Electravan Service Manual

FORWARD

This Maintenance and Repair Manual has been prepared to provide the n2cessary information and data for the correct maintenance and repair of THE ELECTRA VAN 6 0 0 .

J Z T I N D U S T R I E S , INC. AUSTIP; , TEXAS

CHAPTER 1:

1- 1 . 1- 2

.

. 4.

t

COMPOi-JENT P A X T S O F BODY CONSTP,UCTIOIl

C H A S S I S FRAME DATUFI P O I N T

. . . .

. . . .

. . . . . . . . . 1.8 . I N N E R T R I M . . . . . 1- 9 . INNER ACCESSORIES . . . 1-10 . OUTER ACCESSORIES . . .

. . . .

1- 3

11.5 1.6

. . . . . DOORS . . . . . . . . WINDSHIELDGLASS . . . INSTRUMENTPANEL . .

1- 7 .

BODY

BODY PARTS

SEAT

5

. . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . .

. . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 2

3 4

18 20 27

29

31 32

1- 1.

COMPONENT PARTS OF BODY CONSTRUCTION

Rescrvoir tank flap Pillar Front pillar Front panel Weather slrip Drip rail

Bracket

Rear sheli Ccnler pillar (Inner) Side rail Lower slide rail Rcar quarter pancl (Inner) Rear quarter panel ( o u k r ) Upper slide rail Center pillar (Outer) Cussct Chassis frame Front under covcr Center under cover Rcas under covcr Engine room covcr Under covcr brackcl

Shutter Front rail Roof panel Rcar rail Cab floor Fender Back panel Hand brakc cablc protector Reiniorccnicnl Ccnler floor panel

-

Fig.

.

.

I Component parts

-

of

body

construction

Fig. 1 Charsisfrurne datum poiniJ

1- 3. 1.

BODY PARTS

Front Bumper REMOVAL AND INSTALLATION 1)

Remove the screws on bumper pad under right and left combination lights. Remove rubber b~cmpercovering.

2)

Remove the two bolts under the right and left combination lights to disconnect bumbez. Installation is the reverse order of .-remqval.

3) 2.

-

Rear Bumper

k

REMOVAL AND INSTALLATION 1)

Remove the four screws under the right-and left combina-

G

B

2) 3)

Remove the four bolts on bumber uider the right and left combination light to disconnect bumper. Installation is the reverse order of removal. -*

1-4

1-4.

A.

DOORS

i COMPONENT PARS OF DOORS

1

6

Cab door pancl Sash Spring Cab door hinge Weather strip Cab door repulator

7 8 9 10

Regulator handle Oulcr handle Sealitrg cover Pull hsridle

1

2 3 4 5

Fig.

Cab door latch Slrikcr wcdgc 13 Door striker Id Spacer 11 12

IS 16 17

Door glass Cab door remote control

Run ctlanncl

18

Escutcheon

19

Door handlc T21-018

Conlponent parts of cab door

Wcrlher strip Slide glass rail Slide glass frame Slide g l ~ s s Slide door panel Slide door upper arm Outer handle Slide door lower arm Slide door stoppcr Striker

Fig.

.

9

Suspender Plale Inner handle Esculchcon Slide door remote colilrol Door latch Wedge Spaccr

S trikcr Slide door arm

Component parts of slide

m%

door

D€TAIL 'C'

I 2

3 4 5

6 7

DETAIL '0'

Weather strip Wcathcr strip

Joint hloulding Back door glass Back door panel Clip

Fig.

5

8 9 10

Key lock Latch Striker

11

Slop nu1

I2 Back

1,

Ccmtponent ports

&,

13

doar hinge Back door stay

14

Stopper

01back door

2.

B.

CABDOOR

1.

Door lock striker

1) INSPECTION a. When the door rattles in thc axial direction and right angle direction, tighten the hinge mounting bolts. b. When the hinge pin section rattles, replace the hinge assembly. . 2) ADJUSTMENT a. Perform adjustment using the door hinge set bolt wrench. Adjustment is also possible with a common tool if the front grille and front bumper are removed. b. Adjust the door in the vertical and transversal directions by loosening the pdlar side hinge boIts.

1) . ADJUSTMENT

Move the d m r lock striker mounting posilion up and down and left and right, and adjust in the front and rear with shims so that the door is closed easily and does not rattle.

Fig.

.

b

Door hinge

Adjrrsting dour luck striker

NOTE: After adjustment of the door, confirm there is no play around the door when the outer handle is depressed with the door closed. Play, if found, shall be removed according to the following procedure. 1) Loosen four screws; 2 ) Turn the wedge around the pin with the wedge centering on the wedge receiver. 3) ,Loosen screws. 4 ) Close the door to check play of the door.

Fig.

Fig.

8

Adjusting door hinge

c. Small amount of adjustment in the door transversal direction and vertical dircction can be performed by loosening the door side hinge.

1

1

.'

7

Fig. .

a *I-..

q

:

Adjusting door hirye

3.

Door window regulator

1) REMOVAL a. Remove the regulator handle, inner remote k : handle ;Ad..door inner pull handle, and . .. 'remove.Ith;- .door trim. -?

d . Turn the glass while rotating the regulator tlandlc, remove the glass from the regulator and hold the glass so that it doesn't iaII.

NOTE: When-~emovingt h e glass, hold its f r o n t o r rear side up and remove upward.

Fig. 1 0 'Removing door trim

b. Remove the sealing cover. Fig.

13

RemovinggLzsj

e . Remove the window regulator mounting bolts and remove the regclator frorn the working hole.

Fig.

11

Removing senling cover

c. Place the glass in the middle position (vertical) and remove t w o regulator rail mounting bolts.

Fig.

1. Pemoving bolts

Removing r e p l a i o r

INSTALLATION Installation js the reverse of renioval. Pay careful attention to the direction o f the puU handlc, the regulator handle and remote handle installation angle. 2)

Fig. )

. 4

4.

Cab door glass

1) REPLACEMENT a. Remove the glass assembly from t h e regulator in t h e same manner as rcmoving the regulator. , b. Installation is the reverse of removal.

NOTE:. To hold the glass horizonatally and move up and down without iildinalion, finely adjust the rail of the regulztor sub arm up and dcwn.

5.

Fig.

Door lock

I ) REMOVAL AND REINSTALLATION a. Remove rhc d c o r trim, and t h e service hole cover, and raise t h e glass t o the top. b. Remove t h e safety knob, and disconnect the outer handle and inner remote wire connec t ion, c . Unscrew the door lock rnounting screws, and remove the lock through the working hole. d. Installation is the reverse of removal.

I b ' Removing

rear quarter trim

b. Remove t h e stopper (sliding door) from tlie lower rail.

Fig. ./

7.- R ~ m o v i n gStopper (sliding door)

c. Remove the stopper (center arm) from the center rail. Marking the mounting position during removal will facilitate installation.

Fig.

C.

1s

Removing door lock

SLIDING DOOH

I. Sliding door 1)

REMOVAL

a. Remove the rear quai-ter trim (refer t o trim panel item).

Fig.

=-%

.I 8 Removing stopper (center a m ) )

--

d. Move the door to the rear end, pull the lower arm out from the lower rail and the upper roller from the upper rail. When moving the door, be careful that the door is not slanted.

Floor Socurly insert

clearance.

TZf 0 2 2

Installing stopper (sliding door)

Fig.

Fk. 1 9

Removing

slid in^ door

r

0 0

e. SIide the door to the front end 1 rernove the center arm from the center i a l l .

I

0

/

Stopper (sliding door 1

Fk. 251 Stopper (sliding &or)

e. Fasten the door stopper (center arm) ternporarily (so that it can be moved by hand).

2) INSTALLATION a. Fit the upper arm to the upper rail. b. Fit the lower arm from the rear cnd of the lower rail. c. Slide the door to the front end and fit the center arm to the center rait, . d . InstaU the stopper (sliding door). At this time, insert the flange of the stopper securely between the flanges of the rail,

/

Stopper (center arm)

Fig.

13

Stopper (center a r m )

f. With the door closed (striker and ratchet perfectly meshed), tighten the stopper (center arm) securely. g. Install the rear quarter trim.

NOTE: Tightening torque: Stopper (sliding door) 8 mm bolt: 1.2 to 1.4 kg-m 18.7 to 10.1 ft-lb) 5 m m bolt: 0.25 to 0.30 kg-m (1.8 to 1.0 ft-16) Stopper (center arm) 8 mm bolts: 1.0 to 1.2 kg-rn (7.2 to 8.7 ft-lb)

& Adjusting sliding d o o r

Fig.

When inequality has appeared between door and pillar, adjust it by moving the upper arm or striker to the left or right.

-

Removing and installing the galss The glass can be removed and installed together with the rubber. 3)

24

Fig.I.r Moving upper arm

Fig.

3 Rmtovinggh$

Adiustment of thc s1idin.g door when the sliding door is inclined, adjust it by moving the lower arm up and down. 4)

.

Fk.

& Moving striker

i

5) Inspection o f the arms a. 1s there any rattling at the slaked section o f each arm ? -- Staking. b. Is there any leaning wear on the roller ? -Replace roller. c. Is the spring o f the center arm abnormal ? -- Replace when permanently strained or

NOTE: When performing above procedure, pay attention to the contact between striker and suspender.

-

, broken.

d. Does rhe roller turn smoothly-?.-grease on the roller axis.

Apply

NOTE: Tightening torque: Upper arm, lower arm 8 mm bolts: 1.30 to 1.50 kg-m (9.4 to 10.9 tt-lb) Center arm 6 rnm screws: 0.45 to 0.50 kg-m (3.3 to 3.6 ft-lh)

Fig,

28

Suspender

6)

Door latch

Rubber

Difference of the eech canter line should

Striker

I Sliding door

721-023

29

Fig. r r Contact ~ between s t r i k e r and suspender

Fig.

Component ports of door b t c k

1

1 I

a . Adjustment 1 ) Fix t h e connector s o that there is n o looseness when the wire is stretched fully. 2) Adjust and install t h e outer handle so that t h e push lever and adjusting screw contact wheu thc safety rod is pushed d o w n . Aftcr adjustment, push the pushb u t t o n , and confirm moving of the pinion by hand.

4) Rcmove t h e mounting bolt and two mounting screws, then remove t h e latch.

! Adjusting screw

1 Push lwer

Fig.

I

31

T3t 4 2 4

32

&

Removing lorck

Adjustins screw

b. Removal 1) Remove t h e stopper bushing and inner handle. 2) Rernovc the trim pancl (refer t o trim panel item). 3) Remove the connector screw. At this lime, b e careful not to d r o p t h e screw o r washer inside t h e door.

Fig.

Fig.

Removing connector sciew

5) Raise t h e safety rod upward and remove t h e o u t e r handle. At tlus time, be careful not t o drop t h e mounting nut inside t h e door. 6) Remove the safety rod knob while twisting it. 7) Remove the remote by removing two mounting bolts.

Fig.

35

Rcrnoving rcmote

7)

Sliding door inspection

Door 'closcs poorly.

Inspection and corrective action

Cause

Syrnptom

Good if door is locked whcn pltshcd by hand

Is vertical direction good? Is the door too far insidc?

Striker (latch) position incorrect.

~ & in e arrow direction.

-

Stopper (cen ler arm) position incorrect. .-

Stopper (ccn trr arm) bushing deformed or cracked.

I

Temporarily fasten the stopper, close the door complete, and thcn relighten the stopper.

RcpIace bushing. (Install a bushjng which can be easily rotated by hand.) Coat the inside and outside periphery of the bushing with grease.

/ . , i

j-:I,.; I

;.,.-. ,

.

':stopper (center arm) . .. .. - ;:., .c...:;!.,*',..-'f.: .. . . .

'

'

Symptom Door closes poorly.

Inspection and corrective action

Cause

Latch pinion cover and striker mesh when the door opened and closed.

Insert the spacer under the striker as required for adjustment. I

*

T

Striker

~ w s r

cww

T2 1-025

38

Fig. s&t Rattles when vchicle is moving.

Striker protrudes too far.

-

Install inside.

r.

..

,

- _ ...

+

hr.

..

'

.-.

.a-

- ..

.. ..,..- .--. Fig.

Suspender and striker (suspender) position incarrect.

--

&

Adjust so that the difference between the suspender and striker (suspender) position is within 1 rnm (0.04 in) When the strikcr (suspender) is eccentrically worn. replam.

Fig.

&

Symptom Rattles when the d o o r is slide, Door doesn't slide s m o o t h .

Door doesn't open sufficiently. (Door does n o t fly open when outer handle push b u t ton depressed.)

2.

Cause

Roller is not moving.

Apply grease between the rollcr and shaft.

Roller ecccn tric wear znd inside and outside diameter wear.

Replace the roller, coat the shaft with grease, and confirm that rotation of the roller is smooth. - -

Foreign matter such as the sand, mud, etc. are fitted on the roller surface.

Remove the foreign matter and keep clean inside of the rail.

Center arm spring pcrma nently straincd or spring coils are rubbed each other.

Coat the spring with enough amount of grease. When the spring i s permanently strained, replace.

Sliding door rail

Fig.

Ab

Inspection and corrective action

2) Remove the rear quarter trim. 3) Loosen and rerndve six 6 mrn flange nuts under t h e rail. 4) Reinstallation is the reverse of removal.

Sliding door rail

REMOYAL AND REINSTALLATION I)

Remove t h e sIiding door from body.

Fig.

Removing sliding door roil

D. BACK DOOR 1.

Door lock striker

ADJUSTMENT Move t h e installation position t o the front and rear and right and left, and use shims in the vertical direction so that there is n o rattling . when the d o o r i s closed lightly.--

Fig.

&

Adjusting door hinge

c. Perform door transversal and longitudinal adjustment by loosening thc rear pillar side hinge bolts.

Fig.

&'

Adjusting door

lack

striker

Fip.

2.

Door hinge

1) INSPECTION a. Whcn the door hinge rattles in t h e front and rear. left a n d r i g h t , , or top and b o t t o m directions, tighten the hinge bolts. b. Whcn the hinge pin is loose, replace the hinge assembly. c. Adjust d o o r drooping, joggling and split line as fouows.

2)

Adjurtinp door

3.

Stay

1)

REMOVAL

hinge

a. Remove t h e nuts mounting the stay upper from the d o o r (hinge) with the door opened.

ADJUSTMENT

a. Perform adjustment using a spanner or b o x

wrench. b. Perform door vertical and longitudinal adjustn~cnt by loosening the door side hinge bolts,

Fig.

*

Rernovittg stay

b. Rctt~orcIwo stay lower mounting bolls from the body.

nti \

Fig.

Fig.

2)

4.

4%

50

Installing door lock

R ~ ~ n o v i yslay g

INSTALLATION Installation is t h e reverse of rernoval,

Door lock

I) REBIOVAL a. Remove the door trirn. b, Remove the d o o r lock mounting bolts and remove the lock from the working hole.

.I-5.

WlNDSHlELD GLASS

REMOVAL AND INSTALLATION 1) Remove the wiper arms. 2) Bend the weather strip inwards and push the dass, outw3:ds by foot from Ule inside of thc passenger compartment. Then @ass is removed.

Fig.

2)

Retnoving door loch

lNSTALLATlON lnstallalian is the reverse o f removal.

Fig.

Pushing w i n d s h i e l d g b r

3) When installing windshield glass to t h e body, f i t t h e weather strip onto the windsllield glass and insert the work cord into t h e weather strip.

5)

Pushing the glass from the outside, p~adual-

lv pulling t h e work cord at a ri&t angle to the glass.

NOTE: NOTE: a. Overlap the ends of the work cord at the top of the glass. b. After the work cord is fitted to the weather strip, coat all around with clean gasoline, +

a. Fitting is carried out from the upper center of the glass to the l e f t and right. b. Install the glass sufficiently to the body; gerhly pushing it with hands from the outside. c. Fit the weather strip on the outside of the body correctly. d. Apply a sealing compound (Cernedine 8366E3 into the groove of the weather strip.

1 Work cord

5 A

Fig. M

Fitting work cord

54

Fig. alw Appbing senling compound Put the glass into the correct position from the outside, pull the work cord into the inside of h e body.

4)

Body panel I

Sealing compound

A24-090

.

5s

Fig.

6)

S3 Fig.

Installing windthieldglass

glass.

a Sealing pbdtion

Return the wiper arm to surface o f the

; 1 4 . INSTRUMENT PANEL

1.

Component Parts

RIGHT-HAND DRIVE VEHICLE

Front panel stay Instrument panel retainer lnstrurncnt panel lnstrurncnt panel cushion Instrument panel Lighting switch Fuse box lid Wiper switch Washer pump Label

Ash tray holder Ash b a y Glove box lid

Lock Pocket Defroster nozzle Defroster duct Ventilator duct Vcnt Ualor duct Control lcvcr

b.

arp

Fig. Sf-& ,Component parts of instrument panel

LEFT.IIAND DRIVE VEHICLE

Ash tray holder Ash tray Glove box lid Lock Pockc t Defroster nozzle Defroster duct Venfifator duct Venlilator duct Control lever

Front panel slay Insfrurnent panel retainer Instrumenl panel Instrument panel cushion lnslrumcnl panel Lighting switch Fuse box lid Wiper switch Washer pump Labcl

I Fig.

bS'lb Componerlt parts of 21

a -33

inrtrtrmmt

porn1

T2 1 4 2 8

2.

Combination meter

3.

REMOVAL AND INSTALLATION 1) Remove four combination meter installing screws.

Fig.

REMOVAL AND INSTALLATION 1) Pun out the ash tray. 2) Remove two 5 mm tapping screws mount. ing the holder and remove the holder.

ss

6.

P - P Removing combination meter

2) Disconnect the speedometer cable. 3) Take out the combination meter and then disconnect speedometer cable and wiring harness junction block from back side of the combination meter.

Fig. 1-1Et3 Removing l ~ o f d e r

3)

Installation is Ule reverse order of re~noval.

4.

G l o v e box lid.

REMOVAL AND INSTALLATION 1)

r.

.LA.'".

.

.-...-I, Y ' .

Ash tray

Remove three 5 mm screws under the lid.

..

6'

Fig.

4)

-0 e Y

Fig. a-S Removing lid

a-%d ~ i r c o n n c c t i nvbing ~ harness

Installation is the reverse ordcr of removal.

2) Pull out the dove box lid from the instrument panel. 3) Installation is the reverse order of removal.

Glove box lid lock.

5.

2)

After removing the instrument panel, per.

Pull out the fuse box lid from the instrument panel, 3) Installation is the reverse order of removal.

form removing the glove box lid lock.

7.

Instrument panel

REMOVAt-AND INSTALLATION 1) &or to removing the iristrurnent panel, remove the steering wheel. 2) Remove the combination meter. 3) Pull out the ash tray and remove the ash tray holder. 4) Remove the glove box lid by removing Lhc installing screws.

1

2 3 4

Flange nut Rc~aincr lnsrrurncnt pancl Lid

5 6 7

Screw Lock Tapping screw

b4

Fig. 4UOl Removing glove box lid

6.

Fuse box lid

5 ) Remove the fuse box lid by removing the installing screws.

REMOVAL A N D INSTALLATION I ) Remove 5 nirn screw under the lid.

F~~.B-&

Removing screw

Fig.

Removing fuse box

lid

NOTE: When loosening the screws on thc top of the instrument panel, it is recommendable to use short Pillips screwdriver or "L" shaped one.

6) Remove 5 mm screw at the underside of the instrument panel center.

Remove the control knobs from air flow control levcr and heater control lever.

9)

Fig.

bb'

Removing screw

7) Remove 5 mm flange scrcw inslalling rightside of pocket and two 5 mrn lapping screws installing luggage shelf. .(Right-hand drive vehicle only).

I

Fig.

1

%-

Removing control knob

10) Take o u t the instrurncnt panel and disconnect the wiper switc!l wiring harness and

T71-332

Fig.

%-qRemoving screru

8) Remove four 5 mm screws uppcr the instrument pancl.and remove the retainer.

Fig.

Fig.

-4- a

=-& Removing

/

instrument panel

Fig.3 1 4Removing wiper switch wiring hantcss

Removfng retainer

2$

Front luggage s h e l f (Right-hand drive vehicle o n l y )

8.

1)

Remove Ihe instrument panel. (Refer t o Kcnioval of instrument panel.) 2) Removo four 5 mrn tapping screws and takc out thc luggage sl~clf.

Fig. W f f Rcniovirt~~ U ~ Q R ~s
'74

Disconnect the control cable clamp to remove the control cable from the duct assc~nbly 4) Remove the heater fan switch harness. 5 ) Remove three tapping screws fixing the lever assembly t o the body panel. 3)

.

7Y

Fig. LLT-W Renloving topping screw of (LFSL'PTIbly

lcurr

Rernove the lever asscmbly by pulling i t

6) out.

Air flow and heater control lever

9.

REMOVAL AND INSTAL~ATION Remove the instrument panel (Sec "Re1) moval of instrument panel.") 2) Disconnect control cable clamps t o remove the each control cable from the heater unit.

Fig.

J5

Removing lever assen:bly

NOTE:

I

Fig.

d

a - nDisconnecti~rgcontrol cable

When pulling out the lever assembly, take care the soldered portion where cables are connected to the heater fan switch is not damaged by the body panel.

7) Installation the lever assernbly in the reversc order of removal.

4) Remove two screws fucing the v e i i l a t o r duct to the lower part of the instrument panel. 1

I

NOTE: a. When connecting control cables, confirm

all shutters and cock completes are entirely closed.

b. After connection, confirm the operation of each shutter and cock complete.

, Removing wentihior duct installing screw

5 ) Remove the license plate. 6) Remove four tapping screws f i n g the air flow ventilator duct t o the front panel.

3b

~ i gB-m . Shutter closing position

10. Air flow ventilator duct REMOVAL AND INSTALLATION 1) Remove the instrument panel. (See "Removal of instrument panel.") 2) Remove the Air flow and heater control lever. (See "Removal of air flow and heater control lever.") .-. . -

.--

-"

7

i I I

Fig. S- W Removing ventilator duct installing screw

7) Remove the duct assembly after moving i t to left side. 8) Install in thc reverse order of ren~oval.

NOTE:

a. When mounting the duct assembly, replace the urethane (671042040).containing sealing agent by new one t o prevent water leakage through the junction of the front panel and the duct. b. Apply sealing agent (Cemedine 366E) I

I

I

1

t o front panel mounting screws before installation. c. Fix the control cable by attaching the firmly.

11-7. 1.

SEAT

Component parts of seat

2.

Removal and installation

FRONT SEAT I ) Remove the cushion by lifting the front end of it while pushing it to the rear.

2 , . Fig. &b. .Removing bcck 3)

rest

Installation is the reverse order of rcmovd.

NOTE:

Fk. 23-

80

The seat cushion has two positioning pins on right and left sides of it. Mount the cushion so that the pins are inserted in predetermined holes.

Rerrroving cushion

2) Remove the frame under the back rest from the hook attached to the lower part o f the back panel. Remove the back rest by lifting.

I

I

81

Fig. S-= Removing back rest

For truck and flat bed truck, first remove the back rest from the lower hook, then remove the back rest from the upper hook with d ~ e back rest moved upward.

81-8. 1.

INNER TRIM Component parts

-.>J

. -.

DETAIL 'A"

m

DETAIL

.-.

1

Roof trim seal

2

Cab door trim

3

Slidc door trinl pancl Rear quartcr trim panel Back door trim oanc[ Clip Clip Shrorld trim Insulator

4

5 6 7 8

DETAIL "€3.

"C'

9

panel

10

#

2.

Cab door trim

REMOVAL AND INSTALLATION Remove the regulator handle, pull handle 1) and door inner remote handle. 2) Disconnect the resin clip from the door inner panet with a (-) screw driver to remove the door trim.

NOTE: a. When removing the resin clip, take care not l o bend the trim panel. b. The resin clip can be removed easily by using the special tool shown in Fig.

NOTE: Tha resin clip can be removed easily b using Y the special tool shown in F i g S U 5 . )=(

Welded portion

--

,____---

18 (0.70)

About 50

About 400 (15.701

P ~ p e( 12 10.47) dia.1 Unit: mrn linl T 2 1.039

1 2 3

I

Clip

Trim pancl Special tool T2 1.042

I

Fig. a-HSRemoving t r i m 3) 1

T r i m panel

2 3

Clip Special tool

Fig.

Installation is the reverse order of removal.

NOTE: If the removed resin clip is damaged, replace it with new one.

T2 1 -040

Ronoving trim

3)

Inst allation is the reverse order of removal.

3.

Slide door t r i m

4.

REMOVAL'AND INSTALLATION 1) Remove the resin clip from the back door inner panel with a (-1 screw driver or special tool to pull out the back door trim. 2) Installation is the revcrse order of removal.

REMOVAL AND INSTALLATION Remove the inner remote handle. 1) 2) Remove the .resin clip from the slide door inner panel with a (-) screw driver t o pull out the door trim from the rail.

2

Back door trim

Screwdriver

F 9 . S '

Fig. PY-rn Removing resin clip

8&

rn

30

-*

Removing back door trim

1

1

. 1-9.

2.

INNER ACCESORIES

When reinstalling i t , be careful not to damage the screw because the screw is made of plastic. The mirror is adjustable in up and down direction by turning i t .

Sun visor

The sun visor is removed by loosening the tapping screws.

3.

Rear view mirror (inner)

The rear view mirror is fallen down resulring from breakage of the screw made of plastic in case of collision. And it can be removed by loosening the screw.

4.

Assist rail

The assist rail can be removed by loosening two screws.

3)

w -42

El-1O.OUTER ACCESORIES

1.

Component parts

3 -t S

10

Fig. $F-=

2.

Component parts of

Front side grille

b o s c n three screws, and the front side grille is removed.

Fig.

a?-&

3.

Front side grille Ccntcr slide door rail

outer accesories

Rear view mirror The rear view mirror is removcd by looscning two cap nuts.

4.

Splashboard

The splashboard is removed by loosening bolts and nuts.

Fig. H

93 a

CHAPTER 2 :

222-

1.

. 3. 2

2 - 4

.

2 - 5

.

22-

. 7. 6

BODY ELECTRICAL S Y S T E M

. . . . . . . ., . . . . . . . . . . METER . . . . . . . . . . . . . . . . . .

WINDSHIELD WIPER

2

COhIBINATLON

5

. . . . . . . . . . . . . . TURNSIGNALANDHAZARDUNITS . . SWITCHES . . . . . . . . . . . . LIGHTS . . . . . . . . . . FUSE BOX AND W I R I N G HARNESS . . . HORN

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7

10 12 14 17

2-1. 1.

WINDSHIELD WIPER

Construction and operation

\

1 W v r blade 2 wiperum

6 Wanher 7 Cushion A 8 9 10 11 12

Cushion B W~pcrtink Packing Wtpcr motor bracket Wiper motor

Fig. H-I Wiper component parts

The wiper uses a small motor as the drive source and the wiping operation is performed by driving the wiper shaft (shaft mounting the blade and arm) in a reciprocating manner with a link device by means of a clamp and rod at the rotating shaft (wiper motor output shaft) whose speed has been reduced to the specified speed by means of a reduction gear (worm reduction gear). 1) When the wiper switch is turned ON, current flows through the circuit BS2(A)-E and the motor is operated. Refer to Fig. %!-2. 2) The 'motor is kept operated even after turning off the wiper switch while the ignition-starter switch is in "ON" position until the lever is pushed up and the cam inside the motor reaches the specified position, since the circuit B ( Q ~ ) S ~ S ~ < A )is- E closed.

Wipsr motor

T22-002

Fig. a - 2 Wiper wiring diagram

e. Remove both right and left wiper arms by loosening the wiper arm tightening bolt.

3) When the circuit is intempted at the specified position, the circuit (A)S2-S, .P-(A) indicated by the arrows ifl the diagram is formed and the motor is t l t c t r i d y braked and stops a1 the specified position.

4) When the wiper switch is set t o OFF when the key switch is in the OFF position, no currents flow in the circuit and tht motor stops. However, if -the key switch is set to ON, the actions of (2) and (3) above are repeated and the motor is stopped in the specified position.

*.

Fig. x-4

2.

Removing and reinstalling the

wiper motor 1) REMOVAL a. Remove battery grounding wire. b. Remove the light ring on right-hand side (right-hand drive vehicle) or left hand side (left-hand drive vchiclc). c. Loosen headlight adjusting screws and remove the right headhght (right-hand drive vehicle) or left headlight (left-hand drive vehicle), whil* turning it to the right. d. Laosen and remove the wiper motor stailing nuts. w e e flange nuts)

f, Pull out the rubber caps on the shaft and remove wiper link installing nuts. g. Remove the steering wheel. h. Remove the combination meter. 5 i. Remove lighting switch. j. Remove the defroster. k. Disconnect wiring harness of the wiper motor. I. Disconnect the wiper linkage from the motor shaft. m.Take out the wiper motor assembly through the instrument paneI.

Fig. Lt-5 Removing wiper motor

2) Fig. $2-3 R emotting nuts

INSTALLATION installation is h e reverse of removal,

Incorrect wiper stopping

Connection fault or wiring error in S 1 (yellow) or B (blue) circuit. Switch

-

-

Check the connections.

.-

Bad connection between terminals 1 and 2 of switch continuity between

Correct connections.

U-2. COMBINATION METER 1.

Component parts

-.

1

2

3 4 S 6 7 8

9 10 11

Meter visor Combinalion meter glass Combination meter window plate Combination mctcr Thermometer Fuel meter Printed plate Bulb

8

Socket Buzzer Sgccdorneter

TZZ-005

Fig. #-6

2.

8

Combination meter

Removal and installation

1) Remove four combination meter installing screws.

Disconnect the speedometer cable. 3) Take out the combination meter and then disconnect speedometer cable and wiring harnesses junction block, from back side of the combination meter.

Fig. 2 - 7 Removing combination meter

Fig. 22-8 Dirconnecting wiring harness

2)

P-*5

4)

3.

installation is the reverse order ofremoval.

Disassembly and assembly

1) Remove four tapping m e w s on lower back side of combination meter and disasemble the meter visor and lens complete.

Fig. a - 1 1

4) Remove three nuts and remove fuel meter unit.

Fig. s - 9

2) Remove two screws installing the speedomcter gear.

Fig. L k i Z Removing fwel 5)

meter unit

Remove thrce nuts and remove thermom-

eter.

Fig. m-10 Removing speedometer installin2 screws

3) Remove a screw on right side of mmbination meter panel and remove the speedometer and combination meter panel as assembly.

Fig. &!-I 3 Removing thermometer 6)

Assembly is the reverse ordisasscrnbly.

I

Combination meter connecfions

6.

1 2

Thermometer terminals Fuel meter termindl Meter ilturninstion hght High beam indicator light Direct terminal Meter illumination light

3 4 5 6 7 8

Buucr Combination meter c u e

9 Specdomatar a b l e bou 10 Left turn signal light 1 I Right turn signal light 1 2 Charge indicator tight 13 Hand brake and brakc fluid level wuning light

= R 722016

Fig. -9

I 1

42-3. 1.

HORN

Specifications Volt age Current

-

13V , + 0.5 A 3.0 - 1 .o

Basic frequency

330-370 Hz

Sound pressure

100 - 110 dB

4. 1)

NOTE:

Checking combination meter

With the drive shatt turning at 1,020 rpm, the nominal indication i s 60 MPH.

Speedometer

a, Indicated error as measured with a speedometer tester is acceptable if il conforms to values in the following table. With the drive shaft turning at 637 rpm, the nominal indication is 60 kmfh.. -

b. When the pointer fluctuation is large, the cable may be defective or installation may be incorrect.

-

Kilometer indication

Mile indication

Nominal indication {kmlh)

20

Tolerance

-1 -3.5

(km/h)

2)

40

60

80

t0.4

t2

-2.6

-2

t3.8 -0.6

Fuel meter

--

120

Nominal indication

20

40

60

-0.1 -1.9

+f.S

t3.0

-1.1

-0.1

MPH

a. Check for a grounding or open circuit between fuel meter and unit. Check if each conncction a n f c o n t a c t are insufficient. b. When unit terminal connection is disconnected, the meter indicates "0" (empty). If the meter pointer slowly shifts toward the "1" (full) position when the disconnected lead i s grounded through the pilot ljght (12V-3W),the meter is functioning properly. If the plot light does not light in this situation, the heat coil of the meter is open.

--

100

/

t5

-0

-

Tolerance

MPH

2.

Operation

Sound energy is produced by a diaphragm set into motion by electric means. Pushing the horn switch closes a circuit which allows current t o flow through the horn coil and the coil attracts the plunger. The diaphragm COUpled directly with !he plunger is attracted rapidly pnd density of air ir! front of diaphragm becomes low. At tlus time, one part of the plunger strikes the contact spring, opening the coil circuit. The magnetic field collapses and the plunger returns t o its original slate by virtue of spring force o f the diaphragm. This action cornbresses air in front of the diaphragm. At the same time t h e contacts reclose and the sequence repeats itself. Repetition continues as long as the horn button remains depressed. Sound is generated by repeating change o f air density.

Ignltion-ltsmr switch

--

Horn button

-Bansry 10V rrngs T2241B

Fig. m-21Horn inspection

4.

Removal and installation

I ) Disconnect the wiring, and remove the horn installing nut.

Fig. @-20 Horn operation

3.

Inspection

?:., ,

'.

*

7.

When the horn does not sound, check the voltage with the tester as shown in Figure. Fig. m-22Removing horn

\ m e n voltage: below 2V: Horn is abnormal. over 2V: Worn horn button or faulty ground,

2)

Installation is the reverse order of removal.

2-4. 1.

3.

TURN SIGNAL A N D HAZARD UNITS

Operating principles

Automatic flashing and snapping o f those units are accomplished b y expansion-contraction of a heater band and action of a snap spring.

Specifications a Front and rear turn signal light: 23W x 4

A

a Side turn signal light:

Load

Heater band

6W x 2 a Turn signal pilot light:

3.4W x 2 72 - 98 tirnes/min.

frequency

2.

Wiring diagrams

1)

Turn signal unit

122-021

Operation A

Fig. 20

Ptlot

swltch

-

-

f

Battery

4

4

.+

Fig. 2 1

T22-019

Fig. 18

2)

Turn signal circuit

4.

Hazard unit

Operation B

Cautions for handling the turn signal light

1) When replacing the bulb, strictly use specified one as follows: Front turn signal light

-

Rear turn signal - - - - .light - - - - - - - --

.__ _ - - - - ---- _.

T22-020

Fig. 19

12V - 23W (12.8V - .8A)

Rear turn signal light

12V - 23W

Side turn signal light

12V - 6W

Turn signal pilot light

1 2 v - 3.4W (14V - 0.24A)

I

Hazard unit

Hazard unit circuit

,

Front turn signal light

This type of unit operates b y the current through the lights therefore, if wrong rated light is used in the circuit, the turn signal units

does not operale normally since different current flows through the circuit.

at the left end of the bulkhead below the instrument panel.

I f a single bulb is burnt out,'the flashing frcqucncy does not change appreciably (keep light on). . . -.

2)

3) Do not apply large shock on turn signal or hazard unit while handling it. .

.

4) . The turn signal and hazard units arc

getting hot like a vacuum~valveby continuous operation, but this is not an abnromal sign. i'

5.

'

Location of turn signal and

hazard units

Fig. 1Ct-27 Locution of turn signal and

The turn signal a n d hazard units are installed

6.

hazard units

Turn signal circuit troubleshooting

TROUBLE AND POSSIBLE CAUSE

I

CORRECTIVE ACTION

Left and rightaashing frequency differ o r o n e side only functioning properly 1) Burned out bulb 2) Defective switch

3) Improper bulb installed 4) P o o r ground at bulb 5) Poor wirlng comection

Replace bulb Repair o r replace switch Replace with specified bulb C o r r e c t the socket contact C o r r e c t connections .

Both sides d o n o t light 1) Blown fuse 2) Open w i r e between battery and switch o r

Replace the fuse

poor connection 3) Defective switch 4) Both left and right pilot lights burned o u t 5) Defective turn signal unit

Repair o r replace wiring Repalr o r replace switch Replace bulbs Replace turn signal unit

. -s

Both sides remain lit 1) Defective turn signal unit

High flashing frequency

1) Low wattage bulb used 2) P o o r ground a t bulb .. . 3) Defective t u r n signal unit

Replace turn signal unit !,

. q..

'i:

Replace with specified bulb C o r r e c t the socket contact Replace the turn signal unit

Low flashing frequency 1) Low source voltage 2) High wattage buIb used - 3) Defective turn signal unit

.

Charge the battery Replace with specified bulb Replace turn s i g n d unlt

p2-5. SWITCHES 1.

Lighting and parking switch

This switch is actuated both by pulling and turning. Pulling the knob to the first position lights the clearance lights. Moreover, when the headlight beam switch lever is operated, the headlights (low beam). can bc lighted. While pulling the knob to the second podtion, these lights light together (in this case tither high beam or low beam lights up). With the knob pushed in (OFF position), the parking lights are lighted by turning the knob t o the right. Fig. #-29

Lightingswitch

REMOVAL AND REINSTALLATION a . Detach the combination meter. b. After detach the lighting switch knob, unscrew the dress nut.

c. Put the hand into the inside of instrument panel through the combination meter hole and take out the lighting switch. A d. Reinstallation is the reverse of removal.

darter switch

2.

:

For Wt-hand drive, the stdrter switch is Qtached by dress nut to the.dnstrument panel. For !eft-hand drive, the rgnitionstarter switch is attached with stetring lock system IocateC. under the instrument panel. Connections are made by meanyof a junction block. '

. .'j

.

-

3

Fig. s - 2 8 Lighting circuit

T22023

diagram

f . .

Note that the knob cannot be pulled out while it is turned when using as the parking switch and that it can not be turned while it is pulled out when using as the lighting switch. Always operate the switch from the OFF pdsit ion.

Fig.4 - 3 0 Ignition-starter switch

.

Combination switch

REMOVING AND REINSTALLING 1) Remove the steering wheel. (Refer to infomation on steering .wheel in Chapter O.8 15-3, on page Y 4). 2) Remove the hazard switch , h o b by unscrewing it. 3) Separate the switch'assembly by removing the 4 mm screw securing it t o the bracket. ,4) Reinstallation is the rcvemof rlmoval.

ACC

R

4.

ST

. . NOTE: a. Install the steering wheel so t h a t the horn bar lies horixontally. b. Install the canceling cam so that it is located at right angles t o the t u r n signal lever.

T2242

Fig. fP-31

3.

&nnedionr

Combination switch

Back-up light switch

1

REMOVAL AND REINSTALLATION 1) Open the trap door. 2) Take out the insulator. 3) Detach the back-up light switch attached -on the left side of transmission. 4) Reinstallation is the reverse of removal.

5.

Wiper s w i t c h

The *per switch is attached to the instrument i h c l by means of an dren nut. Loosen thc screw at the bottom of the knob and remove the knob. Remove the dress nut and separate the switch from the panel. ,

Pig. 3f-32 Back-up light sul'tch

NOTE: In reinstalling the knob, turn it so t h a t the m e w is located a t the bottom. ,

Fig. 9 - 3 3 Stop light switch (Left-knnd drive)

Fig. a - 3 4 Wiper switch

Stop light switch - ... .- The stop light switch is mounted on the pedal bracket and is operated by the brake

6.

-

pedal.

92-6. 1.

Fig. SZ-36 Stop light switch (Right-hand drive)

LIGHTS

Specification

Headlight

12V - 50W/40W (Right-hand drive vehicle) 12V - 45W/40W (Left-hand drive vehicle)

Front corr~binationlight Turn signal light Clearance light

12V - 23W I Z V - 5W

Side turn signal light

12V- 6W

Rear combination Iight Turn signal light Stop and Tail light

12V - 23W 12V - 21W/5W

Back-up Iight

12V - 12W

License plate light

12V - 10W

Room light

12V- 8W

-

2

Headlight

'. Fig. a - 3 8 Removing headlfight

1 2 3 4 5 6 7 6 9

Hcadllight assembly Screw Ring Washer

Spring Set plate B Screw

Sealed bcarn unit Set plate A

TZZ-025

Fig. 83-37 Hedllighi ussembly

Fig. -0

3.

Front combination light

Front combination light

For Right-hand drive model, the headllight is of an all-glass sealed b q m type. For Iaft-hand drive model, the heaWght is of a bulb type. Two filaments, 50 & 4GW for sealed beam, 45 & 40W for bulb, e n c a k d in the bulb and lights are changed over by means of head-light beam switch. Adjustment is performed with screws. 1) Removal and reinstallation a. Remove the headlight vessel. b. Loosen the head!amp installing screws (adjusting screws) until the spring tension becomes free. c. Hold the ring and remove the headlight by turning it to the right. d. Disconnect the wiring. e. Reinstallation is the reverse of removal.

Fig.ZI340

Front combination

light

Thc ftont conbination Light includes the turn signal light (23W), clearance and parking light (SW). 1) Removal and reinstallation a. b s w n n e c t the wiring harness, b. Remove the lens by removing the lens mounting screws. c. Take out the light case from t h e body. d. Reinstallation is the reverse of removal. 2) Changing bulb Remove the lens mounting screws and lem. Remove the bulb bg depressing it and turning to the left. Fig. -42

5.

Side turn signal light

License plate light

Fig. #Z-41 Rentorring bulb

4.

Side turn signal light

The side turn signal lights are installed on both (right and left) sides of the headlight vessel. When changing the bulb, remove the lens mounting screws and lens, and rcrnovc the bulb by depressing it and turning to the left.

r

Sidc turn signal light bulb

6W

!:..c

Fig. 62-43 Liceti& pbtr light

The lianse plate light lights at both the &st and second pull positions of the lighting sw3d.h. When changing the bulb, remove the c a e r and lens by unscrewing two cover m o u d n g screws, and remove the bulb by depressi- i it and turning to the left.

REMOVAL AND INSTALLATION A.

VAN

Pull down the Iens by turning the mark position ( Q or "OEW' mark) to the lever part. 2) Remove the light assembly by loosening the screws. 3) Disconnect the 64ring harness.

I)

B. TRUCK1) Remove the lens by pushing the lens edge with fingers. 2) Remove the light assembly by loosening the screws. 3) Disconnect the wiring harness. Fig. fP-48 Repkacing fuse

CHANGING BULB Remove the lens and pull out the bulb.

-

..-

R2-7. FUSE AND WIRING HARNESS

(SEE NEXT PAGE)

14

!

Fig. a - 4 9 Fure

I

2.

Cautions for removing and reinstalling the wiring harness

Before carrying out operation, be sure t o 1) disconnect the battery (-1 tennirul. 2) When pulling out the wiring harness which 1 runs through inside of the front pillar, rear ) quarter and,qa& door, tie the wiring harness i with the wire% string and pull it out i 3) I f the &;ing harness is contacted with the I: clamp or other parts, protect the harness ; contacting point with the vinyl tape. 4) When installing the parts, d o not put the ' harness between the parts and its fitting position. 5 ) When connecting the connector, be sure to confirm the color w r d of the connector with the wiring diagram. i 6 ) When connecting the battery cable, turn I off each switch and confirm whether the wiring harness is shorted or not by contacting the : battery cable t o the battery terminal.

i 1

:

c2-'dP),7

6.

Rear combination light

I)

-

.-

\

i b

1 Rear mrnbinatfon light r d y ' 2 Bulb (21I5W) 3 Bulb (12V-23W) 4 Bulb(l2V-12W) . 5 ShadcA 6 Packing

Removal and reinstallation Remove seven (Van) or k lens installing screws and remove the lens. b. Discomcct the wiring harness. c. Reinstallation is the reverse of removal. 2) Changing bulb R'emovc the lens by removing the lens installing screws and remove the bulb by depressing it and turning t o the left. 3) Back-up light When removing, remove two lens installing screws and remove the lens, and disconnect the wiring harness. Reinstallation is the revtrsc of removal. When changing the bulb, remove the lens by removing the lens installing screws and remove the bulb by depressing i t and turning t o the left. 8.

7- Shde B 8 Lens complete 9 Pan-had r a e w 10 S a e w . 11 S u c w

T22432

i

F&.19-46 Remuwt'ng back-up Iight ( T n r c k )

7.

Room light

Truck

Van

1 Rear oornbinalion light ass'y

3 . Bulb (I ZV-2115W)

7 Lens complete 8 Pan hm~dscrew

2

3

Room light Bulb

.

T22034

Fig. L1-45 Rear combimfion light (Truck)

Fig. W-47 Room light

-

2- 7.

FUSE AND WIRING HARNESS In addition to the fuse box located on the instrument

: panel which contain the f.ises shown in box below. FUSE 5A

15A

A

:

2 0A

WIRE COLOR

ITEM

Red-Blue

Tail lights License plate light

Green

Turn signal lights Stop light Back-up light Horn Wiper motor Drive motor fan key switch

Red-Yellow

Headlight upper beams Hazard light Xoom light

Red-Green

Headlight lower beams

r

m 2 5A

Black

Fan motor Vent fan accessory cirpuit (Radio) (Cigarette lighter)

Additional fuses are located as follows: FUSE

WIRE COLOR

ITEM

LOCATION

3ied

Heater

Under dashboard and behind fuse box.

3 5 0 AMP

Cable

Drivemotor

15 APIP

3lack

Controller

16 AMP

1----30 AMP 1----Black

,

Next to auxiliary battery. Above

Aux. Battery Above charger

2- 7.

FUSE AND W I R I N G HARNESS

I n a d d i t i o n t o t h e fuse box l o c a t e d on t h e i n s t r u m e n t p a n e l which c o n t a i n t h e f u s e s shown i n box below. Fuse 5A

Wire Color

Item

Red-Blue

Tail lights License p l a t e l i g h t

15A

Green

Turn s i g n a l l i g h t s Stop l i g h t Back-up light Horn Wiper motor D r i v e motor f a n key s w i t c h

20A

Red-Y e l l o w

H e a d l i g h t upper beams Hazard l i g h t Room l i g h t

20A

Red-Green

H e a d l i g h t l o w e r beams

2 5A

Black

Fan motor Vent fan a c c e s s o r y circuit (Radio) .(Cigarette lighter)

A d d i t i o n a l fuses a r e l o c a t e d a s f o l l o w s : The 1 6 amp h e a t e r fuse i s l o c a t e d i n a s p r i n g l o a d e d fuse h o l d e r , w i t h red w i r i n g , under t h e d a s h b o a r d b e h i n d t h e fuse box.

The

350 amp fuse f o r the d r i v e m o t o r i s located by t h e b a t t e r y power

pack, on o n e s i d e of t h e accessory b a t t e r y . The 1 0 amp fuse, part of t h e d r i v e m o t o r ' s c o n t r o l l e r , i s next t o t h e large fuse. A 30 amp fuse f o r the a c c e s s o r y battery i s l o c a t e d i n t h e l o w e r r i g h t

c o r n o r o f t h e v a n , above t h e b a t t e r y c h a r g e r compartment. This fuse is e a s i l y a c c e s s i b l e , but is not readily seen. I t can be l o c a t e d by r e a c h ' i n g under t h e deck i n t h e r i g h t c o r n o r .

CHAPTER 3:

33-

3-

. 2. 3. 1

CLUTCH

..................... DISASSEMBLY AND REASSEMBLY . . . . . . . . . .

DESCRIPTION

2

CLUTCH

3

TROUBLESHOOTING

. . . . . . . . . . . . . . . . . . .

7

1.

The clutch control mechanism is a mccha.

DESCR IPTlON

.3,.1.

nical type of simple construction as shown in figure. The clutch cover is a n overcover type strap drive system. The spring is a diaphragm type which has an excellent characteristics such as less change o r installed spriqg setting load against the wear of the clutch disc and can be operated with light pedal pressure. Woven asbestos i s used for the facing material of the d u t c h disc,. The clutch disc is provided with torsion springs (coil springs) to absorb rotational shock a t clutch engagement.

Construction

1 Clutch disc 2 Clutch cover 3 Clutch rckav bearing 4 Clutch r c k n w fork 5 Clutch cable 6 Clutch pedal

T 10-001

Fig. W Clutch system

2.

Specifications

l tern

Value

Outer diameter of cover

206 mm (8.1 102 in)

Outer diameter of pressure plate

I 63 mrn (6.4 1 73 in)

Inner diameter of pressure plate

107 mm (4.2126 in)

4

Cover

Setting load of diaphragm spring Fitted diaphragm height (from cover installing surface of flywheel)

1202 10 kg (264.55

24.1

Facing material

Disc

compressed thickness Free thickness

+ 0.8 mm (0.9488 + 0.0315 in) Woven asbestos

Numbcr of facing Dimensions (Out. dia. x Inn. dia, x Thickness)

2 22 Ib)

2 1 6 0 x 11Ox3mm

(6.2992 x 4.3307 x 0.1 18 l in)

+ 0.2 mm (0.2795 + 0.0079in) 7.9 + 0.2 m m (0.31 10 2 0.0079 i n ) 7.1

Number of torsion spring

6

Number of spline hub teeth

23

.

;'

3- 2.

CLUTCH DISASSEMBLY AND REASSEMBLY

T 1c o o 2

1 Clutch di'sc

2 Clutch mxr 3 Balt(6xlSx18) 4 Clutch rekasc bearing 5 Rekut bearing holder

:-

p

,

.. r

6 Release bearing holder spring 7 Clutch release fork 8 Straight pin (5 x 22) 9 "0"ring (10.8 x 1.9) I 0 clutch ~ k a lever s

'

r

Fig.

E Exploded

view of clutch

I. Clutch lever

Fig.

I)

211)

d. Replace the O-ring on the &itch release lever if worn or damaged. 3) Installation a. Apply grease (equivalent t o Unilube No. 2) to groove of the clutch release lever COMPL at t h e point indicated by arrows in Fig. B-3, and install I t t o the transmissibn case with the pin hole aligned t o that of the clutch release fork. ' Then drive in the straight pin (5 x 22) with its split end facing the contact surfau of transmission we.

Chtch fever componmts

Removal

a. Remove the transmission. (Refer t o Chapter 11.)

L

b. ~ e m o b ethe release bearing holder springs

8.

c. Remove the clutch release bearing @ and release bearing holder @ together. d. Using a special tool "Remover I1 (straight pin)'', drive out straight pin (5 x 22) @ until the clutch release lever compl. @ can be pulled out.

Special tool

d.

39879 1600 (Remover 11)

Remove the clutch release foik cornpl. Q .

Fig. llED Driving in straight pin

b. Apply grcase (equivalent to Unilube No. 2) . t o groove of the clutch release bearing holder a t the point indicated by an arrow in Fig. b - 3 , and put it on the transmission case guide along with the clutch release bearing. Join the pawl of release fork and relcaw: ' bearing holder with the release bearing holder sprinp.

2) inspection a. If the bearing is damaged, seized, or unsmooth in rotation, replace the ,clutch release bearing. b. R e p l a u any release bearing holder or clutch release bearing whose contact surfaces are unusually worn. c. Repair if the internal surface of release bearing holder and clutch release lever shaft are seized. Replace them if seizure is excessive. (Also check condition of the transmission case guide.)

I

6

@ and lever

Fig.

Installing holder spring

2. 1)

C l u t c h cover and disc Removal Remove the tral;smission, (Refer to C h p t c r

*-1

a.

b. Insert a special tool "Clutch disc guide" in the clutch disc compl. (Fig. L86)

NOTE: Apply a light coat of oil or grease on 14 mrn dia, shaft, the end of clutch disc guide.

Clutch disc'co~n~l. a. Measure the sinkage of rivets with sl~dc calipers. And rcplace the clutch disc if the facing is worn beyond the limit. -.

0.3 mm (0.01 I R in)

Sinkage limit

b. Replace the c h t c h disc If the torsion springs are broken or fatigued, or if the spline hub rivets are,loose, ,

. .

FivI Guide (Clutch disc)

c. ZJniformIy loosen bolts (6 nim) attaching the clutch cover. cornpl. by slaw degiees, and remove the clutch cover and clutch disc com pl.

NOTE: Be careful not t o let the'disc facing get soaked with grease or oil.

Fk.

FQ.

2)

Removing clutch

Inspection and adjustment Clutch'covet compl. a. Replace the clutch cover if the pawls of the diaphragm spring are excessively worn. b. Replace the clutch cover i T it makes any abnormal sound when shaken up and down, or if its riveted parts are in any way unusual. c. Replace i t if the contact surface of pressure plate is worn, warped, or damaged.

Fig.

Incpec:ing clutch

Meomring facing sinkuse

c. Check disc plate for runout whenever the old disc or a new one is installed. d. If runout e::ceeds 0.5 mm (0.020 in) at the outer circumference of facing [K = 75 mrn (2.95 in) from the hub center], replace or repair disc. See Figure t0-9. e. Put a special tool "Clutch disc guide" in thc clutch disc compl. and install t o the flywheel.

Tighten it with six bolts (6x1 8x1 8 rnm). Special toot

499745400 Guide (Clutch disc) Tightening torque

Fig.

-

1.0 L 0.075 kg-rn

Measuring runout

3)

Installation Instal! the clutch cover w m p l . to the flywheel by aligning two knock pin holes (clutch cover) with knock pins (flywheel).

Fig.

Knock pin

holes

3-

3.

TROUBLESHOOTING , -, . I

Condition and probable cause .-

--

-- - - .

Rem-edy

- -. .-

Adjust.

I . . N o clutch pedal play. 2. h'o play at release fork tips. M

*

Adjust.

,

Replace. _

3.

Oil-soaked clutch lacing.

4.

Worn clutch facing.

5.

Distorted pressure plate or nywhccl.

..

!

.

I

'

I

.

.

.

.. s

Replace. Repair o r replace.

,

. -. 1.

Excessive play of clutch pcdal.

Adjust.

2.

Excessive play o f clutch release fork.

Adjust.

3.

Reduced stroke of dutch release fork tips.

Adjust.

4.

Rusted splines of clutch disc and

Remove rust and grease, or replace.

.

main shaft. 5.

Excessive runout of clutch disc.

Repair or replace.

6.

Defective ~ a r t ( s )in control, or improper installation.

Repair o r replace.

t

I

Condition and probable cause

Remedy 4

3) Judder

.

.

.

The entire body vibrates uncomfortably when vchicle starts in half-clutch condition.

.

.

9 t h emery cloth 'or re-

1.

Hardened facing.

~ e ~ r i r place.

2.

Oil-soaked facing.

Replam.

3.

Broken o r fatigued torsion springs.

Replace disc ycompl.

4.

Improper contact of facing, or cxcessivt runout of disc.

Replace disc cornpl.

5.

Distorted pressure plate or flywheel.

Rcpair,or replace. I

6. Loose disc rivets: 7.

RepIaa.

Tighten, o r replace rnounling'rubber.

Loose engine mounting or fatigued mounting rubber. .

.

4) Noise or abnormal sound Examine whether the noise is generated when clutch is disengaged (1.2) or engaged'(3,4,5). 1.

Broken or worn release bearing, o r insufficient lubrication.

Replace.

2.

Eccenlric clutch cover and .bearing.

Repair o r replace.

3.

Loosened clutch disc hub.

Replace disc compl.

4.

Cracked torsion spring retainer.

Repla'ce disc compl.

5.

Fatigued or broken torsion springs.

Replace disc compl.

5) Rabbit-jump

'

.

.

.

'

.

'

.

.

. :. clutch engages suddenly in half-clutched s t a t c w h c n starting. Vehicle will. not accelerate smoothly, but moves forward jerkily.

1. ' 2.

-

Oil- or grease-soaked facing.

..

rurtrd splines of clutch disc . hub and main shaft.

I + ,

.

Replace. Rcplace.

Worn facing or loose rivets. W O ; ~dr

.:

,

-

Replacc, or remove rust and grease.

4.

Fatigued or broken torsion springs.

Replace.

5:

Distorted or partially worn flywheel and pressure plate.

Repair or replace.

. .

.

'

CHAPTER 4 :

TRANSI4ISSION AND TPANSAXLE

................. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . GENERAL D E S C R I P T I O N

3

.....................

6

. . . . . . . . . . . . . . . . . . . . . ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . INSPECTION

. . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . INSTALLATION

2

. . . . . . . . . . .

COMPONENT PARTS OF TRANSMISSION

DISASSEMBLY

2

11 13 21 22

-,&I,GENJ&~L

DESCRIPTION

...-F*. P)-1 Transmission

.

. .

,-.,.

Fig. a - 2

Ccar train

The transmission provides 4 forward and 1 reverse speeds; forward gears are of the inertia lock type with full synchromesh. Gear shift lever is a IImr shift type. I k a d d i t i o n to the former oil bath type lubrication system, an oil passage is provided in the main shaft to dircctly lubricate the bearings. This dual lubrication system improves lubrication performance. The differential is houscd with the transmission in a 2-section cast separable top and bottom, which is lubricated with common oil.

'

4-

2. SPECIFICATIONS

[

Model 1st

2n d Gear ratio

----.

3rd

4th Reverse Final rcduclion gear ratio Number of side gear teeth Diilertntial gear Number of pinion gear tceth Oil quantity

& T23B 4.363 (4811.1) 2.625 (4211 6) 1.809 (38121)

1 I I

.

5

1

i

1.107 (31/28)., - *.. 4.272 (4711 1) 5.733 (86/ 15) 18 13 0.9 L (0.95 U.S. qt., 0.80 Imp.qt.)

!

.

4-3.

1.

COMPONENT PARTS OF TRANSMISSION

.

.

...

.

.

.

.

Component parts of transmission case 2 Bolt m d washer u s y 3 Transmission cover

4 Caxket 5 Air bruBlrr pipe 6 Plug (8 x 10.5) 7 Shifter fork rail spring 8 BaU (6.350) 9 A h b r u t h c r nipple 10 Accent p1ungcr spring 1.1 Selector plunger 12 Shiftcr rrm shaft 13 Shifter m 14 Spring pin 15 Selector urn 16 Gear selector arm 3h;it 17 Oii level gauge

'

f 8 O h g (14.3 x 2.4) 19 Trmsrnirrion a r c

20 O i l m d ( 1 S x 2 5 x 5 ) 21 Stud (10 x 38 x 15) 22 Wa:hcr 23 Boll (8 x 45 x 20) 24 B o I t ( 8 x 95 x2O) . 26 Bolt and washer , 27 Boll (8 % 65 x 20) 2 8 S t u d ( 8 ~3 6 x 12) 29 Cmkct (20.5 x 26 x 1.5) 30 011 drain plug complctc 31 Transrni,rion case cap 3 *32 Washer (39 x 49.5 x t) 33 Transmislion case cap 34 Plug (1 3 x 5) '35 Washer (39 x 53.2 x 1 ) 36 Straight pin (4 x 22)

37 Shirter fork 2 *39 40 -41 42

Reverse shifter levcr Shifrcr urn 2 Shiftcr fork Shifter fork rail

-

43 Shifter fork rail 2 44 Shiflcr fork roil 3 45 Ball (5.5563) 46 S W t t r r.il plunge! 4 7 Bolt and w v h c r rzsy 48 Shifter I& plate 49- Shifter x a i l plate

I

53 54 55 56 57

Back-up light switch clutch u b l c c k m p )Sluminu,lr gasket Plug (14 x 9) Plug (clutch hourinn timinu hole). 58 Accent plun3e1 spring 2 59 Shifter fork spring ' Selectire puts

I

2.

Transmission gear component parts

.

,-

.-

-.

.

'1

-

.

1.

.

. 16 Thud driven gear 17 Synchxanizcr dctve 18 4 th driven gear 19 Neallc bcving (34 x SO x 20) 20 Ram (needle k i n g ) 21 Drivc pinion 22 Ball bearing (IY6303C3) 23 Washer (17.2 x 26 x 0.2) 24 Transmission main shaft 25 Ball k i n g (#6004) 26 Washer (31 x 40.8 x 0.5) 27 0 a 4 (19.8 x 35 x 7 ) 28 R e v e r r idler gear shaft 29 Straight pin (6 x IS) 30 Reverrc idler gear

Snap ring outer (20) 2 Eall b a r i n g (#6204 NR) 3 Washer (20.2 x 2 9 x 0.2) 4 Ball bearing (n6204) 5 Drivc pinion spacer 6 First driven gear 7 Synchronizer ring 8 Rcversc driven gear 9 Synchronizer hub spring 10 Synchronizer hub insert 1 1 Synchronizer hub 12 Gcax thrust spacer key 13 G e u thrust spacer 14 Second driven gear 15 Gear I h m t mpaccr 1 I

Selective p u t

Fig. S - 4 Exploded view

la - 4

Af

transmission

111-002

3.

Differential gear component parts

?

'

.

.

'5

$8

,

1 Oilseal(27x45x9] 2 Oil -1 retainer 3 BaU bearing ( j 6 0 0 7 ) .4 Washa (27.1 x 4 2 x t) 5 Diffcrcnttl sidegur

,

.

.

e,

'$8 %'asher (53 x 65.5 x t) 9 Diffcrcntial caw 10 Differential pinion shaft 1 1 Straight pin (4 x 35) 12 F i d g u r 1 3 F h l g m lock washer 14 Bolt (10 x 21 x 13)

6 Differential pinion 7 Oil d ( 2 7 x 62 x 9 )

\

.

,

Selective parts T 1 1-003 1

Fig. 1 - 5 Exploded view a - 5

of di/ferential

4-

1.

4. DISASSEMBLY

1)

Clutch lever Refer t o the paragraph "Clutch lever" for removal. 2 ) Transmlss~oncase Pull out the 011 gauge near the differential chamber of the upper case Place the transmission case upside down, unscrew twenty fixing bolts and disassemble the case into two sections T h e twenty fixing bolts to be loosened are 8 m m 18 pcs. and 6 mm 2 pcs.

Removal

1. Jack vehicle rear wheel off floor,. 2. piace jack under motor [for support only) . 3. Disconnect hose clamps and remove hoses from motor cooling fan. 4. Unplug red wire on fan and two red wires on transmission. 5. Remove fan. 6 . Disconnect axle shafts A. tap out spring pins, using a 3/16 inch punch. NOTE: DO NOT DRIVE PINS INTO TRANSMISSION HOUSING . 8. Remove gear shift rod on front of transmission. 9. Remove front and rear support bolts and 4 motor bolts. 10. Separate and removc through bottom.

8 m m Bolt. L = 4 5 m m ( l 77111) : 1 3 L = 65 mm ( 2 56 in) . 3 L = 95 mm (3.74 in) 2 '

6 m m Bolt. L = 3 2 m m ( 1 76in).?-

F ~ 7.

2.

Disassembly

NOTE:

Wipe the transmlss~on clean of grcasc and dirt. loosen d r a ~ nplug ( 7 0 x 10) and drdln oil Remove metal powder etc. attracted o n magnet of the drain plug. Retighten the plug after 011 1s d r a ~ n e d

T~ghtenlngtorque

Disassemhlrnf trnnsmlssion case

3 5 + 0.4 kg-nl ( 2 5 3 + 2.9 ft-lb)

,

When removing the lower case, be careful n o t t o lose the straight pin on the reverse idler shaft

a.

8

Main shaft, drive pinion and differential

3)

assemblies Main shaft

Fig. Pt-10 Components of muin shaft assembly

"

v

Fig. %1-8Disassembling transmission

-3 4

E )

:

.. P

Remove the washer and caps, and take out the main shaft assembly, drive pinion assembly, and differential assembly from the transmission MSC.

5

.

-Main -

shaft ass'y

b. Remove the ball bearing @ (#6004) and two ball bearings @ (#6303C3) with a washer (17.2 x 26 x 0.2) @ using a puller or press. 5) Drive pinion assembly a. Remove the snap ring with a special tool "Expander" and remove ball bearing (#6204 NR), washer (20.2 x 29 x 0.2), ball bearing (#6204) and washer (20 x 38 x 3). Special tool

Expander 899474 100

'Fig. H - 9 Disassembling t r a ~ m k s i o n

Main shaft assembly. a. Remove oil seal @ J (19.8 x 3 5 x 7) and washer @ (31 x.40.8 x 0.5). (Fig. S-10)

4)

NOTE: Before removing oil seal, cover the spline of the shaft with tape t o prevent damage t o the lip.

Fig. 9 - 1 1 Removing rnup ring b. Remove the 1st driven gear. synchronizer ring, and hub assembly (1st & 2nd speeds), Then remove the key (gear thruit spacer).

I

6)

Hub assembly (1 st & 2nd spetds)

Fig. I - 1 2 Removing key (gear thrust spacer)

c. Remove the gear thrust spacer 0 ,synchronizer ring 0 , 2nd driven gear @ , gear thrust spacer II @, 3rd driven gear @ , synchronizer ring @, gear thrust spacer I1 0 ,hub assembly (3rd & 4th speeds) @ , synchronizer ring @, 4th driven gear @ , and gear thrust spacer I1 @ in that order.

Fig. W-f 4 Hub assembly (I st B 2nd speeds)

'

Fig. l - 1 3 Duassembled drive pinion assembly

Remove the synchronizer hub springs @ and pull out the synchronizer hub inserts@ Separate the reverse driven gear @ from the synchronizer hub 0 . 7) Hub assembly (3rd & 4th speeds)

~ & . @ - 1 5Hub assembly (3rd & 4th speeds) r . f-

d. Remove the needle bcaringi:@.,(34 'y 20).

x

50 x

~ e m o v cthe synchronizer hub springs @ and pull out the synchronizer hub inserts @. Separate synchronizer hub sleeve @ from the synchronizer hub @.

8)

Diifcrential assembly

*

7

-

-

"

I

.,.

..>

.

.

.. -'. ->.;..,,.

a,

.

-

.-

Fig. *-I8

Removing side gear

Fig. @ - I 6 Removing oilseal

a. Wind vinyl tape on the spline of side gcar

shaft t o prevent damage l o oil seal lips. Remove the oil seal (27 x 62 x 9) from the differential case side first. Then remove the oil seal (27 x 45 x 9) and retainer from the final gear side.

d. Drive the straight pin (4 x 35) @ out from the differential case @ sidc and then differential pinion shaft @. Remove the differential pinion @, differential side gear @, and washer (27.1 x 42 x t).

b. Straighten the bends of lock washers on the final gear, and remove the bolls (10 x 21 x 13) to separate the final gear from the differential case.

Fig. m-19 Driving out straight . . ,

.

NOTE: 1%' Keep the sidc g e a r s and adjusting washer separate with reference to t h e final gear side and differential case side. '

Fig. #-I 7 Drivivg o u t straight pin

c. Remove the differential side gcar and washer (27.1 x 42 x 1) from the final gear side.'

e. Rcnrove'the ball bearing (lj16007) from the final gear and differential case with a puller or press.

Gear shift mechanism of transmission cover compl,

9)

Fig. 1 - 2 1 Removing plug and sekcrm

phngn Fig. 111-20 Gear shijt mechnism

Loosen four 6-mrn bolts (L = 25) and remove the transmission cover compl. Take out spring pin (6 x 28) using a special tool "Straight pin remover II", separate the gear selector arm shaft compl. @ from the selector arm 0 , and remove the shifter arm @ and shifter arm shaft @.

a

special tool :

-

.

Straight pin remover 11: 398791'700

10) Reverse accent mechanism of transrnission cover (Fig. 8 -21) a. Loosen the plug (8 x 10.5) @ and take out thc shifter fork rail spring @ and ball (6.350) - . .. b. Remove the :&lector plunger @, accent plunger sprin&@ and accent plunger spring 11 @. -

!: .q., Y

I

11) a. Loosen two 6 mrn bolts ( L = 12 mm). Remove the shifter rail spring plate 0 , three shifter fork rail springs @ , and thrcc lock balls (6.350 rnm dia.)@ . Then remove shiflcr rail plate @ by loosening two 6 mm bolts ( L = I 2 mm).

a.

.

,

Fig. &-22 Removing rhiftrr rail spring plate b. Using spechl tool "Shifter fork pin extraclor", remove the straight pins (4 x 22) @ for the 1st & 2nd speed shifter fork 3rd & 4th speed shifter fork I1 0 ,and reverse shifrer arm 11 @. (F~~.'P-23) for 1st ' Then, remove the shifttr fork rail and 2nd speeds, shifter fork rail I1 @ for 3rd and 4th speeds, and shifter fork rail 111 for reverse in that order. Rail 111 should be removed after taking off the back-up Light

a,

a

12)

Fig. B-23 Removing shijter fork

switch (with aluminum gasket). Remove the and 0 ,shifter arm I1 0 , shifter forks and reverse shifter lever @) from the transmission case. c. Four interlock balls (5.55 rnm dia.) are provided in the interlock holes in the transmission case, two balls tach between the threc shifter fork rails. Remove these baUs carefully so as not to lose them. Take care not t o lose the plunger installed on rail 11.

a

Revtne idler gear

Fig..#-25

Removing reverse idler gear

0

Take out the straight pin (6 x 15) and remove the reverse idler gear compl. @ by moving the reverse idler gear shaft @ to the clutch side. The reverse idler gear shaft @ should be removed outside after the plug (1 3 x 5) @ is driven out.

NOTE: Do not remove the reverse idler

ear

shaft

unless necessary.

4-

5. INSPECTION

Thoroughly clean ail disassembled parts and theninspect. *

1 Rail 111 (Shifter fork) 2 Raii I! (Shifter fork) 3 Plunger (Shilter rail) 4 Interlock baU (5.55) 5 Spring (Shifter fork rail) ,. 6rLock ball (6.350) '('7 'Rail (Shilter fork) -

-

-

. r'

NOTE: Oil seal must never be washed in gasoline as it causes their lips t o swell.

-

i.

? 7.

Gears

Tll.007 -

Fig. a - 2 4 Component parts of shiftcr mi! and lock balk

I) Replace gears whose teeth surfaces are broken, damaged or unusually worn. 2) Replace gears if the cone surfaces with which the synchronizer rings are in contact are seized or damaged. 3) Replace any bearings whose inner walls or end faces are excessively worn or damaged. 4) Replace any spacer whose end faces are excessively worn or damaged. 5) Thrust clearance of each gear

3.

Gear

Gear shift mechanism

'.

Standard value

1st

0.050- 0.350 nim (0.0020- 0.C 138 in)

2nd &-3rd

0.110 - 0.430 m m ,(0.0043- 0.0169 in)

I ) Check the clearance between the shifter fork and the groove of the synchronizer hub sleeve. .

Standard clearance'

0.2- 0.4 rnm - 0.0157 in)

(0.0079

0.1 10 - 0.480m m (0.0043- 0.0189 in)

4th

~ e ~ l a c the e ' lock ball (6.350 .mrn dia.), shifter rork rail spring, shifter rail plunger, and interlock ball (5.55 mm dia.) if they are excessively worn or deformed,

2)

2.

Synchronizer ring

1 Back lamp switch 7 Arm (Selector) 2 Rail Ill (Shifter fork) 8 Shaft (Shifler arm) 3 Rail I1 (Shifter fork) 9 Folk (Shifler) 4 Rail (Shifter fork) 10 Fork I1 (Shifter) 5 Straight pin (4 x 22) 11 Arm 11 (Shillex) 6 Arm (Shifrtr) 12 Lever (Reverse shiftcr) Tll-009

Fig. a - 2 6 Ring-lo-cone clearance

Fig. W-2 7 Inspecting gear sliifr mechanism I

1) Replace any synchronizer rings whose internal zurfaces or teeth surfaces are damaged or excessively worn. 2) : Measure; the' clearance "C" between the ends facing ep$h other with the ring pressed onto the cone'of the gear.

3) Replace the shifter fork rail if the edge of . lock ball groove is worn.

4.

Bearing

Replace the bearing if seized, worn,noisy. or unsnioofh rotation. Standard value of "C"

1.3 - 1.7 mrn

(0.051 2 - 0.0669in)

5. i)

Oil seals and caps

3) Replace the ring if its contact surface with

Oil scats Rcplace any oil seal whose lips arc deformed, hardened, or worn. Also replace if its periphery i s damagcd. 2) Caps Replace any cap whose periphery is dam-

the synchronizer hub inserr is excessively worn.

aged.

Lirnil value "C"

of

0.5 mm (0.0197 mm)

-

6.

Other parts

keep the clearince of outer race of the two

Replace any part if it is dcformcd, exccssively worn, or defecfivc.

7.

Differential ..

I ) Replace the 'final gear and drive pinion if the iooth surfaces are damaged or excessively warn. 2) Replace the drive pinion if the contact surface with the needle bearing inner race or the gear sliding spline is excessively worn. 3) Replace the differential pinion, side gear, washcr (27.1 x 42 x t), and pinion shaR if they are seized, worn, or damaged. 4) Rcplace lhc differential case if crackcd or defective in any other respect.

ball bearings. 2 ) Apply grease [equivalent to Uniiube No. 21 between the lips of the oil sea1 (19.8 x 35 x 71, wind tape around the main shaft spline and carefully install the pit seal on the shaft.

4- .6. ASSEMBLY

Fig. 9 - 2 9 I m t a l l b ~ goil seol

The transmission and differential should be assembled in the reverse order of disassembly. Points requiring attention in assembly arc described below. Be sure toapply gear'oil to each part before assembling.

1.

2.

NOTE: The needle bearing has installing direction, when install the bearing, set *Z1" side to the gear side. .

Main shaft a s s e m b l y

.

1) The ball bearings (f6004, #6303C3) should be press-fitfed by a press with the stamped side facing out,

8all bearing (f6303C3)

.I

Drive pinion assembly

L,>L2

-

'

I

To gear side

I Inner

Needle bearing Tll-011

-

-

I

Fig. 01-30 Installing direction of

. needfe Fig. 1 - 2 8 Ball beurings G washer on muin shaft NOTE: The washer (17.2 x 26 x 0.2) is installed between the ball bearings W6303C3) to

1)

bearing

Hub a&drnbly (3rd & 4th spceds) Instal! the synchronizer sleeve s o that the *mark part in Figure 8 - 3 1 may be placed on the H, side of 38 rnm dia. boss of thc synchronizer hub.

4)

Hub assembly ( l st & 2nd speeds)

Fig. 1 - 3 1 Assembling hub ussembIy (3rd G 4th speeds) :

Set the synchronizer spring so that the cut ends of spring on both sides be in opposite direction, and make sure that the insert is properly installed. 2) The hub assembly should be installed on the drive pinion in such a manner that the H2 side of the 38 mrn dia. boss faces the 4th driven gear and the untoothed part of angular spline of the synchronizer hub is placed away from the oil hole in the drive pinion. ( H >~H I )

NOTE: This untoothed part is where the gear thrust spacer key is s e t 3) The gear thrust spacer betwecn the 2nd driven gear and hub assembly (1st & 2nd speeds) should be inserted with the end face with a notched groove (6.6 mrn wide, 1 .S mm deep) facing the 1st driven gear and aligned to the untoothed part of the above spline. Put the spacer key in the notched groove t o lock.

Fig. I - 3 3 InstuIling hub a$sembly (1st ond 2nd speeds)

Install the reverse driven gear so. that the fork groove side may be placed on the H I side o r 38 mrn dia. boss of the. synchronizer hub. (HI
>

.

Washer ft

-

#62M NFi 3)

Washer (20.2 x 29 x 0.21 T I 1.015

Fig. 9 - 3 4 Rear bearings on drive pinion

F*. 11 -32 Instolling g m r thrust spacer

NOTE: The washer (2b.2 x 29 x 0.2) is inPtalled t o keep clearance between bearing outer races.

,

3.

7) Select a snsp ring that will provide a clearance of 0 to 0.05 rnm (0 to 0.0020 in) between the inner race end fact of ban bearing (#6204 NR) and the snap ring. Press fit the snap ring in the groove using a special tool "Prcss assembly" and make sure that the snap ring isrccurely seated in the groove.

; 5-.

.

.-

.,-

-

.

, '

. - - A

.

Differential assembly

1) Press fit the baU bearings (#6007) onto the final gear and differential case i n a d v a n a . 2 ) Select a suitable adjusting washer t o adjust the differential backlash t o 0.05 t o 0.15 mm (0.6020 t o 0.006Win) and install on the back o i the side gear.

: - . . :

1 Adjusting washer 2 Pinion (Differential) 3 Adjusting washer 4 Gear (Dificrcntkl side)

-.-.

NOTE: Always replace the snap ring once it has

A

Tl1-016

Fig. t&36 Adjusting washer

been removed,

NOTE: Selective adjusting washers must be assembled with t h e chamfered face of the washer toward the gear.

Guide (snap ring) 899754121

Special tool: Press assembly 899754 100

Press (snap ring) 899754 102 J

Adjusting washer Snap rings Part No. Part No.

Thickness

805020022

2.5 I t 0.01 5 mm (0.0988 0.0006 in)

+ 2 5 7 + 0.015 rnm (0.1012 + 0.0006 in)

805020024

-

80S020026

805020028

'

2.63+0.01Smm (0.1035 0.0006in)

+

+

2.69 0.015 mni (0.1059 2 0.0006 in)

Thjckness

80312708 1

1.000 rnm (0.0394 in)

803 127082 .

1.050 rnm (0.041 3 in)

803 127083 .

1.lo0 rnrn (0.0433 in)

r;

'<.

3) Tighten bolts (10 x 21 x 13) to the specified lorque and bend the lock washers (final gear).

5)

Reverse idler gear

.

:

Fig, St-39 Installing reverse i d l e r g a r Fig. XI-37 Bending lock wnrher

Install the reverse idler gear shaft @ on the with the pin hole facing outside. Then. put the reverse idler gear @ o n the shaft as the groove i n . which .the lever is placed faces outside, and lock with fhe straight pin (6 x 15). (Apply a small amount of grease lo the pin head t o prevent i t from falling off when assernblingthe-cast I.) Drive the plug (1 3 x 5) into the case. case

Tightening lorque (10 mm Bolt)

6.3 (45.6

+ 0.5 kg-m + 3.6 Tt-lb)

4) Apply gearoilbetween the l i p s o f t h e o i l seals (27 x 45 x 9 , % 27 x 62 x 9). Wind tape around the side gear spline and install the oil seals carefully. Be sure to keep a gap of about 3 m m between the oil seal (27 x 62 x 9) and the end face of ball bearing (#6007). Keep the oil seal (27 x 45 x 9) in close conlact with the oil scal retainer.

Gear shif-t mechanism

4.

I)

Transmission cover

1 2

3

.

Fig. S 3 8 Installing oil scal

Spring (Acotnt plunger) Spring 2 ( A c a n t plunger) Selector plunger

Fig.lP-40Tra~muJionc0verCOMPL Coat the screw of plug (8 x 10.5) with liquid

packing (Fuji Bond "C" or equivalent). While inserting the shifter'arm shafi into the cover as a guide of selector plunger and accent plunger

springs, screw in the plug with the selector plunger pushed fully inward until the plug head becomes flush with the cover surface. Makc sure that the selector plunger pushed ope:ates smoothly. 2 ) Shifter forks and shifter fork rails ., The shifter forks and rails should be installed in the following manner, beginning with the reverk side.

+.

Part No'

, Identification mark on lcver

Remarks Approach to the I st gear side

3A2772101

,.. A

342772 102

B

Standard

342772 103

C

Approach to the 2nd gear

'

side

NOTE: After having determined the lever, use washers of correct thickness t o provide 0.5 t o 1.0 mm (0.0197 to 0.0394 in) clearance between the lever and gear compl. (reverse .idler).

Fig.

a -41

Itutalling shyter a m I I

.

.

a. With the lock ball groove on the shifter fork rail 111 facing down, put the rail through the case. lnstall the reverse shifter lever @ in the reverse shifter lever shaft pressfitted in the case, and put the shifter a r m I1 @ o n top of the lever as shown in Figure -1. Then align the pin holes in rail 111 and a m 11 and drive the straight pin (4 x 22) therein. . . b. Temporarily assernbie the lock ball (6.35 rnm dia.) with the shirter fork rail spring, and shift the reverse shiftcr lcver to the reverse side. Place the drive pinion assembly and main shaft assembly in the normal position (as far over on the d u t c h side as possible), and apply red lead t o the tooth surface of reverse driven gear. Put case I over them with the tip of reverse shifter lever placed in the groove of the reverse idler gear compl. tc check the mesh of the gears, and select the reverse shi fter lever that provides tooth contact of 80%or more.

Reverw! rhilter lever

a

Fig. r-42Adjusting the fiver porition ' 'i. I' I

~ d j u s t i k gL s h e r .

Part No. 803015082

-

.

~hickidss '

1.1 m m (0.0433 in)

803015086

0.8 mm (0.0315 in)

803015087

0.4 rnm (0.0157 in) i

.

Then remove case I and set the reverse shifter Iever t o the neutral position. c. Put two interlock balls (5.55 mrn dia.) in the interlock holes of the case side. Apply a small amount o f grease to the baUs t o prevent them from falling off during anem-

bly. d. Install raii I1 fn the case as in Step (a.) on page 11-17), assemble fork 11 with it, and lock by driving in the straight pin (4 x 22).

(Fig. 8 - 4 1 ) Operation similar t o Step (b.) f. Install the rail. in the case in the same manner as step(a.),assemble the fork with it and drive in the straight pin (4 x 22).

t.

Fig. H4.S Selecting shifrer fork I I

Temporarily assemble the shifter fork rail spring and lock ball (6.35 mm dia.), and place the forks in the neutral position. Select the shifter fork and shifter fork I1 so that the synchronizer sleeve and reverse gear wit1 be set as shown in Figure 8 - 4 2 when the drive pinion assembly is placed in the normal position. Shifter fork

Fig. PI43 Installing sh$er fork

Part No.

Identification mark on the fork

342012101

A

Approach to the 2nd gear side

342012102;

B

Standard

3420 I2 103

C

Approach to the 1st gear side

g.-.Selecting shifter fork and shifter fork 11 Shifter fork I1

Fig. a 4 4 Selecting shifter fork

81 - 1 8

.

Remarks

.

Part No.

ldentificidon mark i;n the fork I1

Remarks

3420221 1 I

A

Approch t o the 3rd gear side

342022 112

B

Standard

3420221 13

C

Approach t o the 4th gear side

h. Tighten the shifter rail spring pLtt and shifter rail plate with two &mm bolts (L = 12 mm) tach. The shifter rail spring plate should be installed with the flange for the harness clamp placed outside. Tightening torque (6 mm Bolt)

1 + 0.075 kg-m (7.23 2 0 5 4 ft-lb)

i. Tighten 'the back-up light switch t o the specified torque. Be sure to use the aluminum gasket.

Tightening torque

1.8

Fig. H-47 Mmsuring ckumacc

+ 0.2 kg-m

FQ. 1 - 4 8 Meusuring clearance

Fig. a - 4 6 Installing lmck-rcp light switch

. 3) Washers and caps a. Place the main shaft assembly, drive pinion assembly, and differential assembly in the standard position (wkijirc?.the main shaft and drive pinion asscrnblies are all the way over on the clutch side and the differential assembly is on the side opposite t o the clutch). Select and install a washer that provides a clearance of 0.01 to 0.2 mm between the washer and each end face of the main shaft #6303C3 ball bearing, drive pinion #6204NR ball bearing, and differential #6007 ball bearing. (Refer t o Figs. a-47 and -48.)

5..I

Wssher (39 x 49.5 x t) for main shaft Part No.

I

Thickness (rnm)

I

Washer

x

53.2 x t) for drive pin'ion,

Part NO.

Thickness (mm) +O

803039031 803039032

-0.03 +O ,

2'20 -0.03

803039033

+O 2.35 -0.03

803039034

+O 2'50 -0.03

Washer (53 x 65.5 x I) for difrercntial

Joining transmission case Iloroughly remove oil and dirt 'from the mating surfaces o i case I and case I1 and ~pplyliquid packing t o case 11. Then place m e I on case 11. Belore doing so, move the tverse idler gear cornpl. to the clutch side ~ n dassemble the' tip of re-verse shifter lever with the groove on the reverse idler gear :ompl.

/E11

-

Part No.

Thjckncss (mm)

;o

80305301 1

2'3 -0.03

+O

SO3053012

803053013

la

-a

2'5 -0.03

+0 .

.2.7 -0.03

After having selected the washer for the differential, place the oil seal (27 x 62 x 9) in contact with the washer using an installer. b. Attach the caps (transmission case) 10 the washers on the main shaft assembly and the side of drive pinion assembly. Install cap I I I (transmission case) with its positioning notch aligned t o the case side positioning groove on the front side of drive pinion assembly. .

Bolt

-

8 x 45 mm 13 p a .

A 8 x 65 mm 3 pcs 0 8xSSmm2pa. 0 6r32mm2pa. T11-021

Fig. M-50 Sequence of tightenittg care

,

b. Tighten t w o 6-mm bolts and eighteen 8-mm bolts in the numerical order given in Figure 11-50.

Tightening torque 6 mrn Bolt

8 rnm Bolt

+

1 0.075 kg-rn (7.23 2 0.54 ft-lb)

2.5 (18.08

+ 0.2 kg-m + 1.4 ft-lb)

c. Install the oil level gauge with the transmission cover up. 5) Checking gear shift a. Assemble the selector arm with the gear s e l t c ~ o rarm shaft compl. and drive in the spring pin (6 x 28). b. Assemble the shffter arm and shifter arm shaft, and check gear shift.

4-

7. INSTALLATION

Installation should be performed in the reverse order of removal. First make sure that the release bearing,is not projecting, and then start installation. Never install the transmission while holding the clutch release lever compl.

..2. Secure the transmission t o the engine with four 10-mrn bolts.

Tightening torque (10 run Bolt)

4.5 2 0.3kg-m (32.62 2.2 ft-lb)

3. Fk. a - 5 1 Checking gear shift condition c. Tighten

the

transmission cover

Remove the oil level gauge and fiU the transmission with gear oil (MP $80). Straighten the bent tip of the oil level gauge.

compl.

along with the gasket using four 6-mm bolls (L = 25 mm).

(0.95 U.S. qt.. 0.80 Imp. qt.) e

Tightening torque

(6 mm Bolt)

6)

1 + 0.075 kg-m (7.23 0 5 4 ft.lb)

+

Clutch lever 3 Refer t o Chapter m,"CLUTCH"

4- 8. TROUBLESHOOTING Remedy

Condition and probable cause

1.

Difficult gear shifling Difficult gear shifting is usually caused by a change rod failure andlor a transmission failure. At the same time, however, when the lever feels heavy and gear shifting is difficult, it may be the result of sn improperly disengaged clutch. Therefore, first check that the clutch is operating properly and then check the change rod and transmission.

(1)

Adjust or replice.

Loose or separated change rod connections.

Re pla ce .

(2) Worn, broken or burred chamfers of internal splines of sleeve and reverse driven gear. (3) Worn, broken, or burred chamfers of gear splines.

Replace.

(4) Insufficient operating stroke due t o worn sliding part or rattling.

Repair or replace.

(5) Improper contact between synchronizcr ring and ring gear cone, or worn contact surfaces.

Repair.

2.

Gear slips out.

( I ) Worn shifter fork, or fatigued or broken shifter fork rail spring. (2) Worn lock bail groove in shifter rail.

Replace.

(3) Worn or damaged ball bearing.

Replace.

(4) Excessive clearance between synchronizer hub and sleeve splines.-

Replace.

(5) Worn chamfers and flank of each

Replace.

Replace. .

gear spline. 3

'4

Noisy transmission

If a noise is heard during idling but stops when the d u t c h is disengaged, the problem is probably in the transmission.

.

(1) -"

Add oil or change t o recommended oil.

Insufficient lubrication or use of inadequate oil.

(2) Worn or broken gear and bearing.

..

Replace.

I

C

Remedy

Condition snd probable cause

NOTE: High humming i s heard at high speeds if the wear has progressed t o the extent that the tooth surface is worn. I n case of breakage rotational knockihg sounds are heard even a t low

a

speeds.

(3) Worn splines. 4.

Replace.

--

.

.

Breakage o f differential (casc, gear, bcaring, etc.) This causes an abnormal noise and a failure i n rotation, making it impossible for the vehicle to run.

(1) InsufOcient oil or use of inadequate oil. (2) I rnproper use of vehicle such as overloading, improper use of clutch.

Disasscmble differential broken parts.

(3) Excessive backlash due to worn side gear, wssher (27.1 x 42 x t) and pinion.

Adjust backlash and tooth contact.

(4) Bolts fixing final gear loose.

Fill recommended oil to specified level.

5.

and

replace

Check parts for condition and replace as necessary. L!

Noisy differential and final gear In the casc of a differential failure and finat gear failure, various distinctive sounds can be heard and the source o f trouble can often be isolated by listening closely to these. Be careful not to mistake a symptomatic sound for one coming from the engine, muffler, tires, bearings, body, elc. Particularly, the sound o f final gear is often confused with other gcar sounds. The different kinds of noiscs arc as follows; ( 1 ) Noisc at starting or gcar shifting

insufficient gear oil, improperly mesfing gears, or broken gears are the cause when the noise increases as vehicle is accelerated.

(2) Bearing noise while acccleraling or coasting Cracked or broken bcaring.

(3) Noisc produced mainly while turning Abnormal noise of differential side gear. differential pinion, and differential pinion shaft. (1) insufficient oil. (2) Excessive backlash between ferential side gear and pinion.

Add oil to normal level. dif-

Replace gear or washer.

-

Condition and

Remedy

cause

(3) Worn teeth of final gear and drive pinion.

Replace as a set

(4) Broken differential pinion shafr.

Re place.

( 5 ) Seized o r damaged bearing.

Replace.

(6) Worn washer .(27.1 x 42 x t ) and pinion shalt.

Replace.

CHAPTER 5 :

SPECIFICATIONS

SUSPENSION

. . . . . . . . . . .

O U T L I N E OF SUSPENSION

WHEEL ALIGNMENT

.......

...........

COMPONENT PARTS OF FRONT SUSPENSION

COMPONENT PARTS OF REAR SUSPENSION

. . . . . . . . . REAR SUSPENSION . . . . . . . . . POSTURE ADJUSTMENT . . . . . . . ADJUSTMENT O F WHEEL ALIGNMENT . . FRONT SUSPENSION

TROUBLESHOOTING

. . . .

. . . . . . . . . .

5 - 1. SPECIFICATIONS 1.

Front suspension

v I

I tem

Torsion bar

Total length

504.5 rnm (19.86 in)

Effective length

434.5 mm (17.1 1 in) 19.5 mm (0.768 in)

Effective diameter

Number of serration teeth

Shock absorber

Helper

4.22 kg-m/deg. (30.5 ft-lbldeg.)

Maximum length Minimum length

278.5 mm (10.96 in) 187.5 rnm ( 7.38 in)

Damping force (at 0.3 m b c )

Expansion

88 kg (194 Ib)

Compression

56 kg ( 1 23 Ib)

Rubber hardness

62"

Outer Diam. x inner Diam. Length

Inner bearing

Outer iriarn. x lnncr Diam.

---

Lcngth

Rear suspension item

-

Helper

Rubber bushing

-

3 0 m m (1.18 in)

VAN (K87) I mm (20.75 in)

Inner end: 3 7

Outer end: 34

269 mrn (1 0.59

hlaximum length Minimum length

ir;) 7

ExPnsion Compression

213 mm ( 8.39 in) 88 kg (194 lb) 6 4 kg (141 Ib)

59.5 mm (2.34 in) 50"

Height Rubber hardness

Outer budling

58.4 mm (2.30 in) x 53.0 mm (2.09 in)

6.7 1 kgm/dtg. (48.53 ft-lbldeg.)

-

Damping force (at 0.3 mlsec)

30mm (1.18 in)

22.5 rnm ( 0.89 in)

Effective diameter Number of serration teeth

absorber

56.4 mm (2.22 in) x 5 I .6 rnrn (2.03 in)

483.5 rnm (19.04 in)

Effective length

Spring constant

1

70"

527

Total length

Shock

57.5 m m (2.26 in)

5 5 mm (2.17 in)

Height

Bearing

Torsion bar

Outer end: 34

Inner end: 37

Spring constant

Outer bearing

2.

VAN (K87)

Outer Diam. x Length Rubber hardness

52.8 mm (2.79 in) x 44 m m (1.73 in)

so0

;. . C.

v

-

NOTE: a. The length of the shock absorber is measured as shown in figure.

Front shock absorber:

. Lsngrh

Rear shock absorber:...--

4~1

b. The length of the helper is measured as shown in figure. Front helper.

Rear helper.

5- 2. OUTLINE OF SUSPENSION ?.. . e.,.

The front suspension employed is of a semitrailing arrn type. The front crossmember, which is integral with the chassis frame and located ahead of the front wheel center, houses torsion bars that are the main springs for the front suspension. Both ends of the torsion bar are provided with serrations; inner cnd is anchored a t the center of the crossmcmber and the outer end is connected to the trailing arrn.

.Y

The trailing arm swings up and down w i t h ' the crossmember acting as the pivot. Slidc occurs between the nylon bearing press-fitted inside the trailing arm, which is adopted t o give a smooth slide, and the metal sleeve press-fitted on the crossmcmber. The upper end of the shock abosrber is attached to a bracket on the chassis frame and the bottom end is installed on a pin welded on the trailing arm near to the center of the wheel.

The rear suspension is of a semi-trailing, independent type using outer and inner trailing arms. A crossmember, integral with the chassis frame and located in front of the trailing arms, houses torsion bars. T h e inner ends or the torsion ban are connected to the center arm st the center of the crossmember, which serves as vehicle height adjuster, and the outer ends of the torsion bars t o the outer trailing arms.

The inner and outer t r d i n e anns rrc connected to Lhe crossmember through rubber bushings. The upper end of the shock absorber is attached to a bracket on the chassis frame, and the lower end to the pin on the inner arm, As an auxiliary mpring. a helper is installed on a bracket welded to thc chassis frame on each side.

Front

275-305 mm (10.8-12.0 in)

Rcar

260-295 mrn ( 1 0.2-1 1.6 in)

Front

2010' -60'

Rear

3 O 15' -60.

Vehicle height*

+30' '

Camber**

CastereL

Front

+30*

15~25' i45'

Front

IN 8-1 3 mrn (0.3 -0.5

Rear

IN 9-1 5 mm (0.35-0.59 in)

in)

Toe -in ,

.

. .+

Front

IN 3 mm (0.1 in) t o OUT 3 mrn (0.1

p i d e slip***

in)

Rear *2O

Inside

37"

Outside

3 3 O 3 0 ' *2O

Turning angle*+**

Distance between ground and center of torsion bar outer end facc, with vehicle unloaded. Difference between right and lcft should be less than 10 mm (0.39 in). * * With vehicle unloade. *++ With driver in vehicle. **++Difference between right and lcft should be less than 3 O .

..

COMPONENT PARTS

1

2 3 4

5 6

7

Lock boll plug Torsion bar Helper bracket Helper Rubber bushing i Shock absorber Washer

OF FRONT SUSPENSION

8 Cushion rubber 9 Torsion bar lock boll 10 Sleeve 1 1 Oil s u l 1 2 Dust cover 13 Nylon bushing 14 Dust covcr

F i g . dC-l Component parts 6E

-5

,

15 16

17

Bolt Torsion b u lock bolt Expansion plug

18 19

Trailing ann King pin bushing

of front suspension

TIP

5-

5. COMPONENT PARTS OF REAR SUSPENSION

Fig. 1P-2 Cornponenl parts of rear suspension

m-6

\

5- 6. FRONT SUSPENSION

.

Or

a. Turn the steering wheel l o the left (right)

1.

Front suspension assembly

fully to disconnect the right (left)-hand brake hose from the wheel cylinder.

REMOVAL 1) Loosen the four w h t d nuts securing the rim to the brake drum. 2) Raise the vehicle front and remove the nuts-the detach the wheel.

Fig. M-5 Disconnecting brake hose from whecl cylinder

Fig. eC3 jacking up

b. Remove the union bolt at the wheel cylinder

and remove the brake hose. Removing the tie-rod end. a. Remove the cotter pin and remove the castle nut. b. Disconnect the tie-rod end irom the knuclc arm by using the special tool (Ball stud remover: 92 1240000).

4)

3) Disconnecting the brake hose from the brake pipe or wheel cylinder. a. Loosen the joint nut connecting the brake hose t o h e brake pipe. b. Pull out the clamp fixing the brake hose to the bracket. c. Pull o u t the brake hose from the bracket;

Fig. f 24 Disconnecting brake hose

N'OTE: Do not tap the knuele arm by hammer.

Fig. L&-6 Removing tie-rod end

5 ) When removing the left-hand side suspcnsion assembly, disconnect the speedometer cable. 6) Remove the splashboard by loosening three 8 mrn bolts.

Fig. 0 - 9 Disconnecting shock absorber

b. Loosen the two Iwk nuts on the upper end of the shock abosrber until the load is released from the rubber bushing at the lower end of the shock absorber. Fig. Y - 7 Removing splashboard

NOTE: The lower end of the shock absorber is used as a reference line to determine the proper ground clearance while the suspension is being installed. Therefore, do n o t remove the upper shock absoiber lock nut unless the shock absorber is out of order.

A

7) Remove the trailing arm stopper bolt.

c. Remove the lower end of the shock absorber

from the trailing arm damper pin. Rernove the torsion bar lock bolts on the trailing arm and at the center of the crossmember.

9)

Fig. --8

Removing stopperibolt

8) Disconnecting the shock absorber lower end. a. Remove the 10 rnm nuts and washen securing the lower end of the shock absorber to the trailing arm.

Fig. a 1 0 Removing torsion bar lock b o l t &-8

10) Extract the suspension assembly from the crossmember by hand.

v

Fig. * - i f

--

Fig. 41-12 Applyinggruzrc on sleeve

-

'\ *< I

_

3) Install ihe front suspension assembly in the reverse order of removal.

Removing suspension assembb

NOTE: a. When installing the torsion bar into the crossmember, align the lock bolt hole in the crossmember with the V-shaped groove a t the torsion bar inner end and install the.lock bolt Also align the lock bolt hole in the trailing arm with the V-shaped groove a t the torsion bar outer end and,install the lock b o l t After completing the above job, adjust the vehicle height and side slip. b. The torsion bar lock bolts are of special design. Always use genuine SUSARU b o l t s c. Tightening torque specifications are as follows.

INSPECTION 1) Check the bearings in t h e lrailing am for wear and damage. 2) Chcck the sleeves on the crossmember for wear and damge. 3) Check threaded parts for wear and damage. 4) Chcck the oiJ scal lips for wear and damage. 5) Check the torsion bar and lrailing arm for any evidence of deformation which may have decreased their strength. Also check the painted surface of these parts ior peeling, and repaint if necessary.

NOTE: If the trailing arm coating has come off or if the trailing arm is rusted, carefully check the affected parts for cracks or damage. If necessary, use a dye test t o determine abnormalities.

INSTALLATION 1) Before installing the front suspension assembly, throughiy clean the b e e ' g s and sleeves with clean cloth and keep these parts free of dust. 2) Apply new grease (about 70 gr. (2.5 02)) to the crossmember sleeves. Autolex A, Sunlite No. 2 or equivalent.

'

r

- 4.4 kg-m I

3.0

Torsion bar lock bolt

(22 - 32

Trailing arm stopper bolt '. 2;

1.1 - 2.6 kg-rn ( 8 - 19 ft-lb)

r'

-.

Brake h e and brake pipe connecting nut

1.5 - 2.0 kg-m ( 1 1 - I4 ft-lb)

.Shock abosrber lower end installing nut

1.8 - 2.6 kg-rn (13 - 19 ft-lb)

Shock absorber upper end lock nut

upper nut

1.8 - 2.6 kg-rn (13 - 19 ft-Ib)

lower nut

1 .O - 2.0 kg-m ( 7 - I 4 ft-lb)

d . When inrtallinp the plupr shown in figure, always replace it with a new one and apply a sufficient amount of sealer when inrtaliinp it on the suspension. s. Before tightening t h e torsion bar lock bolts and trailing a r m retaining bolts, be sure to

apply a coat of sealing compound to t h e threadt.

Recommended sealer:

Ccmtdine CS 1 I 1 5 Ctmedine 540 or equivalent

I

1-

Plug

2 3

Lock bolt Bolt

b

. .

.-. .b.

I-

+

?,

: : . q.L , \'

Fig. S - I 3 Plugs and lock bolts on front suspension

ADJUSTMENT After the front suspension assembly has been installed, check the ground clearance and wheel alignment. If necessary, adjust. (Refer to "Posture adjustment" and "Adjustment of wheel alignment".)

T 2 2-004

2.

Torsion bar

INSPECTION .

MMOVAL

1) Remove the front suspension assembly. (Refer to removal of front suspension assembly.) 2) Remove the torsion bar lock bolt at the center of crossmember underside.

1) Check (he torsion bar for damage and its painted surface for peeling. 2) Check the torsion bar serrations for wear.

INSTALLATION

-.

1) Remove the upper lock nuts from the upper end of the shock abosrber. and then loosen the lower lock nuts. Set the shock absorber so that three or four threads at its upper end are engaged.

Fig. 8 - 1 4 Removing torsion bar lock bolt

3) Pull the torsion bar outward by hand. lf it is hard to pull by hand, tap the end of the torsion bar by using bended bar.

Fig. S l 7 Loosening b c k nut

2) Full the lower end of thc.shock absorber until it extends fully. 3) Insert the torsion bar into the trailing arm.

Fig. H-15 Removing torsion bar

Fig. f t - 1 6 Removing torsion bar by tapping

Fig. S - 1 8 Instulling torsion bar

4) With the torsion bar inserted into the trailing arm, attach t h e suspension assembly to the crossmembcr.

T -

-

\*.

v

-1

'

-.

F&. S - 1 9 I ~ t a l l i n gfiont suspension assembly

Attach t h e lower end of the shock absorber to the trailing arm damper pin. 6) Manually push the torsion bar until thc serration on both ends fits that of the crossmember and trailing arm. 5)

NOTE: If the serration i s hard to fit. turn the torsion bar to locate the point where it -easily fits. .

.

. ;. .

.-. =+ . i.

I'

Fig. S 2 0 Tightening bolts and nuts

NOTE: a. Before tightening t h e lock halts, properly align the V grooves on both ends of t h e torsion bar with the holes i n the crossmember and trailing arm. b. Be sure to tighten all bolts and nuts to t h e specified torque setting. c. Install each torsion bar on the side from which it was removed. I f the torsion bar positions are interchanged between the right and leff early breakage may result The torsion bars are marked as follows for identification.

,

-!? , * .-

7) Tighten bolts and nuts in the following order: a. Torsion bar lock bolt a t lower center o f crossmember. b. Torsion bar at trailing arm end. c. Trailing arm stopper bolt. d. Two 'lock nuts 'at 'upper end of shock absorber. e. Nut a t lower end of hock absorber.

torsion bar

621001381

(FRH)

621001391

(FLH)

d. After t h e front suspension has been installed, check the ground clearance and wheel alignment I f necessary, adjust

3.

2) Drive out thc bearing in h e following manner, using the special tool (Remover: 922290000). a. Attach t h e hook @ to the inner side of the trading arm. b. Open the hook @ until it catches the

Bearing (Traiting arm inner and outer) and Dust cover

REMOVAL I ) Remove the dust cover press-fitted to the inner end o f the trailing arm, by using a screw driver.

NOTE: . . Be careful not to damage the rubber surface of dust cover.

1

4 5

Retainer Hook Cap Screw Special tool:

6

(922290000) Bearing

2

3

.

bearing end. c. Insert t h e retainer @ from the serration side of the trailing a m to prevent the from coming off. d. Attach t h e cap @ to the location formerly occupied by the dust cover. e. Turn the screw @ to tighten the cap @ and drive out the bearing.

T 13-007

i

Fig. N-21Removing hailing arm bearing

e-13

INSPECTION Check the followinp items for abnormalities. lr necessary, replace. I ) Bearing surfaces for wear or damage. 2) Resin and metallic areas for detachment. 3) Dust cover for deformation.

NOTE: Before removing the front suspension assembly, check the trailing arm end play with a dial gauge, using the following procedure. If the dial gauge pointer deflects more than 1 mm, remove the front suspension assembly and replace the bearing.

INSTALLATION 1) With r clean cloth, wipe off dust from the surfaces of the trailing arm, bearing and dust cover. 2) lnstall the bearing onto the end (51.6 mm diarn.) of the special tool (Lnstaller: 922350000), and k e n insert it into the trailing arm. 3) T o d o this, drive the end of the tool with a press or h y m e r until it comes into contact with the end o f the-traiIing arm. Then press the outer bearing into position.

1 2

Bearing (outer) Special tool: Bearing installer

1) Raise the front end of the vehicle until the front wheels clear the ground. 2) Remove the torsion bar lock bolt, and separate the torsion bar from the trailing a m . 3) Using a magnet stand, set a dial gauge at a position within 5 mrn from the end of the trailing arm. 4) Holding the tapered portion of the trailing arm, slowly move the trailing up and down, reading the dial gauge indication.

Fig. iS-23 ~'nstallin~ outer bearing

Fig. ItZ-22 Measuring trailing a

m

4) Install the bearing onto the end (53.0 mm diam.) of the special tool (Installer: 922350000), and then insert it into the trailing arm. To d o this, drive the end of the tool with a press or hammer until it comes into contact k t h the end of the trailing arm. Then press the h e r bearing into position.

.

1 2 3

NOTE: D o n o t a l l o w t h e dust cover t o protrude from the trailing arm more than 1 5 mm (0.06 in).

Bcaring (outer) Bcaring (inner) Special tool: Bearing inslallcr

Our1 cover

1.5 mm 10.06 in)

TI2411 "

Fig. $2-26

4.

Sleeve (Inner and Outer) and Oil seal

REMOVAL Fig. f f - 2 4 installing inner bearing

I Insert the special tool (Puller Cap: 92260000) into the tip of the crossmember. 2) Attach the hook or the special tool (Remover: 92203000) t o the end o f the outer end sleeve. 3) Turn the handle of the tool to drive out the outer sleeve.

5 ) Install thc dust cover onlo the special tool (Installer: 922360000); drive the tool with a press or hammer until the dust cover comes into contact with the end of the trailing arm.

Bearing (outer) Bearing (inner) Dust cover Special tool: Dust cover installer (922360000)

Fig. IS25 Installing a-15

dust cover

INSPECTION 1)

Check the inner and outer sleeves for wear

or damage. If necessary, replace.

NOTE: Measure the outside diameters of the sleeves at points D l and D2 shown in figure. If the difference between D l and D2 exceeds 0.1 mm, replace w i t h a new one.

Fk. S 2 7 Removing

outcr slewe

Fig. S-29 Measuring sleeve

2)

Always replace oil seal after removal.

T o remove the inner sleeve, use thc same procedure as that for the outer sleeve. Pull off the oil seal and inner deeve at a time.

4)

I

INSTALLATlON 1) Attach the oil seal to the crossmember. 2) Insert the inner sleeve into the special tool (Installer: 922330000) and install it onto the crossmember; drive the special tool with a hammer until it comes into contact with the crossmernber. 1

2

Oil sul Inner sleeve

Fig. @28 Removing

T12-014

inner sleeve

NOTE: Check for proper fit of the inner sleeve through the access h o l e in the special tool.

5.

Shock absorber

REMOVAL 1) Remove the two 10 mm nuts securing the shock absorber to the chassis frame bracket. 2) Pull off the washer and rubber bushing from'thc rod.

Crass m e m b e r Hole Special tool: Oil scal and sleeve inctallcr (9 22330000) lnncr slecvc Oil scal TI2416

Fig. Y-30 Illstallirtg inner sleeve

Fig. &?-32 Loosening shock

3) Drive the outer sleeve into the crossmember with a hammer through the special tool (lnstallcr: 922340000).

1 2

Crossmember Special tool: Sleeve installer

(922340000)

3 4 5

Outer sleeve Sleeve Oil s d T12-017

Fig. R-31 Installing otc ter sleeve

m - 17

absorber upper end

3) Loosen the lOmm nut securing the lower end of the shock absorber t o t h e trailing arm, and detach the shock absorber. 4) Remove the washer and rubber bushing from t h e damper pin.

I

Fig. S - 3 4 Checking oil leakage

b. I f oil is found only on the upper and l ~ w e r portions, this does not indicate oil leakage and does not require replacement of the shock absorber.

Fig. a - 3 3 Removing shock absorber lower end

1

Compress the shock absorber, and then detach the upper end of the rod from dre bracket. 6) Remove the lower end of the shock absorber from the trailing arm. 5)

I

!

INSPECTION Check the shock absorber for the following items, and replace it if any of the following abnormalities is found. 1) Excessive oil leakage or damage. 2) Improper functioning. 3) Improper travel strokes(rnin. and max.). 4) Deronncd or damaged rubber bushing.

NOTE: a Fully extend the shock absorber and check the length (PI of the rod wet with oil. I f the length ( 9 ) is more than one-third of the overall length (I), replace the shock absorber.

Fig.- m-35 .

.

5 7

-

.

b. ,-

INSTALLATlON i, . c. .i: lnstdiation is in the reverse order ofremoval. *

NOTE: Tighten tfie 10 mrn nuts securing the upper and lower ends of the shock absorber to the specified torque.

Torque

1.8 - 2.6 kg-m (13 - 19 ft-lb)

-

6.

I

Helper

REMOVAL AND INSTALLATION 1) Remove the 8 mm nuts securing the helper to the chassis frame bracket, and detach

the helper.

Fig. H-37

Fig. 9 - 3 6 Removing helper

2)

Installation is in the rcverse order of removal.

5- 7. REAR S ~ S P E N S I O N 1.

NOTE: Tighten the 8 mm nuts t o the specified torque.

Rear suspension assembly

REMOVAL 1) Looscn the four wheel nuts securing the rim to the brake drum. 2) Raise the vehicle rcar and remove the nuts t o detach the wheel.

NOTE: Torque

1.5

- 2.0 kg-rn (1 l

- 14 it-lb)

lNSPECTlON I ) Check the helper for fatigue or damage. If necessary, replace. 2) Check the height of the helper and replace if it is less than the specified value. Truck: H =49 mm (1.93 in) VAN: H = 5 l mm (2.0 in)

Attach*

jack to the designated points

Fig. a 3 8 Jacking up

3)

Remove the bolts and nuts securing the

underside cover, and detach the covcr. 10 rnm bolt 2 bolts 8 mm nut 2 nuu

............ ............. 6 m m bolt ............. 6 bolts 6 mm tapping screw ..... 2 screws

Fig. W

1 Pulling off cuble

6 ) Tap out the spring pin and disconnect the axle shaft from the engine.

Fig. E239 Removing under cover

Remove the rcturn spring, clevis pin, cotter pin and 6 mm bolt attaching the cable c l m p and remove the cable. 4)

Fig. W 4 2 Disconnecting a l e shaft

7) Looscn the flare nut connecting the brake hose to the brake pipe at the inner arm mounting bracket, and separate the two.

- ,-

- . .

.... .

.-

?.

Fig. n - 4 0 Removing cuble

,..

Pull the cable with the grommet off the outer arm. 5)

Fig. &-43 Disconnecting brake hose

s - 20

8) Loosen the lock nut, then remove the outer bushing lock bolt.

1 1 ) Remove the rear suspension assembly from the chassis frame by pulling it out.

NOTE: T o avoid daniaging the back plab, place the year suspension assembly on a soft surface, such ar r a g or cardboard.

Fig. #-44

Removing b c k bolt

Remove the two bolts securing the inner mounting bracket to the crossmember, and detach the inner a r m bracket. r

-

i

-

..

.

- . .&

Fig. S - 4 7 Rear suspension assembly

DISASSEMBLY I ) Remove the flare nut securing the brake pipe t o the brake asstrnbly.

Fig. m4.5Removing inner arm bracket

NOTE: Be careful not t o damage t h e head of t h e nut

Remove the 10 rnm nut securing the lower end of the shock absorber to the trailing arm, separate the two. 10)

Fig. tlD-46 Disconnecting Bock absorber

Fig. S?-48 Disconnecting brake pipe

2) Remove the four 12 rnm bolts securing the rear hub to the trailing arm.

ASSEMBLY AND 1NSTALLATlON Assembly and installation arc in the reverse order of disassembly and removal.

NOTE: a. Tighten the outer and inner bushing lock bolts only after ail assembling and installation work has been completed, with the wheels on the ground and in an unloaded condition. b. The specified torque setting for bolts and nuts is shown in the chart below.

Fig. B-49 Removing rear hub bolt

3) Pull o f f the rear axle assembly and brake assembly as a unit from the trailing arm.

NOTE: Be careful not t o damage or deform t h e brake pipe or the axle b o o t

.

INSPECTION 1) Check the condition of all parts. Replace parts if neccsary. 2) Check for missing circlip on the trailing outer ann. If it is missing. install a new one.

- 2.2 kg-rn - 16 it-lb)

Outer bushing lock boll

1.8 (13

Inner bushing attaching boll

3.5 - 4.0 kg-m (25 - 29 ft-lb)

Inner bracket attaching bolt

3.5 - 4.5 kg-m (25 - 33 ft-lb)

Shock absorber attaching nut

(13 - 19 TI-lb)

Brake hose to brake pipesecur-ngflarcnut

1.5 - 2.O.kg-m (11-14ft-lb)

Rear hub attaching bolt

7.0 - 12.0 kg-rn (51 - 8 7 ft-lb)

1.8 - 2.6 kg-rn

c. Fit t h e rear torsion bar t o the outer arm by properly aligning the toothless points,

Fig. LT-50 lnstnlling circlip

3) Chcck the trailing inner a r m and outer arm for cracks or damage. If necessary, use a dye test t o check for abnomalities, especially on areas where coating is detached and rust formation exists.

Fig. #Y-51

d. After the rear suspension assembly has been installed, bleed air from the brake system.

.

ADJUSTMENT After the rear suspension assembly has been installed, inflate the tires t o the specified

64.6 mm (2.14 In)

pressure; also make posture adjustments and wheel alignment.

2.

2 3

Rubber bushing (Outer)

REMOVAL Place the trailing outer arm in a vise. Pull off the rubber bushing with the special tool (PuUer: 921330000),as follows: 1) Insert the cap @ into the rubber bushing. 2) Attach the spacer @ to the end of the rubber bushing. 3) Hold the spacer @ and rubber bushing with the body @. 4) Tightening the lead screw @, remove the rubber bushing.

Rubber bushing Outer arm T12-029

Fig. X-53 Instailing outer rubber bushing

3.

Rubber bushing (Inner)

With the special tool (Installer & Remover: 922340000)and a hand press, drive the rubber bushing out from the trailing imer arm as follows: 1) Insert the push rod @ (special tool) into the inner rubber bushing; then place onto the base @ (special tool) with a hand press. 2) Drive the inner rubber bushing out from the trailing arm by pushing the push rod 0 .

Pren

-F

Fig. e - 5 2 Removing outer rubber bushing

INSTALLATION Press the outer rubber bushing into place with the special tool (Installer: 92 1380000) and a press.

N UTE: Be sure t o center the boss i n the trailing arm and rubber bushing when installing.

3 4

Trlilingarm Rubber bushing T12-030

Fig. &-54 Removing inner rubber bushing

.

Check the rubber bushing for cradrs or other damage. If necessary, replace. 3)

49 mm (193 tnl

2 mrn (0.08 in)

INSTALLATION With the special tool (Installer & Remover: 922340000) and a hand press, drive the inner rubber bushing into the trail& inner arm as follows: 1) Ptce soapy water on the inner facc of the die 0 ,and install dic onto the trailing inner arm bushing. 2) Apply r coatofsoapy watertotheouter face of the inner rubber bushing, and install the rubber bushing into the die. Then install the die on the base @ (special toor) with a hand press. 3) Insert the push rod @ (special tool) into the inner rubber bushing. Exert pressure on the inner rubber bushing liner with the press until the end of t h e rubber bushing shows through the access hole in the base @. 4) Make sure that the rubber bushing is pressed to the specified value.

Fig. EP-56

NOTE: a. When pressing the innei bushing, always rlign the center lines of the inner trailing arm of the rubber bushing, die 0 ,rubber bushing and push rod Failure to do so may result in unusua! noise while driving. b. After installing the bushing, a l l w the bushing face t o dry for 48 houm If the trailing arm is installed on the vehicle while the rubber bushing is wet, the rubber bushing may slip out of place while driving, as soapy water acts as a lubricant

a

4.

T o r s i o n b a r and c e n t e r arm

REMOVAL 1) Before removing the torsion bar, detach the rear suspcnsio? assembly from the vehicle. Then pull off the !orsion bar, grasping the serrated portion wit# your hand. If it is hard to remove with han& lightly tap on the end of the other torsion bar to push it out. 2) After the left and right torsion b a n have been removed, remove the center arm from the rear crossmember. - " I 2

@F'urhzod Q Die

3

@Base

4 5

Rubberbushing Trailing m

INSPECTION Visually check the torsion b a n and center am to see if the coating is peeling or if rust is developing. If necessary, use a dyeing test t o check for cracks or damage. Replace any parts which are cracked.

TI2031

Fig. a - 5 5 Installing inner rubber bushing

F3-

.

I

I

INSTALLATION I ) Before installing parts, apply a coal of the same color paint t o any portion from which

5 ) l n s t d each tonlon bar on the side from which it was removed. If the torsion bar positions arc interchanged between the right and left, early breakage may result. T h e torsion bars are marked as follows for identification. .

paint has peeled. 2) Apply a coat of grease to the serrated portions of the center arm and trailing outer arm. 3) I n s ~ r t the center arm and torsion bars into the crossmember. 4) Be sure t o align the toothless points at the serration before assembling the center arm and torsion bars.

Left-hand torsion bar

Fig. fP-57

5. '

621001910

REMOVAL AND INSTALLATION For the removal, inspection and installation of the rcar shock absorber, follow the same procedures as Tor the front shock absorber. In removing and installing the upper end o f the rear shock absorber, be sure to detach t h e trap door beforehand.

.- ,*

,.-

.-..

Fig. 8 - 5 9 XZ

- 25

/

.,

Shock absorber

,.'

..

Fig. t2-58 Installing torsion bar

RLH

Shock a b s o r b a r

c.

;

I

'

!

.

:5- 8. POSTURE ADJUSTMENT

t.

Front p o s t u r e adjustment

1) Park the vehicle on a flat surface and set the steering wheel in the straight-ahead position. 2) With the vehicle unloaded, inflate all tires t o rhe following specified pressure: Front: 2.4 kglan' Rear: 2.4 kgjcmz 3) Measure height ':H'' above ground (ground clearance) at the center of the torsion bar to determine the difference (a)from the standard value. a = 295 - W Where 295: Standard height

Fig. S 6 1 Measuring distance L

8) Remove the wheel and support the brake drum with a jack.

NOTE: a. Be careful not t o scratch or damage the brake drum when jacking up. b. Failure t o use a jack when removing the torsion bar can result in damage t o the brake hose.

Fig. s 6 0 Mearuring vehicle height

. a

. b. *

I'

.-. . . .,. .

Fig. L3-62 Jacking up brake drum

5

Engage t h ~ ? ~ a * n gbrake. Loosen (but do not remove) tht<,fo;r nuts securing the front. wheel. 5 ) Raise the front end of the vehicle with' a jack. 6) Remove the nuts securing the lower end of the front shock absorber to the trailing arm, and detach the shock absorber to fret the lrailing arm. 7) Mark the body fender and wheel center cap and measure distance "L" between the two. 4)

9 ) Remove the lock bolts securing the torsion bar to the center of the crossmember and the trailing arm. 10) Remove the plug from the center of the crossmember. Drive the torsion bar and the trailing arm cap, as an assembly, out of the crossmember by applying hammer blows t o a bent crosshead screwdriver or a bent bar attached to the torsion bar end surface through the hole in t h e crossmember.

OTE: To prevent the tentry of water through the threaded portions, be sure to apply a coat of cemedine to the threads.

-

Fig. PI-63 Removing torsion bar by tapping

.

11) Lower and raise the jack supporting the brake drum until. distance "Ll" between the mark scribed on the fender (in step 7 above) and the center of the wheel is obtained. At this point, the amount of adjustment (a)should be added to, or subtracted from, dimension "L" as necessary, (Examples) 1) If height "H" of the torsion bar above ground before adjustment i s 270 mrn, difference "a" is determined by the following: a = 2 9 5 - 270=25 mm Where a:Amount t o be adjusted The distance' between the mark on the fender.and the center o f the wheel is also determined by: L1 - L + 25 IIXII 2) If height "H" of the torsion bar above ground before adjustment is 325 mm. difference "cr" is determined by the following: a = 295 - 325 = -30m m Thc distance between the mark on the fender and the center of the wheel is also determined by: L1 = L - 3 0 m m 12) With distance "L1" adjusted as above, engage the serration of the torsion bar with that of the crossmember and trailing a m . 13) Properly align the V grooves on each sidc of the torsion bar with the lock bolt holes on the trailing arm and crossmember. Then tighten the lock bolts.

14) Lower and remove the jack supporting the brake drum. 15) Install the wheel. 16) h w e r the front end of the vehicle and remove the jack. Measure the height of the . torsion bar above ground. 17) Securely tighten the torsion bar. lock bolts. 18) lnstall the lower end of the shock abosrber t o the trailing arm. 19) Plug the hole in the center of the crossmember.

NOTE: Apply a coat of cemedine to the plug before installing.

20)

Apply a coat of cemedine t o the end of

the trailing arm, and then install Che plug.

NOTE: . Recommended seajant: Cemedine 11 15 Cernedine 540 or the equivalent 21) Tighten bolts and nuts to the specified torque settings.

-Torsion bar lock bolt

3.0 - 4.4 kg-m (22 - 3 2 ft-lb)

Trailing arm stop bolt

I.1 - 2.6 kg-m ( 8 - 19 it-lb)

Shock absorber attaching nut

1.8 - 2.6 kg-m (13 - 19 ft-lb)

Wheel nut

3.6 - 5.4 kg-m (26 - 39 it-lb)

"

2.

Rear posture adjustment

Park the vehicle on a flat surface, and 1) adjust the front and rear tires t o the specified pressure. 2) Measure height "H" of the torsion bar at its end to determine difference "a" from the standard value. a = 285 - H Where a: Amount t o be adjusted 285: Standard value

5- 9. ADJUSTMENT OF WHEEL ALIGNMENT 7.

F r o n t wheel alignment

Carnbtr and caster need not be adjusted. Toe-in alone i s adjustable. Check the condition of the following items. I f necessary, adjust or replace parts, then adjust toe-in. a) Height above ground b) Tire pressure c) Play at tie rod end ball joint d) Trailing arm-to-crossmember play e) Wheel play due t o wear of kingpin bushing or wheel bearing f ) Deformed traiIing arm 1) Set the steering wheel in the straight-ahead . position. 2) Loosen the lock n u t on each side of the tie rod turn-buckIe.

NOTE: The turning direction is quite different for each of the two lock nuts. Fig. S 6 4 Measuring vehicle height

3) To adjust the rear height above ground, turn the center arm adjusting bolt as required. One clockwise turn of the adjusting bolt increases the height above ground by 4.5 mm.

F k . s t 5 6 Loosening lock nut

3) Adjust the length of the tie rod by turning the turnbuckle. Lengthening the tie rod increase toe-in, and vice versa.

Pig. S 6 5 Vehicle height adjusting bolt

NOTE: Turn the turnbuckle equally on each side until tfie steering angle o f the left and rear wheels are within the specifications.

Steering

Inner wheel:

37" i 2"

Outer wheel: 33.5'

* 2"

1 2

Lock nut Turn buckle

.. .- :.-

Fig. S 6 7

t;.

:. . q,. Measurc toe-in or side dip to see5f i t is within the specifications. Then tighten the turnbuckle lock nuts in the following sequence: a. Tighten tie rod end nut and turnbuckle. b, With the tie rod push all the way backward, tighten the tie rod nut and turnbuckle.

NOTE:

4)

a. Use two wrenches when tightening the lock n u t Failure to do so can cause the tie rod to be dislocated from its end. b. Holding the turnbuckle with ' a wrench, tighten tfie nut and then lock.

r Torque I

8 - 8.5 kg-m (58 - 6 1 ft-lb)

1

2 3 4

5 6 7

.

Tie rod Turn buckle (19 rnm in width rcmss flats) Tic rod end Nut (22 rnm in width across flats) Holding spanner (do not turn) Tightening spanner Nut (left-hand screw) (22 mrn in width across flats)

Fig. S 6 9 Tightening lock nut

c. After tightening the lock nut, move the tie rod to the front and back t o see that it moves equally from side to side more than 35 rnrn (1 -38 in).

712-036

Fig. S 6 8

Fig. 63-70

tP - 30

2.

Rear wheel alignment

Toe-in can be adjusted by changing the number of shims at the inner trailing arm bracket. Check the following items and, if necessary, adjust or replace parts. Then adjust toe-in. a) Tire pressure b) Height above ground (Ground clearance) c) Be'aring play d) Deformed trailing arm

2) Loosen the two 10 mm bolts securing the inner arm bracket t o the crossmember. 3) To adjust toe+, add o r remove shims as requi;ed ,between the inner arm bracket and crossmember.

NOTE: Use the same number of shims on both sides.

Fig. B-71 Toe-in adjusting shim

Tighten the two 10 mm bolts securing the inner arm bracket t o the crossmcmbcr.

4)

Torque 1) Measure the rear wheel toe-in. To obtain the specified value, select the necessary number of shims from among those of0.6 rnm,0.8 mm and 1.2 mm in thickness.

3.5

- 4.5

kg-m (25

- .

- 33 ft-lb)

. 2. Again measure-toe-in or sidg slip t o see if ' it is within the specifications.

5)

r- . T i

i:

5~ 10. TROUBLESHOOTING A. Unstable running

When the vehicle is driven along a flat surface at a constant speed and the hands arc released from the steering wheel, it pulls t o one side. The vehicle wanders immediately after a lane change, even though the steering wheel is held in the straight-ahead position. Remedy

Probable cause

-

b-

(1) lmproper tire pressure.

Inflate properly.

(2) Wheels out. of alignment. (3) Brake dragging or not properly adjusted. (4) Trailing arm not properly installed (substantial

Align. Adjust. Reinstau.

difference in reaction between left and right arms).

(5) Broken torsion bar.

Replace.

(6) Wheel bearing worn or not properly adjusted.

Adjust or replace.

(7) Ray or wear in steering system parts. (8) Front trailing arm bearing or crossmember sleeve worn.

Adjust or replace.

(9) Loose wheel nuts.

Tighten.

Replace.

(10) Deformed tie rod or trailing arm.

Replace.

(1 1) Play in tie rod end ball joint.

Replace.

(12) Worn kingpin bushigg.

Replace.

(13) Loose trailing arm o r steering system installing

Tighten.

bolts. (14) Improper tire (wrong brand). (15) Fatigued o r deformed rear suspension outer bushing. '

Replace. Replace.

. .

.%

B. Incorrect vehicle posture or ground clearance ?

'

Remedy

Probable cause

(1) ' Fatigued or broken torsion bar.

Replace.

(2) Shock absorber not functioning properly.

Replace.

(3) Trailing arm not properly installed. (4) Deformed traiIing arm.

Reinstall. Replace.

C. Hard or rough ride

Large shocks i s transmitted to the seat from the wheels. Shocks d o not dampen o u ~quickly after the wheels have run over obstacles. Large shocks are felt when wheels run over concave spots. Remedy

Probable cause (1)

Broken torsion bar.

(2) Helper i s excessively deformed or-has dropped

Replace.

.

Replace. .

...

off.

(3) Tires excessively inflated.

Reduce to specified pressure.

(4) Improper ground clearance.

Adjust.

(5) Shock absorber not functioning properly.

Replace.

(6) Damaged or deformed shock absorber rubber

Replace.

I

'

.

bushing.

(7) incorrect shock absorber travel strokes.

Replace.

(8) Rear suspension outer bushing is deformed or has dropped off.

Replace.

D. Rear (Drive) wheels run idle

I 1

Probable cause

(I)

incorrecr &ound clearmu.

I

Remedy .

Replace.

(3) Broken torsion bar.

Replace.

(D.O.J.). (5) Excessively deformed trailing arm.

II

,

Adjust.

(2) Insufficient shock absorber extension. (4) Insufficient swing angle of double offset joint

1

I

I

1

Correct engine installation or replace. Replace.

I

E. Unusual noire

Remedy

Probable cause

(1)

Worn or damaged shock absorber parts.

(2) Deformed or damaged shock absorber rubber

Replace. Replace.

bushing. (3) Worn wheel bearing.

Replace.

(4) Worn double offset joint.

Replace:

(5) Worn brake drum splines.

Replace.

(6) Front trailing arm not properly installed. (7) Worn front trailing a r m bearing or crossmember

Reinstall. Replace.

sleeve.

(8) Front trailing lubricated.

arm

bcaring

insufficiently

(9) Play o'r wear in tie rod end ball joint.

Lubricate. Replace.

(10) Loose rear suspension outer bushing lock bolt.

Tighten.

( 1 1) Deformed or dislocated rear suspension ann

Replace.

bushing.

-

( 1 2) Play in rear suspension inner arm bracket.

Replace.

(13) Incorrect shock absorber travel strokes.

Replace.

(14) Helper is dislocated or has dropped off.

Correct or install.

(1 5) Steering angle not properly adjusted.

Adjust.

(16) Broken torsion bar.

Replace.

..

6-

1.

6-

2

.

6- 3 .

CHAPTER 6:

FRONT WHEELS AND AXLES REARMHEELSANDAXLES

TIRES AND RIMS

IJHEELS AND AXLES

. . . . . . . . . . . . . . . . . . . . . . . . .

...................

2

7 16

6- . I . FRONT WHEELS AND AXLES 1.

General description

L d t side-

1 Knuckle (RH.) 2 Knuckle (LH.)

3

0-Ring

4 Covtr 5 0-Ring

6 Thnut washer (Upper) 7 Thrustwuhcr(Lower)

Fig. Ptl

8 Kingpin 9 Knock pin 10 Shim 1 1 Plug 12 S p a a r 13 Taper rolbr tearing

(Outer)

15 16 17 18 19

. Brake drum mmplctc (Front) Washer Lock washer Cap (RH.) Cap (LH.)

20 Oilsell 21 A x k n u t

14 Trpcr rollex beadng finer) Construction offront

The tire is installed on a 3.50 D x 10 split 'type rim which is attached t o the brake drum. The brake drum is provided with two taper roller bearings, which rest on the knuckle spindle. Since these taper roller bearings are used with specified preload, special care should be taken during installation. T h e knuckle is connected to the trailing arm by m a n s of a

wheel and axle assembly king pin. T h e king pin connection is designed as

a maintenance-free type, consisting of an upper and lower bushings made of resin, two thrust washers of high wear resistance, and four O-rings and two plugs. The oil seals prevent the entry of foul water and consequent rusting, so that removal and installation are easily performed.

2.

Brake drum

1) Removal a. With the wheel o n the ground, loosen the four 10 rnm wheel nuts attaching the rim to the brake drum. b. Raise the vehicle with a lift or jack and, in either case, assure the safety by locking the lift or using safety stands. c. Remove the wheel nuts and pull the wheel off. d. Remove the three 5 mrn screws attachhg thc cap t o the drum and remove the cap.

b. If the inner bearing remains attached on t h e spindle when the drum is removed, install Special Tool (BEARING REMOVER: 922120000) as shown in Fig. a-3 and remove the bearing by turning the handle.

2) Disassembly (bearings and oil seal) a. Tap the inner bearing outer race out of the drum by using a brass rod etc. Remove the oil real a t this time. (Fig. B - 4 ) ' b. Tap the outer bearing outer race out of the drum by using a brass rod etc. using care not t o damage the race.

NOTE: Since the left-side cap is provided with a pin t o drive the speedometer cable, be careful not to bend the pin when removing the cap.

e. Spread the lock 'washer and remove the 30 rnrn (width across flats) nut, lock washer, and washer. f. Remove the drum using care not to drop the outer bearing. (Fig. Rl-2) NOTE: a. If the drum is difficult to remove by hand because the bearings stick to the knuckle spindle, install Special Tool (ATTACHMENTS: 921420000) t o the wheel mounting bolts on the drum using wheel nuts. Then, hook the pawls of a puller to the recesses of the attachments, align the lead screw with the knuckle center hole, and remove t h e drum by turning the lead screw. I n place of the standard tool, Special Tool (BRAKE D R U M PULLER: 921 120000) may also be used. . . .

Inner bearing

Special tool BEARING REMOVER 922120000 f 1s o 0 2

Fig. t0-3 Rcmwing inner baring from spindle

.

Fig. S 4 Tapping out inner beoring

3)

Inspection

Wipe off the grease in the bearing mounting bore in the brakc drum. Clean the bearing in

Fig. #-I

Removing w h e r

cleaning solvent. Inspect the disassembled parts and replace defective parts with new ones.

I

NOTE: When it is necessary to replace one of the bearings, always replace both the inner and

.

outer bearings as a set.

!

a. Brake drum I ) Check the drum bolts for damage. 2) check the innsr surface of the brake . 'drum for wear and damage. 3) Check the outer races of the bearings for correct installation. b. Check the bearing inner races, retainers and roUen for damage, wear, seizure, rust and correct fitting in'thc knuckle arm. c. Check the oil seal for damage or deformation, the oil seal lip for wear, and the spacer for damage and wear. d. Check the cap gasket for damage. e. Check the cap for damage and deformation. f. Check the knuckle spindle for 'damage and deformation. 4) Reassembly (bearings and b i seal) Wipe off foreign matters, dust, etc. on the 5 drum surface with clean cloth, a. Place the drum on a support and install the outer bearing outer race into the drum with Special Tool (INSTALLER:9221 10000) by tapping it with a hammer. b. Place the drum on a support and install the inner bearing outer race into the drum with Special Tool (INSTALLER:925080000) by tapping it with a hammer. .

Fig. m-s Instatting benrings

c. Pack the drum with grease as shown in Fig. p - 6 . Appropriate amount of grease to be packed in the drum and applied on the bearing surface is 35 t o 39 g (1.23 to 1.38 02).

Fig. f9-6 Packing drum with pears d. After installing the rollers and inner race of the inner bearing and packing it with grcase, press the oil seal, with its Up and inner surface coated with grease, into position. e, Install. the outer bearing rollers and inner race packed with grease.' 5) Installation a. With the bearings installed in the drum, install the spacer and drum on the knuckle spindle, and tighten them with the 30 rnm (width across flats) nut, washer and lock - washer.

NOTE: '

After having fully tightened the nut to seat the parts, back off about 118 to 1/10 turn so that the wheel rotates with the following starting torque. (Fig.m-7) rn

b. Lock the nut by bending the lock ~ a a e r . c. Install the cap with the gasket'%nd three screws. d. Install the wheel, tightening the wheel nuts finger-t ight ' e. Lower the vehicle to the ground. f. Tighten the wheel nuts t o the specilication.

.

Wheel nut tightening torque

3.6 - 5.3 kg-m (26 - 39 ft-lb)

.

c. Remove U l c upper' plug on the trailing arm

yoke.

i. Removing the king pin 1nstaU the body @ of Special Tool (KING PIN PULLER: 92 1 14 1000) on the trailing arm yokt and then install the stopper @ and insert pin @ as shown in Fig. s - 1 0 . A l j y the lead screw @ with the king pin and turn the screw to remove the king pin.

Fig. W-7 Meusuring starting torque g. Adjust the brake shoe clearances after depressing the brake pedal 2 to 3 times.

3.

Knuckle (King pin)

1)

Removal and disassembly

a. Remove the brake drum in accordance with 3

a\

3. 1).

b. Unscrew the four 8 mm bolts attaching the

.

.

.

Fig. B - 9 Removing pin at knuckle

back plate t o t l y knuckle and remove the

back plate.

. ;..

.-. b.

. .

Fig. i U l O Removing king pin

L

F& S 8 Removing bcck pkztc

-

:-. +. 'i'

b

c. Remove *e trailing arm in accordance with a - 1 in Chapter d. Remove the pin at t h e center of the knuckle by tapping it from the spindle side. (Fig.

B-9)

NOTE: For the removal and installation of the king pin bushing on the trailing arm, refer l a Chapter U&d

2)

e. Apply r thin coat of pease on theking pin

Reassembly

surface. f. Tap the king pin into the upper yoke bushing from the tap of the yoke. g. Hold the parts assembled in a. under the upper yoke and press the king pin ,down until its lower end becomes flush with the thrust washer as shown in Fig. B-13. h. Place the knuckle fitted with O-rings be-

NOTE: Be sure to keep the parts free from dust during this job. the cover, upper md lower h s t washers and O-ring jogether as shown in Fig. m-11, with sufficient grease applied between the upper and lower thrust washers and on the O-ring. . . b. Coal the bushing inside surface with grease and also fill the oil groove in the bushing with weau. . c. Cost the king pin hole in the knuckle with a. Put

tween the thrust washer and lower yoke and align the king pin with the king pin hole in h e knuckle while pressing the king pin down by hand to the position shown in Fig. H-14.

NOTE: Be sure to press the king pin by hand when aligning. Driving the king pin with a hammer will break the 0-rinp on the yoke if tha king pin and the hole in the knuckle are not lined UP.

grease.

hrust washer(lower ) T 13-006

Fig. l3-ll Assembling cover, t h a t washer and O-ring

d. Apply grease on the O-rings,and install them on the upper and lower yokes and both ends of the king pin hole in the knuckle.

3

Fig. -12

Fig. Sf 3 Tapping king pin into upper bushing

Thrust warha (Upper)

Fig. JZi4 Aligning king pin with knuckle

Assembled components

a - 6

k. Apply sealant to *e knock pin and drivc it

i. Direct the cut in thc king pin SO that it will

into the knuckle.

fit on the knock pin, and tap the king pin with a plastic hammer down t o a position slightly above the O-ring installed at &e bottom o f t h e knuckle as shown in Fig.

NOTE: Alwayr use a new knock pin for reessembly.

m-15. ' \

NOTE:

..,

.

,

sure t o stop the kin# pin above the O-ring, othewise t h e protruded O-ring might hinder theinstallation of shirns-or-the-O-ring-might be cut by the shim when it is inserted.

Be

--

1. After applying grease on the top and bottom o f the king .pin,-install plugs- on .both the ends. Hit the center of the plug to spread it and stake the yoke at three poinls arodnd the plug to secure it. ' m. Apply sealant o n the circumference 01 each plug t o perfectly seal the gaps.

NOTE: Before applying sealant, wipe grease, oil, etc. away with clean cloth.

Fig. m-15 Tapping kins pin into knuckle

j. Install proper shims between the knuckle and lower yoke so that the knuckle end play and rotating resistance are as specified below.

Knuckle end play

Knuckle rotating resistance

.

0 - 0.1 mrn (0 - 0.004 in) Approx. 2.5 - 3.7 kg-m (18 - 27 ft-lb)

6-.2. REAR WHEELS AND AXLES 1.

General description

'

The engine output is transmitted t o the rear wheels through t h e axle shafts. The inner end o f the axle shaft is connected through splines to the differential side gear on the engine side, and the spline connection is locked with a spring pin. The outer end of the axle shaft is supported by two ball bearings housed inside the hub and cunncctcd through serrations t o the brake drum, which transmit the driving power t o the wheel. The brake drum, bail bearing, spacer and ccnter piece are tightened at the same time by a castle nut. The ccnter piece makes i t easier t o remove and install the brake drum.

3 A x k shaft 4. Outer r a a 5 Spring pin 6 Hub 7 Spaazr 8 Bdbcuing

Fig. S - 1 6

2.

I

I I Oil sell (A) 12 Ball 13 Cage 14 Spring wuhcr 15 Nut 16 e n t e r pierr (Axle)

Construction

18 Cotter pin 19 Circtip 20 Snap ring 21 Boots 22 Cap T13-011

of rear wheel and a l e assembly

Brake drum

I ) Removal a. Loosen the four 10 mm wheel nuts attaching the rim to the brake drum. b. Raise the vehicle with a lift or jack and, in either case, support the vehicle by the rigid rack or lock the fif! f o ~ safety. c. Remove, the wheel nut6:an'd pull the wheel off. d. Unscrew the two 10 rnrn bolts retaining the diagonal member and the eleven 6 mm bolts retaining the under cover and remove the diagonal member and under cover. e. Remove the center cap with the three attaching screws. f. Pull the cotter pin and remove the castle nut (27 mm in width across flats) on the axle

shaft. g. Make the shoe clearances larger. h. Put a flat blade screwdriver against the slot of the center piece and tap the screwdriver w . . + i t h a hammer to remove the center piece.

F k . Ef-17

Removing center piece

i. P U U the drum off the axle shaft. If it is difficult t o remove the drum by hand, inslall Special Twl (ATTACHMENT;921420000) on the drum by utilizing the wheel nuts and pull the drum with r puller as shown in Fig. 11-18.

Torque (Castle nut)

NOTE:

...

NOT€: In place of the standard puller, Special Tool (BRAKE ..DRUM ...PULLER: 921120000) may also be used. (Fig. f3-19)

Spacial twl: ATTACHMENT 921420000 Conventional puller

-

,

Tighten the cnrtle nut to tho above torque firrt and retighten further until a slot of the castle nut is aligned to the hole in the axle

- . !.- .

shaft

.

"

16.0 kg-m ( 1 16 it-lb)

.

c. I ~ c kthe castle nut with a new cotter pin. d. Install the under cover and wheel. . . 3. Hub and axle shaft assembly 1) Removal a. Rcmove the brake drum in accordance with 2.1). b. Disconnect the axle shaft assembly from the engine b y driving out the spring pin with a 4.8 mm (0.1 9 in) diameter bar. c. Rcmove the parking brake return spring and the cotter pin and disconnect the parking brake cable. .?

~13012'

Fig. S

f 8 Removing brake.dmm

Fig. m-20 Dirconneciing parking brake c a h t d. Remove the bleeder screw and remove the brake pipe joint nut from the wheel cy!.

inder. . ,

2)

Fig. =-I9

Removing brake drum

Installation

a. Before installing the brake drum to the axle shaft, coat the splined portion of the shaft

with grease t o prevent corrosion. b. Install the brake drum, center piece and castle nut and tighten the nut.

t. Remove the back plate by unscrewing the

four 8 rnrn attaching bolts. f. Unscrew the four I2 mm bolts attaching the hub to the trailing arm. g. Remove the axle shaft assembly togcther with the hub.

NOTE:

Be careful not to damage the inner and outer boats.

Disassembly a. Place the hub and axle shaft assembly on a press and press the shaft down out of the hub as shown in Fig. m-21. 2)

NOTE: Do not uw a hammer since the threads at the shsft end may be'crushed. b. To remvoc the bearing (hub, inner) from the axle shaft, pull the bearing with a puller by inserting the pawls between the bearing and oil d.

Fig. #-23 Removing bearing (hub, outer)

3) a.

b.

Fig. #-21 1

! I

I 1

c.

Removing uxk shaft from hub

NOTE: Do not reuse the oil seal. A damaged or worn oil seal will allow the entry of mud and water into the hub, and shorten the life of

4) a.

the bearing.

Inspection Check t h e disassembled parts as follows. Bearing Wash the bearing in a cleaning solvent and check the inner and outer races for cracking and other damage, and also check if the outer race rotates smoothly without noise when the inner race is supported. Spacer Wash the spacer in a cleaning solvent and check for damage and deformation. Hub Wipe the inside surface with clean cloth and check for cracking and other damage. Reassembly Apply 9 g (0.33 oz) of grease to the inner bearing and position the bearing in t h e hub. With the 30 mrn (1.2 in) diameter end of Special Tool (HUBBEARING INSTALLER: 921350000) inserted in the inner race of the bearing, press the bearing into the hub. Special twl: H U B BEARING INSTALLER 921350000

II bearing Y6206C4

Fig. W 2 2 Remuving bearing (hub, inner) T13-015

c. T o remove the bearing (hub, outer) from the hub, use a 50 m m (0.2 in) diameter drift and press as shown in Figure 5)-23.

Fig. # - 2 4 10

Installing inner bearing

b. Coat the oil seal with grease and position it in the hub. With the 30 mm (1.2 in) diameter end of Special Tool (HWB BEARING INSTALLER: 921 350000) inserted into the oil seal, press the oil seal against the bearing.

e. Apply a coat or'grease to the oil seal to be installed on the outer bearing side. Press the oil seal into the hub using a 65 mrn (2.56 in) diameter bar or block as shown in Fig.

8-27.

Special tool:

HUB BEARING INSTALLER

Cross rmion of oil raal 713-016

Cross r a i o n 00 oil teal T13-018

Fig. 3Z25 lnrtalling oil surl

NOTE: Press the oil seal fully u d i l it bonorns. If clearance exists a t A, it will cause the oil seal lip t o wear.

NOTE: c. Invert the hub and apply 14 t o 18 g (0.51 t o 0.65 oz) of grease to the inside surface of the hub. d. Install the spacer in the hub. Apply 5 to 6 g (0.18 to 0.21 oz) of grmse to the outer bearing and position it over the bearing hole. With the 25 mm (1.0 in) diameter end of Special Tool (HUB BEARING INSTALLER: 921 3500G0) inserted into the inner race of the bearing, press the bearing into the hub. Special tool: HU8 BEARING INSTALLER 921350000

8sll bearing 16305C4

TI3017

Fig. -26

~nrtallingq c e r and outer bearing

Using more grease than specified may result i n grease leakage from the outer bearing into the brake drum, causing brake failure.

f. Installing the axle shaft into hub Prepare Special Tool (HUB INSTALLER CAP: 922320000) 0 ,and the lead scrcw @ and handle @ of Special Tool (HUB INSTALLER: 921360000). Insert the axle shaft into the hub by hand as far as possible and secure the shafkin3 vise. Install the lead scrcw @ onto I the &c ;haft end, and install the cap @ and handle @ J as shown in Fig. 13-28 so that the cap @ presses the bearing and n o load is applied to the oil seal. Pull the axle shaft until it stops by turning the handle while holding the lead screw with a wrench. 5) Installation Install the hub and axle shaft assembly in the reverse ordcr of the removal.

NOTE; a. When connecting the axle shaft to the engine. 1) Install each axle shaft on the correct side as the lengths of the right-hand and left-hand axle shafts are different. The right-hand axle shaft is provided with a

.

Broom for identification. (Fig. S 2 9 ) 2) B e careful not to damage the boot, 3) U s r new spring pin. b. The two upper bolts attaching the back plate . are slse used to secure the parking brake bracket

Spacial 1001 921360000

Axle shaft

Special tao1.922320000 Hub installer cap

< TlJ-019

Fig. IS-28 Inctal11ing axle shaft into hub the axlc shaft. This D.O.J.axle shaft transmits power without fluctuation in rotational speed. Furthermore, since the balls inside the D.0J. make a smooth rolling motion, the stiding resistance . i s smdf and there is almost no mechanical loss, thus permitting unnoisy operation and compact construction with little unbalancing factor. Since grmse is packed in the scaled spacer, the D.0J. rarely requires greas. . -. ing... . . e

Fig. &Z-29 Axle skaft identijhztion

4.

Axle shaft (D.O.J.)

General descript ion (Fig. B - 31) The rear axle is of a floating type using two constant velocity joints (D.O.J.) at both ends of 1)

2)

Disasembly a. Removing the boot band 1) Straighten the bent end of the band. 2) h o s e n the band by tapping its end. Pry up the band with a screwdriver and remove it from the boot with a pair of pliers.

-.

b. Rcmoving the circlic I ) Remove the boot from the D.O.J. 2) Pry off the round-section circlip installed at the end of the outer race of the D.O.J. with a screwdriver. (Fig. P - 3 2 ) c. Removing the outer race and balls 1) Remove the D.OJ. outer race from the axle shaft assembly. 2) Wipe off the grease, take out the balls and move the cage towards the boot.

--

,

Fig.

.

mf0

Band

Rcmoving boot

band

1 D.O.J. ass'y (Inner) 2 D.O.J. ass'y (Outer) 3 Shaft 4 Boots (Inner)

5 Boots (Outer) 6 Clip 7 Clip

8 Snap ring 9 Circlip 10 Seal pkrc T13-020

Fig. a - 3 1 Cross section of axle shuft (D.O.J.)!

NOTE a. To remove the cage from the inner race, turn the-cage by a half pitch of the ball tracks aftei,r$moving the balls and pull the cage.

h. Exeyke care not t o loss the balls.

Fig. 0 - 3 2Rcmoving circlip

d. Rcmoving the snap ring and inner race 1) Remove the snap ring retaining thc inner race on the shaft by using special pliers. 2) Pull the inner race off the shaft.

4) a.

Rtassemblmg Install the b wt o n the shaft.

I

!

1

FQ. -33

t:

Removing s m p ring

Take off the cage from the shaft and remove the boot.

NOTE: Be careful not to damage the boot with the squaresection circlip on the shaft.

Fig. S 3 5 Installing circlip and cage

f

b. Place the cage on the shaft with its direction as shown in Figure S 3 5 . c. Install the inner race on the shaft and lock it with the snap ring using special pliers.

NOTE: Make sure that the map-ring is completely inserted in the shaft groove.

Fig. w34 Disassembled D.O.J.

Inspccrbn Clean all the parts and check for defects as follows. Repair or replace as necessary. 3)

a.

.

D.O.J.

Check for seizure, corrosion, wear, excessive play and other damage. b. Shaft Check for excessive bending, twisting, wear and other damage. c. Boots Check for wear. warping and breakage.

d. Install the cage on the inner race by digning the protrusion of the cage with the track in the inner race. Then turn the &ge by a half to line up the holes in the cage with the inner race tracks.

NOTE: Apply grease to the cage holes. Use molybdenumhasa grease for the D.O.J.

Constant vclocity joint grease (Molytex No. 2 or equivalent)

..'i: .C

Fig. M-36 Installing cage on inmr race e. Insert the

six balls into the cage holes. (Fig.

B - 37)

Fig. &8-38 Applyinggrcase to outer race

g. Install the outer race on the assembly of the inner race, cage and ball assembly. h. Install the circlip in the groove in'the outer race.

Fig. U-37 Instalting balls

f. Apply grease in the outer race as indicated in Fig, U 3 8 . . ... .

.-

Grease

Constant velocity joint grease (hlolytex No. 2 or equivplent)

Fig. &-39 Installing outer race

NOTE: a. Make sun that the balls, cage and inner race are completely housed within the interior of the outer race.

b. Do not position the ends of the circlip in the track in the outer race. c. Lightly pull the axle shaft to check that the circlip is securely installed in the groove.

i. Pack the inside of the D.O.J.with grease.

Conslanl velocity joint grease (Molytex No. 2 or equivalent)

Grease

lnner D.0J.

50 g (I .8 oz)

Outer D.OJ.

100 g (3.5.02)

NOTE: When tightening the boot, exercise care that the mir remaining in the hoot is neither excessive nor insufficient. 3) Further tighten the band by using Special Tool (BAND TIGHTENER:925090000) until the band. cannot be moved with figcrs. 4) Lightly strike the band with the punch provided at the end of the tool.

Amount 1

j. Install .the boot on the D.03.

NOTE: Clean the boot groove in the shaft and outer race so that they are free from grease and other substance.

I

k. InstaUing the boot bands 1) Wind the band twice around the boot groove, passing the band through the clip. ?

NOTE:

Use a new band.

NOTE: Be sure to strike lightly so as not to damage the boot. 5) Cut off the surplus part of the band, ' leaving about 10 mm (0.4 in) after the clip t o bend it over the clip.

6- 3. TIRES AND R I M S 1.

Specifications

See the table for the tire and rim specificslions.

2. 1)

Wheel (tire and rim) Removal

a. Apply the parking brake and loosen the four

wheel nuts.

,

b. Jack up the vehicle.

NOTE: Be sure to place the jack straight. The vehicle is provided with four jacking points, one near each wheel. , .

-. b

Fig. W

0

~ ~ t d lboot i h bond ~

2) Tighten the band by pulling the end of the band with pliers while hojding the clip.

c. Remove the wheel nuts and washers, and\ take off the whpel;... 2) Installation :k' Install the wheel in the reverse order of the removal.

T ~ r eand Rim Specifications

Rim size

3.50D

Tire size

x

10

5.00-10-6PR ULT

Valve

TR244A h p h t Load

45 lbs.

Full Load

45 lbs.

Light Load

45 lbs.

Full Load

45 lbs.

Front Tire inflation pressure kg/cm2 (psi)

I

Rear

Spare

45 lbs.

Tlre w ~ d t h

mm (In)

Approx. 136 (5.4) with inflation pressure of 2.4 kg/cm2 (34.1 psi)

Tire outer diameter

mm (in)

Approx. 5 18 (20.4) w ~ t hinflation pressure of 2.4 kg/cm2(34.1 pd) >

3.

outer rim half. Also use care that the drum bolt holes in the rim halves are correctly aligned. T h s . will make the brake drum installation easier. f. Inflate the tire t o the specified pressure and attach the valve cap.

Inner tube

1)

Removal Deflate the tire. Since the rim is of the two piece type, the tube can be taken out by removing the four rim connecting bolts and separating the two halves of the rim It is unnecessary t o remove the tire from the rim. 2) Installation a. Check the interior surface of the tire and repair if necessary. Remove any foreign matter from the surface. b. Before installing the tube, tighten the tube valve and inflate the tube. Check the tube ~ n dvalve thoroughly for leaks by putting the tube in water. c. Insert the tube through the rim gap into the tire and align the valve with the valve hole. d. Inflate the tube sufficiently so that it will not be caught between the two rim halves when reassembling the rim. e. Match the two rim halves and join them together with the bolts, spring washers and nuts. Be sure t o insert the bolts from the

4.

Tire

To remove the t ~ r efrom the rim, remove the four run connecting bolts and separate the rirn ,halves If it is difficult t o remove the tire, insert a large screwdriver between the rim and tire and pry the tire off the rim. Repeat this operation around the rim and the tire will be easily removed.

5.

Tire damage and possible causes

Damage due t o flex, fatigue and heat The side walls of the tire flex as the tire rotates. If the tire pressure is insufficient or the vehicle is excessively loaded, the side wall flexing will become abnormally large, leading to separation of the cords from the rubber and 1)

,

6-17

-%Lz_

CHAPTER 7 :

.

7-

1

7-

2

.

7- 3

.

7-

7-

. 5. 4

BRAKE SYSTEM

............... BRAKEASSEMBLY . . . . . . . . . . . . . . . . . . MASTER C Y L I N D E R . . . . . . . . . . . . . . . . . BRAKE FLUID LEVEL WARNING SYSTEM ........ PARKING BRAKE SYSTEM . . . . . . . . . . . . . . . GENERAL D E S C R I P T I O N

2 4

11

14 14

s

71.

1. G E N E R A L DESCRIPTION

service brake syslem intd the front-wheel brake systcm and rear-wheel brake system. This ensures safety. coupled with the aulomatic adjuster of the front brakes. The front brakes are of t w o leading shoe type and the rear brakes --are of leading and trailing shoe type. The parking brake system is operated mechanically, applying the braking force t o the rear wheeb.

Outline

The brakc system consists of a service brake system and parking brake syslcrn. The service brake system employs dual hydraulic circuit with a tandem master cylindei, splitting the

2.

Specifications

Service brakes Item

TYPC

Brake drum material Brake drum inside diameter

Brake lining material Lining dimensions (Width x thickness x length) Lining surface area (One piece of lining) Wheel cylinder inside diameter

Parking brake

Front brakes

Rear brakes

Hydraulic, internal expansion, two leading shoe type, foot -operated

Hydraulic, internal expansion, leading and trailing shoe type, foot-operated

Mechanical, internal expansion, leading and trailing shoe type, hand- . operated

Cast iron

Cast iron

180 mm (7.09 in)

170 mm (6.69 in)

170 mm (6.69 in)

Molded resin

Molded resin

Molded resin

3 5 x 5 x 173mm

(1.4 x 0.20 x 6.8 in)

30 x 4.4 x 181 m m (1.2 x 0.17 x 7.1 in)

30 x 4.4 x 181 mm (1.2 x 0.17 x 7.1 in)

6 0 =m2 (9.30 in2)

54.0 crn' (8.37 in2)

54.0 cm2 (8.37 i n 2 )

23.8 mm (0.94 in)

19.0 mrn (0.75 in)

.

Cast iron

.

3.

Brake piping components

DETAIL

DETAIL

1 2

3 4 S 6

7 8

9 10

Tube (Brakc pipc) Brrke hose (F) Tubc Brake pipe Brake pipe Bnke pipe Brake pipe Brrkc pipc Brake hose BraLe pipe

'H'

Brake pipe Brake pipc Tube (Secondary) Tubc (Primary) Brakc pipe Maatcr cylinder au'y Clip Sloppcr Spring washer Bolt

Fig.

m-1

a-3

'c'

Spring washer Nut 3-way conneclor Stop lamp switch 3-way conncclor Clamp (Brakc hose) Cap (Ruid levcler) Grommet Rclervoir au'y 2-way conneclor

71.

2. B R A K E ASSEMBLY Front brake assembly

12 14 14

S h o c hold d o w q pin

1 2

3 4 5

6 7

'

Spring w r l h c r Nut

Tube Nut Spring vrrshcr Back p l a t e (F. RH)

8 9 10 1

12

Brakc hot a d y (LH) Spring scxt Shoc hold down r p r i n ~

Back p l a l ~(F. LH) Whctl cylinder

13

(F.UPPER. RH)

IS

Whcclcylindcr (F. UPPER. LH) Return spring Brakc shoe aw'y ( R H )

16

Whccl cylindcr (F.LOWER. RH)

17

Wheel cylinder

I4

(F. LOWER. LH)

Fig. m-2 Exploded view offront brake ussembfy 1) Disassembly a. Raise the front o f the vehicle and install safety stands. b. Remove the center cap. (Fig. R-3) c. Spread the lock washer and unscrew the spindle nut. Remove the spindle nut, lock washer, and washer. (Fig. B4) d. Rcmovc the plug from the brake drum. Using a'screwdriver, force the shoes in the directions of the arrows shown in Figure 13-5 t o make the shoe clearances wider. e. Pull the drum and wheel off the knuckle spindle.

Cenle? cap

I

-

-

--

Fig. m-3 Rcmovifig center cap

-,/?

\

g. Remove the shoe return springs from the

wheel cylinders. h. Remove the brake shoes with the automatic adjusters installed o n them.

NOTE: To make the work easier, remove both the primary and secondary shoes from the wheel cylinder adjuster wheel sides first and then from the wheel cylinder piston sides.

Fig. m-4 Spreading lock washer

NOTE: When removing the brake drum, be careful that the wheel bearing will not fall off.

Fig. m-5 Removing plug

f. Rcmove the shoe set springs.

i. Remove the shoe return springs from the primary and secondary shoes.

NOTE: Do not disassemble t h e automatic adjuster because its nut is staked. 2) Inspection, repair and adjustment a. Measure the Iining wcar. If the thickness of the lining is less than 1.7 mrn (0.07 in), replace the shoe assemblies. Always replace the primary and secondary shoes on both sides of the vehicle at the same time. b. Replace the shoe return springs if they are weak. c: Replace the back plate if warp or wear is evident. d. In case the inside surface of the brake drum is scored, correct with No. 60 sandpaper. Also correct or replace the brake drum if irregular wear or tapered scoring is evident, or if the drum exterior is damaged.

inside

182 m m (7.17 in) 3) Assembly a. Apply a small amount o f brake grease to the sliding surfaces between the back plate and brake shoes, and contact points between t l ~ c brake shoes and wheel cylinders. b. Install the shoe springs on both primary and secondary shoes, and install them onto the wheel cylinder ends.

Fig.-#-6

Removing

broke purrs

NOTE: Be sure t o install the shoe return springs as shown in Fig. S3-7.

c. Hook the mid-point or the spring l o the

a4.

wheel cylinder as shown in Fig. d. Install the shoe set pins. e lnstall the brake drum o n t o the knuckle Y! spindle after wiping off the oil o n the brake lining surface and brake drum inside surface.

approxirnalley 0.3 mm (0.012 in). Therefore, pedal travel will not change even the linings wear out.

Fklurn spring Brake shoe

. -.

/

Fig. 13-7 Installing shoe return spring

Fig. a - 9

f. Install the washer, lock washer, and nut o n the spindle and adjust the preload for the R)See h p bearings. (% g. Test drive the vehicle at about 10 km/h (6 mph) and' apply the brakes forcefully t w o o r three times. Check the pedal travel and make sure that there is n o abnormality in braking operation.

6s

1

Automatic adjuster

4)

1

!I

I-

-

Fig. #i9 L.ocntion

I 1

I

ojarrtomntic adjuster

The front brakes are equipped with the automatic adjuster that automalically keeps the clearance between the brake shoe and drum at

Cross scction o ~ a u f o m o r i c adjuster

When the clearance between the brake shce and brake drum is more than t h e designed clearance S, namely when the clearance is S + .AS,automatic clearance adjusting action takes p!ace as fo!lows. As the brakes are applied, the brake shoes, which have been stopped by A'of the adjusting block, arc forced toward the brakc drum and at t h e same time the adjuster bolts (4) installed o n the shoe webs move away from A and coatact B, travelling the distance S. As the pistons further force t h e shoes outward overcoming the frictional resistance produced b y the friction springs (6), sliding occurs between the shoe web (1) and the friction plate (5) to compensate the surplus cleararlce A S and eventually the shoes contact and press the brake drum. When the b;akes a r t released the sI~ocsmove off the drum and are retnrned inwards b y the return springs until the aGjuster bolts (4) are stopped by A. The shoes d o not move inward more t11a.n that since the frictional resistance of the friction spring is set greater t h a n the pulling force of the rcturr? spring, thus maintaining the shoc ciearance S. 5) Front wheel cylinder The front wheel cylinder components are shown in Fig. R-I0.

/ .'

a. Rcasscrnbly I ) Thoroughly clean the wheel cylinder body and install the bleeder screw, with a rubber cap o n it, into the cylinder body. 2) Wash the piston and cup in alcohol, carefully -wipe them with clean cloth and soak them in clean brake fluid. 3) 111staH the cup into the piston, being careful about the c u p direction. If the cup i s damaged or deformed, replace it with a new one. 4) Insert the piston into the wheel cylinder. Be careful not to damage the lip of the cup. 5) Install the rubber boot on the cylinder body.

2.

Rear brake assembly

The components of the rear brake assembly are shown in Fig. U-1I . 1) Disassembly a. Raise the rear pf the vehicle and place it on the stands. b. Rcmove the wheel and brake drum as described in a - 2 , Chapter -5 c. Release the parking brake and loosen the cable adjusting nut at the rear end of the parking brake rod. Remove the cable return spring from the lever.

b. Torque specifications Wheel cylindcr to back plate (Nut)

8 mrn

6 mm

Back plate to knuckle (Nut)

1.3

(9

- 2.0 kg-m

- 14 ft-lb)

0.6 - 1.1 kg-m (4 - 8 ft-fb) 1.2 - 2.4 kg-m (9 - 17 ft-lb)

I Boo1 2 Piston 3 Cup

Fig. a - 1 0

4 Cup spacer

5 Return spring 6 Wheel cylinder body Components of front wheel cylinder

RCAR

( I ) Boo1 (2) Nut (3) Spring washer (4) Adapter ( 5 ) cap

(6). Wheel cylinder arrcrnbly (7) Brakc shot complctc

(8) Spring (9) Levcr complctc (10) (11) (12) i13) (14)

Anchor block assembly Back p k t e complete Pin Scat

Spring

Fig. S - 1 f Exploded view ofrear brake arsembly d. Remove the shoe set springs. e. Return the brake shoe adjuster wheel of the anchor block so as to make the spring tension smaller.

g. Remove the shoe return springs from the

brake shoes. 2) Inspection, correction and replacement a. Check the linings for wear. When the lining thickness is less than 1.7 mm (0.07 in; replace the brake shoe. Always replace the Icading and trailing shoes on both sides of the vehidc together wirh the slme return springs a t the same time. -

Allowable lining thickness

Adjuster

Fig. a - 1 2 R crnoving brake parts

f. Remove the brake shoes from the anchor block first, and then from the wlleel cylindcr.

1.7 mm (0.07 in)

b. Replace the shoe return springs if the tension is insufficient. c. Replace the back plate, brake shoes, and lcvcr if deformed or worn. d. Rcplace the lever if excessively worn. e. Correct the inside surface of the brake drum with No. 60 sandpaper if scoring is evident. Also correct or replace the brake drum if irregular wear, tapered scoring, or external damage is found.

Drum

Standard

170 m m (6.69 in)

inside diameter

Limit

172 mm (6.77 in)

f. Replace the boot (dust seal) and adapter if defective. 3) Assembly a. Install the lever t o the back plate. Check t o see if the lever is installed on the correct side, as the left-hand and right-hand levers are different in shape. If installed on the wrong side, the lever will contact the wheel .cylinder and spring and may cause damage.

d. Install the brake shoes together with the return springs, by fust instatling the upper ends of the trailing shoe and leading shoe in this order to the wheel cylinder and then the lower ends of the trailing shoe and leading shoe in this order to the anchor block. e. Install the shoe s'et springs. f. Check the brake drum Tor abnormality and carefully install it over the brake assembly, for the installing Refer to 5 2 , Chapter procedure.

S

t 1

1 1

NOTE:

1

a. Be careful that nothing falls into the brake

!

assembly. b. Do not smear grease on the inside surface of t h e brake drum. g. Adjust the brake shoe clearance in accord-

h.

Fig. 13-13 Installing lever

b. Assemble the brake shoes and return springs. Pay attention t o the directions of the brake shoes and return springs. (Fig. B-14) c Apply a thin coat of brake grease to the surfaces of the back plate, wheel cylinder piston ends and anchor shoe supporters which the brake shoes contact.

i. 4)

a. b.

ance with "4) Adjustment of shoe clearance". Adjust the parking brake cable at the parking brake rod end so that the cable does not pull the Iever on the brake assembly. Install the pin, washer, cotter pin and return spring as shown in Fig. B-15. Readjust the parking brake cable in accordance with -5. in this Chapter. Adjustment of shoe clearance Raise the rear of the vehicle so that the rear wheels turn freely. Align the adjustment hole in the brake drum with the adjuster at the anchor block and insert a sctewdrivcr through the adjustment hole to reach the adjuster.

Hang rht return spring lrom back p l a ~ eside.

Fig.

Sf 4 D i r e c t i o n of spring

Fig.

m-f5Connectirrg parking brake cable

1

. I

I

. . , i !

5)

.

Rear wheel cylinder and anchor block

Boo1

1

I

/ Piston head

" Fig. =-16

Adjurtmcnt

hole

in brake

"

Cylidcr body COMPL

Piston

I

.

.

;$r o w + 8

?w d

.

Cup

"r*;s'r'-

Adjuster

Block COMPL

drum 1

Fig. W-18 Components ofrear wheel c y E d c r and anchor b b c k

\

Fig. =I 7 Adjusting rhoc clearance c. Turn the adjusters on both sides in t h e

direction that decreases the shoe clearances until the wheel cannot be rotaled with o n e hand. d. Then back off the adjuster b y 8 riotches. c. After centering the shoes in the brake drum by depressing the brake pedal 2 or 3 times, turn the wheel t o see that it rotates easily and n o noticeable noise is made between the shoe and drum. f. Perform the above adjustment for t h e leading and trailing shoes on both rear wheels.

NOTE: a. Before starting the brake adjustment, fully release the parking brake. b. Be sure to back off t h e adjuster by 8 notches otherwise the brakes may drag. c. When the wheel i s heavy t o turn or noise is distinctly audible, readjust the shoe clearance.

Reassembly a. Rear wheel cylinder I ) Clean the wheel cylindcr, attach the rubber cap on the bleeder screw and install the cap into the wheel cylinder. 2) Soak the piston and cup in clean brake fluid. 3) Install the cup to the piston, being careful about the cup direction. When inserting the piston into the cylinder, use care not to damage the lip of the cup. b. Anchor block 1) One of the two supporters of the anchor block has right-handed screw threads and the other has left-handed ones. If warpage or wear is evident on the threads, replace the supporter together with'the adjuster. 2) The adjusters arc expected t o be rotated lightly with fmgers. Replace tht adjuster if its teeth are excessively deformed or worn. 3) Replace the anchor block body if the mounting bolt is defective. 4) Before assembling, clean the inside surface of the anchor block, iht outside surface and threaded hole of the adjuster, and the threaded part of the supporter, and apply a generous amount of grease to these parts.

2) Operation when secondary (rear wheel)

7- 3. MASTER CYLINDER 1.

brake Line leaks Since there is no pressure rise in the sccondary chamber even if the push rod moves, the secondary piston reaches the inner end of the master cylinder. However the primary piston compresses-the fluid in the primary chamber, thus keeping the front brake system operative. 3) Operation when primary (front wheel) brake line leaks Sincc there is no pressure rise in the primary chamber even if the push rod moves, the primary piston comes into contact with the secondary piston and pushes it, thus keeping the rear brake system operative. (Fig. U-22)

Operation

1)

Normal operation When the brake pedal is depressed, the primary and secondary pistons are maved i n by the force transmitted from the pedal through the push rod. As soon as the return port is closed b y the secondary piston, the hydraulic pressure begins to rise in [he secondary chamber, consequently applyiag pressure t o the rear wheel cylinders, and then the pressure in the primary chamber also rises, applying pressure to thr front wheel cylinders. (ReTcr to Fig. B-20.)

P

I

1 2

6 7

Nipple Nipple

rcpair

8 9

4

Masrcr cylinder repair k i t (B)

10

5

Gasket

3

Master cylindcr

kit (A)

11

Check

vdve

Secondary pircon Spring T u b e scat

Cap Cyiindcr body

rtoppcr

12 13 14

15 16 17

R e t u r n spring

Pbton rrl'y Stop warher Stop ring Boots

Push

Fig. PT-19 Component parts of muster cylinder SrC-

11

rod

Secondary

Fronr our1.1

econdary piston

Return port

~ i g M-20 . S e c t i o m l view of master cylinder

2. I)

Removal

2)

Right-hand drive vehicles

Left-hand drive vehicles

a. Remove the under cover. b. Disconnect the brake pipes from the master cylinder. (Fig. SU-2 1) c. Disconnect the tube, connecting the reservoir t o the master cylinder, from the nipple. d. Remove the pin on the push rod. e. Remove t h e master cylinder from the chassis frame by unscrewing the two attaching bolts.

~ i g f.a 2 1 Removing muster cylinder

NOTE: He careful that brake fluid does not spill / over painted surfaces during removal.

.

Fig. P 2 2 Operation when setondary (rear-wheel) broke line leaks

a. Ren~ove !he brake fluid reservoir from the reservoir holder and empty the reservoir.

4.

Fig. H - 2 3 Removing brake fluid reservoir b. Remove the f l a ~ enuts connecting the brake

pipes t o the master cylinder. c. Remove the cotter pin from the brake pedal-to-push rod connecting pin and separate the master cylinder from the brake pedal.

/

Preparation for reassembly

The inside surface of the master cylinder must be smooth and perfectly round. Replace the master cylinder if irregular wear or defects are evident. Never* correct ... the inside oi the master cylinder with sandpaper or other abrasive material. I) Before assembling, wash the inside surface of the master cylinder with clean brake fluid. Be careful that dust or other foreign matter does not enter the master cylinder during assembly. 2) When washing the cylinder and inserting the piston, use case not t o damage the inside surface.of the cylinder and piston cup.

NOTE: Replace the cylinder and the piston if the clearance exceeds the specified limit. Piston-tocylindcr clearance

I

Standard

I

Limit pin

?'

!

Fig. a - 2 4 Removing master cyIinder

3.

Disassembly

Remove the boot from t h t cylinder body. I) (Fig. S-19) 2) Remove the snap ring and stop plate. 3) Remove the primary piston and the return spring. Remove the piston stop and gasket and then remove the secondary piston. 5 ) Remove the cap and seat, and then remove the check valve. 4)

5.

0.020 (0.0008

- 0.105 mm

- 0.004 1 in)

0.15 mrn (0.0059 in)

Assembly

Insert the secondary piston into the cyl1) inder body with the secondary return spring. 2) Insert the primary return spring and then the primary piston into the cylinder body. 3) Install the secondary-piston stop with the gasket. 4) Install the s t o p plate and secure it with the snap ring. 5) lnsert the check valve' spring into the cylinder block, 6) Install the seat end cap. 7) Install the push rod, with the boot previously installed o n the push rod, to tile cylinder body.

6.

Installation

Install the master cylinder in the I , ierse I) order of the removal. 2) Alter installing, bleed the brake system and check the operation of the master cylinder.

3)

1.

Torque specifications

Master cylinder to chassis frame on Iefthanddrive vehicle Brake pipe flare nut

8.0 (58

- 12.0 kg-m - 87 it-lb)

1.5

- 2.0 kg-rn - 14 fl-lb)

(1 l

Operation

%

In normal condilion, the float is above the 'reed switch; the magnetic field from the permanent magnet placed in the float does not permit the reed switch to operate, the indicator light being unlighted. As the brake fluid level drops the float is also lowered, and when i t reacher the prescribed level the reed switch operales t o turn on the indicator light, warning the driver of dropping of brake fluid level. The indicator,. circuit is connected .to the charge relay so that the light glows when the ignition-starter switch is turned t o ON position and goes out when the engine is started, in order t o provide a means of checking the circuit for disconnection and the bulb for burning out.

7- 4. B R A K E F L U I D LEVER WARNING SYSTEM

2.

Replenishment of brake fluid

If the indicator light glows during operation, immediately replenish the reservoir,with brake fluid t o the embossed level line.

NOTE: The brake fluid level drops as the brake lining wear develops as well as when the brake system leaks. When the vehicle jolts along a rough road, the indicator light may flicker because the float moves u p and d o w n with the waving fluid surface.

Fig. B - 2 5 Cornponenfs of brakc fluid level warning syrtem

?- 5. PARKING BRAKE SYSTEM Checking circuit added

The components of the parking brake system are shown i n Fig. R27.

1. Brake fluid lewl

rn turn on position

I

I Fig. #-26 Sectional view r l j brake fluid reservoir

Parking brake lever and rod

I ) Removal a. Raise the vehicle and loosen the nut at the rear end of the rod. Disconnect the rod from t h k parking brake lever by removing the clevis pin. (Fig. S-28) b. Remove the two 8 mm lever attaching bolts. (Fig. 1 - 2 8 ) c. Separate the rod and cable by reinoving the nuts at the rear end of the rod. (Fig. B-29)

DETAIL ' O m

1 Rod assy (Hand brake) 2 Nut 3 Washer 4 Pipe (Hand brake) 5 Joint (Hand brake) 6 Cable u s y (Hand brake)

7 Spring washcr 8 Bushing 9 Clamp (Hand brakc) 10 Boltauy

Fig. -27

DETAIL

1 1 Hand brake lever assy 12 Button (Hand brake lever) 13 Spring (Hand brake Icvcr) 14 Screw (Pan head) 15 Hand brake switch t s s y 16 Cord assy (Hand brake switch) 17 Bolt (8x18) 18 Spring washer 19 Clevis pin 20 Cotter pin

Components of

m-

15

'Em

21 Grommet (Hand brake) 22 Clamp 23 Bracket (Hand brake RH) 24 25 26 27

Bracket (Hand brake LH) Spring (Hand brake cable) Clevh pin

Clamp (Hand brake cable) 28 Bolt

brake system

d. Install the clip on t h i r o d and attach the clip c.

2.

Fig. B-28 Rcrnoving parking brake lever a n d rod

Fig. B - 2 9 Separating rod and cable

t o the bracket on the crossrncmbcr. Adjust the cable in accordance with "2. Parking brake cable".

Parking brake cable

1) Removal a. Release the parking brake lever fully. b. Disconnect the cable from the leven on the rear brake assemblies. c. Remove the four.cable clamps.on the. crossmember and hub by unscrewing the 6 mm attaching bolls. d. Remove the cable from the rod by removing the joint. e. Remove the cable grommets on the outer trailing arms and extract the cable. 2) Inspection a. Check the parking brake cable for operation. b. Check the inner wire of the cable for rusting and damage. c. Check the outer sheathing of the cable for wear, tear and other damage. d. Check the boots for tear and other damagc. e. Check the clevis pin for wear. 3) .Installation a. Insert the cable into the hole in the outer trailing arm o n each side. b. Install the four clamps, tightening the attaching bolts t o the specified torque. (Fig.

m-27) 2)

Inspection

-

a. Check the parking brake lever for operation. b. Check the ratchet and hook for wear.

c. Check the rod for damagc and wear. d. Check the clip and joint for damage and wear. 3) Installation a. Install the parking brake lever t o the bracket on the floor. Torque (Lever arraching bolts)

0.6 - 1.4 kg-m (4 -, 10 ft-lb)

b. Connect the rod t o rhe lever. c. Install the joint, with the cable inserted in it, t o the rear end of the rod, being careful about the installing order of the nuts,. washers and pipe.

Torque (Clamp attaching bolts)

0.3 - 0.6 kg-m (2 - 4 ft-lb)

c. Connect t h c cable end t o . t h e lever at the brake assembly.

NOTE: Change the cotter pin with a new one and be sure t o bend it into anchor shape.

d. Install the cable return spring on the bracket which is attached t o the hub. e. Insert 'the cable into the joint and install the joint on the rear end of the rod with the nuts, washers and pipe in thc correct order. f. Install the clip on the rod and attach the clip t o the bracket o n the crossrnembcr.

the cable as described i n the following item. 4) Adjustment a. Prior t o the cable adjustment, complete the brake shoe clearance adjuslment. b. Adjust the cable t o the specification below by changing the joint position on the rod. g. Adjust

Norchcs

Standard lever travel [when pulled with approx. 25 kg (55 Ib) of force]

3 notches Fig. st-30 Parking brake lever ratchet

Limitof travel [when pulled with approx. 25 kg ( 5 5 lb) o f force]

5 notches

Total notches provided

8 notches

Joint

Torque (Joint lock nut)

-

0.3 0.6 kg-m (2 - 4 ft-lb)

Lock nut

1

I c. Make sure that the wheel rotates lightly alter adjusting the cable.

1 i

Fig. m-31 Joint

and

lock

nut3

iI

i I

CHAPTER 8:

GENERAL DESCRIPTION

. . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . STEERING WHEEL . . . . . . . . . . . . . . . . S T E E R I N G SHAFT . . . . . . . . . . . . . . . BEVEL GEAR BOX . . . . . . . . . . . . . S T E E R I N G GEAR BOX . . . . . . . . . . . . . . . . TIE-RODEND . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING . . . . . . . . . . . . . . . . . S T E E R I N G SYSTEM

. . . .

S T E E R I N G SYSTEM

2

3

4

5 8 10

15 16

8- 1. G E N E R A L DESCRIPTION

1.

Outline

The steering gcar box employed is of the rack and pinion type, which is simple and rcliablc. As the pinion rotates, thc rack moves laterally. pulling or pustung the tic rods that connects the rack and the knuckle a r m . Thus both the front whcels are turned right and left

2.

to steer the vehicle. 'Th: tie rods are ball.jointed to the knucklt am and l o the rack. The backlash between the rack and pinion is set to 0 using a spring installed in the slecve adjuster. In this sleering system, t h e bevel gcar box is locaied in front of the sltering gear box; therefore, the iorquc from t h e steering wheel is reversed by the bevel gear and is transmitted through the torque rod and rubber joint to the' pinion on the steering gear box.

-

Specifications 7.2 rn (24 ft)

Minimum turning c~rcle Inner

36O

Oulcr

3S0

Turning angle

.

22.5

Steering ratio S~ccringwhcel d i a m c ~ c r

380 m m ( I 5.0 in) TYPC

Rack and pinion

Pinion

7 teeth

Rack

28 tecth

Steering Scar assembly

I

Backlash Thread diameter and pitch

I

L c s than 0.05 mrn (0.002in)

1

18 mrn x 1 .SP (Lcft-hand screw)

Nut width across flats Tic .rod

Turnbuckle width across flats Tie-rod end ball stud

Bevel gear assembly

13 rnrn

12 mm dia. x 1/10 taper

Pinion

15 teeth

Gear

21 ~ c e ~ h

Gear ratio

1.40

Backlash

Lrss than 0.05 m m (0.002 in)

Axial play of bevel pinion

Less than 0.035mm (0.0014 in)

I

Toe-in (with vehicle unloaded)

Sidc slip (with driver)

-

-

8 - 13 m m (0.32

- 0.51 in)

IN 3 mm (0.1 i n ) to OUT 3 m m (0.1 in)

I

I

Fig. *-I

Installing steering system components

Since this stecring system cmploy s the bevel gcar assembly, it is very important to obtain correct alignment bctwcen the bevel gcar box. stccring gear box a n d steering wheel which are installed a n the vchiclc. Whcn installing the steering system c o m p o n e n t s , first temporarily tighten their attachi;;g bolts a n d nuts. Then fully tighten t h e m t o the specifications in thc

o r d e r of @ to @ as indicated in Fig. 14-1, ensuring that the c o m p o n e n t s are aligned correctly with each other. 1) Tighten t h e bolts attaching t h e stccring shaft b r a c k e t t o thc instrument panel. 2) Secure t h e s ~ c c r i n ggear box b y tightenin? t h e attaching bolts in t h c order o f @, @.@ artd @ .

3) Sccurc the bcvcl gcar box with the rubber bushing and clamp by tigh~cningthc allaching bolts to the specified torque. Torque

The construction of thc stccring wheel is shown in Fig. fd-3.

l .O - 2.2 kg-m (7 - 16 it-lb)

1.

Remove the two screws at the back of the 1) steering whcel and remove the cover.

4) Tighttn the clamp securing the torque rod ro thc bcvel gcar b o x .

Torque

2.5 - 3.3 kg-m (18

Removal

- 24 TI-lb)

5) Tighten the clamp securing the steering shaft fo t h e bevel gear box. Torque

2.5

- 3.3 kg-m (18 - 24 ft-lb)

NOTE:

When tightening the clamp, pull the steering shah up so that the gap between the steering wheel and shafi cover becomes as follows.

Fig. S 2 Removing

Remove the s!cering wheel retaining nut and rcmovc the stecring wheel from the shaft. (Fig. sa4)

2) Gap

1

- 3 m m (0.04 - 0.12 in)

Fig. s

cover (steering whcel)

3 Construction of steering wheel

m-4

2.

Inspection

Install rhe cover o n t h e sleeting wheel by tightening t h e t w o screws from t h e back of the steering wheel. 4) Check the horn operation by pushing the horn key.

3)

Check all the parts for damage a n d poor operation, and if necessary replace defective parts with new ones.

Fig. 81-6 Inttalling

8-4.

3.

steering

whect

S T E E R I N G SHAFT

Reinstallation

I) C l e m t h e horn contact points and slide plarc.

The construction o f the steering shaft is shown in Fig. L-8.

1.

Removal

Remove the bolt or the clamp securing the 1) steering shaft t o the bevcl gear.

Clamp

Fig. H-5 Cleaning contact points

With the front wheels in rhc straight-ahead install the stecrir~g whcel with the washer, lock wasller a n d n u t o n t o l h c shaft and tighten thc nut to the spccific;ltion with t h e steerirrg spoke in the horizontal position. (Fig. FI-6)

2)

2 . 2 - 2.8 kg-rn

Fig. 8 - 7 Removing c b m p bolt

2)

Disconnect

t h e c h o k e cable from t h e

stccririg bracket b y removing t h c c h o k e knob.

3) Removc the t w o bolts attaching t h e steering brackct to the instrument panel. 4) Disconnect the c o m b i n a t i o n switch a n d ignition-starter switch harncsses from thc main

5)

Pull t h e steering shaft o f f t h e bevel shaft.

2.

Disassembly

1 ) Separate the slcering whecl from the shaft assembly. 2) Pull out the steering shaft downward (with

the steering shaft placed in its installed direction), 3) Remove the screw on each side of the sleering column cover t o remove the steering bracket out of the steering column cover.

1 Steering wheel

2 3 4 5

Cover (Column)

Combination swi~ch Hazard warning switch knob Brackt~complete 6 Shaft complete 7 Bearing

Fig. I3 Corutrvction ofsteering shaft

Remove the hazard warning switch knob and lake out the combination switch. (Fig.

4)

ra-10)

3.

Fig. R-9 Removing steering bracket

Inspection

1) Check t h e steering shaft for bend and other damage. 2) Check the bcaring for wear, and for noise and smoothness when thc steering shaft is rotated in t h e bearing.

tighten with the clamp. At this time, adjust the gap between the bottom of the steering wheel and the t o p o f the shaft cover to 1 t o 3 rnm (0.04 to 0.12 in). (Fig. m-1 1) '

Fig. S - I 0 Removing combination switch

3)

4.

Check t h e o t h e r p a r t s f o r d e f e c t .

Fk. S

Reassembly

Before reassembling, clean [he sliding parts 1) and apply new grease. 2) Install t h e combination switch in the steering column cover and install the hazard warning switch knob. 3) Pass the combination switch harness through the hole in thc bracket, install the steering bracket in the cover and temporarily tighten the attaching scrcws. 4) Insert the shaft into position and install the stecring wheel on the shaft. 5) Tighten the bracket attaching screws on both sides of the cover. Torque (Screw)

0.06 - 0. 12 kg-m ( 0 , 4 - 0.9 It-lb)

I

5.

Installation

I ) Press the steering shaft o n t o the bevel gear shaft with the notches correctly aligned, and

f 1 Installing steering shaft

Torque . (Clamp bolt)

2.5 - 3.3 kg-m ( I 8 - 2 4 Ct-lb)

-

1

2) Install the stecring shaft assembly to the 'instrument panel with the two attaching bolts.

Torque

I .O - 2.2 kg-m (7 - 16 ft-lb)

3) Connect the combination switch and ignition-starter switch harnesses t o the main harness and clip them o n the steering bracket. 4) Install the choke cable and knob on the steering bracket. 5) Make sure that the steering wheel spoke pisition is correct and install the steering wIlcel cover.

8- 5, BEVEL GEAR BOX The construc!ion or rhc bevel gear box is shown in Fig. q - 1 2 . (1)

Gcu box

(2) Bevel g e u (pinion) (3) Bevel g w (gear) (4) Cover

( 5 ) Retainer.

(6) Buring (7)

Buring

.

( 9 ) Dust r u l (10) Oil r u l (11) Adjusler (1 3) Grounding cord (14) B u r i n g

Fig. S - I 2 Construction of bevelgear box

1.

Removal

Raise the vehicle or place i t on a pit. 2) Remove the clamp bolt connecting the stccring shafi t o the bevel gear box and pull the steering shafr off the bcvcl gear box. 3) Remove the front bumper and under cover. It is unnecessary t o remove the radiator and protector. 1)

4) Remove the two bolts at the rubber coupling and disconnect the torque rod from the pinion shait of the steering gear box ascmbly.

Fig. @-I4 Dirconnecting torqtre rodfrorn Fig. B - 1 3 Rcmoving under cover

pinion shaft

5 ) Remove (he two bevel gear box clamp bolts with the ground wire, and detach the bevel gear box from the chassis frame. (Fig. la-15) 6 ) Remove the torque rod from the bevel gear b o x by removing the clamp bolt.

box

Rubber bushing

Fig. S f 6

Disassembly and assembly

Since the bevel gear box is designed to used without maintenance or adjustment, no1 diusscnlble the unit unless it is to discarded. If it is dcfective replace as assembly.

3.

bushing

3) Place the clamp on t h e rubber bushing and temporarily install the bevel gear box on the chassis frame with the two bolts. washers and spring washers. Be sure to connect the ground wire t o t h e upper bolt. 4) Connect the torque rod ,to the rubber coupling with the two bolts, spring washers and nuts.

Fig. *-I5 Renloving bevelgear box

2.

Installing rubber

be do be

.

Torque

0.9 (7

i

- 1.5 kg-rn - 1 I ft-lb)

an

Installatian

Install t h e clamp .on the torque rod and 1) temporarily connect the torque rod to the bevel gear shaft with the bolt. spring washer and nut. 2) Install the rubber bushing to the bevel gear box, with the marked end downward.

5) Connect t h e steering- shaft to the bevel gear shaft and temporarily tighten the clamp bolt. 6) Fully tighten the clamp bolts attaching the bevel gear b o x t o the chassis frame, after establishing the bevel gear box position in which the steering wheel turns rnost,lightly. TO check the rotating torque o f the steering wheel, rotate t h e rubber coupling with hand.

I

L

I

i

!I

!

!

Tor quc (Clamp bol I)

i

1 I

1 .O - 2.2 k g - ~ n

(7 - 16 [I-lb)

2) 3)

Remove the under cover. Remove t h e r d o bolts connecting the pinion shalt of the srcering gcar box t o the rubber coupling and leave the rubber coupling atlached la the torque rod.

7) Fully tighten the clamp bolls connecting the lorquc rod and steering shaft t o the bevel gcar box assembly. -

-

Toryuc (Clamp boll)

2.5 - 3.3 kg-m (18 - 24 TI-lb)

8) Turn the steering wheel from lock t o lock and check for operation. The condilion is satisfactory if the tangential force o n the sreering wheel is less than 1.8 kg (4.0 Ib) with one pcrson on the seat (front). Fig. PI-18 Removing rubber coupling bolts

Loosen the 16 mm nuts of the turnbuckle. The t i t rod has 1ef1-hand screw thread and the tie rod end has righ-hand screw thread.

4)

!

i

Fig. S - 1 7 Checking steerirlg wheel oprrration

9 ) Adjust t h e stecring wheel position so that the spokes are horizontal when the front whcels are in straight-ahead position. Fig. a - 1 9 Loosening turnbuckle lock nutr

Ei. S T E E R I N G G E A R BOX The construction of the steering gear box is shown in Fig. W-20. 1.

Removal

I ) Raise the vehicle and place i t on safcty stands.

5 ) Separate the tie rod and tie rod end by turning the turnbuckle. 6) Remove the iour 8 m m bolts attachjng the steering gear b o x t o t h e crossmember ,and remove the stecring gear b o x by shifting it rearward. (Fig. M-21)

1 N U ~ ( I D X ~ ) 2 Lock washer (Rnck) 3 Stopper (Rack) 4 Rack compl 5 Cap (Rack) 6 Snap pin 7 S p a a r ( G ubox) 8 Clip (Gear box) 9 Boot (Steering gcar box) 10 Scat ( G a r box spring) I! Spring (Gear box ball) 12 Seat (Gear box ball) 13 Tic r o d end au'y 14 Nut 15 Turn buckle (Tie rod) 16 Nut (18 x 10) 17 Tic rod 18 Clip (Tic rod) 19 Boot (Gear box) 20 Gcar box unit 2 1 Bushing (Gear box) 22 Bushing (Gear box) 23 Bushing (Slcering pinion) 24 Bushing (Steering pinion) 25 Oil scal(l9 x 26 x 6 ) 26 ' ~ o l t 27 Spring washer 28 Covcr (Pinion) 29 Packing ( G a r box) 30 Reraincr (Pinion) 3 1 Lock nut (Steeling gcar) 32 Adjuster (Gear box) 33 Spring (Ccar box) 34 Sleeve (Gcar box) 35 Boot (Gcar box) 36 Pinion tss'y (Gcar box)

FQ. Sir-20

Construction

of steering gcar bor

2.

Disassembly

Hold the steering gear box in a vise a n d 1) remove the covers a t both ends of the gear box. 2) Remove the s n a p pin installed i n the groove in the rack by using a flat blade screw driver. (Fig. kU-22) 3) Remove the cap from the rack, leaving the spacer, spring, etc. in the rack.

Fig. U - 2 1 Removing s t e c r i n g g e a r

box

B-11

6) Turn the pinion shaft clockwise t o pull the rack out of the gear box. ' 7) Take out the spacer, spring and ball retaining seats from the rack.

NOTE: Be careful not to damage the sliding surfaces of the rack. Remove the boot retaining clips and remove the boot from the gear box.

8)

NOTE:

Fig. @-22 Removing smp pin

D o not pull the boot forcefully.

4 ) Remove the tie rod clips from r h t boots and extract the tie rods from the gear box. Remove the clips from the tie rods. (Fig. 1 - 2 3 ) 5) Spread the lock washer at the rack end and remove the rack stopper, lock washer and nut. (Fig. 1824)

Rcrnovc the pinion wver and gasket by removing the two attaching nuts. (Fig. S 2 5 ) 10) Remove the retainer and take out the pinion. 11) Loosen the adjuster lock nut and remove the adjuster, spring and sleeve from the gear box.

9)

3.

Assembly

1) Thoroughly wash all the parts in cleaning solvent.

Fig. 8-23 Removing t i e

rods

Fig. PI-25 Removing pinion

F*. 1-24

cover

2) Hold the steering gear box in a vise and install the boot with the retaining clip at each end. 3) Apply a sufficient unounl of grease to the pinion and the inside of the pinion bore in the gear box. Insert the pinion into the gear box and install the retainer, Also apply grease to the retainer.

Removing rack stopper

tp-12

Fig. tl-26 Knrtallinx pinion 4)

Install the pinion cover with the gasket,

two 6 rnm bolts and spring washers.

.Torque (Bolt)

0.5 - 0.7 kg-m (3.6 - 5.1 ft-lb)

5 ) Apply a sufficient amount o f grease lo the rack. 6) Insert the rack into the gear box from the side opposite t o thc pinion. Engage the tceth'of the rack and pinion, and turn the pinion counterctockwise. 7) Apply grease to the adjuster sleeve and thc inside o f the adjuster bore in the gear box, and insert the sleeve into position. 8) Apply grease t o the adjuster spring and inscrl i t in the sleeve. 9) Apply sealant t o the adjuster threads and screw in the adjuster into the gear box. 10) Install the stopper, lock washer and nut in this order o n the rack end.

11) Adjust the rack-to-pinion backlash by fully tightening t h e adjuster and then back off about 1/15 turn. Turn the pinion from lock t o lock to see its rotating condition. If the rotation i s smooth, back off the adjuster less.than 1/15 turn, ---.-. 12) Measure t h i rotating torque of the pinion. The torque from the slraight-ahead position should be 0.01 to 0.09 kg-m (0.07 t o 0.65 ft-lb), and the maximum torque through the whole range o f travel should be less than 0.22 kg-m(1.59 ft-lb). (Fig. a - 2 8 ) After the above condition is satisfied, lock the adjuster with the lock nut. 13) lnsert the two gear box ball seats, spring, spring scat, spacer and rack cap into the rack holc in this order. 14) Install the tie rods after applying grease o n the ball scats and tie rod ball ends. 15) Insert the tie rods into the holes in the boot and install the rubber clips in position. (Fig. Qr1-23)

Lever Gear box

L '

Spr'w scale

Fig. W 2 8 Measuring pinion torque

16) Fully tighten the rack cap and back it off until its groove is first aligned with the snap pin hole in the rack. To check that-the cap is properly tightened. measure the force t o move the tie rod as shown in Fig. m-29, which should be about 0.3 to 1.5 kg (0.7 t o 3.3 Ib).

coupling with the nuts. Torque

17) Install the covers on both ends of the gear box. Installation

3)

0.9 - 1.S kg-m (7

-ll

TI-lb)

-

Inst all the rubber bushings on the steering gear box and position it on the crossmember bracket. 2) Place the clamps on the bushings and secure the gear box with the four 8 mrn bolts. using care that t l ~ cpinion shaft a n d torque rod a r t aligned. 1)

Torque (Bolt)

bolts, spring washers and

4) Connect the tie rod t o the tic rod end by positioning the turnbuckle between them and turning it in. Be careful in engaging the threads so that the exposed thread lengths of the tic rqd and tie rod end are not noticeably different. 5) Turn the steering wheel from lock t o lock to check its operation. 6) Adjust the toe-in to the specification by turning the turnbuckle, and tighten the 18 mm Jock nuts a f ~ e raligning the mark o n the tie rod with the mold parting l i n t on the tic rod end. (Fig. LI-30)

Fig. H-29Checking tightne~so j t i e rods

4.

IWO

2.0 - 3.0kg-m (14 - 22 ft-Ib)

Toe-in (with vehicle unloaded)

I

I

Torque (Lock nut)

IN

8 - 13 mm (0.32 - 0.5 1 in)

8.0- 8.5 kg-m (58

- 61 ft-lb)

I

7 ) Adjust t h e steering wheel position so that the spoke is horizontal with the l'ront wheels in the straight ahead position. For removal znd installation of the steering whcel, refer to " -3. STEERING WHEEL".

Connect the pinion shaft to t h e rubber

and at1 lor checking Turn buckle

movement.

Movement of lie-rod rhould b e even both front and rear

Fig. B - 3 0 Checking

t i c r ~ movement d

111 - 14

'

8-

1.

7. TIE-ROD END Removal

'

Raise the front of the vehicle and place 1) it on the safety stand,-.2) Loosen the lock nuts of the turnbuckle and remove the turnbuckle. 3) Pull the cotter pin off the castle nut connecting the tie rod end t o the knuckle arm, and remove the castle nut. 4) Press the baU stud of the tic rod end o u t of the knuckle arm, using Special Tool (BALL STUD REMOVER: 921 240000).

2) lnsert t h e ball stud of the l i e rod end into the hole in the knuckle arm and inslatl the castle nut. Tighten the castle nut t o 2.5 t o 3.0 kg-rn (18 to 22 ft-lb) first, and then further tighten within 1 / 6 turn t o align a slot in the cotter pin with the hole in the baU stud.

-

-

-

2 . 5 - 3.0 kg-m (18 - 22 ft-lb)

Castle nut lightening torque

Lock the castle nut with a new cotter pin. Turn the stcering wheel; from lock t o lock 4) t o check its operation. 5) Adjust the toe-in t o the specification by turning the turnbuckle, and tighten the 18 mm lock nuts after aligning the mark on t h e tie rod with the mold parting line o n the tie rod end. (Fig. 1 - 3 0 ) 3)

Toe-in(with vehicle

IN

unloaded)

8 - 13 mrn (0.32 - 0.5 1 in)

r

Torque (Lock nut)

8.0 - 8.5 kg-m

(58

- 61 It-lb)

Fig. S - 3 1 Removing bat1 stud

2.

Disassembly and assembly

T h e tie rod end cannot be disassembled. Replace it as an assembly if defective. 3.

Installation

I ) Connect the tie rod end t o the tie rod by positioning the turnbuckle between them, a n d turning it in. Be careful in engaging the threads so thnl thc exposed thread lengths of the t i t rod and tie rod end are not noticeably different.

6 ) Grip the tic rod and check that it moves t h e same distance forward and rearward with the front wheels in the straight-ahead position as shown in Figure m-32. If it moves unequally, readjust. It is permitted that the tie rod marking is found to be out o f alignment with the tie rod end when this fore and air adjustment of the tic rod has been cornpl;eted.

7) Adjust the steering wheel position so that the spoke is horizontal with the front wheels in the straigi~t.ahead position. For removal and installation of the steering wheel, refcr t o "m-3. STEERING WHEEL".

8-

4. TROUBLE SHOOTING Trouble and possible cause 1.

I

Corrective action

Steering wheel is heavy. Raise the front of the vehicle until both front wheels clear the ground. Then turn the steering wheel. If i l becomes lighter than the case that the front wheels arc on the ground, the tire p r a s u r c or t h e suspension may be responsible and if it is still heavy the steering syslem may have some trouble.

2.

I)

Ere pressure too low.

.Adjust to correct pressure.

2)

Incorrect front wheel alignment.

Adjust toe-in,

3) Stuck ball joint.

Replace.

4)

Lubricate all parts.

Insufficient lubrication.

5) Sruck king pin and bushing.

Replace.

6) Worn out tires.

Replace.

Steering wheel vibrates.

This trouble takes place mostly at high speeds, or rough roads. I)

Improper tire pressure.

2)

Incorrecl front wheel alignment.

Adjust t o correct pressure.

3) Unbalanced wheels and tires. 4)

Loose wheel nuts, drum nuts o r rim nuts.

5) Distortedwhcel.

3.

Adjust toe-in. Correct. Tighten t o correct torque. Correct or replace.

6)

Damaged or worn wheel bearing.

Repair or replace.

7)

Uncven tire pressure.

Adjust t o correct pressure.

8)

Damaged or worn trailing arm bearing.

,

Replace.

9) Worn king pin.

Replace.

10) Unbalanced brakc drum.

Replace.

Shocks at steering wheel, 1)

I n c o r r e c ~front whcel alignment.

Adjust t oc-in.

2)

Excessive tirc pressure.

Adjust t o correct pressure.

3) Defective shock absorber.

Replace.

4)

incorrect engagement or steering gear or bevel gear.

Correct.

5)

Excessive backlash.

Correct.

Corrective action

Trobuble and possible cause 4.

Steering wheel pulls to one side.

This condition is very dangerous t o vehicles, and often atlributable to defective front . suspension.

5.

r

Adjust to correct pressure.

1)

Uneven tire pressure.

2)

Incorrect front wheel alignment.

Correct.

3)

Damaged or worn wheel alignment bearing.

Replace.

4)

Brake dragging,

Adjust.

Abnormal noise. I)

Loose conncclions or insuffi-

Tighten t o specified torque.

c i c r ~ ttightening.

2)

3)

Damaged or warn wheel bearing.

Replace.

Damaged or worn trailing arm

Replace.

bearing. 4)

Defective shock absorber.

Replace.

5)

Damaged or worn king pin and bushing.

Replace.

CIlAPTER 9

HEATER

Page

. . . . . . 9-2 DIAGRAfl . . . . . . . . . . . . 9 - 5 . . . . . . . . . . . . . . . . 9-6

DESCRIPTION--ESPAR MODGLS D1L TROUBLESHOOTING W I R I N G DIAGRAM

&

B1L

9-

1

1.

DESCRIPTION

Beating C a p a c i t y

-

Fuel

I I

Diesel o r C o m b i n a t i o n D i e s e l Kerosene o r Gasoline

0.19 l/hr + 5%

Fuel Consumption Electric Power Consumption

-

40 W + - 10%

Voltage

-

12V

Hot A i r 'I'hrouqhput a t Noted V o l t s without C o u n t e r P r e s s u r e

-

110 k g / h r

- 108 +

F u e l a t low t e m p e r a t u r e s : For t e m p e r a t u r e s above 0 ° C ( 3 2 ° F ) a n y k i n d of d i e s e l oil o r e x t r a light fuel oil may be u s e d . F u e l oil m u s t , h o w e v e r , not be u s e d for t e m p e r a t u r e s b e l o w 0°C (32°F). I f for temperatures below O°C ( 3 2 O F ) no special winter d i e s e l o i l b u t a normal summer or w i n t e r d i e s e l oil i s u s e d , kerosine o r g a s o l i n e s h o u l d b e added according t o the following t a b l e :

TEMPE RRTURE

SUMMER DIESEL +

KEROSINE

OR

01 L GASOLI NE from O°C t o - 1 5 ' ~ 50% 50% from - 1 5 O C to - 2 5 O C --from -25'C t o -30°C --*or special w i n t e r diesel oils

WINTER DIESEL

OIL 100% 505

--

+

KEROSINE OR GASOLINE

--

50% 100%"

Fuel l i n e s a n d f u e l m e t e r i n g pump have to be filled with the new fuel by o p e r a t i n g t h e heater f o r 1 5 m i n u t e s .

--

ESPAR MODEL B1L- P : C O Y ' f Specifications-Heating Capacity

-

1400

Fue 1

-

Gasoline

F u e l Consumption

-

-022 l/hr

Electric Power Consumption

-

35 W + - 102

Vol tag@

Hot A i r Throughput at Noted Volts Plithout C o u n t e r P r e s s u r e

1.J +

108

+-

10%

- 100 kq/hr +-

10%

12 V

The Espar heater is located in the front center of the vehicle inside the frame in front of heater unit attached to the vehicle's ventilating and heating systems to rear of front bumper. To remove, jack front end of vehicle, remove four bolts from plate across underside of frame rear of bumper. Two bolts are on front and back of right and left side of plate. Plate and heater will drop down. Knob is rubber covered on heater case next to control unit. Design and Method of Operation The complete heating system consists of a basic heater and mounting parts, air-flow and exhaust pipes, fuel supply system and controls.

The heater is switched on by means of a switch or optional timer, with which the switch-on time can be preselected up to 22 hours in advance. When the heater switches on, a pilot lamp lights up, the heating-air blower begins to advance the heating air and the combustion air blower begins to advance the combustion air. At the same time, the fuel metering pump advances a precisely metered quantity of fuel into the combustion chamber. Here, fuel and combustion air are combined to form a combustible mixture, which is ignited at the glow plug. The combustion gases now flow through the heat exchanger and over the temperature switch, which switches off the glow plug. The heating air is heated at the heat exchanger and then flows out into the area to be heated.

When the heater switches off, the pilot lamp extinguishes; however, the blower motor continues to run until the heater has cooled off. It is then automatically switched off by the temperature switch. Controls and Safetv Eauiwment The flame is monitored by the temperature switch. This switch acts on the safety switch in the control unit, which shuts down the heater in the event of a malfunction. Sequence after being switched on: a)

After a stable flame has been attained, the temperature switch switches off the glow plug. In addition, a f t e x the heater has been switched off it automatically stops the blower when the heater has cooled off.

b)

If the heater fails to ignite, it switches off automatically not more than 3 minutes after switching on.

The heater can be switched on a g a i n by briefly switching the. off and on. Do not switch on the heater again more than

I f it s t i l l f a i l s t o ignite, remedy t h e m a l f u n c t i o n i n accordance with the TROUBLESHIOTPNG and R E P A I R I N S T R U C T I O N S .

twice.

C )

S h o u l d t h e f l a m e e x t i n g u i s h spontaneously d u r i n g o p e r a t i o n , t h e h e a t e r w i l l automatically switch off after not more t h a n f o u r minutes. It can be s w i t c h e d on a g a i n a s described under b ) .

d)

T h e s a f e t y thermal cutout s w i t c h s t o p s t h e fuel metering pump i f t h e h e a t e r overheats ( e . g . , i n t h e event the heating air ducts cloq). T h e heater then s w i t c h e s o f f automaticaLly a s described u n d e r c).

all meaeuremente are in m

P a r t 11

Electric Power System

Drawing A

Drawing B Chapter 1--BATTERIES/ELECTRICAL WIRING SYSTEM I- 1. Specifications of Batteries Used 1- 2.

Specifications and Description

1- 3.

Removal

Chapter 2--SCR CONTROL SYSTEM 2- 1.

Description

2- 2.

Circuit Operation

2- 3.

Control

2- 4. 2- 5.

General Maintenance Instructions Troubleshooting

Chapter 3--ELECTRIC MOTOR 3- 1.

Description

3- 2.

Maintenance

3- 2a. Bearings 3- 2b. Insulation 3- 2 c .

Brushes

3- 2d. Commutator 3- 2e. Cleaning 3- 2f. Mechanical 3- 3.

Disassembly Instruction

3- 4 .

Repair

3- 5.

Renewal Parts

Chapter 4--CHARGER

1. 4 - 2.

Description

4- 3.

Troubleshooting

4-

Schematic Wiring Diagram

50A FUSE

MAIN

EV-1 CONTROL

1

COLOR CODE

I

I I

I I

I

CHAPTER

1- I .

I:

BATTERIES/ELECTRICAL W I R I N G SYSTEM

SPECIFICATIONS OF BATTERIES USED

............

. . . . . . . . . . . . 1 - 3 . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . .

1- 2

.

SPECIFICATIONS AND DESCRIPTION

1

1 2

BATTERIES/ELECTRICAL WIRING SYSTEM

-q,

d

w/

WARNING--Dropping metal objects on top of the battery pack could cause the batteries to short, result in an explosion, and cause injury to body and property.

'i

Batteries are toxic. They also have the same properties as any exposed'electrical appliance - they can s:lock and ignite. Wear safety goggles or glasses when servicing the batteries. Do not smoke when the battery power pack hatch is off. Do not put tools on the battery pack, even a single light tool. Sparks and shocks may result when it is picked up or moved around on the batteries. 1- 1. a.

b.

-

Specifications of Batteries Used

SGL -- Main Power Pack Type: 2HGC-HC, Lead Acid Plates: 51 Weight: 69 lbs. 20 hr. Rating: 210 Length: 10-5/16 Width: 7-1/8 Height: 10-1/4 Reserve Cap. 25 AMP: 390 mins. Minutes at 75 Amps: 100 mins. SGL -- Accessory Battery Type: 24Ht, Lead Acid Plates: 54 Weight: 55 lbs. 20 hr. Rating: 75 Length: 10-7/32 Width: 6-3/4 Height: 9-7/8 geserve Cap. 25 AMP: 100 mins. Minutes at 75 Amps: 15 mins.

I

or

t

Type: 27HT, Lead Acid Plates: 54 Weight: 62 lbs. 20 hr. Rating: 90 Length: 11-3/4 Reserve Cap. 25 AMP: 115 mins. Width: 6-3/4 Height: 9-7/8 Minutes at 75 Amps: 26 mins.

i

1- 2.

Specifications and Description

'Seventeen 6 volt and one 12 volt battery comprise the ELECTRA VAN'S power pack for the various drive trains and auxiliary power systems. The batteries are under warranty for 12 months. When the batteries start to need replacement one by one, it is recommended that the total battery pack be replaced, in,order to assure even operation of the power pack.

--

The battery compartment and all hold-downs should Installation be free of corrosion and rust. Corroded, frayed or overheated cable connections must be replaced. Clean battery terminals before cables are tightened.

l i -

1

8j

BATTERIES/ELECTRICAL WIRING SYSTEM

WARNING-- A l w a y s u s e c o m p l e t e l y i n s u l a t e d t o o l s when w o r k i n g o n b a t t e r i e s o r t h e - - ~ l e c t r i c a lS y s t e m s . D r o p p i n g metal objects on top of t h e b a t t e r y pack c o u l d c a u s e t h e b a t t e r i e s t o s h o r t , r e s u l t i n a n e x p l o s i o n , and c a u s e i n j u r y t o body a n d p r o p e r t y . T h e y a l s o h a v e t h e same p r o p e r t i e s a s any e x p o s e d e l e c t r i c a l a p p l i a n c e t h e y c a n s h o c k a n d i g n i t e . B a t t e r i e s c o n t a i n s u l f u r i c a c i d and can c a u s e severe b u r n s . A v o i d c o n t a c t w i t h skin, e y e s , a n d c l o t h i n g . I n c a s e of c o n t a c t with a c i d , i m m e d i a t e l y f l u s h s k i n o r e y e s w i t h w a t e r for f i f t e e n minutes, for e y e s , i m m e d i a t e l y g e t m e d i c a l a t t e n t i o n . ALWAYS WEAR P R O T E C T I O N WHEN WORKING NEAR B A T T E R I E S . D o n o t s m o k e when t h e B a t t e r y Fewer P a c k l i d s a r e o p e n . Do n o t p u t tools on t h e b a t t e r y pack, even a single light tool. S p a r k s a n d s h o c k s may r e s u l t w h e n i t i s p i c k e d u p o r moved around on the batteries. 1-

1.

s p e c i f i c a t i o n s o f B a t t e r i e s Used

E x i d e -- 102 Volt Power Pack Type: XPV 2 3 , Lead Acid Weight: 65 l b s . Dimensions Length: LO-3/8" Lqidth: 7-3/16" Height: 11-7/32" Zlectrolyte: S p e c i f i c g r a v i t y f u l l y c h a r g e d 1 . 3 1 5 grams p e r c c at 7 7 F XPV 2 3 - 2 - 1 . 3 0 0 g r a m s p e r cc XPV 2 3 - 3 - 1 . 3 0 0 g r a m s per cc Rating D i s c h a r g e a t 7 5 AMPS t o 5 . 2 5 V o l t s a t 7 7 F - 1 2 5 M I N S . a.

b.

12 V o l t Auxiliary Battery Exide: HC 2 4 , Lead A c i d W e i g h t : 5 0 lbs. Dimensions Length: 11-1/4" Width: 6-13/16" Height: 10" Reserve Capacity: 1 2 0 M I N . t o 1 . 7 5 Volts per cell at 2 5 LIPS. Amp H o u r s a t 2 0 Hour R a t e 90 AMP Hours

1-

2.

Description

S e v e n t e e n 6 v o l t and o n e 1 2 v o l t b a t t e r y c o m p r i s e t h e ELECTRA V A N ' S power p a c k f o r t h e v a r i o u s d r i v e t r a i n s a n d a u x i l i a r y power systems. The batteries are under w a r r a n t y f o r 12 months. When t h e batteries start t o n e e d r e p l a c e m e n t one b y o n e , i t i s recommended t h a t the t o t a l b a t t e r y p a c k be r e p l a c e d i n o r d e r t o assure e v e n o p e r a t i o n of the power pack.

I n s t a l l a t i o n - - T h e b a t t e r y c o m p a r t m e n t a n d a l l h o l d - d o w n s s h o u l d be f r e e of c o r r o s i o n a n d r u s t . C o r r o d e d , f r a y e d o r overheated c a b l e conn e c t i o n s must b e r e p l a c e d . C l e a n b a t t e r y t e r m i n a l s before cables a r e tightened.

BATTERIES/ELECTRXCAL W I R I N G SYSTEM

1-1. S p e c i f i c a t i o n s of B a t t e r i e s Used a.

SGL

--

Type:

Main Power Pack 2HGC HC

--

Type:

1-2.

B C I Group:

Width:

5 1/8"

GC - 2

Volts:

Height:

10 3 / 4 "

AH 2 Hours:

69 l b s .

Weight:

SGL

Lead A c i d

1 0 5/16"

Length:

b.

-

Accessory B a t t e r y 24H

-

BCI Group:

Lead Acid

Length:

10 1/6"

Weight:

45 l b s .

Width:

7 1/16"

AH 2 Hours:

GC 24

Volts:

Height:

12

8 17/16''

90

S p e c i f i c a t i o n s and D e s c r i p t i o n

S e v e n t e e n 6 v o l t and one 1 2 v o l t b a t t e r y c o m p r i s e t h e E l e c t r a V a n ' s power p a c k f o r t h e various d r i v e trains and a u x i l i a r y power systems. A t t h e end of

The b a t t e r i e s a r e under w a r r a n t y f o r 1 2 months. t h a t p e r i o d , s h o u l d t h e b a t t e r i e s start t o n e e d

replacement o n e by one, i t is recommended t h a t t h e t o t a l b a t t e r y

pack b e r e p l a c e d , i n o r d e r t o assure e v e n o p e r a t i o n o f t h e power pack. WARNING--Dropping

m e t a l objects o n top o f the b a t t e r y pack

c o u l d c a u s e t h e b a t t e r i e s t o s h o r t , result i n a n e x p l o s i o n , a n d c a u s e i n j u r y t o body and p r o p e r t y . Batteries a r e toxic.

They a l s o have t h e same p r o p e r t i e s a s

any exposed e l e c t r i c a l a p p l i a n c e

-

t h e y c a n shock and i g n i t e .

Wear s a f e t y g o g g l e s o r g l a s s e s when s e r v i c i n g t h e b a t t e r i e s . D o n o t smoke when t h e b a t t e r y power p a c k h a t c h i s o f f .

Do n o t p u t t o o l s on t h e b a t t e r y pack, even a s i n g l e light t o o l .

Sparks a n d shocks may r e s u l t when it i s p i c k e d u p o r moved a r o u n d on t h e b a t t e r i e s .

6

Controller

.gency Disconnect Switch

Batteries s h o u l d b e s e r v i c e d only when fully charged. The water l e v e l s h o u l d be checked every two weeks and a log s i m i l a r t o t h e o n e m e n t i o n e d i n the Owner's Manual (pg. 41) should be maintained. The battery t e r m i n a l s should b e tightened e v e r y t h r e e months and torqued t o 120 lbs. I f a w h i t e c o r r o s i o n powder forms o n any o f the terminals, t h e y shoula be cleaned w i t h w a r m w a t e r a n d baking soda, wiped dry and c o a t e d w i t h a l i g h t f i l m of n o n m e t a l l i c grease t o minimize c o r r o s i o n . D I S T I L L E D WATER o n l y s h o u l d b e u s e d t o s e r v i c e t h e b a t t e r i e s . One by one, e a c h cap s h o u l d be removed a n d distilled water added. The e l e c t r o l y t e level should be b r o u g h t u p t o 1 - 1 / 1 6 inch b e l o w the l e v e l of t h e i n s i d e c a p , a t the bottom of t h e r i d g e . It should n e v e r be so high t h a t when t h e c a p i s replaced i t forces t h e water u p and o u t of t h e battery cell nor should it be allowed t o d r o p below the top e d g e s of t h e p l a t e s . \

I n case o f a c i d s p i l l a g e o r d i r t a c c u m u l a t i o n , b a t t e r y tops s h o u l d be b r u s h s c r u b b e d w i t h a s o l u t i o n o f baking s o d a -- one-half pound per pail of warm water -- a n d thoroughly r i n s e d .

1- 3 .

Removal

To remove b a t t e r y p a c k , d i s c o n n e c t a l l cables a n d c o n n e c t o r s , l i f t o u t by h a n d . When r e p l a c i n g , b a t t e r i e s s h o u l d be torqued to 120 pounds.

BATTERY PACK b AUXILIARY

Controller

Disconnec

ch

Batteries s h o u l d be servicea o n l y when f u l l y c h a r g e d .

The

water l e v e l s h o u l d be c h e c k e d every t w o w e e k s . a n d a log m e n t i o n e d i n t h e owner's manual.

The battery t e r m i n a l s should be t i g h t e n e d

e v e r y t h r e e m o n t h s and t o r q u e d t o 1 0 0 l b s .

If a white corrosion

-%-

powder f o r m s o n any of t h e . t e r m i n a l s , they should be c l e a n e d w i t h warm w a t e r a n d ammonia, t h e n wiped d r y . o n l y s h o u l d be used t o service t h e b a t t e r i e s .

D I S T I L L E D WATER

One by o n e , e a c h

cap s h o u l d be r e m o v e d a n d distilled w a t e r added.

should be b r o u g h t u p to 1-1/16"

9

The l e v e l

..

b e l o w t h e l e v e l of t h e i n s i d e

c a p , a t t h e b o t t o m of t h e r i d g e .

The water l e v e l s h o u l d n e v e r be s o h i g h t h a t when t h e cap i s r e p l a c e d i t f o r c e s the w a t e r u p and o u t o f t h e b a t t e r y cell. 1-3.

Removal

To remove b a t t e r y p a c k , d i s c o n n e c t a l l cables a n d c o n n e c t o r s ,

lift o u t by h a n d . t o 75 pounds.

When r e p l a c i n g , b a t t e r i e s s h o u l d be t o r q u e d

5

1,

EXAMINE BATTERIES, CABLES,

ETC.

CABLES DEFECTIVE ( c h a r r e d , corroded, sulfated, etc. )

BATTERIES DEFECIVE (broken post,

_t:

broken case, broken cover)

Repair or replace, c l e a n terminals Go to 4 .

Repair cr replace Go to 4 .

4

I

BATTERIES & CABLES APPEAR OK Check Voltages (open circuit)

7 5 Approximately 0 , 2 , 4 volts

\

>

/-I

6

Less than 5.8 volts per battery

JJ 7

5.8 to 6.1 volts

8 6.29 v o l t s

or h i g h e r

O n e or

more

defective cells, repair or replace G o to 4 .

Zero volts may indicate a "dry" cell.

Check e l e c t r o l y t e levels. I f OK, Recharge, Go t o 4. P o s s i b l y a defective cell. P r o b a b l y a c e l l with l o w electrolyte level.

Check e l e c t r o lyte levels. I f OK,. Recharge. G o to '4. Probab ly o n l y disch-

arged. Possibly a cell w i t h low electrolyte

level. 0m -I

Battery f u l l y recharged, . possibly w i t h " s u r f a c e charge1' Go t o 9 . Can also u s e a "load t e s t e r k Tt o detect possible d e f e c t i v e cells.

CHARGING TEST

Connect charger to AC lines. Read i n i t i a l c h a r g e c u r r e n t , and current a f t e r 1 5 minutes. I f you have a s i n s i t i v e volt-meter, connect t h i s from post t o post in p a r a l l e l w i t h each c o n n e c t i o n cable. V o l t a g e drop should b e l e s s than .010 v o l t s (10 mv) p e r c a b l e w i t h charge c u r r e n t - 2 0 amps.

INIT-over

25

INIT-over 25

INIT-over 15 amps, 1 5 Min-less t h a n

amps, 1 5 Minover 1 0 amps

amps, 15 Kin5 to 10 a m p s

B a t t e r i e s discharged. Give f u l l charge. Possibly a d e f e c t i v e cell

5 amps Batteries f u l l y c h a r g e d . ~ a t t e r i e s B a t t e r i e s fully old; possibly a c h a r g e d . Batterdefective cell. ies a r e a l l probably OK.

No Readinq.-

Check charger AC and DC circuits

14,

EXAMINATION AFTER RECHARGE

Check e l e c t r o l y t e gravity and temperature, b a t t e r y voltage.

Gravities Low 6 Uniform Temp-Ambient

Cells overfilled, flushed or spilled. Insufficient recharge, g i v e an equalizing charge.

Gravities-Vary Temp-Ambient

Gravities-Vary Temp-Vary

Check l e v e l s , add water to low cells

"Hot" cells may be defective.

g i v e an equalizing charge.

Gravities-High & uniform Temp-Slightly above Batteries probably OK

CHAPTER 2 :

S C R CONTROL SYSTE?l

Page

. . . . . . . . . . . . CIRCUIT OPERATION . . . . . . . . . S C R COIITROL FEATURES . . . . . . . . GENERAL ,MAINTI?MAYCF TNSY'RUCTIONS . . TROUBLESHOOTING . . . . . . . . . . DESCRIPTIOi4

. . . . .

. . . . . . . . . . . . . . . . . . . .

2-2

2-3 2-5

2-6 2-6

2-

1.

Description

The n e a r t of the c o n t r o l system is a silicon controlled rectifier (SCR). The SCR is a semi-conductor rectifier used as a latching switch; i.e., it may assume either a conducting or nonconducting state ( O n or Off),

CAlHODE (PIGrP

GATE

ANODE (51IUD')

The SCR can be turned ON by a momentary application of control current to the gate. To turn it OFF, it is necessary, i n a d d i t i o n to removing the t u r n - o n signal from the g a t e , e i t h e r to remove a l l power from the SCR or to a p p l y momentary reverse voltage b e t w e e n c a t h o d e and anode.

PHOTOS OF CONTROL

Fig. I . Typical SCR stotic pone)

Fig. 2. Typical conlactor

2-2

i"; -

Fig. 3. Typical accelerator switch with cover removed

2- 2.

Circuit Operation ( S e e Fiq. 4)

The control circuit is energized by closing the Key switch, and then depressing the accelerator, thus closing the Start switch. T h i s applies power to the control card and, if the pulse monitor trip requirements are satisfied, turns on the PMT driver, which will close the main contractor, completinc the circuit to the traction motor. T h e c o n t r o l card s u p p l i e s a q a t e p u l s e t o 2 R E C ,

turning it on to a c a n d u c ' t i n g state, allowing current to flow from the battery t h r o u q h lC, 2REC, lX, notor field, motor armature, current sensor, and back to the battery. After 1 C charges, 2REC shuts OFF due to lack of current. The control card c h e c k s that IC is charged and u n l o c k s the gates to 1 WEC and 5 REC. T 5 e control card than supplies a gate pulse to 1 XEC,

turning it ON to a conauctinq state, allowinq current to flow from the b a t t e r y through L REC, nGtor field, motor armature, sensor, and back to the battery. 5 REC t - u r n s O N a n d allows current to flow T4-T3, lC, I R X , 5 REC L a c k to T4-T3. This current charges 1 C positive ( c a r d ternLt?al 7 i s now positive) This charge is now stored on t h e capacitor u n t i l i t is time to turn OFF 1 3 E C . T h i s charging c y c l e o c c u r s i n less t h a n 1 millisecond ( 0 . 0 0 1 seconds) and 5 REC s h u t s O F F .

.

Current continues to flow in 1 .?EC until the control card turns ON 2 REC. !jlhen 2 ZCC conducts, capacitor 1C discharges around the c i r c u i t composed of IT, 2 9 E C , 1 X and 1 3EC. This discharge current opposes the 1 ) a t t c r y current through 1 ?EC until the resulant current is zero.

100'h-

-

-

PEA%

CURRENT

-

-.-- - - - -. -i .,

,oo/,-

AVERAGE CURRENT

ON OFF O H OFF ON O F F

TIME

Fig. 5. Battery current

W i t h reverse voltage a c r o s s 1 REC, 1 REC i s t u r n e d OFF. Current c o n t i n u e s t o f l o w i n lC, 2REC, motor and t h e b a t t e r y l o o p u n t i l the c a p a c i t o r (card t e r m i n a l 7 ) is fully charqed negative. This charge e x c e e d s b a t t e r y v o l t a g e by a n a m o u n t w h i c h i s a f u n c t i o n of m o t o r c u r r e n t , a n d 2 QEC t u r n s OFF. Figure 5 i l l u s t r a t e s t h e p u l s i n g o f c u r r e n t f r o m the b a t t e r y .

D u r i n g t h e OFF t i m e , t h e energy stored i n t h e m o t o r , by v i r t u e of i t s i n d u c t a n c e , w i l l cause c u r r e n t to c i r c u l a t e t h r o u g h the m o t o r a r o u n d the loop formed by 3 R E C , t h u s p r o v i d i n g w h a t i s called "flyback current." F i g u r e 6 s h o w s the nature of t h e m o t o r c u r r e n t , w h i c h i s c o m p o s e d of b o t h b a t t e r y current a n d t h e inductive flyback c u r r e n t . I t s h o u l d b e noted t h a t t h e average motor current measured w i l l be g r e a t e r t h a n the a v e r a g e battery current. The SCR control, in effect, c o n v e r t s b a t t e r y c u r r e n t a t battery v o l t s i n t o a h i g h e r motor current a n d a l o w e r m o t o r volts. T h e t i m e f o r t h e n e x t On and O f f c y c l e t o s t a r t i s determined by the t i m e that t h e c o n t r o l c a r d t a k e s t o oscillate. T h e o s c i l l a t i o n times are c o n t r o l l e d by the potentiometer i n t h e accelerator. S l o w s p e e d i s o b t a i n e d by h a v i n g maximum ohms i n t h e potentiometer. A S t h e resistance i n the p o t e n t i o m e t e r decreases, t h e speed of t h e motor i n c r e a s e s .

--

ON OFF

ON OFF OM

OfF

TIME

Fig. 6. Motor current

2-

3. S C R

C o ~ t r o lFeatures

oSCTLLATOR--The oscillator section of the card has two adjustable features, creep s p e e d and controlled a c c e l e r a t i o n , and one fixed feature, top speed.

I

q ON 5 CS

Fig.

50 SCR range

7. Oscillator

95 TS

TIME

irequency curve

When the accelerator potentiometer at maximum ohms, the c r e e p s p e e d c a n be adjusted w i t h a trimpot on the card. Top speed is f i x e d b y card design, and is obtained w i t h the a c c e l e r a t o r potentiometer at minimum ohms. T h e r a t e a t which the oscillator nay increase its percent OW tine is limited by "Controlled Acceleration." The minimum time required to g o from creep speed to maximum percent o n time m a y be varied b y an indexed trimpot ( C / A ) on the card, adjustable from approximately 0.5 seconds to 1.0 seconds. T h e p e r c e n t ON t i n e h a s a r a n q e o f a p p r o x i m a t e l y 5 t o 9 5 percent. The center operating condition of the o s c i l l a t o r i s a t 5 0 p e r c e n t O?l time w i t h a n o m i n a l 1 . 7 milliseconds ON time and 1.7 milli-

second OFF time. This corresponds to a maximum operating frequency o f a b o u t 3 0 3 h e r t z . A t creep the 0 l J time will decrease to a p p r o s i m a t e l y 0 . 8 milliseconds while OFF time will become i n t h e o r d e r of 2 0 milliseconds. A t f u l l SC!? operation, t h i s condition will be r e v e r s e d (short OFF time, long ON tine). T h i s variatioc of ON a n d OFF time of t h e oscillator produces the optixum frequencies t h r c u g h t h e SCR r a n q c . See F i g u r e 7. circuit m o n i t o r s motor current by utilizing a sensor in series with the armature. The information detected
C U R R E K T LIMIT--This

#N I

l4 !

d e t e c t e d , this c i r c u i t o v e r r i d e s t h e o s c i l l a t o r and l i m i t s t h e a v e r a g e c u r r e n t . An i n d e x e d t r i m p o t for t h e c u r r e n t l i m i t ( C / L ) a d j u s t m e n t i s p r o v i d e d t o m a i n t a i n t h e peak v o l t a g e o n t h e capacitor within i t s r a t i n g when u s e d o n high source i n d u c t a n c e B e c a u s e o f t h e flya n d / o r l o w motor r e s i s t a n c e a p p l i c a t i o n s . back c u r r e n t t h r o u g h 3 REC, t h e m o t o r c u r r e n t u s u a l l y r u n s 2 t o 3 times t h e b a t t e r y c u r r e n t .

tI

-

i

iI1l

2-

4.

General Maintenance I n s t r u c t i o n s

I

The SCR c o n t r o l ,

l i k e a l l electrical apparatus, does have some

t h e r m a l losses. The s e m i c o n d u c t o r j u n c t i o n s have f i n i t e t e m p e r a t u r e l i m i t s a b o v e w h i c h t h e s e d e v i c e s may b e damaged. For t h e s e r e a s o n s , normal m a i n t e n a n c e s h o u l d g u a r d a g a i n s t a n y a c t i o n which w i l l e x p o s e t h e c o m p o n e n t s t o excessive h e a t , s u c h a s s t e a m cleaning; o r w h i c h w i l l r e d u c e t h e h e a t d i s s i p a t i n g a b i l i t y of the c o n t r o l , such a s r e s t r i c t i n g a i r f l o w . The f o l l o w i n g D O ' S a n d D O N ' T S s h o u l d be o b s e r v e d :

--Any c o n t r o l s that w i l l be used i n a m b i e n t s o f 1 0 0 ° F (40°C) o r o v e r s h o u l d be brought t o the a t t e n t i o n of the manuf acturer

.

--All e x t e r n a l c o m p o n e n t s h a v i n g i n d u c t i v e c o i l s must be filtered. Refer t o v e h i c l e m a n u f a c t u r e r for s p e c i f i c a t i o n s . c o n t r o l s h o u l d not be steam cleaned. I n d u s t y a r e a s , u s e l o w - p r e s s u r e a i r t o b l o w o f f the c o n t r o l . I n o i l y or g r e a s y a r e a s , a mild s o l u t i o n of d e t e r g e n t o r d e n a t u r e d a l c o h o l c a n b e used t o wash o f f the c o n t r o l a n d t h e n b l o w completely dry w i t h l o w - p r e s s u r e a i r . The c o n t r o l c a n a l s o be c l e a n e d with F r e o n TF degreaser.

--The

1

i

2-

5.

TROUBLESHOOTING I N S T R U C T I O N S

T h e p u l s i n g o f the main SCR i s too fast f o r c o n v e n t i o n a l i n s t r u m e n t s

t o measure. be h e a r d .

When t h e c o n t r o l i s f u n c t i o n i n g p r o p e r l y , a l o w hum c a n

M a l f u n c t i o n s of t h e SCR w i l l g e n e r a l l y f a l l i n t o o n e o f t w o categories. They a r e either n o power ( T a b l e 1 ) o r f u l l power (Table 2 1 , when operating i n the SCR c o n t r o l r a n g e . These simple and e a s y - t o - f o l l o w t a b l e s outline t h e various symptoms and t h e c o r r e c t i v e a c t i o n t o be t a k e n . T h e same d e v i c e d e s i g n a t i o n s h a v e b e e n m a i n t a i n e d on d i f f e r e n t Refer t o the e l e m e n t a r y c o n t r o l s but the w i r e n u m b e r s may v a r y .

and wiring diagrams f o r your s p e c i f i c c o n t r o l .

The w i r e numbers

shown on the elementary diagram will have identical numbers on the c o r r e s p o n d i n g wiring d i a g r a m s f o r a specific vehicle but thcse numbers may be different from the numbers referenced in

this publication. BEFORE TROUBLES HOOTING, JACK UP WHEELS, DI SCONNECT THE BATTERY AND DISCHARGE CAPACITOR 1 C .

WARNING :

RECONNECT THE BATTERY A S NEEDED FOR THE S P E C I F I C CHECK.

If capacitor 1C terminals are not accessible, discharge capacitor by connecting from SCR POS terminal t o 2 REC anode. Check resistance on RXlOOO scale from frame to SCR power and control terminals. A resistance of less than 20,000 ohms can cause misleading symptoms. Resistance less than 1000 ohms should be corrected first. Before proceeding, visually check for loose w i r i n g , maladjusted linkage to accelerator switch, signs of overheating of components, etc.

Tools and test equipment required are: (a) 6-volt lamp, 6-volt battery, two A 1 4 diodes ( 1 Amp 400V), clip leads, volt-ohm meter (20,000 ohms per volt) and general hand tools, or ( b ) EV-1 System Analyzer, volt-ohm meter (20,000 ohms per volt) and general hand tools. If the system a n a l y z e r is used, refer to the analyzer instruction book. F U N C T I O N OF EV-1 CARD TERMINALS FOR IC36450SC5 A N D E 5 CARDS

DESCX PTION CONDI TION (Voltage measurements with respect to negative, SCR power t e r m i n a l . )

TERYI: NAL

L3,4,5,7

Card power supply i n p u t m u s t be l o w to satisfy PMT

NOMINAL VOLTS

Key open Key closed

reset.

L6

M o t o r current sensor output

No c u r r e n t

1.8

500 Amps average motor

3.3

c u r r e n t model " B "

Start switch input

Key Open Key closed, Accelerator depressed

Card power s u p p i y

Key off K e y on

0 BV

TERMINAL

DE SCRI P T I O N

CONDI TI ON

NOMI NAL . VOLTS

R2

1 A thermal h o l d o f f c o n t r o l jumper t o R4 to disable 1 A thermal holdoff

Key o n , c o l d T / P Key o n , t h e r m a l cutback

0 0 . 6 6 o r more

Output to PMT Driver

Key off Key c l o s e d , accelerator depressed. See Note 1.

0 Volts

Common r e t u r n t o card for accelerator p o t and 1 A

Key o f f , u s e VOM and Less t h a n 1 read from TBR4 to "Neg. " ohm

5-10 rnilliamps

switch

A c c e l e r a t o r pot input

8 ON time o u t p u t .

R7

Xey o n and accelerator

3-4

at "creep." Key on and a c c e l e r a t o r at top s p e e d .

0-.2

C r e e p speed

Top speed

NOTE I :

C o n n e c t m i l l i a m r n e t e r f r o m t e r ~ i n a lto R4. I f contactor picks up d u r i n g t h i s test replace d r i v e r . If z e r o milliamps open lead and recheck t o e l i m i n a t e possible d r i v e r s h o r t from t e r m i n a l 1 to 2 ,

ALL TESTING SHOULD BE DONS WITH VEHICLE JACKED UP. TABLE 1 FAILURES WHXCH CAUSE REDUCED OR NO IIOTOR TOFQUE WITH SCR CONTROL

Trouble s h o o t i n g i s based on using t h e v o l t m e t e r t o d e t e r m i n e i f the proper voltages a r e a v a i l a b l e t o p e r m i t the c o n t r o l t o o ~ e r a t e properly. SYMPTOM 1A.

C o n t a c t o r s do not p i c k up. No c o n t r o l voltage from positive t o negative.

PROBABLE CAUSE O

O

Check power a n d control fuses. C h e c k battery for l o w s p e c i f i c g r a v i t y and c o n n e c t i o n s f o r looseness or broken f i t t i n g s .

SYMPTOM

PROBABLE CAUSE

LB. C o n t a c t o r s do n o t pick-

O

up. Control v o l t s p r e s e n t from p o s i t i v e t o n e g a t i v e with proper polarity.

O

O

I

Plug i n battery w i t h Key s w i t c h OFF. Volts on L3 s h o u l d be l e s s than 4 v o l t s .

Close Key switch. C h e c k v o l t s a t T2 ( p i n 10). Should be about 5 0 8 of b a t t e r y v o l t s . Above 7 0 % locks o u t 1 REC. ( C o n t r o l card c o n t a i n s a 1 0 K bridge from p i n 5 to L3 and pin 6 . ) I f near b a t t e r y v o l t s , check f o r s h o r t e d 1 REC. I f near z e r o v o l t s , check for s h o r t e d 3 REC ( 4 G ) . Close B r a k e . V o l t s on L 3 , L S , L7 should be battery volts. V o l t s on L9 should b e n e a r z e r o . Wait f o r one second, t h e n depress a c c e l e r a t o r . V o l t s a t L9 and L9 side of F c o i l should be battery v o l t s . I f not, check w i r i n g and s w i t c h e s .

" Connect milliarnetex ( L O m a s c a l e ) Should read 5-10 from R 3 t o R 4 . milliamps. I f n o t , open Key switch, open lead from R 3 t o PMT d r i v e r , r e c l o s e k e y s w i t c h , wait over o n e second and d e p r e s s a c c e l e r a t o r s w i t c h . I f r e a d i n g i s n o t 5 - 1 0 milliamps, r e p l a c e c o n t r o l card. I f reading i s good, the c o i l o r wiring t o t h e PYT d r i v e r i s open o r t h e PNT d r i v e r i s defective. 1C.

C o n t a c t o r s c l o s e . NO power and NO S C R hum w i t h a c c e l e r a t o r i n SCR range.

O

O

O

Check d r i v e r

($El.

Check v o l t s a t S C R p o s i t i v e . S h o u l d be b a t t e r y v o l t s . If n o t , c h e c k power f u s e .

Check v o l t s a t T 2 . Fhould be z e r o . I f n o t , c h e c k v o l t s a t S 1 , 52, A l , a n d A 2 t o l o c a t e open circuit.

Check volts at P5. S h u u l d be 3-4 at creep reducing to 0.2 o r less a t t o p speed. I f R 5 remains about 4 v o l t s , check accelerator. I f R 5 i s zero, check v o l t s at 81. Should be 8 - 8 . 5 v o l t s . I f Rl i s above'l0 or near z e r o a n d L3 i s battery v o l t s , replace c o n t r o l card and c h e c k PXT d r i v e r f3r s h o r t (4E).

-

PROBABLE CAUSE

SYNPTOM 1C.

Contactors close. NO power and >!O SCR hum with accelerator in SCR range. (Cont'd.)

" Check volts at R7.

Should be 2-2.3 When accel2rator is depressed, should increase to about 6 . 2 volts. I f r e m i n s near 2 volts, check volts at 1C ( g r e y wire or 2 REC anode). If more than 0 . 1 2 5 BV check if 2 E C will gate on ( 4 G ) . If less than 0.125 B V , check if 1 REC w i l l g a t e on (45). Check current sensor green lead to card input pin 1 3 -

when Xey s w i t c h closed.

1D. Contactors close. Little " Check 3 E C f o r open c i r c u i t ( 4 H ) . or no power. ?;orma1 SCR hum. " Check 4 REC for short ( 3 H ) .

" Check for open thermal protectpr 1E.

Contactors c l o s e .

or no power.

Little

O

Check 2 REC for short ( 4 ~ ) .

O

Check

O

Check 22 PEC and 2 5 REC (4M).

(43).

Abnormal

SCR hum.

5 REC for short ( 4 G ) .

NOTE: A 2 5 REC which checks good with an ohmmeter can cause a misoperation of 5 REC under load.

IF. Contactor closes, little power, no SCR hum.

O

Check 1C for low resistance ( 4 8 ) .

TABLE 2 F A I L U R E S W H I C H CAUSE FULL MOTOR TORQUE WITH SCR CONTROL

WMPTOM 2A.

Contactors close. Full SCR speed immediately w i t h a u d i b l e hum. NO PMT trip.

PROBABLE CAUSE O

Check volts at R5. Should be 3-4 volts at creep position. If n e a r zero, check Accelerator potentiometer (4D). O

2B. Contactors close once or twice and then remain open. PHT trips.

Key switch on.

O

Replace control card ( 4 A ) .

Check 5 W C for open circuit or open gate ( 4 G ) .

Check

1C

for open and connections (4B).

C h e c k 1C for dead short ( 4 8 ) .

PROBABLE CAUSE

SYMPTOM 28.

Contactors close once or twice and t h e n r e m a i n open. PMT trips. (cont'd.

O

Check 5 RE€! f o r short.

O

Check 2 REC f o r s h o r t .

O

Check 1X c h o k e and transformer T3-T4

O

(4N).

Replace c o n t r o l c a r d ( 4 A ) .

C o n t a c t o r s close, S t a l l " Check current s e n s o r yellow lead currents, under SCR from negative end of s e n s o r to o p e r a t i o n , higher than card i n p u t p i n 1 4 . normal and u n c o n t r o l l a b l e w i t h C / L trimpot. Cona Replace c o n t r o l c a r d (4A). t a c t o r s may o p e n o n c e o r twice a n d t h e n remain

open.

TABLE 3

MI SOPERATI ON OF OTHER FEATURES PROBABLE CAUSE

SYMPTOM 3A.

PMT does n o t open

O

contactor. 3B.

Blown power f u s e . Very h o t power c a b l e s .

O

Operate traction d r i v e . Jumper R 3 t o R4. I f c o n t a c t o r does n o t drop out, replace PMTD d r i v e r . Check 3 IiEC for s h o r t ( 4 H ) . (Possible damage a l s o t o 1 REC a n d transformer

module. )

TABLE 4 C H E C K I N G COMPONENT'S 4A.

Main SCR Control C a r d

All troubleshooting is written to c h e c k all outside d e v i c e s a n d e l i m i n a t e them a s the s o u r c e of s y m p t o m s . The conclusion being then that the card is faulty.

1. Instructions for Removal of C a r d

a . Remove k h e f o u r ( 4 ) screws shown in '+'i?!urc? 3 . 5 . J a c k out t h e r i g h t - and l e f t - h a n d ~ e ; & : i n a l b o a r d , r i s i n c ; 2 screwdriver i n the s l o t s , ;fI-.ea~rir-ir: t h e ..-;ires i n t ~ c t )a s shown i n F i g u r e 1 0 . c. P r y a p e n t h e l a t c h e s c a r e f u l l y w i t h (I .;cre;.v-iirivcr a s shown i n F i g u r e 11. d . .;ack o u t + h e bottom p l u g w i t h .A screwdriver 2s shown i n P3i/:;ure 1 2 .

be .$e:goW& by h i n g i n y 1 0 decr$&b -4rn'CI.~q&&.gn1~ out, OL-, a r e to be 1; p a n e l C'ompon&i'k~e(:?bt r e l a t e d to c a r d :fi&$*'*06e5ri$;-;) r e p l a c e d , d lsrr?i-&'da.11 instructions abos~e:~ e.aY:Csefi,r;~'*:~~ and the card will h i n c ~ eu s to 3 0 d e q r e s s . T h e c ~ r d::an

. .-

Remove T B Retarnrna Screws Retarnrng

Card

Fig. 71.

Fig. 9.

---3%-

insert Screwdriver and Tw~st

Fig.

70.

Fig. 12.

4B.

Capacitor 1C

Disconnect battery and discharge capacitor. Measure ohms through the capacitor using the R x 1 0 , 0 0 0 scale. Meter s h o u l d read zero a n d then s w i n g slowly to above 300,000 ohms. Replace capacitor if above reading i s not o b t a i n e d . 4C.

Contactor

See GEH-4469

NOTE 1: 4D.

.,>.

Most contactor coils are polarity sensitive. The left-hand terminal must be connected to positive.

P o t e n t i o m e t e r in Accelerator

To check operation of the potentiometer, disconnect battery and disconnect wires at card terminal R 4 and R5. Connect a VOM t o wire removed with scale set to R x 100. With accelerator in creep speed position, the ohms r e a d i n g s h o u l d be 4800 to 6000 ohms. With accelerator in top speed position, reading should be 2 0 0 ohms or less. With wire disconnected as above, check for resistance of 1 megohm or higher from pot w5res to truck frame. 4E.

Driver Module

IC3G4 5CPMI RDB2

(a) Connect circuit as shown. (b) Voltmeter should read battery v o l t s with s w i t c h open. ( c ) C l o s e s w i t c h and meter reading should be 3 volts or less. i d ) Move l o a d to terminal 4 a n d repeat steps ( b ) and ( c ) . 4F.

SCRs

+

3

\+ Simpson 50 volts d-c scale

(1 RLC, 2 3 E C , 5 R E C )

These a r e silicon c o n t r o l rectifiers. Before checking, disconnect battery and discharge capacitor 1 C . D i s c o n n e c t o n e power connection o n the rectifier. Disconnect gate leads of SCRs at the card plug. T o check a n S C R ,

it i s n e c e s s a r y to have a 12-volt battery, a 1 2 volt lamp and 2 A - 1 4 diodes.

C o n n e c t the positive l e a d to the anode (I), connect negative Lead to t h e c a t h o d e ( 3 ) a s s h o w n i n F i g u r e 1 3 .

A 1 4 O R ECIIJAL 203 V

Cathoac

Anode

Gnre

Sdfa 12,

,21

(Top V~e..v)

Fig. 13.

(a) The lamp should not light. I f t h e lamp does l i g h t , t h e SCR i s shorted a n d must be replaced. ( b ) I f check ( a ) was satisfactory, test t h e SCR f o r its ability to be turned on by the gate. Connect p o s i t i v e through two diodes to g a t e ( p o i n t 2 ) . I f gate is operative, the lamp will come on a n d s h o u l d remain on when t h e gate i s r e m o v e d . Some S C R ' s w i l l operate correctly even i f t h e lamp does n o t r e m a i n on, particularly with a weak b a t t e r y . ( c ) I f lamp c a n n o t be l i t under s t e p ( b ) the SCR is o p e n and must be r e p l a c e d . ( d l If the SCR is a stud-type device, check c o n t i n u i t y between the red a n d black cathode l e a d s . I f you d o n o t h a v e a t e s t light t o c h e c k the SCR's a s described a b o v e , t h e y may be checked f o r shorts o r o p e n s by u s e of t h e VOM.

iL'OTE:

(1) Measure r e s i s t a n c e f r o m anode t o c a t h o d e ( R x 1 0 0 s c a l e ) . If SCR i s s h o r t e d ( z e r o o h m s ) , i t must be r e p l a c e d . ( 2 ) Measure r e s i s t a n c e from g a t e lead (white l e a d ) to cathode and t h e n from cathode to g a t e lead ( R x 1 s c a l e ) . I f r e s i s t a n c e reads e i t h e r z e r o ohms (shorted) o r i n f i n i t y ohms ( o p e n ) , r e p l a c e t h e SCR.

When reassembling S C R ' s , r e f e r t o TABLE 5. 4H.

Rectifiers

( 3 REC,

4 Q E C , D i o d e Blocks)

When checking d i o d e s , d i s c o n n e c t b a t t e r y and d i s c h a r g e c a p a c i t o r 1C t o prevent burning out the ohmmeter. When r e p l a c i n g r e c t i f i e r s , F o r 3 a n d 4 REC, disconnect one lead or f l e x i b l e r e f e r t o TABLE 5 . connection. 3 and 4 REC are d i o d e s w i t h a b o u t 7 to 12 ohms i n t h e

d conducting d i r e c t i o n ( + -) m e a s u r e d on the R x 1 s c a l e , a n d 1 0 , 0 0 0 ohms o r ;igher, in t h e non-conducting measured on the R x 1 0 , 0 0 0 s c a l e . !- -----4--+ ) direction

Anoae Anode

Cathode

Cathode Anode

Thick End

45.

Thermal Protector ( T P )

Remove both connections from TP and with a VOM r e a d less than 200 ohms terminal to terminal, if heat sink i s at room temperature. Set VOM t o h i g h e s t O ~ Tscale and c h e c k p i n s t o heat sink, r e a d i n g should be infinity. 4K. " F i l t e r Black ( W , 2 3 FIL, etc. To check d i s c o n n e c t a l l w i r e s f r o m filter block. With VOK o n R x 10,000 scale, touch the lead to the filter terminals to charge the filter. After a f e w seconds, reverse the meter leads a n d t o u c h t h e f i l t e r t e r m i n a l s . The VOM n e e d l e w i l l deflect and r e t u r n t o i n f i n i t y . I f this capacitor action is not observed, replace t h e f i l t e r b l o c k . 4L.

Filter Block--23

RES,

etc.

Should t h e s e filters fail, i t will be evidenced v i s u a l l y by severe cracking. 4M.

Filter Block--22

REC, 25 E C

?!>e c a p a c i t o r f i l t e r t e s t , a s i n 4 K , is v a l i d f o r 2 2 REC a n d 25 RCC only t o d e t e c t a n o p e n o r s h o r t e d f i l t e r . T f control h a s s y m p t o m s a s in 16, interchange 22 REC and 2 5 RCC a n d t r y a g a i n . I f problem is c o r r e c t e d the o l d 2 5 REC is mar4inal. If problem is ~ o corrected, t replace both f i l t e r s with k n o w n good filters.

4N.

I X Choke--Transformer Secondary T3-T4

R e f e r to p a n e l wiring diagrams ( p a g e 1 6 ) to locate w i n d i n g s . With scale, check choke w i n d i n g or transformer secondary, r e a d i n q s h o u l d be zero ohms.

VOM o n R X - 1

THERE IS NO POLARITY ChR i l THEP T E W I W L Z A f . HC I 'F 2 .

WIRES \

mC

CARD PLLG

7% RE4R V l EW WI TG CWER R M W E D

-

WIRE TLBLC WIRE

NO.

0 3 512C

DEVICE

arS

4 r)EC

A

3 9EC

A

815 BUS BUS BUS

PTB

T2

3 RfC

4 1EC

A

C N

I R f C

C

1

BU5 #8

:,{

ABWE

TEsl

'IEC

4

P7B T PTB

3 8EC

C

T

P 71

Tt

BLK BLX

U R C C 2IIEC

1x1

T

1x1

A

1

r)

EL*

2

A

18

BLX

REC I RtC

A

2C ZC

2

4 9EC

9EC LEAD

5 ICC SMWT

LC~O LEAD

$22

EL BLU

VIO

I

C

PTB

A1

2 9EC

C

5 arc

c

Z IIEC 22 REC

74

SHT

2

TBZ

1% I

14

5"T

I

re2

13

3 QEC

A

782

6

N I

2

1

12 11 10

m,

I

.a

3

C

T E

QCC

9

2 IEC

C

2 9 ~ ' LEAD

)1T

2 RCC

c

T a TLP

$22

G-7

ZC

1

782

7

:

BLK WT/BLL

I REC

c c

762

5

In7.

1

5

QED

5 5

C

T B TB1

3

t

z

ra

I

12

3

C

5

*

MIICE

111

2

TY,5T{

TCW

*8

4 RCC LEAD

wlsl{

TO

YIRC COLID

RE( L C 4 0 SEC '.FA:

U T

I KC -C

ru

WT/RED

lc

,z2

WT/CIDI

23

m FIL

SEC

8

2

Fig. 18. Model C wiring diagram

CHAPTER 3 :

DC ELECTRIC MOTOR Page

DESCRIPTION

. . . . . . . . . . . . . . . . . .

. . INSULATION . BRUSHES . . . COMMUTATOR . CLEANING . . MECHANICAL . BEARINGS

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

DISASSEMBLY INSTRUCTION FAILURE

REPAIR RENEWAL

. . . . . . .

. . . . . . .

. . . . . . .

.

. . . . . . .

. . . . . . .

. . . . . . a

*

. . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

.

.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PARTS . . . . . . . . . . . . . . . . .

3-2

3-2 3-3 3-3

3-3

3-3

3-4 3-4 3-5

3-5 3-5

DC E L E C T R I C YOTOR

3-

1.

Description

S e r i e s Wound, C l a s s H I n s u l a t i o n , 2 0 h p a t 4 7 0 7 rpm, 4 :#lain i 3 n l c 2 and C o i l s , Shifted Nonadjusted Rrush R i g g i n g , B l o w e r Ventilak5d

The armature assembly consists of a s h a f t , armature core, a r m a t u r e w i n d i n g s , a n d commutator. T h e c o i l e d f ramc c o n s i s t s o f t h e m a g n e t frame, m a i n p o l e s a n d c o i l s , a n d the field t e r m i n a l s . O t h e r b a s i c p a r t s of the motor include the d r i v e e n d b e a r i n g b r a c ! < e t , c o m m u t a t o r e n d bearing b r a c k e t , b e a r i n g s , bearina s e a l s (when s u p p l i e d ) , b r u s h h o l d e r yoke w i t h h r u s h h o l d c r s , b r u s h c s a n d b r u s h h o l d e r s p r i n q s , and c o v e r s . O p e n i n g s o v e r the brushholders p r o v i d e accessibility to t h e b r u s h r i g g i n g a n d commutator f o r inspection and brush replacement. 90 NOT OPERATE A S E R I E S 1 0 T O R UNLOADEn AS EXCESSIVE S P E E D L N Y OCCUP P I H I C I I CAN C A U S E DAPIAGE 'r0

iJARNIi\!G:

TIIE !!OTOR AND I N J U R Y T O PERSONNEL.

3-

2.

Maintenance

IF POSSIBLE, N A K E SURE MOTOR I S DISCONF!EC?'ED FRObI POIqER SOURCE BEFORE PERFORMING ANY ?*IAINTENANCE OPERATIONS ON THE MOTOR. WHEN POlJER IS REQUTRED TO PERFOW1 A N Y MAINTENANCE, VIGILANT CARE A N D ATTENTION SHOULD BE E X E R C I S E D .

WARNING:

S t a n d a r d B e a r i n g s a r e t h e s i n g l e row, d o u b l e d s h i e l d e d , C o n r a d t y p e p r e - l u b r i c a t e d with h i g h t e m p e r a t u r e grease w i t h ABECl t o l e r a n c e a n d AFMBA $ 3 i n t e r n a l r a d i a l c l e a r a n c e . Standard b e a r i n g s do ' n o t r e q u i r e l u b r i c a t i o n . Under n o r m a l c o n d i t i o n s the bearings f a i l after s e v e r a l years s e r v i c e d u e e i t h e r F r o m d i r t y c o n t a m i n a n t i n the g r e a s e o r i n s u f f i c i e n t o i l in the yrease New g r e a s e c o n s i s t s of a b o u t 8 0 % o i l , 2 0 % soap. When b l e e d i n g r e s u l t s i n a r e d u c t i o n of oil t o a b o u t 6 0 8 , t h e bleed r a t e i s r e d u c e d t o a l e v e l that may n o t s u p p l y s u f f i c i e n t l u b r i c a t i o n . For t h i s r e a s o n when m a i n t e n a n c e o v e r h a u l s a r e performed a f t e r s e v e r a l y e a r s of s e r v i c e , b e a r i n g s are a u t o m a t i c a l l y replaced a s a routine practice. A b e a r i n g should b e r e p l a c e d with a n e s a c t r e p l a c e m e n t c r o n e w i t h a l l interchangeable f e a t u r e s . It i s especially i m p o r t a n t that t h e b e a r i n g h a v e high t e m p e r a t u r e grease.

3-

2b.

Insulation

I n s u l a t i o n r e s i s t a n c e s h o u l d be c h e c k e d d u r i n g e a c h m a i n t e n a n c e inspection. Low r e s i s t a n c e m a y b e c a u s e d by e x c e s s i v e d i r t , x o i s t u r e o r impending f a i l u r e . A l t h o u g h motors c a n be s u c c e s s f u l l y r u n with i n s u l a t i o n r e s i s t a n c e a s l o w a s 1 / 4 megohm i t i s well t o i n v e s t i g a t e t h e r e a s o n s f o r a n y i n s u l a t i o n r e s i s t a n c e b e l o w 1 rnegohm. Low r e s i s t a n c e v a l u e s d u e t o d i r t c a n u s u a l l y be c o r r e c t e d by c l e a n i n g f o l l o w e d by a v a r n i s h d i p a n d b a k e . Low r e s i s t a n c e d u e t o m o i s t u r e c a n be c o r r e c t e d by b a k i n g t h e m o t o x i n a 90°C o v e n u n t i l the i n s u l a t i o n r e s i s t a n c e r i s e s above t h i s value a n d stabilizes t o a n e a r l y c o n s t a n t v a l v e . A new motor s h o u l d withstand for o n e minute w i t h o u t b r e a k d o w n t h e a p p l i c a t i o n of 6 0 Hertz potential 1 2 0 0 v o l t s . O l d motors s h o u l d be t e s t e d a t 7 5 % of t h e s e v a l u e s . 3-

2c.

Brushes

B r u s h c o n d i t i o n a n d r e m a i n i n g b r u s h l i f e s h o u l d be c h e c k e d a t e a c h maintenance inspection. i?hen i n s t a l l i n g new b r u s h e s , e a c h b r u s h s h o u l d be s a n d e d i n t o t h e c u r v a t u r e o f the c o m m u t a t o r for m o s t reliable performace. A m i n i m u m of 859- s u r f a c e c o n t a c t with 1 0 0 % brush a r c i s recommended. R e p l a c e m e n t b r u s h e s s h o u l d be e x a c t l y t h e same b r u s h grade a s o r i g i n a l .

3-

2d.

Commutator

Commutator r u n o u t s h o u l d not exceed . 0 0 2 " t o t a l i n d i c a t e d r u n o u t v a r i a t i o n of . 0 0 0 2 " . The m i c a b a r - t o - b a r insulation s h o u l d a l w a y s be k e p t b e l o w t h e c o p p e r s u r f a c e . Khen c o m m u t a t o r wear r e s u l t s i n f l u s h o r p r o t r u d i n g m i c a , the m i c a s h o u l d be u n d e r c u t t o a d e p t h e q u a l t o t h e t h i c k n e s s o f the mica o r about .025", The u n d e r c u t s l o t s h o u l d be k e p t clean a n d free of dirt.

with a b a r - t o - b a r

3-

2e.

Cleanina

B o t h t h e i n t e r i o r a n d exterior o f t h e motor should be kept c l e a n a n d f r e e of d i r t a n d g r e a s e . Loose d i r t may be removed by vacuum c l e a n i n g o r b l o w i n g with compressed a i r . '2acuurn c l e a n i n g i s p r e f e r r e d because compressed a i r m a y d r i v e d i r t d e e p e r i n t o cracks a n d

v o i d s i n the i n s u l a t i o n s y s t e m . L o o s e d i r t c a n be removed w i t h a c l e a n i n g rag or a s o f t b r i s t l e b r u s h . Clogged a i r o p e n i n g s should be c l e a n e d o u t u s i n g c a r e n o t t o damage i n s u l a t e d p a r t s . O i l a n d g r e a s e may be removed by w i p i n u w i t h a c l e a n cloth dampened s l i g h t l y w i t h FREON TF (a fluorinated h y d r o c a r b o n s o l v e n t made by D u P o n t ) o r P e r c h l o r e t h y l e n e .

C A L I : 'FIE: CLOTF Si?OFLD NO'!' OF ::JET, PQR L I Q t ' I D SOLVC?IT >!LAY CARRY E L E C T R I C ; I L C3?:LlXCTI>TC D I R T DEEP INTO CRACKS A N D V O I D S I V T I E I N S U L A T T O S SVSTE.".I.

If insulation resistance is !ow a f t e r cleaninn it n a y be necessary to either Sake the a r m a t u r e a t 3 0 ° C to remove moisture o r t c , varnish t r c a t a n d S a k e .

C h e c k f o r u n u s u a l n o i s e s or v i b r a t i o n which were not present when the u n i t was o r i y i n a l l y i n s t a l l e d . Chcck all e l e c t r i c a l and nechanical connections for tightness. C l e a n screen covers a n d v e n t i l a t i n q ducts. 3-

3isassembly Instruction -

3.

The following instruction will describe t h e disassembly process of a s t a n d a r d motor. I t s h o u l d be recognized t h a t s ~ e c i a lrequirements and special a p p l i c a t i o n s require special construction and there will be many variations to which standard instructions do not a p p l y . The following s t e p s will serve a s a h e l p f u l g u i d e w h e n disassembling a motor: I. 2.

3. 4.

Remove the b r u s h h o l d e r s p r i n g s and brushes from t h e brushholders. W i t h the motor i n a vertical position, drive end up, remove t h e d r i v e e n d bearing bracket b o l t s .

Tap the bearing bracket loose and remove. Remove t h e armature using a lifting eyebolt in the center hole in t h e shaft. Disconnect all connections between the magnet frame a n d t h e commutator end bearing bracket. Remove all bolts h o l d i n g the commutator end b r a c k e t to the magnet frame. Remove t h e bracket from the frame tapping it loose t o disengage the rabbet F u r t h e r d i s a s s e m b l y or replacement of parts can n o w b e accomplished a s required by the situation. Peassembly is accomplished i n reverse order of steps 1 t h r o u q h

.

5.

6.

4.

3-

33.

Failure

WARNING: IF AN ELECTRICAL F A I L U R E O R AN EXTREME OVERLOAD O C C U R S , PERSONNEL SHOULD NOT BREATHE THE FUMES W H I C H li('rVE BEEN GENERATED I N S I D E THE iVWCFJNE. TEE FEAT O F THE FAILURE ARC OR OVERLOAD MAY GENERATE NOXIOUS FUMES B Y PYROLYSIS OF THE I N S U L A T I O l J blATERIALS. ALL POWER SI-DULD RE DISCONNECTED FRO?'! THE MOTOR BEFORE ANY I N V E S T I G A T I O N OF TFE F A I L U R E I S ATTEMPTED. TEE AREA AROUND TEE FlOTOR S fYOULD BE WELL VENT1 LATED.

k?ater should not be applied to a n y electrically energized equipment because of t h e d a n g e r of electric s h o c k which can r e s u l t in s e r i o u s o r fatal injury. I n case of f i r e , disconnect all power a n d use a carbon d i o x i d e extinquisher to quench the flame.

3-

4.

Repair

See \l1arranty

3-

5.

.

genewal P a r t s

T h e n o t o r s e r i a l n u m b e r completely identifies the yotor and e v e r y part therein. It must be g i v e n when o r d e r i n g replacement p a r t s . Any order f o r motor parts should g i v e the number of parts d e s i r e d , t h e d e s c r i p t i o n of t h e p a r t , the serial n u m b e r of t h e m o t o r , a n d t h e ~ o d e lnumber.

ELECTRIC MOTOR

3.1.1

--

Description

S e r i e s Wound, Type H I n s u l a t i o n , 2 0 h p a t 4 9 0 0 rprn, Main P o l e s a n d Coils,

ona adjusted

Brush Rigging

T h e a r m a t u r e a s s e m b l y c o n s i s t s of a shaft, a r m a t u r e core, a r m a t u r e windings, and commutator.

The c o i l e d f r a m e c o n s i s t s o f t h e magnet f r a m e , main poles a n d c o i l s , a n d t h e f i e l d t e r m i n a l s .

O t h e r b a s i c p a r t s of

t h e motor i n c l u d e t h e d r i v e e n d b e a r i n g

b r a c k e t , commutator e n d b e a r i n g b r a c k e t , b e a r i n g s , b e a r i n g s e a l s (when e q u i p p e d ) , b r u s h h o l d e r yoke w i t h b r u s h h o l d e r s , b r u s h e s a n d b r u s h h o l d e r s p r i n g s , and c o v e r s .

O p e n i n g s o v e r the b r u s h h o l d e r s

p r o v i d e a c c e s s i b i l i t y t o t h e b r u s h r i g g i n g and commutator for i n s p e c t i o n and brush replacement.

S t a n d a r d b e a r i n g s are t h e s i n g l e

row, d o u b l e d s h i e l d e d , Conrad type p r e - l u b r i c a t e d w i t h h i g h t e m p e r a t u r e g r e a s e w i t h ABECl tolerance a n d AFMBA # 3 i n t e r n a l r a d i a l clearance. WARNING:

DO NOT OPERATE A S E R I E S MOTOR UNLOADED AS E X C E S S I V E

SPEED MAY OCCUR W H I C H CAN CAUSE DAMAGE TO THE MOTOR AND I N J U R Y T O PERSONNEL.

3.1.2

Maintenance WARNING:

I F POSSIBLE,

MAKE SURE MOTOR I S DISCONNECTED FROM

POWER SOURCE BEFORF, PERFORMING ANY MAINTENANCE OPERATIONS ON THE MOTOR.

WHEN POWER IS R E Q U I F S D TO PERFORM ANY IHAIN-

TENANCE, V I G I L A N T CAFU AND A T T E N T I O N S H O U L D BE E X E R C I S E D .

S t a n d a r d b e a r i n g s are d ( 7 u b l e shielded a n d p r e - l u b r i c a t e d and normally do n o t r e q u i r e l u b r i c a t i o n . Under normal c o n d i t i o n s t h e b e a r i n g s f a i l a f t e r s e v e r a l y e a r s s e r v i c e due t o l a c k of p r o p e r l u b r i c a t i o n , e i t h e r f r o m d i r t y c o n t a m i n a n t i n t h e g r e a s e or insufficient o i l i n the grease.

oil, 2 0 % s o a p .

N e w g r e a s e consists o f a b o u t 8 0 %

When b l e e d i n g r e s u l t s i n a r e d u c t i o n o f o i l t o

a b o u t 6 0 % , t h e b l e e d r a t e i s reduced t o a l e v e l t h a t may n o t s u p p l y sufficient lubrication.

For t h i s r e a s o n when m a i n t e n a n c e o v e r h a u l s

are performed after several years of service, bearings are automatically replaced as a routine practice. A bearing should be replaced with an exact replacement or one with all interchangeable features. It is especially important that the bearing have high temperature grease. 3.1.2b.

Insulation

Insulation resistance should be checked during each maintenance inspection. Low resistance may be caused by excessive dirt, moisture or impending failure. Although motors can be successfully run with insulation resistance as low as 1/4 megohm it is well to investigate the reasons for any insulation resistance below 1 megohm. Low resistance values due to dirt can usually be corrected by cleaning followed by a varnish dip and bake. Low resistance due to moisture can be corrected by baking the motor in a 90°c oven until the insulation resistance rises above this value and stabilizes t o a nearly constant valve. A new motor should withstand for one minute without breakdown the application of a Hertz potential of 500 volts for voltage up to 60 volts or 1000 volts plus twice rated voltage for voltages higher than 60 volts. Old motors should be tested at 75% of these values. 3.1.2~. Brushes Brush condition and remaining brush life should be checked at each maintenance inspection. Each brush should be checked for length and each spring for proper pressure. When installing new brushes, each brush should be sanded into the curvature of the commutator for most reliable performance. A minimum of 85% surface contact with 300% brush arc is recommended. Replacement brushes should be exactly the same brush grade as original. 3.1.2d.

Commutator

Commutator runout should not exceed .002" total indicated runout with a bar-to-bar variation of .0002". The mica bar-to-bar insulation should always be kept below the copper surface. When commutator wear results in flush o r protruding mica, t h e mica should be undercut to a depth equal ot the thickness of the mica or about . 0 2 5 " . The undercut slot should be kept clean and

free of dirt.

3.1.2e.

Cleanin9

Both the interior and exterior of the motor should be kept clean and free of dirt and grease. Loose dirt may be removed by vacuum cleaning or dry compressed air. Vacuum cleaning is preferred because compressed air may drive dirt deeper into cracks and voids in the insulation system. Loose dirt can be removed with a cleaning rag or a soft bristle brush. Clogged air openings should be cleaned out using care not to damage insulated parts. Oil and grease may be removed by wiping with a clean cloth dampened slightly with FREON TF(a fluorinated hydrocarbon solvent made by DuPont) or Perchlorethylene. CAUTION: THE CLOTH SHOULD NOT BE WET, F O R L I Q U I D SOLVENT MAY CARRY ELECTRICAL C O N D U C T I N G D I R T DEEP I N T O CRACKS A N D V O I D S IN THE INSULATION SYSTEM. If insulation resistance is low after cleaning it may be necessary to either bake the armature at 900C to remove moisture or to varnish treat and bake for reliable repair. 3.1.2f.

Mechanical

Check for unusual noises or vibration which were not present when the unit was originally installed. Check all electrical and mechanical connections for tightness. Clean screen

covers and ventilating ducts. 3.1.3. . Disassembly Instruction

The following instruction will describe the disassembly process of a standard motor. It should be recognized that special requirements and special applications require special constructionand there will be many variations to which standard instructions do not apply. The following steps can still serve as a helpfu.1 guide when disassembling a motor: 1. 2.

Remove the brushholder springs and brushes from the brushholders. With the motor in a vertical position, drive end.up, remove the drive end bearing bracket bolts.

3 . a.

On m c t o r s which do not have a restrained drive end bearing

t h e d r i v e end b e a r i n g bracket can be tapped loose and removed.

Next the armature can be removed using a lifting eyebolt in t h e center, hole i n t h e s h a f t .

b. 3n m o t o r s w h i c h have a r e s t r a i n e d drive end b e a r i n g , l i f t the armature and d r i v e end bearing b z a c k e t using--the lifting e y e S ~ l tin the c e n t e r hole i n the shaft, t a p p i n g the bracket loose from the magnet f r a m e a s it is lifted. c, ~ c t h motors with and without restrained drive end hearings may be disassenbled a s described in 3b. A f t s r rernoval t h e drive end S r a k c e t may be slid off t h e bearing. 4. Disconnect a l l connections between the m a g n e t frame a n d the ~ ~ ~ m ~ u t end a t obearing r Sracket. Remove all b o l t s h o l d i n g ?he ;om.nutator end bracket to t h e rnagnet frame. Remove the b r a c . k e t from the frame t a p p i n g i t . l o o s e to disengage the rabbet. 5. Further disassembly or replacement of parts can now be accompl i s h e d as required by the zituation.

6.

3es:$cevqblyis accomplished in reverse o r d e r of steps 1 through 4

-3 .- . 1 . J a .

Failure

IF AN ELECTIXICAL F A I 1 , U R E OR ' A N EXTREME OVERLOAD O C L S R S , ESPECIALLY I N A TOTALT.,Y ENCLOSEC MOTOR, PERSCFJNEL S H O U L D NOT BREATHE THE F U M E S WHICi7 HAVE BEEN GENERRTED I N S T D E THE MACHINE. THE HEAT OF THE FAILUIG ARC OR OVERLOAD Y A Y GENERATE NOXIOIJS FUMES BY P Y R O L Y S I S O F THE I N S U L A T I O N W.'?ERIALS. ALL POWER S H O U L D BE DISCONNECTED FROM THE MOTOR

I\1,T4RYING:

FEFORE A i i Y INVESTT.C;.\'l'ION

O F THE FATLURE IS ATTEMPTED.

AREA AROUND THE Y b T O R SHOU1,D BE WELL VENTILATED.

THE

L'ERSONNEL

StiG'JLD NOT BREATIIE THE T O X I C ?'UKES PRODUCED BY TI-IE F A I L U R E . Tf.' POSSTBL.E,

TI:=

SHOULD BE ALLOWED FOR THE MOTOR T O COOL

AND F O R D I L U T I O N O F THE FUP'ES WITH AIR. W;ter should not bc applied to a n y electrically e n e r g i z e d e q u l l ~ : r \ c n tbecause of the d a n ~ e rof elrctric shock which c a n r e s u l t i n s.::ious or f a t a l injury. 111 c a s e of fire, disconnect a l l yuwex -and use a cazborl dioxide extinguisher to quench the flame.

Repilir -3.1.4. See Warranty.

3.1.5.

--

R e n e w a l Parts

T h e m o t o r serial n u m b e r c o m p l e t e 1 . y i d e n t i f i e s t h e motor

and every p a r t t h e r e i n . parts.

I t m u s t be g i v e n when ordering replacement

Any order fox motor parts should give t h e number of parts

desired, the d e s c r i p t i o n of t h e p a r t , t h e serial number of t h e motor, and e i t h e r t h e model n u m b e r o r t h e OEM-customer i d e n t i f i c a t i o n number.

CHPATER 4 :

. 2.

CHARGER

. . . . . . . . . . . . . . . . . . . .

4- 1

DESCRIPTION

4-

SCHEMATIC WIRING DIAGRAM

I

TROUBLESHOOTING

I

4- 3

.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

4-

1.

/ 1, -

Ffl.

Description

L e s t r o n i c B a t t e r y C h a r g e r , Model 3 4 5 8 - 'I'ype ' , 2 / 1 0 2 L C R 2 5 - i E T Input: 115/230 v o l t s A.C. 60HZ Output: 1 2 & 1 0 2 volts D.C., L 0 / 2 5 amps

4-

2.

Schematic Wiring D i a g r a m

See page 3 .

4-

3.

Troubleshooting

When o p e r a t i n g from 230 v o l t A . C . s o u r c e , the i n i t i a l c h a r g e rate will vary from 18-30 amps, d e p e n d i n g o n t h e state o f discharge o f the batteries.

I f not check:

1) 2) 3)

C h e c k l o w v o l t a g e o u t p u t to charger Check for dead battery ( i e s ) Check charger f u s e

When o p e r a t i n g from a 1 1 5 v o l t A . C . source, the i n i t i a l charge rate will vary from 8 - 1 3 amps, d e p e n d i n g o n the state of discharge of t h e b a t t e r i e s . I f not c h e c k a s above.

The charge r a t e of t h e 1 2 v o l t b a t t e r y w i l l v a r y g r e a t l y d e p e n d i n g on the s t a t e of d i s c h a r g e of b o t h the 1 2 a n d 1 0 2 v o l t b a t t e r y system.

1 '

\" + > ?\

:4ALFUNCTION SYYPTOMS AND TIIETR REPIEDIES

L s s t r o n i c Sat tery Chargers Models 9 4 5 8 a n d 9575 No T r a n s f o r m e r Xum and ,Anmeters Do Not R e ~ i s t e r

I n t h e e v e n t n o hum i s d e t e c t e d f r o m t h e transformer, c h e c k t h e c o r d t o , b e s u r e I t i s s e c u r e l y p l u g g e d i n t o a live AC o u t l e t ( c h e c k line f u s e o r c i r c u i t b r e a k e r ) . Also c h e c k t o b e s u r e t h e c h a r g e r DC o u t p u t l e a d s a r e c o n n e c t e d s e c u r e l y t o t h e i r r e s p e c t i v e batteries. AC.

XOTE:

9 e c a u s e t h e r e l a y , -dhlch c o n t r o l s the t u r n l n g on and-61-f 'of-Ehe c h a r g e r , i s activat-eT%-$-the ' ~ T D + + ~ l E - ' b a t - ~ e r - ~ ~ the ~ ~ s t102 e m ;v o l t charger o u t p u t leads must Se c o n n e c t e d to b a t t e r i e s t o t u r n c harzer on. _C__

I

i

i "

1

I

Push a n d r e l e a s e "START" b u t t o n . IT, I n t h e p r e v i o u s c h a r g e c y c l e , t h e c h a r g e r was allowed t o t u r n o f f automatically the relay w i l l c l o s e a p p r o x i m a t e l y t w o s e c o n d s after the b u t t o n I s r e l e a s e d and only one "click" w i l l b e heard. If t h e p r e v i o u s c h a r g e c y c l e was I n t e r r u p t e d b e f o r e t h e charger t u r n e d o f f a u t o m a t i c a l l y , t h e r e l a y r i l l o p e n when the "START1' b u t t o n is d e p r e s s e d and r i l l c l o s e a f t e r the b u t t o n i s r e l e a s e d , thus p r o d u c i n g two "clicks". 'dhen t h e r e l a y closes and the AC cord 1 s c o n n e c t e d , t h e c h a r g e r . ls o n a n d t h e transformer s h o u l d hum.

If still no hum Is n o t i c e d , a c o n t i n u i t y c h e c k o f t h e A C c i r c u i t i s necessary. Disconnect AC cord from w a l l o u t l e t b u t l e a v e connected t o c h a r g e r r e c e p t a c l e . U s e a s u i t a b l e continuity t e s t e r t o c h e c k t h e c i r c u i t a c r o s s t h e AC p l u g p r o n g s . Circuit should b e c o m p l e t e when r e l a y i s c l o s e d . ( I f relay Is not already c l o s e d , push "START" button.) If not complete, i n d i v i d u a l l y c h e c k A C c o r d s , c h a r g e r A C i n p u t r e c e p t a c l e , r e l a y c o n t a c t s , primary t r a n s f o r m e r c o l l and a11 c o n n e c t i o n s , If m a l f u n c t i a n s t i l l e x i s t s , c h e c k r e l a y c o i l v o l t a g e a t r e l a y terminals using a suitable DC v o l b m e t e r . Voltage s h o u l d b e t h e same a s t h e 1 0 2 v o l t b a t t e r y s y s t e m . If voltage is c o r r e c t c h e c k the r e l a y c o i l resistance.

< /. ----.L

IMPORTANT: '--

D i s c o n n e c t c o n t r o l c a b l e from E l e c t r o n i c , . T i m e r Assembly b e f o r e checking r e l a y c o i l resistance. Damage t o E l e c t r o n i c T L m e r o r meter w i l l result If c o n t r o l c a b l e remains connected.

E r 3 a y c o i l r r s j s t a r l c c should bc* : ~ l ) p r o Jxl r ~ : i t t ~ I y6 , 0 0 0 o l l r n s . If c o i l r e s i s t a n c e i s n o t correct, relay I s d e f e c t i v e a n d m u s t b e rep1 aced.

I f r e l a y c h e c k s g o u d , check continuity o f h e a t sensor. C l r c u i t s b o u l b e c o m p l e t e unless charger has o v e r h e a t e d , In w h l c h c a s e t h e h e a t sensor will b e o p e n . If c l r c u l t i s n o t c o m p l e t e , r e f e r t o 'CHARGER OVERHEATS" for further t e s t p r o c e d u r e s . If n o malfunction c a n be found, refer t o "Charger Does Not T u r n O f f " for Electronic T l m e r t e s t procedures. . ..

Transformer Hums B u t No Ammeter I n d i c a t i o n Check t h e c h a r g e r DC o u t p u t leads t o b e sure t h e y are p r o p e r l y c o n n e c t e d t o t h e 1 2 v o l t and 1 0 2 volt b a t t e r y s y s t e m s . If t h e r e i s s t i l l no ammeter i n d l c a t l o n , a c o n t l n u l t y t e s t o f t h e c h a r g e r DC c i r c u i t m u s t be performed. Disconnect AC cord from charger r e c e p t a c l e a n d DC o u t p u t l e a d s from batteries. Check f u s e s o n charger f r o n t p a n e l . If one o r more fuses have blown, refer to "Charger DC Fuse(s) Blowst1 f o r f u r t h e r t e s t s . If f u s e s c h e c k good, use a l o w voltage c o n t i n u l t y t e s t e r t o perform t h e following / tests:

( a ) Connect t h e t e s t e r l e a d s t o charger 102 volt output leads. Note reading a n d t h e n r e v e r s e tester l e a d s . C i r c u i t s h o u l d c o n d u c t i n one d l r e c t l o n o n l y . Perform same test on charger 1 2 volt o u t p u t leads. If c i r c u i t does not conduct In e i t h e r direction, a n d f u s e s a r e good, l n d l v l d u a l l y check t h e DC output l e a d s , ammeter, d l o d e a n d f u s e c o n n e c t i o n s ( e a c h may be checked w l t h a contlnulty t e s t e r ) .

If clrcult conducts In both d l r e c t l o n s a "short" e x i s t s i n t h e DC c l r c u l t . F l r s t c h e c k DC o u t p u t l e a d s for a " s h o r t " b e t w e e n t h e t w o wires. More probably, one or more d l o d e s have " s h o r t e d " . Refer t o "Charger DC Fuse(s) Blows", p a r t ( b ] f o r c o n t l n u i t y t e s t o f d l o d e s . ( b ) If D C c i r c u f t t e s t I s good, a c h e c k o f t h e c a p a c i t o r s I s necessary. W i t h AC cord and DC o u t p u t l e a d s d i s c o n n e c t e d , r e m o v e o n e t r a n s f o r m e r l e a d w i r e from c a p a c i t o r terminal and c o n n e c t contlnuity tester l e a d s t o c a p a c i t o r t e r m i n a l s . . If c l r c u l t I s complete, o n e or m o r e capacitors a r e " s h o r t e d " a n d must be replaced.

Charger DC ~ u s r ( s )B l o w s T h l s condition m a y b e c a u s e d by: ( a ) R e v e r s e polarity between charger a n d b a t t e r i e s , s u c h a s incorrect f n s t a l l a t l o n o f batteries o r v l r f n g o f c ~ a r g e koutput leads.

(b) A short c i ~ c u l tfailure of one or more dlodes. First d i s c o n n e c t AC c o r d and DC output l e a d s f r o m b a t t e r i e s . Remove f u s e s (tour 30 amp and two 5 a m p fuses) to I s o l a t e diodes. U s i n g a low v o l t a g e continuity tester connect one lead t o diode m o u n t i n g plate a n d o t h e r l e a d t o d i o d e w i r e lead. Note r e a d i n g and t h e n r e v e r s e t e s t e r l e a d s and c h e c k e a c h d i o d e again. If diode conducts current In both directions, the d i o d e is shorted and aust Se replaced. Replace e f t h e r t h e e n t i r e h e a l s i n k assembly o r o n l y t h e defective diode. When replacing a single d i o d e , b e sure t h e new d i o d e 1s p r e s s e d s q u a r e l y i n t o the hole and that i t d o e s not e x t e n d beyond t h e r e a r of t h e heat sink p l a t e . ( c ) E x c e s s i v e h e a t i n g of t h e fuse d u r i n g normal charging. Be s u r e all fuse c o n n e c t i o n s are clean a n d t l g h t . Screwi n t y p e fuses can become corroded a t t h e fuse receptacle contacts, c a u s i n g t h e fuse element to m e l t . Be sure to keep fuses t l g h t and c o n t a c t s f r e e o f c o r r o s i o n . If necessary, replace f u s e r e c e p t a c l e or cartridge. Charqer Output Is Low

The most probable cause Is one d i o d e shorting and b l o w i n g o n e fuse. Refer t o "Charger DC F u s e ( s ) Blows", part ( b ) to c h e c k diodes. The c h a r g e r o u t p u t w i l l b e 1 to 5 amps when one f u s e

has blown,

Charqer Does Not T u r n O f f The E l e c t r o n i c Tlrner c o n t r o l s t h e r e l a y whlch turns t h e c h a r g e r both on and o f f . If batteries have been heavily discharged t h e charger may r u n f o r u p t o 1 6 h o u r s in o r d e r to f u l l y c h a r g e t h e batteries. In cold temperatures or when operating from 115 v o l t s AC, e v e n more t i m e m a y be required. F o r normal overnight charging, use only 230 v o l t AC input. L i m i t u s e o f 115 v o l t AC input t o emergency s i t u a t i o n s a n d occasional charging when vehfcle is n o t In u s e and 230 v o l t lnput is not available, Continual use of 115 volt lnput will lead t o u n d e r c h a r g i n g of the Satteries, thus reducing performance and b a t t e r y life. rf' T h e Electronic Timer Assembly may be c h e c k e d b y measuring t h e voxtages o f t h e c o n n e c t o r p i n s . The following t a b l e s h o w s t h e c o r r e c t voltages o f t h e various p l n s . A l l voltages a r e measured relative to pin #1 (battery negative).

IMPORTANT:

I 6'

.

.

1

CAUTION:

Use extreme c a r e when w o r k l n g internally on charger. DO NOT allow meter probe to short between pins or pcrrnancnt damage to Electronic Timer may result. Charger c a p a c l t p y v o l t a g e is approximately 630 volts, Use care when working n e a r capacitors.

P i n Voltage

PIN NO,

.

.(Use m e t e r with at l e a s t 20,000 ohms per volt input impedance) ---

2

6

Same a s 102 volt b a t t e r y s y s t e m . (Approximately 107 Vdc )

-

I Vdc

-

78 V a c

C h a r g e r ON Charger OFF-

Same as 102 volt battery s y s t e m

7

Charger ON

8

"START" b u t t o n c l o s e d ( d e p r e s s e d ) - 0 Vdc "START" button open (released) - 10 Vdc

10

"SUMMER-WINTER" s w i t c h - SUMMER 10 Vdc WINTER 0 V d c

If all voltages a r e correct, check the c o n n e c t o r terminals t o b e s u r e t h e y a r e making proper c o n t a c t w i t h p i n s . If no r n a l f u n c t l . o n can be f o u n d , or v o l t a g e s a r e not correct, r e p l a c e E l e c t r o n i c T i m e r Assembly and return d e f e c t i v e assembly t o f a c t o r y for r e p a i r . T r a n s f o r m e r Short o r B u r n - O u t F a l l u r e o f t h e t r a n s f o r m e r nay b e c a u s e d b y n a t u r a l aging o r p r e m ~ t u r e shorting of e d j a c e n t coil turns. The transformer may hum when A C and DC l e a d s a r e c o n n e c t e d , however, a low or c o m p l e t e lack of o u t p u t would b e observed on t h e ammeter. To test transf o r m e r , f i r s t disconnect AC cord a n d DC o u t p u t l e a d s a n d perform DC c i r c u i t test a s d e s c r i b e d in "Transformer Hums But No Ammeter Indication". If c i r c u i t t e s t s good, r e c o n n e c t AC cord and m e a s u r e t r z n s f o r m e r output voltages. C o r r e c t voltages are shown in t h e following t a b l e . Voltages will vary sllghtly If AC Input voltage Is other than 115 or 2 3 0 Vac. If measured v o l t a g e s a r e substantially lower t h a n t h o s e shewn, t h e t r a n s f o r a e r I s shorted a n d ~ u s tb e r e p l a c e

T r a n s f o r n e r Ooen-Circui t Vol t a r e s

Models 9458 a n d 9575

I~ ~

Transforaer

-

I

102 volt s y s t e m s C O L ~V o l t a g e tVac) without capacitors connected

with

capacitors connected

coil

ll5Vac

230Vac

ll5Vac

230Irac

Secondary

-

leads 1 to 4

21 9

221

120

165

Secondary

-

l e a d s 9 to 1 2

308

312

167

232

Secondary

-

leads 5 t o 8

27

28

14

20

'

- --

--

Capacitor C o i l

620

633

335

462

S

C h a r g e r Overheats/Charqer Coolinq Fan Does Not Ouerate

The c h a r g e r cooling f a n must operate t o p r e v e n t the u n i t f r o m overheating. A heat sensor, mounted i n t e r n a l l y , is used to turn the charger off should t h e unit overheat. SJhen t h e fan i s operating, w a r m air should b e exhausted from the s i d e vent opposite t h e f a n f u s e . If fan does not o p e r a t e check fan f u s e mounted on t h e s i d e of the c h a r g e r . If f u s e 1s good, check AC voltage at fan connector. Voltage s h o u l d be 80 to 100 Vac. If fuse and fan v o l t a g e c h e c k good, t h e fan fs defective and must be r e p l a c e d .

Battery Voltage T a b l e

Room Temperature 2 5 C = 7 7 F Flood M a x 130 F Spec. Gravity 1.170 1.200 1.230 1.260 #6V Bats

cell 1 2 3 4

5 6 7 8

9 10 11 12 13 14 15

16 17 18 19 20 21 22

23 24 25

26

Nom. Volt

Fully Disch.

25%

50%

75%

100%

Max. Float

Sealed Max 150F 0.015 Spread Gasing 30min. C.Taper CnstCur