Datsun 320-U, Service Manual

Page 1: ...A e t tO DATSUN TRUCK MODEL 320 SfRVICE MANUAL NISSAN y NI55AN MOTOR CO LTD OTEMACHI BLDG OTEMACHI CHIYODA KU TOKYO JAPAN CAlLI ADDRISS I NISMO TOKTO HONU I 211 5281 c f i 1 1 t lJ l E t Book Sale ...

Page 2: ...MODEL 1IO U NEW MODEL 1IO U I i ...

Page 3: ...erVIce and mamtenance of the Model P L 320 U Each assembly of the major components IS descnbed 10 detaIl In addItIOn comprehenSIve mstructlOns are gIven for com pIete dlsmanthng assembImg and mspectlOn of these assembltes It IS emphasIsed that only genuine DATSUN Spare Parts should be used as replacements l cfi4 ...

Page 4: ...ection of EngIne Carburetor BRAKER POINT AND IGNITION TIMING ADJUSTMENT Dlstnbutor AdjustIng the Igmtlon TImIng CheckIng the Spark Plugs CLUTCH Clutch Descnptlon of Clutch Control TRANSMISSION TransmIssIOn DIsassemblIng the Case Assembhng the TransmISSIOn Selector Inner Operatmg Lever Cross Shaft PROPELLER SHAFT UNIVERSAL JOINT Propeller Shaft Umversal jomts STEERING FRONT AXLE Front Axle Settmg o...

Page 5: ...u c Page REAR AXLE 117 Rear Axle 118 AssemblIng Adjustment 122 BRAKE 138 IGNI fI0N SYS FEM 147 ELECTRICAL SYSTEM 150 Starter Motor 164 Battery 171 t v ...

Page 6: ... Name Kmd Cyhnder No and arrdngement Cycle valve arrangement Bore x Stroke Total piston dIsplacement CompressIOn ratio Max power Max torque FInng order 4 185 mm 164 8 m 1 515 mm 59 6 m 1 50S mm 59 3 m 2 470 mm 97 2 In I 170 mm 46 1 In 1 187 mm 46 7 m 177 mm 7 0 In I 850 mm 72 8 m 1 427 mm 56 2 In 406 mm 16 0 In r 945 kg 2 080 lbs 1 2 225 kg 500 lbs 500 kg 1 000 lbs 910 kg 2 000 lbs J 120 KPH 75 MP...

Page 7: ...lj RICA TION SYSTEM OIl pan capacity COOLING SYSTEM t r Coolmg water capacIty BATTERY Type Voltage Capacity Termmal grounded J GENERATOR Capacity Voltage current regulator 2 14 deg B T C 50 deg A B C 52 deg B B C 12 deg A T C 0 35 mm 0 014 m 10 deg B T C 600 rpm NGK Model B 6E 14 mm 0 7 0 8 mm Pnmary 28 mm 21 8 mm 98 48 4Q 145 100 220 Secondary 30mm 25 14 7 mm 115 40 19mm 35 htres 9 3 U S gal 3 1 ...

Page 8: ...16 6 46 2 0 lures 0 53 U S gal Gear ratIOs 1st speed 2nd speed 3rcl speed 4th speed Reverse all capacIty REAR AXLE Type Gear ratIo all capacIty Semi floatIng 4 875 39T 8T for 320 U 320 UN 5 143 36T 7T for 320 UP for other 320 senes as potIonal O 85 htres 0 22 U S gal STEERING SYSTEM Gear mechamsm Gear ratIO Warm and roller 17 3 I FRONT AXLE Toe m Camber Caster Kmg pm mchnatIon 2 3 mm 1 deg 30 mm 4...

Page 9: ...1lckness number Wishbone type Independent suspension TorsIOn bar spnng 20 5 x 604 5 mm Parallel semlelltptic leaf spnng 7 mm x 2 f 320 U 6 mm x 1 or 6mm 4 12 mm 1 6mm 21 5 mm 2 12 mm 1 for 320 UN for 320 UP With helper rubber Shock absorbers Front Rear smgle action smgle action TIRES Model Front Rear 320 U 5 60 14 6PL T 24 lb 5 60 14 6PL T 30 lb 320 UN 5 50 14 6PL T 22 lb 5 50 i4 6PL T 36 lb 320 U...

Page 10: ... 97 2 m 97 2 m CARGO SPACE DIMENSIONS Intenor length 880 mm 2 1 555 mm 1 560 mm 34 6 m 61 2 m 61 6 m F Intenor wIdth 1 245 mm 5940 mm 1 254 mm 49 m 1 180 10 49 4 m t Intenor heIght 420 mm 905mm 430 mm 16 5 m 35 6 m 16 9 m WEIGHTS VehIcle weIght 1 000 kg 1 020 kg 955 kg 2 200 lbs 2 255 lbs 2 100 lbs Seatmg and loadmg capacIty 5 400 kg 2 SOO kg 2 500 kg 880 lbs 1 100 Ibs 1 100 1bs 5 300 kg 660 lbs T...

Page 11: ...pplemental Sp 108 mm 80 mm Shock absorbers Front Single acting Rear Single acting Optional Single action Single action TIRE SIZE AND PRESSURE Front Rear 5 50 l4 6PL T 22 lb 5 50 14 6PL T 46 lb 5 50 14 6PL 5 50 14 6PL 1 PERFORMANCE iT Max speed Grade ability Min turning radIus 110 KPH 70 MPH 0 30 120 KPH 74 6 MPH 0 30 5 2 m 17 ft 5 2 m 17 ft NOTE Other speclftcatlOns are same as Model 320 U 6 ...

Page 12: ...ENGINE I c 1 l I I ...

Page 13: ...s of the thm shell preformed type are fitted to the connect 109 rod bIg ends and to the malO beanngs A counter blanced crankshaft IS fitted The end thrust on this component IS taken by specIal washers at the center malO beanng The centnfugal water pump and coolmg fan are dnven by the dynamo belt GENERAL SPECIFICATIONS No of Cyhnder 4 Bore 73 025 mm 2 875 m Stroke 71 mm 2 796 m Volume 1 189 cc Max ...

Page 14: ...1 Engine Right side Engine Left side 2 ...

Page 15: ...0 the radIator fIller cap controls the pressure at approxImately O 4 kg per sq cm Do not remove the ftller cap If the temperature of the coolant IS above IX Jhng poInt or If the engIne IS runmng ToppIng up should only be requIred occasIOnally to re place water lost through the overflow pIpe Top up when the engIne IS cold and If pOSSIble use clean soft water l i j l Fig 1 Rmliator FIll to wIthIn 1 ...

Page 16: ...p whIch may be utlhzed to ease It from casting When the system has been com pletely emptied It IS essential to allow aIr to escape through the thermostat valve and then fmally top up The ther mostat opening IS set by the manufacturer and cannot be altered It open at a tem perature of 71 5 74 5 C Dunng de carbomslng It IS pohcy to test thiS open lng by Immersing the thermostat In water raIsed to th...

Page 17: ...onnections Ice m the hose wIll stop water cIrculation and may cause bOllmg A muff can be used to advantage but care must be taken not to run wIth the muff fully closed or bOlhng wIll result When frost IS expected or when the car IS to be used m a very low temperature make sure that the strength of the solution IS m fact up to the strength adVIsed by the manufacturers The strength of the solution m...

Page 18: ...d mmute to ensure that all water has been cleaned from the system A SUItable notice should be then affIxed to the radIator mdIcatlng that the water has been dramed I Flushing the Radiator To ensure effICIent CIrculatIon of the coolant and to reduce the fonnatIon of scale and sedIment m the radIator the system should be pencxhcally flushed With clear runnmg water preferably before puttmg m antI fre...

Page 19: ...t Put the pulley hub on the bench FIrst press or knock the shaft end WIth a dnft hard bar and draw out the pulley hub on the U type bench Take out the set pm from the sht whIch locked the shaft assembly to the pump body See Fig 1 Next turn the body upsIde down and press out the shaft assembly from the vane SIde on the U type bench ji 7 ...

Page 20: ... pump IS a reversal of the disassembly procedure but a care should be taken to ensure that the shaft assembly IS fItted correctly for a slIt a hole of set nng wIth a groove of shaft so as to msert and set the saId nng correctly Pulley Pulley hub Set bol t Shaft WJ th bearIngs 2103 5 OOO Set rlDg plD SPrIng washer Body Washer Cover Fig 1 Sectional View ofthe Water Pump 8 ...

Page 21: ...ert the set pm Insertmg thIckness gauge fhlckness O 4 0 5 mm between the vane end on the U block bench Take out the thickness gauge and fmd out good condmon Screw up wIth the cover and cork washer sere Shaft bear1llgs assembly Set p1ll 0 Y f Vane Floatl llg seal Insert here thl ckness gauge 0 4 0 5 mm 9 ...

Page 22: ...ush rod aper tures all from the center camshaft beanng enters a gallery on the left hand sIde of the engme and lubncates the tappets through mdlvldual dnlhngs As the camshaft rotates two grooves m the front Journal regIster WIth a small hole m the camshaft thrust plate thus allowmg a small amount of 011 to pass mto the tlmmg case tWIce dunng case re volution of the camshaft to provIde lubncatlOn f...

Page 23: ...hese cIrcumstances do not attempt to run the engme or serIOus damage may result Refillig When refllltng the sump do not pour the OIl m too qUIckly as It may overflow from the fIller orifIce and mIslead the operator as to the quantity of lubricant 10 the engme Before testing the level of the Oil ensure that the vehIcle IS as near level as pOSSIble Always WIpe the dIp stick clean wIth a non fluffy c...

Page 24: ... remove the body Take care not to lose the rubber seahng nng Remove the element and note the assembly of the components Wash out the bowl WIth pettol so that It IS clean It IS Important to thoroughly dry the bowl to obVIate any contammatIon of the lubncatmg 011 rr J Flg 3 Components of Oil Rlter Replacing the Filter 4 Put the element WIth seat of It on the bracket Cover with the filter body after ...

Page 25: ...losed form Unscrew the long bolts and remove the pump with ItS dnve shaft Dismantling the Oil Pump Remove the setscrews and spnng washers whIch secure the cover to the b6dy and take off the cover On tlltmg the body upSide down the Inner rotor with ItS dnve shaft and the outer rotor wIth shde out Refitting the Sump Clean out the sump by washing It In paraffin the care to remove any traces of the pa...

Page 26: ...Oil strainer ass y Oil pump dnve spmdle 01l pump plaln washer Lock washer Oil pump bolt Oil pump gear shaft ass y I eJV Dowel pin l Oil pump D cover f f i Fig 4 Oil Pump 14 a ...

Page 27: ...amage the washer when breakmg the Jomt If damage does occur fit a new washer cleanmg of the faces of the JOint surfaces beforehand Fag 1 Heavy Duty Shock Type Spanner Removing the Timing Gear JI The tImmg cham IS endless and It 1S necessary to remove both the crank shaft and camshaft gears together Before domg thIS notIce the tImmg marks on both gears and theIr relatIonshIp to each other Draw off ...

Page 28: ...ed agam It IS necessary to dram the system and slacken the cylmder head nuts because four of the rocker shaft ftxmg nuts also secure the cylmder head If the cylmder head nuts are not slackened dlstonatlOn may result and allow water to find ItS way from the coolmg system mto the cylmders and pump Notice that under the nght hand rear rocker stud nut IS a speCIal lockmg plate Completely unscrew the r...

Page 29: ...rocker shaft locating screw and lock plate Replace the spnng and flat washers wIth the spht pms on the ends of the shaft Replace the rocker cover and gasket The vent pIpe should be at the front of the engme Secure the cover by means of the two cap nuts ensunng that the rubber bushed and engme hftlng plates are m positIOn If the rocker cover gasket or the rubber bushes are found to be faulty they m...

Page 30: ...sting Valve Rocker Cltarances Remove the aIr cleaner and rocker cover There should be a clearance of O 014 In 0 3S mm fbetween the face of the rocker and the base of the valve stem Whtlst checking the clearances It IS lm portant to maintain pressure wIth a screw dnver on the tappet adjusting screw to dIsperse the fIlm of 011 from the push rod cup Fallure to follow thIs procedure WIll result In a w...

Page 31: ...een the face of the rocker and the valve stem RaIse or lower the adJustmg screw until the correct clearance IS obtamed TIghten the lock nut and recheck the clearance It IS Important to note that whIle the clearance IS bemg set the tappet of the valve bemg adjusted must be on the back of the cam opposite to ItS peak I 19 ...

Page 32: ... the radIator and other at the rear nght hand SIde of the engme If antI freeze mIxture IS m use It should be dramed mto a SUItable contamer and retamed for future use DIsconnect the negatIve cable from the battery be extractmg the termmal screw and removmg the lug from the battery term mal post Slacken both the retammg chps on the hose connectIng the radIator to the thermostat housmg and remove th...

Page 33: ...rom the pIston crowns Rotate the engme until the pIston to be worked on IS at T D C Protect the other cylinder bore from the entry of carbon particles by pushmg a non fluffy rag mto them Usmg a chIsel shaped pIece of hardwood Carefully remove the carbon from the pIston crowns A nng of carbon should be left round the penphery of each pIston and the deposIt round the top of the cylinder bore should ...

Page 34: ...he 011 seal IS used for the mtake valve only Replace the valve spnng and compress the valve spnng RefIt the cap retamers and secure them by means of the valve cotters Remove the compressor Free length mm Length m use and loaded mm kg Turnmng Nos of COIl Effectlve turn of COli DIa of COli wire DIameter of COlI Inner Sp 50mm Outer Sp 52mm 36 9 13 1 t O 7 8 5 6 5 5 6 tO 2 mm 24mm 38 9 29 t 1 5 6 5 4 ...

Page 35: ...ssary to contmue the gnndmg process until an even matt surface IS produced on the seatmg and the valve face On completion the valve seats and ports should be throughly cleaned WIth gasoltne soaked rag and dned and the subjected to a compressed aIr blast The valves should be washed 10 gasoltne and all traces of gnndmg compound removed VALVES J Valve head dIameter Intake valve Exhaust valve Valve se...

Page 36: ...s FIt the craburetor and reconnect the control hnkage Reftt the IgmtIon 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 Re place the rocker cover takmg care to ftt the cork gasket correctly Place the thermostat and Its housmg m posltJon and secure wIth the three nuts Reconnect...

Page 37: ...n Position Fig 7 Renewmg a Valve Glade In an emergency a new valve spnng can be fitted wIthout removmg the cyhnder head When domg thIS the apphcable pIston must be brought to ItS T D C posltJon to ehmmate any posslblhty of the valve falhng mto the cylmder Remove the spark plug from the cyhnder concerned Hold the valve onto Its seahng WIth the aId of a sUItable tool such as a bent screwdnver WhICh ...

Page 38: ...plate out s de l Il iC 1 a ve roc S I I 5 crew h f h I 71 v J alve rocker I lJ J shalt i Rocker shaft racket t 9b t Sprm8 retalner Tappet adjustIng screw Il Rubber ring Push rod Outer spnng lnner spnns 1 j 1J l Valve rocker ll 1 t 01 r r I ChaIn tenSIon Bolt t L OC wasber lo l l TImIng cha n CAMSHAFT VALVE GEAR ...

Page 39: ...A 2 I e tJ 3 Q I e f lelt o 00 O r e Fr g 9 Cylinder Head I Engine slln 2 011 fIll g brdcket 1 Valv er cap 4 was e er cover over JOint n Thermostat 6 JOint washer 7 Cylmder head ff 27 J A r r ev h I r q w f cr l ...

Page 40: ... radIator Dram and remove the sump from the engme then dIsconnect and remove the od strainer Take out the set screws and rock washers from the bIg ends and WIthdraw the caps It WIll be noted that the caps are off set When used parts are replaced after dlsmantlmg It IS essential they are fItted mto theIr ongmal posltJons To en sure Qorrect refIttmg mark the caps and connectmg rods on the SIdes to I...

Page 41: ...urnal End play of crankshaft Crank pm dIameter Standard DIfference of crank pm dIameter End play when flywheel was mstalled 0 013 0 050 mm Forged steel l o 0127 0 0508 mm 0 0005 0 0020 m i 50 183 50 825 mm 2 0005 2 001 m o 051 0 076 mm 0 002 0 003 m 47 640 47 652 mm 1 875 1 876 m Less than 0 012 mm 0 00048 m Less than O 05 mm 0 002 m The shell beanng are removable by hand The beanngs are reqUIre n...

Page 42: ...r i I I h J q l l o l i lIdA5 r I I r t I J c t i t J 7 8Jr1 t y I Connecting rod asS Y t it Dowel o t f Crank shaft key lower i lo PlSTON CRANK SHAFT ...

Page 43: ...ch It was taken It IS essential that the splIt In the skIrt of the pIston IS pObltJOned to wards the camshaft Compress the piston rings WIth inserting pIston uSing tool FIg 12 and 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 I Fig 12 PIston Adapter if l t 1 it Jf J l 31 ...

Page 44: ... dIffIcult to turn undo the bIg end and examme the shell and seat for dIrt or grit Before reassembhng always apply a httle clean Oil to the pIston surfaces and mto the cyhnder bore Never ftle the connectmg rod caps or theIr matmg surfaces as thiS creates ovallty m the beanng Removing a Piston Remove the clampmg bolt from the small end of the connectmg rod and push out the gudgeon pm The gudgeon pm...

Page 45: ...formed due to wear ThIs may be checked wIth a dIal gauge and must be removed If thIs IS not done there wIll be a tendency to nOIsy operation or a fractured nng caused by the top pIston nng stnklOg the hp PIston and nngs are avatlable 10 0 OlD 10 0 254 mm 0 020 10 0 508 mm 0 030 10 0 762 mm and 0 04010 1 016 mm overslzes The pIston nngs should always be htted from the crown of the pIston and never ...

Page 46: ...ve the 011 gauge and water temperature gauge leads from theIr termmals on the engme Engine Transmtsswn Assembly bemg ltfled from ChasSlS The throttle and choke controls must be dIsconnected from the carburetor DIsconnect the fuel pIpe from the fuel pump Next remove the exhaust pipe from the mamfold From below the vehIcle remove the gear change selector rod from the lever on the transmISSIOn casmg ...

Page 47: ...ft and take off the tlmmg cover and gears The engme front mountmg plate IS now accessIble and may be removed by wlthdrawmg the setscrew and lockmg plates The dynamo swmgmg Itnk must be removed Take out the setscrews secunng the camshaft locatmg plate when the cam shaft can be WIthdrawn from the cyltnder block CAMSHAFT BEARINGS Wlute metal beanngs with steel lmmg are used for the camshaft They can ...

Page 48: ...S located m a recess m the detach able half of the beanng the other bemg plam When flttmg new beanngs no scrapmg IS reqUIred as they are machmed to gIVe the correct runmng clearance of 0 0005 0 002 m 0 0127 0 0508 nn Ensure that the locating tangs are properly engaged m theIr recesses Handle the new beanngs carefully so as not to damage the fme surface ftmsh Remove all traces of dIrt and 011 from ...

Page 49: ... ftrst after each cap IS tighten rotate the crankshaft to ascertam that It revalues freely If It IS tight remove the last cap tightened and examme the beanng and ItS seating for foreIgn matter Check the crankshaft end play by means of a dIal gauge ThIS should be 0 002 m 0 051 mm If a beanng has run It IS essential to clean out all OIl ways m the crank shaft and block Wash out the engme sump and th...

Page 50: ...FUEL SYSTEM 38 16275 08100 16119 08100 ...

Page 51: ...mg the wrench operated dram cock Fuel Tank Gauge Unit Fig 1 Fuel Tank Securing SItuated on the top face of the tank IS the gauge unIt To remove wIthraw the set screws whIch secure the Unit to the tank not forgettmg to dIsconnect the electncallead beforehand Care must be taken not to stram or bend the float lever as thIS may serously effect subsequent gauge readmgs Remember thIS also appltes when e...

Page 52: ...o 2 11 o 1 i coO g s l S 0 ...

Page 53: ... carburetor 1 Check to see If gasohne pIpe IS clogged with dust and dIrt ThIS can be eastly checked by dIsconnecting the connector of the pIpe and blow Ing WIth compressed aIr toward the dIrection of the tank Then from the tank end blow the pipe again and clean the pIpe In many cases the tip of gasohne Intake pIpe of tank umt IS clogged with dust and water Therefore together with cleaning of the p...

Page 54: ...balanced WIth the mdlcator deflectmg m the dlrecnon of F That IS this IS a gauge of electnc resIstance control type E sIgnifIes Empty level and F Full level Troubles with Fuel Gauge and their Remedies When somethmg IS wrong with the readmgs of the fuel gauge fIrst diS connect the wlnng at the Unit and turnm on the IgnitIOn SWItch ground and un ground the term mal end of the saId wlnng to the body ...

Page 55: ... the wIre and remove bowl gasket and screen The strainer body IS made of aluminum alloy Take good care not to break threads of each connectIOn Pay attention not to tighten the strainer nut so excessIvely that the gasket and bowl are broken When mstalhng the stramer assembly the strainer bracket should be cleaned suffICIently Dust and dIrt on the bracket surface prevent plug from keeping aIr tight ...

Page 56: ...nmer lever rod i Cap bolt cap screw washer Fuel pump cap Fuel pump cap gasket Angle connector Rocker arm slde spacer Roc ker arm pln Lower body gasket sheet Rocker arm slde spacel r Rocker j arm ass y Rocker arm pln Rocker arm slde spacer 44 ...

Page 57: ...ure tor Even when the engme IS not runnmg fuel can be dehvered under pressure by movmg the hand pnmer up and down By the rotation of camshaft rocker arm IS pushed and pull rod of dIaphragm IS pulled down At the same time dIaphragm goes down agamst dIaphragm spnng and then IS pushed up agam by ItS spnng By the movements of the dIaphragm and functIonmg of the valves at the mlet and outlet of the pum...

Page 58: ...m gasohne then mspect them I Replace the dIaphragm If any damage ImpregnatIOn by gasohne Replace a valve assembly If any wear or faulty operation IS detected Even If repaIrs are unavoIdably reqUIred the hmlt for repaIrs of warp or wear of the valve IS 0 001 In When the surface of the valve seat or valve IS found Irregular remove the valve seat of the outlet and dress the surface with a fme oIlston...

Page 59: ... all the screws ruund loosely and umformly Then tighten them dIagonally and lastly re tlghten all of them 10 order to make sure As a general rule gaskets should be replaced by new ones Installation on the engme IS done 10 the reverse order to that for dIsassembly Be sure to set the rocker arm so that It IS contacting the eccentnc of camshaft properly not the rear SIde or to one SIde Replace the ga...

Page 60: ...Ine 6 to 7 rotatIOns by means of the crank handle and make sure that there IS sure outflow of gasohne from the outlet port 8 Connect the gasohne pIpe to the outlet port sIde and tighten all the plpmg omts Then turn the engme agam several times to see If there IS any leakage of aIr or gasohne from each connection 48 ...

Page 61: ...ob all the way that IS m the carburetor tne throttle valve and choke valve are fully opened press a compres SIOn gauge agamst each spark plug hole and runmng the starter motor with a fully charged battery read the maxImum pressure ob tamed wIthm 5 8 rotations of xhe motor ThIS measurement must be made as qUIckly as pOSSIble It the compressIOn pressure of anyone cyhnder differs by 10 lb jsq In or m...

Page 62: ... refer to FIg 2 The use of a master motor tester as shown m FIg 2 IS convenIent When a combustion tester IS used mstall a speCIal mtake pIck up m the exhaust tube and after the engme has been started analyze by means of a speclal gauge the combustIOn gas whIch flows through the connectmg hose mto the tester and Judge the combustion condmon ac cordmg to the mIxture ratio of fuel and aIr When measur...

Page 63: ...ndition 4 When above 3 condItIon eXists Indicator Will sWing to 0 In 1f engIne IS raced 5 When Indicator sometimes drops by 4 In or so valve sticking eXists 51 6 When mdlcator drops by several Inches at certalO time alves are burnt 7 When Indicator drops Jy about 2 m valves leak Faulty sllatmg of valves 8 When IndIcator OSCIllates actIvely between 14 and 18 In valve stem gutde IS worD out 9 When w...

Page 64: ...rops down to zero and then returns to 16 In muffler IS clogged 16 When IndIcator moves slowly between 13 17 In carburetor IS poorly ad Justed FIg 3 IAagnosmg Engme by means of a Vacuum Gauge No gasolme In carburetor Batter dlschaq ed or connections poor Tlmmg poorl adjusted Ir bemg sucked In lPlug spark Plug sparking weak il Sparking at termlnalS T r gdl orrect Immg mcorrect U PI d Short m CirCUIt...

Page 65: ...onnectIOn poor C Vlnng shorted or cut Sparkmg form coil hne Plugs dirt or broken ompreSSlOn poor A Trouble Shootmg Chart Compression weak Valve clearance Incorrect Valve spring weak Valve deformed Muffler clogged Continuous lack of power Valve tlmmg Incorrect lgOltlOn retarded too much Carburetor adjustment poor GasolIne supphed InsuffiCIently arbon deposits exceSSive Gasolme of poor grade Intermi...

Page 66: ...y throttle valve IS at 48 openmg Float level 19 mm below the upper surface of the float chamber body t The carburetor has the functIOn of atomIzmg the fuel mlxmg It m sUItable ratio to aIr mId supplymg the mIxture to the engme It IS therefore an Important parr whIch can mfluence the performance of the engm The Model 2D 3OC carburetor IS a hIghly effIcIent carburetor of two barrel two step and down...

Page 67: ...Choke valve 12 Choke control 11l1k 11 Connec lng rod 1 1 Choke wIre blacket 15 Throttle Wl re blacker 16 Lower body 17 AUX 1l Y throttle valve 18 Throttle valve 19 Bv pass hule 20 Iow Jet 21 VentUri 22 Auxlharv valve hdft 21 MaID Jet 24 MaID aIr bleed 25 Pump IDJecler 20 Out let valve 27 Inlet check valve 28 Power valve 29 Pump pl ton 10 AI r vent hole 11 Pump pl ton return pnng 12 Connec l ng rod...

Page 68: ...ed WIth the throttle valve IS adapted When throttle valve IS open the pIston rod IS pushed up with the hnkage wluch pushed up the pIston through the dumper spring When the pIston IS commlng down the Inlet check valve closes the out let check valve opens and the fuel within the pump IS blown out from the pump Jet by the compressed dumper spnng and hIts against the SIde wall of the small ventun to b...

Page 69: ...om of the float chamber passes through the secondary mam Jet and be come mmute drops mlxmg with the aIr commg from the mam aIr bleed and IS blown mto the ventun through the mam nozzle Fig 12 Carburetor 1 Float level 2 Float Model NJkkt 2D 30C 3 Needle valve 4 Needle valve carner When the throttle valve of the normal carburetor IS WIdely opened and the engme produces hIgh power the throttle valve o...

Page 70: ... gasket after removing the float needle valve Installed at the Inlet connector As venulatlon within the float chamber IS of a aIr vent method and pressure wltlun the ventun and the float chamber IS always constant no matter how sucuonal reglstance of the aIr cleaner vanes fuel consumption can be always economIcally maintained Float Chamber Adjusting Fuel Level 3 Pump arm Float valve sheet gasket 4...

Page 71: ...aker brakes contact a spark IS generated In one of the spark plugs Therefore the maintenance of thIS braker must not be treated Itghtly Also because the time dunng whIch the IgnItlon COIl current flows vanes with the gap between these braker pOints see that thIS gap IS maintained at the standard value WhICh IS 0 45 mm 0 018 to 0 022 In The braker pOints must be kept free of grease and 011 If the p...

Page 72: ...DISTRIBUTOR 60 1 tr ...

Page 73: ... run thIS pomter moves when the engme speed IS suddenly changed the advancer IS satisfactory AdJusttng the Pomt Gap ADJUSTING THE IGNITION TIMING The IgnltlOn tlmmg IS adjusted to 10 degrees before top dead center wIth the engme stopped as shown m Fig 1 With thiS adjustment the automatic tlmmg advancer of the dlstnbutor advances the IgnitiOn tlmmg even further at the time the engine starts to rota...

Page 74: ... No 1 pIston Stop the crankshaft 10 this pas man The compress ioriistrblCe of the No 1 pIston can be determmed If the spark plug of the No 1 cyhnder IS removed the hole plugged wIth a hnger and the crankshaft turned WIth the crankshaft 10 the pre vlOusly mentloned posmon the No I pIston IS m ItS posmon of 10 deg before top dead center of compressIOn 5 L fl u fJ L i ftr jj iS l 3 1 I on r 1 7 J q i...

Page 75: ...until spark Jumps across the gap The off set slot positIOn of the dnve shaft when the No 1 pIston IS m ItS com presSIOn top dead center positIOn IS shown here y 5 Next put the dlstnbutor cap on and clamp It securely WIth the cltp 6 To the No 1 spark plug connect the cord from the termmal to whIch the arm of the rotor IS pomtli g Thereafter connect the termmal cords to theIr spark plugs m the count...

Page 76: ...of cahbratlon of the selector corresponds to 2 deg of the dlstnbutor I angle and to 4 deg of the crankshaft angle f When a tlmmg lamp IS used the standard settmg IS 15 deg before top de d cent r WIth the eniJme IdlIng 600 620 In any case the optimum ad J ustlpEmr IS that In whIch a shght knockmg IS heard when WIth tie car runnmg 1 at 9W speed ID HIGH TOP gear acceleration IS apphed suddenly Mof 64...

Page 77: ...ecting thl gaps always be sure to bend only the grounp 9Iae electrode never bend the center electrode If the msulator IS damaged replace the spark plug A wIre feeler type plug gap gauge should be used When screwmg m the spark plugs be sure not to forget the copper washers If these have been flattend out or are worn they WIll not be gas tight and WIll cause such trouble as mter ference with the dIS...

Page 78: ...CLUTCH lklt 1 l 66 ...

Page 79: ...0 15 mm 0 002 0 006 In Less than 0 05 mm 0 002 In O 10 mm 0 004 m Operating method 011 pressure Inner dIa of master cyhnder 22 2 mm 7 8 m Inner dIa of operating cyltnder 19 05 mm 3 4 In Operating hqUJd Genume super brake 011 PRESSURE SPRING Free length Compressed length Surn Effectlve turn CoIl wire diameter Length In use and load 49 5 mm Less than 30 mm 8 6 3 5 0 03 mm 35 7 mm 57 I kg RELEASE BEA...

Page 80: ...e are three release levers whIch PIvot on floatmg pms retamed by eye bolts Adjustment nuts are screwed on the eye bolts and se cured by stakmg Struts are mterpossed between the lugs on the pressure plate and the outer end of release levers Anti rattle spnngs load the release levers and retamer spnng connect the re lease lever plate RELEASE BEARING The release beanng consIsts of a carbon beanng shr...

Page 81: ... correctly set on assembly Interference WIth thiS set tmg unless new parts have to be fItted WIll throw the pressure plate out causmg Judder Dismantling Assembling Gauging By usmg service tool FIg 2 the clutch can be qUickly dismantled reassembled and adjusted to a high degree of accuracy The tool comprises the followmg parts base plate centre pillar spacmg washers distance pieces hlght fmger actu...

Page 82: ...surfaces of the levers eye bolts etc sparingly with grease q Sl mm n yf 7 3 mm f It r t cr li J i 1I l m f n r I J 1 1J v n J c rt 1 1 4 A t t 1 O J J V J 4 r cY 1 1 1 Assembling J j f Y 1 I r4 l1 1 r t r of l 0 t i t o H f I I v 1 J 205 I 4 oW r A e Jl 7 Fzg 3 Assemblmg Tool Place the pressure plate over the three spac1l1g washers on the base plate WIth the thrust spnngs In pOSItIOn on the pressu...

Page 83: ... the driven plate on the flywheel wIth the longer chamfered splIned end of the driven plate hub towards the transmiSSIOn The driven plate should be centralIsed by a dummy drive gear shaft which fits the sphned bore of the driven plate hub and the pilot bearing of the flywheel The clutch cover assembly can now be secured to flywheel by means of the holdmg screws tIghtemng them a turn at a tIme by d...

Page 84: ...e plate with the clearance holes over the heads already formed In fIttIng the first facmg The plate should then be mounted on a mandrel between centers and checked for run out as near the edge as possible If the wabblIng IS more than 0 02 m press over high spots until It IS true wIthm this figure It IS Important to keep friction facmgs free from 011 or grease 72 ...

Page 85: ... 9 I 111m when releasmg 7 3 8 I mm when depressmg Less than O 5 111m 0 05 O IS mm 0 002 0 006 m Oil pressure 15 85 mm 5 8 m 19 05 mm 3 4 m Genume super brake 011 1 6mm 87 mm 136 mml5 kg PRESSURE SPRING Free length Compressed length Turn numbers Power of compo m full Wire diameter Length m use and load 49 mm I1 5 Less than 25 111m 7 8 About 300 kg 3 3mm 29 2 37 5 12 kg HELEASE BEARING ConstructIon ...

Page 86: ...utch controls no adJustment IS necessary to the clutch pedal Removing the Clutch To gaIn access to the clutch It IS hrst necessary to remove the transmiSSIOn complete from the engme Once the transmiSSIOn unIt IS free a turn at a time by diagonal selectIon untIl the sprmg pressmg IS rehved Then remove the screws completely and hft the clutch assembly away from the flywheel Fmally remove the driven ...

Page 87: ...V prcSS l S f I b nt u 1 W t n dra HaJ i Lever with drawa1 lTronnron ut OC1 push 1 00 Clotch dr a embIY p rt llo 30100 10bOO cover as emblY p rt NO 3OZOq IObOO LoCK va ht Bnlt Pl eltSute sp1 tni s 7 rIg z CL UiCH ...

Page 88: ...on until the cover IS fIrmly attached to the base plate at all pOSSible pomts This IS most Important If the best results are to be achieved Mark the cover pressure plate lugs and release levers with a centre pu ch so that the parts can be reassembled m their relative posItion m order to maInta1l1 the balance of the clutch Detach the release lever plate from the eye bolts and remove the three lock ...

Page 89: ...l l Ftg 4 Dtsassembllng 77 ...

Page 90: ...Jon The release levers and sprmgs should be examIned for wear and dlstorslOn Renew these parts If necessary bearing m mmd that the pressure springs must only be renewed 111 sets Clean all parts and lubricate the bearing surfaces of the levers sparingly with grease q 51 Ttttt tP 7 i8 mm 1 1 Ftg 5 AssemblinJ Press the pm mto the eye bolt hole through the lug on the pressure plate as shown 78 ...

Page 91: ...r assembly on the base plate Compress the pressure springs by screwlI1g down the cover to the base plate by uSll1g the special set screw placed through each hole 111 the cover Tighten the screws a little at a tIme by illagonal selectIon to prevent distortIon to the cover Set the release lever on the eye bolt wIth lock nuts lI1sertIng for lug at the edge of pressure plate l I 79 ...

Page 92: ...iX the release lever Release the setscrews and remove the clutch assembly from the base plate Refacing the Driven Plate If a new complete clutch driven plate IS not available new ImIngs may be fitted to the old driven plate m the followmg manner Each rivet should be removed by usmg drill The rivets should not be punched out Rivet one new facmg m posItion then If the correct tool IS not available u...

Page 93: ...DESCRIPTION OF CLUTCH CONTROL The clutch IS operated from a master cylinder oy means of a suspended pedal A cylinder mounted on the clutch bell housmg IS coupled to the clutch operatmg shaft 1 2 It y r I 19 18 15 Ftg 4 Components of the Master Cylznder I Push roo assembly II PIston return sprIng 2 Master Lyhnuer rubber boots 12 Clutl h master Lyhnder body 3 Stopper rIng ass y 4 PJ ton econdary LUP...

Page 94: ...tached Will be ex posed remove the piston assembly complete The assembly can be separated by lIftIng the spring seat edge over the shoulder ed end of the piston Depress the piston return sprmg allowmg the valve assembly to slide through the elongated hole of the sprmg seat thus releasmg the tensIOn on the spring Examme all parts especially the gasket cylinder bore and piston cups for wear or disto...

Page 95: ...ver and mount the cylinder 111 posItIon makmg sure the push rod enters the hole In the rubber boot Secure the cylinder WIth the pll1ch bolt and screw In the pipe umon Bleeding the Clutch System Remove the bleed screw dust cap at the operatll1g cylinder open the bleed screw approximately three quarters of a turn and attach a tube Immersll1g the open end lI1to a clean receptacle contamIng a small am...

Page 96: ...1 1 1 t l I l L 1 o Fzg 6 Clutch Release Lever I Carbon bearIng 2 Clutch lever 84 ...

Page 97: ...TRANSMISSION t CROSS SHAFT ASSEMBLY Olse COUI LING 85 ...

Page 98: ...0 1 73 I 1 49 1 00 I 1 00 6 46 I 5 16 I 17 24 31 28 spur gear 31 26 20 11 spur gear 13 17 spur gear 20 25 31 28 31 26 20 11 13 17 BACKLASH OF VERIOUS GEARS play on revolutlOnal directIon Between mall1 drive gear and counter drive gear Between third gears Between second gears Between low gears Between speed 3 4 Synchromzers and mam Between peripheral gears of speed 3 4 synchromzers and couplll1g sl...

Page 99: ...sh before pressmg In Play of periphery of 3rd gear bush Amendment limit of dIttoed play Inner dla of 2nd gear bearing hole Outer d13 of 2nd gear bush Gap at periphery of 2nd gear bush Amendment limit of dittoed gap Thickness of front thrust washer on mam shaft Thickness of mterlockIng ring on 2nd 3rd gear bush 20 485 20 503 mm 0 8064 0 8072 111 14 460 14 448 mm 0 5693 0 5688 m Needle roller bearin...

Page 100: ...Thickness of front thrust washer ThIckness of rear thrust washer Eng play Amendment limIt of dIttoed play 22 420 22 433mm 0 8826 0 8831 m 16 391 16 401 mm 0 6452 0 6456 111 Needle roller bearing 20 x 2 front rear 3mm x 23 8 mm 0 U8 0 936 In 3 91 3 96 mm 0 154 0 156 111 3 96 3 91 mm 0 1560 0 1540 m 4 013 3 988 mm 0 1580 0 1569 111 4 089 3 140 mm 0 161 0 160 In 4 166 4 140 mm 0 164 0 163 In o 04 0 0...

Page 101: ...en Il1stalled 011 to be used Standard of 011 Oil quantity necessary 75mm 1 2mm 19mm 5 16 111 8 6 t0 4 kg o 94 mm 817mm 10 5 mm 12mm 54 mm 3 tO 3 kg 35 mm 20 mm 16 mm 12 mm 0 3 kg 38 mm 21 mm 23 mm 20 mm I tl kg Genu1I1e gear 011 MP 90 HypOld gear Oil In warmer district than 32 C use 140 I 8 Ir t DltlIIOI lde o r lIg 1 A 32O U uJI L3ZO U riM A y 32010 07300 32010 7400 tlH Ca 32101 01300 3 l10J OJ40...

Page 102: ...positIOn are set bolts and set screw WIth serrated washers all of which must be removed when the cover can be taken off Chanlle Speed Cross Shaft s Select or Arm Once the Side cover IS removed both the selector arm and change speed lever cross shafts can be drawn from the case brIngll1g wIth them the change speed gate Gentle pressll1g prISlI1g may be necessary to assist removal of the gate as Its ...

Page 103: ...4 L r T C bof 9 1 45 1 b C b f Sp l 34 S 30 OO 34483 0 l300 w Ij U 9 1 1S 1 U I 3 3 uvvv 9 1S41 9 1 48 1 34410 30000 y oi U I 0 1611 Sbo 00 111AO 1 speed control1200 con ol leeW 9 2 2 9 e tI 34453 01400 L B 34412 01400 L R A 329 1 100 34394 0 1300 000 S o Aft tIJS 339 1 00100 OUPHng flan R CoupHn d1sC L C t 329 00 U H ill 344 00 U 9 S 4 1 34421 30000 9 1 414 U 9 191 1 8 9 311 8 9 1 44 ...

Page 104: ...iece which must be retrieved from the case when removll1g thIS fork Reverse Gear A lug WhICh IS an lI1tegral part of the mam castIng locates the forward end of the reverse gear shaft To secure the shaft m pOSItiOn a setpll1 IS screwed through the lug locatmg 111 the shaft The setpm IS locked by a tab washer Straighten the tab washer release the setpll1 then tap forward and remove the re verse gear...

Page 105: ...g WIth a suitable piece of metal tubll1g Main ShafL Fzg 3 The mam shaft can now be withdrawn from the transmISSIOn casmg To remove the gears from the mall1 shaft first slide off the third and fourth speed synchrol1lzer assembly then with a piece of wire mserted through the hole m the gear cone de press the small spring loaded plunger whIch locates the splmed washer at the forward end of the mam sh...

Page 106: ...8 11145 1 1 lie 15115 D ...

Page 107: ...rust washer 45 Reverse gear assembly 22 Second speed synchrOnIzer hub If It IS deSired to dIsmantle the fourth and third speed coupling sleeve or the first speed gear these can be pressed clear of their splIned synchrol1lzers but care must be taken to retrieve the three balls and springs 111 each assembly Take out the mam shaft front needle roller beaTings from the end of the drive gear shaft Rear...

Page 108: ...he synchrol1lzer and turned untIl the hole comcldes With one of the three sockets A sprmg and ball are then placed m posItion the ball depressed and the gUIde rotated for each spring and ball m turn untIl they are all depressed The gUIde IS then pushed further along the synchromzer splmes followed by the couplmg sleeve As the coupling sleeve replaces the gUIde the balls fmd their correct locatIon ...

Page 109: ...t J Y l I I 1 f r j f R 2 1f i 1 i t r D Itl o a 555 Ii 3 O 1HI FIg 6 Assembly Order of TransmzsslOn Gears 1 Mam unve gear 2 Mam shaft n Counter gear 4 Reverse gear 00 u 0 rt t o Jl o o i l c 1 4 97 Components of Gears Synchronzzer Fzg 7 ...

Page 110: ...at the counter teeth are below the drive gear shaft beanng housmg Failure to do thIS will result m damage to both the counter gear and drive shaft geared ends The drive shaft can now be drifted mto posItIon from the clutch housmg end Ensure that the spring ring resisters properly m the racess on the gear case Main Shaft Press the mam shaft center bearing complete WIth housmg on to the shaft from t...

Page 111: ...htly forward on the shaft to clear the counter gears and then carefully gUide the mam shaft assembly mto the gear casmg When the housmg surroundmg the mam shaft bearing IS flush with the gear casmg the counter shaft gear cluster should be raised mto mesh with the gears and counter shaft Oiled and fItted mto poSItion The ltpped end must be flush with the gear casmg Reverse Gear Refit the reverse ge...

Page 112: ...t the bottom SELECTOR LEVER INNER CROSS OPERATING SHAFT With the selector lever Fig I B pmned to Its respective cross shaft also change speed cross shaft lever assembly cottered to Its own cross shaft the two shafts should be posItioned m the case with the respective levers nearest to the SIde cover openmg Note that the selector cross shaft takes the forward posItion 111 the case At the same time ...

Page 113: ...S 0 S Z i J o a 1 z o J II 1 o r I i s1 II J 1 L 1 101 LUJ ...

Page 114: ...peller Shaft Jomt 1 Dust cover 8 Propeller shaft assembly 2 Sleeve yoke 9 Flange yoke 3 Journal 10 Compal11on flange 4 all seal bearIng retainer 11 Bolt 5 011 seal 12 Nut 6 anng assembly 13 Plane washer 7 Snap nng 14 DrIve pinIOn nut 15 Cotter pin 102 ...

Page 115: ...22 for each bearing 2 38 mm x 10 3 mm Less than 0 4 mm 0 015111 15 18 ft Ibs 68 9 mm 60 3 mm 1320 mm Lubrication An 011 mpple IS fItted to each center spider for lubricatIng the bearings The central 011 chamber IS connected to the four 011 reservOirs and to the needle roller bearing assemblies FIg 2 The needle roller bearIngE are filled WIth 011 on assembly OIl from the trans mISSIOn Lubncates the...

Page 116: ...rings Remove the snap rings by pressmg these ends together and prIse out with screw driver If the ring done not come out tap the bearing face lightly to relieve the pressure agamst the ring Hold the splIned end of the shaft m one hand and tap the radIus of the yoke with a lead or copper hammer when the bearing will begll1 to emerge If diffIculty IS experienced use a small bar to tap the bearing fr...

Page 117: ... walls of the races wIth petroleum Jelly to retall1 the needle rollers 22 Nos 111 place Insert the spIder m the yoke and tap the bearing 111 posItIon WIth a foot nosed drift smaller m dIameter than the hole m the yoke It IS essentIal that the bearing races are a light drive fIt 111 the yoke trun mons Repeat thiS operatIon for the other beanngs The spider Journal shoulder should be coated WIth shel...

Page 118: ...CONSTRUCTION OF CHAUIS ...

Page 119: ...m 52 mm 140 0 08 0 IS kg o O 2 mm at top center of gear arm 2 5 kg m 14 kg m 4 5 kg m The type of steering gear IS worm and roller and has the drum type of worm gear at the lowest end of mam steering shaft The mam steering shaft IS mcased m the Jacket tube and the steering wheel IS fixed with at the top end of It The worm gear mter locks with the roller which IS fixed on the roller shaft and works...

Page 120: ...The roller shaft Itself IS supported by the two bearmgs both sides m the gear housmg I il let O f iJ t l o 0 J o J t e o c v J II Flg 1 108 ...

Page 121: ...GEAR STEERING rti 48103 07200 CODtact plate tJ J 48405 30800 J 9 16120 COlUlllIl SteerlD ete comp 0 48020 0720 ANY 109 ...

Page 122: ...spection of the Steering Gear After the steering assembly IS dismounted and the gear OlliS completely dramed the steering gear box should be fIxed on the VIce settmg the steering tube on level 1 Tak1l1g off the steering gear arm Take off the nut of gear arm and roller shaft cover and strike out lIghtly the the bolt then pull the gear arm out of roller shaft 2 Dlsmountmg the housmg cover and r olle...

Page 123: ...It IS worn out The roller shaft assembly should be replaced m a Ul1It 111 case the roller pm becomes loose and damages or defacement of surface of roller IS found The replacement can be limited to the worn out parts after dIsassembling FIt the roller shaft to the gear housmg after lI1sertll1g the adJust shims to the adJust screw and adJustmg SaId screw so as the end clearance along the roller shaf...

Page 124: ...osItion of steermg wheel when turned fully to left and nght In case the backlash differs greatly the Interlockmg posItion of worm gear must be adjusted agam The correct backlash at the both ends of worm gear should be made sure of after puttIng the more shim m the Side of larger backlash at the gear arm and for equalIzmg pull out the shIm on he opposIte Side and tighten up the bolt agam adJustmg w...

Page 125: ...heel spmed hardly to left and right the roller shaft adJustmg screw IS loose The adJustment should be carried 111 a way as explamed m adJustment of the POSI tion of steering roller 3 In case the roller shaft shakes to left and right the roller shaft or the bush IS worn out therefore they should be replaced with new one and adjusted 4 In this case the fIxmg bolt for gear housmg front and rear upper...

Page 126: ...S to be 157 mm by turnmg the Idler shaft THE CAUSE OF TROUBLE The cause of the rouble caused m regards with the steering 111 operation IS closely connected with those of the front axle therefore It IS hard to Judge then separately The followmg are mam troubles caused m steering Heavy and difficult operatIOn of handle I The 011 m gear box 2 Adjustment of worm and roller IS poor 3 Damage on corn of ...

Page 127: ... 04100 ZQ t oo III t t l l 1Ul i It rIII Ul jj r 1 0 M III I q Il tI 01 1 3 0 Qc 1 00 0 1 0 Jq tttI1 STEERING LINKAGE CJ1 CrOBB rod Bocket R B 570 ot300 CrOBB rod Bocket L B 48571 04300 48530 04100 od L B JiJJS1del o8700 A 4811 1I 1 33303 1 11047 9 31322 48S0HI7ZOOSteeriq lIear I ll ...

Page 128: ...ed by the vIOlent shock or with any other reason I Unscrew the connector of the brake hose for the front wheel on left and right at the side of frame 2 The front axle UnIt can be disassembled further as follows Takll1g off the cover loosen the spll1dle nut after the hun cap IS taken off It can be easily removed first by tappmg lightly around the cap and pry with the screw driver 116 ...

Page 129: ...d of side rod Tak1l1g out the spmdle of the axle The kmg pm must be pulled out first Pull out the kmg pm lock bolt and take off the spmdle plug on the spIndle by a graver Strike downwards the kmg pm by the dnft and take off the plug at the bottom The pm thus can eaSily be removed The spIndle can be dIsmounted with the spmdle shIm and thrust washer assembly INSPECTION ADJUSTMENT AFTER DISASSEMBLING...

Page 130: ...y m accordance WIth the standard mesurement The kmg pm bush reamer should be employed m this case It can ream the holes at the upper and Fg 4 bottom 111 exactly a straight lme In reammg the upper hole msert the adaptor of taper m the bottom hole from up side and at Its gUIde scrape the upper side SPINDLE lO 1f Q 20 000 19 980mm 08 0 799m D13 of kmg pm Fmlsh1l1g dimenSIOn of mner dla of kmg pm bush...

Page 131: ... both of them well smear WIth new oIL They should be m a condItion that can be turned lightly and be pushed In at the top of It with a thumb without any play It must be noted to open the okl feedmg hole which connect with oil mpple at the top and bottom after the fImshmg of bush IS completed After makIng the hole by the drill of the dIameter m mm adJust the roll at the mterIor of the bush FRONT AX...

Page 132: ...or 50 of the space In tIghtemng up the spmdle nut settle down the bearing by turnIng and clampmg up the wheel hub turn back for about 1 8 and lock with the cotter pm ThiS IS Important to decIde the play at the wheel bearing to the dIrectIOn of the axle There should not be any rattle and It should be turned lightly 7 If the front axle ass y IS mounted on the chaSSIS feed 011 to the kll1g pm After t...

Page 133: ...21Z22 I 1 11741 1 8 F g 5 ANCHOR 54085 04300 R H 54086 04300 L H UPPER LINK MouNTING SPINDLE ANCHOR 54093 PIN 04300 TORSIN BAR 540 I 0 04300 54009 04300 54091 04300 LOWER LINK Flg 6 TENSSION poe 121 ...

Page 134: ...t hn MI MIO d0 w aou OMOI U MM4 04 01 40 FIg 7 FIt the torque arm on the Side of lower lmk Temporarily Insert and tIghten the tensIOn rod FIt the lower lmk to the frame wIth the lower Imk spIndle but tighten temporarily the lower lmk spmdle nut Insert one end of the torsIOn bar to the torque arm In tills case be attentIve to the symbols Rand L marked on the right and left Sides of the bar Insert t...

Page 135: ...FRONT SUSPENSION 8S ctlon Smear the lraphl l I Iree8e bere I TllbteDlOl torque II 14 16 5 m kl I r TOTIIl lOn b v r I I T 1lhte01D torque 85 951 1 f I l on 0 1f mm Dll1lentlon A AS ctlOD Fzg 8 123 ...

Page 136: ...It IS easy to set 1I1 or remove Apply ample chassIs grease before hand to the serrated posItion Apply a few drops of motor OJI to th anchor adJust bolt SETTING OF TENSION ROD Fig 9 1 i i i Fzg 10 124 Fzg 11 I Frdme SIde bracket 2 Bracket 3 TensslOn rod 4 Bolt ...

Page 137: ...ghten these nuts alternately and gradually until the dimensIOn of rubber be come II mm Adjustment of Vehicle Carriage Flg 12 Jack up the vehicle at the posItion as shown and after redusmg the twIstmg torque loadmg upon the torsIOn bar to the mmlmum turn the anchor adJust bolt to right or left so as the dimensIOn as shown IS to be the followmg valve Turmng the bolt to right makes the carriage hIghe...

Page 138: ...7 25860 tens O 5 Fu54090 o43001 on 8129 25880 lcrum R H 540 54086 0 9 I5SI8 l n 93 04300 L H A 54085 o1 hg 9 i 0 k H fchor ass 01 ront spring e 54092 04300 54089 04300 Anchor plug 54009 04300 L H 54010 04300 K HI Torsl on bclr Front spring Fig 13 FRONT SPRING ...

Page 139: ...nK Krelse as much as lhe clearance CapacIty 011 88a1 8paC 40106 32200 J 24 4 1 r Q4 Q6 432 15 32200 Rear Je halt beUIDI 4 g 2 32200 Greue cber 43117 32200 P c klq 40227 32201 03 Wheel p 43070 44000 40225 041001 80 110 40 11 04 fO 1 Lock 127 ...

Page 140: ...h IS supported by the gear case while the side gear which IS so supported as to functIon freely mSlde the gear case IS connected With the splme at the top end of rear axle shaft Thus the constructIon of differentIal gear conbll1ed With these gears has the functIon of controllmg the difference of revolutIon of the rear wheels 111 case of turn lI1g to the variOUS directIons The pmIOn as It stays on ...

Page 141: ... tIme of dlsmountmg the gear carrier pull out the both left and nght axle shaft or pull out for at least 4 mches 3 Take off the Jomt flange from the sIde of propeller shaft 4 Pull off the nuts of the hous 1I1g and dismount forward the carrier ass y 5 Take off the sIde bearing cap vf carrier and pry wIth a lever the dIfferentIal gear case and the bearmg 6 Dismount the differentIal side bearing As I...

Page 142: ...On flange The drive p1l11On flange wrench should be employed sett1l1g ItS four pomts m the holes of flange to keep It from movmg take off the nuts with the box wrench 10 Take out the dnve p1l11On of gear carrier by strIkmg out lightly to the back wards the front end at the side of compmlOn flange of drive p1l11On with the dnft of soft metal Thus the p1l11On would be taken out together wIth the mne...

Page 143: ...DISASSEMBLED PARTS Every parts after they are dIsassembleq should be cleaned and cleaned by the compressed air before makIng an mspectIon and adJustment 1 Each bearing should be mspected m every Ul11t of ass y In regard with the defect and defacement before decldmg to re used them 2 Every gear should be mspected as to the lockmg condItion defacement or any defects on the surface to see If they can...

Page 144: ...ntIoned InspectIon and selectIOn before pushIng m the pmlOn mate to shaft InspectIon should be made agaIn m the clearance of between the washer or the backlash Adjustment must be made m case any abnormal IS found Strike m the pInIOn shaft lockIng pm from the right Side of the case opposIte Side of drive gear and must be fixed by settmg well the strIkmg hole of It after puttmg It to the required pi...

Page 145: ... r fQ ro l J I J 38427 25660 38310 07200 38425 00100 CAoay 38315 01302 38210 25660 38215 01300 38153 4 5 6 25660 38120 041 00 38421 07o OO D1ff gear caB 38153 4 5 6 81 27160 38440 25660 Diff Bide bearing 38153 4 5 6 61 27160 GEAR CARRIER GEAR ...

Page 146: ...1 If the drive gear drive pmlOn and bearing are to the reused they are as a result of disassembling and Inspection they should be assembled In order of disassembling at the prevIOus condition of adJustmg shim In case any Item should be replaced or reqUired to reuse even If any Item IS worn out prepare the variOUS shIms as mentioned later because the posItlon of drive pInIOn to be fIxed with carrie...

Page 147: ... for assembling to prepare It IS convel1lent to Inspect the conditIOn before disassembling In a way as men tIoned later m the measurement of pll1lOn heIght BeSide the condmon of defacement on the carrier the pll1lOn bearIng must be taken II1tO consIderatIon though It Will be explamed In detaIl later B Fixing and Adjustment of Drive Pinion 1 Drive pInIOn rear bearing outer lace should be mounted 11...

Page 148: ...ht as well be done In pressIng In by the use of a certain drift t 4 Mount the drive pInIOn In the carrier and adJust by measuring the posItion The pmlOn height must be adJusted as mentIoned In the prevIOus paragraph by mounting temperarIlly the pinIOn In the carrier and the bearing be given a regu gular pre load On the other hand the bearing of drive pinIOn should be newly OIled after the pInIOn I...

Page 149: ...IS deCided as mentioned m the prevIOus paragraph take off the pll1lOn nut compamon flange to mount agall1 the drive pInIOn bearmg spacer distance piece and nut Tighten up the nut as Fig 7 by USIng the torque wrench at the regular torque of 100 120 ft lbs 1400 1680 kg cm The preload supportedly the bearing In thIS case IS dIfferent accordIng to the condItion of the bearing adJustmg shIm Inserted Th...

Page 150: ...ng seats msert a feeler gauge mto the clearance between the tip of the gauge center rod and the pmlOn head and adJust the p1l1lOn The gauge rod IS made 0 2 mm 8 1000 111 shorter than the standard measurement 21 mm Therefore adjustment IS made by selectmg a feeler gauge 111 accordance wIth the plus or mmus valve marked on the pInIOn head Special when the old bearing IS to be used agaIn In assemblin...

Page 151: ...of thickness calculated m accordance with the follOWIng method of computatIOn There IS a marked numeral of adjustIng baSIS on the bearmg housmg of the gear carrier and dIfferential case The numeral IS the manufacturing error m a Ul1lt of 1 1000 m agamst each standard measurement of A B C D In FIg 8 To measure the WIdth of the SIde bearing on left and right use the standard gauge 20 0 mm thickness ...

Page 152: ...ft SIde Tl A 0 C 0 007 In E Rtght SIde T2 B 0 0 006 m F Example of calculation Left A l 0 2 C 2 E to 2 mm 0 008 111 Rzght B 2 0 3 there fore F 0 25 mm 0 0lO m Tl A O CtO 007E 0 001 0 002 0 002 0 007 0 008 0 016 T2 B 0 0 006 F 0 002 O 003 O 006 O OlO 0 015 ThIckness of left shIm ThIckness of nght shIm 140 ...

Page 153: ...ecessary to use the bearing agaIn at the time of re pairing the thIckness of each shim of left right must bEe reduced for 0 001 0 003 on the baSIS of 80 or 60 agamst standard preload 111 accordance WIth the practical condItIOn of use beCduse over preload IS gIVen to the bearing WIth the shIm of thick ness calculated from above method of computation 141 ...

Page 154: ...ft 4 Ftg 12 Us ng the I fferenttaZ s de Beanng Cap Gauge 142 ...

Page 155: ... bJpoid a IIkiDa backl 0 0 l bearUlg adJu it hJl1I pacer pinion adJust shills Drive pinion UrVC pinion k PI Thrust wa her Pmlm male arlllg haft gear ca e thrust wa hf r 117 dri par Ualrhuiaa rqoe AI Ita ca ft D Itr t la u b d U h 1 4 Ib r T2 ot oDtari t tilfn nhl par n to 1 4 it ad Hckl I 0 1 0 11 I Attor f AlTi r par fO 4u W 1 w adJaninl 41190 p 1I1 41 11 21110 38111 27180 vit h tJdc b CI hd tile...

Page 156: ...011 tlll It comes up to the down sIde of the feedmg hole i 4 e nr1W Ii 00001 10 F g 13 When replacll1g the dlfferentlal axle shaft do not forget the adjust shim between the end of the axle flange and the shaft With the brake diSC assembly so as to keep the end play of the axle shafts Axle Shaft Removal Jack up the axle on the blocks Unscrew and remove the brake drum usmg a screw driver If the brak...

Page 157: ... 322 11 l 43219 44 121 4322 440 2 4 43221 A40 162 GreE 1 ear alLle bear1 ul lock uut 43064 32 100 f 43069 3 12 00 Lock asber roll r 43010 44000 Sllacer 1 1 ar 1 ri 6 04 6 40 11 04 0 43 1 1 3 12 00 Grease catcber pclck1 UI 3 164 012 1 1 ea r le sba ft 4 Y l ...

Page 158: ...s for one sIde Left or Right at the fIrst Insert selected shIms standard 1 5 mm between the axle tube and the shaft assembly fIt the end play of axle shaft O 85 1 10 mm Secondary attach the other Side of axle shaft assembly and adjust end play O 05 0 10 mm by selectIng adJust shIms 146 ...

Page 159: ...he shock IS felt mspect the degree of tIghtness and adJust It r 4 Inspect and confIrm the volume and quality of the 011 In the hOUSIng Inspection in MotIOn I In case of glvmg the high metaiIc nOise when speedmg up the backlash IS at the least or too much at the drive gear and the drive pInIOn 2 GIVll1g any abnormal nOise III speedll1g up or sloWIng down the drive pInIOn bearing IS worn out or dama...

Page 160: ...032 m x 2 BRAKE SHOE Lmmg dimenSIOn both front rear wheel Length x Width x Thickness Lmmg area per brake shoe Adjustment of shoe clearance Front Rear brake Play for pedal 244 mm x 45 mm x 4 5 mm 110 sq cm Fasten adJust1l1g gear notch completely and them make 12 turnmgs back 10 14 mm The brakes on all four wheels are hydraulically operated by foot pedal applIcatlon dIrectly coupled to a master cylI...

Page 161: ... wheel Lock spr1ng 4120 32200 L B 41206 32200 41207 32200 a B 41158 041 I FWh 13 041 9 15211 hous ng ass y 0 41203 322005 L reta1n1ng spr1ng 41213 04100 4120932200 AdJuster AdJuster R H 41002 32200 L B 41110 3270 shoe Fore 41030 32202 e C I 41158 041 Bleeder screw 41128 041 41128 30001 41129 30001 LI1147 1 Lock plate 41214 04100 AdJuster boot 41153 04100 Front brake shoe After 41031 32202 41939 32...

Page 162: ...t mechamcallInkage actuated by a hand brake mounted drivers seat Side left or nght SIde operates the rear wheels by mechanIcal expanders attached to the rear wheel cylmder bodies 1 FRONT BRAKES The front brakes are operated by each one wheel cylinder Each wheel cylInder consists of a body contammg spring spring seats pistons piston cups cylmder cover lock wheel cylmder cover and adJust screw The s...

Page 163: ...fixed but are allowed to slide and centralIse with the same effect as In the front brakes They are hydraulically operated by wheel cyhnder and mdependent hand brake mechamsm BRAKE DRUM SIDE HAN0 BRAKE CABLE BRAKE DISK BACK F g 2 Rear Brake 151 ...

Page 164: ...Only when a complete overhaul IS necessary should the hand brake lmkage reqUire resetmg When thiS IS correct the rear shoes should be locked to the drums the hand brake control Just slightly applied and the wire rope set With the slackness Just re moved by means of a nut at the center rod of the equalizer drag lInk ADJUSTING BRAKES RaIse the truck and place stand Jacks front and rear so that all f...

Page 165: ...rln 41130 04100 II 41213 04100 Spnng lock pl t 41158 04100 41214 04100 44128 32200 41128 30001 Rear brake dISC 44010 32201 R B 44011 32201 L R Rear wheel cyl 44100 07200 I aas y 44060 32201 41129 30001 44035 32200 R B 44036 32200 L R Toggle lever 44033 322oo 070 32 200 Ul l f r H u hraL nturn nnj 4403o 322oo I Haml hnkf xt nlllln J lon 084 32200 i 083 U200 082 322oo 44081 322oo I 44060 32201 Rear ...

Page 166: ...Rear Brake AdjuStmenl FJ g 4 Front Brake Ad1uStmenl 154 ...

Page 167: ... then the master cylInder and flUid reservOir may WIthdrawn complete from the car Remove the fIller cap and dram out flUid Pull back the rubber boot and remove the stopper nng with a pair of long nosed pliers The push rod has been removed the piston WIth the secondary cap Will be exposed therefore remove the piston assembly complete The assembly can be separated by takIng out other small parts Exa...

Page 168: ...eed screw cap suffICiently to seat remove bleed tube This process must now be repeated for each of the other wheel cylinder Always keep a careful check on the supply tank dUring bleedmg smce It IS most Important that a full level IS mamtamed Should aIr reach the master cylll1der from the supply tank the whole of the bleedmg operation must be repeated After bleedIng top up the supply tank to Its co...

Page 169: ... are made to spark to IgnIte the fuel air mixture In the cylinders To diagnose defects of the IgnItIon system always have thiS distribution prll1 cIple m mmd and check the low and high voltage CirCuits separately As shown m Fig 3 the IgnItIon COli has two COlis With primary current which IS sent through the primary cord IS sent and cut the magnetic fIeld WIthll1 the pri mary COli changes and by mu...

Page 170: ...unon 12 Voltage regulator 5 Ammeter 13 Generator 6 Igl11tlOn sWitch 14 Pnmary cord 7 Igl1ltIOn cOil 15 Secondary cord 8 Condenser 16 HIgh tensIOn cord U volts IGNIt Of4 C01L Type PrImary voltage C1Z 01 F g 3 Sect on of grntwn Co l I Pnmary cord terminal 2 Pnmary cord termmal 1 Secondary cord termmal 4 Pnmary cOIl 5 Secondary cOIl 6 Core Iron 158 ...

Page 171: ...ntral electrode on the distributor cap and holdll1g ItS tIp about 6 mm away from a metal portIOn of the engll1e open and close the pomt by movmg the contact arm by hamt If blush white and strong spark are created between the tIp of the cord and Ithe metal portIOn the cOli may be conSIdered to be all right t When the sparks are feeble and reddish or when sparkIng does not take place upless the gap ...

Page 172: ...ILIC11llCAL SYSlIlA e e d tr e d t U 13 t I i U Co 3 o t 3 i 160 ...

Page 173: ... cover Packmg 12 Armature 19 Rear cover 6 Retamer 13 FIeld coIl 20 Brush cover 7 8prmg 14 Yoke ass y GENERATOR Model Voltage Out put Pulley ratIo Amendment limit of deflec tIon of shaft Amendment limit of short dimenSIOn on commutator Shunt V 161 r HItachi GUS 53 12 volts 200 watt 1 93 O I mm 0 004 111 3 mm 0 120111 More than 7A at 1000 r p m ...

Page 174: ...y 5 Fuse 6 Llghtmg switch 7 Lamp The constant voltage type generator when chargIng ma1l1taInS a fixed voltage at the generator termInals regardleds of the vehIcle speed that IS over a Wide range of engIne speeds ana also produces an output conformmg to the load In other words conformmg to the state of battery charge the chargIng current IS au tomatlcally regulated preventmg excessive chargmg or di...

Page 175: ...g the two through bolts connectmg the end covers the generator can be dIsassembled as shown 111 Fig 2 All disassembled parts wIth the exceptIOn of the fIeld COli and the armature COli are washed with gasolme before bell1g mspected and reassembled When reassembling the front bearing bemg of the ball bearing type IS fIlled WIth magneto grease while the rear bearmg IS lubricated WIth a few drops of l...

Page 176: ... the ammeter Indicates higher than the reated values there IS a short or grounded connectlon provided there are no mechamcal defects It should be noted that a fairly large current will flow If the frictIOnal resistance of the rotating parts IS great If the rotatIOn IS Irregular there IS a short or ground m the armature and If the rotatlon IS slow the trouble may be due to short or ground m the fie...

Page 177: ...d so that It should be replaced With new COIL If the test lamp falls to light the field COllIS free from groundmg j i Testing for Shorts in Field Coil The fIeld COllIS placed In series WIth an ammeter between the posItive and negative termInals of a 12 volt electrical source If the ammeter shows an ex ceedmgly high readIng the fIeld COllIS shorted and should be replaced Rated currents are HItachi ...

Page 178: ...Ing rotatIOn so that not only w1ll the output be reduced and the smoothness of rotatIon be destroyed but tlus will cause the shaft to bend and cause the parts to touch The specrl1cauons should be referred to and defectIve parts should be re placed or repan ed Checking Armature Coil ThIs 1S a ViSUal check up The connecuoo betWeen the armature COli and the commutator are 1I1spected and all loose or ...

Page 179: ...y reseatmg However If the brush IS worn beyond the wear limIt or IS broken It should be replaced To reseat the brush a piece of sand paper of about No 150 fmeness IS wrapped around the commutator and With the brush Installed In the holder over the sandpaper the holder IS revolved For fImshIng sandpaper of about No 320 ratIng IS used After reseatmg It should be blown with compressed air and after c...

Page 180: ...Ists of the carbon pIle magnet coIl moving core sprIng and fIxed resIstances The prIncIpal part IS the carbon pIle whIch conSIsts of several dozen layers of thin carbon dISCS By applying pressure to both ends of the carbon pIle as shown in FIg 1 the resIstance wIll change The utllIzatlon of thIS characterIs tlC IS the carbon pIle voltage regulator the WIrIng dIagram of whIch IS shown in FIg 2 I PI...

Page 181: ...he generated current Conversely when the volt age becomes low the generated current lOcreases Thus by properly matchlOg r the carbon pIle regulator hmlts the current by means of the current COli there IS no need of speCIally provldlOg a current cut out Also the COli lo serIes with the fIeld IS for ImprovlOg the charglOg characterIstlcs at low speed whIle the fIxed reSIstances are for preventlOg va...

Page 182: ...oltage regulatlng part of the voltage regulator has been subJected to ngId lOspectlon so that there should be practlcally no changes whIle lo use and no necessity for adJustments If trouble should occur however the regulator should not be touched wIthout prevIOus prepara tlons or thIS WIll on the contrary lead to big ger troubles Before adJustmg the pnncIples outlIned above should be thoroughly un...

Page 183: ...voltage and termI nal B voltage should be practI cally the same If these two voltages dIffer consIderably thIS mdIcates a resIstance In the charging CIrCUit In thIS case check the cut out relay for such defects as burnt contact pOInts and repaIr as necessary When reassemblIng adJustments are made throught the adJustmg core and the pIle pressure screw The regulator IS con nected up to the generator...

Page 184: ...re should be taken to tighten as slowly as possIble when near the push up voltage Ftg 8 Wtnng hook up meassunng push up voltage 4 If by adJusting the F screw the specIfIed push up voltage cannot be ob tamed but IS less than 10 5 volts Case Az the F screw IS unscrewed back nearly to the noload voltage and the P screw IS slIghtly tightened If more than 10 5 volts Case AI the P screw IS lIghtly loose...

Page 185: ... that the proper gap dIstance of the relay parts are Gap to Arm Relay pOlnt gap Ftf 9 Cut out relay upper left shows eut out relay wtndmg detatI Relay pomt gap O 9 mm Arm to core gap pomts open 0 7 O 8 mm Arm to core gap pomts closed 0 4 O 5 mm The cut out relay pomts should be mspected about once 111 every two months Burnt pItted and other poorly contaCtIng pomts should be dressed WIth a fIne hie...

Page 186: ...Voltage Output Startmg current voltage Lock torque Type of pmlOn gear Number of tooth on pmlOn gear Number of tooth on rIng gear Amendment lImIt of short dImenSIOn on shaft dla pmlOn sIde Amendment lImIt of short dImenSIOn of shaft dla rear end Gap between shaft and bush pmIOn sIde Amendment lImit dIttoed gap Gap between shaft and bush rearend Amendment lImit dIttoed gap Amendment lImit of deflect...

Page 187: ...ted on the engme IS on the front nght SIde of the transmISSIOn WIth ItS pmlOn gear dIrectly oppOSite to the nng gear The construction of the starter motor IS sImIlar to that of the generator but dIffers only m that Its armature shaft extends out backwards WIth a pmlOn group mstalled on the end as shown m FIg 2 jI i Ftg 2 A Seehonal Vtew ofStarter Motor 175 ...

Page 188: ...Operational Precautions The mstructlons to be observed when startmg the engme are as follows I The starter should be securely mounted on the engme and should not show any looseness 2 The s arter SWItch should be operated properly and should be released Im medIately when the engme starts Exceptmg In extremely cold weather the engme should normally start wlthm 10 seconds 3 The starter switch should ...

Page 189: ...30100 I St pp t MOTOR U315 30Ioo Return Spr1ng 23314 30Ioo Return stopper QP1n1on 1 23312 30100Au 23316 100 Front cover JJ 23374 301 23370 30100 Screw sl eve 23375 30100 23372 30 OO Spnng coller 23311 30100 Bendex spnng ...

Page 190: ... armature and the front cover are taken out together 6 To remove the pInIon group from the armature shaft the cotter pm on the end of the shaft IS pulled out and by removmg the pmIOn nut the pmIOn group IS removed Inspecting and Repairing Parts The same procedure as that for the generator parts IS followed the part bemg cleaned and mspected after whIch determmatIons are made as to whether they can...

Page 191: ...te can be dIVIded Into electncal and mechall1cal sources Causes for electncal troubles A Current fallure III magnetic CIrcuit When the starter swItch button m pressed and the current falls to pass through the magnetIc ClrCUIt most of the trouble IS due to broken soldered connection between the magnetIc COlI wIre add the magnetIc SWItch termInal and defectIve ground connectIon from the COIl wIre to...

Page 192: ...aratus shown m FIg 4 by whIch brakmg torque IS measured In tills case the normal value should be O 9 m kg To test the starter motor when mstalled on the engme the engme IS fIrst warmed up Then with the throttle velve m fully closed po SItIOn the starter IS actuated In addItIOn If a starter motor tester IS used performance tests can be made eaSIly and accurately Ftg 4 Torque Teshng Apparatus Constr...

Page 193: ...e to the gear teeth bemg badly worn the gears should be re placed but If It IS due to the screw gUIde on the pmIOn shaft bemg dIrty and not allowmg the pmlOn to advance smoothly and causmg Improper meshmg the shaft should be cleaned and OIled 2 Starter exceedmgly nOIsy when m operatIOn The flywheel nng gear IS checked and If the teeth are deformed they should be reprIed or the gear replaced Rattlm...

Page 194: ...m the negative plates and dIlute sulphunc aCId III the electrolyte occurnng wlthm the battery as shown m FIg I A In thIS case the lead dIOXIde and the sponge form lead react with the dJlute sulphunc aCId the lead portion and the sulfate portion com bmmg to form a lead sulfate fIlm on the surfaces of both the posItIve and the nega tlveplates Thus as the dlschargmg contmues the sulphuhc aCId m the e...

Page 195: ...a fIlter such as punc should be sued After replelllshmg the battery flUId the battery should be charged at least 20 mmutes m order to allow the tluld to mIX thoroughly ThIs procedure should be speCIally observed m cold regIOns due to the fact that If the replelllshed flUId IS slow to stand without mlxmg there IS a danger of the water separating to the top and freezmg If the flUId level becomes low...

Page 196: ...wIll concentrate the flUId to a speCIfic gravity of over I 310 If the speCIfIc gravIty becomes hIgher than I30 cautIon should be taken SInce the lIfe of the battery WIll be shortened rapIdly 3 Termmal voltage at each cell By the above method of determmmg speCIfIc gravIty the state of battery charge can be determmed but the followmg methods can also be used to determme the con dltlon of the battery...

Page 197: ...that It IS about 22 mm above the top ot the plates on VISIble type plugs It should be up to the normal level mdlcatlOn Note The vent plugs on all cells should be removed whIle chargmg The termlllals should be polished to remove all dIrt and flUId adherIng to the surface The of the battery termlllalls connected to the dIrect current termmal of the charger and the termlllal of the battery to the ter...

Page 198: ... volts the battery voltage wIll be unable to nse hIgher and the battery can be charged wIth the lease amount of gas bemg generated ThIS IS the constant voltage charg 109 method m whIch an exceedmgly large amount of current flows at the start but as the chargmg progresses the current decreases and when the battery voltage becomes equal to the electncal source voltage there WIll be pracucally no cur...

Page 199: ...every month thereafter 2 If the battery IS not removed from a car whIch IS to be stored the ground term mal on the battery should be dIsconnected m order to prevent dlschargmg and fIre hazards 3 If the battery alone IS to be stored It should be kept m a cool place and away from dIrect sunlight 4 When battery flUId overflows and adheres to the surface of the battery the aCId should be neutralized b...