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Download Service Manual Nissan Cedric Model 31 Series
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f T h t o f If L 1 SERVICE MANUAL NISSAN CEDRIC MODEL 31 SERIES NISSANI A NISSAN MOTOR CO OTEMACHI BLDG CHI OT TOKYO PHONES CHIYODA KU JAPAN CAlLES ADDRESS 211 NISMO 5211 LTD TOKTO 9 c oj i 1 I fk r Ii i J 1 w 4J 1 l v V J J J vv J v J J I NISSAN CEDRIC Model f 31 I r f J 11 1 0 1 70 i 4 o L U VP 31 L U 31 L 4 90 P U 2630 2025 LIG31 U G31S H31 L L 10 4590 790 1505 1373 1420 ill 1070 U 50 4 CEDRIC NIS AN OF elMENSIO Il INTRODUCTION Th1S manual has been butors and dealers for 31 Senes In add1tion deta1l d1smantling It Each 1S e complied fective assembly and that only emphas1sed serV1ce components 1nstructlons 1nspectlon genu1ne aSS1sting d1stn are descnbed 1S for glven 1n complete of these assemblies Spare Parts should be used placements l f7 I r our and ma1nta1nance of the moael of the major comprehens1ve assembling for pourpose of as re GENERAL L G31S DIMENSIONS SPECIFICA liON U L G31 L31 U 3l WP L U U L H31 VP L 3l U U Delux Overall length 4590rnrn 1690rnm 1690mm 4690mm 1690mm 4650mm Overall Wldth Overall 1505mm I505mm 1520mm 1505mm helght 1 4490mf I690mml 1530mm Wheel base 2630rnm 2530mm 2530mm 2690mm Tread front I 338rnm 1338mm 1338mm 1338mm Tread rear 1373mm 1373mm 1373mm 1373mm 190mm 190mm 190mm I90mm Road clearance Room or lntenor Rear Body length 200mm 1885mm 1785mm 2730mm 1750 3 1945mm 990mm 6 persons persons 500kg 400kg lnte rlor wldth l390mm 1390mm 1390mm lntenor helght 1180mm Il 80mm I185mm 1390mm 950mm 1180mm WEIGHT Vehlcle welght 1210kg 1240kg 1180kg 6 Seatlng capaclty 6 1350kg 1315kg 8 3 I 6 6 t persons Max 1260kg r loadage 500 Gross vehlcle welght 1540kg 1570kg 1510kg I40km h 130km h 88m h 81m h 400kg 1790kg 1590kg 1980 2045kg PERFORMANCE maXlmum speed Fuel consump ISkm hter 17km hter tlon Grade sm ablhty o 506 9 o 420 0 496 Mlmrnurn turmng S 6m 5 4m radlus Stoppmg Imtlal 50 krn dlstance speed h 14 3mm 143m 143m 143m CONTENTS l lc i r f o1if Page ENGINE 1 N GENERAL SPECIFICA TIONS f1 LUBRICA TION t l F SERVICE OPERATIONS WITH ENGINE 2 ROCKER MECHANISM 19 ADJUSTING THE IGNITION TIMING 37 FUEL SYSTEM t 40 FUEL SYSTEM 40 CARBURETOR 45 FUEL PUMP 50 ADJUSTMENT AND INSPECTION OF ENGINE REMOVING Ii iI f IN POSITION rf1 R k G N t 55 OF ENGINE 1 lr t ASSEMBLY 3 COOLING SYSTEM IGNITION SYSTEM 5 ELECTRICAL SYSTEM GENERA TOR 62 i 4 I 1 69 4 731 R REGURA T40 BATTERY 6 61 CLUTCH DESCRIPTION OF CLUTCH CONTROL l J74 f 98 1105 113 t J 11 7 f TRANSMISSION 118 I2I DISASSEMBLING THE CASE ASSEMBLING THE TRANSMISSION SELEC TOR INER OPERA TING LEVER CROSS SHAFT 8 PROPELLER SHAFT UNIVERSAL JOIN TS h r tL i o J 1 r 1 29 l 1 ENGINE ENGINE The engIne valves are of monobloc construction IS operated by rockers and f1 tted to the valves shaft wP1ch IS and IS htted WIth overhead rods from the camshaft push Three steel backed beanngs support cham dnven The 011 pump and d1stnbutor ItS dnven from are the camshaft onnectIng crankshaft en by the IS rod fItted dynamo own bIg ends The each dnve shaft component haVing The pIstons are each fItted wIth two compreSSIOn nngs 011 control Beanngs of the thm shell preformed type nng the 011 seals the cam and to the centnfugal maIn a are A counter beanngs water pump and and fan coohng slotted htted to blanced are dnv belt SPECIFICA TIONS GENERAL 1 G Engme Model H Type Over head valve 4 Bore 85x83mm Stroke x c1y 4 3 35x3 Engme cycle 27m 80x74 mm f Total piston dIsplacement CompreSSIon ratio Brake horse power 1 883 8 5 torque 88 4800 15 6 PS SAE 7 lb l13 kg ft 3200 rpm 16 6 488 8 I 95 5000 Max I cc I 71 5000 77 5200 11 5 kg PS SAEH 83 Ib ftl 3200 rpm PS SAE12 0 lb ft l20 kg 0 cc kg 3600 F1nng order CompreSSIon 1 12 3 0 4 kg 2 I l72 cm2 300 rpm 1 Ib m2 11 3 0 4 kg PS 87 Ib ft SAE 2 cm 2 300 rpm 1t12 l581b ln Engme RIgnt SIde f Engme Left SIde 2 Draining the Oil The 011 pan On wIth 5 IS a metal pressIng WIth the draIn plug and recondll1oned engmes the 011 must be draIned and refIlled 011 after the first I 000 km and at Intervals of new new subsequently 000 km DraIn the 011 when the engine IS hot SInce warm 011 flows freely and sludge or sedIment WhICh may have accumulatted takes wIth It any Never dIums petrol or paraffm for flushIng purposes completely dispersed from the engIne use are never and WIll bearIng remaIn to contamInate any fresh 011 Such cleamng me lubncatlOn system ThIS may cause premature faIlure Pressure 0 I The normal 550 rpm at operatmg IdlIng speed 011 pressure and 3 4 IS kg cm2 kg cm21 I 2000 rpm 14 22lb m2 56 81b m2 2000 d rp rpm Ref ling When refillIng the sump do not pour overflow from the fIller onfIce of lubncant In Always possIble takIng the readmg level as allowed for new Check for 011 to sWItch sure IS Increase WIpe the ensure too qUIckly operator as as It to the dlpsl1ck that the vehIcle clean wIth It should be remembered reach to sump before may quanl1ty readmg a non IS as ffuffy near cloth f that l1me must be the dlpsl1ck Low Oil Pressure The 011 pressure gage tJon In the engIne Before testIng the level of the 011 before the 011 and mIslead the turned on IS normally keep normal as The panel fInng and the 011 Installed at the Instrument and when the engIne started Igm pres before menl1oned the It IS engIne runnIng pres sure dunng result of 011 In the 011 pan or the down low shortage too of the 011 pressure of the level gage and top up Check the level of 011 m the 011 pan by means sWItch low after refIllIng the 011 IS too If necessary If the pressure stdl Should It 3 off and ascertaIn that the straIner also that no aIr leakage IS clean and not choked wIth eXIsts at the straIner the pump In the case of 011 pump being defecl1ve unIon remove on sludge the suC110 the umt to side of recl1fy the fault If the engme beanngs are complete beanng remedy necess1tal1ng the 011 pressure WIll be reduced IS the of fltl1ng worn overhaul and the replacement parts the removal of the engIne from 1jr 2 r 4 the chassIs A only LUBRICA TION Circulation Pressure lubncatlon gear pump lS used throughout the umt and lS provlded by nondralnlng The 011 pump camshaft gear by the stralner and lS a lS bolted under the crankcase short vertical dehvered and lS dnven from the 011 drawn lnto the pump shaft lnternal 011 ways through through through dnlhngs The flow then passes ln the crankshaft The con rod lends are dnlled for Jet lubncatlon to the walls nechng cyhnder From the ln the rear cyhnder rockers rear rocker shaft and then dralns back lnto the 011 pan side of the the small hole the center camshaft upward through bracket Vla the a dnlhng to lubncate the push rod aperatures gallery on the left hand englne and lubncates the tappets through Indlvldual dnlhngs camshaft rotates groove ln the front Journal reglster wlth a In the camshaft locating plate thus all oWing a small amount 011 from As camshaft beanng the 011 passes block and the beanng enters a of 011 to pass lnto the tlmlng case durlng each revolution of the camshaft to provlde lubncation for the tlmlng chaln and gears From the tlmlng case the 011 returnes Vla a draln hole back to the 011 pan t 3 r Flg 5 n m h pumP 1 0 h OUgh System pan l O ho arm om Lubncatlo 011 ml rocker o 2 Flg flow overhad h and u 1 Th r 1 1 1 en bean g galery TJ l FIg Removmg the By A new remove the bowl Take note the IS of the only be removed from assembly of the thoroughly dry Replacing pIece in posItIon In unscrew the center bolt when complete with the element Remove the element and rIng pettol so that It IS clean the washer and the sprIng Insert a new element the bowl now The sump mto It Important to lubrIcatmg 011 is IS 3 plug Remove the set flange screw In 011 posItIon by end towards the element Offer up the means The complete assembly of the center DOft ffj ft DraIn the 011 and I htres and the lower bolts from the wIth the Place the dIstance replace the draIn bolts whIch are Inserted from the underside of Lower the 011 pan the JOInt washers flanged together Pan 1 0 capaCIty the be fIlled wIth secure Removmg the hOUSIng seahng 000 km gallery of the engme the crankcase the center bolt wIth securIng all the Filter the engIne and the or fIlter obViate any contammatIon of the the bowl to bowl of fIlter must to 011 components WIth the center bolt over maIn necessary to to lose the rubber not Wash out the bowl wIth collar of Frlter pass part the fIlter It can care Component fIlter element should be fItted every 15 The fIlter forms To 3 from the engIne process 7 the bottom takIng edge of care not to the bell damage i ii1 I Jl I D lt o 1 Flg Removmg the Oil 4 Pump Remove the 011 pan and plck secunng the 011 pump bottom cover are enough to to secure long the pump l f the crankcase Flg In The up stralner bolts 4 lllustrates the pump explosed form pump wlth 7j Unscrew the bolts and remove the f i f Its dnve shaft y S 1 t Y F f l I tt f H 11 f Fig 8 5 Dis ing the Oil Pump mant Remove the the body setscrews and sprIng and take off the gear and Its dnve Refitting Clean traces out of old the 011 pan tIltmg whIch the secure body upsIde cover to down the dnve gear by washIng It wIth gasohne refIttIng the 011 pan sedIment before JOIntIng ma enal Exalnlne The old jOlnt washer advIsable to fIt a new fIt the JOInt washer mto the a the the to flange tlghtmg Reassemblmg can and renew sound IS Pay remove the JOInt washer and be used again 1f It remove It any If but It Smear the faces of the JOInt WIth grease and one LIft the 011 pan them up the Oil to care the engIne attentIon to the 011 pan and crankcase JOInt faces necessary IS shaft wIth ashers the Oil Pan any traces of the patlcular On cover Into pOSItIon and lnsert the setscrews evenly Pump OIL PUMP 22 ltr Performance test 5 8 US Gal mmute at 2000 pressure 4 Engme rpm 5 kg cm2 011 SAE 20 pump 891b m2 temperature 700C 158 F Regulator 3 Vacuum Gear back lash 0 25 0 3 o 04 0 11 valve locked 94 m mm Hg 0 100 010 mm 0 Hg 012 m Clearance between gear cover mm 0 0016 0 0043m n 9 150Z8 3ZZ0 Regurator valve Ol I5I3Z 5800 Req 15133 58000 valve spnng 1 r I 011 Pump 6 St Part No ra I ner Assemb 150 I 0 32200 10 SERVICE OPERATIONS WITH ENGINE IN POSITION Removmg Startmg Nut and Remove the radIator move Sl ac k en Pulley th e dynamo attachment bolts and Bend back the tab startlng nut A few on the startlng bolt lockIng washer by USIng heavy duty Shock type spanner sharp blows m an Pull off the crankshaft the Removing The tlmlng by a shakeproof set screw The cover bolts nut pulley Cover secured s each haVIng washer are Im below the bolt heads Take out the set JOInt Unscrew the clockwlse directIOn WIll slacken the antl Timing spnng washers medIately bolts re the fan belt remove the washer screw cover Care and Its should be taken not to damage the washer If breakmg the omt does occur ht a new damage wahser cleamng of the faces when FIg Heavy duty I Shock type Spanner of the JOint surfaces beforehand j RemOVing the TIming The tlmlng chaIn IS Gear endless crankshaft and camshaft gears tlmlng marks on It IS necessary to Before dOIng remove thIS both the notIce the both gears and theIr relal10nshlp to each other Draw off both the gears shaft gear and together a httle at retaInIng nut a tIme fIrst removIng the crank i the ack As the gears are WIthdrawn care must be taken not to lose from the crankshaft Between the camshaft behind gear lng washers and ensures SI rubber nng whIch acts as a tensloner the ExamIne felt washer and renew It lent operation of the cham dnve J gear teeth IS a If 011 has been los t by seepage 11 CHAIN 2 F1g Poslhon of Refitting the Timing the mg MARK rehthng gears Gear ReplaClng the components of the ttmmg gear 1S largely a reversal of d1smanthng process but speClal attentton should be pa1d to the follow pomts Turn the eng1ne crankshaft unbl the shaft w1th 1tS keyway Fit the crankshaft and camshaft gears key ways aga1nst each posltlOn of at marks are Oppos1te along 1n thelr mto key timing IS T D C and the cam keyway mg the the with the cham as respechve shown m F1g shafts hnd 2 Ensure hne Place the gears 1nto posihon ensunng that the keys are present in the on shafts Ensure keyways agam that the tl1 nmg marks on the gears are Oppos1te The replaced ahgnment gauge to each same s a unle of the To other and in number of shims new crank or hne taken from front of the crankshaft camshaft has been htted gear faces and measunng the the ahgnment it Will be adJust ahgnment Ip this with a must case feeler necessary to vary the number of shims 12 be the 1i 1 t f f i 0 Fig 3 Valve Rocker Cover Removal Remove the lIfhng aIr brackets cleaner Unscrew the cap nuts secunng the engIne cover and the cork JOInt washer Remove the rocker Removing the Rocker Assembly DraIn the It bolts If antI colhng system contaIner for the flUid If It IS neces sary IS to draIn the system because four of the rocker shaft cyl111der freeze IS In use use a clean to be used again and slacken the hXlllg cylInder head bolts also secure the head If the cyllllder head bolts are not slackened dlstonatIon may result the cooohng system lllto the cylInd and allow water to hnd ItS way from ders and pump nght hand rear rocker stud nut IS a speCial locklllg plate Completely unscrew the rocker shaft blacket nuts and remove the rocker Complete wIth brackets and rockers assembly NotIce that under the 13 CYLINDER Dlameter of cyld bore Grade number dupenslons STD I Grade No Dlameter of bore cyld bore 2 3 4 5 85 000 85 010 85 020 85 030 85 85 009 85 019 85 029 85 039 85 049 040 mm 3 34645 3 34684 3 34724 3 34763 3 34802 m 3 34680 3 34720 3 34759 3 34799 3 34838 Cyhnder bore taper Dlfference of each OveI Slze Cyhnder bore cyhnder avallable plston Less than 0 02 mm O 0008 m Less than 0 02 mm O 0008 m 0 25 o 0 010 0 Imm 0 50 o I J 7 020 0 00 030 0 mm 040 m head surface warpage hmlt 0 004 m PISTON Matenal LO Dlameter of plston Skl rt EX Alun l1num Measured at Alloy nght angles to the plston pIn Standard Slze Grade No I Dlameter of 84 pl ston 3 Ove 84 m 3 3 84 975 34547 mm Slze 2 3 966 976 84 3 3455 3 85 995 3 84 34511 avaIlable Clearance 1 8 985 34585 4 34625 986 005 85 3 34665 3 84 996 34629 85 3 34590 5 015 34704 3 006 34669 0 010 0 020 0 030 0 040 0 050 o 25 0 50 0 75 I 00 I 25 0 001 0 0017 o 060 I 50 m mm wall and cyld tplston Checkmg by feeler gauge o 025 1 2 kg 2 4 2 0 043 mm wlth 0 04 4 lb wlth 0 m feeler gauge mm 0015 m feeler gauge Allowable dIfference welght wIth DIameter of of gros rod connectlng plston pm hole Plston pm hole off set s Wlthm 5 gr 21 I 987 22 000 0 95 mm 05 mm 0 8656 0 8661 m 0 0414 0 0374 m Width of nng grooves Compresslon 2 030 2 055 mm 0 0800 0 0809 m 011 control 4 015 4 040 mm 0 1580 0 1591 m 14 11 1 j screw 580 0 1325 32 0 ass 13252 shaft IM70 32 0 Set 130 2 32 0 1504t adjust rocker 580 0 rod 32 0 n Rocker fi C Valve I K Parts 13287 Push 13238 Rocker 6 S80 0 13216 32 O R l l H Hf 32 03 JI ED plate 32 0 ocatlng 13010 t51 4 1 418 32 l 132sa 132S9 rocker Valve I 32 O 13212 32 03 080 0 0410 321o 13209 13207 13203 cha 13202 13201 30 0 as y 32 0 32 0 32 0 G13070 asket 13079 sehaarfnt 13028 13032 ChaIn r 080 0 16316 080 0 9 1 Camshft o tenslo r Valve N lIE 9 18082 CD @ @130 32 0 1l438 13078 OCk CDBalt washer washer i waSher 1 gear shaft 32 0 8sh 08000l Csm 13024 Lock 13030 @Lock IDPlane I en 1 @ 080 0 J3082 VALVE Matenal Inlet Chrome steel Exhaust Umlloy 2 I 12 Valve timlng Valve Inlet opens 14 B T D C Inlet closes 50 A B D C Exhaust opens 52 B B D C Exhaust closes 12 A T D C clearance Inlet Exhaust Dowel o 43 0 525 mm mm 017 0 0207 m m Hot Cold 54 50 angle 0 Head dlameter Valve Inlet valve 40mm Exhaust valve 32 seat angle angle 109 overall length 8 the srIJontlmg 4 30 m mm 0 335 5 from the locking plate shaft Unscrew the m Assembly dismantle the rocker shaft assembly flrst rear remove the grub screw rocker bracket flat washers and spnng washers from each end Shde the rockers brackets and spnngs from the shaft Remove the of the mm 44 30 Lift and m mlet exhaust To m 45 Valve face D 57 26 lnlet exhaust Valve 1 1 mm pht plug pms from the end of the shaft and clean out the 011 way The two end rockers may be dIsmantled wlthout the whole rocker bmg drawn out bly until No 1 push Thls may be achlved by turnmg the engme by assem hand rod reaches ltS lowest pOSltion Unlock the tappet adJustlng screw and screw lt back as far as lt wlll go Wlthdraw the spht pm flat and spnng washers and shde the rocker off the shaft Sometimes the valve Ing a screwdnver under off the shaft easlly ll have to be shghtly compressed by lever Wl spnng 2 rocker thus allowlng the end rocker to shde No Repeat the procedure 16 for No 8 rocker Reassembling the Rocker On reassembly hghten the pedestal bracket secunng worklng dlagonally from nut to nut left nut of No time a bracket If tight rebushed down to a httle at 1 pedestal returmng from the No 4 bracket and repeatmg the process until they are all the rocker assembly has been completely stnpped down and nut of No 2 nght left nut of nuts left of No 3 the 011 holes wlll have before Slze assembly and so on to be rednlled and the bushes reamed the shaft on The rockers and on the ends mg screw spnng must be replaced In thelr onglnal posItion shaft Remember to replace the rocker shaft Iocat of the and lock Replace plate the spnng and flat washers of the shaft Replace the rocker should be at the front of the engme two wlth the and COver spht pinS On the ends The vent plpe gasket Secure the cover by means of the that the rubber bushed and ensunng englne hftmg plates If the rocker cover or the posItion rubber bushes are cap nuts are In found gasket be to faulty they must be renewed otherwlse ad leaks Will re sult Push Rod Removal If the valve malns IS for rocker the push detachlng be taken out wlthout Remove the Slacken all a screwdnver shde spnng When push rods replacmg push reversal of the a IS fulcrum depress push rod rods ensure that the ball ends then uSlng the valve reassembly IS a reglster stralghtforward Clearances of 0 of the valve cover 43 mm stem 0 017 m Whllst between the face checklng the clear to malntaln pressure wlth a screwdnver on the rod to dlsperse the hIm of 011 from the Important pet adJustlng screw Fallure to follow thls In process clearance of the rocker and the base It a to their full extent be wlthdrawn m th S way These w ll removal of the two end rockers from the cleaner and rocker alr There should be re cover as From here onwards dlsmanthng may that the other hand can Valve Rocker Remove the ances They on assembly sc rews rocker shaft been removed all the rocker slde ways and hft out the tappet cups Adjustmg the rocker tappet adJusting wlth the to be wlthdrawn after the shaft the already cleaner and rocker alr the All but the end have has assembly rods to be hfted out procedure wlll result In a wrong push cup readlng being tap taken w 17 Turn the engme over by hand the valve is falhng fully closed To adjust Fig 4 insert and slaken the lock nut a Startmg screwdnver Then msert 0 face of the rocker and the valve stem screw untll the correct clearance Tighten handle is the lock nut and recheck 017 m Raise until the the in push adjusting rod screw stops slot feeler gauge between the or lower the adjusting obtained the clearance c f l r iL Fig It is 4 Adjusting important to note bemg adjusted of the valve the rocker clearance that while the must be on peak 18 clearance is being the back of the cam set the OppOSite tappet to itS ROCKER MECHANISM TAPPETS Type Maushroom DIameter 12 673 12 684 mm O 4988 0 4993 lll 12 700 12 718 mm O 4990 0 5006 lll 57 mm 2 24 Hole dIameter for tappet Tappet length lll ROCKER MECHANISM Push rod Overall run at center of rod out 6 197 196 length Not to exceed 6 35 5 DIameter Rocker shaft 398 length 4mm 36 0 mm arm 0 hole dIameter shaft clearance Arm Arm lever raho 0 20 020 0020 1 20 0 46 2500 67 054mm m 008 0 lll 2504 lll 7874 m lll 7865 033mm 0 77 0 mm 15 mm Rocker shaft dIameter Rocker 74 7 7 2 0 7882 0 00008 0 7887 n 0021m 1 CYLINDER HEAD RemOVing the Cylinder Head Dram the draIn taps One the rear IS coolmg system by opemng the radIator and cylmder block radIator and other at sItuated Inlet tube at the backsIde of the If anh freeze mIxture IS In use hand sIde of the engIne nght futur e use a sUItable contaIner and retaIned for It should be draIned Into the battery by extrachng the ter DIsconnect the negahve cable from mInal screw and removIng the the battery termInal post lug from on the hose connechng the radIator cl1ps Slacken both the retaInIng hose hOUSIng and remove the to the thermostat nuts and Extract the thermostat housmg secunng and thermostat 19 remove the housIng Remove the alrcleaner carburetor rocker and the Inlet and cover exhaust mamfolds Detach the dlsconnect the tensIOn cables and remove the hlgh gauge connection vater temperature also sparklng plugs from the thermostat houslng Take off the rocker cyhnder Wlthdraw the The head not keep10g them In the order of removal be hfted off the can now to slacken the external forgetting time same rods push cyhnder bread10g the cyh htate assembly head bolts at the der head Jo1Ot tap block cylmder each slde To facl of the head wlth a hammer Do not use uSlng a plece of wood 1Oterposed to take the blow When hft10g the head a dIrect exceSSlve force should be glven so pull that the head pulled evenly IS up the studs Remove the head cyl10der gasket Decarbonism9 Remove the the carbon from the valves In head cyhnder W th the valves stlll 10 for th posltIon caused to the seats the by S that ensures operation damage Leavlng cannot be brush whlch should be used for wue remove posltIon the combustion chambers and the valve faces the removal of carbon If the exhaust valve be removed by a uSlng heads 10 let and exhaust coated Wl th finally should the clean the now and uSlng the to be worked plStOn the entry of USlng bon from a the penpherY Wlre IS short plston of each generally runs gasohne wlll plston at T D on lS and compressed dry crowns C and the plston glven of A r10g crowns by an requlre th S a carnon deposlt An IndlcatIon aIr or them out th as type The S may pump ca bon Rotate the eng10e until Protect the other particles by pushing shaped plece of hardwood chlsel deposlt brush clean out the carbon from carbon should not be touched ed wlth ports be removed from the from very hard ports Blowout all traces of carbon dust wlth and a plece of hardwood shaped chlsel Remove the valves the are fluffy Carefully non cyl10der bore rag Into them remove the car should be left round the round the top of the cyhnder to when decarbonl satIon IS bore requlr all round loss of power Cars used malnly on attention more often than those used for long runs Removal and Whllst the To do th S Replacement cyhnder head IS compress the valve of a Valve removed the valves spnng wlth the sor 4 t 20 can speclal be taken out valve spnng compres Removal Release the valve spnng Remove the two cap reta1nlng collets the valve 011 seals and 1tS reta1ner Wlthdraw the valve spnng valve cap from the gUlde the valves Keep to eng1ne ensure the1r relative 1n replacement 1n when removed from the pos1tions the1r valve ong1nal gU1des Replacement Note that the d1ameter of the exhaust valve heads Inlet valve replace To the wards r place spnng the valves 011 seal The 011 seals and are more easlly eng1ne 011 for a short penod before press the valve spnng f1tted 1f To use VALVE they by gU1de and chamfered slde down have been soaked the valve replace Refit the cap retainers and secure them Remove the 1nto 1tS F1t 011 seal reta1ner smaller than the are 1nsert each valve spnng of the valve means 1n com cotters Compressor SPRINGS Free 48 7 length F1tted length 39 load 49 3 mm 5354 Compressed length I mm 30 at I 5 931 kg 663 at In 1 917 31b 4 load 30 4 mm at kg 61 3 198 I at m 134 8 7 8 Ib 6 6 Effective turns of Call D1ameter of cOlI W1re COlI 1ns1de dlameter 7 3 4 25 mm 2 mm 0 169 m 1 992 In CYLINDER HEAD Torque wrench sett1ng Cyllllder head nuts Connecting rod bolts Ma1n beanng cap 6 2 4 4 15 8 9 75 21 6 9 kgm 4 6 2 II 84 kgm kgm 06 kgm 45 50ft Ib 30 35ft Ib 35 45ft Ib 71 81ft Ib In rr 1 1 t Fig Valve I Grinding Before replacement of the cyl1nder head the valves and theu seats should be examIned for sIgns of pIttIng or burnt patches and cllstortlon the valve seats must be recut before If these condltlOns are present attemptlng to gnnd trued or the valve be removed In the In whilst the valves renewed Only trueIng proces the dIstorted valve heads should be minImum amount of metal should s grmdlng a valve onto ItS sealmg the valve face should be smeared l1ghtly wIth grmdmg paste and then lapped n wIth a suctIon type The valve must be ground to Its seat w th a semI rotary gnndlng tool motIon A l1ght cOlI spnng Interposed between the valve head and the port w ll assIst considerably when l1ftlng the valve in order to rotate the face to a different posItIon ThIS should be done frequently to spread the gnndlng compound evenly It IS necessary to contInue the gnndlng process untIl an even matted surface IS produced on the seatlng and the valve face the valve seats and ports should be throughly clean On completIon ed w th gasol1ne soaked rag and dned and the subJected to a compress ed au blast The valves should be washed In gasol1ne and all traces of gnnd ng compound removed When VALVES Valve head dlametel Valve 40 mm I 57 m Exhaust valve 32 mm I 26 m m angle angle mlet length overall seat Valve face Valve Intake valve Inlet exhaust 45 8 exhaust 44 LIft 22 30 I 09 mm 4 30 8 mm 0 335 5 m Reset the valve clearances not hot cold or and fInally check them The cylInder head bolts may the engIne has attaIned ItS normal valve clearances WIll have pull when the engIne down slIghtly workIng temperature In whIch IS after more the case to be checked agaIn and reset If necessary RefIt the Inlet and exhaust manIfolds FIt the carburetor and reconnect the control lInkage RefIt the IgnItion advance Suction pIpe to the connection on the carburetter but do not at thIS stage refIt the aIr cleaner or It WIll have to be removed later to check the valve clearances Replace the rocker cqver takIng care to fIt the cork gasket correctly Place three the thermostat and ItS nuts tor hose to Ensure housIng In and secure With the pOSItion Reconnect the water temperature gauge Wlre and ftt the radIa the thermostat Connect the cables to the hOUSIng that the radIator and battery cylInder block fill the radIator Clean and draIn tapes the sparkIng plugs and refIt fInng order of the engIne IS adJust tensIOn leads The whIch secures part of the electncal The Ignition normal can now be operating tempreTature rocker cover so that the valve rocker cover and ftt the aIr on 3 4 and the Ovel clearances may be recheked STEM 2mm 0 008 In 0 4mm 0 016 m 13202 322J2 Exhaust Valve 13202 32200 Standard Over 13202 32201 SIze 0 2mm 0 008 In 0 4mm 016 m 0 13202 32202 Stem dIameter 7 985 0 3144 8 185 0 3223 8 385 0 3301 connections and 970 7 0 0 0 018 0 3157 mm 8 218 In o 3235 mm 8 418 o 3314 3217 370 8 8 In mm 3138 170 9 GUIde hole dIa 3295 In Stem dIameter 7 960 0 3134 8 160 0 3213 8 360 0 3291 23 1 the the Replace AVAILABLE 13201 32201 0 When the remove cleaner when the fInal check has been made 13201 32200 SIze re SIde of the head engIne started has been reached SWItch off and Intake Valve Standard and clIppmg on the hIgh Replace the clIp WhIlst the engIne IS runnIng check that the water hose fuel lIne umons do not leak TIghten them If necessary OVER SIZE VALVES closed 2 harness to the whlnng SWI tched them 1 are 7 945 0 8 8 In mm 3207 345 0 mm 3128 145 0 GUide In mm 3285 In 8 018 0 3157 8 218 0 3235 8 418 0 3314 8 000 0 8 200 0 0 In mm 3229 400 8 mm 3150 In mm 3307 In hole dIa 000 8 0 8 200 0 8 m mm 3229 400 0 mm 3150 In mm 3307 In Refitting the Cylinder Head cyl1nder healq and cyl1nder block JOInt faces are clean The cyl1nder head gasket IS marked Top so that 1t w1l1 be placed Place the gasket 1nto posItion and 10wE r the cyl1nder head In rectly cor F1t the seven cylmder head securing nuts fmger tight Into place Insert the push rods replacmg them 1n the pOS1tions from wh1ch they Ensure that the were taken Replace the rocker Evenly hghten assembly and screw down the secunng nuts hnger tight the cylmder head bolts a l1ttle at a time fmally pull1ng them down w1th a k all ba Screw the tappet adJust1ng torque wrench set to 45 50 lbs ft screws 6 2 6 9 kgm Removmg and Replacing the Tappets Remove the mg them same m then cyl1nder head and W1thdraw the assembly respective positions so that the top of the cyl1nder block w1th one of then rods push push out the also keepmg tappet from them m locahons Assembly 1nsert the do push rod keep replaced on the tappets Take out the camshaft from eng1ne block same they w11l be IS a It may be neces sary to procedure cyl1nder block keep1ng ups1de down or lay reversal of above tappets from 1ns1de of n ua I 8 I la fllZM 1 EngIne sl1ng 2 011 hller cap 3 Valve locker 4 Washer bracket cover Cover Jomt 5 Thermostat 6 Cyl1nder Cylmder gasket 7 Cyl1nder Head 24 head head irr i i 4I ifjJ if t N r r K2 1 Flg P ston and Draln the move Connecting Rod Removal collIng essentlal they To to are ensure pal When used htted correct Identlfy then Into the englne and radlator then disconnect and the engIne Take out the the caps sldes water from the 011 pan from stramer draw 2 the thelr rehttlng piston 0 r 1 onglnal posltlons mark the caps and connecting rods on the together cy ltnder bores Release the connectmg rod from and rod the nuts and cap nuts from the blg ends and wlth parts are replaced after dlsmantlIng It IS The pIston and connecting rods must be withdrawn the Draln and remove upwards through upwards through the crankshaft SIde and the cylInder bore wIth slowly push the wooden bar Note the top of nng 4 It may be necessary to the cylInder bore with a r move the nng of carbon hand scraper breakage 25 to or IIp from avold nsk of piston Remove assembly from the top of the cylmder block crankpms for ovahty wIth a pan of mIcro meter cahpers the Check the and examIne the eIther defect WIll necessI beanng surface for sconng tate the removal of the crankshaft for regrmdmg CONNECTING ROD Matenal Length BIg Steel center to center end 144 forgmg 67 5 mm m beanng Matenal Thmwall WIdth 24mm 0 945 m ThIckness 1 0 059 m 2 1653 DIameter of bIg end housmg end wIdth BIg End 5 55 steel backed white metal mm 000 mm 28mm play o 2 0 0 02 m 11024m 3 0008 mm 0012m Clearance crank pIn and beanng PIston pm m bushmg 0 03 mm 0 001 0 8661 m reamed 22 posItion mm m CRANKSHAFT Matenal Steel DIameter of Journals 59 94 59 95 crank pm 51 DIa meter of End ply MaIn eanng clearance DeflectIOn RUN OUT intermedIate MAIN forgmg 96 51 97 mm 2 3598 2 mm 2 0457 3602 046 2 o 05 0 15 mm 0 002 0 006 o 03 0 07 mm 0 001 0 0027 o 03 under 0 0012 m m m m at Journal mm m BEARINGS Matenal ThInwall Number of steel backed whIte metal 3 beanngs WIdth Front and Center Beanng thIckness rear 28 33 1 I mm 90 33 83 26 1 84 95 mm mm 10 m I 3346 1 3366 m 0 0720 0 0724 m A QOO o oott toIIo o t tot t O t tt tt 0 01l5 t l t U 9ttU oott 5 ott UOlS d toS g c t f The shell beanng are removable by hand The beanngs are reqUire beddIng In It IS beIng only necessary to ensure that the housIngs are scrupulously clean and dry and to place the beanngs mto pOSIl1on wIth the no tangs located they are crankshaft be r o then correspondIng slots Always renew beanngs m any way or damaged followIng the regnndmg In the latter surfaces case undersIze bearmg bearmgs In scored reqUired or and the kmds of SIzes avaIlable 0 are 010 0 020 O If of the wIll 030 and 040 etc FIg 3 PIS TON J Rer r ng P stons Insert each l YhGI IS t m was posItIoned pIston taken It towards and Connect g Rods and connecl1ng rod IS as essenl1al that the sembly splIt In mto the cylInder from the sknt of the pIston the camshaft Compress the pIston nngs WIth Insertmg pIston uSIng tool FIg 3 gently tap the crown of the pIston WIth the wooden end of a hammer handle untIl the pIston IS clear of the pIston nng clamp and l Now 0 r the p ston down rod Just protrudes push connecl1ng posll1on upper Note w half suffICIent and It In the bearIng Each upper bearmg IS the cylInder block un111 the bIg end of the through the bottom of the cylInder bore then shells lower bearIng has the 011 holes there by ensurIng of the greatest Importance that the shell regIsters wIth the oil pas sage way to correspondIng 011 hole provIde an unobstructed j i 28 Ie f Pull the connectlng rod onto the crankpln takmg care not to lnJure the Insert the shelllnto the connecting rod cap pOSltion the beanng surface cap and the locklng washers torque wrench to 35 45 lbs set wlth the Fmally Insert the setscrews and ft 4 8 6 2 tighten wlth a kgm pal nut th connectmg rod Check end for blg 7 1000 shell on slde beanngs the clearance and m that the see are not crank pin when the crankshaft If 1 t blndmg rotating lS dlfft cult to turn undo the and the shell and seat for examine the end dlrt or gnt Before reassembhng al ways the blg apply httle clean 011 to a surfaces and lnto plston cyhnder bore Never ftle the connecting rod caps or mal1ng surfaces creates uvahty ln the as thlS thelr beanng Fig RemOVing a 4 P ston rod and clamplng bolt from the small end of the connecting the out The gudgeon pln IS a push ftt ln plston at 300 400C push gudgeon pln ensure the When reassembhng gadgeon pin lS posltloned ln the connect rod so that lS mIme wlth the clamp screw hole Check that ltS mg groove the spnng washer fttted under the head of the pltch bolt lS not damaged Remove the 29 PISTON PIN Full Type floatmg Snap nngs at both end of pIn m pIston Pm fIt to pIston pIn hole Thumb fIt at 30 104 86 DIameter 2199 Length 73 FIt clearance connectIng pm and 22 Omm mm TIGHT rod 40 C F 0 01 mm LOOSE 0 018 mm 0 8657 0 2 8740 In 8661 m TIGHT 0 0004 m LOOSE 0 0007 m PISTON RINGS Type of nngs Top Plane type chrome rmg 2nd nng Tape red type all control nng Slot plated chrome type plated Rmg wIdth CompressIon 1 98 99mm 0 0780 0 0783 m all control 3 98 3 99mm 0 1565 0 1570 m CompreSSIon 0 04 0 08mm 0 0016 0 0030 m 011 control 0 03 0 06 mm 0 0012 0 0024 m RIng Rmg clearance gap m In RIng groove bore CompressIon all No I 0 25 0 40 mm 0 010 0 016 In No 2 0 15 0 30 mm 0 006 0 012 m 0 15 0 30mm 0 006 0 012 m 4 00 control tensIon Comp No I I No 2 I esslOn all control There should be PIS TON t0 8 2 t0 95 2 PISTON AND The 1 kg 2 2 t0 1 kg 0 441b 4 t0 33 441b 4 t0 67 44 BORES a clearance of 0 0010 0 0016 m 0 025 016 m 0 25 0 040 mm RINGS top piston rmg gap should In the cyhnder bore when checked control compre SlOn nngs m 0 15 0 30 mm In be 0 010 0 The clearance then grooves 30 0 40 mm of the second and 011 should amount to 0 006 0 012 If the p1ston nngs do not travel to the end of the cyhnder bores a hp This may be checked w1th a dIal gauge eventually formed due to wear and must be removed If th1S 1S not done there w1ll be a to nOlcy 1S operation or PISton hp 0 508 mm 1 270 mm The fractured nng a and nngs 0 030 m 0 m 0 mm the 010 040 tendency stnk1ng top p1ston 0 m 254 mm l 016 m nng 0 and 0 mm the 020 m 050 In should be fttted from of the crown 762 by overS1zes piston nngs always ava1lable re 0 caused the and p1ston pushed upwards over Before ftthng never the skirt the nngs remove deposIt carbon the 1n grooves When any from the piston flttmg that note the second compress1on 1S tapered type and 011 control by type processed s10t IS nng chrom1um plating F1g 5 Withdrawing Camshaft The camshaft shakeproof the ness of 08 0 28 the cam rods mm and w1ll have be to 011 m controlled 1S be checked w1th a by can the thIck d1al mdlcator set a the camshaft the dlstnbutor and 1tS to be removed cover Remove the oIl and gears dnvmg spmdle dnve pump and 1tS The eng1ne front mountmg setscrew dynamo swmglng hnk must be removedl when the setscrews secunng the camshaft locating The plat Take out the camshaft can 0 held access1ble and may be removed by w1thdrawmg the plate and lockmg plates now 003 of the shaft gear w1thdraw1ng and take off the tlmmg 1S 0 by three screws and smalllubncatlng 011 hole 1n the nght of the eng1ne locattng plate pOiHtlOn replac1ng should play locating plate Before shaft 0 a Note the of the ga1nst push pOS1t1oned by when locating plate End 1S washers be w1thdrawn from the cyhnder block CAMSHAFT BEARINGS WhIte metal They can when the The beanngs w1th steel j hmng are be taken out renewed when necessary cyhnder beanngs block can 1S used for the camshaft 1t bemg usual to do thiS being recond1tloned be removed by dnftng 31 them out of their housmgs 318 0 1 32 0 30 0 30 0 10 11 t 1 026 1 120 k C 0 I B r e nd II Cy 4 1 32 0 318 0 151 4 1 414 1 1 121 I I wl 9 1 taken to l1ne up the 011 holes fIthng new beanngs care must be corresponding holes in the cylmder When with the Tap the clearance new of 0 bearings into posihon and 001 0 002 m 0 025 0 051 block ream them to give a runnIng mm RefittlOg the Camshaft ThIs IS a reversal of the lntruchons for removal the taken however to al1gn and engage the dnve pm In shaft camshaft wIth the slot In the 011 pump dnve Care rear should be end of the MaIO beari ng caps 1 If flywheel Remove the t and clutch Take off the hmlng chaIn the 011 pan and the engme rear plate the maIn caps of the cyl1nder beanng the bolts secunng cham cover at front the bolts hmlng the secunng also and remove When fIttIng new beanngs no scrapIng clearance to gIve the correct runmng Handle the new of 0 beanngs carefully fInIsh 33 so IS required 001 as 0 0027 not to of as m cyl1nder they 0 damage are 03 0 Unlock block block machined 07 mm the fIne surface r c ff Remove all traces of dnt and jJ r r 011 from the dry c Make tr sure clear caps the F1g that the 011 ways ensure nght cam fitting the beanng that they are replaced way round Each cap 1S and the marks should face shaft s1de of the eng1ne 6 F1g 7 1 c I1 t 1E o i 1 I L f L d F1g 34 8 are When marked the housmgs and throughly a non fluffy rag them w1th CAUTION Never hle the ovahty Always placed Do not held In to take up exceSSlve beanng caps cover beanng surfaces the to reht the forget set posltIon by screws wlth englne thrust washer The and lock washers playas 011 when maln thlS wlll cause they are re beanng caps Pull the set screw are up loadmg of 75 80 lbs ft IO 36 I 1 05 kgm After When rehttIng the maln beanng caps tighten the center one fust each IS tighten rotate the to ascertaln that It revolues crankshaft freely cap If It IS tight remove the last cap tightened and examlne the beanng and tight Its wlth torque wrench set to a seating for matter forelgn Check the crankshaft end be 0 002 If a m O 006 beanng m has crankshaft and block a O 05 run play by mm It O IS 15 means of a dlal gauge ThlS should mm essential to clean out all Wash out the engme sump and the ollways In the stralner Ensure that no The 011 pump should be dismantled and cleaned cles of beanng metal are left wlthln the englne lubncatIon system parti t Flg 9 Removlng a Maln Bearing Cap 35 Extractor Adjustmg To handle Ing the Brake Points adjust the breaker pOlnts untIl the breaker screw Next feeler gauge of 0 easIly IS by turnIng 45 to 0 55 between the breaker FInally fully check the gap the mm he engIne crankshaft WIth the crank turn I open Then loosen the breaker adJustIng 0 018 to 0 Then pOlnts screw once more 022 tIghten move the pla pOlnt e thickness InS then reInstall the fIXIng fIx untIl a shdes screw securely thr rotor The In and extenor of the IS clean WIth soft a cap WIped dry pIece of cloth extra attentIOn beIng paid to the areas between the termInals Clean the center electrode on the InSIde of the also cap The vacuum type tImIng advancer IS can be de terIor termIned engIne IS changed by functIonIng properly the dIaphragm If the engine speed the InspectIon pOlnter located at run thIS pOInter moves when beIng the advancer Fig IS satIsfactory 10 AdJustIng 36 the POInt Gap as IS the suddenly ADJUSTING The IgnItIon tImIng wIth the engIne automatIc even stopped THE IS as IGNITION TIMING adjusted shown 10 to m degrees before top dead WIth thIS FIg center adjustment tImIng advancer of the dIstnbutor advances the IgnItIon further at the tIme the engIne starts to rotate and the the tImIng tImmg speed maintaIned IS constantly at valves sUItable for the rotatIonal WIth the engIne stopped adjust so that the dIstnbutor breaker pOInt when breaks the Just pIston of the No 1 cylInder IS In ItS 10 degrees be fore top dead the standard 600 rpm deg If a tImIng pOSItIon for compressIon lamp IS 12 IgnItIon tImIng degrees before top dead center IS at used IdlIng speed In the 10 center case 15 of marks whIch deg and 20 deg are not evenly spaced pOInters IndIcate pOSItIons before top dead center DISTRIBUTOR Type D410 IgmtIon tImmg IdlIng B 01 T D D415 01 120 C 550 rpm wIth lOO lIght Adjust tImmg angle by the tImmg engme 600 rpm kmds of gasolme octane value IgnItIon tImIng advance AutomatIc advance and vacuum AutomatIc AutomatIc advance tImIng advance and weIght by vacuum the centnfugal weIght control the by centnfugal control tImIng Governor start advance at 00 375 525 rpm Gover nor start advance at 400 550 rpm MaxImum advance angle 140 160 at 1800 rpm Vacuum advance Start advance at 90 110 3 4 54 33 m Hg MaxImum advance 330 Hg mm 6 5 angle 8 50 Startadvanceat4 7 MaxImum advance 120 at 126m 9 Flnng I order o Pomt gap 3 4 45 0 0 45 55 0 5 320 mm 55 mm 500 540 HItachI l20 SIn 140mm at crank shaft angle I 2 mm mm 3 4 Hg 2 o 018 0 022 m o 018 0 022 m 560 610 MItsubIShI 1 Contact arm spnng 500 tensIon Capacity of condenser o 650 gram 20 0 24 mfd 37 18 o 6 23 20 0 oz 24 mfd Hg fi j I l v r l 7 Fig Adjustment made IS FlTst the by follOWing procedure 1 I on the descnbed pre as gradually unhl the top dead center mark pulley penfery comcides with the mark for 12 before top dead center deg crankshaft approaches itS the on timmg gear cover as posihon to the end of the compression stroke of the No the No I crankshaft piston is can removed crankshaft turned tioned top piston posihon the hole With the No plugged with fmger and the previOusly men posihon of 10 deg before the crankshaft I is in piston In its a the dead center of compression Next the positIOn I The compressiOn stroke of be determIned If the spark of the No I m this the somewhat before that cores pondmg Stop the cylinder Insertmg engme camshaft the shaft dnvmg engage the gear Dunng thiS on 1 of the distnbutor at ts lower and assembly place dnve of the upper end of the shaft hme 4 Igmhon Timmg Turn the crankshaft Fig 3 the Checkmg tw 7 the distnbuter to the correct gap adJust vIOusly 2 i f the AdJustmg shaft slot smaller of the seml the dlTectlon of the the Wi th ClTcles rotor so is If these cond tions In ItS pOSItion do not comCIde 38 angle on to the slot of the distnbutor somewhat to the left placed At thiS toward the front that It engages the dnve mount the dlstnbutor to the engIne the breaker must be an the gear when It they are At the same hme Just beglning made to do so IS to by open turnmg the dlstnbutor shghtly from the away across The off ItS set slot Next 6 put To the No posItIon 1 spark plug arm of the to the the tor to obtaIn as the on IS a pOlnter untIl the 4 mch spark Jumps adJusted to corresponds to 2 deg I pIston IS m shown here clamp It securely wIth the chp connect the cord from the termInal to IS Thereafter connect the pOlntIng spark plugs In the counter clock WIse 1 3 4 2 fInng order now cover start of the octane the left the dlstnbutor wIth a rubber properly selector IS set at ItS zero readIng If the octane number of the fuel be the pOlnter IS adJusted to the nght R Conversely If the octane number IS hIgh low and the engme knocks IS IS and of the wlnng optImum advance angle pOInter spark body on rotor IgmtIon tImIng adJustment the Ing used pOSItIon The engme should Ordlnanly dunng so Upon completIon cap turn open cord about 1 of the dnve shaft when the No dead center termInal cords to theIr 7 I and turn the head the hstnbutor cap whIch the order beglnlng to the gap compressIon top 5 cyhnder To determme the POSl body only when the breaker pOInt IS Just IgmtlOn key hold the end of the No tIon One umt of cahbratlOn of the A of the dlstnbutor angle and to 4 deg selec of the crank shaft angle When a tImmg lamp IS dead center wIth the engme adjustment IS runnIng at low that In speed whIch In used the standard settIng 620 Idhng 600 shght knockIng a HIGH TOP gear In any IS IS 12 deg case heard when acceleratIon IS the before top optImum wIth the car apphed sudden ly it 39 FUEL The fuel tank has a capac1ty luggage compartment the The fuel pump and forces 1t operated SYSTEM of 44 l1tres and au supply sltuated at the rear A large and eff1c1ent to the carburetor FUEL SYSTEM GASOLINE I of off the camshaft draws fuel from the tank mto the carburetor float chamber cleaner ftlters the 1S TANK 44 ltr Capac1ty I F1g 40 12 US Gal au 9 1S41S 1 9 151l5 1 1 14522 @l 1 I 2 FIg S tuated wIthdraw on the the set Gasoline Tank top face of screws whIch the tank secure IS the gauge unIt or Remember thIS also ExamIne the IS remove foregettIng Care must be taken not to bend the float lever as thIS may readIngs ThIS To the unIt to the tank not to dIsconnect the electncal lead beforehand straIn Mounting essential JOInt as applies washer to the JOInt ensure senously effect subsequent gauge refIttIng the umt that It IS In pOSItion and undamage when between the tank and gauge unIt must bp fuel tight REPAIRS OF GASOLINE TANK TROUBLES When Fuel Leaks from Gasoline Tank A When replace It a crack dIstortion To make repaIrs after the fuel through In Leakage put IS only when ordlnanly the above wIll be damage IS found In marks wIth chalk at the the tank has been draIned out the tank to force out should be done sary or the tank repaIr o t danger leakIng pOInts blow WIth compressed stagnant gasoline vapor completely the tank completely dry mended by soldenng When precaution must be stnctly observed of and even aIr Repairs IS weldJ ng IS neces OtherwIse there expoSItion w 41 When gasoline Fails B If the fuel falls to reach the left fac In the gasolIne check the tory tank and the When It IS Reach Gasoline Strainer to straIner when there gasolIne operatIon of fuel pump IS IS fuel some known to be satIs followIng pOInts dIffIcult to confum the of fuel at the straIner dehvery loosen the connector at the fuel Intake of the carburetor I be can Check to see If gasolme pIpe IS clogged WIth dust and dut easIly checked by dlsconnectmg the connector of the pIpe and Ing WIth compressed toward the duectIon of the tank au Then from tank end blow the pIpe agam and clean the pIpe In many cases the tIp of gasohne Intake pIpe of tank unIt wIth This blow IS the clogged dust and water Therefore together should be cleaned Check to see by wIth cleamng of the pIpe removmg the dram If the gasolIne pIpe of plug the Intenor of the tank at the bottom of the tank the tank umt IS so bent as to fall to reach the fuel surface The standard posItIon of the bottom end of the pIpe IS about 3 4 m apart from the bottom u order to prevent ItS suckIng up sed ments on the tank bottom If not normal and adjust Check to see the fIller cap and dut not G remove tank unIt the bend of the pIpe If the vent hole of clogged wIth dust Supply ng au to the IS tank Accordmg uum to the degree WIthIn the tank be drawn up even by of vac fuel cannot the operatIon of fuel pump So be sure to clean the air vent of the cap If you should lose the cap and substItute a wooden plug for It a measure nessed whIch IS tank becomes the It FIg 3 Wlnng of Fuel Gauge 1 Umt gauge 4 IgmtlOn 2 Fuse 5 Ammeter 3 Fuel gauge 6 Battery SWItch 42 same as sealed up Always the standard cap were only sometImes WIt the cond tIon InsIde of the though use and Repa Operahon As shown In Gauge the fuel gauge conslsts of the dash unlt and tank 3 Flg of Fuel rs unlt The dash unlt that each cross movement of WhlCh other at keeper a On the tank unlt Installed IS with plece a hand shdes contact 3 If the Ignlbon sWltch arm lndlcator reslstance a over a has two cOlIs panel magnebc forces control the whose right angles Hon the mstrument on response to In the float level As shown In Flg empty elecbc current w1ll flow from the cOlI A and then through the contact COlI A IS As the float reslstance As IS ralsed and the contact the Clrcult and thus In then flows same IS the ammeter Into ground the lron and the Indlcator plece th S hme dlrecbon the are so arm arm and cOlI B wound and to have theH as Increases through to the finally COlI A ground magnehc poles m the dlrechon where the plece wlll rotate to can be balanced lron tank unlt moves wlth the of the two cOlIs nchcator deflect the dHectlOn of F 1ll That IS th S IS F rrpty level and F a gauge of electric Full level When someth1ng IS wlth the wrong connect the WlrIng at the unlt and unground reslstance control E type slgmfIes Gauge and their Remedies Troubles with Fuel and when the tank the current whlch traveled both contact both A and B COlIs magnetlc power Ing on battery through to attracts the magnebzed turned to E pOlnts the then arm IS of the fuel gauge readlngs on turnlng the fHst chs Ignlhon sW1tch ground body of the car sa1d wHmg to the the termlnal end of the the If the lndlcator of the dash umt sWlngs achvely between E and F IS In the termlnal end conchtlOn between the dash unlt and sald good WlrIng wlth the defect eX1shng elther m tank unlt 1tself or In poor ground of th S un1t In the test menhoned 1n the preceedlng 1f the Indlcator d sechon 4 e not sW1ng but 1t moves moves to E when the dash umt end of the wHmg the wHmg between the dash un1t and tank from the tank umt IS grounded umt 1S defechve Therefore reWlrIng If or repa1rIng when Indlcator falls to sW1ng but WlrIng connechng the battery and the trouble If spark1ng out of order does 1S 1n grounded IS on It proves observed when the the dash umt the wHmg IS IS dlscon sahsfac the dash umt Itself not occur should be requ1red sparklng w1th the termlnal nected at the dash unlt end and tory IS repalred the w1rmg or whlch replaced 43 IS thus Indlcated to be I Incorrect readmgs of the 1nd1cator of the float of the tank un1t In this case adJust the Trouble w1th the umt by a new In 1S 1n means that the height error he1ght are probably of the float d1fficult to by bendmg repair so 1t the rod should be replaced un1t check1ng the tank un1t be battery and the umt sure between the o l 44 to 1nsert a fuel gauge 1n the CirCUl FUEL SYSTEM SpecIfIcahon of carburetor used for G type engIne Pnmary Bore dIa MaIn Jet Mam au Power 21 mm Slow 8 32 8 bleed 8 8 170 60 60 Jet au 27 100 40 Slow Jet Slow Secondary 30 mm Ventun dla D3032A 48 80 bleed FIrst 140 Second 140 150 160 economIzer I Inlet dIa mm Inner dIa 75 Oute r dIa 80 Used for H type engIne D3234A IA Pnmary Bore dIa Mam Jet MaIn au 32 mm Ventun dIa Secondary 24 8 mm 34 8 30 110 bleed 60 Power 16 8 180 60 70 Jet Slow Jet 58 80 Slow aIr bleed Slow Fast 160 Second 150 Inlet dIa mm 100 180 economIzer Inne r dIa Oute r dIa 45 75 80 IA ConstructIon and FunctIon CARBURETOR 1S adopted dla type carburetor w1th new mechanism accordlngly h1gh power gragm type operated by negative pressure A dual can be obta1ned w1th suchon res1Stance to get Acceleratlng system 1S separated from power system of accelerating pump sImultaneously more sufflC1ent operatlon res 15 automatically operation by negative pressure power system the economIcal fuel consumphon to te engme load 50 that tJ pondmg located a valve The needle hIgh speed or accelerahng for rel1able the operahon but honzontally vertically WIll be obtained In Float Chamber Needle valve over accordmgly b Choke vertically as mentioned above caused by parhal wearmg w1ll be prevented located IS flow System Sem1 automatlc eccentnc choke valve 1S adopted for only combmed w1th the throttle valve accord1ngly mary barrel and 1S httle of case fully closmg of choke valve the throttle valve for the easy c 15 Slow pn 1n opened starting System Slow system 1S almost same w1th former one Ie after pass1ng the ma1n Jet proper fuel w1ll be ready by slow Jet and and WIth mlJC1ng the au commg from 1st slow au bleed through vaponzed lnd Jet wh1ch 1S so called then th1s mIXed fuel w111 be re mIXed w1th the slow economIzer suffICIent vapour au taken m by lnd slow au bleed thus the more the above mIXture WIll be gaIn and d MaIn The 1S properly ready by 1nJected mto slow port System used Xture ml In normal cond1t1on from prImary barrel thus system the fuel w1ll be of dual barrel Ie 1S ma1nly prov1ded Just same w1th former type properly prepared by mam Jet 1S and mIXed WIth a1r com1ng from ma1n 46 a1r bleed Th1s vaponzable mlxture mor to be led lt mto the perfectly vaponzed meter of by negatlve pressure and But dla cyhnder nhaled lnto double ventun lS dlffered from former lS Jet one to be matched wlth per formance of englne Acceleratmg System e adoptlon of separate type of acceleratlng system and reasonable acceleratlng power valve system lnstead of unlt type system wlll be glven The dumper sprlng lS set ln the acceleratlng pump plston WhlCh Due to of plston reaches to lower end when rod lS pushed by pump arm dumper sprmg lS pump cyhnder of throttle pressed then pump plston wlll operate up to fully opemng 0 6 mmp hole lS provlded at the top of acceleratlng nozzle valve lS In case that the double unlt type the pump arm have three holes to be get correct amount of gasohne by englne condltlon le the connectlng rod be to lnslde hole ln wlnter and to outslde hole in should lnserted alr mlxture caused sUInmer f Barrel Secondary Changmg to Secondary The throttle valve of most opened by pressure of ventun dla At the lS narrow prlmary lS wlll be operated by negatlve part of venturl placed ln lower slde of both carburetor 1 3 mmp ntake hole of negatlve pres sure secondary wluch phragm Slde secondary barrel prepared and from WhlCh the passage of negatlve pressure lS led to outslde of dlaphragm dlaphragm lS made from rubber be ng added oll proof end of the rod lS connected nylon and flXed to dlaphragm rod other of barrel to throttle valve secondary On the secondary barrel throttle shaft lS eccentncally flxed t J P The agamst the bore negatlve entlrely so that the throttle valve occurs wlll be tend to close when beneath the valve then the throttle valve 1 pressure closed and results no operatlon After opemng the throttle valve lS lncreased ly lncreased but no negatlve pressure at the au negatlve on l prlmary barrel and au accordlng secondary barrells made and the port of secondary barrells not down Both negatlve pressure pnmaryand secondary should be of to the dlaphragm accordmgly the negatlve pressure operated suctlon tr Y pressure of venturllS ventllatlon to of ventun at pnmary barrells not lncreased untll throttle valve 47 i secondary barrel1s pressure port w1ll operate d1aphragm Jr1ll not operatlon of out to because the operated I as a1r barrel negahve secondary On the other hand the bleed operate unless regular pressure w1ll be glven negatlve pressure slde the pnmary slde 1S largely spnng at The throttle valve on opened and pressure to be effected the tenslOn of sprmg and the Accord1ngly negahve supphed d1aphragm w1ll attam beyond and 1t results that the power agamst openmg the throttle valve then the throttle valve 15 open 1S to outs1de d1aphragm pulled the au bleed When the au flow 1n the secondary barrel more au 1S to the of ventur1 tend downward eff1c1ency at the port 1n most narrow part then the he1gher pegat1ve pressure to the maphragm 15 glven accordmgly the d aphragm 1S more pulled to outs1de and secondary throttle valye 1S largely opened fmally opened perfectly of have no res1stance up to 50 barrel pnmary Generally valve open1ng angle and nO neces Slty operate secondary barrel 50 that the secondary throttle valve w1ll not open due to cam mechan1sm Th1s cam mechan1sm p1n fIxed to throttle valve 1S expla1ned shaft that the throttle valve secondary 1n barrel w1ll be arm prevented mstalled at pnmary throttle valve arm untll 50 openmg of so that the secondary throttle pnmary throttle valve 1S obta1ned by cam valve cannot open The pnmary throttle valve throttle valve w111 become free 15 more by puthng opened cam then secondary off from the p1n accord1ngly secondary throttle valve w1ll operate freely by d1aphragm and fully opemng of pnmary throttle valve w1ll result fully openmg of secondary throttle valve se In th1S cond1tlon clos1ng the pnmary throttle valve the condary throttle valve 1S closed by the operatlOn of t then negatlVe carr 15 1ncreased and throttle valve 15 1n mamfold pressure secondary of eng1ne w1ll smoothly reduced therefore rotat10n closed enhrely r Secondary g There 1S a Fuel head between the therefore to spout the fuel from top of nozzle and float chamber nozzie secondary throttle the ma1n To adJust th1S d1screpancy of gasohne remarkably opened m1xture a step port 15 ready at the top of secondary throttle valve alT System 1S valve Th1S wh1ch 1S k1nd of step uhhzed such type carburetor have 1S port as no was prepared choke valve and aWClhary valve necessary 48 1n former ma1n so type carburetor nozzle but th1S new that the un1que step port The fuel In alter passIng the thIs step system secondary mam wIth au from the vaponzed step separated from maIn system Jet properly ready at step Jet IS au and reaches to the bleed step port The sIde maIn and maIn to say that system IS almost Jet IS prepared on case of In wIth the same of pnmary system the wall of float chamber It IS utlhzed so pnmary SIde system In sharp turn operatlon or bad effect by lnchnatlon that the severe hIgh speed IS Ing are out of conslderatlon D1ameter of bore and venturI to take enlarged In of au because of power barrel plenty h Power System The power valve push spIndle IS In When the pressure attaIns negatlve mercury thermometer tensIon of pIston Just on negatlve IS the the power valve pressure In manIfold the throttle valve led from IS the center of float chamber and the connected wIth pIston At the upper sIde of sIde rather are pIston push spIndle the spnng located between than 110 more mm of by pIston beyond the push spIndle and au horn IS hfted the valve power valve IS luted up by valve sprmg and seat then fuel IS cut off contact wIth valve path accordmgly comes m down to When the boost valve IS negahve pressure IS pressed by push spmdIe exceedIng sprIng tenSIOn valve seat IS IS passed mm a head of operated from between valve and sIde wall of Jet placed at maIn system at power valve and meet wIth fuel1n pnmary Idle Ad whIch then the fuel properly ready 110 ustment adJustInent is carrIed out WIth the throttle adJust screw and the Idle adJust screw The throttle adJust screw adJusts the slow Screw In to Increase speed or turn out to reduce running speed The idle adJust screw adJusts the densIty of air fuel mIxture speed Idle Screw In the Idle tIOn for lean mIxture and adJustInent IS screw out for rIch mIxture to be done WIth these two screws Too much screw of It and cause chsorder In of Idle adJust screw Idle runnIng that the screw In In engIne however screw when It is necessary to check whether or wIll If there IS not a In Therefore correla damage IS no the pOInt effect on the normal condltlon not the slow aIr bleed IS clogged the slow Jet slackens or the fuel level IS abnormally hIgh Do the Idle adJustInent after the engme warmed up AdJust the Idle runmng to 600 r p m 49 t Adjustment On the marked Level of Fuel transparent LEVEL cover Carburetor In of the float chamber drawn IS a whIch stands for the standard fuel level line The fuel level should agree wIth thIs l1ne The fuel level IS adjusted WIth the That IS remove the float needle valve carner from adJust shIms outsIde and Increase or decrease adjust the shIms at the root of It of two shIms makes the fuel level up or down about 0 39 mch 1 m When the fuel level IS wrong denSIty of the mIxture gas will become Improper and the engIne WIll get In d1sorder FUEL STRAINER AND FUEL PUMP Remove Newly designed unlbzmg WIth the stramer by slackemng the nut on the top to clean the Interior dram cock to el1mmate deposits at the bottom bowl the the glass Remove Fuel pwnp Type DIaphragm Method dnven Dnven by camshaft Performance Out Max Mm put out let pressure The fuel pwnp o whIch the dIaphragm type nIcally dnven by the IS part of the camshaft of the 3 IS 1 5 per mmute at carn I 000 kg cm2 of mecha eccentnc engIne It draws gasol1ne tank and del1vers sure from the It under pres to the carburetor Fuel pwnp fuel straIner ass y 50 4 3 Ib m2 r p m l The fuel pump by Wh1Ch the eccentnc It draws part gasohne 1S of the d1aphrgm type 1S mechamcally dnven of the camshaft of the eng1ne from the tank and dehvers 1t under pressure to the carburetor Even when the eng1ne sure by By phragm the 1S By not runn1ng rotahon of camshaft pulled 1S pushed can be dehvered under pres up and down rocker up aga1n arm 1S pushed and the movements gasohne 1S drawn up from If the float chamber of the carburetor conta1ns enough the closed 1S gasohne diaphragm Under of d1a the carburetor needle valve Thus pull rod d1aphragm goes down aga1nst d1aphragm spnng and by 1tS spnng of the d1aphragm of the valves at functlOn1ng andi the 1nlet and outlet of the pump chamber tank to the fuel down At the same hme then 1S movmg the hand pnmer 1S 1S kept gasohne stored 1n 1S and the the pump chamber and due to 1tS pressure down and cannot th1S cond1 hon gasohne not allowed 1nto the carburetor return the rocker arm works 1n va1n as the rod remains low The rocker pushed arm spnng serves to prevent aga1nst the eccentnc of the camshaft 51 n01se keep1ng the rocker arm bowl Class 2 2200 IMI1 UZOQ I 18401 1SOSO 11410 36200 eller llter l Iemer 11403 32200 m @ 17 01300 17103 7QT2 32200 1 gm SPrt g 17052 3UOO D1aphr iiI 11015 52100 17075 50000 r g @ lOtapt regm 17053 32200 lt Rock rm r spring Jr @ 11 OIS moo s J 001 17011 FIg D sassembling Components 3 of fuel pump Inspection wIth fuel pump Installed on engme DIsconnect the fuel pIpe at the mlet stop the engme of the carburetor and then turn the engIne WIth the crank handle Checkmg SWItch off and unIon Now the once gasolIne should be every two rotations ejected vIgorously To tes t the functIOn of the pump alone and checkIng the fuel eJection Removal from engIne Fuel pump be unIons and can loosemng from the tip of the pIpe of the crankshaft easIly IS operation of the hand pnmer enough removed by dIsconnecting the 2 attachment nuts 52 the Inlet and outlet I InspectIon prIor to dlsassembhng Pnor to dlsassembhng of the removed pump between the and see rocker arm and If the rocker Method of flange of the lower rocker hnk and pI arm body by s the dIstance measure of means a scale are worn dlsassembhng FIrst wIpe dIrt off the outer surface of the pump and put marks the upper and lower bodIes to make theIr reassemblIng easy It body Into two when the easIly separated IS care Checking not to damage Replace Replace the parts well a are IS 00 I of tIp on a or or valve IS recondItIon It WIth body the surface of repaIrs of warp found a Irregular flat IS faulty pIece of place a cutter and WhICh can gnndlng tool gnndlng very hne sOn e glass plate remove hne OIlstone a the seat surface of the Inlet valve Irregulanty fo and gnnd It lIghtly WIth hnger The hole of the some them In When the surface of the valve compound Inspect the hmlt for requIred unavold lble 0 not be taken off from the of then gasolIne In seat of the outlet and dress the surface WIth case dIsassembly dIaphragm If any damage ImpregnatlOn by gasohne valve assembly If any wear or faulty operatlOns IS detected When the surface of the valve seat the valve thIS dIaphragm dunng the Even If repaIrs wear of the valve the around the upper screws of Parts Reparres Wash the dIsassembled In both loosened are Take great or SIX on breakage IS of JOInt parts ThIs extent IS found not the dIaphragm part shaft and lInk may be but when senous must senous eccentnc worn wear to crack be replaced be compensated for at the tIme of dIsmantlIng and reassemblIng of the body by msertIng a packIng made of thIck paper between the lower body and dIaphragm to raIse the relatlve POSI tIon of dIaphragm shaft WIth repsect to the lower body The rocker arm should be replace when ItS contact face WIth the cam and As a remedIal such measure that WIth the lInk and ItS pIn hole are senously When ItS the rocker not last reemployment by recondltIonmg arm and hnk by weldIng and fmlsh long and Renew the arm pIn when It If chamber nly IS arm of the worn unavoIdable them WIth and a hIe add matenal to but thIS can measure temporary found excessIvely spnng seldon become faulty In but when weak overflow of the float l carburetor The tenSIon of the spnng must not be by hand Check to body a r worn IS dIaphragm spnng replace them always With standard ones the dIaphragm spnng IS too strong It r sults The ened than IS no more I wear can see If there after dlsas IS any warp emblmg IS over on strengthened the JOlnt renew 53 the or weakened arbltra surfaces of the cap and gasket to keep ItS aIrtIghtness I Reassembling Installing standard spnngs for the Employ Install valves In screwmg ahgn where stated before as f1t them to d1sassembhng put and then at the screw 1n down w1th the rocker pos1tion fully pulled pushed to wards the slde of the body by and pressure Do not screw 1n hght one Instead Py one Slnce 1t causes warp1ng all the screws round loosely and clamp umformly Then hghten them d1agona lly and lastly rehghten all of them m order to make As d1aphragm seats respechve of upper and lower bod1es and d1aphragm to the marks wh1ch were before the screw1ng hole to 1tS mate one the preC1sely uses contact w1th the1r 1n gether accord1ng and vanous for close 1S arm sure a rule general Installahon the eng1ne on should be gaskets 1S done replaced by the 1n new ones order to that for d1S reverse assembly Be to set the rocker sure properly not the the cyhnder block camshaft between Fund Checkmg When a mounted camshaft Vdcuum on a Mm should be 0 1f even 22 1S Lper a pump strong 1n Vthe mlet o 5 m A on pump IS port It th tester port arm 1S It any 4 port 1f 3 to as 50 mm test the 1n w1th finger hps suddenly release follow1ng Then the there fit for up air 1S way after ope fmgers can The be heard when test 1tS funchons the mlet post to the outlet dunng only slde and turn the eng1ne 6 port gasohne pipe or more by connechng a hose to gasohne from a he1ght of more than use port to 1S gasohne from each connechon 54 operahqll Leave that 7 rotahons sure Side and Then turn the eng1ne again several hmes to of of the respechvely the pump It the on the eccentnc by 5 seconds thence p1pe on gasohn Side Connect the leakage 1nstalled Then the gauge pressure Hg Max vacuum and of the crank handle and make sure that there hne from the outlet B 1S act1vated means plpmg Jomts gasket one t able to draw mstalhng port the Replace cond1hon should rema1n for S severalhmes mechamcally IS the eccentnc of standard before not ava1lable and outlet Connect the the outlet or I 000 rpm m2 good cond1hons After contachng slde a new arm 1S d1sconhnued 3 mlet and outlet n01se The r 1S one connected to the pump 1nlet port and the pump 150 lb or gauge the rocker 1S to r Clost the mlet rahng over m1nute at than 3 seconds When 1S the rocker kg cm2 operahon 1S gauge 2 or on tester 1 slde and pump w1th When repairs of the pump make a check to see eng1ne IS that 1t arm so rear by outflow of gaso hghten all the see 1f there 1S ADJUSTMENT AND INSPECTION OF ENGINE The engIne must and for thIS always penodlc purpose taIned In Order of I 2 InspectIon Check the the Inspect fIc coohng operated In the best possIble condItIon InspectIon and adjustment must be order whIle certain a be In USe as well as after and Ad ustmet of water maIn overhaul Engine water level and extent of fIlthmes battery all connectIons electrolyte and voltage level of electrolyte s specI of gravlty 3 Inspect the 011 4 Cleamng 5 Measurement of compres of f lth amount spark plugs and ness clasSIfIcatIon and VISCOSity adJustment of theIr gaps pressure of cyltnders The standard compressIon SIon pressure of the engIne IS 172 Ibs per sq approx 12 m r p 0 cm2 kg at 350 m Measurement of pressure made In the followlng IS manner FIrst see warm I FIg up the engIne of temperature coohng 70 BOoC then re water move pull all all out the way that carburetor valve and spark plungs the throttle knob the IS m the throttle and choke valve fully opened press FIg 1 Measunng CompreSSIOn Pressure by Means of a CompreSSIOn Gauge are a com pressIon gauge agamst each spark plug hole and run read the maXI mng the starter motor wIth a fully charged battery 5 8 rotatlons of the motor ThIS meas mum pressure obtamed wIthIn urement must be made as qmckly as possIble It the compresslOn pressure of anyone cylmder d ffers by 10 Ib or more from that of another In the cause must be InvestIgated 6 Check and adjust sq the d strIbutor If the breaker contact pOInts have defectlve contact surfaces them abd adJust the gap to 0 45 0 55 mm 55 dress Also turn the 7 1dJust can carry out checked 1f funchon rectly the funchon of the governor can lllummatlOn of crank 19n1hon hmmg power hmmg light a w1th the together w1ll enable pulley advanc1ng see co 19mhon hmmg By uhliz1ng be of the d1stnbutor clockwise and check to cam the governor the condlhons of runnmg and lnspect to advanClng of the hmmg B T D C 8 Inspechon 9 AdJust 10 12 550 rpm of fuel pump and the slow gasoline settmg of carburetor Checkmg operahon of generator Check the generahng cond1hon and by stra1ner funchomng of the cutout relay of 1nd1cahons of the ammeter means 11 AdJus tment of slack 12 AdJustment of valve m fan belt Engine by D agnoslng of clearance tappet means of Vacuum Gauge and Combustion Tester d1agnos1ng the eng1ne the cond1 cylinder can be assumed by In hon of each measur1ng 1tS compress1on employment For of a connect 1t to the engine and refer to as show1ng When 1nstall tube the tester ond1hon pick means connechng m the of a gas which hose mto and When measurement aH 1n ra1nyor cold weather condenser up and the meter mOlsture damage meter 1f used 1S up the combustlOn the aux1hary exceSS1ve w1l1 p ck analyze by be made use an conven1ent Judge the combushon accord1ng to the m1xture raho of fuel and to 1S and after the engme has spec1al gauge flOWb through 15 Fig combushon tester a been started c master motor tester a spec1al1ntake a exhaust 1n gauge 2 Fig The use of vacuum ntake man1fold the In between the otherw1se the the exhaust gas functlOnmg perm1tted to enter of the F1g 2 Motor Master Tester Avallable for 4 6 and 8 1t Cyhnder Engme 56 When gollowmg tester a IS to be used make Condl tions SUltable WIthout load Low 2 r 000 Ratio i2 70 m p r p IS 5 85 m Trouble 3 WeIght of MIxture HIgh Speed Runnmg FIg to the Speed Runnmg 600 Engine adJustments accordIng table 2 Shooting Intended to be of assIstance In the systematic analysIs and Isolation of symptoms of engIne troubles so that the defective may be accurately traced and economically repaIred 1 4 Normal condItIOn 3 When above Settles between 18 20 ID eXIsts to 0 2 condItIOn Indicator wIll swmg If engme 10 IS raced 5 Normal condItIOn When Indicator sometimes When IndIcator fluctuates between a range of 0 3S pOInts engine and valves 18 raced are m 25 drops by 4 m stIcking m or so I vaive eXists rIngs good conditiOns 3 Even 6 When If IDdlcator settles d readmg IS low rings or 011 are ID faulty condItIOn IDdlcat pr sevual Inches time 57 valves drops by at are certain burnt 7 12 When Ind cator drops by valves leak about 2 In Faulty stating of valvea Wben md cator moves slowly between 14 lt IS 16 m because eIther elect rode gaps of plugs are too narrow Or breaker pomt IS defecbve 8 13 mdleator osell1ates When achvely 18 14 between valve stem g1ude In worn When mdlcator and 5 In IS leakage out or POIDts to there is below or at IDtake manlfold gasket of carburetor Faulty c1arnpIDg of gas ket 9 14 When wIth mg up between with a slight speed mdlcator 10 mcrease 22 When m of speed mdlcator osc regularly between 5 and there at the der head moves IS leakage gasket ctarnpIDg of gasket becomes range larger valve sprIDgs are weak 10 llates 19 m cylin Faulty 15 When md cator remaIDs still between 8 15 m t because elther valve bmmg IS retarded or valve clearances are not correct IS When mdleator first Tlses high drops down zero to and then returns to 16 muffler IS m clogged 11 16 When IndIcator settles bet ween tlmmg 14 IS 17 m When mdleator IgnitIon moves slowly between retarded carburetor IS 13 Justed F g 3 Diagnos ng eng ne 58 by means of a vacuum 17 m poorly ad gauge Battery Plug rk s Plug sparking Wiring ijS COnnecl1011S poor dJUsted Air being sucked j to or ldlfgseicli jY poo TIming In weak IDcorrect lD Plugs dIrty l Sparking at terminals 1 Tlmmg 8v o Cl Plugs do not spark lil cIJ C i Sh ort Incorrect In Nospark Ing at ter L condenser defeehve or Contact pomt dIrty Breaker defectIve mlnals CIrcUIt cOil IgDll10n E Cl i t POint contact poor Breaker Insulal10n defeCl1ve arm JJo shortedlD tank ijoVgasollne St er defective l PIpe No gasoline In carburetor clogged f Float valve sheklng No aIr can enter tank Fuel Wmp not operating No gasoline 0 I trouble tl Com pres S10n J 1W f good or Float m hIgh pOSItIOn wIll Carburetor 9 attachment not P ston rmg 0 is E ompresslon poor Piston or or not deseend secure valve sticky connecting rod broken Valve seatmg poor Breaker o In clogged pIpe Float suuk Carburetor defectIve Plugs spark i hne supply stopped gas Alr hemg Bucked Jet o Cl or Engine seIZed Garburetor arm spring defective contact pOlDt poor No spark Ing from co 1 line Rotor shorted Breaker arm good IgDll10n cOIl or condenser defeetlve Dlstrlbutor wet Cap msutal10n defechve Cord shorted or cbnnectlOn poor SparkIng form Wmng shorted COIl hne C PIugs d I rt y or or j Flg 4 A Trouble shooting i tt 59 cut broken chart weak Compresslon I Valve clearance Incorrect Valve spring weak Valve deformed Muffler clogged Contmuous lack of power V alve hmlng Incorrect Igmhon retarded too much Carburetor adjustment poor Power Gasoline supplied Insulliclently weak Carbon deposits excessive Gasoline of poor grade I EngIne operatIon carburetor I IntermIttent lack of power Valves Pre IgnitIOn defectIve during runnmg defectIve sticking Engine gIves off abnormal Overheating nOIse Bearing I Sparking Irregular worn Plugs dIrty i Breaker pOint defectIve Intermlttent shortIng M xture too MIsfiring rich InsufficIent gasoline supply to carburetor Sparking normal Water In gasoline Nozzle clogged F g 4 B Trouble Bhoot ng chart 60 REMOVING REFITTING ENGINE ASSEMBLY Operations The wIth the Engme Removed following operations from the Although lt may be found remove the as a best posslble more slngle the englne drain the Completely remove lS has shown that lt Expenence and lt posItion ln transmlSSlon To are wlth the enpne removed performed car the englne and OF unlt to carry out certaln attentions wlth convenlent much lS cooling system ltS to upwards the bench on remove than to detach the englne and transmlSSlon battery and to do the work eaSler the englne by ltself proceed as and the transmlSSlon supporl1ng tray raglator hoses by undonng Remove the upper and lower the follows dlaconnect retalnlng clips Dlsconnect the capacltor lead at the dlstnbutor and sWltch Take Wlres off the also the hlgh tenslon at the COlI lead and dlsconnect the dynamo starter motor cable at the end motor Remove the 011 gauge and water termlnals gauge leads from then throttle and choke controls must be dlsconnected from The Disconnect the fuel pl pe from rator temperature the engine on Next the remove haust plpe from the carbu the fuel pump ex the mamfold From below the vehlcle remove the gear lector rod from se change the lever on the transmlSSlon caslng Dlsconnect the earth strap from the starter motor Remove the hand brake trol rod supporting con from transmlS Slon Disconnect the meter cabl e from speed the trans Uncouple the pro peller shaft plmon franges at mlSSlOn rear axle and draw the shaft out of the transmlSSlon To allow the englne transmlSSlon ward and to be drawn for Englne the radlator must be removed by undomg TransmlssIon assembly bemg the four chassls secunng bolts 61 bfted from COOLING SYSTEM RADIATOR Type Maccord closed Pressuhsed o 3 8 4 ltr Total capaClty of coohng water 0 4 kg cm2 2 2 type 0 US 4 0 61b m2 Gal THERllOSTAT Type Bellows type Start to open 721 50C Fully open 801 50C Valve hft temperature temperature 9 5 6 30F 16l 1 30F 176 o mm 374 In An eff1Clent coohng system IS of major Importance to ensure the satisfactory runnlng ot the englne and 1t IS therefore necessary to pay Attenhon IS pahcular attenhon to ItS malntenance especlally drawn to the procedure for w1nter months 1f damage 1S to be avolded DescriptIon The l1ng co maIntalned by Clrculahon an system 1S water pump combIned wIth eff1c1ent fan caoled rad1 ator and thermostat The system sun sed and 1S pres the reh ef valve Incorporate d In the rad1ator fIller cap controls the pre 4 sure at approx1mately 0 kg cm per sq move Do not s re the fIller cap 1f the temperature of the coolant IS above bOll1ng p01nt or If the eng1ne 1S i runn1ng Toppmg up should only be reqU1red occas1onally to re place water lost through the overflow p1pe Top up when the eng1ne poss1ble 1S use cold frt 4 F1g J i T Rad1ator and If clean soft water F1ll to w1thm 1 2 of the bottom of the hller plug well Overf111mg when cause water to flow through the overflow p1pe tem 1S approx1mately 8 4 htres 62 the engme The IS cold may capaClty of the sys Thermostat In order to ensure maXImum efhClency lt essentlal to IS wIthIn certaIn hm1ts engIne bellows operatlng temperatures type thermostat IS htted front of the cyhnderhead volatlle hqUled hlled with a the engme IS cold th whIch controls IS closed and a of metallIc bellows When mushroom valve a the To assIst thIS the water outlet at the In The devIce consIsts valve S beIng located keep the engIne the flow on startmg temporanly restncated Due to thIS the temperature of the water m the cylinder head and The cyhnder Jackets WIll qUIckly nse thus ensunng rapId warmmg up heat so generated wIll gradually expand the bellows so opemng the valve of water to the rad ator and ultlmatelly IS permIttIng The thermostat Itself It anse a old ng up the holes on the When the air should the occaSIOn therfore and the hose hOUSIng Should the thermostat be car reconnected tlght there are to two WhICh may be utlhzed to ease If from castlng completely emptied It IS essentlal to allow top has been system through the thermostat valve and tnen to escape thermostat opemng opens at detachable be removed from ItS can lay tapped full flow of water to the radIator a IS a by set IS t 72 l of SOC temperature by ImmerSing to test thIS opening a new Dunng decarbomsmg the thermostat The valve reqUISIte temperature but If It falls to open hnally tOp The up the manufacturer and cannot be altered In water It IS raIsed It pohcy to the should open under these cond tlons should be fitted unIt Overheating Overheatlng depOSIt In the may be caused slack fan belt a runnIng WIth the cyhnders correct carburetor by Ignltlon excessive too far carbon retarded faIhre of the water to CIrculate adJustment or In loss of wdter Fan Belt Adjustment The fan Ing the IS dnven from the crankshaft by a V belt thIS also dnv dynamo clamp bolts FIg 2 whIch hold the dynamo In posItIOn dynamo towards the fan Sl1de the belt over the fan and onto the pulley engme the dynamo away from the then made IS bnngmg by Adjustment the The belt should be suffICIently tIght to prevent slip yet engme A new belt can be htted by fIrst loosemng the and movIng the belt should have and crankshaft As have and 15 to 20 pulley the dnve IS taken t le fan belt tlght mm when the on 8 3 mIdspan V 4 IS of the slace between the generator pushed fumly pulleys It IS not necessary to to do so may cause exceSSIve wear to the pump beanngs lock the dynamo dynamo After the correct tenSIon has been obtaIned water securely the 5 In pOSItIon agaIn 63 2 Fig Fan belt Frost adJustment Precautions FreezIng hos occur hrst at the bottom ot the radlator or In the Ice ln muff fully car lS strength the hose wlll be used can to closed to be uSf d The stop bOlhng ln a strength but wlll m care up to the degree of protectlon accordance wlth lnstructlons Relatlons of ture s l strength Excesslve afforded appli ed v wIth the expecte topping by toppmg freezlng temperatures SolutlOn must be made up of alchol water and glycenne c o o 5 5 10 10 15 i5 1 10 1 15 I J f 35 J5 q I ItO 1 5 45 102030 40 50 Alcohol up m lth the contalner c 30 manu up wlth water v 25 when or advised by the ratio 10 A bOlling run make sure that the of the solutlon must be malntalned wlth antlfreeze solul1on as necessary reduces the When frost temperature fact cause must be taken not to result very low IS cHculatlon and may water advantage or of the solutlon facturers t lower connectlons e muff the may 7 0 60J 10 J I 5060 70 80 Glycenne water 64 water mD ture mIX Top up when the system IS cold coohng system has to be draIned If the contaIner and use run the mIxture Into clear a agaIn ProtectIon by Draining On coohng dunng frosty frost heavy draIned WIth water It IS IS rugs and musfs There cyhnder be opened whde ground draInIng taps pIece of must the taps ensure are when the engIne ensure A damage due coohng merely are sy stem cover to precautIons must of the free71ng to must complete be the radIator and engIne drain cocks two that they are the left hand one on system and the frequent clear that any so the water The must car mtervals be on level by InsertIng ThIS should be done obHructlon freed the by a Imme WIre should be carned out drammg hot IS draIned the that all water sUItable draIn the to opened by completely When the should be tested at taps to WIre may be flushed out to followIng block and the other at the base of the rad ator block The draIn dIately used the not obvIate any ImmInent not suffIcIent sIde of the Both IS to sy stern When ly where antIfreeze cars be taken engIne should be has been cleaned from should bE then aff xed notlce to run for a tImed Tnmute the system the radIatur IndIcatIng that the water has been draIned F ushmg To tIon the Radiator of scale cally flushed freeze effIcIent clTculatIon of the coolant and to reduce ensure In and sediment wIth In the radIator the WInter and agaIn when At Intervals to the forma should be penodI preferably before puttmg 10 anti The water takIng It out In the spnng system clear runmng water should be allowed to taps dunng draInIng the run a through untll It comes out clear from stIff pIece of enSure that they WIre are the dram should be Inserted Into the becomIng clogged not wIth taps sedI ment ThIS method of radIator the furnng tlce to flow up remove turn the bottom hose WATER IS the rad flushIng may serve well but In cases where excessIve the operator wIll f nd It more effICIent prac radIator and flush In the reverse way to thE ator completely upsIde down and connechon and out of the let top the water flow In through the connectIon PUMP After draInIng the water from the rad ator remove the pump unIt from cylmder block by takmg off the fan belt and releasmg the setbolts wIth spnng washers and hInge bolts to dynamo the 65 Cover 3 FIg Removing the D sconnect The shaft Put the FIrst out the pump Shoft the fan blades and ball hub pulley press pulley Water or hub on beanngs on Assembly pulley IS pump and cover combIned wIth one Ulllt the bench knock the shaft end wIth the U a dnft hard bar and draw type bench Take out the set pm from sht whIch locked the bly the shaft assem See FIg the pump body Next turn the body upsIde to down and press out the shaft from the vane SIde assembly the U on bench type The shaft and bal bly beanng can assem be drewout from the body Thus take out r the vane floatlng seal and seal whIch remaIned pump In the body 1 y It 4 66 Jl 11 r 1 al1 4 J 1 e8 S a 200 pun 2 t th LL W9 c of Sltet V Sltet cover G8de G8 SJ de SJ 1 Body oo t s B1oclt v R eassembl y The reassembhng of the a care sq Uld be pump lS a reversal of the pro taken to ensure that the shaft assembly lS fltted correctly for a sht a hole of set nng wlth a groove of shaft so as to lnsert and set the sald nng correctly cedure dlsassembly but Adiustm9 Fust the Clearance the Vane End and press down the shaft flttlng wlth a Body groove hne to lllsert the set pln Inserhng Thlckness 0 thlckness gauge 4 0 5 mm between the vane va 5 edge and lllslde e end on the U block bench Flg press down the Take out the thlckness gauge and fmd out good condltIon Screw up wlth the cover and cork washer l t Flg 68 6 of the body See IGNITION The fuel generator 6 III I Flg lllto 19mtIon COli The low rupted by necessary for 19n1hng the lS cyhnders power shown as system whlch a mlxture wlthln the englne current from the electnc aH The electnc sWltch lS 19n1uon system compressed SYSTEM through battery source ammeter 5 and and 19n1tIon 7 current voltage contact breaker flows the pnmary COli 14 lS lllter dlstnbutor Thls charges the through of the 9 netlc held wlthln the 19mtIon cOli lntermlttently thus lllduClllg hlgh mag vol tage The the hlgh hlgh voltage chambers of the 19n1te the fuel 16 dlagnose defects pnnClple In mllld parately To As head mlxture butlOn shown III Flg whlch lS sent current to the cyhnder alr lS current tenslOn cord 000 volts of the 19mtlOn The through At thlS moment sparklng In a self at the contact decrease the contact ln more pOlnts through spark to to 19mhon always have thlS dlstn hlgh voltage CHC1l1tS se COli has two Calls wlth pnmary lS sent and cut the magne the prlmary cord lS changes and by mutural created In the secondary In lnductIon voltage of the the pnmary Call secondary a vol call of the dlstnbutor contact breaker Call and causes resultIng plthng of pOlnts Therefore drop system lnduchon voltage the lnduced 10 conbustIon cyhnders and check the low and 2 or spark plugs lllstalled ln the The spark plugs are made the In hc fleld wlthln the pnmary Call tage of 10 dlstnbuted by the dlstrubutor the pnmary ClrCUlt lS provlded wlth condenser to prevent of secondary voltage and absorb the sparks at make and break con tac ts 69 10 4 3 9 12 V Flg I I Wlnng dlagram 2 Battery MagnetIc 3 4 5 6 of 19n1hon 9 sWltch system Contact pOlnt 10 Dlstnbutor Starter motor II Cyhnder Starter button 12 Voltage regulator Ammeter IgmtlOn sWltch 7 IgmtlOn COli 8 Condenser 1 head 13 Generator 14 Pnmary 15 Secondary 16 Hlgh cord cord tenslOn cord IGNITION COIL Hltachl Type CIZ Pnmary voltage 12 volts Pnrnary 1 current 8 ampers lS less than Ol Hanshm HU Check one cause ampere lf 13C current or more than three amperes Gap test 7 mm 0 275 lll or more 800C temperature of cOli 70 at 1800 rpm Flg cord termlnal 2 Pnmary cord termlnal 3 Secondary 4 Pnmary 5 Secondary 6 Core of pnmary 19n1tlon or and the voltage cOli COlis caused secondary heatIng or lntenor damage Wlth such a faulty 19n1tIon Call englne wlll ml can cOli COli non by lt be attnbuted to does not generate functlOnlng over sufflclent second shre except as Check of CHcult short thelr defectIve lnsulahon repalrs of troubles are very dlfhcult nal connechon replace a defectIve 19n1tlon Call But cord termlnal on Most troubles wlth the ary Pnmary SectIon of 19n1tIOn Call 2 I nspect I In cleanlng terml of cOli Remove the cap of the dlstnbutor and turn the crankshaft untIl the contact of the contact arm closes pOlnt Then sWltch on the the central electrode away from a metal lng the contact arm 19n1tIon on portlon by sWltch draw out the dlstnbutor cap and of the englne hand 71 the secondary holdlng ltS cord from tIp about 6 open and close the pOlllt by mm mov If blush whlte and strong and tj1e medii portIon When the sparks spark are feeble and reddlsh place unless the gap wlth the cOli must be defectIve are to be exact nght To check tery th en by lS cases employ means f11easure If there no of IWetal portIon when lS sparklng extremely a the cord does are all ammeter connect the pnmary Call and bat current at all coq the cod tester an thlS slgmfles a break ln the CHC1l1t must be renewed thorough lnspectIon not reduced when the condenser and 19n1tIon sWltch a call tester should be oflr 1 l or tIp of nght th e current In such cases the For created between the the cOli may be consldered to be all take Slnce these are vt 72 employed r c t u 1 j l Step I n Stwl h x ts rj SA DIAGRM 2 IlOor WIRNG ILl31dona 4 3 1 H th l el order 1ndt131 for 12V Ipm 31 NOTE I MODEL w I l GENERA TOR JJ Trouble Shooting LocatIon of trobles ndl tron Generator Equipped with Voltage Regulator Cause of tr uble Hitachi IICK 1 SCRDi W JrIng REGURA TOR ecA Hitachi IICA SCRDI fCCA I almost broken or grounded Replace wlrmg Same as at left Loose terminal defectIve ground MltsublShl DF N RR or grounded repair WJrlng 2 Remedy MltsublSh DF Nl RH Same as at left part 2 TIghten securely termmal or correct ground I Regulator c 2 Voltage voltage I regulator too Resistance voltage low In Cunstant voltage I Adjust by turnmg P relay screw operates at low voltage 2 Replace resistance Temperature regulator shorted is Cut out ill I relay Cut out relay pOints dIrty I or Generator 2 3 I Same damaged as at or WirIng 2 I Same as at left Poor brush contact Armature field COIl shorted broken WJrmg term mal loose or d Iscan nected W iring broken I I J Regulator 0 11 2 Carbon diSC dama ged 1 Cut out relay WIll not close or points Vibrate 0 Cut out relay Dress with pOint Dress paper with and off 011 Reseat or Repair I Same Same as at left sand clean Same as at left replace or replace Re hghten Same as at left as at left 2 or COil lead Wires shorted or broken I Replace wirIng Constant voltage 1 Repair or replace operates at low voltage 2 Re place carbon diSC I Re adJust I Re ad ust 2 He place relay switCh LharglDg 2 c relay cuts In at blgh voluge Yoltage COIl of charging currrht SWItch relay Is 1 AdJu tage t cut or cut out m vol replace the relay charging current SWitch relay broken 1 0 Z 2 It I t broken armature In field cod Poor brush contact Same as al left 1 R 2 Repair pair lt rC 1 e Wlrlng 1 1 Same as at left Poor groundmg Yoltag voltage regulator too I hIgh operated hlSh oltage c Regulatoc 2 Broken Wire on 2 COIl 0 3 A and mlnals Note B ter contactlOg J and B lJ holder hTlto Chec k and Same orrect 1 Adjut P at lousenmg t ter mlnals contactmg 1 1 2 as kit He adjust Tl too Broken Wire In voltage Call of con slant voltage relay A Same as at left commutator replace brush nt grounrlll1K Constant voltagr relay adjusted 10 al p I replace or and t t fi or WIre Generator oJ Short Re adJust brush shorted c 1 sandpaper damaged wire I 1 left Commutator surface dIrty sta blltzer 7 ohms sta blhzer 25 ohms RlplclC on RepldCL volt td nl Wt rtl 3 Repair anSl1tltlon 3 lr RLpc InslIlallOl1 When chargmg Insufficltlntly It IS neccessary to check not only the charKlng CirCUit but also to see If the ammeter needle IS stuck and to check for broken wire 10 coli low flUid level In battery difference an sptlclfic RravltlCs anternal hort clrcu t or damaged plates In battery l nd other cause 74 1 j i @2310a @ @23m @ a 42200 23122 mOO 3118 @ 7 mo 3U 32200 ID23ISI 1 23120 as Generator Flg I Nut 7 Spring 15 Brush 2 Washer 8 Ball 16 Brush holder 3 Pulley 9 Chp 17 Brush spnng 4 Spacer 10 011 cover 18 Front 5 packmg 11 Key 19 Rear Retalller 12 Armature 20 Brush 13 Flied cOli 14 Yoke 6 beanng ass cover cover 1 cover y l 1 AI fJ i 75 iIIIiiIIL J J J GENERATOR G123 Type 03 Voltage 12 volts Out 300 watt put Length Outer of brush dlameter of commutator Rotahon ratio to 2500 rpm 20 mm 0 78 45 mm 177m m crankshaft I pully 46 The generator lS mounted on slde of the englne the front left and lS dnven by times the speed As m shown the a dlagram generatmg system Flg the car body the gene lded to grou and the hne goes through the lator and ammeter to of the 2 termlnalls rator CUCUlt voltage charge The generator lS battery stant voltage type equlpped Flg 2 Voltage I regu 5 6 lator Ammeter t Battery 4 A I S of a generating crabon regu the a con wlth plle type sy stern Generator 1 3 Dlagrarn 2 46 fan belt at I of the crankshaft The constant Fuse generator Llghtmg voltage type charglng mam voltage at the gene rator termmals regardleds of the talns sWltch 7 when Lamp a vehlcle flxed speed that 15 over a wlde range of englne speeds and also the load In other words conformlng to output conformmg to battery charge the charglng current lS automatically regulated 1 or When the load lS lncreased dlscharglng preventing exceSSlve charglng the output wdllncrease correspondmgly so that the l1fe of the s uddenly battery wlll be prolonged produces an the state of 76 H Gfmerafor As nstruction 3 generi shownti lFlg J ventllated by nd called enclosed ServIcIng a ventllated type removable band to faclhtate Care J the shunt wound brush u lnspectlon coverea Wlth part and cleanlng Generator should be taken to see that the exterlor and the generator always kept ntenor of the clean @ t 1 it La FIg 3 Generator sectloral Vlew sVprmg I Frame 5 Brush 2 Armature 6 Ball beanngs 3 Fleld 7 Fan 4 Commutator cOli pulley 1 rS A S T l 77 f II To dlsassemble the b nd fust remove press the brush cover the dnve Then after removlng pulley out the brush from pull through bolts connectmg the end sprmg back and the holder Then by unscrewlng the two the generator can be dlsassembled as shown m Flg 3 All dlsassembled parts wlth the of the fleld cOli and the arma exception ture cOli are washed wlth gasol1ne before and belng lnspected reassembled When reassembhng the front beanng bemg of the ball beanng covers type lS fllled wlth magneto grease whlle the drops of lS lubncated wlth a feYI engme Oll hght lnstalhng When the generator that the fan belt see beanng rear After properly lS all lnstalhng on to the engIne care should be taken to tenslOned electrical connections are securely tightened and cleaned T roubl e Shoot ng Dlagnosls through motonng test dlsassembhng the generator before for lnspection be made cna overall check an through The constant test the up motonng voltage genera tor operates together wlth the vol tage regulator whlch bemg a comp hcated unlt dlscover troubles Thus ln the the by checkmg of the generator alone lng test makes thlS a generator A performance through motor efflClent an For pau operatlOn test F makes lt dlfhcult to the re motonng fully charged battery volts and about 50 ampere ammeter are requlred 12 Flg capaclty Wlth the unlts connected for the tester The motor and from the condlbon of the current and ln the generator can be checked a A The generator lS ln 4 generator speed lS turned as troubles normal condltion 1f the ammeter mdlc occurmg tes from 5 to 7 amperes and the generator rotates smoothly wlth only a famt hum If the generator falls to rotate there lS trouble m the electncal cnCUlt Th rated currents 8 amperes at 750 r p m If the ammeter mdlcates B short are or grounded It should be noted that slstance hlgher than the rated values there lS a provlded there are no mechanlcal defects fanly large current wlll flow 1f the fnctional re connection a of the rotating parts If the rotation lS lrregular lS great then lS a short 78 or ground m the armature and 1f the rotatlOn lS the fleld pomter ground the lntenor parts If the ammeter lndlcated below the rated values C lS uneven there slow or hlgh fnctional part parts are made Wlth test the ed to see troubles shown lf lt case repalrs or ln or lf the rotatlOn the lntenor replacement or parts of defective a be check can faulty and the approxlmately located lS In multltype portable dynamo by uSlng tester be made generator maklng these tester 5 Flg the advanta more use a Furthermore easlly defect connection lve the above motonng generator but lt would be to a troubles wlth Dlagnoslng tester lS In thls a geous the trouble wlll also be due to short or exceedlngly vlbrates ln the trouble may be due to short or ground ln lf the rotation lS normal but the ammeter slow Furthermore calls from the In car the A and F termlnals of the generator connected together can removlng wlthO lt tests a test are the voltmeter connected between generator and A termmal and the ground IS the ammeter regulator at speed lf termlnal and the medlum speed pOlntet current lS lS turned generator 000 rpm about 2 ammeter or connected between The engme battery over B lS falls to If the move belng generated but when the load lS mcreased 20 amperes the voltmeter lndl the generator cated below 13 volts When the the armature generator growler lS lS 5 Flg to Generator and lS defective Regulator and requlres repalnng dlsassembled and the parts used for thlS purpose tester m the are to be followmg lnspected P 0 mahner c 1 ft r ji p Jit Testmg for Grounding in Field Co ground termlnal of the held COli lS lead lS growler lS grounded whlle the other The removed one lead from the contracted wlth the other held call termlnal the fleld call lS grounded so lamp on the growler hghts the If the test lamp falls to hght replaced wlth new COli free from groundlng If the test lt should be held cOlI1S 79 that Testing for Shorts The fleld cOli and an placed lS termlnals of negabve are Lead Wire Test To test the lead both ends the held cOli one that wue to the If the shorted and should be lS poslbve mmeter shows replaced 5 amperes the wlnng from the lS If the test lS a break test lead lS contacted Wlth lead contacted ammeter between the an the two leads from the wue there hght wlth Circuit Test of the lead lf lt falls to senes Hltachl 10 the generator A termlnal If ln 12 volt electrical source a exceedlngly hlgh readlng Rated currents Field Coil In body one growler lamp hghts the lead ln are there contacted wlth are no defects but whlch should be Wlre end of the lead and the test brush holder to plus lamp hghts WH7 the l replaced and the other test ad wue lS grounded Plus Brush Test One lead from the growler lS grounded and the If the test lamp hghts plus brush holder grounded and should be replaced other lead To test If the armature contacted the brush holder lS in Armature Grounding for Testing lS I wlth the grounded lS or not one lead from I the growler lS contacted wlth the armature shaft and the other lead wlth the commutator If the test segment the armature lamp hghts IS grounded and should be replaced Testing for Shorts To growler rotated test for shorts and wlth by hand ln Armature armature call plece held If the armature cOlI1S Ch lron In uon over plece there non the lS shaft lS found to be exceSSlve unlform worn or badly rotatlOn so that not smoothness of rotabon be and cause the bent parts of the lS the only wlll the output core becomes be reduced and destroyed but thls wlll cause the shaft to bend The speclflcabons should be referred to and replaced or repalred to touch defecbve parts should be top beanng bushlng lS checked lt should be replaced If looseness between the armature and the dunng on the armature Bushing The clearance btween the armature shaft and and If the placed replaced Armature Shaft and cking lS call attracted to the armature call lS shorted and should the armature the armature 80 Armature Coil Checking ThlS lS vlsual check up a and the commutator nechons are The connectlOn between the armature cOli lnspected and are Checking exceeded the of the depth that the worn so dlameters between the ln or It largest segments from mlca When the commutator surface lS wlll not dlrty 2 commutator surface paper but lf lt lS Conhnued lS worn use so lS only worn as by supportlng both However FIg 6 result but wlll also hasten commutator surface ends lf of oXldlzed can of the armature worn over a lt the descnbed above 3 rough or 4 mm the lS commu lS worn the brushes that so contachng burmng damage on the of the brushes If the be corrected wlth No 00 sand wear correctlons can be made machlnmg should be lt O correchons should mm ln shaft and mm ovahty of the surface of the or only elhphcal stepped poorly and causmg decreaslng output and further lt or whlch con and smallest dlmenslOns tator becomes less than the allowable hmlt of 0 be made defechve soldered or Commutator When the commutator becomes dlfference all loose corrected only shown as ln replaced commutator that the depth of the segment mlca lS shallow may result ln part of the mlca becomlng hlgher 0 I than the surface of the commutator ThlS condltlon wlll make the brushes Jump and damage The ed by produce sparks to burn and the commutator surface depth under carefully of the mlca the cuts cuthng made wlth condltlon shown m Flg lS bemg 6 Flg A or B the wear plece of are hmlt made or lS sandpaper er lS revolved 150 lnstalled 2 Commutator segment However r I ln the commutator surface 1f the brush replaced flneness 18 wrapped To the holder over the of about No lS worn beyond reseat the brush around the sandpaper 81 320 a commu the hold used sandpaper rahng au and after c1eamng compressed brush lS wlped wlth a dry cloth hnlshlng the Mlca lnsulahon properly agalnst lt should be blown wlth After reseatlng the dust off thoroughly Incorrect hnlsh I It should be of about No For Correct hnlsh Spring by reseahng broken tator and wlth the brush commutator I Brush and Brush If the brush does not seat A corrections Undercuttmg l then hnlshed commutator stone Checking 6 The sandpaper lt wlth 8 correct hacksaw to the a commutator surface by smoothmg lS lS The permlsslble wear should be replaced max brush of the brush 1 18 3 the length over If the brush sprmg does not have the proper tenslOn B whlch the lt should be replaced Slnce the brush spring has conslderable effect on the proper contact lt lS necessary to determlne lng between the brush and the commutator the tenslOn by the tester of spnng tenslon wlth brush lstalled A weak spnng wllllncrease the electrlcal reslstance tlng on brush whlle too the commutator Thus and commutator correct strong when a causlng sparking spnng wlll hasten replacIng a and plt wear ln good grade brush the and used spnng should be Slze VOLTAGE REGULATOR On the voltage regulators used Hltachl lS the crabon plleHltachl 02 generator F Screw P Screw Cl r 4 e F Flg Carbon Plle I 1 1 Carbon PIle 1 ype Voltage settmg m Type Voltage Regulator R123 02 Model Cut Model R123 voltage no load relay Release current 14 5 15 5 volts 2500 rpm generator 12 5 13 5 volts 1300 rpm generator Less e 82 an 5 amp Construction and As shown m the above magnet call Plle Operation movlng hgure core the regulator conslsts and flxed spnng res of the carbon stances pnnclpal part lS the carbon plle whlch conslsts of several By applYlng pressure to both ends layers of thln carbon dlscs of the carbon plle as shown ln A the reslstance Wlll change The Flg uhl1zahon of thlS charactenshc lS the carbon Plle voltage regulator the wumg dlagram of whlch lS shown ln Flg B Wlthout a voltage regulator the generated voltage wlll vary wlth the speed load and other factors but a carbon plle regulator wlll maln taln constant voltage by the followlng actlOn The dozen a UJ IL l a UJ l RESISTANCE III Flg Sectlonal Flg A Vlew of carbon B Charactenshcs of carbon plle plle regulator 1 Plle pressure 2 Carbon 3 Plle holder 4 Movlng 5 6 Compresslon Compresslon 7 Magnet 8 Flux screw plle core spnng f spnng call adJustmg is screw B I Flg 1 2 3 4 2 Carbon Wumg dlagram plle Stablhzer 6 Cut out relay Spnng Magnet call Temperature compensahng reslstance 83 5 When used ln the current hlgh conJuchon wlth the generator and through the magnet cOllmcreases force greater hve current through Thls Conver ed current mcreases Thus lator hmlts the current by speclally provldlng a when the ely reslstance so that the decreases the gene becomes low voltage by properly matchlng means current cut Also the generat pile the carbon of the current call out becomes voltage and makes the attrac the held COlI1S decreased and also rated current held the carbon lncreases the there the cOllln lS no requ need of wlth the senes for lmprovlng the chargmg charactenshcs at low speed whlle the flxed reslstances are for prevenhng vanahons ln charactenshcs due to lS temperature changes Wiring Precautions In connectlng up the generator and the voltage regulator shown hons ln Flg 4 hght and damage other on the termlnals to make the make to get to connect the However should be care taken to note the slgns connec sure ground not to for termlnals cauhon should be taken not to the termlnals and screws parts by hghtemng more For than ne are cessary wlnng heavy used between A A and B B because of large 3 Fig p Voltage regulahng pnnClples currents and nnts F F I Generator 2 Fleld call 3 Carbon plle CompresslOn 4 55r f 6 Wlres spnng ger ovmg core Voltage the COli Wlre lS used between should be taken Slze have penod placed between these flowlng hght Care take the Wlres of these been of hme serVlce ln they are In these cases Slze Wlres wires wound wIth for long repaired or re the used and should be black amply tape to mlS a same or should be used to formerly connechons not to When the Wires lar replace WHe to wlre soldered and preserve the In sulahon 1 RepBris r d ustment i 4 InspectIon J T e oltage regulatmg part of the voltage regulator has been subjected tv ngld mspectlOn so that there should be prachcally no change whlle m use and no If trouble should occur however the regula necesslty for adjustments tor should not be touched contrary lead to above should be ments on hand Wl thout prevlOus preparahons troubles Before blgger thoroughly understood adjustments should be and made 84 adJushng wlth a or the thlS dll prmClple s on the outlmed voltmeter and other lnstru correctly When adJustmg Justlng core dlfflCUlt to the gap between the ad and the movlng deterdnne that lt lt core thls dlstance lS of lmportance menslonally so to make thlS adjustment electncally shown ln Flg lS dl as A 4 Flg Ad usting when Voltage long Period Changes Wumg dlagram after of ServIce Flg 5 D C Voltmeter E Wlnng durIng C P u1ator Ree adJustmg tJ 7 f I adjustments In thlS case As only lS shown Flg battery and vanable WIth the out lS As voltage tage lS lS through connected the Vla an plle t regulator at 2 no cicompreeS wlOrli1 vo1tm t Y a Ul S Wdtch ClrC t T ammeter to the 7 reslstance generator runnlng rated speed generator and meter made 5 to the A termlnal of the TermInal B connected of the In are load 500 battery and reslstance rpm engme I CHC 860 rpm llt CUt the volt read shown so that hlgh ln Flg 1f the tlghtenmg the plle compresslOn spnng wlll and screw ln conversely 1f voltage lS low 5 unscrew 85 ralse the the vol To measure the cut and cut voltage the voltmenter connect ln out current as shown wlth the dotted hne Flg ln 5 to term mal Band make measurements through the CUCUlt of termlnal Band A fully charged battery Measurement of the lS made by readmg output the volt meter and ammeter through the vanable reslstance CUlt wlth the P Screw cut out battery Dunng urement of the 6 Flg ly the the ln charglng ClrCUlt such defects as burnt contact Ad ustmg When are made and the regulator spt ad fifled t lS as no load and 2 after speed F lt shown revolvlng 500 rpm screw be check the cut out as practlcal relay a necessary ln lS t at the I tlght to 15V Q ln Flg at fast but lt wlll 7 voltage nse to agaln SET PoSITION T1GHTEN PILE ADJUSTlNII 8 Flg Posltlon of screw and voltage 86 Plle no re for Reassembly clockwlse dl ThlS wlll cause the drop pOlnts and repaIr The pressure screw connected up to the ge ltmg core enedoby turmng rectlon the termlnal thlS lndlcated conslderably case meas load regu reassembl1ng adjustments throught the adjusting core plle nerator at Regulator In thlS the no termlnal B voltage should If there two voltages dlffer same slstance latlng voltage voltage and A Clr CUCUlt pressure load termlnal Thls lS due to the fact that fust the gap between the at F screw and the movlng core to Increase the of the slstance contaclng re plle sheets and lower the termlnal vol Lock Screw tage As tIghtened the F screw further the movlng core lS the gap to reaches 0 and the termlnal voltage shows a mlnlmum value Wlth further nghtemng the adjustIng screw belng push the duectly and the Thls voltage nses rapldly as the push up voltage The voltage lS measured by flux to connectIng 8 Flg as should be followed ge on as shown m Flg 9 ne from thIS sta Wlth the connections made 1 rator at Flg ln no 9 have Z Z 500 the gene B termlnal dlscon load and rotatIng nected speed maklng In adjustments cessary shown outhned below procedure The core AdjustIng voltmeter be a tween the A and E terrrlnals at speclfled rpm Set the plle pressure screw the adjusting core pOSl tIon 3 Tlghten F screw up and determme the If the F voltage ened beyond the screw push up 5 volts 2 4 If by adJustmg obtamed but nearly than 10 the lS 5 volts procedure voltage Case shown as posslble AI ln lll 5 volts the the speClfled push push up AZ so push up that up up p age v J cJfr1fliould voltage the F screw lS up 87 r voltag J 0 I cannot be unscrewed back If more shghtly tIghtened Then by followmg loosened hghtly screw lS screw lS push extremely fast when near Case and the P the P measunng l nses the F screw the less than 10 to the noload for Wumg hook 9 Flg tight voltage the voltage 500 rpm be taken to tighten as slowly 10 push lS voltage lS redetermlned 5 When the lS pile glven a reqUlred voltage l1ght lS obtamed shock to settle the plles the P screw after whlch the lS flxed and the push up voltage rechecked IS 6 After rechecking load voltage the F 16 volts 2 15 screw 500 rpm unscrewed lmtil the lS shown lS speclfled The F screw lS no then flX ed After the P and F 7 then restarted until lt lS checked to fore maklng see thlS screws are flxed the generator reaches the that lS test speclfled speed speClfled value has the the plle be glven a l1ght and the It lS shock ln lS no It stopped load lS voltage lmportant that order to bnng be lt to stable condltion a When the above adjustments have been completed the output should ThlS IS checked by rotatmg speclfled value and speclfled speed lmpresslng a load conform to the automatically the generator at the Checking The out Cut out Relay at whlch the cut voltage relay pOlnts close lS checked voltage lS determlned by slow AdJust Spnng ThiS Relay p01nt ly slng the speed of the gene rator and readlng the voltmeter con lncrea nected shown as 10 until the Gap The proper cut ln from 12 7 13 3 volts at to Flg ln close pOlnts voltage lS gap L r Arm 250 I lS If the voltage checked rpm found to be too hlgh when the close pomts shown arm the m relay adjusting Flg 10 lS lowered to weaken the flat and lf too spnng low the adjusting arm lS ralsed tt strengthen the spnng However hould be noted that the proper gap dlstance of the relay parts are gap 0 9 Relay pomt Arm to core Arm to core The cut onths with a badly out Burnt flne hie worn After gap pomts Pltted ered 0 open dresslng and other 000 sandpaper replaced out relay Upper left shows relay wlndmg detall out 7 0 0 8 4 mm 0 5 mm be lnspected about once ln every two poorly contaclng pOlnts should be dressed or pOlnt dresser but lt wlll be necessary to readjust the actuating voltage of the cut out If the correct but the meter needle wlll be cut mm pOlnts closed relay pOlnts should should be rect dlmenslOn Cut gap No 10 Flg lt In thlS 88 case the to be pOlnt gap to the relay lS found to cor be ldhng pOlnts ldhng speed should be low vIbrates when the englne qUlckly damaged so that by adJustlng the englne pOlnts found lS the Ammeter Indications Checking through Wl th Those famllar 1 plle type type when changmg chargmg when the the third brush may thlnk that there lS to the over lnsufflClent ammeter there lS no need to worry However durlng dayhght Slnce the Reversely 1f after dnvmg for seve battery lS fully charged shll lndlcated around and the ammeter ral hours durlng the day pOlnte check the slde In thlS case lt shows lble tro 15 amperes on the plug for of Also check lncorrect the battery flU1d level and speClflc gravIty Wl ring and see lf any Wl rlng paired ImmedIately lndlcahon 2 small lS the ammeter Dunng mght dnvlng ampers at 30 to 40 km check 3 Dunng peres charglng y even ln the manner ld l aro lndlcate lld sho pOlnter If the lndlcahon be made lld sho up the d per hour lS as more han descrlbed 0 when 10 mlnus in 30 am lt abo battery fully charged lndlcated lmmedlately after operahng the wlth the current may be There lS no need to worry SInce th s lS to restore the starting motor lt wlll return to the normal charpng temporanly consumed battery and condlhon wlthln 5 mlnlltes STARTER MOTOR power Torque 1 4 HP I 8 o Brush sprlng tenslon Length of brush 14 34 Dlameter of commutator 9 S1l4 03 mm 551 m mm I 340 m i4 3 9 voltage Over Lock torque 5 volts 0 9 kg m Bendex type Type of pmlOn gear on f 120 nng gear Amendment l1mlt of short dlmenslon on shaft dla o pmlOn slde 89 l f 4 r 9 on 98 0 2 Ib 1 0 Less than 500 amps Starhng current plnlon gear Number of tooth 12 NRD kgm mlnlmum I 9 0 I kg 1 13 Number of plnlon gear teeth Number of tooth 4 12 volts Voltage Horse I MA Model I mm 0 004 m f Ammendment hmlt of short demenslon of shaft dla rear Gap end O I 0 o 038 o 02 o 03 o 2 mm 0 008 m O I mm 0 004 m mm 04 m between shaft and bush pmlOn slde Amendment limlt dlttoed gap Gap between shaft and bush rear end Amendment l1mlt dlttoed gap 0 095 0 76 0 mm 0 008 mm 0 mm 0012 Amendment l1mlt of deflechon on shaft Amendment l1mlt of short dlmenslon Dlttoed degree 2 mm 0 m polan o 05 o 4 002 0 mm 016 length Amendment hmlt Construction and m zed wear Bush 08 of real clrcle Dittoed l1mlt of 0 mm 9 mm 0 36 Operation Flg Starter 90 motor In 0015 0 0038m m m 0 0030m The starter motor motor for the front use In right lS a I 4 horsepower shmng startIng extends out backwards wlth m Flg on the englne 16 on slde of the transmisslOn Wlth lt6 plnlon gear directly op The constructlOn of the starter motor lS Slml to the ring gear lar to that of the generator but dlffers poslte type electric lnertla The motor when mounted a only pInlon group that lts ln lnstalled armature shaft on the end as shown 2 2 FIg Bracket I A sectIonal Commutator 2 011 cap 3 Yoke 4 Fleld cOli 5 Fleld Vlew slde 6 Flat head 7 Armature 8 Brakcet Nlpple 11 screw starter 9 10 core of motor Mountmg slde Plnlon group Band 12 Through 13 Termmal bolt bolt 14 Commutator Of The connectIon starter lS shown ln The starter sWltch for dlagram Flg 3 lS a key type the con blned Wlth the 19mtIon sWltch By turnlng sWItch tIon the relay on moves to permlt to the the nght duec sWltC l magnetIc current to flow to the starter and cause the armature to Flg 3 start turnlng Starter Connection 1 2 3 Battery Starter dlagram Magnetic sWltch pInlon ln the 4 Starter motor the However does not pInlon group turn because of the but advances button suddenly along counter the welght screw cut on the plmon shaft and meshed lnto the 91 After advanclng about 14 mm gear the plnlon completes the mesh lnto the and dnves lt Wlth a Ing nng gear The direcbon powerful torque ln whlch the pmlOn moves lS from the end of the shaft towards the starter rlng bracket thus speed ltS reducbng the bendmg torque becomes greater than the After the englne load no starts and of the starter speed the pln klcked back to unmesh and return to ltS former poslbon lon lS Operational Precautions The lnstrucbons to be observed when I The starter should be the englne starbng mounted securely on follows are as the englne and should not show any looseness 2 The starter leased sWltch should be when the englne lmmedlately Excephng m extremely wlthln 3 The starter turnlng 4 the starter When the 10 seconds so cold weather sWltch should not be the englne sWltch should re normally when the englne the pmlon to start come ruimmg lS to rest before agaln englne falls to start after In thlS case battery operated allow bme for do not conbnue turnlng the check for key turnlng bme the starter key for after bme but try to over save the cause of the trouble and correct that the engme w1l1 start While in CheckIng I sWltch does Wlth lS not a used start some reason Slnce the to return 1 s and should be 10 seconds If the englne falls to start the operated properly starts s OperatIon fully charged battery and wlth the lamps l1ghted the starter If the lamps become dlm especlally when the engme the current lS flowlng through the starter motor cot but for the armature lS not Jle trou1 a lsually Careful check should be made turnlng starter plnlOn may be locked caused ln the flywheel by turnlng on nng gear and unable the starter whlle the englne tlll runnlng 2 turn When the If the sWltch nal and checkerJ or a fects hghts ln sWltch remaln sabsfactory lS starter motor the sWltch condltlon connecbons of the If the turned up and the bnght but ltS the above troubles occaslonally so that m starter and shows thlS case are defecbve motor falls to of all the terml sWltch and starter movement reslstance due to loose connecbon a If after starter should hrst be checked then the condltlon battery runs hlgh badly dlscharged battery 3 rate lS ground cates elther starter the although lS ln slugglsh the starter are lt lndl Clrcult corrected and the starter falls to ope performance lt lS due to lnternal de lt should be dlsmantled and checked 92 3010 cover cover 3010 Front23 16 42 233 Brush 3010 23 62 3010 aSher 23 39 VI @ 3010 r23 3 Y 3010 de gu 3010 on asS 23 10 j23369 n p iLI spring e nde 3010 I BrUsh 3010 r23360 w 1 spring Insulatnl Return 23 92 23 6 pe p pJ ij 1 @ 3010 BruSh 23 79 31301 0 It 2 26760 3010 23 6 e t a S A 23 15 Nlo t l3eL r L t Armature to 23 37 @ asher i e C L I 0W I Dismantlng and Disassembling 1 The starter mountlng The two 2 ed be dlsmantled are removmg the two stud nuts front end when mount removed After removlng the band 3 easlly by the englne bolts on the starter rear cover on stay the englne on can the starter the brushes and lead cover re Wires are moved By properly protectmg and hold1ng the 4 shaft lS the armsture body out The armature and the front cover are taken out 5 together the cotter pln the plnlon group from the armature shaft the pln the end of the shaft lS pulled out and by removlng the pInIon nut 6 on pulled starter lon To group remove lS removed Inspecting and Repalflng Parts The same procedure as that for the generator parts lS followed determlnatlons parts belng cleaned and lnspected after WhlCh whether can be reused or lf or to replacements repaHs they are are the made as necessary for defects and lf the tooth face lS worn or lUspected be Worn the should or broken the tooth edge IS damaged repalced plnlOn hasten the on but wlll wear teeth wlll not only make the gear mesh poorly In the wlll cause ben ng the opposlng gear and also poorly meshlng gears The plUlOn I armature shaft lS thlS last reason For to also check the lng lS found worn or care should be taken when lnspect and take remedlal measures lf the nng gear flywheel When damaged the plnlon lS found defectIve replaced the entue plnlon group 2 When shaft to bushlng that for the mature we lS bendlng generator and replaced corrOSlon of the found core are Speclal 3 corrected to the 5 to see that core lnspected speclfled they are not damaged are checked and gap hmlts or the ar contachng and msulatIon tested by ln accordance wlth the pro to lmprove are or At the corrected or correct the same hme replaced carefully mspected and Wlres found should be replaced one part especlally damaged by burnIng wues are An armature found wlth stnctly repaued Especlally and the brushes are reseated sprmg The lnsulatIon on the should be core the same manner as by pol1shlng contachng condltlon or ln 011 The armature lS wlth weak etc the outslde surface of the armature or the lnner surface and the surfaces palnted wlth be removed the brush and brush 4 shaft attentlOn should be glven to the clearance bet cedures outhned for the generator brush In on should preventive check the armature to the armature clearance the armature and the n rust lnspectlng the msulatlOn test 94 Assmbling and Testing Starter Reassembhng lS performed by followlng the reverse procedure for dlS All fnctlOnal parts are lubncated wlth mobIle all SAE 30 assemblmg whlle the beanngs are coated Wlth a small amount of grease CIrCUlt ln the sWItch and causes the magnetic close also opens I CUCUlt maln S2 In the magnetic CIrCUlt to the starter sWltch button opens the magnehc CUCUlt WhlCh Releaslng Sz Causes for sWltch magnetic fallhng operate to can be dlvlded mto electrlcal and mechanlcal sources Causes for electncal troubles Current fallure A the through magnetic and defective sWltch ln pressed cOll magnetic WIre due to broken soldered lS add the magnetic sWltch connection from ground and the current falls to pass most of the trouble cUCUlt connection between the mlnal magnetic CIrCUIt ln starter sWItch button When the the call Wlre to the ter magnehc body Defective contact B When the magnetic CUCUlt ClrCUlt ln maln lS satisfactory due to Sz and Sz lS contact reslstance closing but only and the a Opposlte flOWlng hlgh In elther case the trouble Sl opening but 52 remalnes closed s the of the core or of the hes ln contacting pOlnt faulty movlng roughnes Therefore pohshed the surface well then the operation wlll be surface come satisfactory small current case of sWltch Causes for mechanlcal troubles gUlde shaft on the maln clrcult Sz sticklng agalnst the movlng core be ln thlS case hole can made Correction cover by loosenlng the cover them 4 so that the shaft moves freely and screws pleces retightenmg operate lS caused ln of the magnetic sWItch FaIlure to 2 by the Precauhon In removlng nuts from the when many cases lnstalhng or magnetic sWltch removlng cables maln Clrcult termlnals the lower nut of the double nuts should If the lower nut IS loose whlle unscrewlng the the termlnal to cover the termlnal bolt may turn together and ground be kept and ln cause Starter The a tightened damage Troubles followmg state the starter I state IS lS a Their Causes and Remedies l1st of troubles WhlCh lnstalled lS checked to If lt cannot be cranked can be determmed from the the englne Starter falls to turn The engme If lt on can be cranked easlly cked and corrections made see lf lt can the englne the starter accordlngly 95 lS be cranked by hand at fault and should be checked mcludmg the wlnng should be che Is the flUld battery to see If lt run lS Check the down 1 over speclfic graVlty of the battery recharge or replace the battery as 240 and found necessary All loose battery and ground cables should be cleaned and properly tightened Magneto grease I No or Gargoyle BRB All cord connections carefully tightened and speclal tentlOn glven to the condltion lnsulatlOn by testing slngle umt usmg ed battery Tests a a 4 Flg Torque testmg braklng In thlS motor when lnstalled starter flrst warmed up Then wlth the throttle valve the starter lS actuated In addltion made easlly lf and a starter motor tester lS 9 on lS ln used made wlth or m torque wlth 4 Flg lS by measured the normal value case should be 0 To test the as fully charg are shown apparatus whlch apparatus the starter a starter motor tester the at of The assembly check made lS are kg m the englne fully closed performance the englne pOSltion tests can be accurately Construction of MagnetIc SWI tch and Instructions The magnetic sWltch serves to close permlts starting large a or The starter pnnClples of stopped operation the sWltch can be lS trouble m lmproperly contacting from through to keep Flg 4 the cu Closmg the magnetic lt should be corrected the magnetic Clrcult starter brushes the brushes and corrections or the armature should be checked After motor serves seen sWltch S 1 allows the current to flow If there For apparatus when the englne lS belng started battery and the starter motor and current to flow and actuate the starter when the engme lS cUlt open the lS an the ClrcUlt between the together wlth replacement made as found necessary If all of the above checks wlth theH made and the starter be ln the starter shll falls to corrE operate spondlng the trouble repaus have been be assumed to can ltself so that lt should be removed from the engme and checked Thls ter lS lS exceedlngly not locked pmlon usually caused by lS not too fourth severe speed thlS trouble badly It lS the englne for the worn can and but care should be taken to rare mto flywheel gears checkmg and by plaClng back and forth rockmg frequently repeated car see the starter repaus 96 that the star Cases l1ke meshlng lmproperly and be remedled the nng gear the gear thlS are If the defect shlft lever lnto to free the gears If should be dlsmanted from r III 1 Q l Flg 2 5 Magnetlc Starter turns but ltS sWltch but lts turns turlllng power IS weak and falls to start the englne If the trouble ln lS magnetlc sWltch scnbed a down run and stlcklng the etc tator due to worn ln checklng and repalrs precedlllg chapters the battery are If the outer surface of the armature starter should be dIsmantled BesIdes the above If the trouble be ty lS repalced but 1f lt IS and not allowlng the Starter should be repaired Ratthng nOlse by retlghtenmg correcting commu same manner rubblng agalnst the core as de the repaHed of the plnlon meshlng lmproperly teeth bemg badly worn the screw gUlde on the pmlOn nOlsy when nng gear or the gear caused by ln gears shaft should dir belllg operatlOn checked and lf the teeth lS are deformed they replaced loose starter mountlng by brushes lmproperly contacting only produces nOlse thlS condltion not as bolts are corrected the armature reqUlres but wlll hasten wear on parts NOlses made by caused too lS bushlng so the and bushlllg lS lubncation or Cdse the troubles damaged the bolts NOlse caused tlon the IS due to the exceedlllgly They flywheel both there ln and pllllon to advance smoothly and causlllg Improper the shaft should be cleaned and olled meshlllg 3 lS dirty made dlsassembled and due to the gear loose termlnals brushes by worn the armature large a parts should due to lack of all Lubncate once reqUlred lS about 0 5 be so the core whlle ln opera Wear between the shaft replaced that attention should be glven every half year USlllg moblle Oll and lubncate the of all rubblng agalnst clearance between the armature shaft and the cc parts through the Oll for each bracket 97 good grade mpples to proper of machlne The amount BATTERY lZV Voltage CapaClty 50AM ZOH Earth Speclflc gravlty of electrolyte Level of electrolyte The CEDRIC ZOOC I Z80 at 10 Above mm electrode eqUlpped wlth one of the above makes of battenes The speclhcatlons of the Japanese Standard Type battery lnterlor construction conslsts of 6 cells each havlng a termlnal voltage of 2 volts the voltage produced between the and term nals be lS meetlng the lZ volts lng the on and when Installed ground The battery the car lS the car the termlnallS made when mstalled located slde of the nght on on englne CH4RGER the 4 room whlch makes H easy to lnspect when the hood lS ralsed However there to be lax ln only tendency servlclng the bat care wlll shorten the hfe of the battery ltself but wlll lower the performance of the care car so should be taken to malntaln the of condition 0 a Improper tery not lS of the battery ln DILUTE that always SULPHuRIC Al OISCI t AGIO CljFUC SlJlPI RGINO 8 the best CHA ACID GING The constructlon battery together Flg wlth the chemlcal action caused by charg ng and dlschargmg are shown n Flg The constructlOn Chemlcal actlOn of battery I exceedlngly slmple conSlsting of ebonite cells hl electrolyte ln WhlCh are placed chocolate colored posltlVe plates and gray colored negatlVe plates wlth wooden separaters lnserted ln bet ween the plates When a load lS placed between the ppSltlve and negative termlnals the battery wlll d scharge due to the chemlcal actlon of the active sub 1 e lead dIoxlde In the poslhve stanceS plates sponge form lead ln the negatlve plates and dllute sulphunc aCld ln the electrolyte occur I In thlS case the lead ring wlthln the battery as shown ln Flg dlOxlde and the sponge form lead react WIth the dllute sulphunc aCld lS led wlth the lead fllm on porhon and the sulfate the surfaces of both the portlon comblnmg to form a lead sulfate posltlve and the negatlveplates 98 Thus the as becomes wscharglng dllute more the sulphunc speClflC gravlty drops contmues the aCld the electrolyte dlscharg capa ln and the a charger lS If at thlS hme Clty b ecomes less placed and termlnals and current forced to flaw pOSltive negative between the ln the opposlte dIrection to that of dlscharglng the lead sulfate covermg the plates wlll be decomposed to Increase the denslty of the dllute sulphurlc aCld ralse the The above speclflc gravlty and restore the battery to ltS former state lS an outhne of the dlscharglng and charglng pnnclples of the battery It lS requested that these pnnclples be thoroughly understood before serVl Clng the battery ServI cmg I ExternallnspectlOn Rust corrOSlon or Damage Damage It from so termlnals battery on battery battery posts and lmproper feaslble to check the above pOlnts lS the ln case ln should be taken to Care car that any abnormal corrOSlon keep the remOVIng the battery can qUlckly be battery clean at all times overflowlng of the connechons and other vlslble troubles tery flUld contact wlthout of the bat detected and the cause determlned Battery electrolyte 2 FIUld level battery flUld gradually decreases due to the loss of water the vent plugs In each cell caused by evaporation and electrolyhc action flUld level It lS are removed and the checked Important to malntaln the If the flUld 24 above the flUld level at about 20 to mm battery plates fluld wlll rlse due the speclflc gravlty to level becomes low becomlng con of the wlll become the paste m the exposed part severely centrated plate 5mce the concentrated through oXldahon dlfflculty wlth together the battery performance wlll be lowered recovery ln and shortenlng of the battery bfe The flU1d level should be checked about tWice or a a week hot reglOns In dUring week dunng wlnter the flUld from In If vlsual caps can the or top once cold replemshed and the flUld glOns found low summer and about be observed wlthout the are re lf used PERMISSIBLE HIGHEST LEVEL directly PERMISSIBLE LOWEST LEVEL necesslty I As plugs plug center of removlng th e vent shown wlll ellS level ln Flg 2 the WHEN apear colored 1f the flUld lev whlte 1f the normal and CORRECT Flg WHEN TOO LOW 2 appear lS low Checkmg 99 flUld level through vent plug Replemshlllg flUld The battery flUld lS replemshed due to water lS aCld sulphunc water from water and not to only d not us lS or proVlded the lose Dllute overflowlng If dlstllled water thlS case many cases contalns ln troubles not obtalnable lS other clean water may have to be used malns or Clty lS wlth dlstllled water battery punfYlng agents lron or a As flltel Clty such as used punc should be After replemshmg the battery flUld least 20 mlnutes dure should be replemshed water separatmg due to leakage that caused the cell ln be m cold reglons due to the fact that lf the slow to stand wlthout mlxlng to the Wlth dllute replaced as lS the trouble battery observed speClally flUld battery should be charged at mlX thoroughly ThlS proce the order to allow the flUld to ln there lS danger a of the If the fluld level becomes low top and freezlng by overflowmg from vent plug from or damages m replemshed or speClflc gravlty should be corrected f1rst and the flUld sulphunc aCld made up to the When the flUld becomes there same lt should exceedmgly dnty mlxed the flUld The denslty of replaced lmpuntles replemshlng or replacmg flUld IS determlned by the speclhc gravlty A sl1ghtly determlnatlOn procedure descnbed ln the followlng chapter lower speclf1c gravlty of I 260 lS used mstead of the normal I 280 at 200C the battery lS wlped to remove all traces of splllage and After replemshlng the vent plug crewed ln tlghtly The plug lS cleaned at thls tlme to allow the gas to escape freely from the vent hole smce are ln the Specifi c Gravity The speClf1c gravlty and charge be from normally Vlty 270 to 1 lS vanes battery speClhc gravlty should By measurmg the speClf1c gra fully charged 290 wlth the state of at 200C the battery flUld wlth a hydrometer state of battery charge can be determlned speClflc gravlty lS read at the upper part of The shown order falls below I state of 220 I 280 SpeClf1c gravlty the lS when lS correctlons determlne the actual to harged c factor spec1flc gravlty the flUld temperature of converSlon 10YIlng The the lllustratlon ln that the r Vlt I battery flUld battery of the The so when the of the state of battery r are each battery charge charged converSlon and reversely a nse drop ln In at once of the fol at 20 speClf1c until the o C ln gra fully eached fully charted factor for 0007 the temperature temperature 20 C I C o I C If the as temperature use made to the condltlon should be 0 For graduahon wlth the measured and wlth the I 280 at Temperature the vanes speClf1c graClty decreases 0 0007 the speclf1c gravlty corres lncreases pondmgly The nlshlng reason or for uSlng replaclng a flUld havlng speclf1c gravlty as mentloned above 100 lS of I 260 for reple to take lnto conslderatlon the flUld becomlng concentrated due to chargmg and lowenng of flUld level m the Even lf a speClf1c fully charged speclf1c gravlty about I 280 maklng of I 280 gravlty 22 wlth the of over top I If the taken shown when the flUld of the plates lS at the normal level of about the flUld level when lt becomes wlll concentrate the flUld to plates a speclflc speclflc gravlty the hfe of the Termmal becomes battery voltage hlgher than I 30 wlll be shortened rapldly at each cell determlne the condltlon of the An tester lS By battery tester the values battery charge the voltage drop by used to determme mmals of the cell and A gravlty cauhon should be By the above method of determlnlng speClflc gravlty tery charge can be determlned but the followlng methods to even 310 Slnce 3 lS above the top of the mm permlttlng lS used to measured a large current to state can also be used contactmg both ter flow through the termlnal measure the condlhon of the of bat the voltage of battery charge can the tester each cell be deter mlned A method frequently used to determlne the state of battery charge lS acros s the battery termlnals to permlt a place spark to fly and making the determlnatlOn by observmg the strength of the Thls method should spark absolutely be aVOlded as there lS danger of 19mtlng the gas generated from the battery of nearby combustlble fumes The prevlOusly descnbed methods and the followmg chart should be used lnstead to determlne the condltlon of the battery Although the mternal performance of a battery can be easlly deter mlned by maklng a dlscharge test wlth a battery tester frequent use lS not recommended as lt w1l110wer the capaClty of the It lS nec battery essary that tests be made ln accordancd wlth the followmg chart and wlth to ln a Wlre or metal tool 15 seconds TermInal voltage Under Over SpeClf1c gravlty 20 C I 75 I 80 I 85 1 170 1 190 I 95 I 200 I 220 Under 1 140 I 140 2 00 1 230 I 250 2 10 I 260 I 280 Battery condltlon Complete dlscharge Imposslble to use 1 4 charged 1 2 charged 3 4 charged Fully charged Determinmg Repairab Ify The above completes the lnstructlons on correct use and malntenance of battery battery lS overdlscharged the plates lnslde the cells wlll become warped and the surface of the plates wlll be covered wlth whlte lead sulphate the If the 101 plug the many smaJl holes mternal reslstance and cause the crease ThlS wlll d1fflcult recharglng the place plates It ln separators to In whlch wll1 make thlS case to repair or re battery the m voltage drop l be necessary wl the wooden ln Charging Whenever the battery and when the battery flmd repaired and also whlle the battery replaced has been has been lS ln use and the voltage consumphon the generator lnstalled on the drops In such cases the bat car lS unable to malntaln suff1Clent chargmg or replaced l ln faulty condlhon and the battery lS flmd tery replenlshed due to charged by I large electncal connechng lt to Instruchons The flUld level of the plates on battery charger charglng procedures normal on lS a checked to vlslble that lt see type plugs lS about 22 mm above the should be up to the normal level lt top m dlcahon Note The vent plugs on The termlnals should be lng to the surface of the The all cells should be removed whlle pohshed to battery termmal lS remove charglng dirt and flUld adher all dlrect current connected to the termmal of the charger and the The charglng charger termmal of the termlnal of the lS battery to the made Ylth a current of 6 to 8 amperes nses so that the ltage vo chargmg progresses the battery and the charglng current belngs to decrease whlle small bubbles appear As the speclf1c gravlty starts nSlng charglng current bemg small chargmg long voltage should be ad a In to malntaln from time order time to steady chargmg current Justed 8 When the of 6 to chargmg progresses so that the voltage m amperes 2 5 volts and the speClhc gravlty over than each cell becomes hlgher and the flUld w1l1 presnet a mllkey n I 280 gas wlll be glVE off vlgorously If the charglng continued lS wlll make the 1 l the lS as so time very that the appearance l bout a When thlS lS the reached charglng current 4 amperes and the cha rgmg contmued until the comes tive condlhon That constant readlngs hie charglng lS of the termlna voltage IS reduced to speclf1c gravlty be lS continued until three consecu and the speclf1c gravlty Corrected the charglng taken every hour shows a contant value a 20 hour rate current through the battery to temperature bemg made by passmg If the current lS temperature reduced to until the temperature The above lS half or hlgher the than charglng 450C durmg chargmg lS dlscontinued for uSlng a low completed m a the whlle drops charglng lS made by for ordlnary recharglng chargmg nse generally used long charglng tlme the constant current charglng method Inltial but should one about current and the a current descnbed above lS used and 12 to 16 hours 102 The pOlnt to be observed charglllg should there lS no charglllg lS determlmng the time when the The completion hme must be such that If overcharged more than undercharglng ln be dlscontlllued overcharging or the charglng current wlll be used up ln the water ln the and not only w1l1 the loss be flUld battery great but thlS wlll hasted the aglng of the due to tem necessary decomposlng plates EfflClent nse peratur attalned when the lS made With the least charglng charglng lS posslble a mount of gas beIng generated begllls to be generated at the hme the battery voltage begllls ltS a Gas sudden 2 4 volts ctncal Therefore source allled at 2 tery 3 voltage lS malnt 4 volts the bat wlll be unable battery to nse be char can J wlth the least amount of gas Thls lS the belng generated stant voltage charglng method whlch an exceedlngly large of current flows at the the i i3 w 0 3 to If the ele voltage to 2 and the hlgher ged from around 2 nse o and a 10 the cur voltage prachcally no current flow Clhc gravl ty after charge lt lS the spe completlng the charglng use w a a 0 5 adjust necessary to constant current H a i Z there to 89m when the bat source However lng 2 J 4 5 0 7 OHARG INO HOUR Constant current Flg 3 charglng characterlshcs as W wlll be I amount tery voltage becomes equal to the electrical o III start but charging progresses rent decreases ELECTROLYTE TEMPEqATUAE 2 con 60 N RESOURCE VOLTAGE 2J the 2J r TERMINAL VOLTAGE for thlS purpose CURRENT 2 J CHAROINO HOUR J Constant voltage Flg 4 charglng charactenshcs 2 InstructlOns qUlck charglllg charglng necesslty of removlllg the battery from the car and for maklng the charge ln a short hme the qUlck charger lS used In the lS a a has there to current to uSlng qUlck charger tendency pass large the and also the hfe the hme but ln order to of ten protect charglng plates the battery the speclfled current should not be exceeded and the charglng current made as small as posslble For on wlthout the 103 InstructIons Storing 1 Even lf the Therefore battery should be checked for ltS a full charge not belng used whlch has not been battery a lS state at the start and a ln lt use w1l1 self for a dlscharge long penod of tlme If the battery lS not to glven charge malntammg charge every month l1ght of thereafter 2 If the battery termlnal ground vent dlscharglng the 3 place If the lS on battery battery When to be stored m order to pre battery alone battery lS to be stored car whlch wlped to lt should be flUld overflows and adheres to the keep lt kept m a cool sunhght the aCld should be neutrahzed the surface a and hre hazards and away from dnect 4 lS should be dlsconnected not removed from the ln dry by wlplng condltlon J J l t 104 surface of the wlth alkah soluhon and ConstructIon of ChassIs r n 4 CLUTCH 105 GENERAL DATA Type Clutch cyhnder bore operatmg cyhnder bore Number of faclngs master Clutch Total fnchon Thlcknes s 875 19 05 as s 5 mm 3 mm 8 4 m m 203 x 146 x 3 2 8 x 5 x 0 125 312 area of dlsc 15 plate 2 Slze FaClng dISC Slngle dry Hydrauhc Method of operahon 7 sq mm 48 cm m 4 sq m y Free Compres plate spnng Free length Fltted length load sed Less than 8 45 mm 0 333 m Less than 7 15 mm 0 282 m Pressure 55 6 bearmg mm 56 I Release 2 mm 39 17 m 12 79 at kg 173 at m 41b t4 8 contact ball Angular beanng 40 TNK 20 of release Helght Release plate run Flywheel facmg Clutch 10 52 plate out run out 2 mm 03 mm 0 o 05 mm 0 12 20 pedal play pedal hlght Clutch 2 o m 002 m 0 mm 5 mm 160 10 05 001 6 0 8 3 0 6 at center of pat 01 m m 2 m from toe board DRIVEN PLATE ASSEMBLY Thls to a call dlSC lS the flexlble WhlCh type m whlch the sphned transmlts the power and the spnngs held ln Two fnchon bnlngs poslhon by retalnlng are hub over lS run mdHectly through attached number of a Wlres nveted to the dlsc GOVER ASSEMBLY The assembly conslsts of pressed plate located by SlX springs cover i pressure Mounted on the pressure plate are floatmg plns retamed by eye bolts the eye bolts and secured by staklng on the lugs Anh on the pressure plate steel and a cast three release levers whlch Adjustment Struts are nuts are plate 106 lron plVot screwed on lnterpos sed between and the outer end of release levers rattle springs load the release levers connect the release lever cover and retainer spnng RELEASE BEARING The release the conslsts of sealed bearmg fork and the release operahng beanng type ball bearmg It located by retamer spnng CLUTCH PEDAL When the pedal works so depresslng comes reversely the pedal but when the to half way to push down the that the lower end of the mm full from pedal pedal pedal As goes over the return has tenslon of 2 to 2 5 kg at 182 poslhon about 17 the pedal reqUlred strength kg becomes 12 17 hghter due to the operatlOn of the toe board but lt depressmg return push back until clllS poslhon It spnng lS adjusted the return spnng works to lS ln a thlS spnng TOFRONTAXlEc 351 Tlghtemng torque Clutch Brake Pedal AdjustIng HeIght slum Nos of sheet for standard usage 30611 27260 1 6 t 2 Sheet each 3061227260 3061327260 0 8 0 5 AdJust t able t 6 sheet CI utch pedal full stroke Clutch pedal excess stroke after connectmg clutch All stroke at top of withdrawal 14 5 m r m lever Excess stroke after dlscon nectlng clutch Strength to press the pedal for 3 8 IS m m kg full Brake pedal full stroke Brake pedal stroke at 60 kg strength to 118 68 m m m m Flg press the pedal 107 Retainer sprong 30513 26760 Bearing sleeve Release bearong 30502 32200 Clutch cover 30211 30100 DISC 30100 32203 30501 32200 @l Release lever pin 30225 31300 Eye bolt 30224 31300 Anti rattle sprong 30231 30100 Flg 2 Clutch Ii 1 c 01 S l i D i Flg J A J 3 l ri It J e t V f jt v r ii i L J 1 r St i Flg 108 4 i tl Removing the Clutch To galn access to the clutch lt mlSSlon complete from the englne Once the transmlSSlon unlt untll the spnng presslng Then remove the screws tlon from the unless thlS settlng out plate causmg new are free completely usmg tool adjusted Flg to The tool compnses the a speed brace and metal box the pahcular parts to be used selec plate assembly Interference wlth wlll throuw the pressure Gduging 5 the clutch can be qUlckly dlsmantled of accuracy hlgh degree base plate centre plllar spac setscrews hlght f1nger actuahng mechanlsm thlS tool As for of the hd of the box the mSlde ty dlagonal assembly on followlng parts dlstance pleces lng washers hme Judder serVlce reassembled and set have to be htted parts a and hft the clutch assembly away the dnven remove correctly Dismantling Assembling By turn at a rehved lS Flnally flywheel The release levers lS f1rst necessary to remove the trans lS lS UIllversal patlcular types Tool No a chart lndlcatlng of clutch wIll be found on 4799 Dismantling Wlth tIle clutch assembly select three spacmg washers Flg 5 lnset code letter over the and place them B on the Release lever helght md cator 2 Dlstance plece 3 Center 4 Clutch plllar cover 5 Set 6 Pres 7 Thrust spnng washer 8 9 screw sure plate SpaClng Base plate 10 Lock nut II AdJustlng 12 Release lever Now the holes place ln screw the clutch the cover assembly on the three spnng washer so that tapped holes m the plate msert COlnclde wlth the 109 the setscrews selechon ble ThlS pOlnts Mark the most punch httle at a by dlagonal hme to the base plate lmportant lf the best results that the so be reassembled can parts lS tighten them a fumly attached are at all pas Sl to be achleved cover centre a cover lS pressure and release levers plate lugs Wlth and provlded unhl the thelr relahve posltion in to mamtaln the balance C f1 ln order T of the clutch TT Detach the release lever plate frorn the retalmng spnngs the three eye bolt and remove nuts adjusting nuts Slowly release the or the spnngs on dlagonal pressure unscrewmg by selechon the setscrews secunng the cover to the base The clutch can be hfted plate for to expose all components lnspection The release levers r struts and spnngs eye bolts should be examlned for dIstorhon wear Renew these and parts If necessary beanng In mlnd that the thrust springs must only be renewed the sets ln Clean all parts and lubncate beanng surfaces of the levers eye bolts spanngly etc wlth J grease Flg 5 Ass tool embhng J11bl i ng A I Place the pressure plate over the three spacIng washers on the base wlth the thrust spnngs ln poslhon on the pressure plate see Flg 6 Assemble the release lever eye bolt and pm holdmg the threaded end of pl ate the eye bolt the lnner l1th the other hand sufhclently hole the m end of the lever lnsert to allow the the plalp strut as ln close end of the eye the pressure plate Move the strut upward lnto the slot together the slots on as possIble plate lug the pressure bolt to be mserted m to the ln ridge on ln the short end of the lever and the pressure drop lt plate lug and over mto the groove formed the latter Flt the other two levers ln a slmllar manner Place the cover over oIlr the assembled parts ensuring that the anb rattle spnngs 110 are ln posltlOn and that the tops of the thrust spnngs In addlhon the machlned cover are dHectly under the seats the ln porhons of the pressure plate lugs must cover through whlch they have to pass be directly under the slots ln the Compress the pressure pnngs by screwlng down the cover to tile base plate by usmg the speclal set screw placed through each hole m the cover Tlghten the screw a httle at a hme by dIagonal selectlon to pre vent dlstorhon to the ln caver The eye bolts and pressure the cover at the same hme Flnally repeat are seahng the plate lugs procedure make qUlte to properly and gauge agaln plate on the hps of the sure the holes the release levers the eye bolt nuts and ht Secure release levers the release lever of the three retalnlng spnngs a httle at Release the setscrews gUlded through must be by then secure means remove tr e clutch assembly from by dlagonal tlme a the base selectlon and plate Gaugi ng Screw the nuts mto the eye Screw the centre the plllar plllar followed the by bolts and proceed lnto the base as and shp plate shaped heIght f1nger cam follows the dlstance plece Adjust the over of helght by screwlng unscrewlng the eye bolt nuts unhl the when rotated Just contact the helghest pomt on the tlp of the the release levers helght flnger or release levers Replace see Flg the and helght f1nger Plllar by the clutch actuatmg mechamsm and actuate the clutch several hmes 5 by operatmg the edges handle theH kmfe Thls wlll enable the parts to settle down of the helght flnger and dlstance plece and readjust the helght on Replace checked for the release levers lf the error wlthln thlS or lS more than 0 It f1gure 02 In to as over press lmportant lS out run keep near the edge the as possIble untlllt hlgh spots faClngs free from fnchon as true lS Oll r grease J t Refacing the If a new Driven Plate complete clutch dnven be f1tted to the old dnven plate The nvets should not be the correct tool punched lS plate the m Each nvet should be removed then lf 6 by usmg holes over the heads on Opposlte already formed should then be mounted on a a Rlvet out not avallable the not aVllable followmg use the roll the nvet shanks securely agamst should then be nveted IS a 3 dIameter dnll mm one new faClng In poslhon blunt ended center punch to second facmg The wlth the clearance plate the hrst mandrel between center s 111 may J 5 plate httlng hnlngs manner slde of the ln new faClng The and checked plate fqr 1 rr run out pres ln tant to as near saver keep RefItting Place the edge as hlgh spots faclngs posslble untlllt fnctlon lS lf the wabbhng true wlthln thlS lS more f1gure It tha lS l 0 02 lmpor free from 011 or grease the Clutch the dnven plate on the flywheel wlth the longer chambered sphned plate hub towards the transmlSSlon The dnven plate should be centrahsed by a dummy irlve shaft whlch fits the sphned bore of the dnven plate hub and the Pllot beanng of the flywheel The clutch cover assembly can now be secured to the flywheel by means of the holdmg screws tlghtenmg them a turn at a tlme by dlagonal end of the dnven selection There Remove a 35 ft Ibs are two dowels dummy 4 84 kg shaft on the flywheel to locate screws are ln the clutch cover fully hghrened m Ref1t the release straln ln after these beanng and transmlSSlon case the dnve shaft and dlstortlon of the dnven f r l 112 welght avold assembly plate The DESCRIPTION OF CLUTCH CONTROL The clutch lS from operated a master cyhnder by of means a suspened pedal A mounted cyl1nder operating the clutch bell houslng on lS coupled to the clutch shaft 7 2 J 1 Components of Flg 1 Push rod Master 3 Stopper 4 Plston 6 sembly cyhnder 2 5 as rubber boots cup ring cup 8 Primary cup Master cyhnder plston Let m valve as sembly 9 Let 7 10 ln Return Plston return sprlng 12 Clutch master ass secondery valve spnng spnng seat cyhnder 11 nng Ondery Sec the master cyhnder body y valve release pln 13 Let 14 Rlng 15 Gasket 16 Flller cap gasket 17 Cap 18 End 19 End ln 1 f plug gasket plug When pressure to the clutch pedalls apphed the pIston of the master ln turn the cyl1nder and Vla a plpe hne cy lJnder dlsplaces the flU1d ln of the clutch the lever of the the moves cyhnder pushmg agalnst plston shaft 113 The Master Cylinder The master bore rod and reservou stopper nng spnng The end of conslsts of cyhnder wlth cap The plston rlng cyhnder lS alloy body an a pohshed hmsh assembly lS made up of the push valve and valve sprlng seat spnng cups protected by a rubber boot Cylinder the Clutch Master Dismantling wlth lnner Dlsconnect the pressure plpe unlOn from the cyhnder and remove the the master cylmder and may be wlthdrawn co plete secunng bolts then from the car boot and remove the push Pull back the rubber P and dram out the flUld wlth a The of ring stopper pair long nosed phers the f1l1er Remove rod and nng When the Cd then be removed and unscrew the release pln rod has been removed the plston wlth cups attached wlll can push exposed remove the plston assembly complete the The assembly can be separated by l1ftmg the spnng seat edge over the return shouldered end of the plston plston spring allowlng Depress the valve assembly to shde through the elongated hole of the spring seat be releaslng the thus Examlne all for cups wear tenslOn the spnng espeClally the gasket cyhnder replace the new parts parts or on dlstortlon and bore and plston where necessary Assembl I ng Smear the the assembly assembly well wlth the recommended brake flUld lnto the bore of the cyl1nder end wlth plston cups and l1ps ln lnsert the bore lp mto tl e cyhnder nng place the push rod wlth the secondary C the whlch lnto the engages groove machmed m the wed by stopper rmg cylmder body the umt by means of the two bolts Replace the rubber boot and secure on the flange and ref1t the pressure plpe unlon mto the cyhnder R i fo l The Operating Cylinder Thls cyhnder plston protected the lS of slmple constructlOn spnng and bleed cup by a rubber dust cover wlth startmg screw The motor 114 conslstlng of the the open end of the cyhnder lS body plston cyhnder belng mounted under slde of 41129 30001 l l 30625 27360 30637 33300 30626 3CaOI 30628 32200 30548 32200 ClutCh 0 pe atlng A J I j f t 115 Dismantling Remove the rubber dust cap from the bleed screw attach a bleed tube the bleed screw three open quarter of a turn and pump the clutch pedal unhl all the flU1d has been dralned mto a clean contalp er Unscrew the flexlble plpe umon and The ope adjustable push rod Remove the rubber cover and 1f rahng cyhnder can now be removed compressed hne alr Examlne all avallable lS blowout the especlally parts the seal plston from and replace lf the slde of w orn or damag unlon ed Assembing Place the seallnto the stem of the agalnst the Plstoh wlth the back of the seal plston replace spnngs wlth the small end on the stem smear well Wlth the recommended flUld and lnsert lnto the cyhnder Replace the the the dust push WIth the and mount the cover rod enters the hole plnch bolt and ln screw cyhnder ln the rubber boot ln the plpe posltlon Secure maklng sure cyhnder the unlon the Clutch System Bleeding Remove the bleed screw dust cap at the operatmg cylmder the bleed screw three quarters xlmately of a open appro turn and attach a tube lmmerslng the open end lnto a clean recep tacle a contalnlng amount small of brake flU1d F l r servolr the master cylmder wlth the re c6mmended flUld and by uSlng slow full strokes pump the clutch unhl the flUld the contalner fr m an pedal entenng lS free bubbles down stroke of the screw On a pedal up the bleed screw remove Flg 2 the bleed tube and replace the dust cap transmltted to the When the clutch beanng pedalls depressed the force pushes the release plate and the surface 116 lS TRANSMISSION t jt 1 o 117 GENERAL DATA Model 4 stages for forward reverse Type of gear Speed 1 Speed 2 Speed 3 Speed fI4 remote I Synchro meshed for Synchro meshed hehcal gear 3 94 2 40 I 49 for stage controled 2 speed if 3 4 type I 00 Reverse 16 5 No of tooth of gear Maln dnve gear 20 Maln shaft 3rd gear 25 Maln shaft 2nd gear 31 Maln shaft 1st gear 28 Counter dnve 31 gear Counter thHd gear 26 Counter 20 second gear Counter f1rst gear II Reverse ldler gear 13 BACKLASH OF Play on 17 VARIOUS GEARS revolutlOnal duechon maln dnve gear and counter dnve gear Between Between thud gears 0 075 0 125 mm 0 003 0 005 m 0 075 0 125 mm 0 003 0 005 m 0 03 0 0014 o 075 0 003 Between second gears Between low gears 3 speed and Synchronlzers Between penpheral 3 gears of speed Between synchronlzers 12 mm 0 0048 4 4 and dnve gear Between 0 and couphng sleeve Between speed if 3 couplmg sleeves maln 4 maln 3 speed sleeves couphng speed if 3 gear 4 and 118 0 125 mm 0 005 m m i l Between sneea if 2 j chronlzer fnd syn maln shaft 12 splIne synchro mzer and speed II gear Between speed II gear and speed II 2 gear 0 mm 0t9048 o qI4 Between if 2 125 0 mm i1 05 fO OOJl 005 0 m m I ilo l 1 m It MAIN DRIVE GEAR AND Inner dlameter of at drive Outer front 20 485 of bearmg end of Maln shaft No bearing maln gear dla mam of shaft beanng helght of before gear 448 mm 0 8072 m 460 roller 0 5693 0 5688 m bearmg t mm x 28 mm 0 118 1102 m of 3rd gear hole dla of 14 t8064 i 0 18 33 388 33 401 mm O 3144 33 312 33 325 mm I 3114 o 06 0 09 mm o 15 m 3149m of 3rd gear bush Play 14 Needle 3 beanng Outer mm dlttoed beanng Inner dia 503 nee die roller x 20 at pllot beanng of needles Dla l t end of rear t SHAFT presslng 1 3119 m m of 3rd penphery bush 0 0023 0 0035 J m Amendment hmlt of dlttoed play Inner dla Gap at 0059 m of 2nd gear hole beanng Outer 0 mm dla 33388 of 2nd gear bush penphery 33 33 401mm 312 33 325mm 06 0 09 1 1 3144 3114 13149m I 3119m of 2nd gear bush o mm 0 0023 0 0035 In h Amendment hmlt of dlttoed gap Thlckness of front thrust washer nng on End play 0 mm 0059 m 3 975 4 001 0 1564 0 1575111 4 026 4 051mm 0 1585 0 1595m 4 077 4 102mm 0 1605 0 1614m 3 937 3 962 0 1549 0 4 826 4 801mm 0 1900 0 0 12 mm t lnterlocklng 2nd 8 Thlckness washer of 15 on maln shaft Thlckness o 3rd gear bush of gear on maln mm 559 m thrust shaft of 2nd 8 3rd gear 0 16 mm 0 0048 0 1890m 0062 m t j 119 01 1 Amendment l1mlt of dlttoed o play Synchronlzer 25 0 mm 01 m spnng 127 mm 0 49 Outer dlameter 6 7 mm 0 25m COli dlameter o mm 0 03 lfl Tenslon 2 Free length 8 8 at kg m mm t Outer dla of syn chronlzer locating hole 9 32 7 m 144 mm COUNTER GEAR Inner dla Outer Dla gear beanng 20 3 length Thlcknes s of rear 433 mm 0 8826 0 391 16 401 mm 0 6452 0 1 88311 6456 m 2 x front mm rear 23 x 8 O 118 0 936 154 0 156 m mm m 3 91 3 3 96 mm 0 91 mm 0 thrust washer End 22 of front thrust washer Thlckness 420 Needle roller beanng of needles x 22 16 of shaft of bearmg Type No at dla play 0 1560 3 96 4 013 3 988 mm 4 089 3 140 mm 0 161 140 mm 0 164 4 166 o 04 o 10 4 06 0 0 mm O 1580 0015 1540m 1569 0 m 163 m 0023 m 0 0 m 160 0 Amendment hmlt of dlttoed REVERSE play of bush Outer dla Gap 004 m GEAR Inner dla d 0 mm of 14 reverse between shaft shaft bush 338 o 076 1 1 14 249 376 14 262 0 127 O mm 0 mm mm 0 564 0 0 561 003 0 566m 5614m 005 m SHIFT ROD ShIft rod Free Poppet spnng length x Call dla WHe dla 1 TenSlon when lnstalled Dla of check ball Spnng t reverse Free length Wue dla 34 7 x 4 x 8 mm mm I 366 x o 055 m 65kgat28mm 14 7 o 9 mm 0 32 m 41bat 110m 311 m 1 161 x o 047 m fork pln COli dla 5 29 I 2 120 x 10 mm 5 mm 0 413 m TenSSlon when lnstalled Spnng reverse fork pln Free length Coll dla Wlre dla x 3 20 6 2 x 1 2 kg TensIon when lnstalled 7 6 035 011 capaclty 2 Genulne gear 011 In warmer dlstnct than MP Use 5 mm mm mm Inter lock ball dla 32 20 at kg 4 at 16 6 6 Ib at 0 0 79 o 047 15 mm mm L 0 x 807 244 ln m m 6 Ib at 0 o 25 o 63 US 63 ln ln Gal 90 C 40 I e 001 0 33164 o0100 33391 32290 00100 I 9 15114 1 30 30 3 OOlOO e 04100 32103 l300 3 ll r Flg Components of Transmlsslon Case DISASSEMBLING THE Flrst draln the 011 from the transmlSSlon The dram plug lS sltuated beneath the case 121 at by CASE removlng the draln the left hand slde plug Clutch W thdrawal Lever Bend back the lock washer spnng washer the nut ltS remove and leg of the clutch wlthdrawal sup of the car lS threaded do not therefore bracket on the steenng part port bracket wlll be knock the bolt or the threaded ln the out support try to screw the bolt out of the bracket Screw the bolt out stnpped The the rubber dust Detach wlthdrawallever from wlthln the clutch cover around the houslng Cross Shaft Levers The cross shaft levers are posltloned of transmlSSlOn lf the car has case hand slde of the nght the on and nght hand steenng on the left hand slde lf left hand steenng each lever to ltS spnng washer and nut secures the plns may be and washers have been removed A cotter pln shaft After the nuts tapped out and the levers l1fted off the shafts Side Cover Holdlng the slde cover ln all serrated washers posltlon are set bolts and of whlch must be removed set screws when the cover wlth can be taken off Once the slde speed the lever cross cover lS shafts can recesses on the be threaded off the stage the shafts Oll removed both the selector can slde To the operahng remove seals lever I plvot lS the case and change bnnglng wlth them lS After wlthdrawal seatlng arm and change speed and felt washers can lever the gate At thlS be wlthdrawn from the slde the selector The engagement lever the cover selector 0 case at be drawn from arm Gentle presslng pnslng may be necessary to gate as ltS rounded ends are a tlght ht m the ma change speed gate asslst removal of the chlned Selector Arm Cross Shafts Change Speed arm the shaft anchored connected to the ln ltS tap out plvOt by a the secunng pln nut and bolt whllst cross shaft c Front Cover Release the front cover I f iT sltuated wlthm the clutch mg the nuts and sprmg washers attempt to remove the cover At thlS and front washer 122 housmg by remov stage of dlsassembhng do not The ped w1l1 prove operahon forward Selector Rods USlllg from rods are tap the casIng Forks tap forward for a bhort dlstance keys whlch are htted to prevent and prtbe out the of the each the rods turmng Now dnve the away from cover soft metal dnft a three rods 1f the sh1ft fork selector eaSler the pushlng thus fltted ball each Care case to rod forward each fork Fltted behlnd the the order not to lose ln L1ft out the three forks to respeLtlve pOSItions retneved from clear of the forks and extract them from should be exerClsed assist thJrd the sprmg loaded carefully their notlllg reassembly speed fork lS a dlstance plece whIch must be when reulovlng thlS fork cabe Reverse Gear whlch lug A end of the IS reverse screwed tab washer ward and lS an lntegral part shaft gear the through Stralghten remove To lug 10catmg of the secure m reverse 34498 32200 gear casting locates the forward the shaft shaft the the tab washer the maln ln a pOSItion setplne setpm lS locked by a setplll then tap for The release the shaft L1ft out the reverse gear I@ 0 @ 0 0 9 9 21215 9 11145 1 @ 9 21215 1 1 916115 15416 30000 410 34 9 15415 1 34412 r Q I @ 9111451 34462 01300 1 32922 32200 34490 01300 34421 30000 i I 9 161lS 34466 32200 30000 34421 @ 34423 32200 32200 0@ a 34463 30000 9 11146 1 34440 32 50 Ap l 1 tit H5116 l 32917 9 11146 1 00100 511671 I 9 1 15414 Ij 9 15114 1 9 32923 32200 9 15414 9 15114 I b 34452 32200 9 9 21225 34444 30100 Q 15116 1 1 ii Dt 34443 30100 34441 30100 1ll46 34462 3 250 p 1 1 CY @ 11l44 34446 J r t I I 30000 9 15115 9 11146 I 3 20 k 34445 30100 l 34467 I 34443 30100 Ill 9 sOI j @ 34436l1 00100 344 I 9 11144 1 32917 @ 9 For 9 16116 1 For J 4 1 4516 4 Right Handle Left Handle f 34452 Flg 2 Remote 123 32200 Control Llnkage o 261 3ZBIHXlIOO 32a0S J J OOJD OO 0 829 24 m3HlOl00 23 3l121 f i25 00 101 19 J I 00l00 la l 32829 26760 l 00100l 00100 831 00100 32816 Yo 201 3UiZ926160 r 328ll J rd IlO fSii 2 2 r O 32 m I a 329 lOI00 3288I a2883 10 iT 6 32923 32200 1 J 82 00100 C l 1 1 29lo0081lO AM r 4l21I rr S OOIIlO i1 X 8 21020 I17 9 1 00101 2 @@ i 300I00 U911 j 8 OO100 32814 j 4 I 4 A l It I J 9 11144 I I 1 15415 3291 III 0011lO S 9 329 HOIIlO Il 1 2112 00800 3I f 7 Jr Flg t 4 5 6 fork Shaft Selector 15 Lock pm Change speed cross shaft Change speed operating fork Change speed operatmg fork 16 Plane 17 Change speed gate assembly 18 Reverse fork Fulcrum pin Lever change 19 Reverse fork rod 20 Check ball as s 3 Fork 14 Operatmg change speed 2 3 embly speed cross shaft cross lock washer Lockmg Fork rod lockmg stnp blg 23 Fork rod lockmg stnp Selector 9 Selector shaft 24 First 8 second Taper 25 First second 26 Third fourth 27 Thud fourth pm 11 Selector 12 Cross shaft ad seal 13 Felt ring cross shaft lnner lever 124 nut ball spnng 8 10 plane 22 Lock pm assembly 8 21 1 shaft shaft lever small fork speed speed fork speed fork speed rod rod Counter Shaft USlng Soft metal dHt dnve the counter shaft forward and out of when the counter gear lse c two Gear thrust washers wlll of the cluster and drop Il to the bottom case These gears the casting together wlth only can when the thelr maln be hfted from and dnve respective shafts have gears been removed To remove the needle roller beanng wlthln the counter gear cluster lt lS I iti J nec t essary to break the I fore the l dnvlng out ble plece of metal retalnlng Clrchps be beanng wlth a SUlta tubmg 2l 4 Flg Main Shaft The To maln shaft can now be wIthdrawn from the gears from the remove maIn the transmlS shaft fust shde Slon caslng off the thud and fourth speed synchronlzer assembly then wlth a plece of Wlre lnserted through m the gear cone depress the small spnng loaded plunger whlch lo the washer cates at the forward end of the maln shaft sphned turmng the washer lnto hne wlth the sphnes The thlrd and second speed constant mesh gears together wIth thelr common phosphor bronze sleeve can now be pull ed over the steel As the phosphor plunger and so clear of the maln shaft bronze sleeves and theH common dnvlng washer are a tight f1t on the shaft the shaft should be lmmersed ln warm ollln order to expand the sleeves so that they wlll shde off the shaft when the second speed gear can be removed Take out the steel plunger and spnng for Next remove the sphned washer separating the second speed constant Wi the hole mesh gear as sembly maln the shaft If lt nut lS but assembly and then shde the fHst gear umt To release the speedometer speed gear wheel from the tab washer and unscrew ltS secunng nut maln has been shaft pnsed Do not lose beanng from can be the key separated these can t the then shde Take off the dIs from ltS houslng the shaft be speed couphng sleeve sphned synchro clear of theu pressed must be taken to retneve the three balls and spnngs Take out the mam shaft front needle roller beanngs from care of the dnve gear Rear shaft desued to dlsmantle the fourtheand thud the fust nlzers the fust gear wheel off the shaft and the plece after the mam stralghten speedometer tance or assembly from free of the ln each the end shaft j Oil Seal ThlS all sealls sltuated dlsmantled unless suspected m the end of the of leaklng 125 It rear lS cover almost and should not be lmposslble to take off Gear r 4 p 1 la Flg I 5 Components Gear ca se front of the Transmlsslon cover 2 Front 3 Maln drlve gear nut 4 Lock washer 5 Mam dnve gear 6 Maln dnve gear gasket cover 7 Maln 8 Thud fourth 9 Thud fourth 10 Thud shaft beanng pllot bearmg speed synchromzer II Thud 12 Mam 13 Fust 14 Mam shaft second 15 Malu thnd 16 Mam shaft front 17 Mam shaft gear thud 18 Mam shaft 19 Mam shaft gear 20 Second shaft speed shaft gear Mam shaft Second 23 Synchromzer 24 Second speed rear bush thrust washer speed synchromzer hub spnng speed Shlftll g msert Maln shaft bearing retamer assembly locator retamer Beanng 27 Key 28 Mam shaft 29 Speed spacer meter dnve gear 30 Mam shaft 31 Mam shaft nut 32 Lockmg Lockmg 33 thrust washer second speed bush speed synchromzer nng 22 26 speed gear speed gear cotter throust washer 21 25 1Ifl lock washer peg 34 peg spnng Counter shaft gear 35 Counter shaft needle roller 36 Counter shaft front thrust washer 37 Counter shaft snap rmg Counter shaft spacer 38 39 Counter 40 Snap 41 Rear 42 Needle roller 43 Reverse shaft 44 Reverse gear bush Reverse gear assembly 45 sleeve speed synchromzer nng fourth speed synchromzer hub fourth speed synchromzer nng r 0 yi shaft t nng thrust washer 1 127 the seal wlthout 1f the old plnched one lnto damaglllg lt consequently has been moved Thls poslhon a It Wlll be be removed can new seen by all seal should be f1tted that the Oll seal uSlng a punch houslng lS and hammer On ve Gear Shaft Before now dnft ward dnvlng the dnve the bottom of the m Inserted through wlth complete To the remove and unscrew the The the bearing cnchp shaft the may bearmg shaft nut can now of the outer to maln beanng The counter gears shaft from ltS poslhon case and now tllt the counter gears clear the dnve shaft gear Usmg a long shaft opemng dnve the dnve shaft for from shaft case knock back the tab Thls nut has be dnven from race on case the a left the shaft the Jaws of an lockmg washer hand thread open preferably by restmg and dnvlng the Vlce downward Use a hlde or lead hammer for the exerClsed to prevent the end of the gear I from the Clrchp be removed from Vl 9 Y J 128 operahon shaft from as great case spreadlng must be ASSEMBLING Syncbromesh Sub THE TRANSMISSION Assembly Dunng manufacture speed gear the thnd and fourth speed 2nd couphng sleevs are each paned wlth then res pechve synchronlzers Only mated pans of these parts should 11 il 5 there J fore f1tted 4 Q Flg I 3rd 4th Synchromzer 1 tr i 129 4 7 t t l T ti LJ 9 kl f fl7 Cc 1 j t n j i 1 W 1 g rO i h i l it Flg I 2 t order of Tra nsmlSSlon Gears Assembly F j or f i f l F i I f f 1I f r I d 1 r I 1 7II 00 lIto 0 l till C O0 O 01 A t o 0 0 W lQ Flg t U 0 L j Co t 4 3 Com ponents of 130 Gears 0 J Synchronlzer Gears Counter Shaft First locate that the the gear case Check o or 06 the two thrust washers to the counter gears ensunng lS at the front and then place the gear cluster In washer larger that there 0 mm thInner 0015 rear ThIckness IS 0 end play 0023 and for the cluster gears remedy of front by f1ttlng y 04 thlrker a 91 3 96 mm 0 3 96 3 4 013 3 91 988 mm mm 0 0 1580 4 089 4 064 mm 0 161 140 mm 0 164 154 0 156 156 0 154 m thrust washer rear Temporanly replace cluster to gear of between 0 thrust washer 3 the necessa washer ThIckness of mIt lf 4 166 4 0 04 the counter out remaln 0 06 0 mm shaft wlth a 0015 m 1569 0 0 0 0 ln 160 ln 163 ln 0023 ln thln rod whlch wlll per of mesh wlth the maln and dnve shaft gears Ori ve Gear Shaft The ball Its spnng dnve over the from the ring away shaft should Journal beanng a ln dummy beanng ln geared 3rd and 4th tlghten Smear grease now be dnfted end speed couphng the nut and lock lt the end of the shaft then load the 18 needle rollers so that on to Poslhon the ln shaft geared sleeve put Wl th end of the the washer poslhon where the they the adhere maln ln shaft locates posltlOn by means of the grease Turn the dnve shaft gear caslng to ensure that the counter teeth beanng housmg both the counter gear The drlve shaft are Fvllure to do thlS w1l1 result and dnve can now shaft geared be dnfted lnto m below the damage to ends poslhon from the clutch hous mg end Ensure that the spnng nng reslsters properly ln the races s on gear the i Jr case t C i Main Shaft press the shaft from the maln shaft center rear shoulder of the centt r The beanng complete wlth houslng on beanng must be pressed firmly agalnst sphned portlOn of the 131 shaft to the the Oll the shaft forward of the Llghtly wheel assembly wlth the synchrOlllzer pomtlng Reflt the thrust washer The f1t on mto phosphor the shaft then the thud to the shaft the shaft followed lmmersea Flt the second speed washer and the second bronze dnvlng speed wheel washer Now and The two sleeves are the thud gear posltlon lnto the hole the speed forward the by bronze sleeve WhlCh carnes the second there lt must be f1rst on pOSltlon on and reht the fust bearmg nng speed a lS hght Oll and then shd ln warm wheel baulkmg the over sleeve whlch sleeve carrles the locked together by the dnvlng over sleeve ltS shaft and shde the Place the spnng sphned washer plunger Depress the plunger wlth a plece of wue through the hole ln the thud Then turn the speed and shde the spnned washer over the plunger washer for the plunger to engage wlth a groove ln the washer The gears ln maln assembled are now end movement for the fust speed on the washer at the rear of the second keyed baulkmg shaft and there should be speed A beanng and gear the semble the two s nngs to the thud and When f1tted to the shaft synchrolllzer each maln gear between the center must face towards the front of the box maln ends pomted shaft bearmg of the Also note that ln lugs face lnwards to the Sl1de the thud and fourth synchromzers shghtly forward synchrolllzers and then carefully gUlde the maln on the shaft to clear the counter gears When the houslng surroundmg the shaft assembly mto the gear caslng case the top speed synchromzer and couphng sleeve the large boss of the mner sphnes of the baulkmg flush wlth the gear lS nng caslng the counter shaft gear cluster should be ralsed lnto mesh wlth the gears and counter and f1tted lnto The pOSltlon hpped entl shaft Olled must be flush wlth the gear cas mg THICK lESS FRONT THR US T WASHER 3226426761 3 975 4 001 mm 0 1564 0 1575m 3226526761 4 02b J31 mm 0 1585 0 1595m 3226626761 4 077 i07 mm 4 0 1605 0 1614m Reyerse Gear the t Rtf f Oll the M I reverse reverse gear gear lnto the gear caslng wlth the shaft before lnserhng and g pm and tab washer 132 large secure gear to the rear the shaft wlth locat Sel ector Rods It lS Forks Before commenclng to locate the selector forks wlthln the gear case advIsable to pre load the spnng and ball lnto each fork and wlth the ald of ball sprmg and has entered ltS correlatlve fork a Pllot Wlth the bar retaln the gear ln fork and then locate and fourth fork rod ltS fork untll fork and then gear lt dnvlng posltlon the casmg pOSltlon pOSltlon narrow untll each fork rod fust ht the first speed fork Contmue Now tapplng Next locate speed tap the rod the through the caslng and lnto theu respechve The key ways m the rod ends are Pllot se through reverse forks bars ector the thud the f1rst and second selector fork rod and the the fork rods hole remember to retneve the leave the forks the through reaches ltS f1nal enter fork rod the neutral the thud and fourth ln as gear reverse When they offset and when fltted face should be at the bottom or Ii JI Flg 4 Selector Rods 8 Forks i t 5 r w 133 SELECTOR INNER OPERATING LEVER CROSS SHAFT Wlth also the selector lever change speed shaft cross Flg 4 plnned to lever assembly shaft the two shafts should be levers nearest to the slde poslhoned cover shaft takes the forward poslhon shafts are placed lf the case over the levers and the whole The gate ses lS located of the slde Before each shaft cover flthng ln ln ln respechve cottered to ltS case the case At the the change speed gate assembly put mto the pOSltlon by ltS wlth the cross own rounded ends same shaft cross respectlve Note that the selector openlng ln the ltS cross hme that the should be threaded case as ln one unlt the machlned neces seatlng the levers that order the all seal and felt The levers are rmg must be htted to cottered to theu respectlve shaft S de Cover Secure the sIde ensunng that the cover slde lnto cover lS pOSltlon by means of the bolts and screws lntact Front Cover The front cover and gasket should mg studs and attached by means of the 134 now be seven posltloned over the secur nuts and lock washers 1 i C s i V 1 0 1 co i j t t CD CII C V l o C o U CD o E CD It CII Ii l 2 c 135 X PROPELLER SHAFT UNIVERSAL JOINTS 8 1l Flg I Dust 2 Sleeve 3 Journal I Propeller shaft cover yoke 4 retalner mg assembly 136 Jomt 8 Propeller 9 Flang yoke 10 12 shaft assembly Compamon flange 11 Bolt 12 Nut 13 Plane washer 14 Dnve 15 Cotter pm pinlon nut PROPELLER UNIVERSAL JOINTS SHAFT DlmenSlons Length Outslde dlameter x Inslde x dlameter 1124 x Unlversal 60 25 x 2 x 50 2 x 372 m JOlnt Journal dlameter Beanng 5 63 44 25 14 lnslde dlameter race Number of needle beanngs Needle beanng 70 o 579 m 5 o 769 m o 095 m 19 roller 22 outer dlameter 4 2 Lubr cation An all mpple fItted to each lS center splder for lubncahng the beanngs The central all to the needle chamber roller The needle lS connected to the four all assembl1es beanng beanngs roller Flg reserVOlrs and I are f111ed wlth Oll shdlng spl1nded Jomt between on all from assembly the transmlSSlon Lubncates the shaft and the propeller transmlSSlon Before ref1hng the the propeller shaft to the transmlSSlon case smear wlth the all sphnes Removal Remove the near axle rear by taklng Place clean a surplus all that propeller propeller flange tray under the from the plmon of the flange bolts and lock washers out the secunng nuts may dram off of the shaft end of the gear box to collect any The operator should now take the welght r ar shaft and then draw the sphned end out of the transmlSSlon O smantl ng to Clean away the palnts from all the snap nngs easy extraCltlOn of the beanngs l t ensure Wlth screw t r these ends togeth snap nngs by presslng done come out dnver the not If tap the nng Remove the r e 1 1 pnse t out ahd r fX f t e beanng fa c l hghtly to reheve the pres Hold the yoke wlth If a splmed lead or dlff1culty takmg the lnslde lS sure agalnst end of the shaft care not to use nng tap the radlUs of the 4 beanng wlll begln to emerge bar small to tap the beanng from m one hand and when teh copper hammer expenenced the a damage the race ltse1f loss any of the needles 137 belng careful not to Repeat thlS opera hon the other and the beanng sphned yoke be removed from The same proce spIder dure be uhhzed to can detach the other from can the ltS splder yoke EXAMINATION FOR WEAR CHECKING When the ln for use hkely to beanng The propeller shaft has been long hme the parts most a show sIgns of wear and the splder are complete assembly should be races renewed lf looseness tre observed as no or r be re tlal g flt marks stress overSlze C jr It provlded the journals Journals lS essen hght races are a dnve unlons ln the trunlon the httmg of tness of the deter G by bearlng newyokes shaft lS measunng the offcenter deflechon of the shaft ln rotatlOn wlth I If the dlal gauge apphed both ends deflectlorl exceeds clearance hmlt a Les s than 0 4 mm correct or replace I 138 the shaft mling Reasse that the dnlled holes Inspect wlth the Oll Should dlff1culty walls of the races wlth 22 ln It yoke the yoke The to lS a rollers to splder m foot nosed dnft smaller essentlal that the beanng thlS Repeat trunnlons ln cleaned out and beanng races and f1ll smear assembly ln retaln the are the ln expenenced petroleum Jelly splder Journal f1ttlng be Insert the place wlth pOSltlon the ln Nos ln the hournals ln Assemble the needle f111ed wlth Oll the the needle rollers yoke and the tap bearmg dlameter than the hole races operatlon are a ln dnve ht l1ght for the other beanngs shoulder should be coated wlth shellac pnor the retalners to ensure If the Jomt appears to bmd a good seal tap hghtly beanngs on wlth a wooden mallet whlch w1l1 rehve any pressure of the the end of the Journals It lS advlsable to renew cork washers and washer retalners on speder Journals usmg a tublar dnft the Shaft Replacing Smear the propeller Assemblm9 shaft sphnes mesh wlth those of transmlSSlon Wlpe sure wlth all and sl1de the lnto sphnes shaft flange and flange yoke faces clean to en and the JOInt faces bed pllot flange reglsters properly It lS advlsable around and securely lock them ln posltlon the rear compamon that the evenly lse maln all new lock ln posltlOn It lS advlsable to use new to lock washers t l lJi t 1 1l P t t lot Sy it J F 1 j1 t i rr 5 ir 10 l 4 139 y 1 J S YEERING STEERING GEAR Type Hlndley Gear raho Steenng 19 wheel TurnIng torque out of dla 7 430 worm shaft o worm 16 93 mm 08 0 15 at outer Back lash of worm 8 roller o 0 2 Play of turmng duectlOn set at wheel 35 40 and roller standard 0 mm top posltlOn Off m kgm 0 58 1 09 ft Ib r9und of steenng wheel the at 8 roller I 0 01 m of gear arm I 57 mm 38 1 of center m worm center 4 cllstance between worm ller 5 0 mm 177 m Center Lockmg End 52 play Tlghtemng of worm roller torque Cover Roller shaft 2 mm 05 m t400 le bolts o 02 2 5 bolts 14 Gear box fIx bolts 4 011 capaClt 0 adJustmg shlm fOI housmg end play Shlm for adJushng front end play 0 04 mm 18 0 0008 3 1 0 0 0016 m 2 ft lb kg kg m 102 I ft 5 kg m 328ft m 008 U lb Ib S Gal ThIckness of Slum for adJushng rear end teenng gear iVo m west lng end of shaft the r top lnter pan It to eJof shaft at around to I w lS IS play o 62 mm 0 030 m o 254 mm 0 010 m 0 127 mm 0 005 m 0 075 mm 0 003 m 0 050 mm 0 002 m 0 254 mm 0 010 m 0 127 mm 0 005 m 0 075 mm 0 003 III 0 050 mm 0 002 m worm maln and roller and has the drum type of steenng lncased ln the shaft tube Jacket and the steenng end of lt locks wlth the roller WhlCh turn the and through WhlCh operahon of lS f1xed turns the steenng on the roller steenng arm wheel The mohon of the steenng arm lS that of back and forth ln front of drag 1 hnk and turns the spmdle around the kmg pln Wl th the connectmg knuckle arm gear ill thro owhlch i changes the bushmgs of front wheels roller Tile shaft ltse1f lS supported by the two beanngs both sldes houslng R J w Ii 1jrt l 140 m the b 141 W4 Comp lete Column 48050 322 00 9 0 11245 j4802 8 00 48035 32200 1 2 48037 32200 48064 2716 Y F Steering roller shaft 48100 33500 L H type 48100 32200 R H type h r at 48121 2 3 2 7 t 48102 32201 Set l t4812 8 i200 48135 32200 q 48206 30800 r 9 15422 9 11052 9 210 Fig 1 Steering l 1 142 Gear Assembling and Inspection In case the of replacement damages of the followlng parts lS requued and steenng gear and hOUSlng bush m order Take off the steermg wheel Pull out the three screws of the back slde of steenng wheel boss then take off the horn button retalner After unscrewlng and wheel wlth the 2 on the clamp taklng on plug steermg at the slde off from the gear 4 Take off the 5 arm wlth of steermg gear bolt of steenng assembly and Disassembling the the steenng tube I Takmg drag llnk unscrewmg the drag hnk thus lS taken of on off the steenng gear the bolt Dlsmountlng In hxed wlth the lS Steering Gear of the dlsmounted and the gear all then am pull the dlsmountlng houslng on the lS Vlce com setting arm and roller shaft he gear arm out cover and of roller Ji 1 I 2 lS to the downward duechon steenng gear box should be hxed level Take off the nut of gear hghtly the arm gear box WhlCh InspectIon After the steenng assembly pletely lS steenng Jacket clamp of frame Pull out the steenng dralned remote control rod whlch arm flxmg slde member steermg and dlsconnect the horn cord panel gear out the pull puller and under the bolt under the lnstrument end well as horn button tube after unscrewmg the Jacket Dlsconnect the as off the wheel nut steenng wheel Dlisconnect the hxed 3 adjust of the Steering Dismounting I due to the defacements dlsassemble and cover and roller shaft t I as sl the column the cover after unscrewlng the three nuts the Jacket and roll adjusting shlm Of must be handled wlth care not to loose them 1 3 Takmg off the housmg Unscrew the three nuts also the handled end plate i carefully fC should end of the housmg and th y them to loose not at the front 143 The maln and lnspectlOn of the worm shaft and beanng shaft could be dlsmounted together wIth the roller beanng assembly and upper 4 nountmg Dls of 5 mam shaft beanng corn by f1xmg the wheel nut wlthout damage and stnking out hghtly Take the column The mg out of the gear Jacket housmg the tip thus the outer lace be dIsmounted easlly beanng adjust shlm must be carefully handled off the houslng gear of upper on can not to loose them ln tak dear housmg column Jacket and front Inspection and adjustment of thIckness of cover the steermg gear by changlng the total Adjust the so that shlms of the worm starting torque for the adjust beanng of 0 15 the Circumference lS 0 08 at kg revolvmg worm shaft wIth the cover lt end In thlS case by apply steenng wheel tighten 6 0 mg the J used Use the sald nng 0 ring And further adjust shlms shlms beanng adjust worm Inspection and adjustment 7 I the mm thlcker than the the thlckness of the rear and front shlms of the roller shaft oller shaft The out lS worn 1 by changmg exchanglng Itself should be check and The shaft 3 replaced assembly wlth should be new one when lt replaced ln a umt loose and damages or defacement of ln case the roller pln becomes The surface of roller lS found replacement can be hmlted to the Flt the roller shaft to the gear parts after dlsassembhng houslng after lnserting the adjust shlr ls to the adjust screw and adjustIng sald screw so as the end clearance along the roller shaft out worn to be 0 Jgear arm lS 0 03 mm to be 0 haft and lock the J W 01 lS e1 firolhng r j b to t nut mm ln shlms up after f 1j r Tlig s t pj lIi comf1rmmg 1i RIJg P and so forth are that the roller lS smooth Imkage constructed wlth the spnng sheet and thIs order must be conformed wlth 1 the spnng would not action be shock the to every part of the umt weanng out both lglngv 5 whlch furtherly ste enng gear arm and hnkage of the steenng the umt Otherwlse the l h lly pulled off endangenng the operation efore Important to check and to set aSlde flit ng sse ord r when dIsassembled rv 9 144 t top of center of the roll a It iill J f 1 arts of the Imkage assem15lmg slde w J1J ng t rolhng t Assemble and Dlsassemble of the 8 The back lash at the the vertical 7d vIlr tytrot t t l wIth the 2 the worm gear over H 1t 0 the parts ln f A 43 i t Flg Flg 2 3 AdJustmg of Backlash Worm Components of 145 Roller Steenng Gear Case 0i e g l r 4 Flg Il Inspection It of r ln c Adiustment lmportant that lS J and worm after the center of Assembling lnterlocklng roller lS located In the gear TAhe lnspectlon for thlS should be made In a way as to make sure of the equal condlhons of backlash at the pOSltlon of steenng wheel when tur te fully to left and nght In case the backlash dlffers greatly the g lnterlocklng posltlon of worm gear must to adjusted agaln M The correct backlash at the both ends l of sure l ge r after puttlng the d arrn tlghten h u J worm gear should be made shlm In the slde of larger backlash at the pull out the sh m on the Opposlte slde and adJustlng wlth the shlm In front of and the shlm more f f equahzmg bolt agam iH ear housmg behlIld 10 r rl lash at the center Thp r1 ed locklng should also be checked and adJust Ty a lftne tJ t f 1 Installdt Yf f Inspe l T f1xed t3i t on of y steenng wheel g yheells celatlOn locked wlth the shaft and lt may as be rwardmg dHection tightened may as well be hxed to the rdll forwa dlrectlod 1 f1 i Steeflng Wheel tlghtened wlth nuts t 146 The standard Clrc1e Ib for as measured The play as by revolvlng welght gravlty lt nghtly lS assembled on adjustment nspection and Ad The I lnspectlOn car wardlng on m wheel 0 kgm 58 1 nm 09 it 40 the mm m a reverse order of dlsmountmg of Steering Fixed ustment Car on sy stem lnstalled the ln wlth the front wheels hxed to the for levelhng place dlrechon of s 15 of horn button adjustment of the steenng followmg order Take measure of the flnger 0 and should be made Set the 08 of wheells 35 the cncle The horn button should be lnstalled car 0 the spnng scale allowed InstallatlOn and I of the wheelan the wheel lS one poslhon of lower part of wheel and tube wlth the of spln the wheel to left and nght to the extent another hand When the wheel moves up and down hand play by there shou d be found a play the ln worm to the dnechon of beanng axle In thlS case houslng The the hXlng loose are on bolts the bearlng shlm should be the beanng and pull off adjustment lnspechon and adjustment 2 front and ln ln a lS worn way assembl1ng In case the roller shaft moves to the duectlOn of axle the roller shaft wheel to left and nght lS loose In case the bush and the roller lS worn shaft out shakes therefore of gear lower explalned m the ltem of worm made as explalned ln the ltem of splned hardly The adjustment should be carned roller adjustment of the poslhon of steenng 3 or upper as should be after rear out to left and they In a nght should be shaft as adJushng way as the screw explalned the roller shaft replaced wlth ln or new one adjusted f 5 In case the roller shaft moves to the axle the by returmng l nght the roller shaft adJushng screw a way as explamed adjustment should be made ln lS to left and the shaft poslhon of steenng roller 147 laos wheel the iI l oit rwlpdi a ln e i1 tri of 1 nght the roller shaft replaced wlth new one and In case the roller shaft trembles to left and 6 the bush lS worn they should out and be or adjusted should be found by play holdmg ment for thlS should be done ln In cas arm a as way lS too explalned m the above the steenng wheel at the center of turnlng to left and setbng operatlOn of steenng In case the when the front axle lS Jacked the strongly b lck and The adJust large the arm and move lt the backlash of roller and worm gear forth 8 Imk at the end of steermg gear drag Take off the 7 up wheel felt heavy and section nght hght becomes the trouble lS wlth the front axle sy stem In case the wheel the trouble up lS heavy even when the front axle connectec wlth the front When the front axle 9 still felt lS lS Jacked up emng parts of tle rod socket arm should be posslble the Jacked axle lnspechon arm drag nackle lS of contactlng and tlght hnk and the steenng t 4 DJUSTING IDLER In the standard When the sprmg scre Then adjustment ldler the shaft so that It m overalLhelght lS bghten sl1ghtly compressed and of the rubber after lt is mounted to the spnng lth bolt to 1 hole lS spnng and toe car 20 7 m lS httmg plate r l1Jll tlj rrO t i c 1 f1 1 i f il ff r J I y if r I t 11 J Yo J l f not glven the nut at the cl1nch the nut mm f 148 on the rubber WIth the ldler approx adjusted el1mmate resldual dlmentlons rubber spnng the m lS m lS flt the rubber spnng to lt and that the rubber long pressure posltlOned parallel protrudmg from the body top arm on lS top 34 body mm to the extent In thlS case In the next tighten the rubber by utll1zlng the lt OIE I THII TO lIP 5II1I 1 41 5 I TEITHEIlI T1I1 30 I B 320i4853 4 14854 5 Flg 48531 l 1 H 1 n 9 A i ft Jf I l 0 I 48546 32200 1 24518 9 16215 l 48405 @ 48544 32100 58000 48541 32200 6 48539 32200 I 48521 32200 ll f 9 1Y22 f 9 11052 f c r t f Fig 6 Steering t f 150 Idrer 6 Arm I THE CAUSE The OF TROUBLE of the trouble caused ln regards wlth the closely connected wlth those of the front axle hard to Judge then Separately The followlng are maln troubles caused ln steenng rabon cause lS Heavy I The all gear m Adjustment 3 Damage 4 Hard 5 Steenng ope lS on of box worm corn of locklllg and roller worm of column shaft or tube Adjustment of worm 2 Flxmg port of 3 Locking poslhon Unsteady gear poor bush bended Turning and roller housmg Wl 15 poor th frame of roller shaft and Trembling or lS beanng Jacket lS Insuff cient Amount of 1 ln therefore lt and d1ff1cult opera bon of handle 2 I steenng Too much backlash of Worm 3 Looseness of each bolts 4 Looseness of f1xmg steermg and roller roller shaft beanng and loose arm lS bad Handle in Motion worm 2 lS on bush gear 15 wheel worn play lS too large out hOUSlllg bolts for frame I f i Insufficient Return of Handle I Tlghtnes s of 2 Worn out each parts tlt NOIse In parts parbal defacement a rJri the Gear Housing I Backlash of worm and roller 2 Insuff1clent gear all t 151 FRONT AXLE 1 i J P e i A i t t l l 152 FRONT AXLE Type Independent suspenhon wlshbones ball JOlllt shock absobers telescoplc beanng Inner Tapper type Slze mm Outer 65 Outer Slze Toe Stablhz bar lng Hub wlth double Call spnng x x Camber Caster of lllchnatlOn 2 3 1 30 1 30 6 30 Inner dla 18 25 2 x 55x I Wldth 26xO 7185m roller 52x20x16 mm ln Angle 32 x Taper type roller dla mm 2 0 05xO 08 0 79xO 6j 12 m of SWIvel axle Tread 1330 TurnIng angle mm Inslde 35 OutsIde 29 30 Wheel 36 52 lll of front wheel bearing adjustment Tlghten turnlllg wheel bearmg wheel at the nut same WIth hme the adjust nut unhl reSIstance beanng lS felt then turn back turn and lnsert cotter wrench pull up agaInst nut 1 8 pln tl FRONT SPRING l 54010 32201 668 688 225 8 8610 5401032202 688 708 225 8 86m 5401032203 703 728 225 8 86m 54010 32204 728 748 225 5401032205 668 688 217 5 8 957m 366 54010 32206 688 708 217 518 957m 371 5401032207 708 728 217 5 32208 728 748 217 5 8 54010 14 377 382115 386 15 15 391 8 86m 8 957m 957 m 14 itne 84m 382 15 04m Red tape WIth 1 whIte 04m 386 15 20m Red tape WIth 2 l 20 391 15 40m Red tape WIth 3 15 395 56m Red tape wlth 4 whIte 11l 14 371 m 40m 42m I4 62 m 76m 14 375 92 m 14 379 375 379 hnes hItt hnes l Whl es hoe 62m YeHow tape 14 76m 14 92 m tape wlth 2 whIte hoes yel1o YeHow tape WIth 3whlte hnes 15 384 12m s 153 lth J e li Yellow tape lth 4 te lUles wh FRONT AXLE The front axle spnng and equlpped lS telescoplc lS suspenslOn wlth call mdependent and connection transverse hnks lS of a of the upper and lower ball Jomt type and the not used for It The upper caster wlth the shock absorber sWlvel axles wlth the double sWlvel pln SUSPENSION splndle bracket shlms and the lower lS bolted to the front splndle lS connected to suspenslOn member wlth the lower bracket of the suspenslon member wlth the shlms J r 1 l Flg r i t I Flg 1 1f1i 154 2 mbty U200 r CI At W tJtI rU I Z3A emb r h Front Q 40015 1 h rb u knuck pond Ie left A IvnC on spen K ekle s 4OCII t IIJo nd 32250 ldl O rCht nd n r G ry U P sp k b dlebolt eubbbumpr lUll 4S3I 3DX1 lt s J J rrtJty FO f tsl bAil 1 on Jot jjjl ti jjjl 1 ft rj Lawn hnk p nd frontsu 441 n kJ J Lo Front 31m2 fj S J Suspension 155 Link 6 Sp Ind Ie r Body ThIS at drawma MWUI standard load c 6725 Front Suspension l ro r t i C I t r f 1J j f o t r 156 Section center hne the front hub DIsassembling the front hub Dismanthng of ground plate and then clear of the Lower the car on flrst Jack up the car untll the wheells mdependent suspenslOn spnng under place to the blocks Remove the wh el If the drum the adjuster should be slackened appears to blnd on the brake shoe Lever off the hub cap and then extract the spht pln from the spln die nut box spanner remove the splndle nut and ease flat washer clear of the axle thread by carefully uSlng a narrow rod under the nut USlng a mto small holes ln turn each slde of the splndle and tappmg the race hghtly Wlth the hub removed sertlng a dnft through the outer lnner beanng can be dlsmantled and by In beanng and tapplng the out beanng clear of the hub The lnner beanng and all seal dnft from the Opposlte slde can then be removed by lnsertlng the of the hub Ij lAisnemgb When the front assembl1ng hub the hub and the lnner beanng race should first be lnserted lnto the hub Pack the hub wlth recommended grease Renew the seal Replace the hub all seal over the lnner beanng The hub can now be replaced on the sP1IJdle lf lt lS damaged any way the Gently tap the hub lnto pOSltlon untll the lnner race bear agai st shoulder on the spmdle Place the splndle flat washer lnto pOSltlon and screw the nut down I i fmger tlght I t wheel and examlne the reslstance the Spln I Tlghten the nut j lie h en SIt wlII t A sl1ghtly lncreased reslstance to the splnnlng 0 f tae IN lir imn J L ld be m now and The are be notlced pht beanng preloaded the t mserted to lock the nut l j e the hub after packmg the cap wlth Tap the hub cap to scfe It lS wlth machlne Replace the brake drum and secure lS before screws the drum lS fully home thlS tlghtened lmportant that the drum should be pressed ln pOSltlon by tlghtenlng and If necessary two wheel nut Reflt the wheel and nuts off the lS packmg blocks but lowered to the are best readjust fmally tlghtened when the car lS the brake shoes lf necessary the car ground 157 f1 j REAR Type Houslng DnvIng Seml AXLE floatmg type Banjo type method of teeth Number gear Hypold on wlth steel plate welded bevel gear dnve plmon 35 8 4 375 41 8 5 125 UP31 UG31 UH31 UWP31 U31 U DRIVE PINION Tlghtenlng torque Pre 13 16 6 8 kg 100 cm 120 ft lb load for plnlon beanng wlthout all seal Thlckness of on of plnlon nut adjusting adJushng 0 75 mm 0 030 m 0 25 mm 0 010 m kg 0 cm 07 0 10 Ib ft shlm plnlon beanng Thlckness of beanng on shlm adjusting 10 shlm plnlon bearlng Thlckness of 7 0 125 mm 0 005 m 0 075 mm 0 003 m 0 mm 2 401 m Tlilckness of beanng shlm adJu ting Standard posltion wIth dnve to lnstall plnlon Dlmenslon from center of drlve to rear slde of plnlon set dlmenslOn upper gear 11 Off lo er Thlckness Ba ana l 25 4 mm o 75 mm 0 030 m o 25 mm 0 010 m o 125 mm 0 005 m o 075 mm 0 003 m o 10 o 75 mm 0 030 m o 25 mm 0 010 m oCIllmon adjusting shlm DiuVE G 61 y h i plmon Thlckness of slde 1filladJushng beanng shlm 0 15 mm 0 004 i Thlckness of slde beanng adjusting shlm Thlckness of slde beanng adJustmg shlm o 158 125 mm 0 005 m 0 OO m Thlckness of slde beanng shlm adjusting Thlckness of slde adjusting Tlghtenlng torque for out of bearmg OppOSlt cap slde SIDE washer 003 m 0 050 mm 0 002 ln 4 1 0 for 05 4 8 4 kgm 8 30 35 Ib ft 0 mm 002 m clamp 5 5 kgm 35 40 Ib ft GEAR AND PINION MATE Number of tooth Thlckness 0 of bolt of dnve gear BEVEL mm clamp dnve gear Tlghtenlng torque 075 beanng shlm bolt of slde Run 0 on slde 18 gear of thrust on slde Number of tooth o gear on 76 0 81 0 81 mm 0 030 0 031 m plnlOn mate 10 ThIckness of plnlon mate thrust washer 0 Backlash between slde 76 0 030 0 031 m gear plnlon mate 0 1 0 2 mm 0 004 0 008 m 0 2 0 4 mm 0 008 0 016 m 0 5 Clearance between slde gear case Amendment hmlt of dlttoed clearance Tlghtenlng torque for beanng nut mm 0 020 m wheel l 12 kgm 87 5ft ll t OIL USED Standard of all Gear all MP 90 OIl quantity necessary f 159 If I Flg HANDLING CONSTRUCTION THE The axle rear slowmg transmlSSlon to o nves the left and m ed 3teel 1st nght m rear the form lS for lts bendlng carner gear made out of 15 matenally spl1ne made out of and the lS closely and ae sl ress construchonally strong enough l1ght welght wlth ltS rear cover and strong alloy of alummum constructed as to make easy dlS conr ec gears molybdenum The carner chrome steel of rear axle shaft hlghly strength the dnve pmlOn dnves the bevel gear WhlCh ted wlth the dlfferenhal gear are hxed ln thlS case wlth the pmlOn The each two f wheels urnlng to the stays 0 shaft dnve dnV eS a j i J or nlon re as gear lS plmons and locked each other The plmon whlle case lS gear tructlOn of d1fferenhal gear conblned wlth these gears controlhng the d1fference of revoluhon of the rear Thus has the shaft whlch case supported by the gear whlch lS so supported as to funchon freely lnslde the slde gear lS connec d wlth the sphne at the top end of rear axle shaft 1 lock P lS of the lnvolute gear type Inslde the houslng lng used for hght and the dlfferenclal gear ass y lS so mountmg and the adjustment of each gear cas lS axle wlth the dlfferenhal gear whlch housmg lS made out of the of Banjo and the torslOn or the ne the bevel gear g welded oel lS hypOld The axle housmg the axle plate and the The englne power lS transmltted through the shaft then to the dnve plmon and flnally the y housed floahng seml lS speed propeller down the o well as the rear axle on The plnlon as lt ctlons dlre the side gear on left and nght and In case of turn the stralght l1ne e reslstance of some obstacles on the ground the the plmon shaft and dnves dlfferenhally the slde in rear axlelshen the revoluhon of left and nght wheels self ve the vanous equally on rs dlff The external slde T of axle lncl1ned and f1xed to axle ta ft WhlCh s1 houslng locks wlth the wlth the brake dlsc t 160 i lde gear lS The shaft supported by the taper roller bearmg to the axle tube by the four bolts together wlth the adJustmg lS wlth the brake dlSC f1xed shlm It lS not necessary feed the to to check the lubncahon to the wheel The durablhty of the gear HypOld gear Oll No MP 90 Temperature over 32 C SAE MP 140 It lS prohlblted to use any other kmds 11 fferent V1SCOClty The same mg and f1l1 takmg off the feeler plug full up to the feedmg hole The brake system would not work lf Dlsmounhng Dlsassembhng rear At the hme of nght axle dlsmountmg shaft or pull Take off the 4 Pull off the nuts of the 5 Take off the slde enhal gear Jomt flange case lllustrated axle of gear ollar any Oll of dl always be selected The method of 9 at the rear cover feedmg over feed the all houslng by CaUSlng drum lnto brake out for carner from the slde of housmg pull out the bot 1 propeller shaft and dlsmount forward the beanng cap of beanng cariler and pry wlth arner ass y lever the d1ffer a and the 2 m jk beanng 1 J 1 jt l wltb the ald of slde OlV f l Dlsmount the dlfferenhal dnve gear dlfferenhal gear a edge rlght t1t If by tqosenlng the scrE WS on spreadlng out1the lock washer asher dlagonal h e consldenng to keep from the gear case the I s ln to left and Il1lo Loosen them lt at least 4 lnches beanng puN r Flg The puller should be handled wlth care m c beanng tJ4 of beanng mner race WhlCh s hard to hook lef Both i the beanng should be arranged separately I 7 all of the hous Oll the gear Dlsmount the dlfferenhal side As be used of Dlfferentlal Gear Carner Take off and dram out the gear 3 6 other the trouble m flow out of the bath end of the and must brand must The standard capaclty of OlllS about 0 should be done by to cause must be taken lnto conslderatlOn followlng pOlnts Nommated 1 2 but need when dlsassembl ln lt would shorten the Wlse I beanng beanng grease proper quanhty The proper lubncahon to the gear houslng lS also necessary ed new the and lng 161 bend l Take out the dlfferentlal plmon as well the slde as The plnlon mate gear shaft should flrst be pull ed out 01 out the by stnkmg shaft locklng plmon mate pln whlch dlfferentlal left slde hxed lS case from on the from the slde of nng gear f1xed to the before out nght pulhng the plnlon slde gear and the thrust washer The as gear well separately front and 9 as the thrust should be washer arranged left and nght as rear takmg the nut of the pull out the com The dnve pamon flange wrench should pUllOn flange be employed settmg ltS After carner four pOlnts flange to the holes of ln keep lt from mov take off the nuts wlth lng the box wrench 234 10 Take out the dnve pmlOn of carner gear hghtly font end al lOn by stnklng out to the backwards the at the slde of Flg 2 of slde Usmg beanng puller com of dnve pmlOn Wlth the dnft of soft metal would be taken out together wlth the lnner fla l Th dlstance plece droller er race and the and plnlon of front and Justlng shlm left adJustlng rear race of shlm and beanng as well the carner ln f e plmon rear employed ln rear beanng thlS and the other for one end beanng lnner lnner case taklng race The off of the dnve plnlon replacer adaptor ln race 11 t lS and the adaptor the round form The drlve should be lS easy to handle wlth the Jreplacer of 162 for f1xlng flxlng Vlce Assembly carner gear Wlth gear 38300 37000 41 8 5 125 38300 37800 35 8 4 375 38300 37001 39 7 5 572 38300 36800 37 8 4 625 3 illO 30800 21520116 2 9 9 1 1145 1 5 38UO I I 5 25660 T20 22Kq l L15 14 I3 v 12 3noD 3 JJJ i 9 lo Flg 3 D1fferentlal gear L 1 t 4 Compamon flange 10 t1 PmlOn shaft Carrler assembly II D1ff 3 Drive pinlOn front 12 Rear axle 4 Drlve plnion 13 Gear 5 HypOld drive plnlon 14 Washer 6 Hypold drive gear 15 Nut 7 D1ff 16 Stud 8 D1ff bevel slde 17 Drlve plnion nut 9 D1ff bevel pinlon mate gear bearing rear bearlng case gear 163 slde 1 2 bearm shaft carrier p l I u v I t I i1r t carrler t C q a Io r I Y OJ 12 Taking out the bearmg rear outer race of gear carner The dnve pmlOn beaqng outer race replacer should be employed In other upon the stud so as to make the screw at the thlS case center of To then screw out the front pull the tool adapter the lower fnm at the tommy bar and screw up tlll the Supportmg the adapter 13 and set the carner the wlng nut to take out the beanng lt out wlth body pull outer race adapter m REPAIRING DISASSEMBLED PARTS Every parts after they by I compressed the Each beanng should are be makmg lnspected the defect and defacement before Every gear should 2 or any defects on be mspected placement lS Speclally the the wnenever the surface to drff1cult to an outer race set carner rear race OF mspectlOn every umt of and ass adjustment y ln regard wlth to reused them dlcldmg locklng condltlon defacement they can be reused to the s ee 1f deformatlon cklash or found re necessary dnve plmon and dnv JI gear condltlon lockmg adjust even should be worse gets he because lt would caus progress lr m as In case of lnsuff1clent standard h o closely race touches dIsassembled should be cleaned and clean before an of the rear from the gear the way of INSPECTION ed corn ln wlth proper nOlse Jstment to replaced m and the defacement ln later lS a lS set already operatlon and be made CT The perfect dnvlng e about from I shoufd sta 3 mm PririLth j ou f hp as can lt lS tnjfore dlsassembl1ng 1P orj the gear surface dnve 1 of lt t l t ra on the gear gea ln an be made ordlnary as lt loaded dnvmg lS do otherWlse by cleamng the both palnt thlnly and evenly Wlth the mlxed slde then turn the pmlOn wlth hand to Whlch shows the sltuahons of conslderably t In casE of unloaded three to full surface and tl1e V tlp m lt nspec them wlth thl worn 4 of thlS condltlon I Wlth 3 to rf ouch from fulOn The surface of dnve plmon gear should unloaded dnvmg whlle the gear surface condltlon at the quarter at nd of gear test It the center of 1 on the pltch hne lS perfect that the gears whole gear 4 of if do kP r t 164 length contact for about from tooth mtenor 3 Lock the sIde gear wIth pIllion gear In together wIth thrust respective the 10 case case sIde of the backlash 0 over 2 mm and the clearance between the gear and thrust washer exceeds 0 5 mm the thrust replace washer The else worn out should also be parts The contact when nng gear backlash should be 4 Put the differential gear volve the dnve beanng do not Measure the should be tmg adjusted closely dnve gear w and face and n 0 5 the In to shaft washer mountmg by IS flxed 10 nd cator the the gear the Re case the as scale and the shake clean well the flt of It and flx then correctly 1 Gear the dIfferential 10 should be clear ed and OIled wIth InspectIon Inspection or of ADJUSTMENT Every parts the mentioned It as case shakIng then the pInIon mate sIde gear IS sIde of gear rear Assemble the pIllion and sIde gear by block the d al In nOlse block buoy Assembling differentIal 1 gIves much buoy wIth measured face there should not be any ASSEMBLING measure mm face rear the to pInIon center It or to turn around the d fferential gear gear move on shake at the th on rmg gear case replaced too close IS and t and sel should be the backlash m new case gear 011 hrust washer should be assembled k e lOn before agam Adjustment must In pushIng the pInIon mate In the clearance be made In of between the case any abnormal found Stnke 10 the pIllion shaft sIde of dnve gear a OpposIte hole of It after puttmg It to mg pm from J the the nght sIde of the case d must be flxed by settmg well the str reljUlred pIston so as the pIn klll uld no sh loosen l If f 2 F x the dnve gear The dnve gear ed or they must be OtherwIse they In rnountmg In sureness well as wIth the dIffereti tr e dnve pIllion shoul whenever the repla1 replaced i after assembhiig lock properly case the fltt1ng surface must specIally as set a would not the flxed WIth 8 Nos as nng gear screws as well as lock washer Bend t 1e a h ld l TW1th i 1 shake IS adjusted In tightenIng up Hie screw supported by VIce or any other setting tools so as lot rec screw up In a dIagonal hne wIth a wrench wh ch flt co after the dnve gear It should be set and It and to damage ly wIth the head of the screws 35 ft by lbs one to 40 ft lbs quarter pund Screw Th 10 for standard screwmg sure hammer 165 stnkmg hghtly ue for th tor s IS the head of screw f 25 60 0 10 256 0 01301 256 0 0 10 H 38425 38426 38310 38127 38423 38424 y 50 A O 256 0 0 10 256 0 38426 38425 38427 L @@ Q Gea 4 srA 2S6 0 4Y 1 il J C0 t 44 J r 13 Fi i I I 27160 38161 381 60 i iO 27 I 53 l v I 00 I j 9 3 Mount the sIde Press It IS 10 Important Ing shIm 10 thIS the to gIve beanng 10 the d fferential the both sIde of the beanng to assemble case beanng a proper by putting preload case uSIng the dnft by the beanng adJust sIde wIth the flx1ng In carner ADJUSTMENT BY ASSEMBLING S Y AS GEAR CARRIER It IS to decIde the In an portant exact sample must well be rear adjustment of gear whIch IS most Im and should be carned In accordance wIth the y The cons ructIon and mechanIsm the manufacture assembhng axle shown ass by comprehended refernng to repaInng exactly accordIng to the cond 11 and the adJustment use and beanng are dIsassembhng and InspectIOn If the dnve gear are as a adJusting case In to dnve pIllion result of assembled In 8 practical based on the g me Drive Pinion Mounfi The Preparation for in the Gear Carrier I of exact calculatIon adJustment by A 5 FIg tion order of dlsassembhng the reused they they should be the prevIous cond tion of at shIm any Item should be replacedor requlTed to reuse even 1f out prepare the vanous sh ms as mentIoned any later because the pOSItion of dnve pInIon to be f xed WIth carner d must be adJusted by the adJusting shIm between the carner al Item p1nlOn 2 There by an They 10 0 ment IS worn rear are beanng few numbers WIth 0 electnc pen show the 025 outer race on the manufactunng to mm deClde of standard pOSItIOn from axle center as or besIdes set tIp head surface of dnve Rlli flgure of adJ The ss stanqard FIg d scnm1nate due to the corOOS10n 6 oeo for l p1lliO 001 adJust nm flculf If the scrape t n unIt error In a the th1ckne shown If number marked off t 1 ze to substance p on the surface scrape off by even a some what narrow gnnd stone the mark 1 167 th car not to 4r FIg AdJust 3 5 the d rection of to of PmIOn AdJustment an arrow The th ckness of dnve pIllion In heIght accordance wIth the pInIon mark adJusting sh m are arranged as follow mg 1 t4 tl 7P r yJ Dnve adJustmg ar tN o fad t Standard Th1ckne lil i t Leaf Nos Part No z l Jb p1nlon 1 s s 38153 2660 sblm 0 l 75 mm 1 38127 25660 2 38128 25660 0510 2 38129 25660 03 2 38130 25660 03 0 III l f Ollll 38154 2660 0 25mm 0 38155 26 60 0 125 mntSO 2660 0 075 mm f 3815 6 f Hls 0 III The adJusting sh m w1l1 be explaIned 10 the followIng para graph SupposIng the dnve gear and the dnve pInIOn were adJustment set and the as a new replaced heIght of dnve pInIon prevIously used was sh of whIch equals to the d fference of the m th ckness nght prepare fIg of the use of ures It It the on plus and thIS pInIon new Increase thIckness of the shIm for It IS of In case convenIent to mentloned later Deduct the and have mInus assembhng Inspect to prevIously used shIm In case the general Idea of requIred prepare cond1tlon before the d1sassembhng In a way the measurement of pInIon heIght BesIdes the con d tlon of defacement on the carner the pInIon beanng must be taken Into as cons1deratlOn B In It WIll be though explamed Fixing and Adiustment I Dnve pInIon In th ner sh of Drive Pinion the by sIde of thIs outer rear race must be taken off also mentloned race IS therefore the tools must be handled tIon to to make the as handhng method on the and Ing the by 2 spl1t adaptor the bar the setted housed tW1S pOSItIon properly Mount the front For mountlng sIde mount It The 3 by race IS Mount the up the carner beanng tIghten the adaptor scarcely tlll the In use of a the time as the Inner lace screw support and lace adaptor so eJ d of tlp same gUlde outer rear the come race to be In a carner take off at hrst tli tool at the to be way of h e s l race f stud 1i tlte1 69 10 op then r ntel outer race aged and roller to the dnve pInIon attached to the dnve pInIOn certaIn dnft from adapter e mountlng adaptor Inner race replacer wh ch was employed the dnve pIllion Th s mIght as well be By the corn to on necessary to be taken off unlliss beanng round At the and fIx the as put sItua a Refernng oval pOSItIon screw as uSIng carner up the wIng nut outer lace carner nng at m and the adJustment s In an adaptor race rear sh to aVOId such properly race corn screw the faces InSIde at the the front outer lace rear uSIng the then InSIde at the set ed the front end of the pos1te set the beanng surface corn as put It hole of of tool at the small hole of body the beanng of tool adJusting beanng pIllion heIght Increased or decreased each tlme for th In car tool of dnve pInIon front specIal beanng outer race replacer For adJustment of prevIOusly and carner the In properly selected mentioned between the mount the outer lace the should be mounted outer lace after 1nsertlng the case prevIously as m beanng rear s detaIl later In done rear bhng l d1sassel at In pr ssmg beanng press In by In the 4 Mount the dnve pIllion and carner nng the adJust by pos1tlon The pInIon be adJusted as In the r measu heIght must mentlOne d In paragraph by temperanlly the the prevIOUS mounttng pInIon In beanng load the carner and the be gIven a regular pre the On the other hand drIve pInIon should oIled after the pmIOn beanng of be newly IS Inserted from the InSIde of the carner 2a9 FIg the Inserted end 6 and tlghtened up of pInIon should be locked wIth front beanng WIth the companlOn flange ttll the regular the nut by pmIOn fIxIng corn As th s IS revolVIng torque IS required dIstance pIece the beanng bltng spacer and 011 seal are yet at the f nal beanng adJustIng not assem shun not mounted At the tlme of InsertIng the front brar1ng as pushIng In the Inner race Put the the dnve pInIon from the rear sIde of the carner by pulhng then support the under It and set tool sIde the carner downward rear of ln the beanng by usmg the dnft pre mg the end surface of dnve pmlOn dnve pInIon front bearIng Inner be would eaSIer uSIng out by The operatIon lace Inserter as shown l 3 t r r 11 FIg 7 PlllIOn Bearmg Preload Gauge 170 TIghten up the p11110n nut by turlling It slowly wIth hands wIth the use pre load gauge as FIg 9 to the degree that support the beanng pre load at 7 10 cm of kg When the dnve pInIon tlon It IS whether It IS standa rd hIgher Make IS mounted to measure necessary beanng f xed wIth the flxlng posItIon can be an setting arc rear cond surface of the pInIon of the speClal the bottom of the from mm prevIously mentioned of lower than the or use dnve pInIon arrangement gauge The standard heIght of the pIllion 21 the In heIght the 8t 1 The carner measured of clTcle 11 IS sIde by both sIdes On of arrangement gauge tIon of sIde th ckness ween beanng gauge the clearance bet In the tI p of gauge bar and the pinIon such as to of the at the POSI and Insert the carner push d In by scraplng In otherwIse agonal preload and the pllllOn beanng would comeout of order and tend to In cause an height unexpected of the r Fig trouble 8 Use of dnve pInIon beanng Pre load Gauge future 5 The formal adJustment J q fIxIng pos1tlon preVIOUS paragraph dnve plll10n After the the to mount agaIn the dnve nut TIghten up the nut the regular torque The rectIon of axle as It 8 by lbs beanng spacer In th s USlllg the torque wrench at 13 In 16 83 thIS case beanng adJustlllg much the play ms the Inserted Therefore It must case for more cause be 62 IS kg of mg hst and measunng wIth the as cm 10 kg FIg the It bearlllg tIghtened by to be burned If lefVand 7 so as shim as shown anng thebb 008 10 by decreas1ng fQllow w pmlOn gauge 171 c rn L pre of the dnve p11110n beanng pre to make the revolvlllg torque of f there should not the feeler Ii f or us by any the pllllOry wIth led at 0 2 mm se error III the head mark at 0 and the clearance should be 0 T pIllion to the d d adJusting at 7 cm d fferent aCC Justmentof adJusted by IncreasIng re the number of four kmds of load gauge In companIon flange dlstance pIece and I load preload mentioned Increased sh IS as shIm Inserted mentioned nuts and prevIously turned beanng 20 ft the deClded IS shIm Inserted IS The less of the pInIon and bearmg ff the pInIon nut FIg to the cond tion of the The more of the ve wn 100 preload supportedly dlllg the of 241 f I I I I I I I Remarks When measunng the of the pInIon head I 4 cIrcular sIde I on gauge J Insert set semI of the portlons the sIde heIght the beanng seats feeler gauge mto the a clearance between the tIp of the gauge center rod and the pIllion head and adJust the pIllion The guage rod 100010 8 mm IS made 0 the standard measurement Therefore mm IS I J i Y IS IS regarded crea lllg read 1ng rear pInIon or or on decreaSIng of mInus valve marked or mInus on adJust 2 mm poS1tlon than the the pmlOn heIght outer lace from the number of the because the standard 2 I SIze heIght 0 of the mm take off the dnve pIllion the to carrIer adJustIng sh adJust by as In In other words m the head of the dnve p1111on before the number of deVIce pInIon feeler gauge wh ch case D beanng decreaslllg the mark feeler the plllIOn head the correct at as made shorter for gauge If It IS necessary to well as a accordance wIth the 9 FIg thus pm IOn 21 adJustment by selecting In gauge 2431 1F QlII made plus 2 shorter than adJustIng by mcreas adJustIng shIm to Insert the IS deducted for the number of mark from 0 008 SIde added for the number of mark to 0 008 10 In Increase III of plus For nstance r r r by deduC hng Ith o 002 In 0 010 At the tIme of J if the mark shows number of sh In It pushIng IS the m adJust so as necessary to to the posItion of dnve p1nlOn make the clearance gIve the bearmg outer lace Into the carner a at 0 008 In nght pre load It must be done In f otherwIse nght way SpeClally when the old beanng IS to be used agaIn 10 assembhng the I the r torque than standard 10 accord adJustment should be made at Jo t ance wIth the cond1tlons of ise so as not to gIve It an over pre practIcal a load 6 When the ed as 1ll mer adJustment of pre load paragraph lllspect the prevIous 172 of the beanng IS complet heIght agaIn the pIllion Unless any thIng wrong IS found loosen the pInIon nut take off the the new 011 seal In the rear of the carner and for Insert flange washer and pInIOn flange fIx the merly The nut should be nut the standard torque In case the cotter plll hole tlghtened up fItted the adJustment should be made not by tlghtelling the nut but at the washer by fllhng c the Differential Gear Ass y Mounting in the Carner 1 Mount the the unIt of dIfferentIal gear In the carner and fIx IS a engraved mark on the SIde of cap complete beanng There cap whIch should be fl tted It mountIng beanng hOUSIng each WIth mark on the of beanng hOUSlllg when flxlng part of the cap of leg Important to note that the IS The differentIal IS machlnerly case gear fln1shed up lllserted IS the by beanng adJusting by hOUSIng In the bear of the must be carner Ing hOUSIng beanng glVen the regular pre of nut of the SIde beanng cap load The screwlllg torque the fIXIng and should IS at 30 35 420 490 kg cm be equally locyed lbs ft shIm WIth WIth the SIde fiXIng cotter So far IS rr locked ust only WI th beanng and explaIned as pIn the dIfferentIal unIt IS mounted and the dnve gear J follOWIng adJustment the regular suie beanng pre load the drIve pInIon be made to acqulTe the therefore the gear backlash Z beanng pre load To gIve the nght pre load on the gear case and In pressing the beanng Adjustment by lllS ed In ertlllg lllslde the beanng manufactunng carner error In a of 1 unit III standard gauge board weIght block s mm place 5 kg the error measurement of 20 as E 0 mm on F mInus the sIgn SIde ufllt the 19 8 008 ore left beanng In 173 stand jl andIQgl t agaInst It IS on the each 1 1060 0 2 IS mm use a fYat the WIth kof a1 steady fIgures basIs of mm beanng numeral IS agaInst each Take the left SIde beanng IS the The and d al gauge the standard measurement and the E 0 on 10 acqUlre the on mInus When the measured WIdth agamst to on adJust flcplat c s compUtatIOn In beanng thIckness the load for about Z Calculate of them 20 0 case case shIm of th1cknes 1000 FIg To measure the WIdth of the SIde In th of d1fferentlal and dlfferentlal case ard measurement of ABC D each In adJustlllg beanng the dIfferentlal marked numeral of adJusting bases IS a housIng of the gear the SIde accordance WIth the follOWIng method of There the backlash of SIde sta LIlJ dard and assume for O example 008 10 jy excludlllg the The thIckness of the shIm to the method of followlllg acqUlred by applYIng IS the numerals computatlon Ll A Tl 0 D 007 l I C E m I 0 J Ijl B T2 O D r 006 I F In I 10 FIg ThIckness of sh on Th ckness of sh on Left 1 11 of calculatIOn 0 A 1 D 2 C 2 E 0 b A TI o 002 j fq t 0 mm 007 0 008 B 2 D 3 f 0 T2 E B 0 0 D 002 therefore 25 0 06 F 003 0 j 0 008 0 t as accordance well be 01 o 0 aqsembled by In 010 I 015 ThIckness of nght sIde The left and computation the pre Measure the backlash of the dnve pIllion sure s sh m uSlllg the shIm of th ckness wh ch otherwIse Ing the d al Ind cator to make 0 Th1cknes sIde shIm pressed 006 I wIth above method of Ing must be well mm 0101ll o III 002 kriess of left It may In 2 0 ri6 1 c l RIght c 001 0 m sIde nght Example f m sIde left that It IS nght IS bear load changes nng gear wIth n 0 1 as mm by FIg O 2 mm O us 004 I 0 008 VIce versa If It for 1 much move to left by taklllg off the adJustment 174 I nght shIm and a WlthQut htt1n G ar drlyebypo1d and oil I dnn Nut hen btened tl 62 1 kg em adJult puuon with IJ83 IhiI adJ I It I ng drJ Tepl Dlon be Ilr In g driTe piDIOD tOrqUI to be bearll1C turnlna hypoJd 7 10 kg lurface lnctlon ell Wht n be a llo Jlnt tlo th NP lO V1 I I I I Bo1 t d1ff t1ghten1n 415 485 bearIng torque Kllcm cap 1s t7 4 i l J P ir if l J r t Fig 11 Carrier Section i S of 175 Ji t The numeral marked dnve gear by the electnc pen set number For 6 6 example means 1 I D al gauge 2 S T D I gauge 20 0 mm thIckness 3 WeIght 4 The on the sIde of the shows that of the recommended backlash besIdes the block beanng measured I I I L I r t J J p I of w 4 1 C 176 the backlash of 0 006 In After the Operation at the tlme of repaIrIng necessary to use the beanng agaIn nght must be reduced for 0 001 the thIckness of each shIm of left 0 60 agaInst standard pre load III accor o 003 on the basIs of 10 or 80 because over pre load IS dance wIth the practlcal cond1tlon of use WIth the sh m of thIckness calculated from above glVen to the bearlllg If It IS method of computatIon kt FIg 12 Measurment of Backlash for the Dnven P 177 n on RIng Gear r J1 I j 1 J Ii r FIg 13 USIng the dIfferentIal 178 sIde beanng cap gauge Od seal 38140 04100 PmlOn front Supply chassIs grease to 011 seal lip when ass bearl ng y t 8hiaad ldJu jGatl 8bbtlldJ1Ud1D rrect IIIMal aldrln p1D 10D aad tt bfl cap riD and tooth co ata ct ot par lrJpoid backluh 0 I 0 l shuns Drive Drive pmlotJ adjust shims pImon bearing Shaft gear Side Suie 41 484 un par ti M3 kl eJI gear gear thrust u1lJ ph e torqv hphn b7 tapp 01 bolt hud vitb 1 4 Ib r c Id ootb Dtut of m tb on b h ctl i diffenlltial a 4 of f t 0 1 0 washer widtb bearing Pili i aDd U J I l Mhr U Qp17 t7 ah1 ol djunlDI clrJ 11 lath thicb 381 0 211 bNriD eqaatua Qd c in Fig 14 Differential 179 L Gear ad iepar Carrier I u tasl53 ellilpate4 bIt ai4 cbnet d 17 4UUa 81HIO UlnIlP the prel Section t adJustment Thus the IS the L measurement wh ch If It IS msufhc1ent In th and nght speClal gauge The 1 0 s an should be large SIze for emoloyed way of 40 198 m of 0 add tlonal sh the case By wlthlll 198 55 precautIon mm 002 0 lllS of m1chrometer 2 dIal by measure FIg as 13 05 as mm FIg left In 13 or scahng shake of the back of drIve gear wh1th has been flxed should be measured carner o add completed IS nd cator to w conhrm that It th the IS w th n rom Mounting the Gear Carrier Ass Axle Housing Inten The ro of the axle carner packing Mount the gear down sIde and housmg ass be The 011 of the otl tlll lt mounted on the Rear wIth new one ItS upper sIde wIth then fIX wIth the lock washer nut through 10 studs tightened In a dIagonal IS replaced y wIthout The nut must be When It on should be cleaned well should also carner y the vehIcle mIstakIng hne so as not to feed the gear 011 cause the 011 leaks ImmedIately 90 should be feed gear 011 No up to the down sIde of the feedIng hole Feed the desIgnated hYPOld comes f Ifif o eO fI i 5 t I When placlllg r as to keep the r t end play shaft do not and the shaft wIth flange 0 14 FIg the d fferential axle I etween tne end of the axre so 0000 of the axle forget the the brake d adjust sc sh m assembly shafts J Axle Shaft Removal Jack up the axle USIng a screw on If the brake hllings slack off the brake shoe Tak as shown the blocks Unscrew and remove the brake drum dnver should hold the d adJuster a um when the hand brake off the f1Xcbolts of the brake dISC and FIg Tal out wIth IS released few notches swmg hummer 180 remove holdmg the axle shaft assembly the wheel stud bolts th wl Beanng cage b t12446 0225 0 100 I Fig 15 Rear 181 Axle Shaft 1 the rear axle shaft Draw out the shaft outsIde of the brake d and d sc assembly by gTlppmg It sc C 16 FIg iferTlng brak 1 cag1 np t Bear and FIg 17 assemble assembly Brake d sc d1sc W H eanng whIch to Grease O lock nut seal In th for Axle Tube Assembly to the axle tube wIth the axle Grease catcher Spacer tapper s case the the end roller packIng beanng nes s the of shaft a by regular end the th1ck of ri6ert selected sh F t tne end play Secondary play to Lock washer shaft must be glVen play of dlTectIon sphne adJusting sh ms Inserted at the tlme of as sembhng In adJustment for thIs end play select the adJustIng sh Left or RIght at the fIrst 4v play IS shaft wIth Grease catcher 0 05 0 10 ms between the axle of axle shaft 0 85 1 10 tube and the by selectmg adJust 182 shaft for as one sIde sembly mm attach the other sIde of axle mm ms shIms shaft assembly and adJust end THE INSPECTION WHEN THE CAR STOPS 1 Operatmg the gear the sIde brake and s found by 1nspectmg the motlon of the and the ettmg backlash and the defacement of the revolvIng sphne In shaft propeller the as of axle housmg movIng shaft can be left It to nght SpeClally beanng 2 Another of the dnve pInIon In case IS worn out or the adJustment mspectIon should IS comes out and In the pInIon necessary be carned m a by JackIng way up one of the wheels and spm It back and forth 3 Holdmg dnectIOn adJust 4 In IS 2 3 any of gIvIng the case It IS the the degree hIgh meta C of move to tIghtness of the 011 speedIng damaged n01se In up out beanng that gIves the constant IS a as or penod1c It must gear used when nOIse IS worn of the because If It quahty too much at the dnve gear that makes gear damage or any abnormal beanng and the up and spm and Jacked mspect every and m the housmg in Motion at the least GIvIng pInIon felt and confnm the volume and Inspect I IS t 1 Inspection lash the tHe of the wheels When the shock It and another and so forth IS be fInally or slowIng at the bIg hummmg down tre dnve hIgh speed In case there IS speed ImmedIately d sassembled and repaned nose nOIse at low the broken gear to speedIng up the back theJdnve pIllIon and cause to breake t e other gear aCCldent x I I fi i 183 BRAKE GENERAL DATE Type operated by foot Four wheel operated by hand Mechallical 011 brakIng by pressure for brakIng rear wheels Inner d a of master Inner d a of wheel 22 cyhnder cyhnder 23 05 19 ResIdual pressure of brake Inner d1a 011 o of drum 5 0 254 of real CIrcle of drum Degree Amendment hm1t of d ttoed degree Allowable hm1t of mner d1a 8 kg BRAKE ear Length LInIng 10 mm 05 o 20 mm 008 a 80 x d 0 002 m m x mm 10 2 mm 0 032 2 both front menslOn x wIdth a rea x th1cknes per brake 244 s shoe mm x 1 10 sq pedal The Drakes lc 1 on adJustmg completely and press re of Integrally 10 if all four wheels on dlTectly coupled to a the brake wIth the replellished operatmg master cyhn and a pIpe hne c Inter connected the master pressure mm x 5 mm gear notch then make 12 back 14mm are hydrauhcally operated by master foot pedal wh ch the cyhnder hydrauhc A supply tank case ongmated provIdes a reserVOlT by wh ch the flUld flUld er 4 cm turnIngs for 45 Fasten s T le TJ 0 m Less than 0 wheel Adjustment of shoe clearance Rear brake ifront IS mm cm SHOE L1lling ppl sq wheel 19 05 of drum a Rear mm both front rear Play 810 DRUM BRAKE r 7 mm Front wheel 10 IS onS1stIng of tube flexIble hose and nUl on and the wheel cyhnder cyhnders generated m the master cyhnder by apphcahon wIth the foat pedal1s transmItted wIth equal and und m1llished force to all wheel Th s moves the cyhndeq s multaneously pIstons outwards wh ch In turn the brake shes thus automatlc expand producmg equahzatlon and effIcIency When the pedal IS III dlTect proportIOn to the effort supphed at the pedal released the brake shoe spnngs return 184 the shoes wh ch then return the F wheel cyl RetaIner 44113 31700 AdJuster screw 41146 32200 a H AdJuster AdJuster I L9 Front Front brake shoe After 41031 32202 41021 32200 Front hrake shoe 41039 return sprIng Oomponent 32202 J of F 185 ont Brake 1l147 1 t t t L l t I t f f l IjV Z O 1 f f V f 1 t r ee j 186 J wheel and therefore the flUld back llltO the pIpe hnes and cyhnder pIstons cyhnder master Independent An dnvers cal sIde seat mechallical left attached expanders the to llllkage sIde nght or rear actuated by operates wheel the a hand brake bod cyhnder wheels rear mounted by mechanI es FRONT BRAKES The front brakes are operated by Each wheel cyhnder consIsts of pIston cups cyhnder cover pIstons a each one body wheel cyhnder contaInIng lock wheel spnng cyhnder cover spnng seats and adJust screw The shoes allowed to are shde and centrahse whIch d stnbutes the force dunng the actual brakmg qually over the hnlng area en brakIng operatIon sunng hIgh effec1ency and even hn1ng wear AdJustment for the brake shoes IS by means covers brake connecting the adJustIng screws the teeth of the gear and each adJustIng screw typed for shoes The brake held wIth In shoes posItIon by rest one on the return dImples formed In the back plate and are wIth the hole of shoes spnng Wh1 ch connectIng l I t I j 1 FIg REAR The BRAKES rear hse wIth the operated by brake same wheel shoes effect are as III not flxed but are allowed the front brakes cyhnder and llldependent hand 187 They brake to shde and centra are hydraullcally mechn1sm HAN D BRA KE CABLE i f J BRAKE q DRUM SIDE l e BRAKE DISC BACK 188 J R OQU OCOo o 0 0 c tI 0 1iW I j a t r tJ t C Q 1t d l 2 FIg HAND BRAKE 1 The hand brake pull up type of lever sItuated The cable from the control the rear brake d sc when a complete the along IS rear e wheels only and sIde the dnver attached The hand brake works and should not requ1 Only on operates s IS fi by appl a seat toggle lever connected WIth hnkage IS set when leaVIng the to the any attentIon under normal maIntenance overhaul IS necessary should the hand brake hnkage requIre resetlng When th s correct the rear shoes should be locked to the drums WIth the Just shghtly apphed and the WlTe rope set rod of tpe equah Just removed by means of a nu at the center the hand brake slackness IS control J zer drag hnk f y 189 l 1 ston l rear whee 1 cylInder 44108 4410S 32200 322000 44112 32200 Spacer wheel rear cyl piston wheel rear 44109 32200 44135 32200 44135 32210 Cover dust l Hh 4110 32200 41206 322 Lock spr r n @ 9 11145 0 g W l fi i SprIng l04 SJ r203 32200 f N00 l5 I N G J sprln k r bod cyl Y h pldt t J 4115S 04100 214 04100 44128 3 AdJuster n 4112S 30ool s 44 on 32201 h L B fffiOOO 1 r m Togg 3 I 1 032200 R Tf IUTlI 402l Han tlt i PP pnnK 32200 n XUnll ntl I 4084 32200 r @ i 7 p S3 32200 t 440S2 32200 440S1 32200 i fJo Rear AdJuster H retu m spring Lowe 44071 32200 41 0 0 3 00 R H 41201 shield I L 32200 1147 41208 dus t cover J screw 41023 32200 Rear 44060 f2 322 brake shoe 322 00 L B Componets of Rear l 190 ass I y Brake 2 JO I cyl r Front brake adJustment II K i lc T j iff 1 Rear brake adJustment 191 r ADJUSTING BRAKES RaIse the truck and place stand Jacks front freely the parkIng brake cables at the and rear that all so four wheels rotate DIsconnect ThIS precauhon drag due to should be taken to mIs Remove the adJusted parking brakes adJuster boot and msert Ing hole and engage the teeth on cross ehm1nate the a shaft lever poss1b1hty screw drlyer through adJust the wheel Turn the locked adJuster wheel down upward dnecbon untl druI11 then turn It up approxImately turns hghtly the brake on the wheel MASTER ThIs IS reservOir The of consIsts 1 an alloy body assembly IS mad D1sconnect bacj ph a pohshed p hmshed bore stoper plate and check valve untll and nng pIston seat I tected by a rubber boot as shown cyhnder the cyhnder and remove the fltlld reserVOlT may WIthdrawn v e Remove the flller cap and dram out flUld boot and Pllsp r09 rem rod push valve the Brdke Master the can eI e ha l f r 12 notches the pressure pIpe unIon from then the master cyhnder and bolts complete from ilie WIth f the cap Desassembhng secunng shoe becomes WIth cap return spnng let The open end of the cyllllder IS FIg the CYLINDER Inner secondary of brake shoe g as remove sembly thrplston the can WIth the stoPPECr then secona nng WIth removed a palT of Pull nosed long push rod exposed there When the ry cap WIll be 1ston y1J parts ce assembly complete separated by taklllg out other espeClally the rubber pnmary cap WIth n be nev parts where necessary 1q 1 192 small for parts wear or d1stor 5 13 41 23 12 Jl ll a r I i J I Jt I 1 tl 6 7 6 FIg 1 3 Components of Bralr Push rod assembly cyhnder rubber Stopper plate nng 2 Master 3 4 P1stnn 5 Master 6 P 7 Return 8 boot secondary cup cylmder pIston ston pnmary cup master eturn cyhnder spnng Let out valve as 10 Check eat 11 Brake maste r 12 F1l1er cap 13 F1l1er valve sembly cyhnder body gasket cap spnng seat t k 1 I I 1 1 Bleeding the J Hydraulic System 1 C t4 I A t 4 I fo 1 BleedIng IS necessary any tlme portIOn a been d sconnected or If the level of the brake so low that nections au secure has entered the master and the supply tank from the bleed valve and ht the bleed tube the free end of the tube III a clean Jar WIth all cyhnder topped over s process must now be a thef a turn lId ente downstroke seat 01 remove lc fi s fall con the cap ImmerSIng ld and then ope ng the Jar is the brake bleed tube repeated for each of the other wheel 193 f r dratil1c ove llttle brake f1 quarters of pedal wIth a slow full stroke untIl Then completely free of au bubble s dunng a pedal tIghten the bleed screw cap suffIcIently to Th re the bleed valve conta1lling rate the brake the h up wIth the flUld Unscrew the bleed valve cap about three 1 bf the hydrauhc system fiUld has been llowed to cyhnder r7 Always keep It IS a careful check that most Important Should aIr reach the a on full level master the IS supply tank dunng bleedmg SInce maIntaIned cyhnder from the supply tank the whole of the bleedmg operation must be repeated After bleedmg top up the supply tank to three mately brake system some for before It IS Never up the toppmg extent areated day one quaters full use supply ItS correct level of approxI flUld that has been bleed from tank as thIS brake used agaIn Th s WIll allow the alT bubbles m the Great cleanhness IS essenClal when dIsperse deahng and espeClally so where the brake any part of the hydrauhc system IS concerned DITty flUld must never be added to the system I s t J Lf c y c lo J r l i f iJ J i0rI It t c i d I tl L ltf f to Such flUld must be allowed to stand for at least fluId hme to Ii a flUld may be 7 r J r 1 oJ f1 j 194 wIth flUld w J I I IJ r fi I P f 1 t lI k i f er 1If r l to 0 t 1 i Ir l i r b n v pnnted 11 apal lCanon o t 423 B02305 j t j a v I 9 tf1 rSo iOi1 r A lit Tit i 1
