)betweenth
ed iskand
th
epadt opushbacke achp ist
ontot heo r
iginalposit
ioncompl
etely.
• Loosent h elockboltofe achofthetwot hicktorquepin
sbyt hreetur
ns.Removethetorquep i
n
in
tothed irec
tionthati
tg oesawayfromt hedisk，andthenremovet hepad.
• I n
sta
llanewpad， payingatten
tiontot hedirectio
n0 fth
el i
nin
g.( F
ig.4.13)
・Checkt h
e“O九 r ingoft h
et orquepinandr epl
ace
i
tw i
thanewonei fanyd efec
tisf ound.
BLEEDER
• Applyg r
e as
et othetorquepinandt hetorquep i
n VALVE

hol
ei ntheb rakeheadbeforei n
stallin
gt he
tor
quep in，leavin
gagapof1 .5to3 .0m m[ 0.05
9
-0.118in.]betweent h
ed iskandt het o
rquep i
n.
Note:Makes urethatthetorqu
ep inendd oesnotproject
fromt hefitt
ingsurfac
ea ttheb r
ak eheadf it
ting
surfac
es id
e.
PISTON

PAD

F
ig.
4.1
3

-56-
 4
. BRAKESYSTEM

• Sec
uret h
etorquepinwithal oc
kb o
lt.Movet heto
rquepinintheaxi
aldir
ecti
ontocheckt
osee
i
fthetipofthelockbo
lts e
ttl
esint h
et or
quepingroo
ve.
T
ighteningtor
que:51.
5土2 .5N-m{ 5.
25土0 .
25kgf-m}[ 3
8.0土1.81
bιft]
Note:I ns
uffi
cien
tt or
quemightc a
uset h
eb o
lttocomel o
ose，let
tin
gthetorq
uepincomeoffandth
en
lead
ingtothemalfunct
ionoft hebrakesyste
m.

LOCKBOLT
TORQUEPIN

Good Notgood

F
ig.
4.1
4

• A
fte
ra l
lthepad
sarer
eplac
edwithnewo
nestigh
t
ラenth
eb le
eders
ecu
rel
yandb
lee
dai
rou
tof
t
hesystemus
ingth
eproc
edureg
ivenonth
epagetha
tfoll
ows.

-57-
4
. BRAKESYSTEM

4
.2 .4 AIRBLEEDING
Makes uretogetth
ef ol
lowingi
tems
:
• Vinyltube(6 7m m[
蜘 0.
24-0.28in.
]ind
iam
ete
r，300 500m m[
幽 11.8-1
9.7i
n.
]inl
eng
th ラ

tran
spare
ntandsoft
)
• Oilrecei
vingpan(200-500cc)
• Minera
lb ra
keoil(500cc)

国 Pre
parati
ons
• Connectoneendofavi
nylhosetoth
ebl
eed
erofe
achb
rak
eheadandp
utt
heo
the
rendi
nth
e
oi
lr e
ceiv
ingpan
.
• Fi
lltherese
rvetan
kwi
thbrakeoil
.

• Airbleedin
g
• Loosent heble
ederplugofeachb rakeheadandl eav
eitf o
r2t o3m i
nutesunti
lb rak
ef l
uid
sta
rtscomingfromt heb le
eder
.Whenb rakef l
uidsta
rtscomingfromt heble
eder，tig
htenthe
ble
eder.
• Makes ureal
lt hebleede
rsa r
et ight
eneds e
curel，p
y ressthebrakepedalafewt im
es.Bringthe
lin
ingp ad
sinc los
ec ont
actw i
tht hedis
k.
• Fore a
chb ra
kehead， repea
tt h
ef ollowi
ngs te
psunti
lf lu
idcomingfromt hebleede
rc on
tain
sno
ai
rb ubb
les:
1. Pressthebrakepedalandh oldit.
2. Loosent h
eb leed
ert odischa
rgeb rakeflu
id.
3. Tightenthebleederandr e
leasethebrakepedal.
• Addb rakeflu
idi n
tother es
ervetankandmakes urethebleed
ersares ec
urel
yt i
ghtene
d.
• Removet hevinyltubefromt hebleederandwipeaways pi
ltflu
id.

国 5
8-
 4
. BRAKESYSTEM

4
.2. 5 INSPECTION
(
1) Checkingbra主epads
Checkt h
et hi
cknessofthebrak
epadusin
gt hepadwearcheckgaugeasshowni nF
ig.4.
15.
Thepadwearl i
mitis2.0m m[0.07
9in
.]exc1ud
ingt h
ebackmeta
lt h
ickn
ess.
Ifthebrakepadiswornbeyondt h
ewearlim
i
ラtt hebackm
etalwil
lcomesi ndir
ectco
nta
ctwitht
he
d
isktog iv
edamaget ot hedi
sk.

U
ni:
tm m[
in
.]

PADWEAR
CHECKGAUGE

- - 1 14.0[0.551]
1--
X
ω

止:
;22
%ー￨」」
一円]

Beforeth
egapbecomeszero，
replac
ethepadw
ithanewo ne
.

F
ig.
4.1
5

(2
) Checkingbraked is
k
Checkthebrakedis
kf o
rseri
ousdamageonthepads
lid
ingsur
faceandre
pla
cei
twit
hanewon
ei f
beyondre
pair
.
Inadd
ition checkt
ラ hebra
ked i
skforthi
ckn
ess.Ift
hethic
knessisle
sstha
n17.
5m m[0.
69i
n.]，
rep
lacet
hed i
skw it
hanewo ne.

(
3) Changingbrakefl
uid
Checkth
ebraef
k 1u
idlev
ela
tpe
rio
dicin
ter
valsandaddbr
akef
1uidofthesamebra
ndi
fth
ele
veli
s
l
ow.
Inadd
iti
on，
thebra
kef
1uidi
nthee
nti
rebrak
es yst
emmustbechangedonceaye
ar.

-59-
4
. BRAKESYSTEM

4
.2.6 DISASSEMBLlNGBRAKECAL lPER
Thebr
akec
ali
perc
ons
ist
soft
hef
oll
owin
gcomponentp
art
sasshowni
nFi
g.4
.16
.

. BLEEDER
1 7. LININGPADB 1
3. PISTON
2
. LOCKBOLTA 8. LININGPADA 1
4. PISTONSEAL
3
. LOCKBOLTB 9. BOLT 1
5. BACK-UPRING
4
. TORQUEPINB 1
0. COVERPLATE 1
6. SCRAPERRING
5
. TORQUEPINA 1. PISTONPLUG
1 1
7. CAP
. “O"-RING
6 1
2. CAPSEAL 1
8. TORQUEPLATE

F
ig.
4.1
6

園 Disassembly
1
. Loosent h
eloc
kb ol
tsAandB，4i nall
.Removet h
et o
rquep
insAandB.
2
. Removet hel
inin
gp ad
sAandB .Ifyouwanttoreus
ethem u
ラ sec
aut
iontoco
nta
min
atethemw
ith
oi
landkeepitinorder
.
3
. Removet heb
oltssecur
ingth
ec ov
erpla
teandthendetac
htheco
verpl
ate
.
4
. Removet hep
istonplugandthe
nremovethepis
ton.

聞 60-
 4
. BRAKESYSTEM

5
. Removet hescra
perring，p
istonsealandb ac
k-uprin
gfromt h
et o
rquepla
te.
Note:D i
scardtheremoveds cra
perringp i
s
ラtonse
alandback-uprin
g.Don otre
uset he
m.
6
. Cleanthein
teri
orofthetorqueplat
e( p
isto
nh o
lesandoi
lpassag
es)withclea
nin
gf l
uid
.Checkt
he
sea
lf i
tti
nggroovesandp ist
o nholesfordamageord e
nt.Ifsuchad e
fec sfound，r
ti e
pla
cet
he
brakeheadassemblywithanewo ne
.

ミ
ミ
Nodamageo
rdentallowed

Nodamageo rdentallowedwi
thi
n
aspacingo
f11m m[ 0.433in
.]

F
ig.
4.1
7

7
. Checkthepi
stonintheareawhichcomesincontac
twitht h
ep i
stons
ealfo
rdamageorundue
wea.I
r fanydef
ectisfound r
ラepl
acethepi
stonwit
hanewo ne.
8
. Checkth
etorquepininthear
eawhichcomesincont
actwi
t hthebackm
etaloft
heli
nin
gpadfor
unduewe
ar.Ifsuc
had efecti
sfound r
epl
a
ラcethetor
quepinwithanewo n
e.

国 6
1-
4
. BRAKESYSTEM

1R
1 eassembly BACKUPRING
司

1
. Applysilic
onegre
aseth
eback-upr
ingandth
e
scr
ape
rr i
nginth
earea
sen
clo
sedbydo
tte
dlin
esi
n
Fig
.4.1
8.

2
. R
eins
tallthebackべl
pring，p
istonsea
lands c
rap
er
r
ingint
ot h
esealgro
ovesinthetor
queplat
einth
at
o
rder
.Applyat h
incoa
tofs ili
con
eg re
aseonthe
SCRAPERRING
p
istonseal
.
F
ig.4
.18
3
. Applyat hincoatofs ilicon
egrease ont he
cham
feredareaatt
heendoft h
episto
nBandinst
all
SCRAPERRING
th
episto
nBont hetorqu
ep l
atecyl
ind
erfromin
side
BACK-UPRING
th
etorquep
late
.Usec auti
onnottoforc
ethep
iston
ob
lique
lyintothecyl
inde
r. PISTONSEAL

F
ig.
4.1
9

TORQUEPLATE

COVERPLATE

PISTONB

PISTONPLUG

PISTONA

F
ig.4
.20I
nst
all
ingP
ist
ons

-62-
 4
. BRAKESYSTEM

4
. In
sta
llthecapsealinthepis
tonpluggroove
.Applyathincoatofs i
licon
egreaseonthecapse
al
andins
tal
1t h
epistonplugont
ot h
et o
rqueplat
ew i
tht
hec apse
alp oi
ntingtowardthepi
sto
n.The
pis
tonplugshouldbef l
ushwithth
et o
rquepla
te.Donotpushinthep is
tonplugtoofa
r.
Note
:I fthepis
tonp l
ugispushedintoofa，apoors
r ea
lingperformancewil
lr e
sul
t.

5
. Applyg r
easetoth
et or
quepinandint
othefit
tin
gholeandin
sta
llth
etorq
uep i
nt oth
etorq
uepla
te.
Secur
et hetor
quepinwithalockbo
ltwhi
l emovingtheto
rquepini
ntheaxi
aldirec
tio，
ntig
hte
ning
thelockbol
tandp ut
tingth
et i
pofthelockboltin
tothegro
o v
eofthetorq
uep i
n.

N
ote
:R eadju stme
nti
srequ
ire
dtoen
suret
hatt
hegapbetweent
het
ipo
fth
eto
rqu
epi
nandd
iski
s
l.~酬 3.0 m m[
0.0
59-0.11
8in
.]
.

Uni:
tm m[
in
.]

10[
0.0
39]

土
干一- 5
' 20R
10R

350[
13.
78]

65.0
[
2.56
]

F
ig.4
.21P
ist
onP
ush
-inJ
ig

-6
3 伽
4
. BRAKESYSTEM

4
.2.7 MAINTENANCEOFB005TER
"
* Removeth
eb oo
sterfromthetruc
k
① Movet hetrucktoaleve
lsurfa
ceanda p
plythep
ark
ingbrak
e.Blockth
ewh
eel
s.
② Opent h
ea i
rta n
kd r
ainval
vetod r
ainai
rfromth
erese
rvo
ircom
plete
ly.
③ Removet hetubing
sfromt h
eboost
er.
④ Draintheoi
lr es
ervoi
randhydrau
liccyl
ind
er.
⑤ Removet hebooste
rfromthebrack
et.

聞Disassembly
Wipeawaymudanddustfromth
eboo
ste
rs ur
fac
eandpu
tmatchmarksonc
onn
ect
ionstoen
sur
e
c
orre
ctreassem
bly
.Thed
isassem
ble
dpa
rtssho
uldbekep
tinor
dert
omakeitea
sytor
ein
sta
llt
hem.

① Removet h
ebolt
ss ec
uringthehyd
rau
licc
yli
nde
r
andremoveth
eh yd
rauli
cc y
lind
er.

F
ig.
4.2
2

② Removingt h
eo i
lpisto
n
a. Supplycompressedairof98-196kPa{1-2k g
fl
2
cm} [14.2ω28.4ps
i]int
othea
ircy
lin
derandmove
th
ep is
tontoitsstro
keend.

F
ig.
4.2
3

-6
4 輪
 4
. BRAKESYSTEM

b
. Removet h
er i
ngfromtherin
gg roo
veandmoveit
towardt h
epushr o
d.
Pusho utthepinwithabarandremovethepis
ton
complete，pushguideandri
ng.
c
. Removet heo i
lp is
tonandthend i
sch
arg
et he
compre
・ s
sedair丘omt heai
rcylin
der.

F
ig.
4.2
4

③ Removingsea
l(h yd
raul
icpis
ton
)
Usingaspa
tula removet
ラ h
ecupandback-upr
ingfromt
heh
ydr
aul
icp
ist
on.

④ D isassembl
inga ircyl
inder
a. Makes urethattherei
snop res
sur
ei ntheaircy
lind
er.
b. Loosenthesixboltsandremovetheaircyl
inder，
pisto
n& rodcomp
leteandsp
ringfromt
hec
ove
r.
c. Usec au
tionwhenl oose
ningthebo
ltsbecausethes p
rin
giscompressedbyabo
ut100m m[3.
94
in
.]andhasar eacti
onf or
ceof637N{65k gf}
[143.2lb丹
.
I
tisgoodp racticetouse2o r3continu
oust h
read
stu
d s(th
el engthunderhead:about150m m[ 5.9
in
.])asal oos
e n
in gto.
o1

F
ig.
4.2
5

⑤ Removingpac
king
Usingaspa
tul
a removet
ヲ hep
ack
ingfromt
hep
ist
on& r
odc
omp
let
e.

-65-
4
. BRAKESYSTEM

⑥ D isassemblingcover
a. Usingaf 1at-
bladedscrewd
river，removet hestop
rin
g.Removet h
eCUps uppor
ter ，secondaryCUp，
space，secondaryCUp，CUpands
r up
porterint h
at
ord
er.
b. Hosingtheb ushi
ngtoi n
sidewit
has patu
la，pul
lit
ou
t.Removet heC-rin
gandpusho utthefilt
erfrom
theoppos
i t
ed ir
ectio
nw i
thabar.

F
ig.
4.2
6

• Cleaningandinspe
ction
① C leani
ng
a. Cleanthem
eta
llicpar
tswithcle
aningf
1ui
dandd r
ythems u
ffi
cie
ntl
y.
b. Cleanther
ubberpa
rtswit
ha l
coholanddrythemsu
ffi
cie
ntl
y.

② I nspec
tion
Thes er
vicekitcomponentp arts(rubberpart
sa ndexpendablepart
s)needt ober ep
lacedatper
iodi
c
int
erva
ls.
a.A ircylinderanda i
rp istoncomplet e
• Ifcorros
iono rrusti
sn oticedi n
sidet h
ea i
rcylinde
r，removei twiths an
dp ap er( a
round#500).If
anys c
ratchord eformationisfound，r epla
cethewholea ssemb l
yw ithanewo ne.
• Ifexces
sives cr
atchesOI・score
sa refoundont heai
rp i
ston，repla
cethewholea s semblywithanew
one.
・ Ifexcessivescratcheso rscoresa refoundont heo ut
erd iameteroft her od，replacethewhole
assemblywi t
hanewo ne.
b.O ilcylinde
rando ilp i
st o
n
• Ifexcess
ives crat
cheso rs c
oresar efoundont heinnersurfaceofthec y
lin d
e r，repl
acethewhole
assemblywi t
hanewo ne.
• Ifexce
ssives cr
atche
so rs cor
esa r
ef oundont h
eo ute
rd iam
et erofthepiston，replacei
tw it
hanew
one.
c.S pring
• Anys pringwhose白' e
el engthisl es
st ha
n236m m[ 9.29in.]orshowinge xce s
sives c
ratch
esor
scor
ess houldber eplacedwithanewo ne
.
d. Cover
• Anyc overshowingc r
ac ksord ef
o rmati
ons ho
u l
dber eplacedwithanewo n
e .
e. Cups uppor
terands p a
ce r
• Anycups upport
ero rspacershowingc rack
so rexcess
ived eformat
i o
ns houl dber epla
cedwitha
newo ne.

-6
6ω
 4
. BRAKESYSTEM

I
1
1
IReassembly
I
I

① Reassemblet hebooste
rinther e
verseorderfromd i
sassembly
.
② Paya t
ten
tiontothedirec
tio
nofi ns
talla
tionwheni ns
tall
ingthepacking
sands ea
ls.
③ Applyingg reas
e
a. Applyas ui
tabl
eamountofl ithium
-basedg r
easetotheouterdiame
ter，cupgrooveandcupoft
he
ai
rp i
stonandthei n
nerdiamet
ero ftheaircyli
nder(sli
dingpar
t).
b. Applyas ui
tabl
eamountofb rakeoiltot heoute
rd i
ameter，cupgroove，andcupoft h
ehydr
auli
c
pist
on andt
ラ hei n
nerdiamet
erc
ラ overi n
nerd ia
meter(cupg roov
e)andtwoc upsoft h
ehydr
auli
c
cyl
inde
r.
④ T ighte
ningtorque
a. Fortight
eningtorqe，s
u eeFig
.4 .2
7.

副Runtheperformancetestafte
rr e
assembly.
① Aft
errei
nsta
llin
gtheb o
osteronthetruck，blee
dairou
toft h
es y
ste
m.
② Makesuretheoilcylin
derhasano i
lpressureofmoret h
an17.7MPa{ 180kgf/cm2} [2
567psi]
whenanairpre
ssureofO.78MPa{ 8kgf/cm} [
2
113
.1psi
]isappl
iedt
ot h
eairc
ylind
er.I nadd
iti
on，
makesurethe
reisnoa i
rl e
ako ro
illea
k.
③ Makesuretheoi
lp re
ssureis0whent heairisdis
char
gedfromtheai
rcyli
nde
r.

-67-
 {-CTい心一ド寸む円 E C・円。円}
{EU4040N寸 E 。山門}εsZN.F寸 B 円・寸円
一
ωコU ﹂OHOC-coH
工。一
﹂'

7
2

8-
4.

6
i
Fg.

自
[
-c一a
u肝心一寸 . F山ω a 由
・0
. BRAKESYSTEM

{ε04040phE 。。ω}EE2ω ・円ド s ∞・∞町

一∞コ 一
U ﹂OHacCω 日Z O一
ト
4
 4
. BRAKESYSTEM

BRAKEVALVE
(RIGHT)

しOWPRESSURE
SWITCH
392 294kPa
幽

{4
.0-3.0kgf/cm2}
[56
.9 42.6p
幽 si
]

BRAKEVALVE
(LEFT)
CHECKVALVE

AIRDRIER

困
fこ
為
市 OILRESERVOIR

，
'-
--
L
「

閏+/……~:=:=~三三ー
i :r~省
国
‘E
AIRGOVERNOR

/
SAFETYVALVE
1.03MPa
{
10 .5kgflcm2}
[149.4ps
i]

BOOSTER DRAINVALVE AIRTANK

，
，
，
B

p
.O
'

、‘，ノ
a
e

n
，，、、
i

I'
ウ
k

4EEA
f

ム
b
・ 唱Eゑ

F
ig.
4.2
8
vi

A
EA

-69-
4
. BRAKESYSTEM

BRAKELAMP
SWITCH

DOUBLECHECK
VALVE

LOWPRESSURESWITCH
118-49kPa{ 1.2・ 0
.5kgf/cm2}
[17.1-71.psi]
LOWPRESSURE
SWITCH
196kPa{2kgf/cm2}
[8.
2 4ps
i]

View1
001
くigfrom開
n

}一 、
、 〆 /

、 、 〆
¥ /
戸一

Viewl
ook
ingfrom悶 Viewl
ook
ingfrom国

F
ig.4
.29 BrakeP
ipi
ng(
2/2
)

附 70-
 BRAKEVALVE
(
問 GHT)
LOWPRESSURE
SWITCH
A
irl
ine 118-49kPa AIRCLEANER
{1
.2-0.5kgf/cm2}
[1
7. 幽
1 71.ps
i]
O
ill
ine

PRESSURE
、JDER
S目
OILRESERVOIR
540cc

JA
Em

'
UF
BRAKELAMP

R 化
2
}

sqC uzね
‘

ph
、
SWITCH

W 灯川 4
引

LSHhp
、 ハMHnO
門 ﹁ 円 ) 門 ﹁ 門V
RHam1 J
49kPa{0.
5kgf/cm2}
[7
1.ps
i]

AIRDRIER

明山間

E 、
司 HE
- h 苧・い明。
BRAKEVALVE
(LEFT)

BOOSTER

LOWP問 SSURE
SWITCH
392・ 294kPa
{4
.0-3 .0kgf/cm2} SAFETYVALVE
[56
.9-42.6p si
] 1.03MPa
{
10 .5kgf/cm2} AIRGOVERNOR
[149.4ps
i] 755kPa
{7
.7kgf/cm2}
[109
.5psi
]
ム回刃﹀〒ハm

AIRTANK
36li
ter
s[9
.5USg
al]
↓ ω ︿ω m
mz
4
. BRAKESYSTEM

NOTE

-7
2-
 5
. STEERINGSYSTEM

5 STEERINGSYSTEM
幽

よ¥ぐ空 FD160-2 FD180-2 FD200-2 FD230-2

Type H
ydr
ost
ati
cty
pe
S
tee
rin
gwheeld
iam
ete
r 360m m[
14.
2in
.]
O
rbi
tro
l
Type Lords
ens
ing，n
on-
Ioa
dre
act
iont
ype
D
isc
har
ge 599c
c/rev
S
tee
rin
gcy
lin
der
Type D
oub
le-
act
ingp
ist
on
C
yli
nde
rbo
re 130m m[
5.1i
n]
Rodd
ia. 90m m[
3.5i
n.
]
S
tro
ke 396m m[
15.
6in
.]
P
rio
rit
yva
lve
O
ilp
res
sur
ese
tti
ng 1
7.1MPa{175kgf/cm2}
[24
80p
si]
S
tee
rin
gpump
Type Geart
ype
Discharge 56c
c/r
ev
S
tee
rin
gax
le
Type Centerpi
ns u
pport
e d，E
lli
ottyp
e ラ

box-shapedc
rosssec
tionweldcon
struc
tio
n
Kingp
ins
pac
ing 1900m m[
74.
8in
.]
Kingp
ina
ngl
e 。
。
T
oe-
in om m[0in.]
Camber
。
。
C
ast
or 。
。
S
tee
rin
gan
gle
I
nne
rwheel 7
80 ぐ
一一 7
50 モ
一一

Outerwheel 540 ぐ
一一 51
.50 ぐ
一一

Wheel
Wheels
ize 12.00-24-18PR(ID) 1
3. ID) 1
0・24・20PR(
0 4.0か2424PR(ID) 1
明 4.0 (
024-24PR
四ID)
Rims
ize 8.50Vx24 モ
ーー モ
ーー モ
一一

I
nfl
ati
onp
res
sur
e 785kPa 8
09kP a 883kPa モ
ーー

{
8.
0kg
fJ
cm2} [
113
.9p
si
]{8.
25k
gfi
cm2} [
117.
3ps
i]{
9.
0kg
fJ
cm2} [
142
.6p
si
]

側 73削
5
. STEERINGSYSTEM

5
.1 GENERALDESCRIPTION
Theste
eri
ngsystemi
sahyd
ros
tat
ictypest
eeri
ngth
etruc
kw it
hre
arw
heels，andcon
sis
tsp
rim
ari
ly
ofaste
eri
ngwheel anO
rbi
t
ラrl，ap
o r
ior
ityva
lve，ast
eeri
ngaxl
eandast
eer
ingcylin
der
.

5.1.
1 STEERINGWHEELASSEMBL Y
Thes t
eeri
ngwheeli
sa rr
ange
dasshowninFig
.5 1，
. opera
tingtheO
rbi
tro
lunde
rthes
t e
eri
ngwheel
post
.
Thes t
eeri
ngwheelpos
tissuppo
rte
dwiththepinatth
ep oit閣 andbyt
n hep
oint圃. Theti
lta
ngle
betweentheste
eri
ngwheelpos
tcanbechangedaroundthepoint園.

STEERINGWHEEL

E
LOCKL医VER

JOINT

ORBITROL

F
ig.
5.1 S
tee
rin
gwheel

-74-
 5
. STEERINGSYSTEM

5.1.2 ORBITROL
TheO rb
itrolsendsthep re
ssureoilfromt hepumps elect
ivelytot hesteeringcylinde
rs.I tconsi
sts
primari
lyofac on
trolvalveandam eteringdevi
ce.
Thec ontrolvalveusedint heOrbitro
lisnotano r
dinaryspoolv al
v ewhoses poolmovesi nt h
ea x
ial
direc
tion，butarotaryvalvewhichc onsi
stsofas l
eeveandas poolthatrotatetogetherformingd i
ffer
ent
oi
lp assagesthroughtheco mb
in a
tiono fthei
roilhol
es. Thev alvehou singispr o
vi de
dw ithf o
urports
whichl eadtothepump， tank，rig
htandl ef
tchamberso ft
h ecyl
inder.Betweent hei n
letportandr et
urn
portisacheckv alve.
Them e te
ringd e
vicec o
nsistsofani nte
rnal
lytoothedstat
orandane xternal
lyt oothedro
tor. During
normalo pera
tion，i
to p
eratesasano ilmotor
.I nanemergencyiラtc anb euse dashandpump. Ther o
tor
smechanical
i 1ylinkedwitht h
es leevethroughthedri
ves ha
ftsot hatf e
ed backoperationispossib
le.
Thes leeveisinterl
ockedwitht h
em otor
'sr o
torthroughthecrosspinandd ri
ves haf
tw hi
l ethespool
i
ss plinedtothesteerin
gs h
aft.

. CENTERINGSPRING
1 9.“ O九 RING 1.P
7 IN
. DRIVE
2 1
0. GEROTOR 1. SPOOL
8
. BALL
3 11
.“O九 RING 1.“
9 O九 RING
. ADAPTER
4 1
2. GEROTOR 2. RETAININGRING
0
. RETAINERSCREW
5 1
3.“ O九 RING . OILSEAL
21
. ENDCAP
6 1
4. SPACERPLATE 2. DUSTSEAL
2
. DRIVE
7 1
5.“ O¥RING
ラ 2. SEALGLAND
3
. SCREW
8 1
6. SLEEVE BUSHING
2
4. BEARINGRACE
2
5. THRUSTNEEDLE
F
ig.5
.2 O
rbi
tro
l

-75-
5
. STEERINGSYSTEM

(1)O p
er a
tionofO rbit
rol
a
) Ne utr
alstat
e
Whent hesteerin
gwheeli sat“NEUTRAL"s ta
te
ラ

theo i
lfrompumpf lowst hroug
ht heoilpassage① t o
theoilg roov
e②. Theo uterperiphe
ryoft hesleev
eh as
24o ilholes③ t h
atcommunicatew itht h
es poo
lh oles
④. T herefor
et
ラ heoilthatente
rstheoilgroove②ヨows
throught heoilholes③ and④ t ot hegap⑤ between
spoolandd rivesh at
. Theni
f tflowst h
r o
ught h
es pool
groove⑥ andt hesleevegroove⑦ backi n
tot heoil
tan
k .
Sincet hec yl
i nd
erp orts⑫ and@ r espectively
communicatew iththesleeveholes⑬ and⑪ ，n otw ith
eit
h e
rt hespoolgrooves⑬ o r⑬，t heoilinthecylinder
doesn otflow.
Theo ilp ass
age⑬ t hatleadstotheh ydr
aulicmotor
communicatesw iththes le
eveholes⑭ forthehydrauli
c
motor . The o il passage⑬ ラ however，does not S
QUT
骨

communicatew it
he ith
ert h
es poolgrooves⑬ o r⑬ so
tha
tt heoildoesn otflow
. F
ig.
5.3

b)C ounterclo
c kwiset u
rningofs tee
ringwheel
t •
When t he steering wheel i s turned i n the
counterclo
ckwised irectio
ラnt h
es poolgroovesshiftto
theleftinrela
tiont ot h
es leeveholesandg roovess o
tha
tt h
es po
olhol es④ don ota l
ignwiththesleeveholes
③. Asar esul
toft hs，t
i heoilthatflowsi n
tot heoil
groove② i sdirec t
edt ot h
es leeveholes⑫ andt hen
f
10wst hroughthes poolgrooves⑫ and⑬ ，s leeveholes
⑭ andh ousingo i
lp assage⑬ t ot hehydraul
icmotor .
Thisallowst hehydraulicmotort or o
tatei nt he
counterclo
ckwis edirecti
on. Theo ildischargedfrom f 畢

thehydraul
icmotorf lowst hroug
ht hesleev
eh oles⑭，
spoolgroove⑬ ands leeveholes⑬ t ot hehousing
cylind
erport(L)t oa c
tuatet h
es t
eeringcyl
inder
.
Theo i
lr e
turning企omt hecylinderf
10wst hroughthe
cylind
erp o
rt( R)，hous inggroove⑫ ，s lee
veh oles⑫，
spoolgroove⑬，s lee
veh oles⑫ andh ousinggroove③
totheoiltan
k.
ー ー

Fig.5.
4

-76-
 5
. STEERINGSYSTEM

c) Clockwiset u r
n i
ngofs teer
ingwheel
4
Whent hes t
e eringwheelist urnedinthec lockwi
se ー
d
i r
ection，thespo olgroovesshifttotherig
htinr e
lation
t
ot hesl ee
veh olesandg roovessothatthes p
oolh ole
s
④ don ota li
gnw i ththesleeveholes③. Asar esu
ltof
t
l出ラ theoilthatf lowsi n
totheo lgroove② i
i sdirecte
d
t
ot hesl e
eveh o
l es⑫ andt henflowsthroughthes poo
l
groovs⑫ and⑬
e ラs l
eeveholes⑬，s poolgroove⑬ and
slee
veh oles⑪ t othec y
linderp o
rt(R)i nthehousing
t
oa ctu
at ethecyl in
der.
Theo ilr e
turningfromc
・ y
linderf lo
wsthrought h
e
c
y l
inderp ort(L)，h ousinggroove⑬ ラs leeveh o
les⑬ラ
spoo
lg ro o
ve⑬ラs leev
eh ol
es⑫ andh ousiggroove⑨
n
t
ot hetank.

• t
OUT !
N

F
ig.
5.5

ー77-
5
. STEERINGSYSTEM

COLUMN
2
. CENTERING
SPRING
N
eut
ral

今
3A
CHECKVALVE
1
J
lj SPOOL

﹃戸﹁
SLEEVE

d
ぷU 勺 /
DRIVESHAFT
ROTOR

コ
H
F
ig.
5.6O
per
ati
onofO
rbi
tro
l

(2
)R el
ationbetweenrotat
iona
ls peedando pera
tingf o
rce
I
np r
incip
letラhefor
cer e
quire
dtoo per
a t
et heOrbi
trolisonlythef or
cetochangeo v
ert h
evalveヲl.e
.
theforceofcompressingthecenteringspringasl a
rgeas2 .9N-m{ O.3kgf-m}[2.2lbs
-ft
].I nother
words s
ラ incetherei
snom echanicalconnectionbetweent h
es tee
ringwheelandt hetir
esando nlythe
springcompressingforc
eisr eq
uired，constantsteer
ingf o
rceisk eptevenatani ncrea
sedrotat
ional
speed. However ，i
ftheamountofo i
ld ischargedfromt hepumpr educesbelowt h
eamountofo i
l
necessa
ryfrot h
eo p
erati
ono ft
heO rb
itrol，th
er o
torwhichi susuall
ya ctu
atedbytheoilsuppl
iedfrom
thesteer
ingpumpi smovedbys te
eringwheelo pera
tion，resul
tinginheavys te
eri
ng.

(3
)N eutralfeedbackofOrbit
rol
Then e
utralfeed
ba c
ko ft
heO r
bitr
olisperformedbyswitch
ingtheo
ilpassagesof
thev a
lvethrough
th
er ea
ctionsfo
rceoft h
ec e
nterin
gspri
ng. (Whent hest
eeri
ngwheelisturnedandthenrele
asedwith
th
ee ngineatrett
s hes
ラ t
eeri
ngwheelreturnstotheini
tia
lposit
ion
.) Unlesstheneu
tralfeedbackis
comp
letelyperformed thewheelmaybet
ラ u
r n
ed，eventhoughtheope
ratordoesnotturnthesteer
ing
whee.
l

(
4)S tee
ringwhenpumpi sdefect
ive
Whent hepumpf ai
lstosupplyhydrau
li coil，theOrb
itrolservesasanemergencyhands te
erin
g
d
evice
. Whent heste
eri
ngwheeli sturned，thes po
olrotat
es. Whent urnedbya bout8，t
0
hespoo
l
c
ontac
tst hecro
sspinwhichint u
rnrotat
est hed r
ivesha
ftwhichi nturnrotat
esther o
t . Thus，
or th
e
me
teringdeviceser
vesasas t
eerin
gwheelpumpt osupplyoi
lt oth
ec yl
inde
r.I nthiscaseth
echeck
v
alveprovide
dbetweentheret
urnportandt h
es ucti
onpor
to pens，s
ot h
atoilflowsfromthecyl
indert
o
t
hesuctionsi
de，the
rebyeff
ectin
gemergencys t e
erin
g.

-7
8-
 5
. STEERINGSYSTEM

5.1.
3 PRIORIτYVALVE
Thep r
ior
ityvalv
eisi ns
tall
edbetweenthest
eeri
ngpumpandt heO
rbitr
oltoredu
c eflu
ctu
ationsi
n
pumpd is
charg
ecausedwhent hee
nginespeedv
arie
s，th
erebya
ssuri
ngcon
stants
tee
ringwheelope
ratin
g
fo
rceands t
eerin
gspeed.
Thep r
ior
ityvalv
ea ls
oh asaloadsensi
ngfunct
ionwhichall
owstheamountofoi
lr equ
ire
df orth
e
st
eerin
gsystemtof lo
wt otheCFpor t
.

1
1 1098 76 5 4 3 2
A寸 1

13 EF CF

A
"""
"斗J
C
ros
sse
cti
ona
lvi
ewAA

N
ote
: Usec aut
iontoprev
enttheentranceofdus
t
ordir
ti n
tothev
alvewhend isa
ssemblingo
r

i己
.<
1>
..
reasse
mblin
g.Av alvec
10ggedw i
thf o
reig
n
matterwillcausethemalfunctionoft h
e T

stee
ringwheelu
nit
.
P

1
. HOUSING 5
. RING 1
0. SPRINGGUIDE
2
. SPOOL 6
. VALVESEAT 1
1. ADJUSTMENTSCREW
3
. SPRING 7
. BODY 1
2. PLUG
4
-11
. RELIEFVALVE 8
. POPPET 1
3. PLUG
4
. SCREEN 9
. SPRING

F
ig.5
.7P
rio
rit
yVa
lve

倫 79
蜘
5
. STEERINGSYSTEM

Operationo ftheloads en
singsystem
Thel oa
ds ensin
gs ystemsendsonlytheamountofo i
lrequir
edforste
erin
go p
erati
on合omt hetot
al
disch
argeoft hemainpump， totheOrbit
rolands en
dst heremai
ningamountofoilnotrequ
iredfor
ste
eringoperat
iontot h
eh ydr
aulicsystem(co
ntrolval
ve).
Forexample whent
ラ hes te
eringwheelisinneutrl，
a alm
ostalltheo
ildischar
gedfromthemain
pumpf lowstothecontrolvalvefordri
vingth
el oadhandlin
gsystem
.Thel oadsen
singsys
tems e
rves
tousetheoildisch
arg
・efromt hemainpumpw hi
lep roduc
ingenergysavi
ngofthehydra
uli
cs ys
tem.

(
1) Whenthest
eeri
ngwheelisinne
utr
al(withtheeng
inestopp
ed)
Whenth
ee n
gineisa
tr e
st，t
hepr
iori
tyval
ves pol① i
o spushedt
othel
ef
tbyt
hec
ont
rols
pri
ng②
，
s
ot h
att
heCFp or
tisopenedful
lyandtheEFp o
rtisclos
edcomp
let
ely
.

STEERINGCYL
lNDER

STEERINGWHEEL

「
ORBITROL

t
oCONTROLVALVE

L___
PRIORITYVALVE P

MAINPUMP

F
ig.
5.8 S
tee
rin
gWheeli
nNe
utr
al(
wit
hen
gin
est
opp
ed)

-80 削
 5
. STEERINGSYSTEM

(
2) Whent h
es t
eeri
n gwheelisinneutr
al( wi
ththeenginerunni
ng)
Thep ress
ureoilfromt hesteer
ingpumpf low
sthrought h
ePp ortandtheCFp ortoft h
ep ri
orit
y
va
lveintot h
eO r
bitrol
.Itpassesthroughtheinne
rthrot
tleCoandTp o
r
ラtbacki n
totheoiltan
k.
Inthisstat
et
ラ he
reo ccursap r
essured i
ffer
enceacrosstheinne
rt h
rot
tleCooft h
eO rbi
trolint h
e
p
ressurechambersAandB oft hepri
orityvalv
ラesothatthespol① i
o smoved1t othefigh
tshowni n
F
ig.5.9.
Therefo
re，theEFp ortoftheprior
ityvalveisopenedfull
yandt heCFp o
rtissli
ghtl
yo pene
d.
Almostalltheoi
ld ischar
gedfromt hestee
ringpumpr et
urnstothetankthr
oughthemainv alve
.

C
1

L ー ー 一 一
P
T

F
ig.
5.9 S
tee
rin
gWheeli
nNe
utr
al(
wit
hen
gin
eru
nni
ng)

-8
1-
5
. STEERINGSYSTEM

(3)Whent h
es teerin
gwheeli st ur
ned
Whent h
es teeringwheeli sturnedfrornthen e
utralpositi
on，theoilp a
ssagesi ntheOrbit
rolare
switche
do v
er.Asar e
sut，
l t
heo i
lthatflowsf ro
rnthePp o
rtoft heOrbit
rolpassesthroughthethr
ott
le
Cl.A tthi
st i
rne，si nc
et hepressuredifferenceacrossthethro
ttleCli stran
srnitt
edtot hepres
sure
charnb
ersA andB oft hep r
iorityvalver e
s p
e c
tivel，t
y hes p
ool① r novestot hepositi
onwheret he
dif
fere
ntia
lp res
s u
r eofthep ressur
ec harnbersA andB isbalancedw iththecontrolsprin
g② f orc
ラe
thusset
tin
gt h
er ateofd i
visionofs t
eeri
n gpurnpd i
schargeoi
ltot heportsCFandEF .
Thee xt
entofopeningofthet hrot
tleC lint heOr
bitro
ld ependsont hespeedatwhicht hesteeri
ng
wheelisturned. Whent hesteerin
gwheeli st urnedquickl
y，thee xt
entofopeningi slargewhereas
whent hest
eeringwheelist urnedslowly，theexten
tofo peningissrn
al.
lT herefore，whenthesteeri
ng
wheelisturnedslowl yr
ラ nucho i
lf lo
wsin t
ot heCFp ortsothatthesteeri
ngs pee
di ncr
ease
s.

GEROTOR
ド
コ

C
1
a思5
n﹁
引針

F
ig.
5.1
0St
eer
ingWheeli
nTurn

-8
2-
 5
. STEERINGSYSTEM

(
4) Whent hesteer
ingc y
linderi
satt h
es trok
eend
Whent hes te
eringwheelist u
rnedunt
ilt h
es t
eer
ingc y
linde
rr e
achesthestr
okeend，ther
ea r
enoo i
l
f
10wsa cro
sst hethr
ottleC1oft heOrb
itrol，duetowhicht h
ep re
ssuredi
fferen
cea l
sodisapp
ears.
Consequently，thep re
ssureint h
ep ressur
echamberB oft h
ep ri
ori
tyv al
ver i
sesalongwiththe
p
ressureint h
ecircu
it，andt h
er e
lie
fvalve③ o pe
rate
st odecr
easethepres
s u
reinthepress
urechamber
B
.
Inthi
ss t
ate，thepressur
ei nthepre
ssurechambersAandBoft h
eprio
rityvalv
eisc o
ntrol
ledbythe
t
hrot
tleC2， andthes p
ool① movest ot h
er igh
ttoclosetheCFp ortandopentheEFp ortalmostfu
lly
.

「
A

C
1

F
ig.
5.1
1 S
tee
rin
gCy
lin
dera
tSt
rok
eEnd

-8
3-
5
. STEERINGSYSTEM

5.14 STEERINGCYL
. lNDER
Thes t
eerin
gc y
lin
derisin
stal
ledintheste
erin
gaxleandisope
ratedbythehyd
raul
icoilcon
tro
lle
d
bytheOrbitr
ol.
Thepistonrodendiscon
nectedtotheknuckl
ew i
thap i
nw h
ilethecyl
indert
ai
ltothecen
terofth
e
st
eerin
ga x
lewithap i
n.
Thec y
lindercaphasabusin
go i
ラlse
al，anddustsea
landisins
tal
ledontothecy
lin
der
.

2 3

岡ト -
j一一一(:← -
7
H

1
. DUSTSEAL 6. DUBUSHING 11.“O"-RING
2
. WEARRING 7. CIRCLIP 12
. CYLINDER
3
. RODSEAL 8. PISTONSEAL 13
. PISTONROD
4
. RODCOVER 9. WEARRING 14
. SPHERICAL
5
.“ O"-RING 1
0. COLLAR BUSHING

F
ig.
5.1
2 S
tee
rin
gCy
lin
der

-8
4-
 5
. STEERINGSYSTEM

5.1
.5 STEERINGAXしE
Thest
eeri
ngaxl
eisanEl
lio
tty
peofweldc
onst
ruc
tio
nandc
onsis
tsofacen
terarm，t
ier
ods，kn
uckl
es
andst
eer
ingcyli
nde
r.
Theste
erin
gaxleisi
nst
all
edt
otherea
rpar
tofthefra
methr
oughbush
ingswithtwosupp
ortpi
ns.

KNUCKLE(LEFT)

KNUCKLE(RIGHT)

固 SeeFig.5.14
STEERINGCYL
lNDER

PIN
OILSEAL

一
関口市 @

D
eta
ilofaxlesupport
⑪

D
eta
ilo
fki
ngp
inbushing

F
ig.5
.13S
tee
rin
gAxle

勝 8
5-
5
. STEERINGSYST巨M

(
1)Knuckleandk
ingp
in
Theknucklei
si n
sta
lloneachendo ft
hestee
ringaxl
ew it
hak i
ngp i
nwhichisintu
rns u
ppo
rtedby
ab ushi
ngont hestee
ringaxle
.
Theknuckl
eh a
sawheelhubi ns
tall
edonthespi
ndl
ew ithtwota
perrol
lerb
ear
ing
s.Thehubc o
ntai
ns
greasefil
ledfo
rlubrica
tingthebeari
ngs.
Thekingpinissecuredtothek nu
cklewithataperpin
.Thea re
awhichcomesi ncon
tactwit
hthe
bushinghasgreasefi
lledforlub
ricat
ingthe“0"-r
ingandt h
eoilsea.
l

KINGPIN

THRUSTBEARING
CAP

0
“ '
二RING

BUSHING OILSEAL

LOCKWASHER

LOCKNUT

ADJUSTM巨NTNUT

TAPERROLLER PIN
BEARING

OILSEAL

F
ig.
5.1
4

自 86-
 5
. STEERINGSYSTEM

5
.2 MAINTENANCE
5.21 DISASSEMBL
. lNGORBITROL
Priort
oa t
tem
pti
ngtod
isa
sse
mbl
eth
eOr
bit
rol，c
lea
nth
eex
ter
ioroft
heu
nitands
ele
ctac
lea
n
workingpl
ace
.

(
1) Holdt
hef
1angeoft
heO
rbi
tro
linav
ise
.

F
ig.
5.1
5

(
2) Removet
hebo
ltss
ecu
rin
gth
eendc
apandremove
th
eendca
p.

SCREW

F
ig.
5.1
6

(
3) Removetherot
orsetfromtheh
ous
ing.
Usecauti
onsoasn ottolo
sethest
arint
hero
tor
se
t.
Removethe“0"-r
ingfromthes
pac
erandth
ero
tor
se
tinthest
ar
.

ROTORSET

SPACER

F
ig.
5.1
7

-87-
5
. STEERINGSYSTEM

(
4) Removeth
esp
ace
rpl
ateandt
hed
riv
efromt
he
ho
usin
g.

F
ig.5
.18

(
5) Removet h
ehousingfromt heviseandp u
titon
cle
anclo
thw i
tht h
emachinedsurfa
cedown.
Removethereta
inin
gr i
ngfromth
eh o
usingbyfi
rs
t
pry
ingit
sendo ffwithasmalls
crewdri
ver
.

F
ig.
5.1
9

(
6)Turnthespo
olands lee
vesothatthep
ini
sp a
ral
lel
withtheportsurf
ace. Thenpusht hes
pooland
s
l ee
vei n
tothehousing，removingth
esealgland
SEALGLAND
b
u shin
gfromt h
eh ou
sing. BUSHING

F
ig.
5.2
0

(
7) Removet
he" X
"-rings
ealandt
hed
usts
ealfrom
th
esea
lglan
db us
hin
g.

DUSTS阪AL
SEALGLAND
BUSHING

F
ig.
5.2
1

-88-
 5
. STEERINGSYSTEM

(
8) Removet
het
hru
stb
ear
ing
.

RACE

F
ig.
5.2
2

(
9) Removethes
p o
olands l
eev
efromthehous
ingin
th
edire
cti
onindic
ate
dbyarrowinF
ig.5.
23.
Removeth
epinfromthes
poo
landsl
eevea
ssemb
ly.

F
ig.
5.2
3

(
10)Removethes
poolapa
rtwayfromthesle
eveand
removet
hece
nte
ringsp
rin
gfromth
es p
ool
.

F
ig.
5.2
4

-89同
5
. STEERINGSYSTEM

5.2.
2 REASSEMBL YOFORBITROし
Insp
ecttheconta
ctsurfaceofal
lpartsfo
rscor
es，scr
atchesorburrswhichwouldcauseoi
lleakif
neg
lecte
dandi
ラ fun
sati
sfact
ory，r
epla
cewithnewones
.C lea
na l
lmeta
llicpar
tsanddrywit
hcompressed
a
ir
.F ordryin
gp ur
pose，donotuseclot
ho rp
ape
r;other
wiselinto
rp a
pe rd
uststi
cksonthesu
rfac
eand
wouldcaus
et ro
ubleinthehydra
uli t
cequipmen.Replacethe“O"-r
ingsands e
alswit
hnewo nes
.

(
l)A
fte
rap
ply
ingLOCTITE#242ont
het
hre
ade
dpa
rt，t
igh
tent
hes
etscreww
ithanA
lle
nwr
enc
h.

(
2) Alignthegroovesi
nt h
es po
olwiththos
ei nt
he
SPRINGGROOVE
slee
veandputthesp
oolint
othes
leeve，
turn
ingt
he
spools
lowl
y.
SPRING
GROOVE
CONTROL
SPOOL

F
ig.
5.2
5

(
3) Alignthespr
inggroovei
nth
espoo
lwitht
hatin
t
t
h
h
es
es
l
p
r
e
i
e
v
n
eandp
g.
utthemonapla
nepla
te.I
nst
all
一一¥

F
ig.
5.2
6

(
4)I
nse
rtt
hep
int
hro
ught
hes
poo
lands
lee
veh
ole
s.

PIN

F
ig.
5.2
7

輔 90-
 5
. STEERINGSYSTEM

(
5)Ins
ertthespo
olandsl
eeveassemblyi
nt h
eh o
using
fromr e
ars
ide.Usecaut
ionnottoallowthesle
eve
assemblyendfacetogof ar
therins
idefromt he
housingsh
oulde
rsur
face.

F
ig.
5.2
8

(
6)I
nst
allthet
hru
stbearingand“0"-
rin
gont
he
h
ousin
g.

F
ig.
5.2
9

(
7)I
nsta
llt
hedus
tse
alandt
he“
X"-ringt
oth
ese
al
gl
andbu
shi
ng.

F
ig.
5.3
0

(
8)I
nst
allthesea
lg l
andb us
hingin
tothesp
ool，tuming SCREWDRIVεR
t
helatt
erslowl
y. Drivethebu
shinginpla
cew itha DUSTSEAL
p
lasti
cm al
let.I nsta
llt h
eretai
ningringont he
RETAININGRING
h
ousing.

F
ig.
5.3
1

-9
1-
5
. STEERINGSYSTEM

(
9) Holdtheh
ousingi
navi
se. Makesu
retha
ttheend
fac
esofthesleev
eandspoolaresunkfromthe
housi
ngsur
fac
e.

F
ig.
5.3
2

(
10)I
nsta
llt e"0ヘr
h in
gont h
ehousin
g. Cleant
he
su
rfacesoft
hehousingandspac
erpla
te，t
henp
ut
t
hes p
acerpl
ateonthehous
ing
.

F
ig.
5.3
3

(
11)Turnthespoolandsl
eeveassemblysothatth
eport
surfa
ceisp a
ral
lelt
ot h
ep inandinst
allthedri
ve.
Drawal ineonthedr
ive'
ss pl
ineendface，pa
ral
lel
tothepin
.
A Thi
ss t
epi
simp 側 制 Followthepro
叫 lrec or
制 ly.

F
ig.
5.3
4

(
12)I
nst
allt
he“O
"-r
ingont
her
oto
rst
e.

“
Oに RING

F
ig.
5.3
5

-92-
 5
. STEERINGSYSTEM

(
13)Putti
ngt he“O"-ringsideofther oto
rs e
ttoward
thespace
rp l
atesie，
d placeth
er o
toront h
eh o
u s
ing，
withthestarsr
ラ ootaligne
dwitht h
ed ri
ve(seeFig
.
5.36
). Then s
ラecurin
gt h
eengagementoft hedriv
e
andthesta，
r a
lig
nt h
eb o
lthole
si ntherot
orsetwith
thos
ei nthehousing
.

A Thisstepisimportant.Followtheprocedure
c
orr
ect
ly. PORT
SURFACE

F
ig.
5.3
6

14
( )Inst
allthes
pace
rinther
oto
rse
tanda
tta
cht
he
END
“O
"-ringonth
eendca
p. “
O"-RING CAP

F
ig.
5.3
7

15
( )
Putt h
eendc apont herotorse
tanda lignthebol
t
holeswitheacho ther
. Applyoilont hethread
ed
partofeachboltandt ig
htenthemtot h
et orq
ueof
14
.7N m {
削1.5k gf-m}[ 1
0.8lb
f-f
t]. Thent i
ghte
n
themt ot
het o
rqu eof25.5to28.4Nィn{ 2.
6to2 .
9
kgf- }[
位l 18.8to21 .0lbιf
t]int h
eo r
d e
ri nd
icat
ed
i
nFig.5.
38.

F
ig.
5.3
8

-9
3 悶
5
. STEERINGSYSTEM

5.2
.3 MEASURINGPOWERSTEERINGOILPRESSURE
(
1) Parkt hetruc
konal evelsurfaceanda pplytheparkin
gb ra
ke.
(
2) Makes ureth
att hetemperatureoftheh y
d r
aulicoi
lis50t o600C[ 122to1400F].
(
3)Turnt hesteeringwheeli ntheclockwised i
rec
tiontobringthesteer
ingcylind
ertoitstrok
ee n
d.
(
4) Lowert h
ef o
rksont h
egrounds u
rfac
ラes hutoffth
ee ngin
eandb lockthedrivewheel
s.
(
5) Removet hepowers teeringoi
lp res
suremeasurementp lugandi n
sta
llap r
essuregauge( 2
5MPa
{250kgf/cm} [
2
3626psi])
(
6)S t
arttheengine，tur
nt hesteer
ingwheelandmeasuret h
eoilpressu
reatwhicht hepr
iori
tyvalveis
r e
liev
ed.
N ot
e:Thee ngi neshouldber unathighi dl
erpm.
(
7)A f
termeasurement ，shutoffthee ng
i n
eandremovet hepress
uregauge.
(
8) ApplyLOCTITE#572ont hethreadedpartoftheplugandrei
nsta
lltheplugintheori
gina
lpositi
on，
u si
ngc au
tiontop re
v en
tt heentranc
eoft heseali
nga ge
nti n
tothecirc
uit
.
(
9)S t
arttheengineandmakes u
ret h
ereisnoo illea
kagefromt heplug
.S hutofftheengi
ne.

5.2
.4 ADJUSTINGPOWERSTEERINGOILPRESSURE
(
1) Removet h
el ow-p
ressurehos econnectedtotheT
portoftheprior
ityv a
lvea l
o ngwiththeadapt
er.
(
2) Turnt h
ea djustmentscrewi ntheTp orttoadjus
t
Adjustmentto
ol
thereliefpress
ure.T ightent h
escrewwhent h
e
press
ureislowandl ooseni
twhenh ig
h. λIl
enwrench
7/32or5 .
5m m
N
ote: Eachcompletet
changest h
er el
ie
ur
fp
noft
ressu
h
r
eadjustmentscrew
ea ppro
xima t
ely6 .
9 E 苛
MPa{ 70kgf/cm2} [ 1
000p s
i].
(
3) Connectt h
ea da
pterandl ow-press
ureh o
se.
(
4) Checkt h
ep re
ssuresett
ing
.Ifitisnotproper，a
djus
t ADJUSTM忘NTSCREW

thesett
ingagain
.
Fig
.5 .3
9P rio
rit
yV a
l ve

聞 94-
 5
. STEERINGSYSTEM

5
.2.
5 TROUBL豆 SHOOTINGGUIDE

Problem Probablecause Checkingmethod Remedy

Lif
tt h
erearwhe
elsofthe
D
efec
tivemotionoft
hes
tee
rin
g Grease，di
sas
sem
ble
groundsur
fac
eandc h
eckthe
l
ink
age andrepa
ir.
motionofeac
hp ar
tmanu
ally
.

Lowi
dlerpmi
sto
olo
w. Measuree
ngi
nes
pee
d. A
dju
stt
o700r
pm.

Measuret
ir
epr
ess
urew
itht
ieA
r djustinf
lat
ion
Lowt
irei
nfl
ati
onp
res
sur
e
gaug
e. p
res
sure
.

A
era
tio
nduet
olowo
ill
eve
l Checko
ill
eve.
l Addt
osp
eci
fie
dle
ve.
l

I
nsu
ffi
cie
nta
irb
lee
din
g Bleeda
ir
.

Checkoi
lf lo
wo rcompareoi
l
In
suf
fic
ien
tdi
sch
arg
eofs
tee
rig f
n lowbe
tweenwhent hesteer
ing
Checks
tee
rin
gpump.
pump wheeli
sturnedquick
lya n
d
whenturne
ds lo
wly.

Theamountofoili
sin
suf
fic
ien
t Measureoi
lfl
owa
nd Checkpri
ori
tyv
alv
e
inst
eer
ingli
ne. pre
ssure
. andpump.

Hardste
eri
ng Cloggedt
ubi
ngofs
tee
rin
gli
ne Measureo
ilf
low
. R
epa
iro
rre
pla
ce.
wheel
Hyd
raul
ichosebrokenorp
ipe
V
isu
all
ych
eck
. R
epa
iro
rre
pla
ce.
j
oint
shavi
ngoilleaka
ge

Exce
ssiveo
illea
kageduet
o
damagedse
alofste
eri
ngcy
lin
der Disassembleandc
hec
k. Replacedamageds
ea.
l
pl
ston

Adjus
tr e
liefval
ve
pr
essureset
tingto
Lows
tee
rre
lie
fpr
ess
ure 恥1
eas
urep
res
sur
e.
17
.2MPa[ 175kgfl
2
cm] [2495psi
].

Cloggedscr
eeno
ro r
ifi
ce(LSラ

Disassembleandc
hec
k. C
lea
n.
PP)ofpri
orit
yval
ves p
ool

P
rio
rit
yvalv
esp
rin
gde
ter
ior
ate
d
o
rbroken
Disassembleandc
hec
k. Replacep
art
s.
Pr
iori
tyva
l v
es p
oolstu
ck，
damagedorget
tingf
oreig
nma
tte
r
cau
ght.

Mal
funct
ionofO
rbi
trol，worn
Disassembleandc
hec
k. R
epl
ace
.
r
otoro
rdamagedspoo
l

側 9
5-
5
. STEERINGSYSTEM

Problem Probablec
aus
e Checkingmethod Remedy

Cloggedscr
eeno
rori
fic
e(s，
L
D
isa
sse
mbl
ean
dch
eck
. C
lea
n.
PP)ofpri
orit
yva
lve

P
rio
rit
yvalv
esp
rin
gde
ter
ior
ate
d
o
rbroken
Dis
assembleandc
hec
k. R
epl
acep
art
s.
Prio
rityv a
l vespoo
ls tuck，
damagedo rgetti
ngforeignmatt
er
S
teeri
ngwheel caught
.
c
annotbe
t
urnedori
s Steerin
gr eli
efpressur
eu nsta
ble ~easure pr
ess
ure
R
epl
acep
art
s.
som
etlmes →d ef
ectiver e
lie
fv a
lve D
isassemb
leandchec
k.
s
tuck
~alfunction ofOrbi
trol，worn
roto
r，damageds poo
leラ n
t r
anceof D
isassemb
leandchec
k. R
epl
ace
.
forei
gnm atter

Loosen4bolt
ss e
curi
ngthe
ofs
~isalignmenttee
rin
gcolumn Orbi
trolandtu
rntheste
eri
ng
R
ead
jus
t.
andO
rbi
tro
ll wheeltochec
kf o
r
misali
gnm
ent.

Loosest
eer
ingw
hee
lorcolumn See“Looses
tee
rin
gwheelo
rcolumnj
ack
et"onn
ext
ja
cket p
age.

Changeo
iItos
pec
ifi
ed
A
era
tio
nofp
rio
rit
yva
lve Removeo
ila
ndc
hec
k.
typ
eofoi1
.

LoosemountingofOrbi
tro
l Vis
ual
lyche
ck. R
epa
ir.
Truckwanders
duri
ngn o
rmal Uneveni nf
1atio
npressu
reofrig
ht
Checkus
ingti
reg
aug
e. A
dju
st.
dri
vingor and l
ef
t t
ire
s
pul
1stoone
si
de. Unevenwearofr i
ghtandle
ft
Vis
ual
lyche
ck. R
epl
aceo
rro
tat
ion
.
Ir
t es

~alfunction ofO
rbi
tro
I D
isa
sse
mbl
ean
dch
eck
. 立e
pla
cea
sse
mbl
y.

Improperi
nst1a
altio
noft
ir
e V
isu
al1yc
hec
k. Adjust
.

Wheelb
ear
ingb
rok
eno
rnu
t
D
isa
sse
mbl
ean
dch
eck
. R
epl
aceo
rad
just
.
loo
se

-96-
 5
. STEERINGSYSTEM

Problem Probablec
aus
e Checkingmethod Remedy

S
tee
rin
gsh
aftb
ear
ingworn
D
isa
sse
mbl
ean
dch
eck
. R
epl
acep
art
s.
S
tee
rin
gsh
aftb
ush
ingworn
Looseste
eri
ng
wheelor Loosemountingofst
eer
ingwheel
Checkf
orl
oos
ene
ss. R
eti
ght
en.
column ontost
eerin
gs h
aft

Loosecolumnj
ack
etmounting
Checkf
orl
oos
ene
ss. R
eti
ght
en.
bol
ts

S
tee
rin
gsh
aftb
ear
ingb
rok
en
Movest
eer
ingwheelt
och
eck
R
epl
acep
art
s.
Ste
erin
gcy
lin
derp
ino
rbu
shi
ng fo
rno
ise
.
Noise worn

S
tee
rin
gc y
lin
derp
ist
onr
odb
ent
D
isa
sse
mbl
ean
dch
eck
. R
epa
iro
rre
pla
ce.
o
rbroke
n

Orb
itro
loils
ealo
rdu
sts
eal
D
isa
sse
mbl
ean
dch
eck
. R
epl
acep
art
s.
damaged

S
teer
ingcy
lin
dercappac
king ラ

O
ill
eak
s V
isu
all
ych
eck
. 立e
pla
cep
art
s.
d
ustsea
lo
ラr“O九 r
ingdamaged

S
tee
rin
gli
necon
nec
tion
slooseo
r R
etig
htn，r
e epa
iro
r
V
isu
all
ych
eck
.
h
ydr
aul
ichos
eortub
edamaged r
epl
acepa
rts
.

-97
回
5
. STEERINGSYSTEM

5
.2.
6 5TANDARDVAしUEFORMAINTENANCE
Unit
:m m[
in
.]
I
tem Standardv
alu
e
L
oos
ene
sso
fst
eer
ings
haf
tina
xia
ldi
rec
tio
n O
S
tee
rin
gwhee
lplay(out
erper
ipher
y) 70-8
0[2
.76-3
.15
]
S
tee
rin
g
w
heelun
it S
tee
rin
gwh
eelmountingnu
tt or
que N-m{
kgf
田m}
[lb
f-f
t] 4
.3-4
.9{
0.44 0
.5
凶0
}[3
.2 3
.6] “

Toqueofb
olt
sse
cur
ingO
rbi
tro
ltos
tee
rin
gpo
st
1
¥
Jm {
凶 k
gf-
m}[
lbf
-ft
] 3
.5 4
幽.1{
0.3
6 0.
43
“}[
2.6-3
.0]

P
rio
rity P
res
sur
ese
tti
ng MPa{
kgf
/cm2}[
psi
] 1
7.2{
175
}[2
495
]
v
alve V
alv
eun
itmountingb
oltt
orq
ue Nm{
幽kgf
-m}
[Ib
f二f
t
] l
.5田l.7{
0.1
5・ 0
.17
}[ .2
.11-l
l 5
]

-98-
 . HYDRAUL
6 lC SYSTEM

6
. HYDRAULICSYSTEM

n ¥¥¥￨ FD160-2 FD180-2 FD200-2 FD230-2

Mainpump
Type Geart
yped
ualpump
むi
sch
arg
e F
ront
:63c
c/r
evR
ear
:56c
c/r
ev
C
ont
rolv
alv
e
Type 2
-sp
ools
lid
ingt
ype
P
res
sur
ese
tti
ng 2
0.6MPa{
210kgf/cm2} [
298
8ps
i]
L
iftc
yli
nde
r
Type S
ing
le-
act
ingp
ist
ont
ype
C
yli
nde
rbo
re 1
20mm[
4.7i
n.
] 1
35mm[
5.3i
n.
] ぐ
一一 1
50mm[
5.9i
n.
]
P
ist
onr
odo
ute
rdi
ame
ter 8
5mm[
3.3i
n.
] 1
00mm[
3.9i
n.
] ‘
一一 1
10mm[
4.3i
n.
]
S
tro
ke 1
500mm[
59.
1in
.] モ
一切 モ
一一 モ
ーー

T
iltc
yli
nde
r
Type Doublea
cti
n
田gp
ist
ont
ype
C
yli
nde
rbo
re 1
55mm[
6.
1in
.] モ
一一 モ
ーー 1
70mm[
6.7i
n.
]
P
ist
onr
odo
ute
rdi
ame
ter 7
0mm[
2.8i
n.
] モ
一一 モ
ー一 モ
ーー

S
tro
ke 318mm[12.5in.] I ぐ
一一 モ
一一 モ
ーー

O
ilt
ank
O
ilc
apa
cit
y 1
80l
it
er
s[4
7.6USg
al]
O
ilt
obeu
sed ISOVG32(
Har
dwe
ari
ngh
ydr
aul
ico
il
)

6
.1 GENERAlDESCRIPTION
Theh
ydr
aul
icsystemc
ons
ist
spr
ima
ril
yofano
ilt
ank，
amainpump ac
ont
rolv
alv
etwol
ラ if
tcyl
ind
ers
ラ

andtwot
il
tcy
lin
der
s.

-99-
6
. HYDRAUL
lC SYSTEM

6.
1.1 OILTANK
Theoiltankhasastru
ctur
easshowni nFig
.6 .1andisweldedtotherig
htsideframeasapartofi
t
.
Theproperoill
evelofth
et an
kvarie
sa cco
rdingtothemaximuml i
ftheightofthemastin
stall
edt
o
t
hetruck，s
ot ha
tthegaugeforchecki
ngt h
ep rop
e ro
illeve
lisins
tall
edont hesid
eoft het
ank.
Thetanki
sp rovi
dedwithasucti
onfil
te
ratitsbottomtoprev
entdustintheoi
lfromcomingi n
toth
e
c
irc
ui.I
t talsohasar e
turn自lt
ertha
tremovesm et
allicpowderinthecir
cui
t.

CAP

VIEWGAUGE
i
I
ll-
-d-
H

ドILTER
DRAINPLUG

F
ig.
6.1 O
ilTank

-1
00-
 6
. HYDRAUL
lC SYSTEM

6.1.2 MAINPUMP
τhemainpumpi sag e
ar-typ
edual-pumpunitwhichisinst
alle
dont h
etorq u
econverte
rh o
using.
Ast heengi
ner u
ns，themainpumpu niti
sd riv
entopickupoilfromtheoiltankands e
ndsittothe
con
trolval
ve.Asshowni nF i
g.6.2，th
etwog earpumpshavethesames t
ruc
ture，withonesucti
onport
andtwod is
chargepo
rts.
Themainpumpu nitemploysafloat
ingtyp
ep res
sur
eb al
ancesystemsothatanoptimumc lear
ance
betweenthegearflan
kandt hepres
surepla
tecanb eachi
eveda c
cord
ingtothed is
chargepre
ssure
.

⑩
④??
s
.
c"
.
一
忠
司
除問問山川

Crosss
ect
ion
alviewCC Crosss
ect
ion
alviewBB Crosss
ect
ion
alviewAA

1
. MOUNTINGFLANGE 7. DRIVENGEAR 1
3. ISOLATIONPLATE
2
. GEARPLATE 8. REARDRIVEGEAR 1
4. DOWEL
3
. CENTERPLATE 9. DRIVENGEAR 1
5. “O九 RING
4
. GEARPLATE 1
0. PRESSUREPLATE 1
6. OILSEAL
5
. COVER 1
1. PLATESEAL 1
7. SNAPRING
6
. FRONTDRIVEGEAR 1
2. BACKUP 1
8. COUPLING

F
ig.6
.2 MainPump

開 1
01-
6
. HYDRAUL
lCSYSTEM

6.1
.3 CONTROLVALV主
Thecon
trolval
vei
sa2 -
spoo
lslid
ingtyp
ec on
sist
ingo
ftwos
poo
lsf
orl
if
tandt
i
lt av
alv
eh
ラo
usi
ng
andare
lie
fvalv
e.
Thet
il
ts p
oolhasat
il
tlockval
veinco
rpora
ted.

crosss
ect
ion
alviewA-A¥'¥11

Crosss
ect
ion
alviewB-B

1
. COVER 8. PLUNGER 1
5. RELIEFVALVE
2
. BOLT 9. PLUG 1
6.“ O九 RING
3
. RETAINER 1
0. “O九 RING 1
7. BACK-UPRING
4
. SPRING 1
1. SPRING 1
8. PLUG
5
. DISTANCEPIECE 1
2. PLUNGER 1
9.“ O九 RING
6
. PACKING 1
3. SPOOL
7
. SPRING 1
4. PACKING

F
ig.
6.3C
ont
rolV
alv
e

-102-
 6
. HYDRAUL
lC SYSTEM

6.1
.4 VALVECONTROL
Eachspoolofthec
ontro
lv al
veisoperat
edbyt helev
ersshowni nFig
.6.4. Thele
ver
sarearr
ang
ed
onashaf
ts upp
ortedwit
hab racke
twhichisi ns
tal
ledont h
ec a
bine
t.
Themovementofe achleve
rist r
ans
mittedthroug
ht h
ec ab
letot h
es po
ol.
Thecont
rolv a
lvei
si n
stal
ledunderthefloo
ra l
ongwithap ri
ori
tyv a
lve，throu
ghabrac
ket
.

TILTLEVER

lFTLEVER
L

/
/
/
/
/

し 』 … CONTROLVALVE

PRIORITYVALVE

F
ig.
6.4V
alv
eCo
ntr
ol

-1
03 田
. HYDRAUL
6 lC SYSTEM

6.1.5L lFγCYL lNDER

Thel if
tcylin
dersareofthes i
ngleacti
ngp i
stontypeandi ns
tall
eda ttherea
rs i
deofeachouter
channe.
l Eachlif
tcyli
ndercon
sistsprim
arilyofac y
linder
，apistonrod，acyli
ndercapandpac
king
s.
Thep istonrodandpisto
nareassembledw ithas naprin
g. Thepistonisgivenawearringanda
packingonitsoute
rcircumf
erence.
Thec ylin
dercapsupp
ortsthepisto
nrodthroughab ush
ingtopreven
tc or
rosioninthec
yli
nderwi
th
apackingi n
sid
eandan“ O九 ringontheouterperi
phery
.

DUSTSEAL

“
Oに RING

WEARRING

PACKING
~
COVER

“
O"-RING

BUSHING

BEARING

PACKING

PISTON

・
0 ERING
“
SPRING

F
ig.
6.5L
iftC
yli
nde
r

-1
04-
 6
. HYDRAUL
lCSYSTEM

6.1.6 FLOWREGULATORVALVE
Theflowr e
gulatorv alveislo catedbetweent h
ec ontr
olv alveandthetwolif
tcylinde
rst ole
tthe
fork
sl oweratac o
n s
tan ts p
eedr egardlessofwhetherl oadedornotload
ed.
Itconsi
stsofap iston，as leeve，as pringandav alv
ebodya sshowninFig.6.
6.
Theo i
ld el
iveredfromt hecontrolv alveflo wst hroughchambers⑧ andopening⑮ c harr批 r⑥ラ
opemng⑨ ， andchamber⑧ i n
t otheli丘c ylinders.
Whent h
ec o
ntrolvalv eisswit ch
e dtothe“ down"p ositi
o n，
theoi
lintheli
ftcy
linde
rsf low
st hro
ugh
伽 m ber⑤ i nt
o伽 m 帥be町r⑥ @
.Th 追ep 郎 sur
閃e n
吋
泊
1ωch悶a
卸I

⑥ accordingt ω
o批t
heo i
lflowp assing伽thr∞
ou悼
ght 批he叩0pe
叩n
凶lng⑨
時 ⑬. Whenthepressureinchamber⑥
overcomesthespringfo rce，th
ep istonmovest ot herigh
t， narr
owingdowntheopening⑧ Theh igh
er
thediff
erent
ialpressurebetweenchambers⑤ and⑥ ， thesmallertheopening⑧ becomes. The
amountofoilpass
i昭 t hrm 砂 t heo pening⑧ i sc ontrolle
dbyt hepress
uredi
ffer
encebetweench a
n批 rs
⑥ and⑥-

アア⑥ア 1
. SLEEVE
2
. “O"-RING
3
. SNAPRING
/
4
. SPRING
5
. PISTON
6
. PLUG
7
. “O"-RING

F
ig.6
.6 FlowR
egu
lat
orV
alv
e

-1
05-
. HYDRAUL
6 lC SYSTEM

6.1.7 TILTCYL lNDER

Fig
ure6.7showst h
ec ons
tructionof th
et i
ltcy
lin
der. Thepisto
nr o
diss e
curedt
ot h
eo utercha
nnel
andt hecyl
i n
dertai
lt othe企amew ithap in，resp
ect
ively
.
Thepistonrodisg ivenajointwhicha llowstheadjustmen
to fthepis
tonr o
dleng
ths.
Whent heti
ltleverispulledback t
ラ h eoi
lf lowsint
othepistonrodsideofthecyl
inder，cont
racti
ng
thepistonr
o d
.Att hesamet imetheoilatthec y
lind
ertai
ls i
deisforcedoutfromth
ec y
lindertoretu
rn
in
t othetank，sothatthemasti sti
ltedback.
Whent h
et i
ltlev
e rispushedf o
rw ard，oi
lf lo
wsintothecylin
dertai
l，extend
ingthepis
t o
nr o
d. The
oi
la tthepistonrods i
deisforcedo uto fthecyli
ndertoretu
rntot h
eoiltank
.

1
. JOINT 5
. CYLINDERCAP 9. CYLINDER
2
. LOCKNUT 6
. DUSTSEAL 1
0. WEARRING
3
. LOCKNUT 7
. PACKING 1
1. PACKING
4
.“ O九 RING 8
. BUSHING 1
2. PISTONROD

F
ig.6
.7T
iltC
yli
nde
r

-106-
 . HYDRAUL
6 lC SYSTEM

6
.2 MAINTENANCE
N
ote
:Fo
rth
een
cir
cldnumbers，
e seeF
ig，6
.2.

6
.21 DISASSEMBL
. lNGGEARPUMP
(
1)B efo
reproc
eedingtodi
sassemblyofthegea
rpump，removedir
tfromthepumpsu
rfa
ceandth
e
dr
ivesha
ft.Putd i
sassem
bledp a
rtsinorderonaclea
np ap
ero rc
lothandus
ecaut
ionnott
o
con
tami
nateordamagethem. Thedisass
embli
ngp
rocedur
eisasfol
low
s:

(
2) Holdt
hef
lan
geoft
hepumpi
nav
isew
itht
hef
lan
ges
urf
acedown.

(
3) Removetheassemb
lingnutandth
ewashers
tudb
olt
. Disassemblyandr
eas
sem
blyc
anbee
asi
ly
donebyremovingthes
tudbo
lt.

(
4)P
ullt
hecov
er⑤ i
nth
eaxi
aldir
ecti
o t
nandremovei.I
fthecov
eri
stoot
igh
ttoremove，
tapi
tou
t
w
ithama
lle
t.Iti
sun
nec
essa
ryt oremovet
hedowel⑭ fromt
hec
ove
r.

(
5) Removet
hes
eas⑬ and⑫
l ，th
eis
ola
tio
npl
ate⑬ andt
he“
O"-
rig⑬ a
n tth
eco
vers
ide
.

(
6) Removeth
epre
ssurep
lae⑮. R
t ais
eth
esh
aft
soft
her
eard
riv
ege
ar③ andd
riv
eng
ear⑨ s
lig
htl
y
andwit
hdrawthe
m.

(
7) Removethepress
urepla
te⑮ fromthebottomofthegea
rplat
e④. Duringthi
sp roc
edure don
ラ ot
t
il
tthepress
urepla
te.Ifthepr
essur
eplateisstu
ckandc a
nnotberemoved i
ラ ns
ertthere
ard r
ive
gea
r③ i n
tothegearpl
atebyholdingi
tssplin
eareaandpushingth
ehigherpar
toft hepres
sure
pl
ateli
ghtl
yi n
tothei
nit
ialp
osi
tio
n. Thentrytoremovethepr
essu
replat
ea g
ain.

(
8) Removet
hes
eas⑪ and⑫
l ラ andi
sol
ati
onp
lae⑬ fromt
t hebottomoft
heg
earp
lat
e④.

(
9) Tapt
hec
irc
umf
ere
nceoft
heg
earp
lae④ andt
t hec
ent
erp
lae③ w
t itham
all
etandremovet
hem
.

(
10)Removeth
e“O r
円四i
ngfromth
em atin
gsu
rfa
ceoft
hec
ent
erp
lat
e③. I
tisu
nne
ces
sar
ytoremove
tedowel⑬ fromt
h h
ecent
erpla
te.

(
11)P
ullt
hes
pli
nec
oup
lig⑬ o
n utfromt
hes
uct
ionp
orto
fth
ece
nte
rpl
ate③.

(
12)D
isa
sse
mbl
eth
efr
ontpumpi
nth
esamep
roc
edu
rea
sfo
rth
eit
ems(
5)t
o(9
)ab
ove
.

(
13)Removethe“0"ィmg⑬ヲsn
apnng⑪ ando
ils
eal⑬ fromt
hemountingf
lan
ge①. I
tisu
nne
ces
sar
y
toremoveth
edowel⑭.

-107-
. HYDRAUL
6 lC SYSTEM

(14)Taptheoilse
alw ithaflat-
blad
edscre
wdri
verto
SCREWDRIVER
l
etitcor
neou t
. Rernoveth
es na
prin
g⑪. Att h
is
/
t
irn
e，usecau
tionnottodarnaget
heb
earingh
oleor
th
eoilsea
lpress
-fitt
ingho
le.

F
ig.
6.8

6.2.2 INSPECTIONANDREPAIR
Checkdisas
ser
nbl
edpart
sont hec
ontar
ninati
onordis
colo
rat
ionandth
enwashthe
rnwit
hk e
rose
ne.
However ，donotir
nrn
erserub
berpar
tsink e
rose
ne.
P roce
edw itht
heinsp
ectio
nont hefollo
wingpoin
ts，andrep
airorr
epla
cepar
tsifa
bnorr
nali
tyis
foundatthe
rn.

(1) Gearp lates②，④

Theg e
arp l
atesares odesi
gnedt h
atthegearsrot
ate
rnonthlywhi1et hegearteet
ha relight
lytouchingthe
11v
問
ハ
gearp latet o obtainagoodr otationeffici
ency.
Accordinglyt
ラ h
eg earplat
es，onceused，surel
yg e
tfine
scrapingtra
cesaroundt hein
letport
.
Then o
rrnallengthofscrapingtra
ceislessthan1/2
oftheinnerperipheryofth
eg e
arh o
le，andnoロnaldepth
Contactbearing
(a
“ "inF i
g.6.9)isl es
st h
an0 .
05r n
rn[ 0.0
0197in]
.I f
thed e
pth“ a"ex cee
d s0.15rn
rn[ 0.00
591i n
]t
ラ hegear
shafto rt he bearing is considered to be worn Fi
g.6
.9S
cra pingT raceIn
sid
eGearP
lat
e
s
ign
ifi
cant
1. Check，
y the
refor
eals
ot
ラ h
esepa
rtsc
are
full
yatal
lti
rne
s.
→Ifth
edepth“a"i
sfoun
dtobeov
er0.15r
nrn[
0.00
591in
]repl
aceth
eg
ラe
ara
sse
rnb
lyw
ithanewo
ne.

(2
) Driveg ears⑥，③ andd riveng ears⑦，⑨
:
Unitm m[
in
.]
Asl ongasclearhydrau
licoilisu sed，thegearsha
f t
andgearf l
ankwi 1
1getleastdarnage，a s
suringsrno
ot h 1
2.1 12.1

gearc
ontact
.I fther
ef ac
esarer o
u ghedenought ohit
c h
onanail，th
er o
otoftoothiscrackedort h
et oo
thsurf
ac e
i
swornu
→Ift
n
h
eve
nly，r
egears
e
h
p
a
l
f
a
cet
tdia
h
eg
rne
t
e
e
arwit
r“d"i
hnewo
nF ig
ne
.
.6.10i s
土
二コ
dir
nin
is h
edtolessthan31
.627r n
rnd i
a.[ .2452i
1 n
.d i
a.]，
rep
lacethegearw it
hnewo ne
.
F
ig.6
.10L
irn
itofS
haf
tDi
rne
nsi
ons

-1
08-
 6
. HYDRAUL
lC SYSTEM

(
3) Pressureplate⑮
Asshowni nF ig
.6 .11thenormalp re
ssur
ep l
ate S
uctio
n
O si
de
ap
pearslustrou
satt h
ec opperallo
yside.
Ifthefollowingabnormal
itiesthefoundwhent he
p
ressur
ep la
teisdisassembldr
eラ eplac
eitwithnewone.
→ Manys c
rapingtrac
eshitchi
ngonan aila
refound
a
tthec opperallo
ys ur
face，appe
aringcoars
e.
→ Thet hic
knessoftheplatediminis
hedtoles
sthan
6.
656m m[ 0.
2621in.
].
F
ig.6
.11 S
poto
fPr
ess
ureP
lat
eSu
bje
ctt
oWe
ar
(
4) Mountingf l
ange①
，c over⑤ andc ent
erplat
e③
Asf o
rt he
sep ar
ts，checkthedegreeofunevenwear
oft
heb ea
rings.
Sinc
et h
etef10nlaye
rh avin
gabluishgrayapp
earan
c e Suction
side
i
ssofth
ラ andleitwithcarenottogivedamage.
→I fthetef10nlayeriswornt osuchane xt
entthat
t
h
i
ebrownc
nt h
ed ire
c
o
t
l
i
o
o
re
nt
dg
ot
r
h
ou
eb
ndi
e
a
se
r
in
xp
gp
o
e
s
e
ri
df
ph
o
e
rmoret
r
ラyrepl
a
h
c
an1500
ethem S
l
b
i
e
d
a
r
e
ing
O
Discharge
w
ithnewo ne
s. side

F
ig.
6.1
2 S
pot
sofBearingS
ubj
ectt
oWear
(
5) Besur
etorepl
acete“0"nng⑬
h ラpl
ates
町eal⑪
， backupp
lat
e⑫ ando
ils
eal⑬ withnewo
nes
whendis
ass
emble
d.

6
.2.3 REASS正MBしYOFGEARPUMP(
Fore
nci
rcenumbers，
l ref
ert
oFi
g.6
.2)
(
1) Cleana
lld
isa
sse
mbl
edp
art
s.

(
2)D
ire
ctt
hes
pig
otb
ossoft
hemountingf
1ange① downwardsandholdt
hec
ast
ingp
arti
nav
ise
.

(
3) Makes
uret
hatt
hetwodowelp
ins⑪ a
red
ulyi
nse
rte
d.I
fno
t，i
nse
rtt
hem
.

(
4)Se
tthe“O"-
ring⑬ i
ntothegr
ooveofthemountingf
1an
ge.
Atth
isti
me，besu
retofi
tthefou
rsmal
lt i
psprovide
dinsi
det
he“
O九 r
ings
ure
lyi
ntot
heg
roo
ve.

(
5) Mountth
egea
rplat
e② overt
hemountingf
1ange① w
hilepo
sit
ion
ingt
hep
lat
ewithus
eofth
etwo
dowelp
ins⑬. I
fthedowelp
insarehardt
oi n
ser
ttaptheml
ラ i
ght
lywi
thawoodenhammer
.

-1
09-
6
. HYDRAUL
lC SYSTEM

(
6)I
nse
rtt
hei
sol
ati
onp
lat
e⑬ t
oth
efa
rendo
fth
ege
arp
lat
e.

(
7)I
nse
rtt
hep
lat
ese
al⑪ andt
hebackupp
lat
e⑫ i
nco
mbi
nat
iondeepi
ntot
heg
earp
lat
e.

(
8)I
nse
r tthepress
ureplae⑮
t ラ withit
sc op
perallo
yf ac
eb ein
gd i
rect
edupwards， deepint
ot h
eg e
ar
p
late，payingatte
ntio
nt othedi
recti
onofpressu
rep la
tesuctionsi
deandd ischarg
es i
de.I ft
he
p
ressureplat
eisslante
dandh ardtomove，gras
pt hedriv
es h
aftendoft h
ef r
ontd r
ivegear⑥ to
i
nse
rtiti n
tothegearpla
te，andpre
ssitlig
htl
yatitshighe
stparttofac
ili
tat
ei n
s e
rtio
nw or
k.

。) Insertthefrontdrivegear⑥ anddrivengear⑦.
A
fte
rth
ein
ser
tio
nap
plya
bou
t5c
ラ cofh
ydr
aul
ico
ilt
oth
ege
arg
roo
ves
.

10
( )I
nse
rtthep
ress
ureplat
e⑬，withit
scopp
era l
loyfac
ebeingdi
rect
eddownward，i
ntot
heg
ear
p
lat
e，p
ayinga
tten
tio
ntoth
edire
cti
onofsuc
tionsi
deandd
isch
argesid
e.

(
11)I
nse
rtt
hei
sol
ati
onp
lat
e⑬，p
lat
ese
al⑬ andbackupp
lat
e⑫.

12)Makes
( ur
ethatth
eis
ola
tio
npl
ate⑬
，pl
ates
eal⑪ andbackupp
lat
e⑫ a
ren
otd
isp
lac
edfromt
he
c
orre
c 1o
tposI
t ns
.

(
13)Makes
uret
hatt
hef
ourdowelp
ins⑬ a
red
ulyi
nse
rte
dinc
ent
erp
lat
e③. I
fnt，
o i
nse
rtt
hem
.

14
( )
Fitthe“O
"-ri
ng⑬ i n
tot
heg
roo
veoft
hec
ent
erp
lat
e.I
nse
rtt
he“0"-
rin
gast
ofi
tit
ssm
all
lip
s
su
rel
yinthegro
ove
.

15
( )
Putapropofabout1 0m m[0.039in.
]ont heupperfaceo fthegearplat
e②， andp r
essthecenter
p
lat ，w
e③ it
hi t
sdi s
char
ges i
def a
cingdownwards，g entlyovert h
eg ea
rp l
ate
. Atthistime，put
yourfinge
ri n
totheb e
ari
ngh ol
e，throughwhichthereardriveg e
aroft h
ec e
nterp
lateissup
p os
ed
tobei n
serte
d，tofitthesp
linecoupling⑬ intoth
es pli
neoft hefrontdriv
eg e
ar⑥. Removet h
e
s
uppor
tandpushi nthecen
terplat
e.I fthecent
erp l
atec ann
o tbepushedi ncom
pletelywithit
s
rearendproject
edmoret hanabout3m m[ 0
.12in]，i
tiss usp
ec t
edt h
atitems⑪ラ⑫ o r⑬ hasn o
t
beenproperぢi ns
tall
ed.Star
tr ea
ssemblyagainfroms tep(12)
.

回 1
10-
 6
. HYDRAUL
lC SYSTEM

16
( )Reassemblet herea
rpumpi nthesamep r
ocedure
asforthefrontpump. Geart
oot
hoff
ron
tpump

Fitthereardrivegear③ in
tothesplin
ec ou
pling Geart
oot
hofr
earpump
⑬s ot h
att h
et ee
thofreardr
ivegearandthoseof
企ontdrivegear⑥ arear
rang
edalte
matelya
sshown
inFig
.6 .13
.

F
ig.
6.1
3

(
17)Whent h
erearpumph a
sbeenr e
ass
emb
led，se
curei
tbythestu
dbo
ltss
crewingt
hei
rs h
ort
ersh
ank
s
witht
ighte
ningt
orqueof29.4-49N-m{3.
0-5 .
0kgf-m}[21
.7-36
.2lbι
ft]
. Wetthethr
eado
fth
e
bo
ltsbys p
rayofan
tir u
s
欄toi.
1

18
( )Se
tt h
ewasherandthenuttothelongershankof
t
hes t
udbo
ltandtigh
tenittoth
etorqueof1 3
2.4-
137
.3N-m{ 13.
5 1削4.0kgf-m}[9
7.7-1 01
.3l b
ι Pumpi
nsi
de

f
t]
. (Wett
hethrea
dwithanti
-ru
sto
il)

19
( )Then，unclampthepumpfromt hevic
ラe andfitthe
oi
ls e
al⑮ ands naprin
g⑪. Applyl ith
i umgrease SEALL
lP

spari
nglytoth
elipoftheoilseal⑬. Whenp re
ss-
fi
ttin
gtheoilse
alu
ラ secarenottodamaget heseal GEARSHAFT
li
pasw e
llasnottosl
anti.F
t ormountingd i
r e
ctio，
n
ple
aserefe
rtoFig.6.1
4. Top ro
tecttheoils ea
llip
fromdamage，itiswisewayt owrapupt hedrive Fig.
6.14
gearsha
ftendwithseali
ngtape.I nth
isc ase，neverfa
ilt
oremovet h
et a
pea f
ter
war
ds.
I
tisrecommendedt ou seajigasshowni nF ig
.6 .1
5 whicha
ラ s
sur
est h
ec or
rec
toilse
alp
res
s-
fi
ttin
gwork.

(
20)Tumt hedr
ivegearsha
ftendwit
hat o
o.1 Wheniti
stumedeas
ilybyhand，nof
orei
gnm
att
ersnor
sea
lsmaybei nv
olve
d.( I
fthe
yareinvol
vedtラh
esha
ftendwi
llnotbetumedbyhan
d.Inth
isca
se ラ

resumeth
ed i
sassembl
yandre-ass
emb
ly.)

Thepumpr eas
semblyi
scompletedwitht
hest
epabo
ve. However，checkth
epumptoseei
fth
e
assemblyandt
herot
ati
ngdi
rec
tionofthepumpa
reno
twrongb ef
oremountingi
ttot
het
ruc
k.

-1
11 蜘
. HYDRAUL
6 lCSYSTEM

Checkth
ef ollo
wingp
oin
tswhenmountingth
emainpumpun
ittot
hetruck
.
(
1) Checkwhetherorno
tther
eisanyd
efectint
hesp
igo
tbos
swhichbecomesth
ere
fer
enc
epo
intf
or
cent
enng.

(
2) Checkwhethero
rno
tth
erea
reanydamageo
rdu
stsont
hef
itt
ingf
aceofthemountingf
lan
ge.

(
3) Checkwhethero
rno
tth
erei
sanydamageo
rdu
stsont
hef
lan
gedp
art
softhep
ipe
s.

B
esides，payatten
tiont
ot hefoll
owingpointsforr ea
s s
embly:
(
1) Thepositi
onandt h
edir
ectio
no fth
er ea
ssemble dgearpla
tes④ラ②， driv
engea
rs⑦，⑨ andpre
ssu
re
pla
te⑩ s hou
ldbesomea sthoseb e
fored is
as sem
bly.P arti
cul
arly，a
sforthedr
ivenge
ar
ラsthe
engagementwiththedri
veg ea
rb efo
red is
a s
se mblyshouldbeassu
red.
(ti
I srecommendeda tthet
ラ imeofdisassembly，tomakematchmarksa tth
eshaf
tendsoft
hedri
ve
gearanddrivengearusingoi
ls
ラ to
ne，etc
.)

(
2) Whenrep
laci
nganyoneo
fthemountingflane①
g ラcen
terp
lat
e③ andco
ver⑤，b esu
retor
epl
ac e
al
sot
hedriv
eg e
ar⑥，③ anddriv
eng ea
rs⑦，⑨ w i
thnewone
.Ifsuchrep
lace
mentisn
egl
ectedラ
th
espe
cif
ieddisch
arg
emaynotbeattain
ed.

6.2. 4 TE5TRUN
Testrunistobeconductedforbrea
欄kino perat
ionofthepumpa swel
la stocheckwhetherth
e
reas semb
ledpumpe xer
tsthesp
ecifi
edperformanceorno
t.
Theb estwaytoconductthetes
tr uni
stodoi tont h
ee xcl
usi
vetes
tstan
d. However i
ヲ tmaybe
eonductedi n“on-th
emachine"s
同 t
ate
. The“on-the-machine"te
strunshouldbeconductedinth
e
foll o
wingorde
r.
I fthepumpisfounds e
ize
dbyh e
atorabnormallyworninsid
e，cha
ngethehyd
rau
licoi
landr ep
lac
e
thef i
lt
er.
()I
1 nsta
llapress
uregaugeatthePportofthecontro
lvalv
e..

(
2) Runthee
ngineat500-1000rpmwithth
eco
ntr
olva
lvesetatth
eneu
tra
lpos
iti
on.Makesu
reth
e
pr
ess
uregaugereadsapr
essu
reofO.98MPa{10kgf/cm} [
2
1
42ps
i].Ope
ratethepumpfor1
0
mi
n.inth
iscond
itio
n.

(
3)A
cce
lerat
ether
eaf
terth
ero
tat
ings
peedupto1500-2000rpma
ndo
per
atet
hepumpw
ith
outl
oad
f
oradd
iti
ona
l1 0min.i
nth
esamecon
ditio
nasin(2
).

(
4)Opera
tet hepumpa tthesamerpmw hil
einc
reasingt
hepres
sureby2-3MPa{ 20-30kgf/cm2}
[285-427p si
]s tep-
wisefore v
ery5m in.un
tilitrea
chesthemaximumworkingpres
sure
. To
inc
reasethepre
ssurestep
-wise，cont
roli
tbyrelie
fval
veorapplyanapp
ropri
atel
oadtoth
epump.
The
reaftero
ラperat
ee achcir
cuitforabout5mi
n. andr
ラ epl
acetheret
urnfi
lt
erele
mentwithanew
oneorc l
eanit
.

-1
12 剖
 6
. HYDRAUL
lC SYSTEM

Checkt
heo
iltemperature pumps
ラ urf
acetemperatureando
per
ati
ngn
ois
ewhilei
ncr
eas
ingt
heo
il
p
res
sur
e.
I
fth
eoi
ltemperatureont
hepumps
urf
acetemperaturer
ise ，
sabnormallyunloadt
hepumpt
olower
t
hetemperaturet
onormals
tat
e andproceedwitht
ラ heo
per
ati
on.

(
5) Whent
het
estruni
sover r
es
ラe
tth
ere
lie
fvalvet
oth
eor
igi
nals
tat
e.

(
6) Thedischarget
estshouldbeconductedunderbothloadedandno-loadc
ond
iti
ons
.
Makes
uret
hel
if
tandt
il
tspeedsa
renormal
.

6
.2.
5 TROUBL正SHOOTINGGUIDE
Trouble Cause Remedy
O
ilwi
llnotcome Lowo
ill
eve
lino
ilt
ank Addoi
ltot
hespe
cif
iedo
ill
eve
lun
der
o
utofge
arpump sp
eci
fie
dco
ndi
tio
n.

Cloggeds
uct
ionp
ipi
ngo
roi
lst
rai
ner l
mme
di a
telyc
lea
ni.I
t fo
ili
sco
nta
min
atd，
e
c
hangeit
.

Gearpump • Ex
cessi
vel
ywornpr
essu
rep l
ate⑮ R
epl
acei
t(t
hem
)wi
thnewo
ne(
s).
pres
sur
ewi
lln
ot • E
xcessi
vel
ywornbe
aring
s( p
ress
-fi
tte
d
nse m ①ラ③ and⑤)
• D
efec
tivep
lat
ese
al⑪ o
rb ac
kupp加 e⑫

Maladjustmentofr
eli
efv
alv
e Usepres
sur
egaugea
ndi
ncr
eas
epr
ess
uret
o
spe
cif
iedle
vel
.

A
irs
uck
edi
npr
ess
ures
yst
em Ret
ightensuct
ionp i
pe.
Addo i
lintotan
k.
Checkpumpo ilsea.
l
Ref
rainfromo pe
rationun
tila
irh
asb
een
purge
do utoftan
k.

Gearpump C
avi
tati
onocc
urri
ngduet
oco
llap
sed S
tra
igh
tenh
oseo
rcl
eans
tra
iner
.
prod
ucesn
ois
e s
uct
ion
-sid
ehoseorc
logg
eds
tra
iner

A
irs
uck
edfroml
oos
esu
cti
onp
ipej
oin
t R
eti
ght
enj
oint
.

C
avit
ationo
ccu
rri
ngduet
oto
ohi
gho
il Changeo
ilwi
thoi
lhavi
ngade
q u
atevi
sco
sit
y.
V
1SC
OSlt
y Oper
atepumpata
ppr
opri
ateo
iltem
per
atur
e.

Improperc
ent
eri
ngo
fpumpa
nde
ngi
ne R
e-c
ent
eri
ng

A
irb
ubb
lesi
n Lookupc
aus
ean
dremovei
t
.

Oil
lea
ksfrom • D
efe
cti
vepumpo i
lse
al
. R
epl
acei
twi
thnewo
ne.
pump • D
efe
cti
ve“O九 nng⑬ hy
dra
uli
coi
l

• Poorpumpp
erf
orm
anc
e R
e-c
hec
kpump.

開 1
13-
 α・工︿O刃﹀C﹁
一

Givel
arg
eroundness

⋮
山
のω︿
ω

一
村一
↓m三

主LEEV

一
Afte
rthecapandoi
lsealarese
t.
presso
ilse
alherebysleeve
¥0 Presso
ilsea
lbymeasureso
f
、
司
handpres
s.

80
巳
企E
85 Coverth
ecapi
npu
tsh
aft
110 wit
hi.
t

'回目
OILSEAL
Setth
eoilsea
lt othecapas
MOUNTING

hHS
明山間・。・]{一明
125 showninth
ef ig
ure FLANGE
:
t0.1
17.2

OILSEAL
PRESS-
PUMPINPUTSHAFT FITTING
HOLE

、
'
l
，
:

由
O
O

'
l
，
;'
O 。
CコZ・

/
3 3ココ
 STEERINGCYL
lNDER

TILTCYL
lNDER
CONT只OLVALVE
92 I一一ーーーアー一一 寸
;

L
lFTCYL
lNDER

明仲間・。・]向。
CHECKVALVE

出 uk
し
去一一
一一 一ーーー一一」
P

s- 山 一 山 '
FLOWCONTROL
VALVE

)
￨
(
1 CHECKVALVE

凶お己目。(︺円。ロル片口百加55
PUMP

RETURNFILTER

SUCTIONFILTER
。 工 ︿ む 刃 ﹀C亡のω︿
↓
mz ω
 1
gDiagram(1)
2
>JO区トZ00
出﹀﹂︿

p
iin

“
6
(ト比凶﹂)区凶Q Z一﹂﹀O ト﹂一ト

cP

1
1
uli

副
a
一Zコ凶﹀一go
↑

i
Fg6
..7H
1 d
yr
仏哀コ nL
lC SYSTEM

区凶ト﹂一比 ZKコト凶広
(ト工の一区)区ωozコ﹀O ト﹂一↑
. HYDRAUL
6
 . HYDRAUL
6 lC SYSTEM

α凶0 2コ ﹀OOZ一区出凶トω
ハ比三コ仏

ト
一Z
コω﹀一広口

J
o
α
ト一∞
ω﹀﹂︿﹀﹀ト一区OEaEOJL

αo

F
ig.
6.8H
1 y
dra
uli
cPi
pin
gDi
agr
arn(
2/2
)

-1
17-
6
. HYDRAUL
lC SYSTEM

NOTE

-1
18ω
 . LOADHANDL
7 lNGSYSTEM

7
. LOADHANDLINGSYSTEM

FD160-2 FD180-2 FD200-2 FD230-2

Type R
oll
ingty
pe，]-s
hape
doute
rchan
nel，
J
-sh
apedi
nne
rchann
el，twost
agete
les
copi
cmast

Stand
ardmax .li
ft
ingh eigh
t 3000mm[ 118
.1in.
]
Forklifti
ngsystem 討ydr
auli
c
Mastt i
lti
ngsystem Hy
draul
ic
L
凶i
凶
汗f
泊t伽
c
lh
叩a
a
i
訂
州i
加n Leaf伽 Leafch
ainBL-1646 Leafc
hai
nBL-2044
Mastchannel∞
conf
五i
gu
別 lr
a
ぽ
汀悶副ti
on
1:
工
広

Crosssectio
nofo uter
chan
nel

C
-In
0&ρ3
9 1
ABC

mmm
m叶 m

n ーペJn
ri
ウん戸、 U 1 1
勺h A V Q U
﹀

-
- LFIL

A:
250m m[
9.8i
n.
]
p

モ
一一
恥司

・ 9
IAU

--

モ
一一 モ
ーー

モ
一一 ぐ
一一

C
rosss
ect
ionofi
nne
r
c
han
nel

A :225m m[8
.9in
.] モ
一一 A:
250mm[
9.8i
n.
]
B :50mm[ 2
.0in
.] ぐ
一一 ぐ
一一

C :100m m[3
.9in
.] ‘
一一 モー

D: 45mm[ 1
.8in
.] モ
一一 D :50mm[
2.0i
n.
]

-1
19-
7
. LOADHANDLJNGSYSTEM

7
.1 GENERAlDESCRIPTION
Theloadhan
dlingsys
ternu
sesatwo-st
age，r
oll
ert
ypet
ele
sco
picr
nas
tas
ser
nbl
yco
nsi
sti
ngofan
o
uterrn
ast，anin
nerrn
astandacar
ria
ge.

7.
1.1 OUTER& INNERMAST
Theouterandi n
nerrnas
tsareofweldedc o
nstru
ction
. Theb ot
tornoftheoute
rrna
stispro
vided
wit
has uppo
rtbywhicht herna
stas
sernbl
yisi n
stal
ledonthedriveax
le.
Thernid
dleoftheou
terrnas
tissu
pportedonthefrar
nethroug
ht h
eti
ltcyl
ind
ers.Therna
sta
ssernb
ly
i
stilt
edforwardandbackwardbyopera
tionoft h
etil
tcylin
der
s.
Theouterrnas
tchannelhasa]-sha
peds e
ctionandisprovidedwit
hendr ol
ler
sands i
der
olle
rsat
t
heirupp
erp a
rts.
Theinnerrnas
tchannelhasaJ-sha
peds e
ctionandisprovidedwithendrol
ler
sands i
der
olle
rsat
t
heirlow
erp a
rts.

. OUTERMAST
1
2
. COVER
3
. BRACKET
4
. INNERMAST
5
. ENDROLLER
6
. SNAPRING
7
. ENDROLLER
8
. SNAPRING
9
. PIN
10
. SHAFT
11
. SPACER
12
. SUPPORT
13
. SIDEROLLER
14
. SHIM
15
. OILSEAL
16
. BUSHING
17
. SLlPPER
18
. SHIM
19
. PIN
20
. STOPPER
21
. WASHER
22
. BEARING
23
. SHEAVE
24
. CHAIN
25
. PACKING
26
. BUSHING
27
. CAP

F
ig.
7.1 O
ute
randI
nne
rMasts

-120国
 7
. LOADHANDL
lNGSYSTEM

7.1.2 CARRIAGE
Thecar
riagehasendroll
erst
hatro
llalongth
ei ns
ideoftheinne
rmastchan
nes，eachi
l ns
tal
ledon
theendrol
lersha
ftthroug
hab ea
ringwit
has na
pr i
ng. Theendro
lle
rsha
ftsa
reweldedtot
hecarr
iage
.
Thes id
erolle
rsthatro
llalongontheinsi
decoll
aro feachinn
ermastchan
nelarebol
tfitt
e
ヲdb ei
ng
shima d
jus
ted.
Fig.7.2

. FORK
1
2. SCREW
3
. FORKSHAFT
4. STOPPER
5. CARRIAGE
6. ENDROLLER
7. SNAPRING
8
. SUPPORT
9. SIDEROLLER
1
0. BUSHING
1
1. SHAFT
1
2. SPACER

亡?
%
長
〈 1
3
1
4
1
5
. OILSEAL
. SHIM
. HANDLE

F
ron
t

F
ig.7
.2C
arr
iag
e

国 1
21-
. LOADHANDL
7 lNGSYSTEM

7
.2 MAINTENANCE
7.
2.1 SHIMADJUSTINGし1FTCYL lNDERROD
Whenevertheli白 cy
linderi n
n
ラero route
rmastis INNERMASTCHANNEL
r
eplacedwithanewone，a djus
tt helengt
hoftheli
ft
c
ylind
err o
dinthefollowi
ngprocedur
e:
(
1)I ns
tallthepistonheadont herodofeachl i
ft
SHIM
cyli
nderwit
houtusinganyshim.

(
2) Slowlyextendtheli
ftc
yli
nderro
dsandcheckth
e L
lFTCYL
lNDER

dif
ferenc
eoft h
et im
eti
lleac
hoftheri
ghtandl
ef
t
cyl
inderrod
sr eac
hesthest
rokee
nd.

(
3) Addshimsbetweent
hep
isto
nheadandr
odwhich
sto
ppe
dfirs
t. F
ig.
7.3
Shimth
ickne
ss:1m m[0.
039in
.]

(
4)R
epeatth
es t
eps(2
)and(3
)unt
ilther
igh
tandl
ef
t CHAIN

c
yli
nderrod
ss t
opatt
hesametim
e.

(
5) Lowert h
ef o
rksont hegroundorflo
orsurf
aceand
ANCHORPIN
t
iltthemasttothefull-b
ackti
ltpo
siti
on.
Adju
s tth
et e
nsionbetweentheri
ghtandle
ftcha
ins
tothesamev al
ueusingt h
ec h
ainanchorpi
natthe ADJUSTMENT
NUT
mastside
.
LOCKNUT

Fig.7.
4

7
.2.
2ADJUSTINGCARRIAGEHEIGHT
(
1)Parkthetruckonlev
elsur
faceandti
ltthemastback
t
othefull
.
(
2)Adjustt h
ep ro
ject
ionofthecarriageslowerend
ラ OUTER
MAST
r
oll
ertot hevalu
eshowni nT abl
e7 .1，usingthe
c
hainanchorpinatthemastsid
e.
Table7.
1
T
ruc
kmo
del Dimens
ion[A
J
mm[
in
.]土 5mm[ 0.
197i
n.
]
FD1
60-2 7
3[2.9
]
FD1802
拘 10[0.
39]
END
FD2
00-2 40[.5
1 7] ROLLER
FD2
30-2 80[3.
15]
F
ig.
7.5

劇 122-
 7
. LOADHANDL
lNGSYSTEM

7.
2.3 REMOVINGCARRIAGE
(
1)P utal o
adofa bout1t onont h
epalle
tandi ns
ertthe
for
ksi n
tot h
ep all
et(Fig.7.6
).
(
2) Movet oal evelsurfac
eandl owe
rt h
ef or
ksont he
groun
d.
(
3) Removet helif
tc hai
nsi nthefollowi
ngp ro
cedur
e:
① L i
ftthelif
tc ha
i nbyana reanearthesheaveusmg
ラ

awire( Ri
ghto fFig.7.7)
.
② Removet hecotterpinoft hechainanchorpinand
thenremovet helocknu tanda d
justmentnut(Left
ofFig
.7 .7
).
③ Lowert hec h
aing rad
uallytoremovet h
ec hai
nfrom F
ig.
7.6
th
es hea
ve.

(
4)Extendthel
if
tcyl
ind
errodandra
isethein
nermast
un
tiltheuppe
rendrol
ler
softhecarr
iagelea
vethe
mnerm a
st.

(
5)D
riv
ebackt
ose
par
atet
hec
arr
iag
efromt
hemast
.
J

F
ig.7
.7

7
.2.4 REINSTALL
lNGCARRIAGE
(
1) Makesur
ethei
nne
rmasti
sth
esamep
osi
tio
naswhent
hec
arr
iag
ewasremoved.

(
2)B
ringt
het
ruc
knea
rthecar
ria
geands
topt
het
ruc
ksot
hate
achendr
oll
ero
fth
eca
rri
agei
sal
ign
ed
w
ithth
ece
nte
rofeacho
utermas
t.

(
3) Lowert
heinn
ermastgr
adu
all
yanda
dju
stt
hec
arr
iag
eandt
ruc
kpo
sit
ions
oth
att
her
oll
ersa
re
se
ttl
edi
nth
ei nn
erma
st.

(
4)R
ein
sta
llt
hel
if
tch
aini
nas
equ
enc
eop
pos
itet
odi
sas
sem
bly
.

(
5)A
dju
stt
hel
if
tch
aint
ens
ion
.

-1
23-
. LOADHANDL
7 lNGSYSTEM

7.2.
5 REPLACINGSIDEANDENDROLLERSOFTHEMAST
(1)Par kthetruckonal eve
ls urfaceandl owerthef o
rks
ont heg round.
(2
) Applyt heparki ngbラraket il
tthemastbackt othe
fullands huto ffthee ngine.
(3
) Blockf rontandr earwhe elsasshowni nFig.7 .8
.
() Remove t
4 hel iftc yli ndersi nt he following
pro c
edure:
① Removet heh igh -pressurep ipingfromt hel i
ft
cylinde
r.
② Removet heboltss ecur i
ngt heli白 cylinderinits F
ig.
7.8
low erpar
t.
③ Removet her odc onnectingp i
nfromt h
eu pperpart
oft heinnermastc hann el
.
④ T ieeachl iftcylin dertot hemastw ithr opes( F
ig.
7.9).
⑤ L ifttheinnermastc han
n elwithac raneands ep
arate
ther odfromt hei nnermastchannel .
⑥ U ntiet her opeofones i d
eu sedi nstep④，l if
tt he
li
ftcylinderwithac ranea ndremovefromt hemast.
Unt ietheropeoft heo t
hers ideandl i白 thel i
ft
cylinderwithac raneandremovei tfromt hemast . F
ig.
7.9
(
5) Removet heb oltss ecuringt heinnerc hanneland
bracket，andl owe rthei nnermastc hanneluntilthe
siderolle
rscomeo utoft hechannel.
(
6) Replacet helowers ider ol
lersoft hei nnermast
channeli nthef ollowingm anner:
① Removet hesupp ortmountingb oltsandremovet he
sideroll
era ss
emb ly.Putt heremoveds h
imsi norder
forreuse.
② Removet h
eg re asef i
tt i
ng-sid
es upportfromt he
sha
ft.Removet h esidero l
lersalongwi t
ht h
es pacer
ando i
ls eal
.
③ Withanewo i
ls e
ラali nst
a l
lanews i
der o
lleront he
shafta
ラ longw itht hespa c
erands upport
.
④ Witht heshimswhichwereremovedi ns te
p① ，
ins
tallthes id
er olleras semblyandf i
llg r
ease.
(
7) Removet hes napr ingsfromt helowerendr o
llers
。fthei n
nermastc hannela ndremovet heendr oll
ers
usingap ull
er.
F
ig.
7.1
0
(
8)I n
stallnewendr olle
rsands ecurewiths naprings.

ー 1
24-
 7
. LOADHANDL
lNGSYSTEM

(
9) Replacet heuppersiderol
lersoftheoutermastchan
nelinthefo
llo
w i
ngmanne
r:
N
ote:Replacementworks h
ouldbeperformedt hrought
heopeningi
nthebra
cke
t.
① Removet hesup
portmountingbolt
sandremovet he
siderol
lerassem
bly.Puttheremoveds him
si nord
er
forreuse
.
② Removet heelbow-
sides up
portfromthes h
aftand
thenremovet h
es id
er o
lleralongwiththes pa
cer
ando i
ls eal
.
③ Withanewo ilsel，i
a nst
allanews idero
lleronthe
shata
ラ longwiththespacerands u
pport
.
④ I nsta
llt hesideroll
erassemblyu singt heshims
whichwereremovedi ns te
p①.

10
( )Removeth
es n
aprin
gfromt h
es h
aftandremove
th
eendro
lle
rusin
gap u
lle
r.
(
11)In
sta
llanewendrol
lerandsecu
rewiththesnap
nng.
12
( )Lif
tt hei n
nermasts othatther ol
lersares e
ttle
d
ins
idethei nnermastc h
an n
el， u
singc aut
ionnotto
los
et heslip
pers.
13
( )Lif
tt hei nnermastf urtheruntilitc on
tactst h
e
brac
ket.S ecuretheb ra
ck e
ti nsid
et heinnermast Fi
g.7.11
channel
.
14
( )Li
ftt h
ei nnermast500m m[ 19.7in.
]andi nsta
lltheli
ftcyl
indersint
hef o
llowingmanner:
① P uttheright-s
idelif
tc y
linderont heoutermasts up
portandsecureth
el owerpar
tofthec y
lind
er
withab o
lt.
② T ietheup perpartofthec yl
indertotheo ut
ermastw itharope
.
③ I n
stal
lt heleft
-sideli
ftcylinde
ri nthesamemanne r
.
④ Lowert heinnermastg r
aduallyandi n
stal
lther o
dtot h
einnermastcha
nnelwh i
leadjus
tingthe1
泊
cyli
nderposition
.
⑤ Connectt h
er odandi nnermastc hannelwithpins
.
⑥ I n
stal
lt hehighp
欄 res
surep ipi
ngandu ntietheropes
.

-1
25-
. LOADHANDL
7 lNGSYSTEM

7.2
.6 REPALCING51DEANDENDROLLER5OFCARRIAGE
(
1) Removet hecarriag
efromt hemast，ref
errin
gt o“7.2.3REMOVINGCARRIAGE".
(
2) Removet hesnapr in
gsfromt hesh
aftandt henremovet heendroll
ersusi
ngapul
ler
.
(
3)I n
stal
lnewendr oll
ersands e
curewiththesnapr in
gs.
(
4)R eplacethesideroll
ersinthefollo
wingmanne r
:
① Removet hesupportmountingbol
tandremovet hesiderol
lerass
embly.Putt
heremoveds hi
msin
orde
rf o
rr e
use.
② Removet hegreasefitti
ng-
sidesup
portfromt heshaftandt he
nremovet h
esider
oll
era l
ongw i
th
th
es pace
rando ilseal
.
③ Withanewo i
ls e
al，ins
tal
lanews i
deroll
eront hes h
aft，alongwit
ht h
espac
erandsupport
.
④ I n
sta
llthes i
derolle
rassemblyu s
ingthes himswhichwereremovedi nst
ep①.Fil
lg r
ease.
⑤ I n
sta
llthec a
rriageont h
emast，refer
ringto“7.2.4REINSTALLINGCARRIAGE."

ム J

久4
竹 1
に?F
ron
t
v 句
つ

F
ig.
7.1
2

-1
26ω
 . LOADHANDL
7 lNGSYSTEM

7
.2.7 INSP主CTINGL lFTCHAINS
(
1) Checkforl u
bricat
ionvis
ual
ly.
Ifth
el i
ftchainsurfa
ceiscontam
inat
edwithwear
dus
to rlooksredord ar
kbrown，itsu
gges
tstha
tit
i
sp oorlylubric
ated.Lubri
catetheli
ftcha
insat
per
iodi nt
erv
als( e
very200hour
s).

(
2) Whent ryi
ngtolub
rica
tetheli
ftchai
nlラoos
eni
tand P
oin
tst
obel
ubr
ica
ted
applygenu
ineTCMo il(ChainCoatM SuperM
ult
i)
orlubri
cati
ngoi
le qu
ival
entt oSAE30.
Afterappli
cati
onl
ラ i
fttheforkstot h
emaximum F
ig.
7.1
3
heig
h tafewtimestopermeateoilthrou
ghallt
he
pms.

N
o

(
3
te
:Don
otu
seg

) Checkt
r

h
ea
s

el
ef

i
o

n
rt

kp
h

l
i

a
t
sp

e
ur

sf
p
o

o
s

rc
e
.

rack
sandifanyoneof
位E
Areaswherecracks
tendtodevelop
th
el i
nkpla
tesofthec
hainshowsc
racks，r
epl
ace
Cracksi
nli
nkp
lat
e
th
echain
.

(
4) Checktheli
nkpl
ate
sforwearandi
fanyoneoft
he F
ig.
7.1
4
li
nkpla
tesi
sworn5p e
rcen
tinwidt
hfromtha
tofa
newlinkpl
ate，
repl
aceth
ec h
ain
.

DimensionB U
nit
:m m[
in
.]
B
Truckmodel Standard Limit
FD1 6
0-2 FD1
80-
2 4
7.7[
1.8
8] 3[
45. 1
.78
]
FD200-2 Weara
tpl
ateedge

FD230-2 60.
3[2
.37
] 57.
3[2
.26
]
F
ig.
7.1
5
(
5)Ifth
econnect
ionpinsofanyli
nkp
latea
ret u
rne
d
fromnormalpos
iti
on，re
plac
ethee
nti
recha
in.

を三台を三台Normal R
ota
tio
n

R
ota
tio
nofp
in

F
ig.
7.1
6

-127-
. LOADHANDL
7 lNGSYSTEM

(
6) Checkt hechainanchorpinhol
esforwearo r
de
format
ion.Ifdef
ect
ive，r
epl
aceth
ech
ainanchor
x
西信
pi
nw i
thanewo n
e.

を
三ト
Oblongh
ole

Wearo
fchainanchorp
inh
ole

F
ig.
7.1
7
(
7) Measurethee
lon
gati
onoft
hec h
ainandi
fitexce
edsth
espec
ifi
edlen
gthrep
laceth
echa
ラi
nw i
tha
newo ne
.
Wh enmeas
uri
ngthec
hai
nleng
thlif
tth
ef
ラo
rksfromth
egrou
ndandme
asuret
helen
gthof1
0-1
inkpi
ns.

c ト叩i
:申告予告
品聞広問 B

T
ruc
kmo
del Nominald
esi
gna
tio
nofc
h
L-J
ai
n A
B
C
D(10I
ink
s)
S
tan
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imi
t S
tan
dar
d L i
mit
FD1
60-2 BL1634
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180-
2 5
0.8 4
7.7 4
5.3 7
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08 5
23
FD
200-
2 BL1646
F
D230-
2 BL2044 6
3.5 6
0.3 5
7.3 9
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35 6
54
F
ig.
7.1
8 ChainS
ize

(
8)I
fthecha
inshowsbendort
wis
tasshowni
nFi
g.
7
.19，r
eplac
eth
echainwi
thanewon
e.

×鼠χ

Bend T
wis
t

F
ig.
7.1
9

-128 目
 8
. ELECTRICWIRING

8
. ELECTRICWIRING
Thee
lec
tri
ccomponentsoft
het
ruc
kar
ewiredthroughs
eve
raltypesofwireharnessesandc
olo
r
codedbyc
irc
uit(
wir
enumber).
Thewireharnessesa
reconnectedwithconnectors(
2ty
pes
)ors
cre
w.

Table8
.1 Colorcodeandexamples

Y 22 W
ire
日L
:-m ー
18￨ B
lak IR￨
c Red

G Green W White

L B
lue Y Yellow

O Orange Lg L
igh
tgr
een
E
xam
ple
:Wirenum
ber22，Y
ell
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xam
ple
:Wirenum
ber110，Wh
ite
c
oat
ingw
it
habluema
rki
ng P
ink Sb L
igh
tbl山￨ c
oat
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ith
outmar
kin
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Table8
.2 Connectorsymbol

C
onn
ect
iont
ype P
lug
-ins
ide R
ece
pta
c1es
ide Remarks

Thenumberssigni
fywire
。 Housing
直E
E 属国
Q)
b
同 numb
ers.
ロ Thea l
pha
bet
icle
tte
rsmean
ou
コ co
lor
s.( T
abl
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1)
企4 P
lug 型~ じ〉竺 11

Screwt
ype Y竺~ ×

Thewiresmayhaved
iff
ere
ntwirenumberseveni
ftheyhavet
hesamewirec
olo
r. Beforet
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ngt
o
checkt
hewires，r
efe
rtowireharnessandc
irc
uitdiagramsonpagest
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oll
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.
Thed
ott
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ine
sint
hec
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regivenf
oro
pti
ona
lequipment.

-1
29-
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x
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OPTION
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由
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田 佳子2
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もら 且
c

F
ig.
8.3E
lec
tri
calC
irc
uit

-1
33-
No.SEF・90SAE
I
ssu
ed: March2003

TC
Ntc 脚 ORATION

INTERNATIONAしMARKETINGDIVISION: 1
-15・5，Nishi-shimbashi，
Minato-ku，
Tokyo
105・0003，
Japan
FAX:JAPAN+81・3・35918152，
3・35918153

A
IIr
igh
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幽 rin
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nJapan