1. Roll up a thick piece of paper to a size where the shaft can pass through, and affix with tape to form a cylinder.
2. Attach a new O-ring on this cylinder.
CAUTION:
• Use new O-rings.
• Be careful that there are no scratches or attachment of foreign objects on the O-ring.
• Attach the O-ring so that there is no twisting.
• Do not spread the O-ring over 30 mm (1.18 in) inner diameter.
|
(1) |
O-ring |
|
(2) |
Cylinder made with thick paper, etc. |
3. Insert the cylinder onto the shaft, and slide in the direction of shaft axis.
|
(1) |
Cylinder |
|
(2) |
O-ring |
|
(3) |
Shaft |
4. Clean the shaft boot groove, and wipe clean any grease.
5. Slide the cylinder near the boot groove of the shaft, and move the O-ring from the cylinder material to the shaft boot groove.
|
(1) |
Shaft |
|
(2) |
Cylinder |
|
(3) |
O-ring |
|
(4) |
Boot groove |
CAUTION:
• Attach the O-ring on the center of the shaft boot groove.
• Be careful that there are no scratches or attachment of foreign objects on the O-ring.
• Attach the O-ring so that there is no twisting.
• Do not wash with kerosene or gasoline with the O-ring installed.
6. Pass the PTJ small diameter boot band through the shaft.
7. Wrap vinyl tape around the spline part of shaft.
CAUTION:
To prevent damage to the boot, always make sure to wrap with vinyl tape to protect.
8. Install a new PTJ boot.
CAUTION:
Attach securely to the shaft boot groove.
|
(1) |
PTJ boot |
|
(2) |
O-ring |
|
(3) |
Boot groove |
9. Align alignment marks and install the trunnion on the shaft.
10. Attach the snap ring to the shaft.
CAUTION:
Confirm that the snap ring is completely fitted in the shaft groove.
11. Fill 100 to 110 g (3.53 to 3.88 oz) of specified grease into the interior of the PTJ outer race.
Grease:
NKG302
12. Apply a thin coat of specified grease to the roller kit and trunnion.
13. Align the alignment marks of the roller kit and trunnion, and install the roller kit.
CAUTION:
Be careful with the roller kit position.
14. Align the alignment marks of the shaft and outer race, and install the outer race.
15. Install the snap ring in the PTJ outer race groove.
CAUTION:
Pull the shaft lightly to make sure that the snap ring is completely fitted in the groove.
16. Apply an even coat of the specified grease 30 to 40 g (1.06 to 1.41 oz) to the entire inner surface of boot.
17. Install the PTJ boot, taking care not to twist it.
CAUTION:
• Clean the large end of the PTJ boot and the boot groove well, to remove grease and other materials.
• When installing the PTJ boot, position the outer race of the PTJ at the center of the stroke.
18. Set the new boot band at the specified position.
19. Tighten the band using an ST, torque wrench and socket flex handle.
| ST 28099AC000 | BOOT BAND PLIER |
CAUTION:
Tighten the large boot band so that the omega part is at the position indicated in the figure below.
|
(1) |
Omega part |
|
(2) |
Boot band |
|
(3) |
Outer race |
|
(A) |
Large boot band |
|
(B) |
Boot |
|
(C) |
Torque wrench |
|
(D) |
Socket flex handle |
|
(E) |
Outer race |
Tightening torque:
Large boot band
178 N·m (18.2 kgf-m, 131.3 ft-lb)
Small boot band
145 N·m (14.8 kgf-m, 106.9 ft-lb)
20. Extend and retract the PTJ repeatedly to spread the grease evenly.