S erv c e

Snap

ij

i
Jd
s

NISSAN ENGINE
MODEL P

SERVICE MANUAL

I NISSAN I

NISSAN MOTOR CO
TOKYO JAPAN

LTD

if

NISSAN ENGINE
MODEL
P

SERVICE MANUAL

INISSANI

1
r

NISSAN MOTOR CO

LTD

TOKYO
t

JAPAN

FOREWORD

This manusl has been complied for pourpose of assisting NISSAN distributors and dealers for effective service and maintenance of the Model P engine Model P engine has been used for the various models of vehicles such as Model 680 Model 4W73 and Model 60 series In addi Each assembly of major components is described in detail tion

comprehensive instructions pectioo of these assemblies

The difference between Model

are

given

for

assembling

and ins

680 4W73 and 60 are also given in this engine concerned It Is emphasiged that the ooly genuine Nissan Spare Parts should be used as replacements manual
as

far as

CONTENTS
GENERAL INFORMATIONS SPECIFICATIONS FERFORMANCE CURVES OF NISSAN MODEL P ENGINE GENERAL INSPECTION OF ENGINE SHORT CUT FOR TROUBLE SHOOTING SECTION
1 1 1 2

Page
1 4 7 10

CYLINDER

CYLINDER HEAD

15
15

Cylinder

Cylinder

head PISTON RING PISTON PIN CONNECTING ROD

20 23 23
25

SECTION 2
2 1 2

PISTON Piston

2
2 2 2

3
4

Piston ring and piston pin

28 30 32 37 39 43 TIMING
47

Connecting

rod

SECTION 3 3 3
1 2

CRANKSHAFT of crankshaft Rear bearing seal

Disassembling

SECTION 4
4 4 4 4 4 4 1 2

CAMSHAFT
Removal of

VALVE
head

TAPPET

cylinder

Removal of valves

51 52 52 52 53
54

3
4 5

Replacement
Valve

grinding Refitting the cylinder head camshaft Timing gear

MANIFOLD Removal

SECTION 5 5
5 1 2

57 57
57

Inspection
Heat control

assembly

57

SECTION 6 6 6
1

WBRICATION SYSTEM

59 60 63 67 67 68
72

Adjusonent of oil regulstor

Oil filter COOLING SYSTEM
fan belt Water pump fan Repair of water pump heat indicator Radiator thermostat

SECTION 7 7 7 7
1

2 3

Page
SECTION 8 8
8 1 2

FUEL SYSTEM
Fuel pump Repair of fuel pump

77 77 78 80 84 87 87 gauge 89 93 95 100 103 103 104 105 106 1I0

8 8
8

3
4 5

Carburetor

Adjusanent

of carburetor

8
8

6
7

Air cleaner Gasoline strainer Gasoline tank

gasoline

SECTION 9
9 1 2

IGNITION SYSTEM Check repair Adjusanent GENERATING SYSTEM

SECTION 10 101 10 2 10 10 10 10 3
4 5

Generator Cautions for handling generator Carbon pile type voltage regulator Troubles and remedy of generator and regulator Test of generator

Wiring of generator voltage regulator

STARTER MarOR

and out put

adjusanent

III lIS lIS 119 119

SECTION II
1I 1

Repair
BATTERY
of

SECTION 12 12
1

Handling

battery

GENERAL

INFORMATIONS

SPECIFI CA TIONS

ENGINE PROPER Model Maker Kind of P Engine for 680 60 4W73 Series Nissan Motor Co Ltd Gasoline Engine

Engine

Cooling
Cylinder Arrangement Cycles
Combustiem Chamber Head Bore x Stroke rom Total Displacement Volume

Straight

Water 6
4

Cylinder

Bath tube type Over head valve 85 7 x 114 3

cc

Compressiem Compressiem

Ratio

Pressure IbiD 200 rpm Maximum Horse Power HP Irpm S A E 235 ft Ills 2000 rpm Maximum Torque m kg rpm Minimum Fuel Conswnptiem at Full Load h rpm Dimensions rom Engine

3 956 I 7 6 157 145 3800 32 5 2000 220 1600 904 655 882 293
2 I

P S

Width

Rear

Support

Length right to Air

Oil Pan

Fan to Cleaner

Fly wheel
left

Height

Air Cleaner

to

Engine Weight Equipped

Number of Piston

Rings

dry kg Compression
Oil

Type

of Pistem

Material of Piston Valve Timing Inlet Valve Inlet Valve Exhaust Valve open degrees B T D C closed degrees A B D C open degrees B B D C closed degrees A T D C

Steel strut LO EX

140 SOO 520

Exhaust V lve

120

Valve Tappet Clearance

mm Inlet Valve hot mm Exhaust Valve hot

0 38 0 38

0 4
0 4

Ignitiem Method Ignitiem Timing Firing Order

Battery
B T D C

IgnitiCll coil
100 450 5 3 6 2 4 Crank Handle
1

Irpm
Startor Motor

Starting

Method

IGNITION SYSTEM

Ignition Coil
Distributor

Model Model

HITACHI D608 01

Type of Spark Advancer

HITACHI CIZ OI D6Q8 5IA 60 series Vacuum Control Centrifugal

Sparking plug

Model

854E or B6E N G
mm

Maker Diameter mm Sparking Clearance Number of pole

or

HITACHI 14 O 75
I

Insulating
FUEL SYSTEM Carburetor

Material

Porcelain

Original
Type
Maker Dia

Model VC42

IA 680 Series

Stromberg
VC42 4A SA 60 E690 FG60 4W73 HITACHI 42 36 17 IO 1 43 VC42 IA lo

Dia
Dia

of lbrottle Valve mm of Ventury Tube mm of

High Speed Jet mm

VC42 35

4A

SA

Dia Dia
Air Cleaner

of Low

Speed Jet mm
mm

of Econanizer Jet Draft Direction

0 55 loW Downward Oil Bath

Type
Maker
Nwnber

Tsuchiya
I

Fuel Feed Pump

Type
Maker

Diaphragm
Showa Seiki K yosan Denki

LUBRICATING SYSTEM Method Pressure Feed Gear Pump

Type of Oil Pump

Type

of Oil Filter

Paper Filter
5 3 6 7 680 series 60 series

Oil Pan

Capacity Itr

COOLING SYSTEM Method Radiator

Forced Circulation with

Fin and Tube

Type of Water Pump

Thennostat

Centrifugal Pump Type Centrifugal Pump

PeIlet

BATIERY Model 2SMC

12 volt hr

Voltage Capacity
Number Tenninal

amp

60

20 hr

rating

E690

120Aj30h
I

grounded

positive

side

GENERATOR Model Maker

Type of Winding Voltage Capacity kw Type of Voltage Regulator

RIIS SO STARTING MOTOR Model
Maker

HITACHI Shunt wound 12 volt 200W Carbon pile GI4Q 07 F680 E690

MFB Power
v

HRZ

HITACHI

Volt

hp
8114 23

12

S114 21

I 0 E690

PERFORMANCE CURVES OF NISSAN MODEL P ENGINE

Max

150 I Max
Min

P SAE Torque SAE Fuel Consumption B H

145 HP 3800 r p m 32 5 kg m 2000 r p m 220 gr jHP h l600 r p m

V
140

130

J
F

120

17
E

no S

J
100 35 30
I C1

iii

Iii
c

u c

5 aJ I

80
c

70

Ii
cI
60
I

E
c

50 V 40

11
c

1
r

30

250 aJ0

8
0
I

12

16

20

24

28

32

36

38
u

c en

Engine Revolutions

Xl00

pm

G1NE

LE

SIDE

i
P

tf

Jt

m
ir

7 X

1
4

ENGINE RIGHT

SIDE

GENERAL
In order to maintain the

INSPECTION
at

OF
a

ENGINE
periodical
and

engine

the beBt condition

orderly

adjuBtment
1

have to be made

Check of Cooling Water The cooling sYBtem must be full of water which is required clean Refer to the line up of Cooling System
to

be soft and

Check of Banery The quantity of electrolyte is required to be as much aB 3 8 inch above the The voltage The specific gravity should be more than 1 220 kg plates at each cell Bhould be more than 17 5 volt on the excell tester Refer to the line up of Electrical

Check of Engine Oil The oil level should be between the upper and The oil capacity is 6 2 Itr The Btandard oil pressure is 3 5 4 kg cm lower lines of the oil level gauge at running speed 49 5 57 Ib in

Refer
4

to

the line up of Lubrication

System

Check of Spark Plug The gap should be adjusted Refer to Ignition SYBtem
to

O 7

mm

0 024

O 028 in

Check of CompreBsioo Pressure of

Cylinder

when The compreBsioo presBure should be over 135 poundB per square inch difference of The pres meaBured by rotating engine with Btarting motor inch This sure at each cylinder should not exceed 10 pounds per square water at test should be made under the conditions temperature of cooling 800 all 700 plugs removed and the throttle and choke valves of

carburetor 6

spark completely

open

Check of Distributor

Adjust 7

the

point gap

at

0 020 inch

Check of

Ignition Timing
timing
at

Adjust
8

the

20 before top dead

center

crank

angle

Check of Carburetor

Refer
9

to

Fuel

System

Check of Fuel Pump and Strainer

Refer

to

Fuel

System

10

Check of Tension of the

Fan Belt When
i

pressed by a hinge the deflection of fan belt should be 25 mm I in at the middle of

water

ft f

pwnp pulley and crank shaft pulley Check of the Valve Tappet

II

Clearance

Adjust
0 38
at

the clearance at

0 40 mm 0 015 0 016 in for both intalce and ex haust valves when engine is suf ficiently wanned

600C

12

Cheek of Slow Refer

to

for Carburetor

Fuel

System
of

13

Check of

Tighteness
be 55

Cylinder

Head Bolts

Adjust them
14

to

65 ft lb

Check of Charging Rate of Generator It should read

more

than 10

amperes at the engine speed of 30 40 lcm Ihr Refer to Electrical 15

Fig

Disgnosis
See Fig

of

Engine by

Means of Vacuum

Gsuge

N Aramd 18
aum to

IlUIl
2
ftC

OU

wlth

IIfaht ftuc 1dIIopeed

1 CoDdItIoa a tbe to 2 aDd IplUp bock to 25

81 fa Po CooodItIoa

3
to zero

hllDll d

drupe
comes

emIdDa R III

apwer
2

bKk to about

tuatiDD at

wheD enafDe

accelentilll

reodbIll

23 wbea

openiq

and

c1adng throttle

8t1ellT Drops
four normal risions di

Val 1IIIIy m fn

IkImt

e VaI

V
a

regularly
aldi

dhl

reading

GaIde Vibrates fast between

14 aDd 18

Vain

8pr1q

Late

of 11m1
ea Val

Late Jpido 11m1

be Remam be

From 10 to 22 when

accelerating mgIDe and becomes areater s Increasing speed

8 k Pia Gap too 8ma11 kn Point Contact

Remains

steady 15

steady

Improper
l between 1 and 16 F1oat

tween 8 to

tween 14 to 17

LalIT
of

CuRt

LalIT

Ia
or

Maalfald
5
or

CyU Hsd c bL
be

Choked H Normal at tint drops

to zero 3l d builds up to 1 theD

InclJcates

lea

FIoaregularly tween 5 net 19

Cuf fa Oat afttor of Adlaat t Floa ts lIIowly between

13 and 17

Fig

Diagnosis of engine by

Vacuum

Gauge

SHORT cUT

FOR

TROUBLE
1

SHOOTING
of fuel

Damage

pipe

or

insufficient

soldering Piping
system 2 Insufficient

tightening

or

damage

of

union nut 00 the fuel

pipe
seat

Worn needle valve and chamber

in float

Leakage
dfuel 1be fuel level

Dust at needle valve and seat in the float chamber or inccxnplete move
ment of needle valve

high flowing
too

or over

3
4

Fuel infiltrated in the float

1be float is too heavy due weight of solder

to

the

5 Carburetor
I

Too much pressure of fuel pump too big needle valve seat hole

or

Improper fastening of needle valve

seat ass y

Improper fastening of
cover

screws on

the

of the float chamber

outer

Improper fast ening of jet

screws or

3
4

Loose emulsiCII

tube

dam

aged

washer

Improper fastening

of pump

injector

5 6

Improper fastening of low speed jet

Improper fastening
sence

of the upper and lower bodies of carburetor or pre of cracks low speed
or

Adjustment
1 rburetor 2

Poor adjustment for

Clogging
of

improper

of low speed jet size used

of low

the jet

Loose Crack
or

fastening

speed jet

Repair

on the joint surface of the and lower bodies of carburetor upper

fastening

Improper assembling of the throttle

valve

10

l5
Poor

Intrusion of air due to valve shaft

Air

worn

throttle

leaking

frem carburetor

flange

and intake manifold

flange

idling
l Difference of compression of each

cylinder
2

Irregularity

of

spark plug

gaps
or use

Engine and

etc

Poor quality of spark plugs of different kinds

hnproper ignition timing

Intrusioo of air from the intake mani fold or the rubber tube joint of the window shield wiper is leaky
No fuel

aupply

to

the carburetor

Intrusioo of air from the throttle valve shaft and its flange fixing the
same

Car buretor

too much Use of poor quality fuel mixture of substitute fuel such as alcohol kerosene etc

Erroneous

use

of choke button
of

Imperfect insulation wiring

high

tension

Hard to start or

unable to start in cold climate 3

4

Poor ignition current due to the under charging of battery

Disorder

of

ignition

circuit

accwnula Troubles of spark plugs tion of carbon damage by heat ir of regularity of gaps ccmdenaaticm and water oil quality lubricating poor
etc

Insufficient compression of

cylinder

Engine and other parts

6
7

Air intrusion into the intake manifolds

Insufficient seating of engine valves

or

broken or weak valve

springs

11

l
Carburetor

Insufficient
motor

cranking speed
oil

of

starting

9 1
2

Poor

quality lubricating supply

low
use

No fuel

to the carburetor

Too lean mixture due to poor

ment

adjust

for

speed
of choke button

3
4

Erroneoua

Hard to start or unable to stan

In hot climate

Insufficient lower body

tightening of upper and or damage of gasket

or

Trouble of engine valves valve springs

broken

Engine

Poor ignitioo or insufficient cranking apeed of starting motor due to drop of battery voltage Disorder of ignition circuit Trouble of startor motor

3 4 1 2

Dirty

intake manifold

Excessive resistance for suction due

to

partial clogging

of air cleaner
to

Insufficient fuel supply due lock In fuel pump and pipe Disorder of fuel pump

vapour

Carburetor

Clogged

main

jet

power jet

or

main

air bleed

Wrong assembling
carburetor
sizes

Insufficient and power

speed
1

and adjustment of ignorance of relative of venturi tube main jet main

air bleed etc

Too much friction and resistance of bearings and other parts Insufficient compression of cylinder

2 3

Overheating
Poor

of

engine

Engine

cooling system
octane

5 6
7

Wrong setting of

selector

Disorder of ignition system Misfire of any spark Brakes

plug adjustment

dragging

due to poor

12

Carburetor

Wrong assembling
ance

of carburetor

ignor
main

of relative sizes of venturi tube

jet Overheating of engine

1

main air bleed Too much friction and resistance

Poor

cooling

system
effect of radiator

Engine
others

and

3
4

Inefficiency of cooling

Poor circulation of lubricating oil

5 6
7

Wrong ignition timing Wrong setting of

Over
The octane selector

loading
of

porcelain part

spark plug gets

stained black with the carbon

Judgement

The color of exhasst gas is black and has the unpleasant odour
Uneven

3 Air mixture is
too

running of engine
and adjustment of ignorance of relative main jet
main

rich

Wrong assembling
carburetor

sizes of venturi tube air bleed

etc

Cause

The jet hole is

too

big

3 4 5 6
1

Insufficient fastening of main jet

Leakage

in the power

jet valve

The level of fuel is

too

high

Disorder of air cleaner The porcelain part of

white

spark plug

is

2 3

Uneven running of engine Back firing in carburetor

Judgement

Engine overheat particularly exhaust pipe overheats Engine power diminishes

Poor adjustment of carburetor

the

5 Air mixture is too lean 1 Cau8e

2

Instrusion of air frem the throttle valve shaft and the fitting flange

13

Jets tampered

or

remodelled

or

imitation parts used 1

Too lean mixture

Wrong Ignition timing Pre ignition

Catch fire due
Disorder of Insufficient
or to

Back fire

3
4

engine overheat

ignition system seating of engine springs

valves

broken valve

Disorder 6f

accelerating accelerating

pump pump injector

Clogging
hole

of

Insufficient acceleration

Leakage

frem

accelerating

pump check

ball valve

4 5 6 1
2

Disorder of distributor governor

Wrong ignition timing

Poor adjustment of carburetor
Erroneous

adjustment

of carburetor

Improper
ratio

fuel

relating

to

compression

Knocking

3
4

Dirty cylinder inside

Wrong ignition timing

isorder of spark

Pre ignition

plug

14

SECTION
CYLINDER

1
Br CYLINDER HEAD

1 1 CYLINDER

Fig DATA
Diameter of

cylinder

bore

85 69 85 739 mm 3 3754 in 3 376 in

fhe limit
0 06 in Thickness of

for over size

piston

is

cylinder

wali

13 64 in sleeve if over size more that Use The outer diameter of O 060 in sleeve should be less than 3 5695 in
5

15

mm

Difference of top and bottom bore Difference between the and shorter diameter

Less than O 025 mm Less than O 025 mm

0 00 1 in

longer
inside

0 001

in

limit of
73 Not

use

0 08 in
2 875 in

of

an

oval bore of

cylinder
dia

Main

bearing housing

73 025
to

mm

874
mm

Block

cylinder

head surface exceed O 1

warpage

0 004

in

Tightening

torque of main 10
11

bearing cap bolts

kgrn 72

80 ft lb

15

The engine is a six cylinder valve in head type equipped with counter balanced crank shaft The displacement of this engine is 3956 cc it develops 145 horsepower at 3800 revolutions per minute SAE Maximum torque is 32 5kgm at 2000 rpm shows a view of the engine assembly in side cross The illustration Fig 2
section

904

oC N or

Fig Repair operations when

should be

Sectional View

of the Engine

completely

it beccmes necessary to overhaul an engine assembly it disassembled and all parts throughly cleaned before starting the

the overhaul operations

In order to

simplifty

various parts in the order in which an overhaul

following instructions we well cover the repair job would be performed

of the

Checking Cylinders
By far the best method to be used indetermining dial gauge engine preparatory to reconditioning is the use of a
the coodition of a

cylinder

in an

such as is shown

Fig

16

Fig

Checking Cylinder Walls with Dial Gauge

The dial gauge hand will

instantly

and automatically indicate the

slightest

variation in the cylinder bores In use the dial gauge is simply inserted in the and down its full length It is then turned spirally be desired

cylinder
or

bore

and moved up
at as

completely rated

may

taking readings

at

each

point

In this

manner

all variations in the

cylinder
If

to bottom may be determined gauge corresponding with the exact diameter of a standard cylinder bore is used to set the dial gauge it is easy to determine the oversize piston to use as well as the amount of metal which must be removed from the cylinder walls to make them true a master

walls from top

17

Cllliruler Borillll
oversize When it becomes necessary to rebore the cylinders of an engine to install pistons the instructions furnished by the manufacturer of the equipment
must

used should be carefully followed ht this engines the piston clearance is allowed on the piston and this taken into consideration when setting the cutter in the boring bar 1be piston to be fitted should be checked with a micrometer below the lower ring groove and at right angles to the piston pin should be bored to the same diameter as the piston If micrometer is not available to measure the piston bored 0 002 less than the oversize piston to be fitted
For the

be

measuring just The cylinder

be

cylinder should

example

when

fitting

a0

020

oversize

piston

the cylinder should be

bored O 018

oversize

Cylinder
After
a

Hone

cylinder has been r ebored within 0 002 of the size desired it should polished with a cylinder hone ht operation the hone is placed into the cylinder bore and expanded until it can 1be hale is then operilted up and down in the bore until just be turned by hand it begins to run free During this operation kerosene should be used as a cutting
be refinished or

fluid

to keep the stones of hale clean This procedure should be followed until the piston being fitted can be pushed through the cylinder on a O 0025 feeler gauge 1be feeler gauge must be inserted vertically 900 around pistm from the piston pin and draw out the feeler gauge with the scale under I 3 kg powers

18

F g

19

1 2

CYLINDER

HEAD

Fig

DATA
Power up En 06 mm 86 72 i O 5
cc

Former En 100 I mm 99 80 121

cc

Cyl

head

height Cyl

all

length

Comhustion chamber volume

Length

of

head

119mm Within 0 004 O lmm 55 65 ft lb 31 36 it lb

mm

Warpage of surface

Tightening torque Cyl head holt

Rocker bracket holt

l 6 9 0 Kgm
4 3 5 0

Kgm

One of the most important units of any overhead valve engine is the cylinder head but the valves It contains not only the combustion chambers and spark plugs inlet ports exhaust ports and the necessary water passages to maintain the proper temperature of these important parts No maintenance operation is more important than valve grinding from the stand point of engine economy and performance be used whenever valve are ground to maintain Extreme care should therefore and as limits cllellrances only by maintaining these limits and clearances can factry

good engine

economy and

performance

be obtained

Checking

Valve Guide

to worn valve Lack of power and noisy valves In many instances can be traced is very important valve stem the vlave and the clearance between The guides guides and the exhaust be The intake guides should be checked with a new Intake valve beCause the dismeters of the stems are different checked wltl1 a new exhaust valve

20

t r

Fig

21

SERvreE

NEWS

REFERENCE

NO DATE CONTENTS

OF SERVICE AND BULLETIN

JOURNAL

22

SECTION

2 PISTON PIN

PISTON PISTON RING CONNECTING ROD

2 1

PISTON
are

The pistons
above the

made of LO EX aluminum

alloy

with three

ring groove located

piston pin

The skirt is eliiptic These pistons are furnished in standard size as well as O 010 O 020 O 030 O 040 0 050 O 060 Any time a piston removed from the cylinder It should be examined for carbon ls and any carboo deposit removed on the inside This helps keep the engine oil clean The piston pin is fixed 1 5 mm off set towards the thrust direction at the
center

of

piston
are

The pistons

serviced with the

piston pin fitted

in them

Should it become

necessary to Ins tali oversize piston pins The proper fit of the piston pin is a thumb push fit at 20oC The plstoo pins are serviced in standsrd size as well as 0 0025
size

0 005

over

Note

Over size pistons for service use are as foliows Piston is usually supplied as Set pistoo with pin

For

Connecting

rod 12100 58000 Piston pin bolt

w

clamp

type Pin pistoo

Size STD 0 12 0 25 0 50 0 75 1 00 1 25
1

Set piston

pin

Piston 12011 58002 12012 58002 12013 58002 12015 58002 12016 58002 12017 58003 12018 58003 120 I 9 58003

12010 58022 12010 58023 12010 58024 12010 58025 12010 58026 12010 58027 12010 58028 12010 58029

12024 95960 12024 95960 12024 95960 12024 95960 12024 95960 12024 95960 12024 95960 12024 95960

50

Part Name

No

Remark

Set piston

pin std

12010 58022 12011 58002 12024 95960

For

use

with

piston
Pin piston

combined oil ring bolt locking type con rod

23

Part Name Set conrod

w

Part No 12130 58002 12100 58000

Remark

lOOsh

Ass y conrod

Rod connecting Washer spring Bolt hex

12104 58000
9 15116 I 34632 12106 58000 12109 58000 9 11246 12112 58000 12lll 58001 12024 95960 12028 95960 12025 95960 12026 95960 Service spare parts

Cap

ccmrod Bolt ccmrod Nut hex Palnut Bush ccmrod std Pin piston std Pin piston O S Pin piston O S Pin piston O S 0 06 mm O 12 mm 0 25
mm

Fig

II II I

I I
0
N

i l

f
Fig
2

8R
mm

74 68 74 42

Fig

24

2 2
Interchangeability
New
coo

rod
con

can

be used with former type

can

piston pin
Former rod
not be used with tbe new

piston pin

Applied Applied

model from

All P engine E E E P 32473 for 680 series Except Fire P 32423 for 60 series PF 2686 for all P type fire engine NEW CON ROD
20 618 20 630
mm

Engine

Fig
Part Name Set piston Piston Pin pistoo
w

New No 12010 58100 12011 58100 12024 58000

Remark For
use

pin std

with

combined 011 ring ill press fit type

con

roo

e e
r

J
0

roC

iil

Applied Applied

model from

All P engine E P 31592

74

68

mm

74 42

Fig

25

Part Name

Part No 12130 58003 12100 58001 1210458001 Ncne None

Set

con w

Ibush
rod

Ass y

con

Rod connecting
Washer

spring
rod rod

Bolt hex

Cap
Bolt

con con

12106 58000 12109 58000 9 11246 12112 58000

Nut hex

Palnut Bush
Pin Pin Pin Pin
con

rod

std

12111 58001 12024 58000

piston std piston O S pistro O S piston O S

0 06 mm O 12 O 25
mm mm

12028 58000 12025 58000 12026 58000

For

Connecting

rod 12100 58001

Pistcn pin tight press fit type

Piston

Size STO o 12 0 25 0 50 O 15 1 00 I 25 1 50

Set piston
w

Pin piston 12024 58000 12024 58000 12024 58000 12024 58000 12024 58000 12024 58000 12024 58000 12024 58000

pin
12011 58002 12012 58002 12013 58002 1201558002 12016 58002

12010 58100 1201058101 12010 58102 12010 58103 12010 58104 12010 58105 12010 58106 12010 58101

12011 58003
120 18 58003 12019 58003

PISTON
Piston pins
are

tightly

fitted in the ccnnecting rods

shown in the It is advisable to use a special assembling tool NT 4245 oil on the outer the coat To ease engine 6 fitting light following figure surface of pin and inside of con rod pin hole before press in be When assembling with the special tool the end of the piston pin must 3mm 1 8 in out of the piston boss face so that the connecting

approximately rod is position

in the center of

piston pin

26

Pressure 1 5 3 5 ton

Piston Pin Cat Rod

Guide

Pin

Insert
must

Bushing Stopper

hold piston mly 00 the boss face Return spring

Base

Special TooI P Engine Pisten pin Fitting NT 4245

Fig
Inorder
to

avoid distortion of

the inner ribs snd the base of

groove depth is

slightly

Into the con rod modified and also the 011 ring pin slightly deepen for the newly adopted combined oil ring

piston during press fitting pin

boss is

T7

3 PISTON 2
All the

RING

AND

PISTON

PIN

compression rings are marked with the word Top cast in the upper side of When installing compression rings make sure the side marked ring Top is toward the top of the piston Piston rings are furnished in standard size as well as 0 005 0 010 0 020
O 030

O 040

O 050
fit new

O 060
into the bore

piston rings proceed as follows Slip the ring into the cylinder pressing it down about 2 inches with a piston This will square the ring in the cylinder Check the gap between the ends of the ring with a feeler gauge
This should be from 0 006 0 010 Top 2nd 8 oil 0 006
to to to

To

properly

0 015 0 015 O 012

0 25 0 IS

0 38 mm

0 30

mm

If the space between the ends of ring is less than 0 005 remove the ring and with a fine file dress the ends lfitil proper clearance is obtained Fit each ring

separately

Carefully
the

remove

piston
up

and

inspect

all particles of carbon from tbe faces of the ring grooves in the grooves for burrs or nicks that might cause the rings to

hang

DATA PISTON

Type
Material

Weight
Diameter of piston skirt Standard Over size O 12 Over size O 25 Over size O SO Over size 0 75 Over size I 00 Over size I25 Over size I SO
mm mm mm mm mm mm mm

Flat head invar steel strut Aluminum alloy Lo Ex 445 460 gr 15 692 16 226 85 650 85 699 85 775 85 824 85 900 85 949 86 150 86 199 86 400 86 499 86 6SO 86 699 86 900 86 949 87 1SO 87 199

oz

mm mm mm mm mm mm mm mm

3 3719 3 3739 in 3 3769 3 3788 in 3 3818 3 3837 in

3 3916 3 3935

in

3 4015 3 4034 in 3 4113 3 4132 in 3 4212 3 4231 in 3 4310 3 4329 in

Difference of major and minor diameter Width of ring groove

0 30 0 34

mm

0 012 0 0135 in

Compression
Oil

2 530 2 555 mm 4 765 4 790 mm

0 0996 0 1005 in

0 1876 0 1885

in

Depth of ring groove Compression

Oil
Distance from
to center

4 045 4 045

4 4

120 120

mm mm

0 0

1592 0 1692 in 1592 0 1692 in

piston pin hoie Clearance between cylinder wall and piston measured at skirt
of

the top of

53 25 53 35 0 031 0 049

mm

mm

0 0012 0 0019

in

28

Checking

of feeler gauge Diameter of piston pin hole Off set of piston pin hole

I 5 3 5 kg at 0 0025 in feeler gauge 20 650 20 663 mm 0 8130 0 8135 in I5 mm 0 059 in NDt tD exceed 15 gr Not tD exceed 5 gr
0

Weight Weight

difference of pistDn only difference of pistDn and

rod

0 5

DZ

connecting

assembly

5 DZ

PISTON

RING

Compression ring Compression ring

No No

I 2

Inner bevel type

chrome

plated

Taper type
Slotted scraper chrome plated O 12 0 25 O SO 0 75 I 00 1 25 1 50 mm 0 005 0 010 0 020 0 030 0 040 0 050 0 060 in 2 477 2 490 mm 0 0974 0 0980 in
4 72 4 74 mm
mm mm

Oil control ring Oversize rings available

Compression ring groove width Oil control ring groove width Compression ring width Oil control ring width
Tension

0 1858 0 1866 in

3 8 3 6 3 3 3 5

0 1496 0 1417 in 0 1299 0 1377 in

Compression
Oil control

No

I 2

CDmpressiDn No

I 45 1 7 5lcg 3 1967 3 8581 lb 1 6 1 9 kg 3 5274 4 1888 lb 2 1 6 kg 2 6455 3 5274 lb I

Ring Gap
CompressiDn CDmpression
Oil control
ND No I 2 0 25 0 40 mm O

0 0098 0 0157

in

15 0 30 mm O 15 0 30 mm

0 0039 0 0118 in 0 0059 0 0118 in

Ring

groove clearance
I 2 0 04 0 05 mm

Compression
Oil control

0 025 0 070

mm

0 0016 0 0020 in 0 001 0 003 in

PISTON

PIN

Diameter Standard Oversize available 0 062 Oversize available 0 125

mm mm

20 653 20 648 20 722 20 710 20 785 20 773 74 8 74 4 mm 74 68 74 42

mm

0 8131

0 8126 in

mm mm

0 8158 0 8153 in 0 8183 0 8178 in

Length
Fit

9448 2

mm

Thumb fit at 200C Press fit 1 5 3 5 metric

2 9291 in 2 929 in 9402 680F

ton

29

Slip
to

make sure that the

the outside of the ring into the groove and roll it entirely around the groove ring is free and does not bind in the groove at any point Proper clearance of the piston ring in it groove is very important and when fit
new

ting

rings

the

following

At the top ring a O 002 feeler 0 001 feeler should cause the ring to lock in the

groove
If a the

the O 002

clearance should be adhered to 0 015 should be very free but 0 003 At the second or oil control groove feeler should produce a light drag

of proper size is not available select one which fits slightly tight emery No I placed upon the flat plate Rub the lower side evenly sure the ring will not warp

ring
on

grind

ring

making

LOCATION OF

RING

GAP

The leakage of compression pressure is often caused from the improper location of ring gap in relocation to each other When assembling the rings locate the gap of first compression ring toward Front Direction the second ring at 1800 toward
Rear Direction of the

angle

engine

and the oil

ring

at same

directioo of first compression

ring

4 2
The engines from the number P 31592 are assembled with combined ring This ring compose of two side rails and a special spacer is designed to control the This flexible type which follows closely the sur quantity of oil up and blOW by gas face of the cylinder walls even when they are slightly out of round will perform better sealling
new

Side rail gap P Engine Side rail tension

0 2 0 8mm

Maker

3 5

kg

RIKVENT NIFLEX

RIKVENT

NIFLEX

Fig

30

Size

Make

fop

Set Piston Ring Second Oil 12033 58004 12033 58005

Remark

STO
STO

Niflex

From P 31592

Spare parts
Rikvent From P 31592

Spare
Over Size 0 12
0 0 12 N iflex Rikvent Niflex Rikvent

parts

12034 58002 12034 58003 12035 58002 12035 58003 12036 58002 12036 58003 12037 58002 12037 58003 12038 58002 12038 58003 1203958002 12039 58003 12040 58002 12040 58003

Spare parts only

25

0 25 0 50 0 50 0 75 0 75

Niflex
Rikvent Niflex Rikvent Niflex Rikvent N iflex Rikvent Niflex Rilevent

1 00 1 00
1 25 1 25

1 50 1 50

lnstructions for

lnstalling Combined Type Oil Ring

for Following instructions and illustrations are mainly for Rikvent but as rail for Rikvent the of it is the same as gap Niflex oil rings except positioo just

angle

450

Installing Spacer
lnstall spacer in bottom groove with spacer For easy installation hold gap over piston hoss one end of spacer in the groove and fit it gradually Make sure spacer ends around into the groove shown as below are butted properly

Top

Rail no right
or

Use either of the two steel rails

wrong side

Holding ends
Place Coil
one

of spacer with thumb end of rail on top side of spacer ends rail across ends and on around into the

groove

Botton Rail
lnstall remaining steel rail spacer with gap
on

lower side of

approximately

20 30 mm right of spacer ends

31

FiTUJI

I1Ulpection
assembly
to

Check final

make certain

Rails are not off spacer

Gaps of rails and spacer are nor lined straight Spacer assembly can be turned manually
ease

with

Spacer gap

is

directly

over

piston boss

Installing
cylinders

Pisto1Ul into

Cylinders
into

Use steel band tool for

installing pistons

For NifleJ Oil

Ring
so

Install two rails from spacer gap

that each gaps are 450

Fig

Lower Rail

Upper Rail Gap Spacer Gap

NlFLEX

Fig

5 2

CONNECTING

ROD

DATA

Material

Steel

forging

F SOO

Length center to cetner Big end housing width

200 199 9 mm 1 874 7 870 in 31 55 31 50 mm I 2422 I 2402 in 60 180 60 199

mm

Big

end

housing

diameter

2 3693

2 3700 in

Type
Overall length Outside diameter

Thinwall steel backed white metal 25 9 26 1 mm 1 0196 I0275 in 60 199 mm 2 3700 in

32

Thickness Standard Undersize available 0 25 mm 0 OlD in

O SO mm

1 508
1 633

1 SOOmm 1 625 mm

0 593

0 0590 in O 0640 in 0 0689 in

0 0738 in O 0787 in O 0025 in

0 0643 0 0692

0 020 in 0 030 in 0 040 in

clearance

1 758 1 883
2 008 O OlD

1 750 1 875 2 000

mm mm mm

0 75

mm

0 0741
0 0790

1 00 mm

Big end bearing

0 064 mm

0 0004

Connecting
clearance

rod side
O

IS

0 28
m

mm

0 0059

O OllO in

Tightening

torque of cap bolt

5 5 kg

40 ft lb

Every

time a
an

removed from

connecting rod

is

connecting rod is engine or a new being installed it

should be checked for

alignment

on a

connecting rod alignment fixture as shown in figure Place the piston pin in the eye of
the rod and

tighten the clamp screw connecting rod on the aligner arbor and tighten the con
Place the

necting rod bolts

bent or twist

If there is any
it With a bend

correct

install the piston and check the alignment as the illustration The maximum allowable limit of bend

ing

bar

Next

is 0 004 The bearing metal should have a good contacting surface over an area more than 70 of it Such a bearing
too

carnk

much clearances between the pin and big end of the connecting

rod will be found scored over the sur faces of the metal And in extrem
cases

the metal surfaces will even be cracked

tually

If the metal is
with new

so

much own

replace

bearings
Fig
10

Check connecting rod end clearance

between the upper half of the rod and the side of the crank

connecting pin with

feeler gauge Lock the The bolt

bore

connecting

rod bolts

nuts

by installing

new

pal

nuts

pal

nuts

must be installed with the open side of the nut coward the end of the

As a final and last checkto be sure that the

assembly will travel true with the check the clearance between the crank pin and connecting rod side This should not be less than 0 004 0 10 mm

33

tl 0
f
J

rEgE

GAlJ GE
0 15 028

t
1

Fig

11

ti

t f

i Fig
12

Inserting Piston
Insert
was

Connecting Rod
and

each

piston

connecting
F

rod

assembly

into the

cylinder
piston

from which in
is

taken

it is essential that the

mark on the boss of the

positioned

towards the engine front side The oil hole of big end of connecting red must be positioned and toward the of manifold the Compress the piston rings with inserting piston using tool and gently tap is clear of the piston bar the the wooden until the with end of the piston top of piston
unit

clamp

34

Now push the piston down the cylinder block IDUil the big end of the connecting rod just protrudes through the bottom of the cylinder bore then position upper half bearing shells

3S

SERVICE

NEWS

REFERENCE

NO DATE CONTENTS

OF SERVICE AND BULLETIN

JOURNAL

36

SECTION

CRANKSHAFT

Fig DATA CRANKSHAFT

Material

Special
With

steel

Construction
Diameter of main

forged

counter

forging weight
mm

journals
68 229
in

No No

68 204 69 275

2 6862 2 7283

6852

69 300
in

mm

2 7273

Out of round limit Crankpin diameter Out of round limit

Runout of crankshaft

Not to exceed 0 0125 mm 0 0005 in 57 ISO 57 131 mm 2 2500 2 2492 in Not

to

exceed 0 0125

mm

0 0005
003 in

in
at

Not to exceed 0 075 mm

center

bearing
0 0037 in O 006 in

Main

journal

clearance

Crankshaft end play float Shims available for above Pilot bearing hole diameter Pilot bearing length Number of teeth crankshaft gea

0 03 0 096 mm 0 0012 O 125 O ISO mm 0 005 0 07

O 13 0 76 mm 0 003 0 005 O 030 in 23 774 23 800 mm 0 9359 O 9370

in
mm

31 8 27 37

1 252 in

MAIN

BEARING Type
Number of

Thinwall steel backed white and clevite metal F500

bearings

Length
No
No 1

2
4 7

33 8 mm 1 3307 in White 26 mm 1 0236 in Clevite

41
mm

No No

1 6142 in

Clevite Clevite

49

mm

1 9291 in
mm

Outside diameter ltiside diameter No No

1

73 025

8749 in

68 283
in

68 299 69 371
mm

mm

2 6883
2 7304

2 6889 2 7311

No

69 355
in

mm

Thickness white metal Undersize available

O I
O 12

O 2

0 25

0 004 O 008 in 0 75 1 00 1 25 0 030 0 040

1 50 mm 0 005 O OW 0 020 O 050 O 060 in

Tightening
cap bolt

torque of

bearing
10
11

kg

J2

80 ft lb

38

3 1

DISASSEMBLING

OF

CRANKSHAFT

Fig

39

being removed check it carefully in the following order remedy any defect according to the requirements called for Measure the journal and crank pin with a micrometer and if they are oval shaped or tapered more than 0 002 or of the surface of journal or crank pin is dam aged correct those defects Support the No 1st and No 7th journals with V block
and

When the crankshaft is

Fig Apply
a

the shaft to

to sixth fifth fourth third and second journals if there is the deviaticn of more than 0 002 inch The belt shaft should he corrected with a press see

dial gauge

and rota

the

Support flange

and rotate the crankshaft same as the said way apply a dial guage to the part to connect the flywheel If the surface of flange is wabbling
or

more

than 0 001 0 025 mm have it fixed up When the journal or crank pin is worn flat

oval

or

if

they

are

scored

cut

or

rough
Clear

beyond the limit

0 004

or over

replace

it with a new one

out throughly the oil passage by blowing out wIth a compressed air Main bearing is manufactured to be easily removed with the crankshaft in place A void repeated use of old hearings Check throughly before it is installed

Such
scores

side

bearing as excessively worn out or making poor contact or having rough or hardened surfaces are to he replaced Carefully inspect the thrust part of the No I bearing and if there is any wear take up the wear by
a cuts

removing the shims

If the
wear

and washer

is

beyond

the

these shims

13 1000 in When replace these shims tap up the crank gear with a adapter and measure the clearance between the bearing back plate and the thrust washer and correct the clearance of it

the thrust washer and crankshaft side thrust clearance of O 004 0 007 replace 2 1000 in 6 1000 in

placed between

regular

40

Fig

41

Fig

42

2 REAR 3

BEARING

SEAL

This resr main bearing is sealed by a wick type seal installed in a groove To install a new wick seal at the rear main bearing machined in the block and cap cap
insert the

packing

in the groove with the

fingers

FIg
Then using
When
a

rounded tool
the

roll the packing into the groove

start at one end and roll the

rolling

packing

packing

to

the

center

of

the groove The above Then starting from the other end again roll toward the center bottom into the of the groove procedure insures that the wick is finnly pressed each end at wick which from the small of the groove The protrudes portion
cut flush with the surface of the bearing cap To prevent the possibility of pulling the wick out of the groove while cutting off the ends it is recommended that a round block of wood the same diameter as the be used to hold the packing firmly in position while the ends are crankshaft

should be

glange

being cut

off

of the wick seal it will If it should become necessary to replace the upper half be necessary to remove the engine from the chassis and remove the crank shaft is exactly the same The procedure for installing the wick in the cylinder block
as

for installing it in the bearing cap 1 2 3 Wash and clean the crankshaft and bearings

Apply marking compound lightly

over

each

journal

of crankshaft
the

Install upper and lower bearings in their crankshaft in the cylinder Rotate the crankshaft hack and forth the contacting condition of bearings

own

position and install

Remove the crankshaft and check

43

The upper half bearings have

its

to

make contact

evenly

and more than 70

of
a

contacting

area

If any insufficient contact is found

replace

it with

new

me

The lower half the area

bearings

also should be

making

contact

journal case replace

excessive clearance of the lower half makes it impossible to show the contacting condition with the lll1dersized

Sometimes

evenly over 70 bearings

of
to

the

in case of absolute necessity the clearance Re check the work until you are sure 7 After

Make shift repair bearing by filling off the cap and bearing to take up bearing fit after the above work Repeat the satisfactory fit is obtained cmdition

In such a can be made

appl y
8

checking the cmtacting engine oil plentifully

wipe

off

marking compound

and

the

Install the seventh bearing and cap and tighten with tighteness by rotating the crankshaft

regular force

Check

10

11

80 72

ft lb

Fig

Tightening
bearing

Torque of Main Bearing Cap Bolt

Proceed

to

the next

in the same manner

and have all the

bearings

adjusted
10 If bearing fit is properly adjusted rotated by grasping No 2 and No
on

all

journals

the crankshaft can be

or

5 crank pins

No

3 and No

4 crank

pins
II

with a

slight starting

but without any resistance after started be sure to lock the cap bolts with torque

After above work is rench with the scale

completed

44

SERV

NEWS

REFERENCE

NO DATE CONTENTS

OF SERVICE AND BULLETIN

JOURNAL

45

SERVICE

NEWS

REFERENCE

NO DATE CONTENTS

OF SERVICE AND BULLETIN

JOURNAL

46

SECTION
CAMSH
FT

4
VALVE TIMING
Bracket bolt Set
screw

TAPPET

Adjusting
screw

Rocker shaft cliP

WaSher

Rocker shaft bracket A Rocker shaft bracket B

Lock

nut

2
Bush

f
o 0

fl Valve cotter
13209 Valve

o Valve
retainer

i
Pu

Valve rocker Right side Valve rocker Left side h

r

Outside spring

L ExpansIOn plug

58000

spnng

ii

Valve

IS
Intake Ex

ad

Exhaust

Timing gear

Thrust washer 9

r
70 1518

V81vedr ilO
27319 13006 58000 13005 58000 Oil pwnp drive gear

70 1519

@ J

Carn

shaft bearmg

A
1

8 I

5800J

Figo

Camshaft

Valve

Lifter

Fig

47

Fig

DATA CAMSHAFT

Material

Special
49 149 48 945 48 641 48 336 41 246
cam

steel

forging
1 9349

Journal
No No No No Cam
1

diameter

49 124

mm

1 9339in 1 9260 in 1 9140 in

1

2 3
4

48 920Iilm 48 616
mm

1 9270
I 9150

48 311mm
mm

1 9030

9020 in

height
offset

1 6238 in O 1220in

Fuel pump

3 00

3 IOmm 0 1181

Runout of camshaft Drive Cam gear number of teeth

Not to exceed O 025mm 0 001 in Helical gear 54 O

Bearing clearance
Bacldash of camshaft gear and
crank gear

Ql

O 10

mm

0 0004

0 004 in

O 1

O IS

mm

limit of

use

O 25

mm

48

CAMSHAFT

BEARINGS
steel backed white metal

Type
Frcnt

Thinwall

bearing before fitting

reamed in 49 303 29 49
52 476

Out dia

52 555

52 530

mm

2 0690
1 9410 1610

2 0680 in

Inside dia

position

49 238 29 24

mm

1 9384 in

Length
Housing diameter
Second bearing Outside dia
Ins ide ma

mm

1 1511 in
2 0684 in

52 541

mm

2 0659

before fitting
reamed in

62 375

52 3SO

mm

2 0619

2 0609in

position

49 123 19 0

49 058

mm

1 9339

1 9313 in

Length
Housing diameter
Third bearing Outside dia Inside dia

mm

0 748

in
mm

52 273

52 248

2 0579

0569 In

before fitting
reamed in

52 070

52 045

mm

2 0500

0489in

position

48 818 19
mm

48 753

mm

1 9220

1 9194 in

Length
Housing diameter
Rear

0 748

in
mm

51 740

51 943

2 0370

2 04SO in

bearing before
51 740 reamed in 48 488 31 8 48 423
mm

Outside dia

fitting
Inside ma position

51 715

mm

2 0370

2 0360 in

1 9090

1 9064 in

Length
Housing diameter
Undersize available

mm

1 2519in
mm

51 664 0 25 O SO

51 638

2 034

2 033 in

mm mm

0 0098

in

0 0197 in

VALVES

Timing
Inlet opens Inlet closes Exhaust opens Exhaust closes Head diameter inlet valve Head diameter exhaust valve 140B T D C SOo A B D C 520 B B D C 120 A T D C 43
mm

36 2

mm

1 692 In 1 425 in

49

Seat

angle
45 14
1 8 mm
use

Inlet and exhaust Seat width

inlet and exhaust

0 055 in 3 32 in

O 071 in

Limit of Stern diameter Inlet Exhaust 8 650

8 and exhaust

8 637

mm

0 3405 0 3401

0 3400in 0 3396in

640

8 627 mm
mm

Length inlet
Lift

131 5 9 6

1772 in

overall

mm

0 378 in 0 016 in

Working clearance

0 38

O 40mm 0 015 Water tamp 80 C

VALVE

GUIDES

Length
Inlet exhaust 72
mm

8346 in

Outside diameter Inside diameter Hole for valve

15 048 8 685

15 030 mm 8 700 mm

0 5923

0 3916 in

0 3419

O 3425 in 0 5912 in

guide

diameter

15 000 0 035 0 045

15 018 0 063 0 073

mm

0 5905

Valve stern clearance inlet Valve stem clearance exhaust

mm mm

0 0013 0 0017

0 0024 in 0 0028 in

VALVE

SPRINGS
2 2638 in

Free

length length
and load

57 5 49 5

mm

Fitted

mm at

23 5 kg

1 9488 in

at

52 lb Number of working coils Diameter of coil wire Core diameter 5 3 4

turns

4 5

mm

0 1771

in

33 5

33 Omm

1 3189

1 2992 in

TAPPETS
Hollow barrel 23 990
in

Type
Diameter

23 W5
2

mm

0 9445

O 9438

Length

55

mm

1653 in

50

ROCKER

MECHANISM

Push rods

Length
Stem diameter Rocker shaft

388

mm mm

7 15

0 2815

in

Length
Outside diameter

641 mm 25 24 in 20 000 19 971 mm

in

0 7874

0 7862

Rocker

arm

bushing
Rolled 23 45 reamed in 20 020 20 033
mm

Type
Outside diameter InBi de diameter

phosphorus
23 43
mm

bronze bushing 0 9232 in O 9244 In 0 7882 0 7887 in

position
Inside diameter before reamed Clearance between shaft and
bush

19 98

19 93

mm

0 7865

O 7846 in

O 02
arm

O 054

mm

0 0008

O 0021 in

Rocker Bore

22 40 1 47 I

22 37

mm

0 8818

0 8807 in

Lever ratio

Tightening
B

K T

torque of rocker boit

4 3

5 0 kgm

4 1

REMOVAL
cooling

OF
water

CYLINDER

HEAD
drain

Drain the

by opening the radiator and cylinder block side

taps Disconnect the radiator hose Remove the air cleaner carburetor manifolds Detach

rocker cover and the inlet and exhaust

high tension cables and remove the spark Remove the rocker cover and the corle washer Detach the manifold assembly
Talee off the rocleer
time
same

plugs

assembly for getting to sladen the cylinder head bolts Withdraw the push rods Keeping them in the order of removal The cylinder head can now be lifted from the cylinder blocle
To facilitate

at

detaching

the

cylinder

head joint

tap each side of the

cylinder

head

51

III1IIIIIIII

Fig

REMOVAL

OF

VALVES
out

After the cylinder head is removed the valves can be take To do this compress the valve spring with the valve Remove the
cotters

spring compressor
Withdraw the

of valve retainer retainer and oil seal from stem

Release the valve spring valves from the guide

3 4
place

REPLACEMENT
are

The diameter of exhaust valve head

the valves insert each valve into its retainer and compress the valve spring

smaller than the inlet valve To re and the oil seals replace guide spring

Refit the valve cotters and Remove the compressor

secure

them by

releasing

the compressor

4 VALVE

GRINDING

Before replacement of the cylinder head the valves and their seats should be examined for signs of pitting or burnt platches and distortion If these conditions are present the valve seats must be recut before attempting to grinding the valves wilst distorted valve head should be corrected or the valve renewed

Only

the minimum amount of metal should be removed in the

trueing process

52

When

grinding

valve

on to

its

the valve face should be smeared lightly with grinding paste

sealing

and then lapped in with grinding tool The valve

seat must

suction type
to

be

ground

its A

with a semi

rotary

motion

light coil spring interposed

between

the valve head and the port will assist considerably when lifting the valve in

order

to rotate

the face to a different

position
This should be done

spread

the

frequently to grinding compound evenly

an even matt

It is necessary to continue the

grinding

process until

surface is

produced

on

the

seating

and

the valve face On completioo the valve seats and ports should be throughly cleaned with gasoline soaked rag and dried
and the

subjected

to a

compressed

air

blast
The valves should be washed in

gasoline and all traces of grinding compound removed

Fig

5 4

REFITTING

THE

CYLINDER

HEAD

Fig

53

joint faces

Ensure that the cylinder head and cylinder block are clean The cylinder head gasket is TOP
so

marked upper face head in correctly head

that it will be placed

Place the gasket into positioo and fit the cylinder

securing bolts finger tight They screw into cylinder block at the front and rear bolts holes on the manifold side and guide the head into positicm Insert the push rods replacing them in the posi tions from which they were taken Screw back all
the tappet

adjusting

screws

Replace the rocker assembly and screw down the securing nuts finger tight Evenly tighten the cylin
der head bolts

diagcmally
them down

from the center to out side

a

finally pulling
ft lb

torque wrench

set

55

65

Reset the valve clearances and finally check engine not so hot or cold The cylin der head bolts may pull down slightly more after the
them when the

engine has

attained its normal

working temperature
un

in which case the valve clearance will have to be

checked again and

at

reset

if necessary 0 38 0 40

60oC

Fig

6 4

TIMING

GEAR

CAMSHAFT

If there is an excessive amount

of end

play

in the camshaft

it is

necessary to remove the gear and camshaft assembly and correct the falts When the camshaft and gear are assembled to the engine it is im portant that the punch marks on both the camshaft and crankshaft gear must be fitted as 7 The cam shaft will then be in its proper posi tion so that the valves will open and
close in the proper relation to the
movement

Fig

of the position

After the camshaft and crank shaft gears are in their proper places check the crankshaft timing gear for run out with a dial indica tor This should not exceed O 15mm Then check backlash of the camshaft This should not exceed gear O 25 mm

Fig
54

SERVICE

NEWS

REFERENCE

NO DATE CONTENTS

OF SERVICE AND BULLETIN

JOURNAL

55

SERV

NEWS

REFERENCE

NO DATE CONTENTS

OF SERVICE AND BULLETIN

JOURNAL

56

SECTION 5
MANIFOLD
5 1

REMOVAL
assembly
from

Remove intake and exhaust manifolds

cylinder head

These manifolds are held together at the center bos by the stud bolts After removal wash and clean both intake and exhaust manifolds
16174 58000
11

194

oft

14628
2

Q
14518

11638 1 9 15116
1

31628

14020 58000 70 1956 14006 58000 9

11 16110

9 11140 1

Fig

2 INSPECTION 5
flanges must be all em the same plane Inspect manifolds by placing flanges on a flat surface If it is found warped resurface on surface cutting equipment
Manifold their Also check for cracks and lr eakages and replace if defective for warpage

HEAT
This
a

CONTROL

ASSEMBLY

deflects a parts of the hot exhaust gas to and around the intake Heat control has a thermostatic valve and facilitates fuel evaporation the action above spring controling automatically If this spring is worn replace it Gaskets between intake and When installing manifolds place new gaskets manifolds head and manifold assembly exhaust and between cylinder

assembly

manifold by

gasket

57

SERV

NEWS

REFERENCE

NO DATE CONTENTS

OF SERVICE AND BULLETIN

JOURNAL

58

SECTION

6
SYSTEM

LUBRICATION

Fig

Oil Pump Assembly

Relief valve Oil pump body Shaft Drive gear Drive shaft pin Bottom pump cover 1 11412 9 15114

Fig

Components of Oil Pump

59

the engine oil forced out by the oil pump Is ramified circulating through crank shaft main bearings cem bearings lappet valve rocker arm and other lubricating by connecting rod splshes the postons and cylinder walls The oil regulator is instrument to adjust the pressure of oil so as to keep il at specified This adjustment can be done by either increasing or de pressure

As

showing

in

Fig

into two series and the one necting rods camshaft

creasing

the number of pressure

adjusting

washers

6 1

ADJUSTMENT

OF

OIL

REGULA TOR
the connecter of

Remove the
The oil

fixing bolts of the pump body at regulstor is attached directly to the

4 0

driving spindle

oil pump

Oil pressure should he kept 3 5

kg

em

JJ

Fig

Lubrication

of Engine

Fig

Disconnect Oil Pump from the Block

regulator valve into the oil pump body and measure the clearance A hetween end of valve and Slop pin This clearance between the end of valve where spring cOlltact should be 18 mm Fig
5

Insert

60

18mm

Pump body

Oil

Regulalor

valve

Fig

Setting the Stop

Pin

61

RELIEF

VALVE

SPRING

Free

Valve

Length of Spring
mm

Length
30 3

when

Compressive
Load

fitted
mm

Thickness of Adjusting Washer

41 5

2 24 kg

Immand2mm 0 040 O 080 in

After

following

the above points calculate thickness of the the equatioo below and assemble it Thickness of adjusting washer A t 18 mm 30 3 mm

inspecting

adjusting

washer

DATA
OIL

PUMP

Type

of gear Number of teeth Gear diameter

Spur
8 39 40 39 35 mm 1 5511 1 5492 in 29 960 29 935 mm 1 1795 1 1785in 3 18 3 23 mm 0 1251 O 1271 In

Gear

length

Knock pin diameter Oil pump shaft Diameter

12 TI6 190 2 0 025 If

12 958 189 8

mm

0 5108

0 51011n

Length
Gear back lash

mm

7 4882
0 001

7 4724 In 0 003 In

over

0 1175 mm O 008 in O 115 O 260

mm mm

Replace 0 0016 0 006

O 0045 In O 010 in

Gear vertical clearance Gear in Oil Oil

0 040 O ISO

body

clearance

regulator regulator

Built in pump Min 0 5

body
cm

kg

7 lb

in

at

running

speed
Measurement of oil pressure

regulator
Pressure of

regulator spring

2 24

kg

30 3

mm

high
If
over

Clearance between pistem and and body Pressure

O 002

O 0025 in

0 005 in

Replace

Running Idling Sump capacity

Oil

3 5 0 5

4 0

kg

em

SO

57 lb sq in
in
at

kg

cm

7 lb sq

oil temp

70 SOoC 5 3 litres 1 4 gal U S A S A E MS No 20

For temperature
No 30

above 300C MS

62

Check the clearance between the drive gear and bump body The clearance should be O ISO O 260 mm If this clearance or others which showed in the series data should too much over replace the gear with a new part depending em whichever may be the cause of the
excessive clearance

6 2

OIL

FILTER

The oil filter is mounted on the left side ci the engine As for the oil filter which serves to filter of engine oil within the oil pan Is of the full flow type using the paper elements This elements should be taken out for periodical check and

cleaning
For

disassembling

unscrew

the

shaft at the cap bolt of the center of filter after draining oil top body from drain plug The filter element should be changed at each 4 000 miles or at shorter intervals if the oil get dirty socmer In assembling be sure the

tightening
new

bolts
and
to

tightl y
gasket
of

in

place and
used if

packing
The

are

considered

leak the oil

capacity

engine oil should

be checked every

day

the oil level gauge

right

The oil capacity is measured by vided at the pr side of cylinder The oil level

kept between the upper and lower lines of the gauge Change engine oil every I SOO iniles in its of oil degree of viscosity Select a good quality
must be

Fig

63

Relief valve

Out let hole

In let hol

Drain

PIug ft1
Fig
7

Sectional view of oil filter

tightening

torque Center bolt 2 Relief valve 7 5

kg m opening pressure

2 5

0 6

kg

cm

64

SERV

NEWS

REFERE

CE

NO DATE CONTENTS

OF SERVICE AND BULLETIN

JOURNAL

65

SERV

NEWS

REFERENCE

NO DATE CONTENTS

OF SERVICE AND BULLETIN

JOURNAL

66

SECTION
COOLING

7 SYSTEM
2 3

Radiator Fan Thermostat Water pump

2 3 4 S 6

Cylinder

head

Cylinder block

Fig

7 1

WATER

PUMP

FAN

FAN
I 15

BELT
14 11

16

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Water pump body Cover Vane and shaft BSS Y

Pulley
Seal retainer spring Seal retainer Rubber seal

B8 kelite

seal

Vane soap ring Water pump shaft bearing 5

Bearing spacer Front seal plate Rear seal plate Felt cover plate
Felt seal Shim snap ring Lubricator fitting

Beailng

10

17

Fig

Sectional View of Water Pump

67

DATA

Water pump type

Centrifugal
1 28
4
to

Pulley

ratio

Fan blade

Number Diameter Thickness Fan belt

476

mm

18 7 In

1 6mm

Type

V
outer

Lengtb

Angle of V 40 degrees 1175 1181 mm 46 250 46 500 in

mm

Deflection

tensioo

adjustment

25

1 in

Fig

2 7
In

REPAIR OF
case

WATER

PUMP

of troubles in the water pump such as water leakage worn or burnt ball remove the unit to repair It is better to remove the bearings radiator before the water pump is displaced
of the pump shaft

Disa88emblll
1 2 3
4

of Water

Pump
water

Remove fan blade from the

pump

Move the generator toward the engine after generator and take off the fan belt

pulley removing the eight loosening bolts holding

screws

the

Remove the

by pass rubber hose at water outlet spacer Remove three bolts which hold the water pump body to the

cylinder

block

68

Draw

out

cotter

pin

in the castle nut on the pump shaft and remove nut and

washer 6 7

Pull

out pump

pulley from

the shaft

using a puller

and

remove

8 9

fastening water pump cover to its body and displace the and gasket Take OUt vane from bearings in pump body assembly As a rule this ope ratiem is to he done with the use of press When the hammer is used in stead never fail to use a copper hammer and tap the end of shaft lightly If other wise you are likely to bend the shaft or damage the screw threads Now the vane assembly will Come off from pump body together With five accessorieB such as seal retainer spring seal retainer rubber seal bake lite seal and vane anap ring Remove the vane snap ring first and the seal retainer seal retainer
cover

woodruff key Remove four bolts

spring

rubber seal and bakelite seal are removed from the vane assembly In case shaft bearing or felt seals is in bad shape remove shaft bearing snap ring and take out the front seal plate washer shim shaft

bearing spacer
pump

rear

seal plate

bearing

felt

Ner C

plate and felt seal from

washer

body
of Water

Auemblg

Pump
having finished
necessary repair works However the follOWing

In order to assemble tIle parts after

invert the order of disassembling work mentiooed above care is to be taken in handling

Put the vane assembly with the shaft pointing upward Grease the shaft lightly and insert the seal retainer spring so that the smaller diameter comes to the bottOm of the shaft

Fig
69

See that the rubber seal fits on the shafl with proper tighteness
mined
em

fi tt

1Sj VI

t
I

il
if

The proper tighteness is deter by the rubber seal sliding the shaft when

pushed lightly
the vane

with

fingers

After

having assembled
water

tg

assembly with
i
e

seal system

seal retainer

spring

seal

retainer

rubber seal

bakelite

check snap ring whether the unit is In proper The unit is in working order good shape If the bakelite seal
vane

seal

snaps back to its proper place when depressed with a thumb and freed If the seal does not return

ff
t
i

instantly
tainer

and without
or too

drag

it i

due to weakness of the seal re

spring

tight fitting
C

of the rubber seal Remove such a seal and inspect the bore of the seal and if found blamable for

ff
fo

fitting rebore Until it properly On the cemtrary

stiff
cause

fits
if the

is found in weak seal re it with a

tainer
new

spring replace spring

0 A Wi

Jii
F

Yc

r t

j
r

In order to assemble shaft first insert the bearing etc

vane

Fig

assembly

to

the pump

body

set it to the shaft

together with felt

spacer

stall the shaft

bearing

Cover the felt seal with sufficient grease and cover plate and rear seal plate Then in shim washer front seal plate and snap spring

to F Jt
2 f

4
Jiil

t
Fig
6

l
r

1 f1
70

1 r

In fastening the cover 10 the pump body with four SCrews proceed as for two screws in the follows upper middle use spring washers for the one positioned lower left facing toward the pump use a copper washer and for the fourth SCrew in the lower right use a shake proof washer All of
them have to be screwed up is thaI it prevents water

tightly The reason for using the copper washer leaking through the screw hole After installing the cover on pump body put the woodruff key em the shaft and fix water pump pulley Examine turning the pulley if the vane assembly
runs

smoothly

the pump always use new gaskets for cover and body Better result would be obtained if the new gaskets are coated with shallac or white lead before they are replaced for keeping water tight effect

In

assembling

Water

Pump

Troubles and Remedies

waler

Ordinary
noises

troubles in the

pump are water

leakage

vibration

wabbling

and

I
a

Causes of waler

leakage
shape

Rubber seal in bad

b
c

Bakelite seal in bad shape Retainer spring fatigued Friction surfaces of pump body and bakelile seal
worn

d
e

Body

or cover

f Wrong g
h

Wrong
Worn

in poor shape or loose screws of the pump cover or loose screws of the pump body

gasket

vane

shaft bearings

or

bent shaft

Anyone
have
to

of the above will cause water

screws

be

replaced and loose

leakage
2
a

The wear of the friction

leakage and damaged or worn out parts tightened up in order to SlOP the surface of the pump body can be reground
have to be noises

Causes of vibration Worn

or

wabbling and

burnt ball bearing

b
c

Bent vane assembly shaft Loose pump body screws

Of the above burnt ball bearing is caused from poor Replace it with a new one and feed grease sufficiently

supply of oil through lubricator

to

fit

ting

in the pump

body
water

Periodical supply of chassis grease to kilometre run

pump is

be made for each 1 000

A4justmellt

of Fan Belt

The tensiem of fan belt is to be adjusted so that the belt has 1 2 3 4 inch free movement as illustrated in Fig 7 To make the adjustment Loosen No 1 bolt first and next No 2 Move the generator and push the belt with a hand so that there is a free movement of 25 mtl
on

the bolt
to

belt

wear

adjusted too loose it would make the fan and generator as well as premature of the slip resulting performancl of the belt and the overheating of engine in summer If it is held too tight
If the belt is
in

Fasten the bolts

bearing

would be

damaged

71

Fig

Adjustment of Fan Belt

RADIATOR

THERMOSTAT a HEAT INDICATOR

DATA RADIA TOR

Type
Pressurized

Water tube

Cooling

water

capacity

pressure type 0 4 0 5 kg cm2 5 7 7 lb sq in Model 680 4W73 60 16 ltr 16 ltr 17 5 ltr

4 227 U S Gal

4 6 U S GaI

THERMOSTAT

Type
Temperature to start open Temperature full open

Pellet 71 50 86 50

74 50C 89 50C

1600
1870

l660F 1930P

REPAIR OF
1

RADIATOR of

Cleaning
Neglect
impure

Cooling System

of the cleaning of radiator for a long while or use of improper or for cooling purpose bring forth the overheating as formation of rust and sedlment in radiator and water pump will result in poor water circulalion To clean the radiator proceed as follows
wster

Drain the radiator

cooling

water

by opening

the drain cock at the bottom of tbe

at

Loosen the clamps of radiator inlet hose and the outlet hose of radiator and disconnect them from the engine

the sides

72

Plug

using a wootl block clamp

4

up the Inlet hose opening that connects with cylinder water outlet of proper diameter and securing it in place with the

Remove the radialor filler cap and pour in pure water letting it to run out freely from the outlet hose The cylinder Water jacket is cleaned in the same manner as for radiator Clean water is poured in from the cyllnder water outlet ilnd drained from the radiator outlet hose When the water tubes of radiator Core are clog ged and cause overheating remove the radiator from the chassis to clean
First remove radiator from the chassis

6 7 8

up the outlet port of radiator tubes

Plug

at

the bottom of radiator and fill

water

up to the top

Heat the soldered that

seam

they

are

separated

of radiator core and upper tank With a burner so Never heat the soldered when the radiator sean

Is empty

If other wlse

the heat will melt away the soldered parts of the

radiator tubes and will 9

cause

leakage

Scrape off completly

a

impurities in the water tubes with thin stick and flash the insides of water tube and lower tank with clean

the scales and other

waler

10

After Care

finishing

the above operation

assemble the

core

and upper tank by

soldering
must be taken to make the connections stremg enough to withstand vibrations of the vehicle in leakage by motioo and to prevent it from be

caning leaky 2 Pressure Test of Radiator

After disassembling and cleaning of a radiator test it by water pressure of than 5 pounds per square inch to locate any leaky spot As even a little leakage will cause overheating while running the leaks must be repaired by sold
more

ering 3 The
1

Cooling

Water
must be filled

Cooling water
radiator Hard water

always up

to

the overflow pipe at the top of

use

or water

cootaining

alkali substance is to be avoided for

of

cooling

water

Such water liable to form scale or sedimenls and will cause poor circu latioo of cooling water with the result of an overheating 3 After an inevitable use of improper waler fill up the system with solutiem of two pounds washing soda and four gal1ems of warm water and make the solution circulate the system by running the engine at low speed for twenty or thirty minutes Then open the drain cocks locsted at the right of en of the cylinder block and the radiator to drain the whole solution To gine l ave no drops of the solutiem within the system clean the radiator with

flashing
Care

water three or four times

must

the time of

not to let color would be affected 4

filling up the cooling system with soda solutiem or at overflowing due to boiling of the solution in circulation so as the liquid splash over the painted parts as otherwise the paint

be taken In

When the engine has been overheated and old water is introuduced in the system cylinder block or cylinder head is liable to crack or warp

73

So 5

keep

the

engine

is

stopped before feeding cold

water

it will not circu

and will have undesirable effect the cold winter or whenever is liable to freeze During waler from the radiator and engine
water

late the

never

fail

to

drain
the

Be

sure to

rear

right

open both drain cocks at the bottom of the radiator and side of the engine to completely drain the water

at

74

SERvreE

NEWS

REFERENCE

NO DATE CONTENTS

OF SERVICE AND BULLETIN

JOURNAL

75

SERV

NEWS

REFERENCE

NO DATE CONTENTS

OF SERVICE AND BULLETIN

JOURNAL

76

SECTION
FUEL
8 1

SYSTEM
PUMP

FUEL

4 1

Upper body
Valve retainer

2 3 4 S 6
I

Cap

Diaphragm
Valve Coonector Rocker ann Rocker arm spring Rocker arm pin Lever Hand primer pin

7 8
q

14

to 11 12 13
14

Packing cap Diaphragm spring Lower body

Valve

15 16

Diaphragm

Fig DATA

Fuel Pump

Type Diaphragm spring Free length Fitted length I tload

Rocker
arm

Mechanical 60 4 22
21

diaphragm
mm

pump

61 6 23 lb 30 5

mm at

9 5

2 3779 2 4251 in 10 5 kg 0 8661 in at

spring
29 5
mm

Free length Valve spring Free

1 1614 in

1 2007 in

length

7 05 15

l5mm

0 2776

0 2815 in

Valve thickness

mm

0 590 in

Performance Max output 2 8 litres min or over 0 74 gal USA cam 1000 rpm suction height 600 mm 23 6 in 220 400 250
mm

Max
Max

outlet pressure suction vacuum

hg
mm

66

9 84 in

hg

15 7 in

hg

or over

Hand primer output

Approximate
10 strokes

200

cc

12 2

cu

in

77

2 REPAIR 8
1

OF

FUEL

PUMP

Measurement of Rocker Arm

Before disassembling the fJlel pump measure lhe gap between the rocker arm and the flange of lower body with a square and a scale as illustrated in Fig snd check lhe wear of rocker arm rocker link and pin be 1 9 64 When the play of the arm is taken up the above mentioned gap should and hecause the arm link rocker pin inch and if found less than this il is The gap measurement is excessively worn and therefore it needs remedy ward the body until the resistance of diaphragm delermined by pushing the arm clearsnce spring is felt as well as the rocker arm and the rocker link leave no al the shaft of diaphragm
are

Fig 2

Construction

of Fuel Pump

and Measurement of Rocker Arm Wear

Inspection

of Ports

air before Wash and clean the parts wilh gasoline and blow tith compressed attended items should be Undermentioned specially making the inspeclion 1

Whether

or

not

gasoline

is

infillrating

due to the wear or

damage of

dia

phragm
2

Whether

phragm
3

there is any crack or wear in the shaft and link

or not or

connecting part
arm cam

of dia

Whether
are worn

not lhe

conlacting surfaces

at

rocker

and the link

78

4 5

Whether or not locker arm and diaphragm shaft are worn or cracked Whether or not diaphragm spring arm spring and valve spring are fatigued Whether or not there is wear or deformation in valve and seat

Troubles
1

COllses

and Repairs
of

Poor fuel supply This will happen when gasoline leaks

due

to

crack

damage

or

fatigue

Replace a new diaphragm diaphragm spring is fatigued or broken The regular height of spring are one inch placed for outer spring Any spring of less height has to
disphragm
In
case

of

a new one must

be re

for inner be

and two inch

replaced

3
4 5

In case fuel or air leaks

If this does
In case the

through cap gasket not stop the leakage gasket is to be replaced wash it with gasoline screen is clogged with dusts
and valve

check csp bolts for tighteness

place

check if valve is bent and re In csse there is leak in inlet or outlet valve with a new one if necessary Allowable limil of bend is 0 001 inch
eat are

When the conlact surfaces of valve

remove

found in poor condition

The the oUllet valve seat and polish the face with a fine oil sleme Therefore to amend the sur inlet valve seat is not removable from body When the surface of valve is face of valve seat use a cutter and grinder
not

smooth

polish

the valve

lightly

em a

glass plate

compound limit replace Standard height of valve spring is 7 05 7 15 mm and if it is found extremely fatigued replaced with new spring In case there is an extreme amount of play at the contact surface of rocker or when rocker arm pin hole is worn too much replace arm and camshaft
the arm with
a

Slandard thickness of valve is 1 16 inch

coated with fine emery If worn beyond the

new one

and remove the dia To correct the above condition disassemble the body of between lhe lower Inslall a packing thick paper body and dia phragm and raise the relative positiem of diaphragm shaft with the lower

phragm body
7
arm

part the surface with file

In case the contact surface of rocker arm and rocker link is worn replace the But for a makeshift repair emboss the link at the and link altogether means of where it contacls the arm welding and then finish

by

exygen
can

Also in 4

simpler repair

be done

by using paper

dia

phragm
8 9

as

explained

In case the contact part of diaphragm shafl and rocker link is worn out re place the diaphragm assembly broken or bent replace free of is fatigued In case the rocker arm

spring

spring 4

is 29 5

30 5

mm

Over Flow of Gasoline from Carburetor

I it In case spring pressure of diaphragm is tampered and made too strong Don t monkey will happen that gasoline overflows from the float chamber with the pressure of locker arm spring be sure to use the flange In case fuel pump is installed on cylinder block The failure of installing the gasket is sure to cause overflow

gasket

gasoline leaks damaged or worn out

In case

the cause will either the

diaphragm

is cracked

Replace

it with a new one

If the ventilation hole of the lower

body

is

clogged

with dirts oil

gasoline will

leak into the engine oil pan

resulting

in diluted

engine

79

5 Attention for
I

Assembling

the

Pump

2 3
4

spring pressure of valve diaphragm and locker arm by com pressing or expanding When setting the Inlet and outlel valves in the upper body as well as valve seats and gaskets be sure the valves seat snugly in place Always use a new cap gasket in the upper body
After

Don t tamper the

assembling

valve action is not

spring
seats

tight conditw and free actiw of valve If the il is due to the poor fitting of valve valve spring and To obtain air tight valves holder they must seat snugly In the valve and the springs should not be bent
good
the upper and lower bodies line up screw holes of upper and diaphragm Push rocker arm toward the body so that the dia is at the bottom of its slroke Then tighten the body screws

check the air

In

assembling

lower body and

phragm

it sure that the

making
will

diaphragm
move

does

not

wrinkle

alemg

its

help diaphragm 6

up and down

freely

and insure

edge a long

This life

care

Inspection
When the

assembling

is finished

the

following

items are to be checked before

installing
1

The distance from the rocker arm to the flange of lower body is Set a vacuum gauge in the inlet port of lhe upper Operate the rocker y arm with hand three or four times to its full stroke The gauge should show 450mm hg vacuum and keep it for more than three seconds To check the pump without gauges choke the inlet and outlet ports with fingers and push
lhe rocker arm After about three seconds let go the finger from inlet Also leI go the finger from outlet port after about five seconds If a strong suction sound is heard in the former and If a strong blow out sound is heard in thlatter case you can assume lhe pump is in good working shape After the pump has been installed to the engine

port

Connect the

on the side of Inlet port leaving intact the pipe em Rotate the engine six or seven turns with the crank handle and see If gasoline flows out from the outlet port Connect the gasoline pipe to the outlet port and tighten up connections Run

gasoline pipe

the outlet side

the

engine idling

and check ccmnectims if they

are

fuel and air tight

3 CARBURETOR 8
The carburetor used is the Hitachi Model VC 42 and is of lhe down draft type It is equipped with a boOSl type power system and the main carburetting system consisting of a triple venturi and an air ventilation pipe a low speed carburetting system
burelor functions The pislon lype accelerating pump and a fuel economizer system appropriately for each of the various conditions of starting medium speed high speed and accelerating
a car

idling

80

DATA

Type

Hilachi VC42 IA for Model 680 VC42 4 for Model 4W73 and 60 series VC42 5A FR40 Downdraft
linked

throttle and choke valve

Throat diameler Venturi diameter Main jet

Main air bleed Slow

42 mm I6535 in 36 x 17 x 10 mm I417 in 0 393 in

No

669 in

143 for Model 680 Model 4W73 and 60 70 55 210 110

Imm
mm

No 135 for

jet jet by pass

No No
No

Slow air bleed

Power Slow hole

No
4
x

Needle valve diameter C dimension

0 1575 in xO 0394 0 ff787 in 7 8mm 0 3070 in

2 0 19
m

in

Accelerating pump
Idler hole diameter Choke valve Fuel level height

bore

2 0 mm

0 7480 in 0 ff787 in
valve

Poppet
20

Power valve start open Degree throttle valve open

at

22 mm 0 7874 O 8661 in 4 3307 in 1I0mm hg

full choke stroke accel pump

II

Output

Pressure em fuel

I8 cc 0 1098 cu in 0 3 kg cm2 4 26 lb sq in

Functioning

of the Main Carburetting

System

from the fuel pump is The fuel which has been sent under constanl pressure needle valve and float The the float the action of chamber sent into the float by and is connected vent pipe becomes the vent passage subject to negative pressure In spite of the variations in the resistance to the interior of the float chamber the fuel level constant thereby maintaining lhe op lhe cleaner acl to of air keep timum mixture ration constant the venturi lhe air flow velo As the intake air passes through the throat of of becomes high and the air pressure near the opening the throat city through it is the that becomes lower than atmospheric pressure

the injection nozzle

becomes

negative

Because of this suction

the fuel stored in the float chamber

Fig

81

is melered

Simulta jet and drawn out through the injection nozzle entering thorough the main air bleed mixes well with this fuel which is lhen expelled as a fine spray from the tip of the injection nozzle The float valve spring is located within the float needle valve assembly and prevents lhe fuel level from rising excessively or overflowing because of the move ments during operation

by

the main

neously

the air

Functioning

the Slow

Speed Carburetting System

idling
During slow speed
of course the opera and the air flow rate

lion

is low

This system operates for lhe slow speeds the throttle valve is opened only slightly

Ccmsequently

the main

carburetting
The

system is inactive
of

The mixture
is

for lhe slow

as

speed operation

is created

principally by

developed below
follows

lhe throttle valve

functieming

negative pressure the slow speed system

ber is
10

The fuel in the floal cham by passed al the main jet

Power valve

Piston

the slow

jet by

which it is

metered

and mixes with the air which has entered through the slow The fuel speed sir bleed regulated suitably by lhe slow speed adjusting screw and is injecled The by pass port consists is then

lengthwise slot and a Imm hole snd delivers lhe mixture for slow speed when the open ing of the throttle valve is ex
tremely
opens
small

of a

However

as

the throttle valve the from the hole tion from slow

gradually mixture is ejected

snd the transi

speed

to

inter

mediate speed is made smooth ly without irregularities such as pauses in the ction
Throule valve shaft

Fig 3

Functioning

the

Accelerating Pump

and Economizer

The acceleraling device of this carburetor is of the piston type synchrcnized with the lhrottle valve shaft It is equipped with lhe pump piston and pump injector which temporarily supply a rich mixture and the power valve and power jet which supply a very rich mixture when sudden acceleration or high power is required The device functions as follows If while the vehicle is driven at a conslant speed the accelerator

being

pedal

pressed down for acceleratiem the pump pislon descends in accordance with the descent of lhe connecting plate and injects the fuel below into the venturi from the tip of pump injector This fuel had previously been drawn from the float chamber through lhe check valve and stored below lhe piston This action

is

82

provides

the necessary acceleration

If the accelerator is depressed further the throttle valve will open further Then which its

Pump injector

opening becomes 110 mm Hg from the fully closed position the end of together
with

power valve roo moves down

descent of the connecter to push down the valve Simultaneously a new fuel passage is formed between the float chamber and
main

jet

enlers

and the fuel of the float chamber through the fuel port is metered by

the power jet goes oul of the end of lhe main jet and is ejected from the injection nozzie

together with fuel of

system
As a result and is

the main

carburetting
mixture Air check bowl

extremely righ

supplied

Because the various parts such as the venluri jels and air bleeds of this carbu
retor

have been

designed

and constructed

provide optimum fuel air mixtures practically no adjustment other lhan that for slow speed and fuel level is necessary
80 as to Choke valve

Fig

Fig

The parts mentioned above have been assembled in accordance wilh the re sults of rigid tests Therefore arbitrarily varying lhem must be avoided How ever as a general rule making a jet larger will make the mixlure richer and

making
richer

the mixture will become ieaner

it smaller will make the mixture leaner If an air bleed is made large if it is made smaller the mixture will become

83

4 ADJUSTMENT 8
The slow and lhe siow

OF

CARBURETOR

speed adjusting is made by means of the throttle valve adjusting screw The throttle valve adjusting screw regulates speed adjusting screw the rOlational speed for slow speed Screwing it in causes lhe speed to increase and unscrewing it causes the speed to decrease The slow speed adjusting screw adjusts the fuel air mixture ratio it in cause the mixture to become Screwing leaner unscrewing it causes the mixture to become richer The slow speed adjusonent must be made with correct coordination between the settings of these two adjusting screws The procedure is as follows

h
I

7
t

l I

i f
I
C

Fig

First set the

engine speed approximately

al

slow

speed
the

of 350 10 400 rpm

rotates

by
2 3

means

of the throttle valve

the slow

Next

adjust

adjusting screw speed adjusting screw so that

engine

smoolhly
Then adjusl the rOlating speed pre cisely with the throttle valve
Needle

valve

adjusting

screw

If lhe slow

speed adjusting

screw

in with too much force its tip will be damaged and become the causes of be careful in
even

improper operation screwing

when this
screw

therefore it in

If
Float

is screwed the mixture

to see

in a certain amount is still 100 rich that the slow

not

check

not 100

clogged high

speed air bleed is that the fuel level is

and that lhe

seating

of the floal needle valve is

good

Fig

84

Adjusting

the Fuel Level

be high If the fuel level in the float chamber is too high the fuel consumption will too the if lhe fuel level is low and over flOWing will be caused On the other hand lhe correct level be maintained at In lean therefore it must mixture will be too

general
made

when the

chamber must first be

engine adjustments are adjusted correctly

to

be made

the fuel level in lhe float

correcl

Otherwise

adjustment

cannot

be

directly
I 2

Without special equipment the correctness of the fuel level cannol be determined Ordinarily the following method will produce lhe correct level
First remove the fuel pipe from the float chamber cover Remove the three float chamber cover screws and take off the cover Turn carburetor cover upside down so lhat the float is on lop and the float

needle valve is held in its closed position by the weight of the float then gently lower it untillhe flap like contact Lift the float with a finger touches the upper end of the needle valve and hold the the float of plate just
valve spring float in this position without pressing down on lhe needle Ll belween lhe lower lhe distance in this check With the float position the chamber cover surface of the end of the floal and the upper surface of the adjustment is correct If this distance is from 20 to 22 mm

Fig

If

not

extract the float

angle

of the

contact

holding pin plate as shown

because

remove

in the

making this adjustment

be broken off from

if the

lhe float and adjust the Be careful in photograph bending is forced the arm may
not

the float

Also because the needle valve is

headed

be careful not to let it

drop

out

togelher

with its

spring

85

Fig
6

10 the valve
seat

Check the seating of the needle valve replace the needle valve assembly
As described valve

to

If

leakage

exists

the power jet starts to function when the throttle mm This adjustment is determined by the opening If the position of this posilion of the adjusting nul of the power valve rod the functioning of the power jet will be delayed and not is on the low side

previously
becomes

110

if it is on the For correct

press down lightly with a finger on the power in as shown the valve rod accompanying illustration until the resis Move lhe throttle tance of the power valve is felt then hold this position The lever until its matching mark coince des with that on boss part Then raise or lower the throttle valve opening will then be 110 rom HG nut so thaI connecting plate jus I touches the upper surface of the

high side adjustment

the

functioning

will be hastened

adjusting adjusling

nut

1 e

the

point

at

which the power valve

begins

10

function

Adjustment of Connecting Rod

Insert the connecting rod inlO choke lever post Keeping downward the arroW the marked on choke lever post sel its tip to lhe side groove of the connecting rod and As for its poSilion fix it up with setscrew it is so arranged lhal when the choke valve
is

Connecting rod

Setscrew

totally closed

the

opening degree
at

of
Rod

throttle valve will stand

11 Side groove

post

Fig

11

86

5 8

AIR

CLEANER
Air Cleaner

Cleaning of

The air cleaner serves to clean the air before it is suctioned into the cylinder If the cleaner has been in
a

service

for

considerable length of lime withoul having been cleaned the accumulated

dusts within the cleaner interferes free This will of the air

passage

re

for Model 4W73 and 60

sult in poor engine performance and As any increased fuel consumption dust

particle

mature wear

in the air will cause pre of cylinder wall air

cleaner should not be and it should be

dispensed with kept clean aU the time by periodical inspection and cleaning
2
unscrew the To clean the apparatus nut on top of the cap and remove wing the Take out the steel wires and

for Model 680 12 Air CleaneT

cap

clean them in

Fig

with

gasoline Filllhe bowl oil up to the specified level engine ReinstaU the wires after having been dried and soaked with oil

If The cleaning of the apparatus should be made every 3 000 miles fre districts more in dusty however the vehicle is used customarily

quent cleaning is advisable

6 8

GASOLINE

STRAINER

j 2
lj lSjr
1
I

Q f ii
J

ii

li
1

i
i

Ik
CD Bowl j Clamp nut @Srrajner element

f l 1 Jr

8D
I

J@

264t2

Fig

13

Gasoline Strainer Ass y

87

Repair
1

of Gasoline

Strainer Disassembly
and

Instructions for

Assembly

of Gasoline Slrainer and remove lhe

To remove the bowl from the wire to a side

body

loosen the strainer

nut

nut

Take off the bolt

screen

and washer from the wire and remove

bowl 2 3
4

gasket and

Wash those disassembled parts with clean gasoline and blow with compressed air As a rule lhe strainer bowl gasket has to be replaced The used gasket is nol air

tight alloy
Take

Strainer body is made of aluminum

threads of each connection

good care

not to

break

Pay

attention not to
are

tighten

the strainer nut so

excessively

that the

gasket

and

bowl 6
When

broken the strainer

installing

assembly

sufficiently
air 2

Dust and dirt

em

the bracket surface prevent

the strainer bracket should be cleaned plug from keeping

tight
of Fuel

Poor

Feeding

Causes of this trouble are as follows 1 2

When the

screen

is

clogged

with dirls

Air leaks from the bowl

gasket
strainer connector or

Air leaks from strainer nut

plug

as

the result of

imperfect tightening
3 Disorder of Nem relurn Valve This is caused from either corrosion
to
or

wear

of valve seat which makes it hard

open

or

shut

In this case

replace

a new

valve and flatten the seat

to

Somelimes the troubles in non relurn valve will discontinue feeding gasoline the engine when the lalter is over heated

Inspection
1

Cleaning

of the Screen and the bowl is

screen become clogged with dust After ioug run dust and water in its bottom and will result in poor

depositted

with

straining efficiency

Check

Periodically
deposilted therein
remove

In case of dust and dirts are up

bowl and

screen

clean

completely

with

gasoline

and

compressed

air

S8

8 7 GASOLINE

GASOLINE

TANK a GAUGE
2

CVResistance wire OOTerminal iFloat

Fig

14

Gasoline Gauge Tank Unit and Dash Unit

Fuel tank capacity

Model 680 110

29

4W73 100 26 4

60 50 ltrs 13 U S Gal

Repair
1

of Gasoline

Tank

Gasoline Gauge
and

Troubles of Gasoline Tank

1 The

Repairs

is clogged with dust or water tank unit and blow the pipe with compressed air in In this case remove Take off the drain plug at the bottom the reverse way to the flow of fuel

gasoline pipe

of tank unit

of lank and clean inside of tank 2 Fuel does not come into the
a

gasoline pipe
in the filler cap is

This dust

happens when the ventilation hole

clogged

with

the tank would take vacuum effect which prevent the flow Clean up the ventilation hole of fuel into the fuel pipe unit is bent and dows not reach the fuel level of tank The gasoline pipe The lower end of pipe should be 5 8 inch above the bottom therefore if other wise remove the tank unit and correct the bent pipe In this case

Fuel Leaks from the Gasoline Tank

a

First

locate the leaking spot and mark it with

chalk
lhe

and drain the

fuel
b

com

pletel y
out

Blow the compressed air into the tank and expel therein Get it dried completely

stagnant gas

89

Repair completely the leaking spot by soldering or oxygen welding If the broken spot is comparatively spacious a steel plale of proper
size is 10 be

patched

lhereto

Failure

to

explosion

the gas at the time of

expel

stsying in lhe lank will induce a dangerous Good care is invited to wilding operation

this matter

Trouble and Check of Gasoline Gauge

The trouble in

gasoline

unri and poor wirings

1

gauge is attributable Check them as follows

to

the trouble in lank unil

dash

and set on ignition switch Alternately to and look at movement of indi the terminal chassis touch and detouch cator in dash unit If then the indicator oscilates quickly across the dial Replace the from E to F dash unit and wirings are in good conditiem tank unit to locate the trouble try to earth the In case the indicator does not move in the above test
Remove the terminal of tank unit

running from the wiring moves

wire

the back of dash unit to tank unit is no

If the indicator

In case the indicator does not move in the above mentioned test earth the If spark is seen it indicales the trouble wiring from battery to dash unit is in dash unit In case of no

good

spark

Defective dash unit should be replaced is seen when the wiring from the battery is

grounded

it indicates the lrouble is in

wiring

90

SERV

NEWS

REFERENCE

NO DATE CONTENTS

OF SERVICE BULLETIN

JOURNAL AND

91

SERV

NEWS

REFERENCE

NO
DATE

OF SERVICE AND BULLETIN

CONTENTS

JOURNAL

92

SECTION
IGNITION

9
SYSTEM

@ j

@
1 Battery VStartor m or l @Ceneraror

@Voltage regulator
Ammeter

@ Ignition Ignition

switch coil

@ Condenser IJ Breaker point @ Distributor @ Spark plug

Fig

Ignition System

Circuit

DATA IGNITION COIL

Hitachi CIZ Ol
12 volt 3 95 n
st

Type Primary voltage

Primary coil resistance
Insulation resistance Current consumption approx

10M

n at

200C 680P SOOC 1760P

Running
Slall

1 4 Amp distributor lS00 rpm

2 0

Amp

93

o
o

11

T
0

Fig

94

DISTRIBUTOR

Type Ignition timing

Automatic advance system Advance angle characlerislic
Advance start at Max Breaker advance

Hitachi 060S 01
water

D608 02

proof
vacuum

Centrifugal
lOoorpm
340
0

100 B T D C and

engine angle

rpm

point gap Dowel angle

Contact arm Condenser

at 3600 rpm crankshaft 45 0 55 mm 0 018 0 021 in 350 400 at point gap O 5 mm

spring capacity

tension

O 020 in 500 600 gr

O 20

17 6 21 1 O 24 Micro farad

oz

Insulation resistance
Clearance distributor shaft and

5M n or over

bushing

0 015
in

O 035mm

0 0006

0 0014

SPARK

PLUG
B 54E or B 6E 14 ffim

Model
Size of thread

Gap

o 6

O 7

mm

9 1
1

CHECK
Coil

REPAIR

Ignition

When the ignition coil is found unreliable

ooe

test

it

by comparing

with a new

Test of Primary Coil

Usually misfiring of spark plug will occur when the ignition coil fails supply enough secondary voltage due to poor insulation over heating

to or

internal fault of primary winding In this case measure the amount of electric current from baltery 10 pri mary coil by connecting an ammeter of thirty amperes capacity between
the 4

battery and primary coil The primary current generally is about 5 amperes at the instance the circuil is closed and will settles at about 3 5 amperes
If the
ammeter

indicates

that lhe coil is short circuited

flow of current over six amperes it suggests If it regislers no CUrrent flowing lhrough and a new coil should

the circuit
be used

it is because the coil wire is broken

Test of

Secondary

Coil

Pull coil wire out of distributor cap remove the cap and crank the engine until distributor points are fully closed Turn em ignition switch hold the

95

cap end of coil secondary wire aboul 3 8 inch away Crom metal part of

engine and open breaker points with fingers If a good spark jumps from wire to the melal part the coil is in good con dition If the spark is weak or absent the coil is to be blamed provided that condenser and ignition switch are in good order For more perfect testing use a universal electric testing machine and check the spark gap Tesling machine is illustrated in Fig
2 Distributor
I Removal and

Assembly
the distributor from the

engine take off colter pin and re Then remove screw take out lhe spring distributor together with the clamp arm To install it loosen lhe clamp of the distributor Rotate the cam and the dislribulor will be settled at a Then tighten all condition point Distribulor can also be removed from the engine by simply loosing the screw of the clamp arm but generally this melhod is not taken except lhe case as engine is overhauled If Ibis method is adopled ignition timing musl be adjusled thoroughly before the distributor is installed
remove move

To

lhe stud washer and

After the parts of distributor have been taken apart clean the inside with gasoline and remove any rust at the part where it is connected to the engine as the rust will result in poor of the distributor

grounding

Before
at

assembling

supply three

or

four drops of engine oil

to

the Celt

the center of earn Check the grease cup lubricated

and make sure the distribulor shaft in

sufficienlly

Trouble
a

Burning

of the

When lhe

point points are

burnt due to
remove

long

service
arm

improper point gap

and
a contact arm

or

defeclive condenser

the breaker

Redress the contacling surface of the poinl with

b their gap after installalion Adjustment of point gap Loosen the lock screw Turn the

fine file

and

adjust

0 020 inch with the heel of contact Tighten lock screw recheck gap
c

adjusting screw until poinl gap arm riding em a lobe of cam

of cam

is

Wear of heel of

contact arm

and

wear

When the contact arm is new its fibre heel will wear and harden quickly If it is left attended the cam will wear soem To prevent wearing coat the cam with a small amount of grease at the time of each d

inspection

Short circuit

contact arm

and arm

spring

The breaker plate pin which holds the contact arm is furnished with an insulalor Also the arm spring has a bakelite washer as a insulator at terminal connection If these insulators are loose or in poor shape
lhe

primary current will be grounded and will lead to misfiring Keep tightly in placed and if contact arm is short circuited at lhe pin hole replace it with s new one
them

96

GREASE CUP GAP ADJUST SCREW

Fig

97

Improper spring

tension of contact arm

D
contact arm

When the tension of

spring is too strong it induces quick wear of fibre heel and cam When the spring is too weak it cause misfiring at high engine speed Never change the bending of Slandard spring recklessly spring tension is from nineteen
to at

twenty
the

two ounces

measured

contacting point just before

it starts to open

When
arm arm

replacing

a new contact

scrape the hole of contact so as it can be easily in

not

breaker

stalled and freely work on the When it is plate pin

working easily the regular spring tension will not be strong

enough
speed
f

to

work

on

the

cootact arm at

Fig

Distributor Governor

and will
as

cause

misfiring

in lhe case of weak

high spring

Q Governor iPlt wei @ Governor spring

Short circuit Df distributor cap There will be a short circuit when distributor cap has cracks and it will
a new

cause

misfiring

Replace

with

cap Distributor rotor If the distributor rotor has any crack replace it with a new rotor Governor
or

if it is

excessively

worn

There is an automatic advancing syslem of centrifugal governor lype placed under the breaker plate in the distributor Sometimes it may happen the governor fails to work at the high speed due to dragging or friction In such a case the engine will lose its
power em account of the faulty ignilion timing Push or pull the cam on the shaft to the left as far as it The release the cam and if it goes snaps back quickly lhe system is in good condition L

Condenser troubles Almost all of condenser troubles are short of circuit The shorted condenser weakens the secrodary voltage burns distri butor points and causes the engine revolution to become irregulsr or
to stop If cemdenser is shorted

replace with

a new one

Tesl of Condenser

1 When sparks

are

weak the condenser is

suspecled
tester

of trouble

test

il

by comparing
i 2

with a new roe

tester

Using
the

lighting
bulb

touch

one

of the

terminal

to

the lead

wire of condenser and the olher end to tbe bracket of condenser

tester

If

lights

it indicates the condenser is short circuiled

98

3 Flow for just

native
or lWO

from

through approach the end of the body of condenser

current

momenl 200 volts current either of direct or alter After a minule lead wire and body of lhe condenser lead wire to about 1 If a

sprak jumps

the gap

16 inch distance lhe condenser

is assumed to be O K

heated when the

is no
ser

On the contrary if lhe condenser becomes is supplied as described above or if there

wire is

spark when the lead is probably defeClive

approached

to

lhe

body

the conden

Vacuum Control

The vacuum control is installed on the distributor as illustrated in Fig It is connected to a hole below the throttle valve of carburetor and automatically ignition timing together with lhe governor of distributor

ajusls pipe

Possible troubles of vscuum control are air leakage due to poor connection of In such case the vacuum and inefficiency due to broken diaphragm inside does not work when the is accelerated even control engine To locate lhese troubles check the pipe connectiem and if they are good the Remove the vacuum control and install a new dia trouble may be in diaphragm

phragm

Fig
4

Spark Plug
The

spark plug

used

is fourteen millimeter spark ap is 0 6 O 7 mm

Nissan is N G K B54E or B 6E model and screw size It is essential for spark plugs to be kept clean and accurate
on

0 024

0 028 in

Adjusting of Gap
If the cleaner is At first clean it completely with the spark plug cleaner and lhe carbon to remove clean not available use a brush or waste cloth

Also check carefully whether

or not

there is any

damage

on

the

porcelain

99

After that
When side

adjust the spark gap 10 lhe said inch with thickness gage spacing the electlodes to obtain correct gap always work on the ground of lhe electlode only Never attemp to adjust the gap by bending lhe
center

electlcxie which is in the

b

of the core

Diagnosing Engine
I

Condition through by Spark Plug

If the inside of

spark plug

is well

dry and

ilS white

brown colour without any carron element making a satisfactory combustioo b 2

this

porcelain is in light cylinder is assumed to be

Accumulalion of carbon in lhe spark plug indicates that the engine is supplied with too rich mixture and lherefore ilS combustion is imperfect When the spark plug is found
is
wet

3
4

with gasoline

it means the

spark plug

missing
an

When there is
wet

accumulalion of carbon like coal powders or when it is engine oil is pumped up into the cylinder If due consideration is paid to lhe above condilion of the spark plug
with oil it indicates the

whenever it is removed

fairly

accurate

diagnosis

of the

cylinder

is pos

sibly

made

9 2
1

ADJUSTMENT Efficiency

Test of Distributor

After inspection of each of a distributor assemble them and check the dis assembly on a universal eleclric tester to check the performance of lhe distributor By this test we obtain accurate knowledge of the advancing angle
lributor

spark condition
2

profile of

cam etc

Ignition Timing
After

installing all

the parts of

ignition system

set

the

ignition timing

as

follows

Fig

100

Crank the engine slowly by hand until No I piston Set the mark on the crank pulley compression stroke timing gear case cover
Loosen the screw of octane selector the screw

comes near to

the top of
on

in line with a

poinler
and

the

and set the indicalor to

tighten

screw at the bottom of the distributor Remove the cap and adjust the contact point gap to O 020 ness gauge

Loosen the

measured with thick

Cemnect one of the wires of the

liming lamp

tester to

the

primary wire

of lhe

distributor and

connect

other wire to earth the timing lamp is lighted when the distributor body point begins to open and lhe lamp is off when the poinl

Turn ignition switch on Adjust the distribulor so

is turned to the right unlil the is lightly pushed with a finger

as

Connecl No
rotor arm

spark plug

is

facing

wire to the dislributor al its terminal to which the and connect other wires in counter clockwise order and follow 5 3 6 2 4

ing

lhe

firing
a

order of 1

lamp tester is not available Pull out lhe high tension wire at the gine block

When

proceed

as

follows
8 inch away from the en

cap and hold it 1

Fig

on the ignition switch Turn the distributor to the right untillhe spark is seen from the wire Stop there and fasten the clamps of lhe distributor tighlly

Turn

high

tention

Connect the spark plug wires Finally tighten all the terminals and connections

101

SER

CE

NEWS

REFERENCE

NO DATE CONTENTS

OF SERVICE AND BULLETIN

JOURNAL

lO2

SECTION

10 SYSTEM

GENERATING

DGenerSCOT OOVoltage regulator

Ammeter

@Ba ery

Fig

Generating System

10 1

GENERA TOR

D Frame j Terminal @Terminal

@ Commut8cor @ Brush spring @ Field coil

Armature

@ Ball bearing

@ Fan pulley @ Throw bolt

Fig

Sectional View of Generator

103

Fig
DATA

Generator

Type

HITACHI G1l5 09
x

Voltage Output amp Pulley ratio

Shaft
runout

Volt

12 volt 200W 13V

l5A

1 84 limil

Conlnlutalor diameter
Wear limit

Not to exceed O I mm 0 004 in 37 mm 1 4567 in 2 0

m

0 0079

in

Out of round limit Irregular wear limit

Brush

length

O 05 mm 0 002 in 0 3 mm 0 012 in 16 mm 0 630 in 0 433 in 700 gr 17 6 0 3 mm 0 012 in 500 6

II mm

Amendment limit Brush spring tension Armature Field coil

core

24 6

oz

clearance
core screws

pole

Torque wrench setting

7kg

44

51Ib ft

2 CAUTIONS 10
1 2 3
4

FOR

HANDLING

GENERATOR
excepting

Keep always clean the inside and

the field coil and
armature

When the generator is disassembled

outside of the generator wash the pans with gasoline

coil

In case of assembling And when assembling After

blow away the dirl and dust

by

make sure all cemnections are

the compressed air tightened securely

armature

assembling bearing

feed

eight

10 ten

drqJs

of engine oil 10 lhe

shaft

104

To set the generator on the engine don t adjust the fan belt too tightly The proper tentlem of belt IS to have one inch deflection when pushed with a thumb If the engine is to be run wilh lead wire disconnected between lhe generalor and battery ground the wire of the

If
7

generator

the generstor will be burnt The terminal of circuit must be tightly fastened
not

ground

and kept clean

3 10

CARBON PILE REGULATOR

TYPE

VOLTAGE

qPiIe preS ure @Csrbon pile @Pile holder

screw

@Moving core @Compre6sion spring

@Yolce VMagnet l coil j Flux adjusting
screw

Fig
DATA

Type Voltage adjustment No load voltage setting Flux screw locating voltage CuI out relay point gap
Armature air gap CUI in voltsge Reverse current Number of carbon

Hitachi R 115 02 Caron pile

15

16 volt generator 2500 rpm 10 volt generator 2500 rpm

point

closed

0 7 O 9mm 0 028 0 035 in 0 25 0 45 mm 0 010 O 18 in 12 5

generator
piles
5 ampere 45

13 5 volt 1300 rpm

The carbon
crease

pile system

is so

designed

when

applied

higher pressure is applied With this function lhe carbon

The

field coil in series conlrol the

plate spring
sure

pressure higher voltage produced by

that its electrical resislance will de and will increase when lower pressure is pile placed in the circuit line of generator by means of a combination of magnet and
the generator will exert less pres voltage will induce more pressure

and therefore more resistance

the lower

and therefore less resistance when the generated voltage is 100 high strong current flows For instance lhrough the magnetic coil 6 and attracls the moving plate 4 of the pile and lessens the tension of pressure spring This will increase the electrical resis
tance

of the carbon

pile I

and reduce field current of the generator

As the re

sult of iI

the

voltage

will be reduce

105

Fig
On the very low contrary
the carbon

VoUage Regulator

in Model4W73

when the

voltage

of the electric current from generator

drops

pile system

will functiem in inverse order as described above

and raise the Thus the

voltage voltage will be stabilized all the time This regulator has no Current limitter II is because the magnetic coil of voltage regulalor incorporates a current coil when functions to automaticaly regulate the resistance of the carbon pile when excessive current flows and reduce the vol
tage
so

thaI it will not exceed a limit The

Note

voltage regulator of vibrating point lype has the current limitter independently This is because to prevent the generator from burning by the excessive high voltage caused by contact point of voltage regula
tor

melted and fused on account of

sparks

at

lhe

points
cause

However the this trouble

carbon

pile type has

no contact

point which may

104

TROUBLE AND REMEDY AND REGULATOR

OF

GENERATOR

The charging current of generator equipped Wilh voltage regulator is increased decreased in direcl proportion to the charged condition of battery In normal driving where the battery approaches fully charged condition the current from
or

the generator will drop and stabilize at five to six amperes This is to prevent the battery from being overcharged and therefore should not be mistaken of the gene
rator

106

When the lerminal is loosened

tighten securely

Troubles in the

voltage regulator

Set the volt meter between lhe Band E terminal of the regulator with the engine running at 1000 rpm check troubles by voltmeter
a

In case the cover of

regulator regulator
cut out

is

contacting

with the inside electric circuit

repair the
b
c

cover

When the wire of the If the contact

is broken or shorted

replace

or

remedy

opening
d

points replace the

of the cut out

relay

are

found unstably closing and

relay
of cut oul

When the face of conlact

points

relay

are

pitted

or

rough replace

dress them down with a fine file or emery cloth

e

In

case

the

voltage
relay

coil of the cut out

relay

is shorted or broken

the cut out

f When the current coil of cut out

broken g
h

replace

the cut out

relay relay

is found broken or aboUl to be

When the carbon

aged replace
tage
i

the

plale of plate
or

lhe automatic

voltage regulator

is found dam

If there is any broken

shorted wire in the

magnetic ooil for

or

the vol

regulator

replace

lhe part its wire

If the resistance coil of the voltage regulator is shorted broken replace the coil

Troubles of generator
a

If the brushes
brush

are

found making poor

should be

contacl

remedy
or

or

replace

the

b
c

Weak or refective

spring

repaired

replaced
turn

When the surface of commutator is found If there is any short or it

rough

down on a lathe

damaged
wiring

on

the armature coil

repair

or re

place
e

If any broken or shorted

is located in the

generator

replace

or

repair 4 Over

Charging
is too

If the ammeter

generated voltage
Check
I

regislers anbormal high charged condition high

follows

it means that the

causes as

Troubles of eXlernal wiring The lead wire belween generator A terminal a nd voltage regula lor A ter F terminal minal may be rubbing against the lead wire connecting generator and of wires lhe of F with result lerminal exposure and voltage regulator
short circuit

Repair

the

exposed

wires

or

replace

Troubles of

regulator

Hook up a volt meler to Band E terminals of regulator as already described With the engine running at 1000 rpm speed check troubles by voltmeter

109

b
c

adjusted voltage of the regulator is too high reduce lhe by turning counter clowise lhe adjusling screw for variable flux When the spring for pile pressure is weak it should be r placed In case the magnetic coil of the regulator is broken or shorted replsce it
Where the

voltage
with d
a

new one

If lhe resister for

pile

coil is broken

or

shoned

replace

lhe coil

Troubles of the battery

If it so the

happens that the actual reading of the volt meter relay

defective

rate

of

charge

current

is

always higher
battery

than

the trouble is located in the

Cut out

If the ammeter

registers

discharge

while the

engine

is

ing
a

speed

voltage

the cause of trouble is no doubt in defective cut put Check as follows regulator

running at a charg relay of the

If the points of the cut out relay do nol open check their closing voltage To recover normal The voltage will be infallibly found to be very low condition push the adjusting arm up and make the spring tension to
Correct

the

closing voltage

to

the rated value

12

13 5 volts

spring plate of the cut out relay is found coming apart from the moving coil and is found swinging replace the cut out relay complete
If the

10 5 TEST
1

OF

GENERATOR

Motoring
Have a

Test fully charged battery

a

and a 30 amperes ammelers

ready

for the use of

test

Build up
to

circuil conneclioo from generator A terminal

through

ammeter

Also connect generator body and positive pole of negative pole of the battery Then the generator will turn as a motor battery with a wire Checking the flow
of current in this manner locate the inside trouble of the generator
a

If the

ammeler

indicates

discharging

rate

if the generator keeps running amoothly with a be regarded as perfect condition 2

of less than five amperes and slight sound and it should

If the generator fails to run the troubles is in the circuit In the above test if ammeter reading is over five amperes discharges it any mean a short or grounding of internal circuit provided that the gene
ralor

is

mechanically

in

good shape

Usually

lhe internallrouble is

located in defective

armature

If the generator lurns in the above test there must be a short circuit internally

but if the ammeter needle vibrates of below four amperes there must

If the
be
a

ammeter

shows

discharging

rale

poorly contacing

or

highly

resistance parI in the internal circuit

2 Internal Troubles of Generator By

the above test
a

idea of the location of trouble

can

go into the detail it is recommended to make test If the tester is not available an armature growler

on a

However 10 obtained universal electric tester

Fig

can

be used

110

Low

Charging

Current keeps
on

When the
current

ammeter

check first the ammeter and remedy in the following order 1

registering unreasonably low If it is found in good order

rate

of

charging

locate the trouble

Troubles of External wiring

a

If any wire is

worn or

broken

replace

or

repair

b 2

When any terminal is found loose

tighten securely

Troubles of
a

regulator
replace points
or

When there is any shorted or broken wire

repair
or

Check the cut out dress with

a

relay

and if the contact

are

dirty

pitted

fine file or emery cloth is too low turn counter clock wise the and increase the vollage

When the

adjusted voltage
screw

adjusting
d
e

for variable flux

Check the resister for pile coil Check the magnetic coil

If it is burnt and shorted

replace
or

If any part of the coil is shorted

broken

replaced
3 Troubles in Generator
a

When the surface of commutator is

dirty

or

extremely rough
with
commutator

polish or
is poor

remedy the
b

surface

Check commutator brushes

If their

contact

redress the brush surface

c

or

replace
as

Check coil of
any

armature

and of field

well
or

broken part is disclosed

replace

as wiring repair

connection

If

2 No Current
If the ammeter registers no charge at all trouble may be worse lhan described unless the ammeter is out of action check and remedy as follows 1

above

Troubles in external wiring

a

If any wire is broken

or

about to break

replact

it

Check the insulation of wire

If it is broken and

grounded

to

the

body

of

generator
c

replace

or

repair
or

Check terminals

If found detached

loose

tighten securely

Generator troubles Connect these Remove the wires from A and F terminals of the generator two terminals with a different wire Have anolher piece of wire ready for later use With the engine funning al about 1000 rpm connect one end of the third wire
to

A terminal and
a

ground

the other
occures

to

the generator body wilh

the

light

bouch

If then
Note

remarkable

spark

generator

is in

good

order

This method of test is used only when a voltmeter is not available If the voltmeter is al hand connect the meter 10 A and E terminals leaving lhe original wire as it is and read lhe amount of volt regis
tered

by

the meter

107

Check the wirings inside the generalor

be

Broken or shorted wire should

replaced

or

repaired
If their wires are hroken or

Check the armature coil and field coil shorted replace the complete parI

If they are found worn and not contacting Check commutator brushes with the commutator or if the spring is found broken replace lhese

parts If the surface of dress

commutator

is found

extremely

scored

replace

or

re

Check the brush holder

If it is shorted due to poor insulation

repair

Troubles of voltage
a

regulalor
is found

If tbe

regulator

cover

making

contacl

with the

wiring replace

resulting
or re

in a short circuit b

repair the

cover

In case any wire in the

regulator

is shorted or broken

pair
c

If the

contact

points

of cut out

finger
men

it is because the core and

relay do not close when pushed Wilh a Make adjust moving plate are stuck

Note

In

making

lhis test

be sure to have the fifteen volt

battery disconnecling
to

Next the

hook up a voltmeter

Band E terminal of

regulator engine running at 1000 rpm close the contacl points Read lhe voltmeter registration of cut out relay with a finger and if it is found more than closing voltage the cut oUl relay musl be blamed for such troubles as menlioned in d to f be
With the low

out relay may have a shorted or broken coil replace the relay complete CUl oul relay is out of proper adjustmenl and the closing voltage is unduly high Bring the adjusting arm down to oblain proper adjustment

CUI

The

current

coil may be broken

or

shorted

If so

replace

cut out

relay

complete
When the cut out

relay

is O

K ed

and lhe volt meter

reading

is below

closing voltage
g h
i

or zero

the trruble will be in

voltage regulator
adjusling

In In

case

screw

voltage is low raise up the voltage by turning lhe for variable flux to the counter clock wise
of
wear or

case

damage
coil of

When the

magnetic

replace it and adjusl again voltage regulator is broken or s hurled re

of carbon

pile

place
3 Fluctuation

it

of

Charging

Current showing
a

the ammeler

When the ammeter needle surges check lhe following I

charge

unless the trouble is in

Cisorder of external wiring

a

Wiring may
or correct

be aboul to he broken
v

replace

it

In case the insulation of it

ire is Orn and is

grounded

to

the body

replace

108

Test of field coil

connect

grounding

Dis

the earth wire of field coil

and

ground one of the terminal of the growler Touch an end of lhe olher side of the growler to the
terminal of the field coil If lhen

testing lamp
does
not

is illuminated the field coil has a short circuit If

light

good condition replace the coil

2 Lead wire test

the field coil is in In the dormer case

Contact the
to

two

wires of the

growler
Fg 6 A Tma tUTe G TOW IeT

both ends of the lead wire and if the lamp lights the wire is O K If not the wire is defective

and should be

replaced

Test of

positi ve brush

With the end of a wire of growler grounded and the other wire touched to the positive brush if the test lamp lights the brush holder is grounded and it should be replaced
4 Test of

grounding

of armature

To check the armature whether

growler
ment

or not it is grounded Contact one of the wires 10 the armature shaft and the other to the commutator seg If the test lamp lights the armature is grounded and should be re

placed
5

Short circuit of Place the

a

armature

armature on the growler and put a piece iron em the armature with If lhe iron piece is attached to the armature core the armature coil is shorted and should be replaced

hand

10 6 WIRING

OF GENERATOR VOLTAGE REGULATOR AND OUT PUT ADJUSTMENT

Wiring
I

Connection of wire

Fig

Be sure each wires is connected to its regulator Also each wire should be

right place on both the generator and tightly in place especially the one
al

grounded

to

the terminal E

Make it also sure that eleclricsl resistance

the lerminal be minimized

by clean light
Generator A to

connection

Regulalor

lerminal

to to to to

terminal

Ammeler

battery
terminal
to

F
E

Generator F

body

III

Size of wires The following sizes

From A
are to

be selected for different

wirings

on generator to A on voltage 5 5 sq Inm B regulator From voltage regulalor B lhrough ammeter to ba tery From voltage regulalor F to O 9 sq mm B generator From E on both regulator and to body

S gauge No 8

S gauge No 16

w
I

@
ifJ J
tt

i W
J

611
otQJ
J C
1
1

mI
Iif

Fig
A M

Wiring Diagram
O 15A

Ammeter D C Motor

I HP Variable

speed Fig
8

B
V R

Battery
meter O C O 15V Variable resistance 0 0 2 ohm 30 Amp

Volt

Universal Electric Tester

Switch

on

volt

meter

Adjustment
to the wiring diagram shown in Fig The adjustment of a generator is better done by the use of a universal illustlated in Fig 8

Reference should be made

teSler

Adjustment of voltage regulator

Connect the voltmeter 10 the A terminal of the regulator and run the generator at 2000 rpm with no load When the voltage is 100 high Adjust the voltage while reading the meter and the 9 turn clock wise the adjusting screw for variable flux Fig

voltage will drop

The vice versa will raise lhe is

voltage

Each quarter

of a turn of lhe screw

equal to I volt The adjusting screw

for

pile

be utilized for pressure may

voltage adjust

ment

112

F ScreW

Fig
However it is used

Adjusting
turning

Screw for Variable Flux

only

when the carbon

repair work

In this case

voltage and lhe vice versa regulated to specified limils

with a current limitter

pile has been reassembled after the screw clockwise will raise lhe As the ammount of current is automalically
this type of the

regulator

is not provided

Adjuslment

of Cut oul

realy
the

Connect the volt

meter to

A terminal of the

regulator

and while the

reading the
of lhe The
cut

meter

gradually

increase the generator

speed until

poinl

oUt

relay
lhat

starts to close

voltage

at

shown by the voltmeter

momenl

should he 12 5 10 13 5 volts If it is found higher push down the

arm to

P Screw

adjusting
If is

decrease the
tension

spring
on

the contrary the raise arm

closing voltage
lower

up 10 increase the

sprIng tension The points will

open when lhe ge nerator is slowed down and ilS

Fig
out

10

put is reduced to three amperes or less

113

SERV

NEWS

REFERENCE

NO DATE CONTENTS

JOURNAL

OF SERVICE AND

BULLETIN

114

SECTION
STARTOR
DATA

11
MOTOR

Type

Hitachi S114

20 4W Series S114 2l E690 S114 22 L4W Series S114 23 680 690 60

1 4 HP

Voltage
Power

12 volt

1 0 KW
current

Starling

voltage

Lock torque Pinion gear type Pinion gear number of leelh

Less than 420 amp 9 5 volt Over 1 8 kgm 130 ft lb

Sliding
9

over

running clutch

Flywheel
teeth

gear

number of

Gear ratio Pinion shaft diameter Amendment wear limit

Shaft and

146 16 2
14

2 mm
mm

O 1

0 559 in 0 004 in
0 003 0 0012 in

bushing

clearance

Amendment wear limil Commutator diameter Amendment

wear

0 076 0 030 mm O 2 mm 0 008 in 34 mm 1 3386 in 3 0 mm 0 3 mm 0 1181 in 0 0118 in

limit

Irregular

wear limit

Oul of round limit Brush length Amendment limit Brush spring tension

O 05 mm 0 002 in 16 3mm 0 6417 in 11 3 mm 0 4448 in O 9 kg 1 98 lb

11 1
1

REPAIR

Removal
1 2

Remove the
Loosen two

startor

pedal

and remove startor motor from and remove head cover

engine

through

screws

3
4

Remove armature shaft center

bearing and pull

out armature

Remove shift lever from head cover

5 6

Remove pinion and clutch Remove fOOl switch

assembly

Inspection
Inspect

of parts cleaning
and

each parts after

judge

if il be reusable

or not

Reusable

parts should be amended

I

if necessary
and amend commutator out of round

Check distorted

armature

by lather

Be sure there is an air gap between armature and field core The best way Full contact brush on lhe commutator should be maintained is to clean and redress the commutator holding a fine sand paper against

115

it and

revolving

the armature with a hand

Brush which is worn to a

length

of less than

half inches should be

re

3
4

placed InSpeCl pinion gear for

Polish outside of
with oil

crack and inside of core if

armalure

they

are

rusty

and coot

6
7

Clean and redress lhe contact surface of swilch Check wirings for perfect insulation and replace defective parIS If any specific parI of armature is found to be burnt make careful test for insulat ion

Replace

head cover

bushing

if

excessively

worn

Assembly
i

and

testing
engine oil
and assemble lhe parts in the and be sure

Coat all friction surfaces with

reverse

order of

disassembly
the terminals of each wire

Carefully lighten
insulated

lhey

are

well

Adjust

the

length

of switch button so as the shift lever will make contact after the

Wilh the cutton

instantly
with

pinion gear

is

engaged

with

flywheel

ring gear Tesl performance

5 6

Starting
speed

torque

must

be over eleven feel

When motor is tested of about

fully charged haltery pounds on engine it should ordinally

crank the

engine

at a

eight

carburetor closed

revolutions per minutes with the throttle valve of And if unusual noise is heard when the motor is crank

ing the engine

4

check the

flywheel ring gear

for

provable

trouble

Inspection
I Poor
a

and trouble
Power

shooting

Cranking

Check the specific gravily of electrolyte in the battery over I 270

and see it is

b
c

Check battery cable ground cable and each connections for tighteness Check foot switch for perfect contact

When motor does nol revolve

a

Stem of foot SWilCh buttem is adjusted

contact

too

short and fails 10 make

Screw
b

out

button until the

length

of

stem

become

enough

to act

Poor connection of hattery cables Disconnect the terminal and clean and
case

tightly connect again

ring gear when
armature

In

pinion gear does

t

not

mesh with flywheel

is

revolving
a

Stem of fO

switch buttem is gear teeth are

too

Flywheel ring

long Adjusl it excessively worn Replace

the

ring gear

In case lhe
a

pinion gear and flywheel ring gear bind

lhis lrouble has occurred shift the transmission into high and jerk the car back and forth lhen gears will be released

In

case

speed gear
b
wear

Remove motor from

engine

check gears

or

head cover

and check

armalure

shaft for distortion

Amend

bushing for or replace if

necessary

116

c lt

ii

1
1

In case of excessive noise in

revolving

check the

flywheel ring

gear

and

replace

if gear teeth are worn out

e
J c c

f
t
j

flit

id

117
i

SERV

NEWS

REFERENCE

NO DATE CONTENTS

OF SERVICE
AND

JOURNAL

BULLETIN

118

SECTION
BATTERY
DATA

12

Model

2SMC
12

Voltage Capacity
Plate per cell

60AH 20H 19 1 270

10

rale

SPecific gravity of eleclrolyte Electrolyte level

Initial charging current Ground earth term inal

1 280

3 8 in above plate 10 amp

positive
3 5 3 6 ltr 20 kg 0 92
44 lb O 95 U S

Electrolyte capacity
Weight dry

Gal

Approx

12 1
1

HANDLING

OF

BATTERY

The most Battery has to be inspected from time to time during service Check of the specific gravity important matter is to keep it fully charged is the means to detect how much the battery is charged The specific gravity Therefore fluctuates according to the atmospheric temperature temperature The full charged coodiliem of battery is is to be taken into cemsideratiem shown with the specific gravity at around 1 280 in hot weather or 1 300 in cold weather To check lhe specific gravity use the hydrometer

Fig

Hydrometer

119

If the specific gravity is found below 1 200 il means the battery is over dis If an excessive discharging is kept em it charged and should be recharged will do harm
minimum
to the battery specific gravity

Discharging should

not

be allowed

beyood the

Check the volume of the level as

high

be as low as to

electrolyte in lhe cell and fill it from time to lime up to When the level is allowed to 3 8 inch above the plates but it will not only do harm to the plates expose the plates
as

also will result in

much the

decreasing efficiency
Keep
the

If the

electrolyte
of

is found to be too

liquid

is liable to overflow from the case with the result of

causing

corrosion of metal parts 4

regular height

liquid level

If the replacement or replenishment is necessary due to dirt of fllow out of electro fill the diluted solutim of sulphuric acid having the specific gravity of about 1 260 Under no circumstances the diluted sulphric acid solution should be used except

lyte

for this replacement and replenishment The increase of specific aravity resulting

replenishment of diluted sulphuric If you acid will shorten the life of battery
from have any doubt as to the

reliability of speci fic gravity check up the cmdltlon of charge with the Ex cell tester This is a method
to

judge the crndition of charge by the drop of voltage at the time of heavy discharge
In

using

this tester

cemtact

the arms to enain aa

tester

both terminals of each cell for

length

of time

as

specified
at

em

the

Fig

Ex cell Tester

More than 1 75 volt

200 specific

Charge

and specific gravity

good

gravity
Less than 1 75 volt less than 1 200

specific gravity
Less than 1 75 volt
more

Fully discharged
than 1

200 Too much specific gravity

specific gravity
More than 1 75 volt

less than 1 200

Too little

specific gravity Voltage drops cemtinuously

5
When the

specific gravity

Inside trouble
the

specific gravity is low

Therefore
case must

electrolyte
not to

weather
causes

be taken

is liable to freeze in cold let the specific gravity drops

Keeping the battery fully charged

in winter seasem

unexpected troubles such as the damage of the cell of electrolyte at different specific gravity are under Specific gravity l5OC
1 100 1 ISO 1 200 1 2SO 1 275

Freezing of electrolyte Freezing point

Freezing temperature
7 70C
l4 4OC

270C

520C
65OC

120

The low atmospheric temperature will decrease the battery efficiency and will also make lubricating oil heavier Both combined the battery will be imposed a heavy load during cold weather in starting an engine This will make it all the more necessary to keep the hattery well charged in cold
weather

battery will self discharge more or less This makes it necessary to check the charged condition when the hattery has been left unused for a long while lf it has been kept unused for more than a month it should be fully re charged and afterward it should be charged lightly about ooce a mooth
To prevent

leakage

of

small ventilation hole in the the cell 9

When

Be Sure electrolyte keep the vent pluge tight plug is kept allowing free passage of gas

the

from

electrolyte
to

is overflowed on the outside of a

battery wipe

it with alkali

soluliem 10 11 On

neutralize the acid and

keep

it

dry

all the time

Nissan

vehicles

the

positive

pole

is

grounded

When the baltery is discharged to the extenl that the electrolyte specific gravity shows lower than 1 180 remove the battery from the car and have it recharged from the other power source

121

SERV

NEWS

REFERENCE

NO DATE CONTENTS

OF SERVICE AND BULLETIN

JOURNAL

IZZ