No.

SEF-43AAE

TCM@
@~[ÆWD@~ 阻&G江田&0コ

FORKLIFTTRUCK
D
ies
el&GasPowered
FD35c9 FD35T9
FD40C9 FD40T9
FD45c9 FD45T9
FD50T9

FG35T9
FG40T9

TCMCORPORATION
 FOREWORD
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 SPECIFICATIONS(
1)

I
te「一一一一J竺 o
del FD35c9 FD35T9 FG35T9

Performance
民1ax.load kg 3500 ←
- ←
-
Basicl o
adc en
ter (mm) 600 ー
← ←
Liftheigh
t (mm) 3000 一
← 一
←
Til
ta ngl
e(fwd-r ev
) (
0) 6-1 2 ←
- ←-
Freelif
t (mm) A 150 ← ←-
Liftspeed (mm/s)
(u
nloaded) 580 ← 540
lo
( aded) 540 ←
- 500
Travelin
gs peed (
km/
h)
fwd 1 s
t 1
0.0 Whenf i
xed ←
a
t1s
tg e
ar:17.
0
2nd 1
9.5 2
6.0 ←
rev 1st 1
0.0 19
.5 ←
-
2nd 1
9.0
Max.drawbarp ull kN{ k
gf}
(unl
o aded) 17
.7{
1 800} ←
- ←
-
lo
( aded) 2l
.1{2150} 3
3.3{3400} 3
1.4{3200}
Gradeabi
lity
(unl
o aded) 1
/5 ←
- ←
-
lo
( aded) /5
1 .
5 1
/3 1
/4
民1in
.t urningradius (mm) B 2730 ←
- ←
-
Min.i nt
ersectingais
le (mm) 2500 ←
- ←
-
Dimensions (mm)
Overalllength C 4155 ←
- ←
-
Overallwidt h D 1480 ← ←
-
Overal
lh eight(a
to v
erheadgu
ard) E
EXB/EXC 2230 ← 一
←
EXE/EXN 2250 ←
- ←
-
Over
allh eig
htw ithexte
ndedmast F 4265 一
← ←-
Wheelb ase G 2000 一
← ←
-
Tread
(
fron
t) H 1180 ←
- ←
(rear
) 119
5 ←
- ←
-
Forkoverhang J 560 ←
- ←
-
Rearoverhang K 525 ←
- ←
-
Forks i
ze 1070x150x50 ← ←
(Lengt
h( L)xW idth(M)xT hick
ness(N)
)
Forks pacing P 300-1290 ←
- ←
-
Underc learance 1
55(a
tmast
) ←
- ←
-
Weight
Operatingweight (k
g) 6100 6140 6110
 SPECIFICATIONS(
2)

ItJ7 一一一ど竺 l
FD40C9 FD40T9 FG40T9

P
erf o
r m
ance
Max.load kg 4000 ←
- ←
-
Basicl o
adc e
nter (mm) 600 ←
- ←
-
Li
fth eig
ht (mm)
(
0)
3000 ← ←
Ti
lta ng
le(fwd-r ev
) 6-1 2 ←
- ←
-
Freelif
t (mm) A 150 ← ←
Li
fts peed (mm/s)
(u
nloaded) 580 ー
← 540
(
loaded
) 540 ←- 500
Travelin
gs peed (
km/
h)
fwd 1 st 1
0.0 Whenf i
xed ←
a
t1s
tg e
ar:17.
0
2nd 1
9.5 2
6.0 ←
-
rev 1st 1
0.0 19
.5 ←
-
2nd 1
9.0
Max.drawbarp ul
l kN{kgf}
(u
n l
oa d
ed) 17
.7{
180
0} ←
- ←
(
loaded) .1{
21 215
0} 3
3.3{3400} 31
.4{3200}
Gradea
b i
lity
(u
n l
oa d
ed) 1/5
.5 ←
- ー
←
(
loaded) 16
/ 1
/3.
5 1
/4
Min.t urn
i n
gr adi
us (mm) B 2790 ←
- ←
-
民1in
.i nte
rsecti
nga i
sle (mm) 2550 ←
- ←
-
Dimensions (mm)
Overalllength C 4205 ←
- ー
←
Overallwidth D 1480 ← ←
Overa
llh eigh
t(atoverhea
dg u
ard
) E
EXB/EXC 2230 ← ←
EXEIEXN 2250 ← ←
Over
allh e
i g
htwithe x
tendedmas
t F 4265 ← ←
Wheelb as e G 2000 ← ←
Tread
(仕o n
t) H 1180 ← ←
(
rear
) 1195 ← ←
Forko verhang J 560 ← ←
Rearoverhang K 575 ←
- ←
Forksize 1070x1 5
0x50 ← ←
(Lengt
h( L)xWidth(M)xT hick
ness(N)
)
Forks pacing P 300-1290 ←
- ←
-
Underc learanc
e( a
tm as
t) 155(m
ast) ←
- ←
-
Weight
Operatingweight (k
g) 6520 6560 6530
 SPECIFICATIONS(
3)

ItJ 一一一一」竺 ±l
FD45c9 FD45T9 FD50T9

Performance
Max.load kg 4500 ←
- 5000
Basicloadcenter (mm) 600 ← ←
Liftheig
ht (mm)
(
0)
3000 ←
- ←
TiI
ta ng
le( fwd-rev
) 6-1 2 ←
- ←
-
Freelif
t (mm) A 155 ← 160
Liftspeed (mm/s)
(u
nloaded
) 520 ← ←
-
(
loaded
) 480 ← ←
Travelin
gs pe
e d (
km/
h)
fwd 1 st 1
0.0 Whenf i
xed ←
a
t1s
tg e
ar:17.
0
2nd 19.5 2
6.0 ←
rev 1s
t 9.5 19
.0 ←
-
2nd 19.0
Max.drawbarp ul
l kN{ kgf
}
(u
n l
oa d
ed) 18.6{1900} ← ←
-
(
loaded) 21.6{ 2200} 3
4.3{
350
0} ←
-
Gradea
b i
lity
(u
n l
oa d
ed) 1
16 115 ←
-
(
loaded) 1/6.5 1
13.
7 1
/4
恥1in
.t urnin
gr ad
ius (mm) B 2825 ←
- 3040
Min.i nt
ersecti
ngaisl
e (mm) 2550 ← 2700
Dimensions (mm)
Overalllength C 4285 ←
- 4635
Overallwidth D 1480 ← ←
Overa
llh eigh
t(atoverh
eadguar
d) E
EXB/EXC 2230 ← ←
EXE/EXN 2250 一
十 ←
-
Over
allh ei
ghtwithextend
edmast "
F 4265 ← 4420
Wheelb ase G 2000 ← 2200
Tread
(fron
t) H 1 180 ← ←
(rear
) 1 195 ← ←
-
Forko verhang J 590 ← ←
-
Rearo verhang K 625 ← ←
一
Forksize 1070x150x5 5 ← 1220x1
50x60
(Lengt
h( L)xW idth(M)xT h
ickne
ss( N
))
Forks pacing P 300-1290 ←- ←
-
Underc learan
ce(atmast) 140( ma
st) 一
← ←
-
Weight
Operatingweight (kg
) ， 7030 7070 7280
 Uni
t:m m

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uckDimensions
 TABLEOFCONTENTS
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1
0. ELECTRICWIRING… .
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.1
09
 1
. ENGINE

1
. ENGINE
且
・
・
UM 乃

E
・
mm 戸
see

egd
n
n ・冒且
q ﹄口

S6S-31TFL
4-cy
cle，wa
ter-
coold，
e o
verhe
adv
alv
esw
irl
chamber
-typed
ies
ele n
gine
No.ofc yli
nders-Borexstroke 6-94x120mm
Tota
ld ispl
acement 4996cc
Compressionratio 22
Performance
Rateds pee
d 2300rpm
Ratedo u
tput 64.7kW{ 8
8PS}
Maximumt orque 284N-m{ 29kgf-m}11600rpm
Full-
loadratedfue
lconsum
ption 260g/kWh{191g /ps
-h}
No-loadminimums p
eed 820rpm(Sepa
rateengine)
Dryw eight 350kg
Dimensions 1002x587x8 01m m
Ign
itionorder 1-5-3-6-2-4
Rota
tionaldirec
tion Clock
wis
ewhenviewedfromt hef
an

• Gas
oli
neEngines
Name TB42KA4GR60
Type 4-c
ycle，wa
ter-c
ooled，o
ver
hea
dva
lve
gas
olineengi
ne
No.ofc yli
nders-Borexs tro
ke 6-9 6
. 0x96.0m m
Tota
ld ispl
acement 4169cc
Compressionratio 8.
3
Performance
Rateds pee
d 2300rpm
Ratedo u
tput 59.6kW{ 8
1PS}
Maximumt orque 269N-m{ 27.
4kgf-m}/2000rpm
Full-
loadratedfue
lc on
sumptio
n 354g/kWh{ 2
60g/ps-h}
No-loadminimums peed 750rpm(Sepa
rat
ee ngi
ne)
Weightcontainin
gw ate
randoil 310kg
Dimensions 1000
.5x720x915m m
Ign
itionorder 1-5-3-6-2-4
Rota
tionaldirec
tion Clockw
isewhenviewedfromthefa
n
1
. ENGINE

1
.1 GENERALDESCRIPTION
These
rie
scomesineit
hert
hegaso
lineorth
ed i
esele
nginety
pe.
Theeng
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tedtothe.
dr
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Theeng
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ati
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ame
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CUSHION

G
aso
lin
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gin
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CUSHION

D
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lo

F
ig.1
.1 EngineMounting

-2-
 1
. ENGINE

EXHAUST
MANIFOLD AIRINLET
WATERINLET

WATEROUTLET

DRAINPLUG(
OIL
)
一
b
一u

PRESSURE
SWITCH DRAINPLUG
STARTER REL
lEFVALVE (WATER)
∞
↓0 5 C (ZE

-
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2
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16 r
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F
ig .2 D
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elEngine(
S6S
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-3-
1
. ENGINE

s
sd
fo v
MainC
ons
tru
cti
on

a
o

V
v

v
e
e

e
LU

PA
VA
V
alv
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ste
m

戸
し
W
F
uels
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em
I
nje
cti
onpump ，
BoschVEt
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P
lun
ger(
dia
.) llmm
I
nje
cti
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le T
hro
ttl
ety
pe
F
uelf
eedpump Vanetype
F
ilt
rat
ion Paperf
il
te
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pe
Govemor
Goveming C
ent
rif
uga
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l-s
pee
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L
ubr
ica
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n F
uel
lub
ric
ati
on
L
ubr
ica
tio
nsy
ste
m
Pump T
roc
hoi
dalt
ype
D
riv
e Timingg
eard
riv
e
O
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res
sur
ere
gul
ato
r P
ist
onands
pri
ng
O
ilp
res
sur
ein
dic
ato
r S
wit
cht
ypetumsona
t(4
9kP
a{0
.5kgf/cm2})
F
ilt
rat
ion F
ul-f
l ，
1owpa
perf
il
te
rty
pe
C
ool
ing W
ate
rco
oli
ngt
ype(
bui
lti
nlu
bri
cat
ions
yst
em)
C
ool
ings
yst
em
C
ool
ing Waterc
ool
ing
C
ool
ingf
an P
ush
ert
ypew
iths
eve
nbl
ads，
e O.Dof480m m
D
riv
e B
eltd
riv
e
u
m
Dl

nr

S
wir
lin
gty
pe
D
riv
e B
eltd
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e
T
her
mos
tat
Type Waxp
ell
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ype
T
emp
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eatwhichi
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gin
stoopen 7
6.50C
T
emp
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eatwhichi
top
ensf
ull
y 900C
S
tar
termotor
m
TVO
e

Engagemagnetザpe
泊凶
etn3
砲

24V
mp.m m

5kW
de
釦
O

v
e1
CU
σbny

puvpLW
・官

F
uelc
ut-
off
typ
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ole
noi
dty
pe)
AF-
e
E
・

n
時

P
rov
ide
d(G
low
)
i

-4-
 1
. ENGINE

C
har
gin
gge
ner
ato
r
Type A.C
.ge
ner
ato
r，d
iod
ere
cti
fic
ati
on
V
olt
age 24V
O
utp
ut 35A
D
riv
e B
eltd
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V
olt
age
/cu
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egu
lat
or ICt
ype(
bui
lti
nch
arg
ingg
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rat
or)
R
efe
ren
ced
ata
O
i 四n
ls pc
apa
cit
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s
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uct
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xha
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(
clo
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E
xha
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I
nje
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I
nje
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ons
ta
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sur
e 1
1.8MPa{120kgf/cm2}
Compressionp
res
sur
eat300rpm 3.
2MPa{
33kgf/cm
2
}

-5-
1
. ENGINE

GENERATOR
GOVERNOR

CARBURETOR
r
'
l

FUELPUMP
PRESSURESWITCH
OILFILTER
STARTER

，N
ー
目
_
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.
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32寸 320

zHZ802
，
4 白
24-
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，
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， 1
1: 。.JO
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D D e PS.h ム5 0 0 g刃
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F
ig.1
.3 G
aso
lin
eEn
gin
e(T
B42
)

-6-
 1
. ENGINE

MainC o
nstruct
ion TB42
Valveoper
ation
Sucti
onv alv
e opensatBTDC: 160
c los
esa tABDC: 520
Exhaustv a
lve opensa tBBDC: 620
clos
esa tATDC: 60
Valvec l
earance，s ucti
onv al
ve 0.3 8m mwhenwarm
e xhaustvalve 0.3 8m mwhenwarm
Ignitionsystem Ig n it
io nt ype
Ignitiontiming 7/750rpm
0

Ignitionorder 1 -5-3- 6-2-4

Ignitioncoi
l STC・146(HanshinE l
ectric
)
Distribut
or TOT7227乱 (1 itsubish
iE le
ctric)
Ignitionplug B4ES(NihonTokushuYogyo)
Sparkgap 0.8-0.9m m
Governor Mechanicalt y pe( Al l-ra
ngec ontol
r )
Carburetor NihonC arb uretor
Gasv alvediameter Primarys i
de:36m m，s ec o
ndarys id
e:40m m
V entur
id iameter Primarys i
de:32m m，s ec on
darys id
e:36m m
Fuelpump Diaphragmt ype
Airc leane
r F i
lte rpapert ype
Lubricationsystem Forcedl ubr ica
tion
Lubricationpump Troc hoi dalt ype
Lubricationoi
lf i
lte
r Fil te
rp a per
F i
ltrati
on Full-f1owf ilt
rati
on
Coolingsystem Wat er-c ooling
Coolingf an Pushert ype，7 ・b
・ lade，O.D.of480m m
Drive V-beltd riv e，pu lleyrati
o1 :10
Waterpump Cent rifuga ltype
Drive V-beltd rive， pul leyratio1:1.53
Watert emperatu
rer egulato
r Waxt y pe
Starti
ngmotor Magnets hiftt yp
e
V oltag
e 12V
Output 1.4k W

圃 7-
1
. ENGINE

Chargi
ngg ene
rator A7T033(M
itsubi
shiEle
ctr
ic)
Voltag
e 12V
Output 35A
Generati
on A.
C.
Drive V-b
eltdr
ivep
ラ ulleyr
ati
o1 :
2.7
7
Waterandoilcap
aciti
es
Lubr
icationoi
l 8
.3l
it
er
s
Coolingwater 8
.0l
it
er
s

-8-
 1
. ENGINE

1
.1.1 FUELSYSTEM
Thefu
elsy
stemcons
ist
sofafue
ltankin
teg
ralwit
hth
ef r
ame，afu
elfi
lt
er，
andanin
jec
tio
npump
(
fordi
ese
leng
inemodel)oraf
uelpumpandcarbu
ret
or(
forgas
oli
neeng
inemode
l).

(
1) Fueltank
Thefuelta
nki
sweldedi
ntoonei
nte
gra
lbodyw iththeframeandloc
ateda
tth
elef
ts i
deofthe
f
rame.Thefue
lta
nkha
sonit
stopata
nkcoverwhereale
velsende
rispr
ovide
dtoch
eckthefue
lle
vel
i
nt h
etank
.

C
apa
cit
y:110l
ite
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ilei--mv
- ne
一切
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C
apa
cit
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CAP
LEVELSENDER

FILTER

一.~←一

F
ig.1
.5 F
uelTank(
forg
aso
lin
een
gin
emodel
)

-9-
1
. ENGINE

Thel eve
ls en
de rconvert
st hefuellevelinthet ankint
oa nele
ctri
cc u
rrentsigna.F
l igure1.7shows
it
sc onstr
uctio
n.Forc o
nversiono ff
uel le
veli nt
oe l
ectr
icsignl av
a a
ri
ラab
ler e
sisto
rw ithni ch
r o
mew ire
isu sedw
ラ ithslid
inge lementlinkedtoaf loat
.
Ast hefloatmovesupanddownt her e
sistancevarie
sa ccor
d i
nglys othattheamounti felec
tric
currentpassingacrosstheresista
nceal s
ov a
ries.Thef u
elm e
terisab im
etalt y
pewhosep ointe
rs wing
s
dep endingupont heamounto fele
ctriccurrentpassingthroughtheheatingunitoftheb imet .When
al
thef l
oatisthehighestposit
ion，theresistan
cebetweent heGt erm
i n
alandt hegroundisa bout9.5to11
ohms.T hisa llo
wsal ar
geamountofe le
ctri
cc urre
ntt opassthroughtheresista
nce，thusc ausin
gt h
e
bimetaltobendl argelysothatthef u
elm eterp oi
nterindi
catestheFmar .Ast
k hefue
ll eveldrops，th
e
flo
a tgoesdownandt heresista
ncebecomesg reate
rt o
FUELLAMP(OPTION)
reducet heamountofe le
ctriccurrentpassingt hrough
t，t
i hu
sc ausingthef u
elm eterpointertoswingtoward
theEmar k.
Thelevelsenderisprovidedwithal ev
elsensorwhich
informst heoperatorw ithano ption
a l'
lampwhent he
fue
ll eveldropsbelowac ertainvalue.Thef uelmeter
andt heo ptionalf ue
llampa r
ei nco rp
oratedi nt he
combinationm eterpane.l
FUELMETER

F
ig.1
.6 CombinationMeterP
ane
l

FUELMETER
G

r-ー ー ー 四 回 目 ー ー ー ー ー ー ー -1
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Viewl
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Float Resistancevalu
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FULL 10
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EMPTY 8
7:!:1.
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FLOAT

F
ig.1
.7 L
eve
lSe
nde
r

ー 1
0-
 1
. ENGINE

(
2) FuelFilter
Thefuelfil
terremovesd u
standdir
tfromt hefue
lt ob
es upp
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gin.I
e tislocate
dont he
i
ntakemanifo
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rthed i
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lengin
emodel)andont h
eoutl
etpipefromthefu
eltank(f
orthegasol
ine
e
nginemode1 .
)
Thefilt
erele m
entf orthedi
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le nginemodelisac a
rtrid
get y
peanditcanb erepla
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thout
u
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otheengineeven
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WATERDRAIN
PLUG

F
ig.1
.8 F
uelF
ilt
er(
ford
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ele
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FUELFILTER

F
ig.1
.9 F
uelF
ilt
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forg
aso
lin
een
gin
emodel)

ー11-
1
. ENGINE

1.1
.2 COOL lNGSYSTEM
Theco
olingsys
temcon
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sofaw a
terpump，
afan，
ara
dia
to，
randares
ervet
ank，
andi
t
scons
truct
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i
sshowninF i
gs.1
.10and1.11.
Thewate
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 1
. ENGINE

F 一 n

Li

v-Z︿ト凶﹀ NL凶
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F
ig.1
.11 C
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forg
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-1
3-
1
. ENGINE

・
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(
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thes olenoidvalveoft h einjectionpump，t huscompleting

叩
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prep
arationsfors t
artin
gt heengine.
Theglowp i
lotlamp， theoilpil
otlampandt hechargep i
lotlamp
comeo n.
(
3) Theglowt ime
rtumso fftheglowr ela
yi nabout1 5s e
condsafte
r
thestar
ters w
itchise nerg
ized.( Theglowp ilo
tlampg oesout.)
Ifth
es ta
rterswitchisplacedinthe“ St"posit
ionatthispoint，th
e
F
ig .1
.1 2S
tar
terS
wit
ch
enginestar
ts.

GLOWPLUG SAFETYRELAY

OILPILOT ALTERNATOR
LAMP

STARTER
SWITCH INJECTIONPUMP
SOLENOID

/〆

BATTERY

F
ig .1
.1 3 EngineE
lec
tri
calSystem(
ford
ies
ele
ngi
nemodel)

-1
4-
 1
. ENGINE

(
4)Ifth
ee n
ginerot
ate
sn orm
ally，t
hev o
lta
geatthet e
rmina
lPoft heal
terna
torris
es，s
otha
tthesaf
ety
rel
ayturnsof
fitsterm
inalS.( Thechar
gepilotlampg oe
so u
t.)
Thenthesta
rte
rr e
layistur
nedo f
f，thu
ss to
ppingtheoperat
ionofthestar
ter
.
Afte
rthat，t
hestar
terdoesnotactua
teevenift h
es t
art
erswitchi
sp la
cedint h
e“St"pos
iti
on，as
longasthevol
tageattheter
minalPoft healt
ernat
orisatthenormallevel
.

• Stoppingtheengine
Whent h
esta
rte
rs w
itchi
sturn
edt
othe“OFF"p
osi
tio
n，t
hes
ole
noi
dof
thei
nje
cti
onpumpi
stu
rne
d
off
.S incethefu
eliscutof
f，t
heeng
inest
ops
.

・
S

(
1
t
a
S
r
t
t
a
i
r
n
t
gands
in
) Whent
gt
h
h
t
ee
est
a
o
n
r
p
g
t
p
i
e
i
n
rs
n
e
gt

wi
t
h

c
ee

hi
n

si
gi

nt
n
e(

h
gas
oli

e“OFF"p
nee

os
n

i
t
g

i
i

o
nemodeI)

n，th
et er
minal
1o fthesta
rte
rs w
itchisnotconnect
ed
toanyo t
herterminal
.
(
2) Whent hesta
rterswitchisturne
dtot h
e“ON"p ositi
on，theba
tterypowers ou
rceoft heter
minal1
i
sc onnec
tedtot h
et er
m i
na12. Thus，thebatt
erypowers our
ceisc on
nectedtot h
ef i
eldco
ilofthe
alt
ernat
or，passin
gt hroughthechargel a
mp. Thepowers our
ceisa ls
oc onnectedtotheigni
ter，
complet
ingp r
eparati
onsf o
rs t
arti
ngthee n
gine.
(
3) Whent hestar
terswitchisturnedtothe“St"positio
n，thesta
rteract
uatesandt h
ee ngin
es t
ar
ts.
(
4)I ftheengin
er ot
atesnormally，th
ev ol
tageatt h
et er
minalLoft healte
rnato
rri Esa
s: ndthec ha
rge
lampg o
eso u
t.

圃 Stoppingtheengi
ne
Whent h
estar
terswit
chistur
nedt
othe“OFF"po
sit
ionthepowers
ラ our
ceoft
hei
gni
teri
scu
tof
f
andthes lowc
utsoleno
idistu
rnedof
f，t
husst
opp
ingth
eeng
ine.

DISTRIBUTOR

SPARKPLUG

CARBURETOR

F
ig .1
.1 4 EngineE
lec
tri
calSystem(
forg
aso
lin
een
gin
emodel)

-1
5-
1
. ENGINE

1
.1.3ACCELERATORPEDAL
Theacc
ele
rato
rpedalco
ntro
lse
ngi
neout
put
.Itisi
nst
all
edonthef
loo
rasshowninFig
s.1
.15and
1
.16.Themovementofth
ep e
dali
str
ans
mit
tedth
rought
helin
kag
eandwirec
abletoth
eengi
ne.

5
8mm

ACCELERATOR
PEDAL

目豆旦豆坐
CABLE

~Fig. .1
1 5A
cce
ler
ato
rPe
dal(
ford
ies
ele
ngi
nemodel)

白亜旦豆坐

F
ig.1
.16A
cce
ler
ato
rPe
dal(
forg
aso
lin
e.e
ngi
nemodel)

-1
6-
 1
. ENGINE

1
.2 INSPECTIONANDADJUSTMENT
ti
I snec
essar
yt oi
nsp
ectandad
jut，
s i
fne
cessa
ry，
theeng
ineatper
iodici
nte
rva
lstokeepi
tingood
o
perat
ingcon
diti
on.Theproc
edu
refori
nsp
ect
ingandad
justi
ngth
ee ng
ineisexp
lai
nedonpagesth
at
f
oll
ow.

1
.2.
1 AIRCLEANER
(
1) Removet heai
rcleanerelement
.
(
2)I ns
pecttheelementforconta
minat
io nanddamage.
Ifelem
entisdirt
y，cleani
tbyblowingl ow-p
r e
ssu
reai
rfromins
idet
oou
tsi
de.
Ifth
ee lem
entisdamagedo rclogged，rep
lacei
twithanewon
e.
(
3)C leanthefi
lt
ercover
.

ELEMENT
lvu
t

e
n

n
v

門司
H

BODY

F
ig.1
.17A
irC
lea
ner

A Becare
f
凶山f
l
削u
dn0
刷
叫 ω
ttotO l 叫 伽 ml
削 削 uf
日
:
f
削fl
era凶
nd叫仙l
au 削剖附
E

i
srunningandf
お oraw
hil
eaf
teri
tisshutぱ
0f
f;o
the
rwi
seyoumightburnyourhand.

-1
7-
1
. ENGINE

1.2.
2 FUELFILTER
.Di 州 E ngineModel ~lR
(1
) Removeadamagedo rclogge
dfil
te
ru s
ingasui
tabeI
l
fil
te
rw r
ench.
(
2).Applyfuelonthepa
ckingofanewf i
lt
erandi
， ns
tal
l
thefi
lt
er
.A ft
erthepac
kingcont
actsthef
ilt
erbody，
CARTRIDGE
giveanothe
r2 /
3ofat u
rn. (FILTER)

“
Q"-RING

。
A
ト
c
mm
ce
Km
07
Na
DMい

e
a
O
F
ig.1
.18

• GasolineEngineModel
(1) Removeadamagedo rc l
oggedfi
lteraccord
ingto
thefoll
owingpr
ocedur
e.LoosentheOUTs id
ehose
bandtoremovethehose
.Removet heINs i
denip
ple
andremovet h
el oc
kb o
ltfromthefilt
er
.
(2)C leantheINsidenip
plescre
w.Bindt h
es cre
wwith
as e
altapeandins
tal
litinthefi
lt
er
.
FILTER
ASSEMBLY

グ “
IN"NIPPLE

F
ig.1
.19

幽 1
8-
 1
. ENGINE

1.
23 OILFILTER
冨

圃Dies
e lEngineModel
(
1) Us in
gas ui
tabl
efilt
erwrench，removeth
efil
te
r.
(
2) Applyo i
latthepackingofanewf il
te
randins
tal
l
thefil
te
r.Afte
rt h
epackingtouchestheb
ase，gi
ve
thefil
teran
other2/3ofaturn
.

F
ig.1
.20

• GasolineEngineModel
(1) Us i
ngas ui
tab
lefil
terwrench，removeth
efil
te
r.
(2) Applyo i
latthepackingofanewf il
te
randins
tal
l
thefi
lte
r.Giveth
ef i
lte
ra n
othe
r2 /3ofatur
nafte
r
i
tt ouc
hesthebas
e. FILTER
CARTRIDGE

VALVE

F
ig .21
.1

-1
9-
1
. ENGINE

1.2.
4 COOL lNGSYSTEM
(1
) Checkingc ooli
ngliqu
id
Checkt h
ec oo
lingli
qui
dl e
velintheres
ervetan
k.If
CA
th
el e
velisbelowtheLOWmark， addc o
olingliq
uidof
30% c o
ncentra
tion(50% incold-w
eatherregi
ons)to
br
inglevel
:
Upt otheFULLmarkwhent heengineiswarm. F
Ul
l
2/3ofthecapaci
tywhent h
ee n
gineiscold
.
⑨
匝問削岬酬
(
2) Changingc oolingl iq
uid 1
:
J:
I
1:
I
1t
J
:IU
J
J
① Shuto fftheengineandw aitformoret ha n30
ロunutes.
② Removet h
er a
diatorcapandl oosenthedraincock l
OW
attheradiat
orside.
③ Loosent hedraincocka tthee nginesidetod rain
offthecoolingliqu
id.
④ T ightenthedraincocksatbotht h
er ad
iatorandt h
e
engineside
s. F
ig.1
.22 R
ese
rveTank
⑤ Addc oolingliqui
do f30% c oncent
ration(50%i n.
cold-weat
herr e
gions)intotheradi
ator
.Ther a
teof
addi
tions hou
ldbel e
ssthan2l iter
s/mi
n.
⑥ A fteraddingc oolingliqud，
i st
artthee n
g ineand
le
titruna tidlerpmf oroneo rtwom inu t
esand
checkt h
ec oolingliqui
dl e
vel.Ifthelevelislow ，
addc ool
ingl i
quidoft h
esamec oncen
trationused
instep⑤，a srequired
.
⑦ Tightent h
er adiatorcaps ecur
ely.Addc oo li
ng
liq
uidtob rin
gl eve
lupt o2/3oft hecapacit
y.

DRAINCOCK DRAINCOCK

D
ies
elEnQine GasolineEnQine

F
ig.1
.23 DrainCock

-20-
 1
. ENGINE

(
3) Adjustingfanbeltt e
nsi
on
① Loosent hege
ner
a t
o r自tt
in ts園 and固
gbo1 .
② Movet h
eg en
era
t orawayf r
orntheenginet
oadju
stth
ebeltten
sion，sot
hatthefanb
elthasa
def
1ectionof10rnrnat囚 onthespanwhenpres
sedbyafi
ngerp
ress
u r
eofabou
t9 .
8N {10kgf
}.
③ T ightenthe自社ingboltsa
:
Jandthen固.

.
，
.，
--
---ーー--、‘、

D
ies
elEnQine GasolineEngine

F
ig.1
.24 A
dju
sti
ngFanB
eltT
ens
ion

閉 2
1-
1
. ENGINE

NOTE

-22-
 2
. CLUTCHSYSTEM

2
. CLUTCHSYSTEM
Type Wet，s
ing
le-
plat
ety
pe
Operation Fo
ot-p
edaltyp
e
Facingsize
Out
e rdiamet
er 300mm
I
nnerd ia
meter 190mm
T
hic kn
ess 7.8土 0.
3m m
S
urfacea r
ea( o
nesid
e) 423cm2
Clutchcoverweight 17kg

2
.1 GENERALDESCRIPTION
Theclut
chsyste
mc on
sistsofac
lut
chcov
erassembly，aclu
tchdik，ar
s el
easecy
lin
der，acl
utch
b
ooste
r，andcl
utc
hp ed
ala s
sembl
y.Itt
urn
sonandoffthepowerfromthee
nginet
othetr
ansm
iss
ion
.

2
.1.1 CLUTCHHOUSING
Theclutchhousingcons
istsofashif
tblok，
c yoke r
ラ e
lea
sebear
ingandsh
iftarmassem
bly.
Theclutchiss p
linedtot h
eshiftarmshat，witht
f heY-bendmeshedwiththepinont h
eoute
r
p
eripher
yo ftheshi
ftblock.
Theshi
ftb l
ockhast herel
easeb
earinga
ttachedandit
soute
rringi
sincon
tactwitht
hec l
utc
hcov
er
r
eleas
eleve
r.
Theclut
chd is
kisl u
bric
atedwithoi
lwhichispickedupfromthec
lutc
hhousin
gands pra
yedbyt
he
n
ozzle
.

¥ノ-

圃 23-
2
. CLUTCHSYSTEM

1
.CLUTCHCASE
2
.CLUTCHCOVER
3
.CLUTCHDISK
4.THRUSTBEARING
5
.MAINDRIVESHAFT
6
.RETAINER
7.LOCKPIN
8
.SPRAYNOZZLE
9.SNAPRING
1
0.PLATE
1.BUSHING
1
1
2.YOKE
1
3.SNAPRING
1
4.BUSHING
1
5.OILSEAL
1
6.ARM

F
ig.2
.1C
lut
chHousing

-24-
 2
. CLUTCHSYSTEM

2.
1.2 CLUTCHCOVER
Asshowni nFi.2
g .2，theclu
tchcoverco
nsist
sofapres
sureplae，ar
t ele
asel
eve，acoveranda
r
p
ressu
respnng.
Thepres
sureplateisforce
da gai
nstthefly
wheelbyt
hep r
essur
es p
rin
g. Astherel
eas
eleveri
s
p
ressedt
ot h
ef l
ywheels i
de，t
hep r
essur
epla
teispull
edt
othec o
versid
e.

PRESSURE
SPRING

←固

RELEASE
LEVER

PRESSUREPLATE

S
ect
ion
a f囚岨
lviewo

Viewl
ook
ingfrom閣

F
ig.2
.2 C
lut
chCover

帽 25-
2
. CLUTCHSYSTEM

2.
1.3 CLUTCHDISK
Asshowni nFig.2.3，t
heclut
chdiskco
nsi
stsofas
pliehub，ac
n lutchp
lae，ar
t e
t a
inin
gp l
ateand
t
orsio
ns pr
ing
s.
Thec l
utchpla
teh a
st h
edrivepl
ate，b
othside
sofwhicha
recover
edwIthfa
cing，mountedwith
r
ive
ts. Thedriv
ep l
ateisali
tt
lewar
ped.

TORSIONSPRING

CLUTCHPLAT
RETAININGPLATE

TORSIONSPRING

DRIVEP上ATE

町
白ω
則
陶g
肘
肺
1…
問
馴
吋
抑
9叩
i
r
川n
山
1
旧e

F
ig.2
.3C
lut
chDisk

-26-
 2
. CLUTCHSYSTEM

2.
1.4 CLUTCHPEDAL
AsshowninFi
g.2.4
，t heclu
tchped
al，asse
mbledonthesamebra
cketasthe?
lra
kepeda
l，conv
ert
s
p
edaleff
ortt
ooi
lp r
essue，
r t
husope
ratin
gtherel
easecyl
ihd
er.
Abrakebo
ost
er，aclutc
hb oo
ster
，arelea
secyl
inderandapeda
laremountedtotheb
racke
t.

BRAKEBOOSTER

CLUTCH
BOOSTER

/
l
'
h ご
.
t
.
::
:
:
:
::
:
.
-
._ ，/

Jコご》ごと
パ
パ
lil--
ハ円
﹂ 1111﹁ll
υ-ハヤザ

CLUTCHRELEASE
斗ノ

CYL
lNDER

F
ig.
2.4C
lut
chandBrakeP
eda
l

-27-
2
. CLUTCHSYSTEM

(1
) Clutchb ooster
Asshowni nFig.2.5，thec lut
chb oosterconsist
sofac o
ntrolvalvewhichc on
v e
rtsp e
dalefforttooil
pres
sure，amasterc yli
nde randaf 10wd ivid
er.I tuti
lizestheoi
lp ress
ur eforthel oadhandl
ings ystem.
Thep eda
lmovementi stransmittedthr oughthepushr odtot hereac
t ionpistoninthecontrolv ale，
v
thu
sn arrowingthea ra囚
e .Asaresu ，t
1t heo ilpressu
rei nthearea国 r ises，producingforcetomove
th
epowerp is
tont otheleft. Whent hepowerp istonmovest ot hele
ft， thearea囚 opens， andt heoil
pres
sureint hearea固 s t opsrising，thuss toppingthemovementoft hepowerp isto
n.I ns hort，the
movementd ista
n c
eoft h
epushr odandt ha
toft hepowerp is
tona rethes ame.
Themovemento f
t hepowerp i
s to
np ressesthemasterc yl
inderpiston，raisin
gt heoi
lp r
essurei nthe
re
leasecylind
er;
Partofthepressureint hea r
eaa:Jworksascounterforcet ot hereact
i onpiston，andistransm
i ttedto
th
eo per
atorandr ecogniz edaso p
e rat
ingf ee.
l
Thec lu
tchb oosterworksa sar egularma stercylinderevenwhent heo ilpressureiszero，though
gr
eaterpedaleff
ortisr equired
.T h ere
fore， i
ti shardtoo p
eratethec l
ut chwhent hee ngin
eiss topped.
Whenyous to
pt heen gine，makes ur
et op l
ac ethetransmissio
ni nthen eutra
lp os
ition
.

ー
-
.
，
毘 ~=J O

1
.BODY 6.STOPPER 1
1. SEAT
2
.CUP 7.PLUG 1
2.REACTIONPISTON
3
.FLOWDIVIDER 8.PISTON 1
3.PUSHROD
4
. SPRING 9.POWERPISTON
5
.CHECKVALVE 1
0.CONTROLVALVE

F
ig.2
.5C
lut
chB
oos
ter

-28-
 2
. CLUTCHSYSTEM

2.
1.5 RELEASECYL lNDER
Fig
ure2 .
6showsas e
cti
onalviewofth
erel
eas
ec y
lin
de.I
r tisi
nstal
ledonthele
ftsid
eofthe
t
ransml
sslOncas
e.
Th
isc y
linde
rc o
nsi
stsofapist
on，asp
rin
gandapushrod，andt
hepis
tonmovementist
ransm
itt
ed
t
hroughthepushrodtothesh
iftar
m.
①

② ③ ④ ⑤ ⑥ ⑦ ⑨ ⑨ ⑩

1
.BLEEDER 6.CYLINDER
2
.SPRING 7.PUSHROD
3
.CUP 8.BOOT
4
.PACKING 9.LOCKNUT
5
.PISTON 1
0.CLEVIS

F
ig.2
.6R
ele
aseC
yli
nde
r

-29-
2
. CLUTCHSYSTEM

2.1
.6 OILCLUTCHHYDRAUL lC CIRCUIT
Whent heengi
nes t
ars，
t thepumpmountedt otheengin
eg e
arca s
esendsunderpres
suretheoi
lfrom
t
hec l
utchhousin
gt otheoi
lc ool
erintherad
iato
r.
Aft
erb e
ingcooledint h
eo i
lcoole，
rtheoi
le n
terstheclu
tchhousing，pa
ssingthroughthefi
lt
er
.
Theclutchhousi
n ghasar e
gulat
orvalveintheoilin
letp
ort. Theoili
sp r
essu
re-regul
atedbythi
s
r
egula
torvalveandlubri
catesandcool
stheclutchpl
ateandthenretumstothelowerpar
toft h
ec l
utc
h
h
ousing.

RADIATOR

PUMP

-
::
:3
:エ
タと
ミ
~
弓〆0'
o 宅ヂ

、
、、

F
ig.
2.7C
lut
chH
ydr
aul
icC
irc
uit

-30-
 3
. CLUTCHTYPEDRIVEUNIT

3
. CLUTCHTYPEDRIVEUNIT
¥
¥¥_
__ Truckmodel
FD35c9，
FD40C9，
FD45c9
I
tem ----¥
Type 43C-25
Speedrange Twog
ear
seachforfwdandr
ev
Reduct
ionrati
o
Fwd 1
st 6.2
24
Fwd 2nd 2 .
993
Rev 1
st 6.
425
Rev 2nd 3.
089
Weight 350kg
Q' t
yofoi
ltobeus
ed T
ran
smi
ssi
on:Gearo
il1
7li
tter
s C l
utc
hsi
de:ATFo
il1
2li
te
rs

3
.1 GENERALDESCRIPTION
Thec
1ut
cht
yped
riv
eun
itc
ons
ist
sofasynchromesht
ypet
ran
smi
ssi
onandad
iff
ere
nti
alu
nit
.

3.1
.1 TRANSMISSION
Thet r
ansmi
ssioncons
istspri
mar
ilyofamains ha
ft，anou
tputgearandaninputsh
afte
ラ a
chsha
ft
havin
gg e
arsofvaryin
gs i
zes
. Thegear
sareshi
fte
dw it
htheaidof
theslidi
ngsle
evesin
sta
lle
donthe
mainshaf
tbyo per
ationofthesh
i武 ar
ms. Thepowerfromtheou
tputgearist
ransm
itte
dthroug
hthe
di
ffer
ent
ialtothedri
veaxle.

-3
1-
3
. CLUTCHTYPEDRIVEUNIT

BREATHER DIPSTICK

INPUTSHAFT

RETAINER

MAINDRIVESHAFT

CAP

MAINSHAFT

SNAPRING

OUTPUTGEAR

F
ig.3
.1C
lut
chTypeT
ran
smi
ssi
on

-32-
 3
. CLUTCHTYPEDRIVEUNIT

(
1) Inputsba
ft
Theinpu
tshaftcon
sis
tsofapairofg
ear
sp r
ovidedonthes
haf
tandacoun
tergea
rmountedont
he
s
haft
.S eeFigu
re3 .
2.
Thespli
neinsid
ethesha
ftmesheswi
ththespl
ineofth
emaindri
vesh
aftofth
eclut
ch.

BALLBEARING

SNAPRING

SNAPRING

CAP

THRUSTWASHER

F
ig.3
.2I
npu
tSh
aft

-3
3-
3
. CLUTCHTYPEDRIVEUNIT

(
2) Mains ha
ft
Themainshaf
tcons
ist
soffo
urg e
arsass
embl
edonth
eshaf
tandtwosy
nch
ron
ize
rs.SeeFigu
re3.
3.
Eachgea
rismountedtot
hesha
ftthro
ughne
edleb
ear
ins，
g andth
esyn
chro
niz
ersar
emountedtot
he
c
lutchhu
b.

NEEDLEBEARING NEEDLEBEARING

WASHER

SNAPRING
SNAPRING

BALLBEARING

THRUSTWASHER NEEDLEBEARING THRUSTWASHER

INSERT

BLOCKRING

SPRING

SNAPRING
SPRING

CLUTCHHUB

D
eta
i farea囚
lo

F
ig.
3.3 乱1
ainS
haf
t

-34 司
 3
. CLUTCHTYPEDRIVEUNIT

• Synchronizer
Thes ynchroni
zersync
hroni
zesgea
rswhicha
reabou
ttomeshbylett
ingth
eb l
ockr
ingcomei
n
conta
ctw iththetap
ere
dflan
kso f
thege
ar.I
s tsc
ons
tru
ctio
nisshowni
nFig.3.
4.

1
.GEARTEETHOFBLOCK
RING②
2.BLOCKRING
3.DOGTEETHOFGEAR⑨
4.SYNCHRONIZINGCONE
5.SLEEVE
6.SPLINESOFSLEEVE⑤
7.INSERT
8.CLUTCHHUB
9.CONSTANT-MESHGEAR
1
1.TEETHOFGEAR⑨
1
2.CONSTANT-MESHGEAR
1
3.TEETHOFGEAR⑫
1
4.RINGSPRING

F
ig.3.
4 S
ync
hro
niz
er

Thesynchromeshmechanismconsi
stsp r
imarilyof
:( 1)synchroni
zingcone，(2)b l
ockr ingand( 3)
I
nse
rt.
(
1)SynchronizingCone: Thismeshesw iththegear⑨ t hro
ughs p
lins，
e andh asamalec on efrict
ion
surf
aceandt h
edogt e
eth③ whicha reengagedw iththesleevesplines⑥.
(
2)BlockR ing: Thishasaf emaleconef r
ictio
ns ur
facewhichist h
em atingsurfaceo fthe
male企i cti
ons u
rfaceoft h
es ynchronizi
ngcone④ ， andita lsoh a
st hree
notche
sa rrangedont hecircumferenc
et oposit
ionont heinde xposition
toge
therwiththesleevespline
s⑥ a swellastheg e
ar① t opresst h
eb lock
rin
gtot h
ec onefri
ctio
ns u
rfaceinaxia
ld i
rect
ionthroughthesleeves p
lines
⑥.
(
3)Inser
t: Thec ent
erp r
o j
ectionoft heinse
rtisf i
tte
di nthei n
nera n
nul argroove
provid
edint h
es pl
ines⑥ oft heslee
ve⑤ andf orcedagai
nstthei nnerside
oftheslee
vespline
s⑥ byt her in
gs p
ring⑭ sothataninit
ia
ll oadiscreated
toguidetheblockring② t othei n
dexposit
ion.

-35-
3
_ CLUTCHTYPEDRIVEUNIT

3.1
.2 TRANSMISSIONCONTROL
Thetra
nsmissi
onspeedrangeanddire
ctiona
res h
iftedbytwolev
ersshowninF
ig.3
.5.
Thele
versaremountedtot
het r
ansm
issionsh
iftleve
r，soth
atth
es le
eveoft
hemains
hafti
smoved
t
hroughth
es h
iftarmbyt h
eoperat
ionofthelev
ers.

SPEEDCHANGE
DIRECTIONAL LEVER
CHANGELEVER

SPEEDCHANGE
LEVER なと-~ロ==--==二~=---==--==--==--==--==--=
「 1II j
少 、 . / DIRECTIONAL
一 、 ， / CHANGELEVER

F
ig.3
.5T
ran
smi
ssi
onC
ont
rol

-36-
 3
. CLUTCHTYPEDRIVEUNIT

(1) Synchronizeroperation
Theo perat
ionoft hesynchromeshmechanismhast
hefol
lowi
ngs i
xstep
sfromt
hen
eut
ralpo
sit
ion
tothec omp
letionofm eshin
g.I ntheexpla
nati
ongive
nbelow，t
heg e
ar⑨ i
nFig
.3.
4isreg
ardeda
s
thegeartob esynchron
ized.

①F i
rststa
ge
Asthesh
iftarmismovedtothele
ftbyth
eshif
tlev
er，
b
oththesleeve⑤ andin
ser
t⑦ movet othele
ft
. When
t
heinset⑦ h
r asmovedbyt hedistan
ceXl，i
tl e
tsthe
b
lockring② movebyt hedist
anceX2.

F
ig.
3.6

② Seconds tage
Ast h
es lee
ve⑤ movesf urth
er，theproject
ionofthe z
ins
ert⑦ tr
iestorid
eont h
ea nn
ulargr o
o v
eoft hesle
eve
spli
nes⑥. T h
atf o
rcepress
estheb lockring② furt
her
towardthegea
r. Whent heprojec
tionoft heinse
rthas
ridd
enont h
ea n
nulargroo
veo f
theb l
o ckrig，
n thesle
eve
⑤ movesbyt hedistan
ceZ.

F
ig.
3.7

③ T h
irds t
age
Thef o
rceappl
iedth rou
ght h
ei n
set⑦ t
r ot h
eb loc
k
ri
ng② creat
esfri
cti
onf o
rceontheconefri
ctionsurf
ace
.
Asshowni nFigure3.8，th
isforceallow
st hen o
tchof
th
eb loc
kr i
ngtocomei nc on
tactwiththesidef a
ceo f z
th
ei n
sert
. (Thepositionoccupiedbyt hebl oc
kr in
g
te
eth① andsle
evespli
nes⑥ iscall
edanindexpositi
on.
)

F
ig.
3.8

-37-
3
. CLUTCHTYPEDRIVEUNIT

④ Fourthstage
Whent heblockr ig② i
n sbroughtintothe3rdstep
p
osit
ion，thes lee
ve⑤ s hif
tsbyac le
aranceZs othat
t
hechamfer⑮ oft h
et oo
thoft heblockring② comes
i
ntoconta
ctw i
t hthechamferoft h
es lee
ves p
lin
es⑥.
Atthistime，t heconet orqueTcnecessaryf or
s
ynchr
o n
izationiscreate
dont heconef r
ict
ionsurf
ace，
c
ausingprac
ticall
ys yn
chroniz
ation
.

F
ig.
3.9

①ーー命
⑤ F i帥 s tage
Whent herela
tives p
ee dofthesynchr
onize
dc ons
t a
nt
meshgear⑪ a ndthesleeve⑤ hasbecomezer
otoc o
mplete
sync
h r
o n
ization，t
hec onet o
rqueTcbecomesalsozero.
Att hi
st imeasT iissmallerthnTc，
a t
heblockring②
sh
ift
si nthepe
ラ

ri
pheraldir
e c
tiont
oa l
lowthesl
eevespl
i n
es
-
--，
i

τc=c
匝・ 4-
Ti= 。
⑥t opa s
sb etweentheteeth①.
Att hi
smoment ，thesynchron
izationi
scompleteds
ラ o
th
attheb lockrin
g② i sfreeofextemalfo
rceandbrought
in
toa nidlesta
te
. Thes leevespli
nes⑥ can，ac
cordingly， F
ig.
3.1
0
pas
sb etwe e
nt h
et ee
th① o ftheblockrin
g② f r
eel
y.

⑥ Sixthstag
e
Whent h
es ync
hronizat
ionhasbeencompleted，theslee
vespline
s⑥ p assacr
ossth
eb lo
ckrin
g②，
s
hift
ingbyac leara
nceYli ndic
atedinFi
gure3.9. Thus，thechamferofthesleev
espli
nes⑥ comes
i
ntocont
actwiththechamferofthedogtee
th③ o ft
h eger⑪. Witht
a hechamf
ersincont
actwi
the a
ch
ot
her，t
orqueTGa ct
sont hedogt e
eth③ t
op a
ssbetweent hesle
evesplin
es⑥ sothatt
hegear⑪ sh
ift
s
i
nt h
eperiphe
raldirec
tion
.T hisa ll
owsth
es le
eves pl
ine
s⑥ t opassbetweenthedogteet
h③ ofthe
ge
ar⑪，t ocompletemeshing.

Ti=O
・
e

F
ig.3
.11

-38-
 3
. CLUTCHTYPEDRIVEUNIT

(2
) Powerf low
[Inneutr
alpositi
on]
Thepowerfromt hemaindri
vesh
aftist
ran
smi
tte
dt ot
heh ig
hg e
arandlowg e
ar， whichar
ea l
way
s
meshingwiththeinp
utgea. But，s
r inceth
espeeds
hiftsle
eveandd i
rect
ion
alshiftsleev
eareinth
e
neu
tralpos
itin，
o themainsha
ftandoutp
utgea
rarenotro
tatedandthepowerisnott r
ansm
itte
dtothe
dif
fere
nti
a.
l

[Gearshi
ftin
g]
Whent hechangelev
erisshifted，theshif
tarmsmovet h
esleeve
st oall
owgear
stomeshw i
ththe
1u
c tchhubandt hemainsha
ft. Poweri st rans
mit
tedint
hef o
llowingor
der:Maindr
ivesh
aft，in
put
gea
r，highgearorlowg ear，synchronizer，mainsha
ft，s
ynchron
izer，re
versegea
rorforwardgea，
r
cou
ntergearoroutpu
tgear
.

PowerFlow
InForward1sts
peedgearp
osit
ion: @→⑤→④→@→⑭→③→⑫→⑪
InForward2ndspeedge
arposi
tion: ①→②→③→⑬→⑭→③→⑫→⑪
InReverse1s
tspeedge
arposi
tion
: ⑥→⑤→④→⑬→⑭→⑬→⑦→⑨→⑩→⑪
InReverse2ndspe
edgearpo
sitio
n: ①→②→③→⑬→⑭→⑮→b →⑨→⑩→⑪

叫J⑦~T凶⑫
円
。
T
⑪

OUT《

F
ig.3
.12 PowerFlow

-39-
3
. CLUTCHTYPEDRIVEUNIT

DIPSTICK

NEUTRALSWITCH

9
PUMPOIL
PRESSURE

@ Q
I Q
I Q
I Q
I

DRAINPLUG

在三事

DRAINPLUG

F
ig.3
.13O
ilP
res
sur
eCheckP
ort

-40-
 4
. TORQUECONVERTERTYPEDRIVEUNIT

4
. TORQUECONVERTERTYPEDRIVEUNIT
Torquec onver
ter

'
l

a
enb
v
p
a
e

e
e
e
e
m
n

p
は

d
、
ウム
1i

+t
司

A
3

4at

、
戸
"
ド
r
Type

3・
4EEA
Stal
lt or
queratio

J
Chargingoilpressure
(press
ureato u
tlet) 0.
49-0
.69MPa{
5-7kgf/cm2}
Chargingpump

p
uc

m
eqdc
ec
n

Mv
-

u
-

p
，
-
-
-
U
-
A

A
••

A且
Type

ゐ
EL

ラ唱

FIl
同
今ム

氏
Discharg
e

Ei
Transmission
Type P
owe
r-s
hit，
f c
ons
tantint
erm
esh
ingt
ype
Reductionrati
o(fwdf i
rs
tgear
) 3.443
(fwdsecon
dgear
) 2.259
(re
v) 2.905
h
d .ロ . 白 川 刀
CO
tF
l n n cbb
-
aF

d
m 問日民

m
、
n
σbσ
， a o u

c
日 amAd

・噌

d
F3F3

15
6m mx1 08m mx2 .6m m
a

ivi
A
aC

9947m m x 1
2
0
む旬
lH

‘
.
沼
，
山

0.98-1.18MPa{ 10-1 2kgf/cm2}

戸
t

L相
c

Torqueconv
ertero
ilSAE 存10W1 8liter
s

4
.1 GENERALDESCRIPTION
Thetorq
ueconve
rtertyp
edriveuni
tcons
ist
sofatorq
uec on
verte
r，apo
wer-s
hifttr
ans
missi
on，and
adif
fer
ent
i lI
a. tssect
ion
alviewsareshowninFig
.4.2to4.5
.
Thetra
nsmiss
ionhastwoforwar
ds pe
edsandoner
evers
es pee
d. Thespe
edr a
ngei
sauto
matic
ally
sw
itchedoverbytheATMc on
tro
lle
r.

-4
1-
4
. TORQUECONVERTERTYPEDRIVEUNIT

CHARGINGPUMP
TRANSMISSION
CONTROLVALVE

TORQUECONVERTER

FWD/REV
CLUTCHPACK

FWDSECONDGEAR
CLUTCHPACK

t
o

OUTPUTGEAR

COUNTERGEAR
STRAINER

F
ig.4
.1D
riv
eUn
it(
112
)

-42-
 4
. TORQUECONVERTERTYPEDRIVEUNIT

CAP
(WITHDIPSTICK)

REGULATORVALVE

SPEEDSENSOR

STRAINER

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

-43-
4
. TORQUECONVERTERTYPEDRIVEUNIT

4.1.1 TORQUECONVERTER
Thet orquec onverte
rc on
sistsp ri
marilyofapumpwheel， turb
inewheel， ands ta
torwheel.F igure
4.3showsi tsstruc
ture.
Ast hee ngi
n ei
ss tar
ted，thepumpwheelr otatestolettheoilinthec o
nverterhousingflowa longthe
van esoft hepumpwheelbyc e
ntrifugalforc
e. Theo i
li sthenthrowni ntot hevanesoft heturbine
wheelt ot ransmitt h
epowert ot h
et urbinewheel. Theo i
lt henflowsfromt heturbi
newheelt ot he
sta
t orwheelwherei t
sd i
rectioniscontroll
eds othattheoilflowsagaini n
tothepumpwheela tap roper
angle.
Ther eactiontorqueg en
erateda tthi
st imeisaddedt ot heturbinetorquetomaket h
eo utp
utt orq
u e
greaterthant heinputtorque.
Whent herotati
onals pee
do ft h
et urbi
newheni ncreas
ese ilou
ght oreachthei n
putrota
tionalspeed，
thechangei nf lowingangleoft heo i
ld ecreasesandt hust h
eo utputtorqueal s
omakess ma
ll e
r，and
fin
a llytheoilf lo
wsi nreverseinr el
ationtoth evanesoft hestato
rwheel.T hi srever
sesthed ir
ection
ofth ereactiontorque.
I fthi
si sthec ase，theoutputt orquebecomess mallerthant h
ei nputtorq
ue. Top reventthisfrom
happening，t hes t
atorwheeli sd esign
e dtorotate企e elytomakeb oththei n
putt orqu
eandt heo utp
u t
torquee qualfore nsuri
ngah i gh-performanceo p
eratio
n.
Asd escribedabove， thet orquetransmissionism echanicallysw it
chedo verandt husthi
st ypeof
torquec o
nverterisad oubleph asetypewhichf eature
ssmootho pe
rationands uperbpowertransmissi
o n
eff
i cie
ncy.
Thepumpwheeloft hetorqueconverterisco nnec
tedt hroughtheinputplat
et otheengineflywheel，
witht helatchoft hepumpwheelb ossengagedw iththed r
iveg ea
roft hec h
arg in
gpump.

TURBINEWHEEL

PUMPWHEEL

STATORWHEEL

ONE-WAYCLUTCH

INPUTPLATE

F
ig.4
.3 TorqueC
onv
ert
er

-44-
 4
. TORQUECONVERTERTYPEDRIVEUNIT

4.1.2 CLUTCHPACK
Thec lu
tchpackc on
sistspri
maril
yofclut
chdisk
s( s
eparat
orplat
esandf r
icti
onpla
te) ap
sラ istonand
anendp late. Thec1utchd is
kassemblyconsi
stingof5f ri
cti
onp l
atesand5s e
parat
orplatesis
inc
orporatedint
ot h
ec1utchdruma longw
ithapist
on. Betweenthepistonandthedrumisas e
alring
toensureoi
lt i
ghtne
ss.
Thec lu
tchdisksurfac
esandg ea
rb e
ari
ngsar
ec o
nstant
lyl u
bric
atedbyoiltoprev
enttheclu
tchdisk
sur
facesandb ear
ingsfroms ei
zin
g. Whenreplacem
ento fanyclutc
hd is
kisneeded，th
ee n
tir
ec lu
tch
dis
ka ssemblymustber epla
ced.

INNERDISK

THRUSTWASHER

/I
THRUSTWASHER

NEEDLEBEARING

SNAPRING

SPRING
ENDPLATE

F
ig.4.
4 Fwd/RevC
lut
chPack

-45-
4
. TORQUECONVERTERTYPEDRIVEUNIT

INNERDISK
OUTERDISK
SNAPRING

PISTON THRUSTWASHER

BEARING GEAR

BEARING

SEALRING
THRUSTWASHER

NEEDLEBEARING

SNAPRING

GEAR

ENDPLATE
SPRING

F
ig.4
.5 SecondGearC
lut
chPack

-46-
 4
. TORQUECONVERTERTYPEDRIVEUNIT

4.1.
3 TRANSMISSIONCONTROLVALVE
Thet ra
nsmissio
nc ontr
olvalvecon
sistsofs o
lenoidvalve
s，ani nc
hingspool，anaccumu
lato randa
modula
tionv al
ve.Itismountedont het rans
missioncase
.
Twos olenoidvalves，onef o
rdirec
t i
ons h
iftandt heotherf o
rs peedrangeshit，
f areinstall
edas
showninF ig
.4 .
6.
Thed i
recti
onshif
ts olen
oidvalvehasabuttonateachend s oth
ラati
tc anbeoperat
edmanuallywhen
th
ee le
ctri
cals yst
e mhast r
oubl
e. Thes olenoi
dv alveiskeptONw hileyoua repre
ssingab utto
n.
Whenyour e
leaseyourhandfromt hebutton，thesolen
oidvalv eisreturn
edtot h
eneutr
alp o
sitionby
sp
ringforce
.
Them odulat
ionv al
v eactu
ateswhent h
ec lu
tchesarechangedo ver，todela
yt hetim
ef o
rt heclut
ch
o
ilpressur
et oreachthemaximump r
essureslight
lyusingthea ccumul
ator.

SOLENOIDVALVE MANUALOPERATIONBUTTON
(f
orspeedranges
hif
t) (pressf
orFWD.)
SOLENOIDVALE
(f
ord
ire
cti
ons
hif
t)

REVCLUTCHOIL
PRESSURE
FWDSECOND
CLUTCHOIL
PRESSURE

FWDFIRST
CLUTCHOIL
PRESSURE

MANUALOPERATIONBUTTON
(Pressf
orBWD.)

INCHINGSPOOL
OILSEAL

PIN

SPRING

SPRING(INNER) SPRING
SPRING(OUTER)
SPRING(MIDDLE)

ACCUMULATORPISTON

INCHINGPISTON

SPRING MODULATIONVALVE

F
ig.4
.6T
ran
smi
ssi
onC
ont
rolV
alv
e

-47 田
4
. TORQUECONVERTERTYPEDRIVEUNIT

4.1.4 OILCIRCULATIONROUTE
Whent heengineisoff，eachv a
lveislocateda
sshowni nFigure4.7，byspri
n gfor
ce.
Whent hee ngin
ei sstartd，
e thec ha
rgingpumps up
pliesoilt othereg
ulato
rv alveinthet or
que
conv
e r
terh ous
i ngandt h
eo i
lp r
essureisregu
late
dt o0.98to1 .18MPabyt here gu
lato
rvalve.
Theo i
lr eliev
edfromt h
er eg
ulatorvalveissupp
liedtot hetorqueconv
erter，pass
ingt hr
o u
ghthe
conv
e r
terr e
liefvalve. Theoilp r
essureatthetorqueconverterinl
etiscontr
olledbyt heconvert
er
re
liefvalveto0.49t o0.69MPa.
Theo illeav
ingt hetorqueconver
teriscooleddownbyt heoi
lc oo
lerandclearedofforeignmat
ter
bythei n
linefil
teranditf10wst oeachparttocoolandl u
bricat
eb ef
oreretur
ningtot h
etransmiss
ion
ca
se.
Thec lutchoperatin
go i
lp ass
est hroug
ht h
ei n
chingspoolandi sblockedbyt hefwd/revsolen
oid
va
lve.

TORQUE
CONVERTER
OILCOOLER

I
NLlNEFILTER

CONVERTER
RELlEFVALVE
0.
49-0.69MPa

SELECTOR

l
己l
REGULATORVALVE
0.
98-1.18MPa
CHOKE 1
.2m m
SOLENOIDVALVE
(f
ord
ire
cti
ons
hif
t)

CHOKE 1
.7m m
CHARGINGPUMP

STRAINER

F
ig.4
.7T
ran
smi
ssi
onH
ydr
aul
icC
irc
uit

-48-
 4
. TORQUECONVERTERTYPEDRIVEUNIT

(
1) Forwardf irs
tgear
Whent heF/Rl everisplacedi ntheforwardpositi
on，thesoleno
i dvalve(fordirec
tions h
ift
)is
swit
chedovertot hef or
w a
rdp os
it i
ontoallowtheoi of
lt 10wi n
tothef or
w a
rdc lu
tchpackthr oug
ht h
e
ou
terperi
pheryo ftheselect
ors poo.
l Thespoolofthemodu
lationvalvemovest otheri
ghttolettheoi
l
f
10wi n
tothea c
c u
mula t
or.
Aslonga stheoilf10wsi nt
ot h
ea ccumu
lator，thecl
utchoilpr
essureincrea
sesg r
adu
ally. Oncet h
e
acc
umulatorisfil
ledw ithoi
lt h
ヲec lu
tchoi
lpressur
ei n
creas
esrapid
ly，thuslockinguptheclutchdisk
s
co
mplet
ely.

TORQUE
CONVERTER
OILCOOLER

CONVERTER 田
明+
RELlEFVALVE
0.
49-0.69MPa

SOLENOID
VALVE(forspeed
L
.
!.
J
ranges
hif
t)
ー
--
l砂

じl

REGULATORVALVE
O.98-1.18MPa
CHOKE 1.2mm

CHOKE 1
.7m m

CHARGINGPUMP

F
ig.
4.8 ForwardF
irs
tGear

-49-
4
. TORQUECONVERTERTYPEDRIVEUNIT

(2
) Forwardsecondgear
Whenthetruc
ks p
e e
dr ea
chesaspee
ds hi
ftpoit，
n th
es ol
enoidval
ve( f
orspeedranges
hif
t)ac
tuate
s
andth
esele
cto
rs p
ool(forspee
drangeshi
ft)movestotherig
ht，soth
剖 theoilflow
ingint
otheforw
ard
fi
rs
tgearcl
utchoftheclutc
hpackbeginstoflowint
ot h
ef orwa
rds eco
ndg ea
rclutc
h.
Theoi
lintheforwardfi
rs
tgearc
lutchisdrai
nedpass
ingt h
roughtheoute
rperiphe
ryofthes
ele
cto
r.

TORQUE
CONVERTER

CONVERTER 一
→
RELlEFVALVE
0.
49-0.69MPa

SOLENOID SELECTOR →
-
VALVE(forspeed
ranges
hif
t)
争園田

REGULATORVALV
0.
98-1.1
8MPa
CHOKE 1
.2m m

ー
-
i惨

F
ig.
4.8 ForwardSecondGear

-50-
 4
. TORQUECONVERTERTYPEDRIVEUNIT

(
3) Reversegear
Whent eFIRl
h e
veri
sp l
ace
dinth
er e
ver
seposi
tio
n，t
hesol
enoi
dvalve(fo
rdire
cti
onshif
t)i
sswit
che
d
o
vertotherev
ersepo
siti
ontoall
owth
eoi of
lt 10wint
other
ever
seclu
tch，andth
espoolofthem
odu
latio
n
v
alvemovestothelet
. Ther
f ema
ind
eroftheope
rati
oni
sthesameastho
s ei
nforwar
dg e
ar.
TORQUECONVERTER

NL
I lNEFIL
TER

CONVERTER ー
-l砂
RELlEFVALVE
0.
49-0.69MPa

u
REGULATOR
VALVE
0.98-1.18MPa CHOKE 1
.2m m

F
ig.
4.1
0 ReverseGear
4
.1.5 CHARGINGPUMP
Thecharg
ingpumpisani n
ter
nalgeartye，a
p ndbu
iltintheconv
ert
erhous
ing.Itsup
plie
so i
lu se
dto
l
ubri
cat
ethetorqu
econ
vert
er，th
ec1utc
hp a
cksan
dt h
etransm
issio
n.
Thecha
rgingpumpco
nsi
stsofadri
vegear，
adr
ivengea，
racaseandast
ato
rsupp
or，
tasshowninFig
.4.11
.
DISCHARGEPORT
t
oTORQUE
CONVERTER DRIVENGEAR

OILSEAL

DRIVE
GEAR
Oに RING
“ Tigh
ten
ingtor
que
SUCTIONPORT
目

42.3N-m{4
.3kg手m}

F
ig.4
.11 ChargingPump

-5
1-
4
. TORQUECONVERTERTYPEDRIVEUNIT

4.
1.6AUTOMATICTRANSMISSIONCONTROLLER
Thea ut
omatictransmi
ssioncont
roll
ers wi
tchesovert h
espeedra n
gesofthetransm
ission(for
ward
f
irs
tgear ←
→ forwa
rdsecondg ea
r).Itsextern
ala ppea
ranceisshowni nFig
.4.12.
Thetravel
ingspeedisdetect
edbyt hesenso
rmountedt ot h
etran
s m
issi
on. Whent h
es ens
ordetec
ts
atrav
elingspeedof7km/h，t heautomat
ict ransmi
ssionc o
ntro
llertur
nsont hesolenoi
dv al
ve( f
or
spe
edr an
geshift
)o fth
et ra
nsmiss
ioncontr
olv al
ve，toshif
ti n
tosec
o n
d. Whent h
et r
uckspeedfal
lsto
6km/ho rless，theautomatictrans
missioncontr
ollerturnsoffth
es olen
oidvalve(forspeedrange
s
hif
t)，toshi
ftdownt ofir
st.

Note: Thes pe
edshi
ftpointcanbechangedbyth
eswi
tch，s
ot h
atthesp
eedrang
ew i
llbeshi
ftedi
nto
secondwhenthetrave
lingsp
eedr ea
che
s9km/handtofir
stwhenthet
ravel
ingspe
edd r
opsto
7km/ho rle
ss. Thespeedrang
ecana l
sobeh
eldtofir
st
.

~&i摺
ATMCONTROLLER

O PART NO.
SERIAL NO.
135H2-60201
O
MADEI
NJA
PAN
135H2
-抱0
E 1
1

こ
強 ゐ

SOLENOIDVALVE
(
forspeedranges
hif
t) KEYSWITCH
FUSE

10A
¥1
コ
二二一 BATTERY
VF 7k
mJh SPEEDSHIFT
SF POINT
ADJUSTMENT I
SPEEDSENSOR SWITCH
+9 SR (Canb
ehel
d10 _
，_
1s
l)
I
N
SG
GND B・

F
ig.4
.12 AutomaticTransmissionController

-52-
 4
. TORQUECONVERTERTYPEDRIVEUNIT

Clulchoi
lpres
sure: 0.98-1.18MPa
Chargingpumpoilpres
sure: 0.98-1.18MPa
Torqueconv
erterin
lelpor
toi
lpr
ess
ur: 0.
e 49-0.69MPa

CHARGINGPUMPOILPRESSURE

CLUTCHOILPRESSURE(
F1)
CLUTCHOILPRESSURE(
F2)

CLUTCHOILPRESSURE(
R) TORQUECONVERTERINLET
PORTOILPRESSURE

SPEEDSENSOR

fromOILCOOLER

1
0OILCOOLER

F
ig.
4.1
3 O
ilP
res
sur
eCheckP
ort

-5
3-
4
. TORQUECONVERTERTYPEDRIVEUNIT

NOTE

-54-
 5
. DRIVEAXLE

5
. DRIVEAXLE
Type F
ul-f
l 1o
ati
ngt
ype
Wheel
S
ize 300-15-18PR(
1)
Tread.p
atte
rn J-LUG
Rim
S
ize 8.00V-15
Tir
einf
1atio
np r
essu
re 687kPa{ 7kgf/cm2}
Di
ffer
ent
ial
Name 43C-35
Reductio
nr a
tio 33
6. 3

5
.1 GENERALDESCRIPTION
Thed riv
ea xl
eh a
sac onstru
ctiona
sshowni nFig
s.5 .
1and5 .
2andismountedi nthefron
tareaof
theframe
.
Ithasawheelhubandawheelb rak
eatitseachspindl
eendandana xl
es h
aftrunningthrou
ghits
cen
ter.
Thewheelhubi sp r
ovidedwithabrakedrum，whichisins
tal
ledonth
es p
indlethroughtwotap
ered
ro
llerbear
ings.
Thetwot a
peredroll
erbearing
shaveoilsea
lstop r
eventgreas
eins
idefromo o
zi n
go utandwater
fromenterin
gt h
eb rak
eu n
it.

-55-
5
. DRIVEAXLE

Uses ea
lanton
matingsurfa
ce Seali
ngrease(240c
c)
(ApplyLoc
tit
e#503)

Tight
e n
ingtorq
ue: Tight
eni
ngto
rqu
e:
275-324N-m 471-549Nィn
{2800-3300k gf-cm} {4800-5600kgf
・cm}
(ApplyLoc
tit
e#270)
Tigh
ten
ingto
rque:
96-111N-m
{980-1130kgf-cm}

Tight
eni
ngto
rqu
e:
471-549N-m
{4800-5600kgf
・cm}

Tight
eni
ngtor
que
目

471-549N-m
{4800-5600kgf
-cm
}

1
. ADJUSTMENTNUT 5
. TAPEREDROLLERBEARING 9
. OILSEAL
2
. AXLESHAFT 6
.HUB 1
0. WHEELCYLINDER
3
. LOCKNUT 7
. BRAKEDRUM
4
. 01LSEAL 8
. TAPEREDROLLERBEARING

F
ig.
5.1D
riv
eAxle(
for3
.5-t
o4.
0-t
ont
ruc
ks)

-56-
 5
. DRIVEAXLE

Umμ

n
asL

ne#
田副W
e

MMum

&tgMh
、 nHEM

nupν
唱団
gy
，
汁 4A

)
qv
nu
Rd
けは
畠M
凶
叶

Tighten
ingtorq
ue: Tight
eni
ngto
rque:
275-324N-m 471-549N-m
{2800-3300kgf-cm} {4800-5600kgf-cm}
(ApplyLoc
tit
e#270)

Tight
eni
ngto
rque:
471-549N-m
{4800-5600kgf-cm}

t
、
T4'V

q
o
e sぃ
rn
n
、

uqv
qrfno
・ hHllnu
nRU
仏国一
Tm

-pu
ト1
45

﹁
0

}
k

m
一
nu

1
. LOCKNUT 5
. TAPEREDROLLERBEARING 9
. OILSEAL
2
. AXLESHAFT 6
. HUB 1
0. WHEELCYLINDER
3
. ADJUSTMENTNUT 7
.BRAKEDRUM
4
. OILSEAL 8
. TAPEREDROLLERBEARING

F
ig.
5.2D
riv
eAxle(
for4
.5・ t
o5.
0-t
ont
ruc
ks)

-5
7-
5
. DRIVEAXLE

5.1
.1 DIFFERENTIAL
Thed i
ffer
ent
ialisfitt
edtothecarr
ierthroughtaper
edroll
erbeari
ngswithbear
ingcapsandcove
red
withtheaxlehousi
n g. Thediffe
rentia
lc r
ossc as
eisas p
littypecont
ainingtwosidegear
sandf ou
r
pin
i o
ng ea
rs，withthrustwashersi n
stall
edbetweent hecros
sc as
eandeachg earaccordi
ngtothei
r
ba
cklash. Eachofth epinio
ng ear
siss upporte
dbyt hespide
r，whichissupport
edbyt hecro
sscas
e.
Ont h
eo u
terdiamet
e rofthecros
sc aseisaringgearbol
ted
.Eachs idegea
risspline
dtothedriv
eshaf
t
sothatthepowers entfromt hetransmissionthroughther e
ductiongearisfurth
erreducedand
d
iffere
ntia
tedbythisd evi
cetod r
ivet h
ed ri
veshaft
.

T
igh
ten
ingt
orq
ue:
217.7-325.6N-m
{2220-3320kgf-cm}

T
igh
ten
ingt
orq
ue:
392.3-441.
3N-m
{4000-4500kg
f・cm}
⑩
T
igh
ten
ingt
orq
ue:
95.1-142.
2N-m
{970-1450kgf
・cm}
Tight
eni
ngt o
rqu
e:
127.5-1 9
0.3N-m
{1300-1940kgf-cm} Tight
enin
gt o
rqu
e:
127.5-190.3N-m
{1300-1940kgf-cm}

1
. CAP 9
. BEARINGCAGE 17
. ADJUSTMENTNUT
2
. TAPEREDROLLERBEARING 1
0. TAPEREDROLLERBEARING 18
. CROSSCASE
3
. ROLLERBEARING 1. NUT
1 (FLANGEHALF)
4
. TAPEREDROLLERBEARING 1
2. DRIVEPINION 1. RINGGEAR
9
5
. “O"-RING 1
3. CARRIER 2
0. CROSSCASE
6
. SHIM 1
4. SPIDER (PLAINHALF)
7
. OILSEAL 1
5. PINIONGEAR
8
. SPACER 1
6. SIDEGEAR

F
ig.5
.3D
iff
ere
nti
al

:
.58-
 6
. BRAKESYSTEM

6
. BRAKESYSTEM

よ々竺空 FD35c9，FD35
FD40C9，
T， FG35
9
FD40T9，
T9
FG40T9
FD45c9，
FD50T9
FD45T9

Wh e
elbrake
Type Duo-
servo句rpe(
wit
hau
tom
ati
ccl
earan
cea司j
ust
er)
Wheelc y
lind
erbor
e 31.7
5m m ←
Brakedrumi n
nerd
ia. 314m m 31
7.5m m
Brakelini
ngsiz
e 3
48x76x7 .
67m m 330x63x1 0m m
Linin
gs u
rfae訂 e
c a 4x26450m m2
4x20800m m2
P
arkingbrake
Type F
ron
ttw
o-w
hee
lbr
aki
rtgi
nte
male
xpa
nsi
on，
mec
han
ica
lty
pe
B
rak ebo
oster
Type Hy
dra
ulict
ype
Oilpres
sure 6
.9MPa{70kgf/
cm2
}

Servora
tio 4
.5

6
.1 GENERALDESCRIPTION
Thebr
akesy
stemco
nsist
sofabra
kepeda
l，abra
keboos
ter，wheelbrak
esandb
rak
edr
ums
. The
b
rakebo
oste
rhelp
sth
ed r
ivert
oop
eratet
hebra
kebysl
igh
tp e
daleffo
rt.

6.1.
1 BRAKEPEDAL
Thebrakepedaluniti
sinsta
lledontheupperpartofthetran
smiss
iona sshowninFig
.6.1. The
pushro
dmountedt othebra
kep e
dalpre
ssestherea
ctionpis
tonofth
eb ra
keb o
oste，c
r on
verti
ngbrake
peda
leffo
rttooi
lp re
ssue，
r whichissen
tt oth
ewheelc yl
inde
r.
Thebrakepe
dals ha
ftislub
ricat
edwithgreas
etomakei tmovesmoothly
.

-59-
6
. BRAKESYSTEM

BRAKELAMPSWITCH

BRAKEPEDAL
(INCHING)

5
mm
Inc
hingpedalst
rok
e
bef
orethebrake
s
tartsfu
nctio
nin
g
Brakepedalp
lay
:25m m

S
eeF
ig.2
.6f
ort
ruc
ksw
ithc
lut
ch.

F
ig.
6.1 BrakeP
eda
l(f
ort
ruc
ksw
itht
orq
uec
onv
ert
er)

-60-
 6， BRAKESYSTEM

6.1
. 2 WHEELBRAKE
Thewheelb rake，a ninte
rnalexpansion，hyd
raulictypeconsis
t i
ngofb rakeshoes，as p
ring，awheel
cy
linder，ana djus
terandab ackingplate，i
smountedono pposi
tee ndso fthefron
ta x
le.
Theb ra keshoe， oneendofi tb eingconnectedtot h
eanchorp inandt heothertot h
ea dju
ster，is
for
ceda gainsttheba ckingplat
ew ithah oldspri
ngandp in.
Thep ar kingbrakel everismountedt ot h
ep rimaryshoeandt heactuatorleverofthea utom
at ic
ad
juster，tothes econdaryshoe.
Wheelb rakeoperationinf orwardtrave
lisasshowni nFig.6.2.O perationofthewheelc ylinder
p
ressest hepri m
aryands econdaryshoestot h
edrumw ithane qualfor
ce. Whent helini
ngcomesi n
c
ontactw iththeb r
ak edrum， t
hep rimaryshoepres
sesthea d
justeralongw i
th t
hel in
ing-to
-brak
edrum
f
rictio
nf orce. Asar esu
lt，thea dj
usterpressestheadjusterendoft hesecondaryshoewithf orce
g
reatert hanthatofferedbyo perationofthewheelc ylin
der，sot h
atthea nchorendoft hes econ
da ry
shoeiss t
ronglyp r
es sedagai
nstthea nchorpinandt hu
sp roducinglargebrakingforce
.
Inbackwardt rav
el， th
eb rakin
gf orceworksint herever
sed ire
ctionint h
ec aseoff or
wardt r
avel，
p
rod uci
n gthesameamounto fbrakingf o
rceasinf orwardtrav
el.( SeeFig.6.3.
)

ANCHORPIN
.
.
'
，，，
一
，・
，
e

，-'
.
'
.
"
，/

.
.
-
.1

.
"
"
・
‘
.
"
.
・
.

ADJUSTER

Fig.6，2 I
nForwardT
rav
el F
ig.
6.3I
nBackwardT
rav
el

欄 6
1
副
6
. BRAKESYSTEM

~ー囚 ⑥ S
ect
ion
alviewo
fwheelc
yli
nde
r

Theshoeexpands
i
nthi
sdire
ctio
n
S
ect
ion
alview同ー聞
4

S
ect
ion
alview岡」悶

1
.PUSHROD 6.WHEELCYLINDER 1
1.HOLD-DOWNPIN
2
.BOOT 7.RETURNSPRING 1
2.CUP
3
.PISTON 8.STRUT 1
3.SPRING
4
.PISTONCUP 9.BRAKESHOE 1
4.ADJUSTERLEVER
5
.CYLINDER 1
0.ADJUSTERCABLE 1
5.ADJUSTER

Fig.6.
4 WheelBrake(
for3
.5-t
o4-
tont
ruc
ks)

-62-
 6
. BRAKESYSTEM

① ② ③ ④

expands~l
Theshoe

4 i
十四
S
ect
ion
alview聞
-f
7i
l

S
ect
ion
alview聞
-I
Bl

1
.CYLINDER 6.STRUT 1
1.SPRING
2
.PISTONCUP 7.RETURNSPRING 1
2.SPRING
3
.PISTON 8.BRAKESHOE 1
3.ADmSTERLEVER
4
.BOOT 9.HOLD-DOWNPIN 1
4.ADJUSTER
5
.PUSHROD 1
0.CUP

F
ig.
6.5 WheelBrake(
for4
.5・ t
o5.
0-t
ont
ruc
ks)

-6
3-
6
. BRAKESYSTEM

6.
1.3 PARKINGBRAKE
Thepark
ingb r
akeunitco
nsi
stsofap ar
kingbrak
el ev
erandcab
les，
asshowninFig
.6.
6.I
tus
est
he
b
rakingshoesandbrakedrumofe achwheelbra
ke.
Thetogg
let y
peparkingbrak
el e
verisins
tall
edintheposi
tio
nshowni nF
ig.6.
6.
Torel
easethepark
ingb r
ake，ho
lddownt h
ereleas
eb ut
tonwh
ilepull
ingth
eleve
r.

RIGHT-SIDECABLE

F
ig.6
.6P
ark
ingBrakeLever

• Adjustingparkingbrakel everoper
atingforce
RELEASE
(1)P lacethepark
ingbrak
el e
verinth
erelea
sepos
itio
n. BUTTON
囚
(2)A djustthelev
ersotha
tithastheoper
atingp
ositi
on
asshowni nthesketchwhent hepoint固 ofthe 固

lev
erisp u
lledwithaforc
eof29.4to4 9
.0N {3-5
kgf
}.
Turnt hepoint囚 clockwis
et omaket hepull
ing
forcestrongerandcountercloc
kwiset om
.akeit
weaker.

F
ig.6
.7 Adjust
mentofPa
rki
ngBrake
LeverOpe
rati
ngFor
ce

-64-
 6
. BRAKESYSTEM

6.1.4AUTOMATICCLEARANCEADJU5TER
Thea utomaticclearanceadj
usterauto
matica
llyk ee
psal in
ing-to-d
rumcleara
n c
eo f0.25to0.4m m
fo
r3 .5
-t o4.0-to
nt ruc
ksandt h
atofO.4to0 .
6m mf or4.5・ t
o5 .
0-tontru
ck.I
s tactuat
eswhent hetruck
i
sb rakedinr eve
rset ra
vel
.
Whent hebrakei sapplie
di nrever
setravl，t
e hes ho
ess ta
rte xp
anding. Whent h
es econ
d a
rys ho
e
andthep ri
m aryshoecomei nc on
tactwiththebrakedrumt
ヲ heyrota
tetogeth
erwi ththedrumu n
tilth
e
topendoft hep rimaryshoecomesi ncontac
tw iththeanc h
orp i
n.
Ast hes econdarys hoepar
tsfromthea nchorp n，
i t
hea djust
erl e
verispulled，andthea dj
usteri
s
rot
atedbyt heleve
r.Ast heped
ale f
for
ti n
creas
esf u
rthe
r，thec ompress
ionforceappliedtotheadju
ste
r
incr
eases，thusexpan d
ingt h
er es
istan
ceinthes c
r eware
a. Thent headjus
tercannotb erota
tedbyt h
e
forc
eo ftheadjusterleve
r.

F
ig.
6.8 AutomaticC
lea
ran
ceA
dju
ste
r

-6
5-
6
. BRAKESYSTEM

6.1.5 BRAKEBOOSTER
Theb rakeboo
sterconsi
stsofac ontrolvalve，whicht u
rnsp ed
ale f
fortint
ooilp r
essue，
r amaster
cylinderandaf lowdivi
der，asshowni nFig.6.9.Itoperatesonpowers t
eeri
ngoilpres
sure.
Thep ed
almovementi stransm
ittedthroughthepushr odtothereacti
onp i
stoninthecont
rolv alv
e，
thusn arrowin
gt h
ea ra困
e . Asar esul
t，t h
eoilp re
ssureint h
ea rea園 increa
ses，produci
ngf orceto
movet hepowerp isto
ntot h
elef
t. Whent h
epowerp istonmovest othelef
t，thearea囚 opensandt he
ri
sei ntheoilpre
ssureinthearea園 stops，thu
ss toppi
ngt h
emovementoft hepowerp is
ton
.I nshor
t
ラ

theamountofmovementoft h
epushr odandt hatofthepowerpistona rethesame.
Themovemento f
thepowerp ist
onpressesthepistonofthemastercylinde
rtoraisetheoi
lp re
ssure
int h
ewheelc yli
nder
.
P a
rto fthepre
ssureinthearea園 worksa sco u
nterfor
cetot hereac
tionpisto
nandi stra
nsmittedto
theo p
eratorandrecognize
da sopera
tionf e
e.
l

二J 0

1
.BODY 6.PLUG 1
1.SEAT
2
.CUP 7.STOPPER 1
2.REACTIONPISTON
3
.FLOWDIVIDER 8.PISTON 1
3.PUSHROD
4
. SPRING 9.POWERPISTON
5
.CHECKVALVE 1
0.CONTROLVALVE

F
ig.6
.9 BrakeB
oos
ter

-66-
 7
. STEERINGSYSTEM(ORBITROLTYPE)

7
. STEERINGSYSTEM(ORBITROLTYPE)
S
tee
ringA
xle
:
T
ype: C
ent
er-
pinsup
ported，E
lliott
ypewit
hbox-
sha
ped
cr
osssec
tio
no fweldcons
tru
cti
on
KingP inSpacing: 1020m m
KingP inAngle: 00
Toe
- i
n: Omm
Camber: 10
Cas
t e
r: 00
Steeri
ngA ngl
e:
Inne
rWheel: 760
OuterWheel: 540
Orb
itrol:
Type: O
pen
-ce
nte
red，
non
-loadre
act
iont
ype
Disch
arge: 159c
c/r
ev.
Steeri
ngC yl
inder:
Type: D
oub
le-
actin
gpi
sto
nty
pe
Cylind
erB or
e: 90mm
Pis
tonRodD ia
mete
r: 60mm
Str
oke: 184mm
ValveUnit:(Incl
udecont
rolv
alv
e)
FlowR a
te: 22l
iter
s/m
in
Pres
sureSetti
ng: 1
0.8MPa{ 1
10kgf/cm2}

N
ote
:Fort
hes
emi
-in
teg
ralt
ypes
tee
rin
gsy
stm，
e r
efe
rtoC
hap
ter1
0.

7
.1 GENERALDESCRIPTION
Thestee
ringsys
temconsi
stspr
imar
ilyofasteeri
ngwheel，o
rbit
rol，fl
owregula
torvalve，a
n dst
eeri
ng
c
ylin
der.Whent h
es t
eeri
ngwheelisturn
ed，th
er o
tatio
nistran
smitte
dtot h
eo r
bitr
ol
.Theo ilpassa
ges
i
nt h
eo r
bit
rolarechangedovertodir
ectthehydrau
licpres
surefromt heflowregul
atorvalvetothe
s
teeri
ngcylin
derwhichextendso
rc o
ntra
ctsdependingonthehydrau
licpress
ure，ther
eb yste
eri
ngthe
t
ruck
.

-67-
7
. STEERINGSYSTEM(ORBITROLTYPE)

7
.1.1 5TEERINGAXLE
Thestee
ringaxl
eisofs te
el-weld
edc o
nstruc
tionwit
haboxshapedc rosssec
tion，i
ncorp
orati
nga
s
teer
ingcyli
nderins
idei
t.SeeF i
gure7.1
.Thes teer
ingc
ylin
derishousedinth
ea x
letopro
tecti
tfrom
b
eingdamagedbyo bsta
clesont heroa
ds ur
face
.Thea xl
eisinsta
lle
do nt
othetruck丘amet hr
ougha
c
enterpi
nw ithbq
shingandc ap，andi
tc ra
dlesaroundt
hiscen
terpin
.

Tight
eni
ngtor
que:
一一ー「
147-196N-m
{1500-2000kgf-cm}

2
.
Tight
eni
ngto
rque
:
232-348N-m
{2370-3550kgf
・cm}
rー
-一-
i
Tight
eni
ngto
rque
:
470-549N-m
・cm}
{4800-5600kgf

t
jjO t
l

J
f
f
F
il
lha
lft
hespacew
ithg
rea
se.

1
.CAP 7.LOCKNUT 1
3.OILSEAL
2
.BUSHING 8.LOCKWASHER 1
4.KINGPIN
3
.THRUSTBEARING 9.ADJUSTNUT 1
5.SHIM
4
.OILSEAL 1
0.HUB 1
6.NEEDLEBEARING
5
.TAPEREDROLLER 1
1.TAPEREDROLLER ]
7.KNUCKLE
BEARING BEARING ]
8.JOINT
6
.CAP 1
2.LOCKPIN

F
ig.7
.1 S
tee
rin
gAxle

-68-
 7
. STEERINGSYSTEM(ORBITROLTYPE)

(
1) Knuckleandkingp in
Thekingpinissecure
dtok nuck
lew ithaloc
kpinatit
sflan
kandt ot
heboss
esoftheaxleassemb
ly
withnee
dlebearin
gsatitstopandb otto
m.
Betweentheupperbossandthek nu
ckleisathr
ustbea
ringtole
ttheknu
cklerot
atearoundthekin
g
p
insmoothlyu n
derheavyl oa
d.
Theneedl
eandt hru
stbearing
sa relubr
ica
tedwithg
reasesup
pliedth
roughth
egreasefit
tin
gsatth
e
t
opandbottomoft hekingpin.

NGPIN

患
l
:
わ> r
> N
N
4
ト
、
‘
可
¥
、
恒l
恒
旺E
庄E
白由D
旺叩一、
旺
旺旧凹

F
ig.7
.2 Knuckle

(
2) Wheelhub
Thewheelhubi
sfi
tte
dtot
hes
pin
dleoft
hek
nuc
klew
ithtwot
ape
redr
oll
erb
ear
ing
sandp
rel
oad
ed
w
ithanut.

-69-
7
. STEERINGSYSTEM(ORBITROLTYPE)

7.1.2 5TEERINGWHEELA55EMBLY
Thes tee
ringwheelassemblyi
sa rra
ngedasshowni nFigu
re7.3
.Theo r
bitro
lisl o
cate
datthe
bottomofthea s
sembly
.Atthecen
terofthewheelist
hehornbutt
on.
Thes t
eerin
gs h
afti
sc o
nne
ctedtot
hed r
ivesh
aftoft
heorb
itro
landthes
tee
ringwheelcanbemoved
toac e
rta
inextentbackandfor
thtosu
itthedr
iver
'sphys
ique
.

LOCKLEVER

UNIVERSALJOINT

!
!//
/
よI '
(
下ll
1
1 _____

F
ig.
7.3S
tee
rin
gWheelAssembly

-70-
 7
. STEERINGSYSTEM(ORBITROLTYPE)

7.1.3 ORBITROL
Theo r
bitr
ols endsp r
essureoilfromt h
epumps ele
ctive
lytothepowerc ylin
der.Itcons
istsprim
arily
ofac o
ntrolvalveandam eteringd e
vice.Figure7.4showsac r
o s
ss ect
ionalviewoft heorbi
tro.
l
Thec on
trolv a
lveu sedi ntheorbi
trolisnotano rd
inaryspoolvalvewhoses p o
olmovesi ntheaxial
dir
ectin，
o butar ot
a ryvalvewhichc on
sistsofas le
eveandas poolthatrot
atetogethe
rf orm
ingdiffer
ent
oi
lp a
ssagest hro
ug hthec ombinatio
noft hei
ro i
lholes.Thev al
veh ousingisprovidedwithfourports
whichleadtothepump， tank，righ
ta ndle
ftchambersoft hecyli
nder.Betweent heinl
etportandr e
turn
por
tisac heckv al
ve.
.
Them eteringdevicec o
nsistsofa ninter
nallytoot
heds t
ato
randa nexte
rnallytoothe
dr o
tor
.D uring
normaloperati
on，ito p
eratesasano i
lm ot
or.I nanemergency，i
tc anb eusedasahandpump.Ther otor
i
sm ech
anicallyl inkedwiththes lee
vet hroughthedriveshaf
ts othatfeedbackoperatio
nispossib
le.
Thes leeveisint erl
ockedw iththem otor'
sr oto
rt hroughthecrossp i
nandd riv
es ha
ftw hil
et he
spoo
liss pli
nedtot hes t
eeringshaft
.

CHECKBALL
“
O"-RING

RETAINER
SLEEVE

S
ect
ionA-A

F
ig.7.
4 O
rbi
tro
l

-71-
7
. STEERINGSYSTEM(ORBITROLTYPE)

(1) Operationofo rbi

tr叫
(a
)I n“ N
e ut
r a
l"
Whilet hesteerin
gwheeli sins t
raig
htposition，the
oi
lfromt hepumpf l
owst hroug
ho i
lp assage① t ooil
groove②.Thes leevehas24o ilh ol
es③ whicha re
nowi nl in
ew iththeholes④ inthes poo
ls othattheoil
tha
tf l
o wedintogroove② p assesthroughoilholes③
and④ t ospace⑤ betweent hespoolandd rives h
aft
.
Thent heoilf lowsthroughspoolg r
oove⑥ ands leev
e
groove⑦ backt otheo i
lt a
nk.
S incecylinderport
s⑫ and⑫ a rerespec
tivelyopen
tooilholes⑬ and⑪ i nthes l
eevebutnottog roove⑬
nor⑬ i nt hespool，theoilinthec y
linderdoesn otgo
anyw here.
O ilpassage⑮ t hatl e
adstot hehydraul
ici noto
ris
opent oo i
lh ole⑭ i nthes l
eevewhichi suseda st h
e
inl
etando utletf o
rt heh y
draulicmotor ，butnott o
grooves⑬ n or⑬ int hespoolandt hu
st heoilremain
4 官
unmoved. ouT

F
ig.
7.5

(b) Whens teerin

gwheeli st urn
edc ount
erclockwise
官
Ast hesteerin
gwheeli stumedc ounte
rclockwie，
s th
e ー
groovesinthes poolshif
ttot h
el e
ftinrela
tionwiththe
holesandg roovesi nthesleevesot h
atholes④ i nthe
spoolgetouto flin
ew ithholes③ inthes l
eeve
.Theo i
l
tha
th asflowe dintogroove② t husfarb e
ginstoflow
int
oh ole⑫ i nthes leev
e，passingt h
roughg rooves⑫
and⑬ i nthespoolh ole⑭ inthes l
eeveandoilpassage
⑬i nt h
eh ousingt
ラ otheh yd
raulicmotor.
The hydraulic motor thus rotates i n the
countercl
ockwised ire
ctionandtheoildischarg
edfrom
4
thehydraulicmotorf lowst hr
ougho i
lh ole⑭ i nthe ー
sle
eve，glove⑬ i nthespoolando
ラ i
lhole⑬ int h
es lee
ve
tothec ylin
derp ortL andt husa ct
uatesthes tee
r i
ng
cyl
inder
.

• t
OU1

F
ig.7
.6

-72-
 7
. STEERINGSYSTEM(ORBITROLTYPE)

Ther e
turnin
goilfromthepowerc
ylin
de 1ows，
rf pass
ingthr
ought
hecyl
inde
rpo
rtR groove⑪ m
t
hev a
lveh o
using，o
ilhol
e⑪ inthesl
eee，
v gro
ove⑬ int
hesp
ool，o
ilh
ole⑫ int
hesl
eee，
v andg r
oov
e
③i nthevalvehou
s i
ng，backtoth
eoi
ltank
.

(c
) Whens teeri
ngwheeli sturnedc lockwise 官
Ast h
es teeringwheeli sturnedclockwise，t he ー
groove sinthes poolshi
fttother ig
hti nreactiontothe
oi
lh olesandg roovesinthes le
eves ot ha
to i
lh oles④
inthes poolgeto utofl i
new i
thh oles③ i nt h
es leev
e.
Theo ilthathasf10wedi nt
og roove② t husfarbeginsto
f
10wi nt
ooilhole⑫ i nthesleev
eandt h enf
10wst hr
ough
grooves⑫ and⑬ i nthespoolo
ラ ilh ole⑭ i nthes lee
ve
ando i
lp assage⑮ i nthevalvehousingt otheh ydrau
lic
motor.Theh ydraulicmotorthusrotat
esi ntheclo ck
wise
dir
ectionandt heoildisch
argedfromt hehydraulicmotor
f
10wst hroug
ho ilhole⑭ int h
es leee，
v groove⑮ i nthe
spool，ando i
lh ole⑪ i nthesleevetot hec y
linderp o
rt
Ri ntheh ousingandt husactuate
st hepowerc ylind
er.
Ther eturn
i ngoilfromt hepowerc ylinderf1ows，
passingt hrought hecylinde
rp otL，groove⑩ i
r nthe
housing，oilhole⑬ i nth
es le
eve，groove⑬ i nthes po
ヲol
oi
lh ole⑫ i nt hes l
eeveandgroove⑨ i ntheh ousing
t
backt otheoilt an
k.
ー
F
ig.7
.7

(2
)R elationshipbetweenr otati
ngspeedando per
at ingforc
eo fsteerin
gwheel
Inprinc
ipe，
l theforc
er eq
uiredtoope
ratet
heorbi
trolisonlytheforcetochangeovert
hevalve， i
.e
.
th
ef orc
eofcompressingt hecenter
ingspr
ingor2.9N-m{ O.
3kgf-m}.Ino t
herwords，si
ncethereare
nomechanicalc o
n n
ectionsbetweenthest
eeri
ngwheelandt hetir
esando nlythespr
ingcompressing
for
ceisr e
quired，cons
tantsteer
ingforcei
skeptevenati ncr
easedrotat
iona
ls pe
ed.Thedischargeof
oi
ls u
pplied合 omt herot
oroft h
eo r
bit
roltot
hecylinderi
s277cm/ 3
r
evol
ution
.

(
3) Neutralfeedbackofo r
bit
r叫
Theneutr
alf ee
dbackoftheorb
itr
olisperformedbyc han
ging-ove
ri no
ilpass
agesofthevalve，due
t
ot h
er ea
ction
sf orc
eofc e
nter
ingsprin
g.(Whent heste
eringwheelisturn
edandt h
enr e
leas
edw ith
t
hepumpa tret，t
s hesteeri
ngwheelr et
urnstot h
ei n
iti
alposit
ion.
)Unlesst h
eneutra
lfeedbacki s
c
ompletelyperformed，t
hestee
ringwheelmaybet urn
ed，eventhroughtheope
rato
rd oesnotturnthe
s
teeri
ngwheel.

-7
3-
7
. STEERINGSYSTEM(ORBITROLTYPE)

(
4)S
tee
rin
gwithd
efe
cti
vepump
Whent hepumpf a
ilstosupplyhydraul
i coiltheorb
itro
ls erv
esa sanemergencyhands t
eering
devi
ce.Whent heste
eringwheelist ur
ned， t
hes poo
lrotat
es.Whent urn
e dbyabout8，
0
t
hes poo
l
cont
actsthecro
sspin，whichrot
atesthedriveshaf
t，whichinturnrota
testhero
tor
.Thusth emeterin
g
deviceser
v esasahandpumpt os u
pplyoilt othecyli
nder
.I nthiscasethecheckval
v ep rovi
ded
betweentheretu
rnportandthesuctionportopens，sothato
ilf10wsfromt hecyli
nde
rtot hesuctio
n
sie，
d ther
eb yef
fect
inganemergencys t
eeri
ng.

7.
1.4 POWERCYL lNDER
Thepowercyl
inderisin
stal
ledintheste
eri
ngaxleandisoper
atedbyoilfromtheorbi
trol
.The
c
ylind
erbodyissec
uredtotheaxlewit
hbothrodend
sc onn
ectedtot
hek n
ucklewit
hjoin
ts.
Thecyl
inde
rcaph asabushing，o
ilsel，andd
a u
sts e
al，bei
ngsecu
r e
dtot h
ecylind
erwithal o
ck
w
asher.
d
、
、
.
ζPL
，

-
0-
J

、
t
、ノ

-
0- -
0-

寸E 二二五
i
i
ll
(日
コ
」に二二Y

1
.WIPERSEAL .“
4 O九 RING 7
.CYLINDERCAP
2
.PACKING 5
.PACKING 8
.BACK-UPRING
3
.BUSHING 6
.CYLINDER 9
.ROD

F
ig.
7. ，
8 Powe
rCy
lin
der

-74-
 . HYDRAUL
8 lCSYSTEM

8
. HYDRAULICSYSTEM

よ
廼竺!
:! FD35c9 FD40C9
FD35T9 FD40T9
FG35T9 FG40T9
FD45c9 FD45T9
FD50T9
Mainp urnp
Type GearType
Modeln arne SD3227F2Hl SD3232F2Hl ←-
D rive Cra
nkshaftPTO
D ischarge(No.l) 32.5cc/rev 32.
5c c
/rev ←-
D ischarge(No.2) 27.4cc/rev 32.
5c c
/rev 一←
Controlvalve
Type 2・spo
olslidi
ngtyp
ew ithrel
iefva
lve，f
10wd
ivi
derandtil
t-l
ock
Modeln arne KVS-120-2-VPF
P re
s s
ures e
ttin
g 1
7.7MPa{ 1
80k g
f/crn
2
}

Li
ftc yli
nder
Type Sin
g l
e-actingpist
on ←- ←
-
C ylind
erb ore 65rnrn 71rnr
n
Rodd ia
rnete
r 50rnrn ←- ←
-
S troke 1495rnrn ←- ←
-
T
iltc yli
nder
Type D
ouble-actingpiston ←- 一←
Cyl inde
rb ore 90rnrn ←- ←
-
Rodd ia
rnete
r 45m rn ←- ←
-
S tr
o k
e 1 9
9r nr
n ←- ←
-
Oi
lt ank
C ap
a cit
y 60l i
ter
s ←- ←
-

8
.1 GENERALDESCRIPTION
Thehyd
rauli
cs y
ste
rnc
onsi
stsofarna
inpur
np，aco
ntro
lva
lve，l
if
tcy
lin
der
sandt
i
ltc
yli
nde
rs.The
o
ilissu
pplie
df r
ornth
etanka
ttherig
htsid
eofthef
rar
ne.

8.
1.1 MAINPUMP
Therna
inp u
rn pisag ea
rt y
pedirec
tlydriv
enbyt heeng
in ePTOd eviceandpicksupoilf
rornt
heoi
l
tan
kands en
dst othec on
trolval
ve.
Thernai
np urnpc o
nsistsofap u
rnpbodyap
ラ airofgears，bushi
ngsandp acki
n g
s.T h
ispurnpuse
s
pr
essur
e-balancedbearingsandas peci
all u
bricat
ionmethodt ornini
rniz
et h
ec 1ear
anceofthegea
r
f
1ank
.Thep ress
u re
- b
alancedrne
thodistopressthepre
ssureplat
et owardthegea
rs id
ebyi n
trodu
cin
g
p
artofthedischarg
eo ilbetweenthepress
urep l
ateandthep u
rnpb od
y.

-7
5-
8
. HYDRAUL
lC SYSTEM

① ② ③ ④⑤ ⑦ ⑧ ⑨

.SNAPRING
1 8.BODY 1
5.SIDEPLATE
2
.OILSEAL 9.DRIVEGEAR 1
6.BUSHING
3
.FRONTCOVER 1
0.WASHER 1
7.DRIVENGEAR
4
.SIDEPLATE 1.BOLT
1 1
8.GASKET
5
.BODY 1
2.PLUG 1
9.GASKET
6
.DRIVEGEAR 1
3.REARCOVER
7
.ADAPTERPLATE 1
4.DRIVENGEAR

F
ig.8
.1 Pump

-7
6-
 . HYDRAUL
8 lC SYSTEM

8
.1.2 CONTROLVALVE
Theco
ntr
olva
lveco
nsis
tso
fani
nle
tse
cti
on，
twop
lun
gers
ect
ion
sandano
utl
ets
ect
ion，
whicha
re
a
ss e
mble
dwitht
hre
ebolt
s.

TILTPLUNGER
L
lFTPLUNGER
MAINREL
lEFVALVE

PSREL
lEFVALVE

T ，
2 T

TILT

lF
L T

P
F
C
irc
uitc
har
t

F
ig.8
.2C
ont
rolV
alv
e

-77-
8
. HYDRAUL
lC SYSTEM

(1
)I nle
ts e
ction
Asshowni nF
ig.8.3，thein
letsecti
onhasarel
iefva
lv
:ewhichregul
atest
hest
eeri
ngc i
rcu
itoi
l
pre
ssue，
r andaf lowd
ivid
erwhichdivi
destheo
ilf
lowfromthemainpumpint
otwol
ine
s:loadhan
dli
ng
andste
erin
g.
Theinle
ts e
ctiona
lsohasacartr
idgetyp
emainrel
iefval
vewhichse
tsthelo
adh
andlingci
rcu
itoi
l
pre
ssu
re.

同
-l・

t
oTANK

モ
ーー
fromPUMP

R
eli
efv a
lvemountingarea t
oeachSPOOLSECTION
(
main) ー

l
↓ユ
RETURNPORT

F
ig.8
.3l
nle
tSe
cti
on

ー 78-
 8
. HYDRAUL
lC SYSTEM

(2
)L if
ts poolsect
ion
Thelif
ts p
ools e
ctionh a
sac onstr
uctionshowni nFi.8.
g 4
，w iththespoolintheneu
tra
lp os
itio
n.
Whent hespoolispulledout，theoi
lflowf ror
nt h
ep a
rall
elf e
edertot h
en e
utra
lp as
sageisstopped，
th
usraisin
gtheoilpressureatthepar
alle
lf ee
der.
Sinc
et hehigh
-pressurepassageandthepassagetotheportA areconnected，th
eoilinthepar
all
e l
fe
ederpushesopent h
el oadcheckvalve，flowingint
ot h
ep o
rtA.
Whent hespooli
spushedi n，thepor
tA andt helow-pr
essurepassa
gea reconne
ctedtoallowtheoi
l
i
nt h
ep o
rtA toreturnthroughthelow-press
urep as
sagetothet a
nk.

LOADCHECKVALVE

HIGH-PRESSUREPASSAGE PARALLELFEEDER

NEUTRALPASSAGE
LOWPRESSUREPASSAGE
幽

F
ig.8
.4 S
poo
lSe
cti
on(
forl
if
t)

-79-
8
. HYDRAUL
lC SYSTEM

(
3)T iltspoolsection
Thetil
ts po
ols ec
tionhasac on
structio
nshowni nFi
g.8.5，withthespoolintheneutra
lposi
tion
.A
loc
kv alv
eisb u
iltint h
ep or
tBs ideofthes pol，s
o ot hepass
agetot h
ep or
tA d oesnotopenwhent he
pr
essureintheh ig
h-pressur
ep assageisl ow
.
Whent hes po
olisp ull
edo ut，theportA openstot hehig
h-pre
ssurepassagewhilet h
ep o
rtBopens
t
ot h
el ow-pre
ssurepassage.
Theo i
lint heparal
lelf ee
de rpushesopent h
el oadcheckvalveandf lowsintot h
eh ig
h-pre
ssure
pas
sage，andt heni n
tot heportA. Theo ilinthep o
rtB r e
tur
ns，p as
singt hro
ug hthelow-p
ressure
p
assage，intothelank.
Whent hes p
oolispushedi nt h
ラep o
rtBopenst othehigh-
pres
s u
rep assa
ge，thusenablin
gtheoilin
t
hep o
rtBt oflowi ntotheportB .
Sincethehole③ l eadstot heh i
gh-pressur
ep assa
g eandthehole⑧ t ot h
el ow-pr
essurepassa
ge，
t
hel o
ckv a
lvemovest ot hele
ft， s
ot h
eo i
lint h
ep or
tA f l
ows，pa凶 ngt hr
oughtheh oe⑥ andt
l hehole
⑧i ntothelow-pressurepassa
g e.

LOADCHECKVALVE

PARALLELFEEDER
HIGH-PRESSUREPASSAGE
PORTA

LOW-PRESSUREPASSAGE NEUTRALPASSAGE

F
ig.8
.5 S
poo
lSe
cti
on(
fort
il
t)

-8
0-
 8
. HYDRAUL
lC SYSTEM

圃Operationo fmainreli
efvalve
(
a) Theo i
li ntheh ig
h-pre
ssurepassageHPflows
throughtheoilholeinthepist
onCt oaff
ectt h
e
twoareas園 and園 whicharedif
fer
entind
iarne
ter，
sotha
tt hepoppe
tsD andK aresecur
elysea
ted.

F
ig.
8.6

(
b) Whent h
ep r
essur
einthehig
h.;.
pres
sur
epassag
eHP
re
achestheset
tingpr
essur
eoft hepil
otspr
ing，th
e
pi
lotpoppetE opens
.Theo ilp asse
saroundt h
e
popp
et，flowsthrou
ght h
ed r
ille
dh olet
othel o
w-
pr
essur
es id
eLP.

F
ig.8
.7

(
c) Asthepilo
tp o
ppetEisopened，thepre
ssurebehind
thepoppetD drop
s.Thep res
sure，ascornparedto
thepressureathigh-p
ressuresideHP ，becornes
unbalanced，causingthepoppetD t oopenand
ther
ebys e
ndingtheoi
ldire
ctlyt
ot helow-p
ressure
passag
eL P.

F
ig.
8.8

(
d) Whent hepres
sureinthehigh
-press
urepassag
eHP
i
sl owerthantha
tinthel ow-pr
essurepass
ageLP ，
th
ep oppetD opensduetot hedif
ferenc
ebetween
th
ea re
as囚 and[ B
J
， allowingenoughoilfror
nt h
e
low-pressu
repassageLPt ot heh ig
h-pressu
re
pass
ageHP.

F
ig.
8.9

-8
1-
8
. HYDRAUL
lC SYSTEM

8.
1.3 VALVECONTROLS
Thecontr
olv a
lveplun
gersa
reactu
atedwit
ht h
el e
versa
sshowninFi
g.8.1
0，eachle
vermounted
onasingl
es ha
ft
.
Theshaf
tsaresuppo
rtedbyb
rack
etswhichar
ea t
tache
dtoth
e仕ontgu
ard.Movementofeachlev
er
i
strans
mittedthrou
gharodtother
espe
ctivep
lunge
rs.

TILTLEVER

Tm
MO
TUV
訂正﹁l

叩四一，

一訂
一、

一司す
，

CONTROLVALVE

SPACER

S
ect
ion
a f囚
lviewo ・国

F
ig.8
.10V
alv
eCo
ntr
ols

-8
2-
 . HYDRAUL
8 lC SYSTEM

8.1.4LlFTCYL lNDER
Thelif
tc y
linderisasingle
-act
ingpistontyp
econsist
ingofacyl
inde
r，pi
stonrod，p
istonandcyl
inde
r
cap，andinsta
lledintheouterrnastfr
arn
e.
Thep ist
oniss ecure
dt othepisto
nr odwithas n
apr ig，w
n ithawearringandpackingonitsout
er
dia
rne
ter.
Att h
eb o
ttornofonec yli
nderisacut-off
valvewhichwilla
ctasasafe
tyd e
viceifth
eh ig
h-p
ressu
re
hoseconnectingtherigh
tandl ef
tc y
linders
burstsforanyrea
son.
Thec yli
nderc aphasab ushingandano ilsea
lp r
e s
sedtosuppo
rtthepistonro
dandp rovid
ed u
st
proof
nessforthec yl
inde
r.

• Cut-offv alveo pe
r at
i o
n
Whent heoi
li nthecylinde
rr e
turnsintotheoiltank，
i
tp assest hroughthehole圃 i nthepiston.
Iftheflowr ateoft heoilpassingth rou
ght hehose
holesisl es
sthant h
es e
ttingoftheflowr egu
latorvalve，
thep r
ess ur
ediffe
rent
ialacrossthepistonissrn
alle
rtha n
thes pringforcesothatthep is
tonwon'tr nove.
Ifitsflowr atebecornesg rea
terthant heflow
regulat
o rvalv
es et
tingduetoab ur
stofth ehigh
-press
ure
→10CONTROL
hoseo rf oranyo the
rr eason，thepressurediffer
enti
al II
亙 VALVE

acrosst hepis
tonb ecor
nesg re
aterthant hesprin
gf o
rce
torn ovethepistontotheright
.T heref
or e，t
heoilflows
outoft heh oe固 a
l lone，tolettheforksd ropslowl
y.
F
ig.8
.11 FlowR
ateS
rna
lle
rth
anS
ett
ing

→1
0CONTROL
VALVE

F
ig.8
.12 FlowR
ateG
rea
tert
hanS
ett
ing

-8
3-
8
. HYDRAUL
lC SYSTEM

Cylindersuppo同

1
.PISTONHEAD
2.SHIM
3
.WIPERSEAL
B 4
.“U"-RING
5
.BUSHING
g
6
.CYLINDERCAP
.“O九 RING
7
8
.CYLINDER
9
.PISTONROD
L
if
tbrackets
ide 1
0.PISTON
)
Q
1
1.LOCKRING
1
2.WEARRING
Masts
ide
1
3.PACKING
1
4.SPRING
1
5.CUTVALVE
1
6.SNAPRING
1
7.SHEAVE
1
8.CHAIN
1
9.ANCHORPIN
2
0.ADJUSTMENTNUT
2
1.LOCKNUT

F
ig.
8.1
3Li
ftC
yli
nde
r(V1ι43A)

国 8
4-
 8
. HYDRAUL
lC SYSTEM

C
yli
nde
rsuppo吋

1
.PISTONHEAD
2
.SHIM
g 3
.WIPERSEAL
.“
4 U"-RING
g
5
.BUSHING
6
.CYLINDERCAP
.“
7 O"-RING
8
.CYLINDER
L
if
tbr
ack
ets
ide
9
.PISTONROD
日
1
0.PISTON
Masts
ide 1
1.LOCKRING
1
2.WEARRING
1
3.PACKING
1
4.SPRING
1
5.CUTVALVE
1
6.SNAPRING
1
7.SHEAVE
18，CHAIN
1
9.ANCHORPIN
2
0.ADJUSTMENTNUT
2
1.LOCKNUT

F
ig.
8.1
4Li
ftC
yli
nde
r(V1ι43F)

-8
5-
8
. HYDRAUL
lC SYSTEM

C
yli
nde
rsupport

1
.PISTONHEAD
2
. SHIM
3
.WIPERSEAL
.“
4 U -RING
g
円

5
.BUSHING
9 6
.CYLINDERCAP
.“O"-RING
7
8
.CYLINDER
9
.PISTONROD
10
.PISTON
)
0
: L
iftbracket
s
id e 11
.LOCKRING
)
1
12
.WEARRING
Masts
ide
13
.PACKING
14
. SPRING
15
.CUTVALVE
16
. SNAPRING
17
. SHEAVE
18
.CHAIN
19
.ANCHORPIN
20
.ADJUSTMENTNUT
21
.LOCKNUT

F
ig.8
.15L
iftC
yli
nde
r(VM・43H)

-86-
 . HYDRAUL
8 lC SYSTEM

8.15 FLOWREGULATORVALVE
.
Thef lowregu
lat
orv a
lvecon
tro
lsfor
kd es
cendi
ng
speedandactsasas a
fetyde
vicei
fthehig
h-pre
ssur
e
hoseburs
tsf o
ranyr eas
on.Iti
sloca
tedasshownin L
lFTCYL
lNDER(RIGHT) 国
Figu
re8.16.
L
lFTCYL
lNDER(LEFT)

• Flowr egula
torv alveoperation
Theoilreturn
ingfromt heli
ftcylinde
rse nt
ersthe
chamber巴 p assingthroughchambers[ EJ，固，固，園 and t
oOIL
TANK
困
， backt othec o
ntrolv a
lve.
Themoret heoilf lowsthrought hehole固 i nthe
piston⑤
，t hegreat
erth epres
surediff
eren
tialacros
sthe
piston⑤ becomest omovet hep i
ston⑤ t otherig
ht.
Fort h
isreason，theh oe園 i
l snarrowedbyt heh o
le
固 sot hattheoilflowi sr e
strict
edt oslowt hef o
rk %
dヲ
--
--
descendingspee
d.
Whent h
ef o
rksarer ai
sed，th
eh i
gh-pres
s u
reoilfrom
thecontr
olv al
vef lows，passingthrough園，園，固，園， F
ig.
8.1
6
[
EJand巴 i n
tothelif
tc yli
nders
.

- FREEFLOW

ー
→ CONTROLLED
FLOW

1
.SPRING 6.SLEEVE
2
.CASE 7.0RIFICE
3
.SPRING 8.SPRING
4
.BALL 9.“O九 RING
5
.PISTON 1
0.NIPPLE

F
ig.8
.17 FlowR
egu
lat
orV
alv
e

回 87-
8
. HYDRAUL
lC SYSTEM

8.1.6 TIL TCYL lNDER

Thet i
ltcylinderisad ouble-ac
ti ngtype，andi t
sp istonrodendi ss upport
edtot h
emastandt he
cylinderta
ilisc o
n nec
tedt otheframew ithapin.T hi
st ruckisprovidedwithtwotil
tcylinde
rsonb oth
sidesoft hetru
ck.
Theti1
tc yl
indera sse
m blycons
istsp r
imarilyofac yl
i nd
erbody ，cyli
nderca
ラpp ist
onandp ist
onrod.
Thep iston，weldedt othep ist
onr od，hastwop ac
kingsandonewearr i
ngont hecircumfere
nceand
movesa longthei nn
ers urfa
ceo fthec y
linderbyt heforceo fhyd
r a
u l
ico il
.A bushingispres
s-fit
ted
insidethecylindercaptos uppor
tthep isto
nr od，withap ackingandad ustsealtoprovi
deoiltightn
ess
fort hepistonrodandt hecylinde
rc ap.Thec ap，fit
tedw ithan“O九 r ingont heouterperiphe
ry，is
scr e
w edintothec y
linderbodyandf asten
edw ithal ockring
.
Whent heti
ltl e
verint heoperator'scompartmenti st il
tedforward， hi
gh-pres
sureoilentersthe
cylinderta
ilside，movingt hepistonforward.T h
isc aus
e sthemastt i1
ot tforward6degree
s.Whent he
t
il
tl everistilt
edback hラigh-p
ressureoilentersthecylinderc a
ps id
eandmovest hepistonbackward，
ti
ltingthemast1 2d egreesbackward.

① ② ③ ④ ⑤ ⑥ ⑦ ⑧⑨⑩⑪⑫

1
.JOINT 5
.OILSEAL 9
.CYLINDER
2
.SPACER .“O"-RING
6 1
0.PACKING
3
.DUSTSEAL 7
.BUSHING 11.WEARRING
.CYLINDERCAP
4 8
.PISTONROD 1
2.PACKING

F
ig.8
.18T
iltC
yli
nde
r

-8
8 回
 . HYDRAUL
8 lC SYSTEM

8
.1.7 OILTANK
Theoiltan
kisinte
gralwit
hthefra
meandlocate
datther
ight
- h
ands
ideoft
het
ruc
kbo
dy.F
igu
re
8
.19showsitscon
stru
ction
.
In
sideth
eo i
ltankaretwosuc
tio
nfil
ter
storemovedu
stfromoil
.

CAP(W/LEVELGAUGE) BREATHER

1FTCYL
fromL lNDER

fromPRIORITYVALVE

STRAINER

F
ig.8
.19O
ilTank

ー 8
9-
8
. HYDRAUL
lC SYSTEM

8
.18 HYDRAUL
. lC PIPINGDIAGRAM

比
n三コaz一︿妄
凶﹀﹂︿﹀﹀↑一区O-ga

F
ig.
8.0H
2 y
dra
uli
cPi
pin
gDiagram(
Clu
tchModel)

幽 90-
 . HYDRAUL
8 lC SYSTEM

aE
コaz一︽足
(
↑ H凶
)NL
凶h﹂
Q Z一﹂﹀O ト﹂一↑

F
ig.
8.1H
2 y
dra
uli
cPi
pin
gDiagram(
Tor
queC
onv
ert
erModel
)

圃 9
1-
8
. HYDRAUL
lC SYSTEM

NOTE

一一一一一一一一一一一一一一一一一一一一一一一一一‘一一一一一一一一一一一一一一一一一一一一一一一一一一一一一一一一一一一一一一一一

-92-
 . lOADHANDL
9 lNGSYSTEM

9
. LOADHANDLINGSYSTEM
FD35c9，FD35T9， FD40C9， FD45c9，
FD45T9 FD50T9
F'D4
0T9，FG35T9， FG40T9
Name VM-43A VM-43F VM-43H
Type R
oll
ert
ype2
-st
age
dt el
esc
opi
cmastw
ithf
reeli
ft
Stan
dar
dmax.l
ift
ingh
eig
ht 3000m m
Forkl
ift
ings
yst
em H
ydr
aul
ic
Mastt
itl
ings
yst
em H
ydr
aul
ic
Lif
tchain Leakc
hai
nBL834
Mastrai
ldimens
ions
(
uni
t:mm)
Crosssec
tio
nofo ut
er
chan
n e
l

C
¥J
C
¥J
σN
3

寸寸
寸
れ
』

F
F

J
60 σ
Rコ
I C
¥J
104 C
¥J

C
ros
sse
cti
onofi
nne
r
仁日
N
N

c
han
nel σ3
N
寸寸
寸NF

れl
σ3
C
¥J 104 C
¥J

-9
3-
9
. LOADHANDL
lNGSYSTEM

9
.1 GENERALDESCRIPTION
Theloa
dh a
ndlin
gs ys
te misar
oll
ertypeh
avi
ngat
wo-
sta
gedt
ele
sco
picm
as.I
t tc
ons
ist
sofan
o
uterch
annel，i
nne
rc h
annel，andc
arr
iag
e.

9.1.
1 OUTERANDINNERCHANNELS
Theo uterandinnercha
nnelsa r
eofweldedc o
nstruc
tion
. Thelowerp a
rtoft heoute
rchannelis
provid
edw ithasuppor
ttob eusedfori n
sta
lli
ngthemastassemblyont hedri
veaxle.
Thec ent
eroft h
eo u
terchanneli
ss uppor
tedbyt heframeviatheti
ltc
yli
n d
er. Themastassembly
ti
lt
sf orw
ardandbackwardbyexpandingandc onst
ractin
gtheti
ltcyli
nde
rs.
Theo ute
rc ha
nnelhasaJ -sh
apedc r
osssect
ion(コ- s
hapedsect
ionforV M・43A)，withanendroll
er
andas id
er o
lle
rmountedont herightandlef
ts i
desofitsuppe
rp a
rt.
Thei nne
rc ha
nnelhasaJ- s
hapedcrosssect
ion，withanendrolle
randas id
er o
lle
rmountedont he
ri
ghtandl e
ftside
so fi
tslowerpar
t.

1
. INNERCHANNEL
2. OUTERCHANNEL
3. PIN
4. SLIPPER
5. SHIM
6. SPACER
7. SHIM
8. SIDEROLLER
@匂 9. BUSHING
1
0.CAP
1
1.ENDROLLER
日 1
2.SPACER
1
3.SHIM
1
4.SIDEROLLER
1
5.SNAPRING

F
ig.
9.1 O
ute
randI
nne
rCh
ann
els(VM-43A)

-9
4-
 9
. LOADHANDL
lNGSYSTEM

1
. INNERCHANNEL
2. OUtERCHANNEL
3. PIN
4. SLIPPER
5. SHIM
6. SPACER
7. SHIM
8. SIDEROLLER
9. BUSHING
1
0.CAP
@匂 1
1.ENDROLLER
1
2.SPACER
1
3.SHIM
1
4.SIDEROLLER
1
5.SNAPRING

F
ig.
9.2O
ute
randI
nne
rCh
ann
els(VM-43FandVM-43H)

-9
5-
9
. LOADHANDL
lNGSYSTEM

9.1. 2 CARRIAGE
Thec arri
ageh astwoendr o
ller
srollin
gi ns
idethei n
nerchannel，mountedt hr
oughb eari
ng swith
sna pring
st otheendr oll
ershaftswhichareweldedt othecarr
iage
.
Thes ideroll
ers，whichr o
lla lo
ngt h
ef lan
geoft heinnerchannel，arebol
tedtot hecarri
agew ith
shims.
Besides，t
oa bsorbsidethr
ustofthecarri
age，re
tainin
gr o
lle
rsareinsta
lle
dono ppos
itee nd
ラs onefor
each. Theyr ol
lo uts
idet h
ei nn
erchanne.
l
Thel ongit
udinalloadissusta
inedbyt h
eendr ol
ler
s. Whent hefo r
ksarerais
edtot hetoppositi
on，
thet opendrolle
rsproject企omt hemas t
. Thelatera
lloadaresust
ainedbythetopretainin
groller
sand
bottoms ideroll
ers，res
pectiv
ely.

. PORK
1
2. CARRIAGE
3. ENDROLLER
4. SNAPRING
5. SNAPRING
6. SIDEROLLER
7. SHAPT
8. SHIM
9. SNAPRING
1
0.RETAININGROLLER

F
ig.9
.3 C
arr
iag
e

-96-
 9
. LOADHANDL
lNGSYSTEM

9.1
.3 LOCATIONSOFROLLERS
Theend，sid
eandr e
tai
ningro
lle
rsa
reins
tall
edontheout
erandinn
erc h
ann
elsandtheca
rri
age
.
Theinne
rc h
annelsandcarr
iag
ea r
era
ise
dandl owe
redsmoothlybytheendro
lle
rssu
stai
ningth
e
lon
git
udina
lloadandthesi
derol
ler
ssu
sta
inin
gt h
elate
ral
loa
d.

Uppers
ect
ion Lowers
ect
ion

ENDROLLER ENDROLLER
INNERCHANNEL

RETAININGROLLER

RETAININGROLLER
OUTERCHANNEL SIDEROLLER
(ad
jus
tedw
ithshims)
SIDEROLLER
(ad
jus
tedw
ithshims)

OUTERCHANNEL
INNERCHANNEL

ENDROLLER
SLlPPER
(a
d j
ust
edwi
thshims)

Fig.9.
4Ro
lle
rLo
cat
ion
s(VM-43A)

Uppers
ect
ion Lowers
ect
ion

ENDROLLER

RETAININGROLLER

RETAININGROLLER

OUTERCHANNEL SIDEROLLER
(ad
jus
tedw
ithshims)
SIDEROLLER
(ad
jus
tedw
ithshims)
OUTERCHANNEL
INNERCHANNEL

ENDROLLER
SLlPPER
(a
d j
ust
edwi
thshims)

F
ig.9
.5R
oll
erL
oca
tio
ns(VM・43FandVM-43H)

-97-
9
. LOADHANDL
lNGSYSTEM

NOTE

-9
8-
 1
0. STEERINGSYSTEM(SEMI-INTEGRALTYPE)

1
0. STEERINGSYSTEM(SEMI-INTEGRALTYPE)

瓦¥¥竺竺1 FD35c9，FD35
FD40C9，F
T
D40
T
，F
9
，F
9
G35T9
G40T9
FD45c9，
FD50T9
FD45T9

Type R
ear
-wh
eels
tee
rin
gwi
thpowers
tee
rin
g
Steeringgearbox

dP2
.4al
M27L{ 陶

tv
叫は
e(5el

cm
g)Gaulu

pk
nd2
口
CF
、
uoo
Type

・l
Reductionrati
o
Workinga ngle
Bal
ls crewd ir
ectio
n

予
.
g n・
、
AV

今，&
-E-A
Maximumo ilpressu
re

aJ
.m
Maximumf l
owr a
te
Powerc ylinder

.ummn
D
o
u

M05m

n
hu

曾
n
時 mmm

0
-
か6
'EE且

r
03
Type

4EL
Cylinderbore

2 引
Cylinderroddiameter
Stroke
Steeri
nga xle
Type C
ent
er-
pins
upp
ort
ed，
Ell
iott
ype
Stee
ringa ngl
e
I
nnerwheel 780
Ou
t erwheel 540
Kingp inspacing 1020m m
Swivelr a
dius 85mm
Camber 10
Wheel
Wheels ize 7.00-12-12PR
(I)
T readpattern J-LUG
Rims ize 5.00S-12DT 5.00S-12TB
T i
rei nfl
atio
np re
ssure 834kPa{
8.5kgf/cm}
2

N
ote
:Fo
rth
eOr
bit
rolt
ypes
tee
rin
gsy
stm，
e r
efe
rtoC
hap
ter7
.

1
0.1 GENERALDESCRIPTION
Theste
eri
ngsy
stemi
sarea
r-whe
elsteer
ingty
pew it
hpowerste
ering，c
ons
ist
ingp
rim
ari
lyofa
s
teerin
gwhee
l，as
tee
rin
gge
arbox，apowercyl
ind
er，andast
eer
ingaxl
e.

-99-
1
0. STEERINGSYSTEM(SEMI-INTEGRALTYPE)

10
.1.1 STEERINGWHEELUNIT
Thesteer
ingwheeluni
tc on
sist
sofas te
eringwheel，as t
eeri
ngsha
ft，andast
eerin
ggearbox.
F
igure101showsi
. tsco
nstru
ctio
n. Thest
eerin
gs h
afti
sc o
n n
ectedtot
hestee
rin
gge
arboxthroug
ha
u
niver
saljo
int
. Theste
erin
gcolumns u
pport
ingthestee
ringsha
ftcanbeti
lte
dtoacer
tai
nex
tent
.
市川町

D
eta
ilo
flo
ckl
eve
r
STEERINGWHEEL

LOCKLEVER

UNIVERSALJOINT

STEERINGGEARBOX

F
ig.1
0.1 S
tee
rin
gWheel

10.1.2 STEERINGGEARBOX
Thes tee
ringg earboxi sas emi-int
egraltypewhichc onsis
tsofac ombina
t i
onofabal 1rtu
ttype
worms haf
tandac ontrolvalve
.
Inthes crewgr o
ove sbetweent heballnutandworms haftaresteelbal
lswhichr eci
rcu
lateasthe
worms haf
tr o
tates，thusprovidingsmooth， easyac
tionoft h
es te
eringwhee.l Thethreade
da reaofa
ba
llnutisinmeshw iththet h
readedareaofthesect
orshafttoconvertline
armotionofthebal
ln utin
to
ro
tatin
gmotionoft hesectorsh a
ft
.
Thes e
ctorsha
ftiss uppo
rtedt hrou
ghbushingsbythegearboxandt h
es i
decoverandhasanadjustm
ent
screwatthesidec oversidetoa dj
usttheengagemento fthegears
.
Undert h
ebottomo ftheg earboxisac ont
rolvalveconsis
tingo fah o
using，aspool，asprin
ganda
rea
ctionpisto
n. Thes p
ooli sfitte
dtot heworms h
aftw ithnuts
. Thepowerc y
linderoilflowis
co
ntrolle
dbys witchingo vertheoilgroove
si nthecon
trolvalvehou s
ingandt hos
eont heperiph
eryof
th
es poo.
l

-1
00-
 1
0. STEERINGSYSTEM(
SEM
I-I
NTE
GRA
LTY
PE)

Tigh
ten
ingto
rque:
34.3-53N-m
{350-540kgf-cm}

Tigh
ten
ingt
orque
:
34.3-53N-m
・
{350-540kg.
fcm}

O
9

Tight
eni
ngtor
que
:
37.3-56.9N-m
{380-580kgιcm}

1
. STEERINGSHAFT 13
. THRUSTBEARING 25. PACKING
2. OlLSEAL 14
. WASHER 26. CAPNUT
3
. NEEDLEBEARING 1.“
5 O"-RING 27. SHIM
4. BALLNUT 16
. SPRING 28. “O"-RING
5
. NEEDLEBEARING 17
. BODY 29. ADJUSTERSCREW
6. THRUSTBEARING 1
8.“ O"-RING 30. BUSHlNG
7. WASHER 1
9. GEARCASE 31. SECTORSHAFT
8
. PISTON 2
0.“ O"-RING 32. NEEDLEBEARING
9. SPRING 2
1. TOPCOVER 33. OILSEAL
1
0. SPOOL 2
2. SIDECOVER 34. SNAPRING
1
1. LOCKNUT 2
3. PACKING
1
2. FRONTCOVER 2
4. LOCKNUT

F
ig.1
0.2 S
tee
rin
gGearBox

ー 101-
1
0. STEERINGSYSTEM{SEMI-INTEGRALTYPE)

(1
)S teer
ingwheelinstra
igh
tp os
ition
Whent h
estee
rin
gwheelisinstr
aig
htpo s
ition，t
hespool④ isi
nth
epo
siti
onshowni
nF ig
ure103，
.
byoper
ationoft
hecente
ringsp
ring③. Att his，t
heg a
psA，B，CandD areequ
alinsi
ze，andth
eoil
frompumpf l
owsthro
ughthecon
trolvalve，backintotheta
nk.

F
ig.1
0.3N
eut
ral

(2) Whens tee

ringwheeli stu rnedcounterclo
ckwise
日川~ f
r叩
Whent hes t
eerin
gw heelistumedc ounter
clockwise，
thebal
ln ut① applie
sf o
rcetot hesect
orshaf
t.Duet othe
resis
tanceofthet r
uckbody ，thesecto
rshaftwon'trota
te
andt heworms ha
ft② s hi
ftsdownwardi nst
ead. Along
withthis，th
es poo
l④ a lsomovesdownward， closi
ngthe
gapsAandCw hilewide ni
n gBandD . Theoilfromthe
p田 npt hsf
u 10wst hroughthegapBt othetai
lsideofthe
powerc yli
nde
r.Ont heotherhand ，th
eoilretumingfrom
thepowerc y
lindercapp assest hro
ught egapD，
h back
intothetank. Thea boveo peratio
nc on
tinueswhilethe
steer
ingwheeli sbeingtumed . Whent herotat
ionofthe
steeri
n gwheeli sd i
sco n
tin u
e d，theworms haf
t② lS
retumedt otheo r
igin
alp os
itionbyt hec e
nterin
gs pr
ing
，t
③ huspu抗ingt h
eg apsA，B，CandD i nneutra
.
l
F
ig.1
0.4C
oun
ter
clo
ckw
iser
ota
tio
n

ー 1
02-
 1
0. STEERINGSYSTEM(SEMI斗NTEGRALTYPE)

(3
) Whens teer
ingwheeli sturnedc l
ockwise
Whent hes tee
ringwheeli sturnedclockwise，th
e 日 NK4f
r 叩 P

worms h
aft② movesupward， c
losin
gt h
eg ap
sBandD
whil
ew ideni
ngA andC，s otha
tt h
eoilfromt h
epump
flow
sthroughthegapCt ot h
epowerc ylin
dercap
. The
o
ilretu
rningfromt h
epowerc ylin
derta
ilflowsthroug
h
th
egapA i ntothet a
nk. Thes ubseq
uento p
erationi
s
th
esamea sd es
cribedinstep(2)
.

F
ig.1
0.5 ClockwiseR
ota
tio
n

10.1.
3 POWERCYL lNDER
Thepowercylind
eri sad oubl
e-actingpisto
nt ype，th
ecyli
nderta
ilbei
ngfit
tedt
othefr
ameandth
e
rodsid
etothestee
ringa xlecenterarm.
Thepowerc y
linderisco nt
rolledbyt hecontr
olv alvei
nthesteer
inggea
rb o
x. Whenthes
tee
rin
g
wheelist
urne
dc ou
nter cl
ock w
ise，oilpressu
reisa p
p l
iedtoth
ec y
linde
rta
ilsid
eandwhenthes
tee
rin
g
wheelistu
rnedclockwise，itisapplie
dt othecylindercapsi
de.

①②③④⑤⑥ ⑦ ⑧ ⑨ ⑩ ⑪

.BALLJOINT
1 5
.CYLINDERTUBE 9
.CAP
2
.NUT 6
.ROD 10
.PACKING
3
.PISTON .“
7 O"-RING 11
.DUSTSEAL
4
.SLEEPERSEAL 8
.BUSHING

F
ig.1
0.6 PowerC
yli
nde
r

-1
03-
1
0. STEERINGSYSTEM(SEMI-INTEGRALTYPE)

10.1
.4 STEERINGL lNKAGE
Theste
erin
glink
ageco
nsis
tsofadra
glinkandapowercy
lind
er，a
sshowninFig
s.10.7and10
.8.
Thedra
gl i
nkfee
dsbackmovementoft
hepowercy
lind
ertothese
cto
rsh
aftofth
es t
eer
inggea
rbox.

Tight
eni
ngto
rque:
245-294N-m
{2500-3000kgf-cm}

Tight
eni
ngtorque
245-294N-m
{2500-3000kgf-cm}

lNK
DRAGL
Tight
eni
ngto
rque
:
133-200N-m
{1360-2040kgf
・cm}

STEERINGGEARBOX

Tighteningt
orq
ue:
133-200N-m
{1360-2040kgf-cm}

Tight
eni
ngto
rque:
294-343N-m
{3000-3500kgf-cm}

STEERINGAXLE

F
ig.1
0.7 S
tee
rin
gLinkage(
for3
.5-4
.5t
on)

-1
04-
 1
0. STEERINGSYSTEM(SEMI-INTEGRALTYPE)

Tight
eni
ngto
rque
:
245-294N-m
・cm}
{2500-3000kgf

Tighteningt
orq
ue:
245-294N-m
{2500-3000kgf-cm}

lNK
DRAGL

Tight
eni
ngtor
que
:
133-200N-m
{1360-2040kg・c
f m}

STEERINGGEARBOX

Tight
eni
ngto
rqu
e:
133-200N-m
{1360-2040kgf
・cm}

Tight
eni
ngto
rque
:
294-343N-m
{3000-3500kgf
・cm}

STEERINGAXLE

F
ig.1
0.8S
tee
rin
gLinkage(
for5t
on)

-1
05-
Hl
. STEERINGSYSTEM(SEMI-INTEGRALTYPE)

10.1
.5 STEERINGAXLE
Thes tee
rin
ga x
leisanElio
tt yp
ec o
nsis
tingofac e
nte
rarmatthec
ente
r，kn
uckl
esatbotho
ppos
ite
ens，
d andti
er o
dswhichtransmitmovemento f
t h
ec e
nte
rarm
.
Theb a
lljoi
ntsattheop
positeendsofeachtierodhav
elef
t-ha
ndthr
eadsa
tthecen
terarms
ideand
r
ight-handthr
eadsattheknu
ckles i
de.

CENTERARM
KNUCKLE(LEFT)

TIEROD(RIGHT)

Tig
hteni
ngto
rqu
e:
232-348N-m
j2370-3550kgkm}
4poi
nts)
囚 SeeF
ig.1
0.1
0
ゥ
，

o
河沼4
141(

n1JH

e1
崎一 -
WGus

叫
匂6 )

‘
b'

.
‘
&z

‘
，
‘

Hu
、

，
、

、
m

m
ト

n
n

n
n
n

'ト
.内

内〆-
u
u

u
u
u
nド

Lkn

FU
円
M
m

F
ig.1
0.9 S
tee
rin
gAxle

ー 1
06-
 1
0. STEERINGSYSTEM(SEMI-INTEGRALTYPE)

(1
) Knuckleandkingp in
Thek nuc
kleisins
tall
edtot h
ea x
leint h
eElli
otmethodinwhichitisin
sert
edbetweentheto
pand
bottombossesofth
ea x
let hr
oughthek i
ngp i
nalongwiththr
ustbe
aringsandshim
s.
Thek ingpinissecuredtot h
eknucklewithal oc
kpinw ithi
tsbothendssupporte
dbyn eed
le
bear
ingstha
ta r
efit
tedtotheaxleboss
es.Inaddit
ion，o
ilse
alsaref
itte
dtothetopandbottomofeach
needl
eb e
aringtose
alinneedlebearin
gg re
ase
.Thek ingpi
nh asagre
asefit
tin
gthroug
hwhichgreas
e
canbeapplie
d.

Tig
hten
ingtorq
ue:
470-549N-m
(App
lyLOCTITE#270.)

KINGPIN

OILSEAL

TAPEREDROLLER
BEARING
NEEDLEBEARING

ADJUSTMENTNUT

THRUSTBEARING
LOCKNUT

LOCKWASHER

Sealingreaseofthe
quan
tity(about100
cc)equiv
alentto50%
ofthespace

0"・RING
“ HUB

OILSEAL

LOCKPIN

F
ig.1
0.1
0 KnuckleandKingP
in

-107-
1
0. STEERINGSYSTEM(SEMI-INTEGRALTYPE)

(2)Tierod
Thetierodhasrig
ht-andl e
ft-th
read
smachinedonoppos
iteends，res
pectiv
ely，withtherig
ht-
thre
adedsid
eatta
chedwiththelocknuttoat
ierodendwhichisintu
rnattach
edtothek n
ucklearm，
andthelef
t-th
rea
dedsid
ea t
tachedwiththel
ocknuttoati
er odendwhichisintur
na ttac
hedtothe
cen
terarm.

(
3) Centerarm
Thecent
erarmhastwon e
edlebe
ari
ngsinsta
lle
dint
otheb
ossesandi
smountedtot
heaxl
eas
sem
bly
t
hroughthetopandbottombos
seswithapin.
Thecente
rarma l
sohasthepowercyI
inderandti
er o
dconn
ectingb
alls
tudatt
ach
ed.

CENTERARM OILSEAL

NEEDLEBEARING

NEEDLEBEARING

OILSEAL
PIN

F
ig.1
0.1
1 C
ent
erArm

-1
08-
 1
1.E
LEC
TRI
CWI
RIN
G

1
1. ELECTRICWIRING
Theelec
triccomponentsofthetruckar
ewiredthroughse
ver
altyp
esofwireh
arn
ess
esandc
olo
r
codedbycirc
uit
.
Thewireharness
esa r
econnectedwithcon
nect
ors(2t y
pes
)orsc
rew.

Table1
1.1 Colorsymbolsandexamples
YL w
IB I Bla
ck IR I Red
日
ご G G
ree
n w W
hit
e
L B
lue Y Y
ell
ow
O O
ran
ge LgL
igh
tgr
ee
E
xam
ple
:Ye
llo
wco
at
in
gwi
thab
lu
ema
rki
ngIPI P
ink LbI
Lig
htb
lue E
xam
ple
:Wh
itec
oa
ti
ngw
ith
outm
ark
ing

Table1
1.2 Connectorsymbol

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

q
a
A
.
t
ー
-
ロ
圃

、
Housing l
w￨川 E国 Thea
(Ta
bl
lp
ha
e11
b
e
.1
t
)
icl
ett
ersmeansc
olo
rs.

o
ll
ー
ロ
同
。 P
lug w
空 亡> じ~竺ー

Screwt
ype 土亡。 *
:

Thed
ott
edl
ine
sint
hec
irc
uitdiagramsa
reg
ive
nfo
rop
tio
na t
lequipmen.

A DANGER! Usedueca 凶 onwhenhandling伽 ba伽 ' yunit.

1
. Nevershortthecircuit，spark，smokeorusefireneartheb a
tteryun
it.Sinceflammablegas
i
salwaysr el
easedfromt h ，
ebattery t
herei
sadangerofcausingane xp
losio
n.
2
. Thebatterye l
ectrolyteisd i
lutesulf
urica
cid.Itwil
lcauseburnsi fitgetsonthes ki.I
n f
elec
troly
tecomesi ncontactwitht hes k
in，
flu
shwithw ate
r.I tcancauseblindnessi
fitget
s
intoeyes felectrolytegetsintoyoureyes，
.I flu
shyoureyesoutwithwaterandg ettoa
docto巴

ー109-
 44
目

t
oWIREHARNESS，OVERHEAD
GUARD
t
oWIREHARNESS，ENGINE
m﹁問。↓刃O

t
oLlGHTINGSWITCH
一 E刃
一 Zの

t
oHORNSWITCH t
oKEYSWITCH

明由開・]{同・]戸
老町oZRDO∞∞リ明

'︼︼
C'
BECSE(向
t
oTAILLAMPRELAY

。三
t
oHEADLAMPRELAY(HIGH)

時Erg-己ZZZF)
f
orOPTIONALELECTRICCOMPONENTS
 t
oWIREHARNESS，OVERHEAD
GUARD(RIGHT)
t
oWIREHARNESS，ENGINE
t
oT/MCONTROLLER

同即間四・回一回・N
t
oLlGHTINGSWITCH

者
町
t
oHORNSWITCH t
oKEYSWITCH

内 w国RDO
~育、

∞ωリ問
t
oF/RSWITCH

'H--E
t
oHEADLAMPRELAY(HIGH)

BEGEE(﹃。三言。w∞主任件。258g
ロ 円件。ご昌弘全
2 0
-g加古 O)
f
orOPTIONALELECTRICCOMPONENTS
コ-m﹁問。↓刃一の︿︿一刀一Zの
 言

t
oWIREHARNESS，OVERHEAD

明
GUARD(RIGHT)

-
t
oWIREHARNESS，ENGINE
t
oT/MCONTROLLER

m ・岡田・u
t
oLlGHTINGSWITCH
コ-mF問。↓刃一の︿︿一刀乏の

老町o
EO
t
oHORNSWITCH

Hロ
O∞∞
ゆHU
t
oF/RSWITCH

。
向
'--MI
t
oHEADLAMPRELAY(HIGH)

Bロ件。gE( zgoE三FE258
君主oEEm凶切。ロロogmEO)
f
orOPTIONALELECTRICCOMPONENTS
 t
oFUSEBOX

t
oAIRCLEANER
(OPTION)
t
oWIREHARNESS，FRONTGUARD

司肋間四・回一回・
h早
婦
、
、
2
WI
Z日 t
oFLASHERUNIT

5BW

t
oLlCENSENUMBER
PLATELAMP(OPTION)
t
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No.SEF-
43AAE
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pri
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TC
I¥W CORPORATION

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

A
IIr
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TC
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