Engine Nissan Service Manual I

Transcript

S erv c e Snap ij i Jd s NISSAN ENGINE MODEL P SERVICE MANUAL I NISSAN I NISSAN MOTOR CO TOKYO if JAPAN LTD c NISSAN ENGINE MODEL P SERVICE MANUAL INISSANI 1 NISSAN MOTOR CO r TOKYO t j JAPAN LTD 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 comprehensive instructions pectioo of these assemblies tion 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 The difference between Model manual as far as CONTENTS GENERAL INFORMATIONS Page SPECIFICATIONS FERFORMANCE CURVES OF NISSAN MODEL P ENGINE GENERAL INSPECTION OF ENGINE SHORT CUT FOR TROUBLE SHOOTING SECTION 1 CYLINDER 1 1 Cylinder 1 2 Cylinder SECTION 2 2 1 2 2 2 3 2 4 2 5 15 PISTON RING Piston ring and piston pin 28 Connecting 30 32 rod CRANKSHAFT CAMSHAFT VALVE 1 Removal of 2 Removal of valves cylinder 4 3 Replacement 4 4 Valve 4 5 4 6 1 5 2 Inspection 5 3 Heat control 1 2 7 3 43 TIMING head MANIFOLD 5 7 7 TAPPET 39 grinding Refitting the cylinder head camshaft Timing gear SECTION 5 SECTION 7 37 of crankshaft Rear bearing seal 4 1 23 23 4 2 CONNECTING ROD Disassembling SECTION 4 6 PISTON PIN 25 1 6 7 10 20 Piston 2 SECTION 6 4 15 head PISTON SECTION 3 3 3 CYLINDER HEAD 1 Removal 47 51 52 52 52 53 54 57 57 57 assembly 57 WBRICATION SYSTEM 59 Adjusonent of oil regulstor 60 Oil filter 63 COOLING SYSTEM fan belt Water pump fan Repair of water pump heat indicator Radiator thermostat 67 67 68 72 Page SECTION 8 8 1 8 2 FUEL SYSTEM Fuel pump Repair of fuel pump 77 78 80 8 3 Carburetor 8 4 Adjusanent 8 5 8 6 Air cleaner Gasoline strainer 8 7 Gasoline tank SECTION 9 9 1 9 2 gasoline 84 87 87 gauge 89 93 Check repair Adjusanent 101 10 2 95 100 GENERATING SYSTEM 103 Generator 103 104 Cautions for handling generator Carbon pile type voltage regulator 10 3 10 10 4 5 10 6 105 106 Troubles and remedy of generator and regulator Test of generator Wiring of generator voltage regulator SECTION II 1 STARTER MarOR Repair SECTION 12 12 of carburetor IGNITION SYSTEM SECTION 10 1I 77 1 1I0 adjusanent III lIS lIS BATTERY Handling and out put of battery 119 119 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 Water 6 Cooling Cylinder Arrangement Cycles Straight 4 Combustiem Chamber Head Bore x Stroke rom Total Displacement Volume Bath tube type Over head valve 85 7 x 114 3 Cylinder Compressiem Compressiem 3 956 I 7 6 157 145 3800 cc 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 g 32 5 2000 220 1600 904 P S Width Rear Height Length right to Air Support Air Cleaner to Cleaner Fly wheel left 655 882 293 Oil Pan Engine Weight Equipped Number of Piston Fan to Rings dry kg Compression 2 I Oil Type Steel strut LO EX of Pistem Material of Piston Valve Timing 140 SOO open degrees B T D C closed degrees A B D C Inlet Valve Inlet Valve Exhaust Valve Exhaust V lve 520 open degrees B B D C closed degrees A T D C 120 Valve Tappet Clearance 0 38 0 38 mm Inlet Valve hot mm Exhaust Valve hot Ignitiem Method Ignitiem Timing Firing Order Starting Battery B T D C 0 4 0 4 IgnitiCll coil 100 450 Irpm 5 3 6 2 4 Crank Handle 1 Startor Motor Method IGNITION SYSTEM Ignition Coil Distributor Model Model HITACHI CIZ OI D6Q8 5IA 60 series Vacuum Control Centrifugal HITACHI D608 01 Type of Spark Advancer I Sparking plug Model 854E or B6E Maker Diameter mm Sparking Clearance Number of pole Insulating N G K HITACHI or 14 O 75 mm I Material Porcelain FUEL SYSTEM Carburetor Original Model VC42 Type IA 680 Series Maker Dia Dia of lbrottle Valve mm of Ventury Tube mm Dia of Dia Dia of Low Stromberg VC42 4A SA 60 E690 FG60 4W73 HITACHI 42 36 17 IO 1 43 VC42 IA High Speed Jet mm lo of Econanizer Jet Draft Direction Air Cleaner 4A VC42 35 Speed Jet mm SA 0 55 loW Downward mm Type Oil Bath Maker Tsuchiya Nwnber Fuel Feed Pump I Type Diaphragm Maker Showa Seiki K yosan Denki LUBRICATING SYSTEM Method Pressure Feed Gear Pump Type of Oil Pump Type of Oil Filter Oil Pan Paper Filter Capacity Itr 5 3 680 series 6 7 60 series COOLING SYSTEM Forced Circulation with Method Radiator Centrifugal Pump Type Centrifugal Pump Fin and Tube Type of Water Pump Thennostat PeIlet BATIERY 2SMC Model Voltage Capacity 12 volt amp 60 hr 20 hr rating E690 120Aj30h I Number Tenninal positive grounded 2 side GENERATOR Model Maker HITACHI Shunt wound 12 volt Type of Winding Voltage Capacity kw Type of Voltage Regulator RIIS SO 200W Carbon pile GI4Q 07 F680 E690 STARTING MOTOR Model MFB Maker Volt HRZ HITACHI Power v hp 12 8114 23 3 S114 21 I0 E690 PERFORMANCE CURVES OF NISSAN MODEL P ENGINE Max 150 I Max Min 145 HP 3800 r p m 32 5 kg m 2000 r p m 220 gr jHP h l600 r p m P SAE Torque SAE Fuel Consumption B H I V 140 130 J F 120 17 E no J S 35 100 I C1 iii 30 Iii 5 u c c I aJ I 80 1 c o I 70 Ii cI 60 E I c I 50 11 V 40 c 1 E r 30 8 12 16 20 24 32 28 36 250 8 aJ0 0 I 38 u c en Engine Revolutions 4 Xl00 r pm E G1NE LE SIDE r 5 tf i P T i Jt f m ir c z j t 1 7X S 4 ENGINE RIGHT 6 SIDE GENERAL In order to maintain the adjuBtment 1 INSPECTION engine at OF the beBt condition a ENGINE periodical orderly Check of Cooling Water The cooling sYBtem must be full of water which is required clean Refer to the line up of Cooling System 2 and have to be made 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 3 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 Check of Spark Plug The gap should be adjusted Refer to Ignition SYBtem 5 System the line up of Lubrication to O 6 O 7 Check of CompreBsioo Pressure of mm 0 024 O 028 in 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 point gap at 0 020 inch Ignition Timing the timing at 20 before top dead Check of Carburetor Refer 9 the Check of Adjust 8 open Check of Distributor Adjust 7 spark completely to Fuel System Check of Fuel Pump and Strainer Refer to Fuel System 7 center crank angle 10 Check of Tension of the Fan Belt i ft f When pressed by a hinge the deflection of fan belt should be 25 mm I in at the middle of pwnp pulley and crank shaft pulley water II Check of the Valve Tappet Clearance Adjust the clearance at 0 38 0 40 mm 0 015 0 016 in for both intalce and ex haust valves when engine is suf ficiently wanned at 12 600C Cheek of Slow Refer 13 to Check of Fuel for Carburetor System of Tighteness Cylinder Head Bolts Adjust them 14 to be 55 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 Fig Electrical 15 Disgnosis See Fig of Engine by Means of Vacuum 2 8 Gsuge 1 N IlUIl Aramd 18 aum wlth to 1dIIopeed 8t1ellT Drops W ftC IIfaht ftuc tuatiDD at four normal 2 t wheD enafDe risions di CuRt Ia Maalfald or or J lea of 11m1 steady tween 8 to Late Jpido 2 bKk to about openiq d and GaIde Vibrates fast between 8 k Pia Gap too 8ma11 kn Point Contact 11m1 be Remam 15 steady be tween 14 to 17 CyU Hsd c bL FIoaregularly tween 5 net 19 Fig comes zero V dhl a ea Val LalIT hllDll to 14 aDd 18 Late Remains 3 drupe 23 wbea 2 c 1 V regularly 8pr1q LalIT 5 reodbIll apwer aldi accelerating mgIDe and becomes areater s Increasing speed InclJcates emIdDa R III e VaI From 10 to 22 when of 81 fa Po CooodItIoa c1adng throttle 1IIIIy m fn reading Vain accelentilll IkImt Val O OU 1CoDdItIoa a tbe to 2 aDd IplUp bock to 25 Choked H Normal at tint drops to zero 3l d builds up to 1 be Diagnosis of engine by 9 Improper l between 1 and 16 F1oat theD Vacuum Cuf fa Oat afttor of Adlaat t Floats lIIowly between 13 and 17 Gauge SHORT cUT FOR TROUBLE 1 Damage SHOOTING of fuel pipe or insufficient soldering Piping system 2 Insufficient tightening union nut 00 the fuel Leakage high flowing too damage of 1 Worn needle valve and chamber 2 Dust at needle valve and seat in the float chamber or inccxnplete move 1be fuel level dfuel or pipe or over seat in float ment of needle valve 3 Fuel infiltrated in the float 4 1be float is too heavy due weight of solder 5 Too much pressure of fuel pump too big needle valve seat hole I Improper fastening of needle valve to the or Carburetor seat ass y 2 Improper fastening of cover Improper fast ening of jet screws or aged screws on the of the float chamber 3 Loose emulsiCII 4 Improper fastening 5 Improper fastening of low speed jet 6 Improper fastening tube outer dam washer 1 Repair Clogging Loose 3 Crack of low speed jet size used or the jet fastening of low speed jet on the joint surface of the and lower bodies of carburetor upper or fastening Improper assembling of the throttle valve 10 low speed improper 2 4 of cracks Poor adjustment for of rburetor injector of the upper and lower bodies of carburetor or pre sence Adjustment of pump l5 6 Poor Intrusion of air due to valve shaft Air throttle worn frem carburetor leaking and intake manifold flange flange idling l Difference of compression of each cylinder Engine and etc of spark plug 2 Irregularity 3 Poor quality of spark plugs of different kinds 4 hnproper ignition timing 5 Intrusioo of air from the intake mani fold or the rubber tube joint of the window shield wiper is leaky I No fuel 2 Intrusioo of air from the throttle valve shaft and its flange fixing the aupply to gaps or use the carburetor same Car buretor Hard to start or 3 too much Use of poor quality fuel mixture of substitute fuel such as alcohol kerosene etc 4 Erroneous 1 Imperfect insulation wiring 2 Poor ignition current due to the under charging of battery 3 Disorder unable to start in cold climate 4 use of of choke button ignition of high tension 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 Engine and other parts Insufficient compression of 6 Air intrusion into the intake manifolds 7 Insufficient seating of engine valves or 11 cylinder 5 broken or weak valve springs 8 l Insufficient 9 Poor 1 No fuel 2 Engine quality lubricating supply oil to the carburetor for low adjust speed Erroneoua 4 Insufficient lower body 1 Trouble of engine valves valve springs 2 Poor ignitioo or insufficient cranking apeed of starting motor due to drop of battery voltage 3 Disorder of ignition circuit 4 Trouble of startor motor 1 Dirty 2 Excessive resistance for suction due to Carburetor starting 3 Hard to start or unable to stan In hot climate of Too lean mixture due to poor ment Carburetor cranking speed motor use of choke button tightening of upper and or damage of gasket or broken intake manifold partial clogging of air cleaner 3 Insufficient fuel supply due lock In fuel pump and pipe 4 Disorder of fuel pump 5 Clogged main jet to power jet vapour or main air bleed 6 and adjustment of ignorance of relative of venturi tube main jet main Wrong assembling carburetor Insufficient and power sizes speed air bleed etc Engine 12 1 Too much friction and resistance of bearings and other parts 2 Insufficient compression of cylinder 3 Overheating 4 Poor 5 Wrong setting of 6 Disorder of ignition system 7 Misfire of any spark 8 Brakes of engine cooling system dragging octane selector plug due to poor adjustment Carburetor Wrong assembling ance jet Overheating of engine Engine and of carburetor ignor of relative sizes of venturi tube 1 Too much friction and resistance 2 Poor 3 Inefficiency of cooling 4 Poor circulation of lubricating oil 5 Wrong ignition timing 6 Wrong setting of 7 Over others 1 main main air bleed The cooling system effect of radiator octane selector loading porcelain part of spark plug gets stained black with the carbon Judgement 2 The color of exhasst gas is black and has the unpleasant odour 3 Uneven 1 Wrong assembling Air mixture is too rich running of engine carburetor and adjustment of ignorance of relative sizes of venturi tube air bleed Cause main jet main etc 2 The jet hole is 3 Insufficient fastening of main jet 4 Leakage 5 The level of fuel is 6 Disorder of air cleaner 1 too big in the power jet valve too The porcelain part of high spark plug is white Judgement Air mixture is too lean Cau8e 13 2 Uneven running of engine 3 Back firing in carburetor 4 Engine overheat particularly exhaust pipe overheats 5 Engine power diminishes 1 Poor adjustment of carburetor 2 Instrusion of air frem the throttle valve shaft and the fitting flange the l Back fire 3 Jets tampered or remodelled or imitation parts used 1 Too lean mixture 2 Wrong Ignition timing Pre ignition 3 Catch fire due 4 Disorder of ignition system 5 Insufficient seating of engine springs or to engine overheat valves broken valve 1 Disorder 6f 2 Clogging of accelerating pump accelerating pump injector hole Insufficient 3 Leakage frem accelerating pump check ball valve acceleration 4 Disorder of distributor governor 5 Wrong ignition timing 6 Poor adjustment of carburetor 1 Erroneous 2 Improper adjustment fuel relating of carburetor to compression ratio Knocking 3 Dirty cylinder inside 4 Wrong ignition timing 5 14 isorder of spark plug Pre ignition SECTION 1 CYLINDER Br CYLINDER HEAD 1 1 CYLINDER Fig 1 DATA Diameter of cylinder 85 69 85 739 mm 3 3754 in 3 376 in bore fhe limit for over size piston is 0 06 in Thickness of cylinder 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 wali 5 Difference of top and bottom bore Difference between the and shorter diameter of an Main Block oval bore of 0 00 1 in Less than O 025 mm longer Less than O 025 mm inside limit of use 0 001 in 0 08 in dia 73 73 025 Not to mm 2 874 2 875 in head surface warpage Tightening mm cylinder bearing housing cylinder 15 exceed O 1 torque of main 10 bearing cap bolts 15 11 kgrn 72 mm 0 004 80 ft lb in 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 2 Sectional View of the Engine it beccmes necessary to overhaul an engine assembly it disassembled and all parts throughly cleaned before starting Repair operations when should be completely the overhaul operations In order to simplifty the following instructions we well cover the repair job would be performed of the various parts in the order in which an overhaul Checking Cylinders the coodition of a By far the best method to be used indetermining dial gauge engine preparatory to reconditioning is the use of a Fig 3 16 cylinder in an such as is shown Fig 3 Checking Cylinder Walls with Dial Gauge The dial gauge hand will instantly and automatically indicate the 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 taking readings at each point walls from top In this cylinder or bore slightest and moved up completely rated manner at as may all variations in the 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 If a master 17 Cllliruler Borillll When it becomes necessary to rebore the cylinders of an engine to install pistons the instructions furnished by the manufacturer of the equipment oversize 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 example bored O 018 Cylinder when fitting a0 020 oversize piston the must be measuring just The cylinder cylinder should be the cylinder should be oversize 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 After a 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 3 t F g 4 19 1 2 HEAD CYLINDER 5 Fig DATA head Cyl height all length Comhustion chamber volume Length of Cyl Power up En 06 mm 86 72 i O 5 Former En 100 I mm 99 80 cc 119mm head 121 cc mm Within 0 004 O lmm Warpage of surface Tightening torque Cyl head holt Rocker bracket holt 55 65 ft lb 31 36 it lb 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 Checking Valve Guide performance be obtained 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 6 SERvreE NEWS REFERENCE NO DATE CONTENTS OF SERVICE JOURNAL AND BULLETIN 22 2 SECTION PISTON PISTON RING CONNECTING ROD 2 1 PISTON PIN PISTON The pistons above the are 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 The pistons are 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 0 005 size Note Over size pistons for service use are as foliows Piston is usually supplied as Set pistoo with pin For Size STD Connecting rod 12100 58000 Piston pin bolt Set piston w 12010 58022 12010 58023 0 25 12010 58024 0 50 0 75 12010 58025 12010 58026 1 00 12010 58027 1 25 1 50 Piston pin 0 12 clamp type Pin pistoo 12011 58002 12024 95960 12012 58002 12013 58002 12015 58002 12024 95960 12024 95960 12024 95960 12016 58002 12024 95960 12010 58028 12017 58003 12018 58003 12010 58029 120 I 9 58003 12024 95960 12024 95960 12024 95960 Part Name Set piston No 12010 58022 For piston 12011 58002 combined oil ring bolt locking type con rod Pin piston 12024 95960 w pin std Remark 23 use with over Part Name Set conrod Part No Remark 12130 58002 12100 58000 lOOsh w Ass y conrod Rod connecting 12104 58000 Washer spring Bolt hex 9 15116 I 34632 Cap 12106 58000 ccmrod Bolt ccmrod Nut hex 12109 58000 9 11246 Palnut Bush ccmrod std Pin piston std 12112 58000 12lll 58001 Pin piston O S Pin piston O S 0 06 mm O 12 mm Pin piston O S 0 25 mm 12024 95960 12028 95960 12025 95960 12026 95960 Fig Service spare parts 1 J I I II II r I I N I f 8R 74 68 Fig 74 42 2 Fig 24 0 0 3 mm i l 2 2 Interchangeability New coo rod can be used with former type piston pin Former con rod can not be used with tbe new piston pin Applied model All P engine Applied from E E E P 32473 for 680 series Except Fire P 32423 for 60 series PF 2686 for all P type fire engine Engine NEW CON ROD 20 618 20 630 Fig Part Name Set piston 4 New No Remark 12010 58100 For Piston 12011 58100 combined 011 ring ill press fit type Pin pistoo 12024 58000 w pin std mm con use with roo e e r J 0 I 1 74 68 roC iil mm 74 42 Fig 5 25 Applied model All P engine Applied from E P 31592 Part No Part Name Set 12130 58003 Ibush con w Ass y con 12100 58001 rod 1210458001 Rod connecting Washer Ncne spring Bolt hex None Cap con rod 12106 58000 Bolt con rod 12109 58000 9 11246 Nut hex 12112 58000 Palnut Bush For con std rod 12111 58001 12024 58000 Pin piston std Pin piston O S 0 06 mm 12028 58000 Pin pistro O S O 12 mm 12025 58000 Pin piston O S O 25 mm 12026 58000 Connecting rod 12100 58001 Pistcn pin tight press fit type Set piston Size w Piston Pin piston pin STO 12010 58100 12011 58002 12024 58000 o 12 1201058101 12012 58002 12024 58000 0 25 12010 58102 12013 58002 12024 58000 0 50 12010 58103 1201558002 12024 58000 O 15 12010 58104 12016 58002 12024 58000 1 00 12010 58105 12011 58003 12024 58000 I25 12010 58106 120 18 58003 12024 58000 1 50 12010 58101 12019 58003 12024 58000 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 Guide Cat Rod Pin Insert Bushing hold piston mly 00 the boss face must Stopper Return spring Base Special TooI P Engine Pisten pin Fitting NT 4245 6 Fig Inorder to Into the con rod modified and also the 011 ring pin slightly deepen for the newly adopted combined oil ring avoid distortion of the inner ribs snd the base of groove depth is slightly piston during press fitting pin boss is T7 3 PISTON 2 RING AND PISTON PIN All 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 the O 030 To O 040 O 050 properly fit new O 060 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 0 015 0 015 O 012 0 25 0 38 mm 0 IS 0 30 into the bore 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 piston hang remove and all particles of carbon from tbe faces of the ring grooves in the grooves for burrs or nicks that might cause the rings to inspect up DATA PISTON Type Flat head invar steel strut Aluminum alloy Lo Ex 445 460 gr 15 692 16 226 Material Weight oz Diameter of piston skirt Standard 85 650 85 699 mm Over size O 12 mm 85 775 85 824 mm Over size O 25 Over size O SO mm 85 900 85 949 86 150 86 199 mm Over size 0 75 Over size I00 Over size I25 mm mm 3 4015 3 4034 in mm mm mm 86 400 86 499 86 6SO 86 699 86 900 86 949 mm 3 4113 3 4132 in 3 4212 3 4231 in Over size ISO mm 87 mm 3 4310 3 4329 in mm Difference of major and minor diameter Width of ring groove 1SO 87 0 30 0 34 199 mm mm 3 3719 3 3739 in 3 3769 3 3788 in 3 3818 3 3837 in 3 3916 3 3935 0 012 0 0135 in Compression 2 530 2 555 mm Oil 4 765 4 790 mm 0 0996 0 1005 in 0 1876 0 1885 in Depth of ring groove Compression 4 045 4 120 mm 0 1592 0 1692 in Oil 4 045 4 120 mm 0 1592 0 1692 in 53 25 53 35 mm 0 031 0 049 mm Distance from the top of piston pin hoie Clearance between cylinder wall and piston measured at skirt to center of 28 0 0012 0 0019 in in Checking of feeler gauge Diameter of piston pin hole Off set of piston pin hole Weight Weight difference of pistDn only difference of pistDn and connecting PISTON rod assembly I5 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 5 0 DZ 5 DZ RING Compression ring Compression ring No I Inner bevel type No 2 Taper type Oil control ring Oversize rings available Compression ring groove width Oil control ring groove width Compression ring width Oil control ring width chrome plated Slotted scraper chrome plated O 12 0 25 O SO 0 75 I00 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 3 8 3 6 3 3 3 5 mm mm 0 1858 0 1866 in 0 1496 0 1417 in 0 1299 0 1377 in Tension Compression No CDmpressiDn No I I45 1 7 5lcg 3 1967 3 8581 lb 1 6 1 9 kg 3 5274 4 1888 lb I2 1 6 kg 2 6455 3 5274 lb 2 Oil control Ring Gap CompressiDn CDmpression ND I 0 25 0 40 mm No 2 O Oil control Ring 0 0098 0 0157 in 15 0 30 mm O 15 0 30 mm 0 0039 0 0118 in 0 0059 0 0118 in 0 04 0 05 mm 0 0016 0 0020 in 0 001 0 003 in groove clearance Compression I 2 Oil control PISTON 0 025 0 070 mm PIN Diameter Standard Oversize available 0 062 Oversize available 0 125 Length 20 653 20 648 mm mm 20 722 20 710 mm mm 20 785 20 773 74 8 74 4 mm mm 74 68 74 42 Fit 2 mm 0 8131 0 8158 0 8153 in 0 8183 0 8178 in 2 9291 in 2 929 in 9402 680F 9448 2 Thumb fit at 200C Press fit 1 5 3 5 metric 29 0 8126 in ton Slip to 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 make sure that the ting new rings the 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 following At the top ring a O 002 feeler 0 001 feeler should cause the ring to lock in the groove the O 002 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 the If a ring ring on LOCATION OF RING grind making 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 0 2 0 8mm P Engine Side rail tension RIKVENT 3 5 kg Maker RIKVENT NIFLEX NIFLEX Fig 7 30 Set Piston Ring Second Oil Make Size Remark fop STO Niflex 12033 58004 From P 31592 STO Rikvent 12033 58005 From P 31592 Spare parts Spare parts Over Size 0 12 N iflex 12034 58002 0 12 Rikvent 0 25 Niflex 12034 58003 12035 58002 12035 58003 12036 58002 0 25 Rikvent 0 50 Niflex 0 50 Rikvent 0 75 Niflex 0 75 Rikvent 1 00 1 00 Niflex 1 25 1 25 N iflex 1 50 1 50 Niflex 12039 58003 12040 58002 Rilevent 12040 58003 lnstructions for Spare parts only 12036 58003 12037 58002 12037 58003 12038 58002 12038 58003 1203958002 Rikvent Rikvent 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 Use either of the two steel rails no right or wrong side of spacer with thumb end of rail on top side of spacer ends rail across ends and on around into the Holding ends Place Coil one groove Botton Rail lnstall remaining steel rail spacer with gap approximately on lower side of 20 30 mm right of spacer ends 31 FiTUJI I1Ulpection Check final assembly to make certain Rails are not off spacer Gaps of rails and spacer are nor lined straight Spacer assembly can be turned manually with ease Spacer gap Installing is directly over Pisto1Ul into Use steel band tool for piston boss Cylinders installing pistons into cylinders For NifleJ Oil Ring Install two rails from spacer gap so that each gaps are 450 Fig Lower Rail 8 Upper Rail Gap Spacer Gap NlFLEX Fig 5 2 CONNECTING 9 ROD DATA F SOO Material Steel Length center to cetner Big end housing width 200 199 9 mm 1 874 7 870 in 31 55 31 50 mm I2422 I2402 in Big end housing diameter Type Overall length Outside diameter forging 60 180 60 199 mm 2 3693 2 3700 in 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 1 SOOmm 0 593 0 0590 in 1 633 1 625 mm 0 0643 O SO mm 0 020 in 1 758 1 750 mm 0 0692 0 75 0 030 in 0 040 in 1 883 1 875 2 000 mm 0 0741 2 008 mm 0 0790 0 0738 in O 0787 in O OlD 0 064 mm 0 0004 O 0025 in mm 1 00 mm Big end bearing Connecting clearance Tightening time a removed from an connecting rod is O 0640 in 0 0689 in rod side clearance Every 1 508 O torque of cap bolt IS 0 28 5 5 kg m mm 0 0059 O OllO in 40 ft lb 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 bar If there is any correct it With a bend install the piston and check the alignment as the illustration The maximum allowable limit of bend ing 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 much clearances between the pin and big end of the connecting carnk rod will be found scored over the sur faces of the metal And in extrem the metal surfaces will even cases tually be cracked much own replace If the metal is with new so bearings Check connecting rod end clearance between the upper half of the rod and the side of the crank Fig 10 connecting pin with feeler gauge Lock the The bolt pal connecting nuts rod bolts nuts by installing new 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 bore 33 tl 0 rEgE J f 1 GAlJ GE 0 15 028 t 1 1 Fig 11 ti t f c i 12 Fig Inserting Piston Insert was taken each piston Connecting Rod and connecting it is essential that the F rod assembly into the cylinder mark on the boss of the piston from which in is 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 JOURNAL AND BULLETIN 36 SECTION 3 CRANKSHAFT Fig 1 DATA CRANKSHAFT Material Special Construction With Diameter of main No steel forged forging weight counter journals 68 229 I 68 204 mm 2 6862 2 6852 in No 2 69 300 69 275 mm 2 7283 2 7273 in 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 Not to exceed 0 075 mm center Main journal clearance Crankshaft end play float Shims available for above Pilot bearing hole diameter 0 0005 0 in 003 in bearing 0 03 0 096 mm 0 0012 O 125 O ISO mm 0 005 0 0037 in O 006 in O 13 0 76 mm 0 003 0 005 O 030 in 23 774 23 800 mm 0 9359 O 9370 0 07 in Pilot bearing length Number of teeth crankshaft gea mm 31 8 27 37 mm 1 252 in at MAIN BEARING Type Thinwall steel backed white and clevite metal F500 Number of 7 bearings Length No 1 No 2 No 4 41 mm 1 6142 in Clevite No 7 49 mm 1 9291 in Clevite 3 5 33 8 mm 1 3307 in White 26 mm 1 0236 in Clevite 6 Outside diameter ltiside diameter No 73 025 1 68 283 mm 2 8749 in 68 299 mm 2 6883 2 6889 69 371 mm 2 7304 2 7311 in No 2 No 7 69 355 in Thickness white metal Undersize available O I O O 2 12 0 004 O 008 in 0 75 1 00 1 25 mm 0 25 1 50 mm 0 005 O OW 0 020 O 050 O 060 in Tightening cap bolt torque of 0 030 bearing 10 38 11 kg m J2 80 ft lb 0 040 3 1 DISASSEMBLING OF CRANKSHAFT I Fig 39 2 When the crankshaft is 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 Fig Apply 3 dial gauge 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 a the shaft to the Support flange and rota see 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 than 0 001 0 025 mm have it fixed up When the journal or crank pin is worn flat more or beyond the limit rough 0 004 or over or oval replace or if they are scored cut it with a new one Clear 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 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 scores side a cuts removing the shims If the wear these shims is and washer beyond placed between the thrust washer and crankshaft side thrust clearance of O 004 0 007 replace 2 1000 in 6 1000 in the regular 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 40 Fig 4 41 Fig 42 5 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 insert the cap packing in the groove with the FIg Then using When a rolling rounded tool the packing fingers 6 roll the packing into the groove start at one end and roll the 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 Wash and clean the crankshaft and bearings 2 Apply marking compound lightly 3 Install upper and lower bearings in their crankshaft in the cylinder 4 Rotate the crankshaft hack and forth the contacting condition of bearings over 43 each journal own of crankshaft position and install the Remove the crankshaft and check 5 The upper half bearings have its contacting make contact to evenly and more than 70 If any insufficient contact is found area replace it with of a new me 6 The lower half the area bearings also should be making contact Sometimes evenly over 70 bearings excessive clearance of the lower half makes it impossible to show the contacting condition journal case replace with the lll1dersized of to the In such a can be made 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 in case of absolute necessity the clearance Re check the work until you are sure 7 After appl y 8 checking the cmtacting engine oil plentifully cmdition wipe off marking compound Install the seventh bearing and cap and tighten with tighteness by rotating the crankshaft a and regular force Check the 10 Fig 9 Proceed to 11 7 the next ft lb 80 72 k Tightening bearing Torque of Main Bearing Cap Bolt in the same manner and have all the bearings adjusted 10 If bearing fit is properly adjusted rotated by grasping No 2 and No pins II with a slight starting After above work is rench with the scale on all journals 5 crank pins the crankshaft can be or No 3 and No 4 crank but without any resistance after started completed be sure to lock the cap bolts with torque 44 SERV E NEWS REFERENCE NO DATE CONTENTS OF SERVICE JOURNAL AND BULLETIN 45 SERVICE NEWS REFERENCE NO DATE CONTENTS OF SERVICE JOURNAL AND BULLETIN 46 4 SECTION CAMSH FT TAPPET VALVE TIMING Adjusting Bracket bolt Set Lock Rocker shaft bracket A Rocker shaft bracket B k Rocker shaft cliP screw WaSher screw nut I 2 O Outside spring f e o i 0 Bush 1 0 o Valve fl L ExpansIOn plug I 58000 ii 13209 Valve Pu retainer Valve cotter spnng Valve IS Valve rocker Right side Valve rocker Left side h r ad Intake Ex Exhaust V81vedr ilO Thrust washer Timing gear 9 r 27319 70 1518 @ J 70 1519 Carn A shaft bearmg Figo 1 13006 58000 13005 58000 Camshaft Fig 2 47 Valve A t 8 I Oil pwnp drive gear Lifter 5 5800J Fig 2 B DATA CAMSHAFT Special Material Journal steel forging diameter No 1 49 149 49 124 mm 1 9349 1 9339in No 2 48 945 48 920Iilm 1 9270 1 9260 in No 3 48 641 48 616 mm I 9150 1 9140 in No 4 48 336 48 311mm 1 9030 Cam 41 246 height Fuel pump cam offset 3 00 1 9020 in 1 6238 in mm 3 IOmm 0 1181 O 1220in Runout of camshaft Not to exceed O 025mm 0 001 in Drive Helical gear Cam gear number of teeth 54 Bearing clearance O Ql O 10 mm 0 0004 0 004 in Bacldash of camshaft gear and crank gear O 1 48 O IS mm limit of use O 25 mm CAMSHAFT BEARINGS Frcnt steel backed white metal Thinwall Type bearing Out dia before fitting Inside dia 52 555 52 530 49 303 49 238 mm 2 0690 2 0680 in 1 9410 1 9384 in reamed in position 29 24 mm 1 29 49 Housing diameter 52 476 52 541 mm 2 0659 2 0684 in 62 375 52 3SO mm 2 0619 2 0609in position 49 123 49 058 mm 1 9339 1 9313 in Length 19 0 Housing diameter 52 273 52 248 mm 52 070 52 045 mm 2 0500 48 818 48 753 mm 1 9220 1 9194 in mm 1610 1 1511 in Length Second bearing Outside dia Ins ide ma before fitting reamed in in 0 748 mm 2 0579 2 0569 In Third bearing Outside dia Inside dia before fitting 2 0489in reamed in position 19 Housing diameter 51 740 51 943 mm 2 0370 2 04SO in 51 740 51 715 mm 2 0370 2 0360 in 48 488 48 423 mm 1 9090 1 9064 in Rear mm 0 748 in Length bearing Outside dia before fitting Inside ma position reamed in Length 31 8 Housing diameter 51 664 Undersize available mm 1 2519in 51 638 0 25 mm O SO 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 49 1 692 In 1 425 in mm 2 034 2 033 in Seat angle 45 Inlet and exhaust Seat width inlet and exhaust 14 0 055 in 1 8 mm Limit of O 071 in 3 32 in use Stern diameter Inlet 8 650 8 637 mm 0 3405 0 3400in Exhaust 8 8 627 mm 0 3401 0 3396in Length inlet Lift and exhaust 640 131 5 9 6 overall mm 5 1772 in 0 378 in mm 0 016 in O 40mm 0 015 Water tamp 80 C 0 38 Working clearance GUIDES VALVE Length 72 exhaust Inlet Outside diameter Inside diameter 8 685 Hole for valve guide diameter 2 mm 15 048 8346 in 15 030 mm 8 700 mm 15 018 15 000 0 5923 0 3419 mm 0 3916 in O 3425 in 0 5905 0 5912 in Valve stern clearance inlet 0 035 0 063 mm 0 0013 0 0024 in Valve stem clearance exhaust 0 045 0 073 mm 0 0017 0 0028 in VALVE SPRINGS Free length Fitted length and load 2 2638 in 57 5 mm 49 5 mm at 23 5 kg 1 9488 in at 52 lb 3 4 Number of working coils 5 Diameter of coil wire 4 5 Core diameter turns mm 33 5 0 1771 33 Omm in 1 3189 1 2992 in TAPPETS Type Diameter Hollow barrel 23 990 23 W5 mm in Length 55 50 mm 2 1653 in 0 9445 O 9438 ROCKER MECHANISM Push rods Length 388 Stem diameter 7 15 mm mm 0 2815 in Rocker shaft Length 641 mm 25 24 in 20 000 19 971 mm Outside diameter 0 7874 0 7862 in Rocker arm bushing Type Rolled phosphorus Outside diameter 23 45 23 43 InBi de diameter mm bronze bushing 0 9232 in O 9244 In reamed in position 20 020 Inside diameter before reamed 19 98 20 033 19 93 mm mm 0 7882 0 7865 0 7887 in O 7846 in Clearance between shaft and bush Rocker O 02 O 054 mm 0 0008 O 0021 in arm Bore 22 40 Lever ratio 1 47 22 37 mm 0 8818 0 8807 in I Tightening B 4 1 K T torque of rocker boit REMOVAL Drain the cooling OF water 4 3 CYLINDER 5 0 kgm HEAD by opening the radiator and cylinder block side taps Disconnect the radiator hose Remove the air cleaner carburetor manifolds drain rocker cover and the inlet and exhaust Detach high tension cables and remove the spark Remove the rocker cover and the corle washer Detach the manifold assembly 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 Talee off the rocleer same time To facilitate detaching the cylinder head joint head 51 tap each side of the cylinder at III1IIIIIIII Fig 4 REMOVAL OF 3 VALVES After the cylinder head is removed the valves can be take To do this compress the valve spring with the valve out spring compressor Remove the cotters of valve retainer Release the valve spring valves from the guide 3 4 retainer and oil seal from stem Withdraw the REPLACEMENT The diameter of exhaust valve head place are the valves insert each valve into its retainer and compress the valve spring Refit the valve cotters and Remove the compressor 4 VALVE secure smaller than the inlet valve To re and the oil seals replace guide spring them by releasing the compressor 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 52 trueing process When grinding a 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 with a semi be a suction type ground to motion rotary light coil spring interposed its A 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 the spread frequently to grinding compound evenly It is necessary to continue the grinding process until surface is produced an even matt 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 Fig 53 5 HEAD 4 Ensure that the cylinder head and cylinder block are clean The cylinder head gasket is joint faces marked upper face head in correctly TOP so that it will be placed Place the gasket into positioo and fit the cylinder head 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 finally pulling them down from the center to out side a torque wrench set 55 65 ft lb 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 attained its normal engine has working temperature in which case the valve clearance will have to be checked again and at reset if necessary 0 38 0 40 un 60oC 6 4 Fig TIMING GEAR a 6 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 Fig shaft will then be in its proper posi tion so that the valves will open and close in the proper relation to the movement 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 7 SERVICE NEWS REFERENCE NO DATE CONTENTS OF SERVICE JOURNAL AND BULLETIN 55 SERV E NEWS REFERENCE NO DATE CONTENTS OF SERVICE JOURNAL AND BULLETIN 56 SECTION 5 MANIFOLD 5 1 REMOVAL Remove intake and exhaust manifolds assembly from 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 2 2 2 11638 1 15116 9 J 1 1 Q 14628 14518 14020 58000 70 1956 14006 58000 9 A 11 16110 31628 9 11140 1 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 for warpage their Also check for cracks and lr eakages 5 HEAT CONTROL and replace if defective 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 This assembly manifold by a gasket 57 SERV E NEWS REFERENCE NO DATE CONTENTS OF SERVICE JOURNAL AND BULLETIN 58 SECTION 6 LUBRICATION SYSTEM Fig 1 Oil Pump Assembly Relief valve Oil pump body Shaft Drive gear Drive shaft pin Bottom pump cover 1 11412 9 15114 Fig 2 Components of Oil Pump 59 As in 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 showing Fig 3 into two series and the one necting rods camshaft creasing 6 1 the number of pressure ADJUSTMENT OF adjusting OIL washers REGULA TOR Remove the the connecter of The oil oil pump fixing bolts of the pump body at regulstor is attached directly to the Oil pressure should he kept 3 5 4 0 kg driving spindle em JJ t t Fig 3 Lubrication of Engine Fig Insert 4 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 60 18mm Pump body Regulalor Oil Fig 5 Setting the Stop 61 Pin valve RELIEF Free VALVE Length of Spring Length Valve 41 5 After SPRING when fitted 30 3 mm mm Thickness of Adjusting Washer Compressive Load Immand2mm 0 040 O 080 in 2 24 kg 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 following adjusting washer DATA OIL PUMP Type Spur Gear 8 39 40 39 35 mm 1 5511 1 5492 in 29 960 29 935 mm 1 1795 1 1785in of gear Number of teeth Gear diameter length Knock pin diameter 3 18 3 23 mm 0 1251 O 1271 In Oil pump shaft Diameter 12 TI6 Length 190 2 189 8 0 025 0 1175 mm O 008 in 0 001 Gear back lash If 12 958 mm 0 5108 7 4882 mm 0 003 In Gear vertical clearance 0 040 O 115 mm 0 0016 Gear in O ISO O 260 mm 0 006 body clearance regulator Built in pump Oil regulator Min 0 5 kg 7 4724 In Replace over Oil 0 51011n O 0045 In O 010 in body cm 7 lb in at running speed Measurement of oil pressure regulator Pressure of regulator spring Clearance between pistem and and body 2 24 kg O 002 30 3 mm high O 0025 in If over 0 005 in Replace Pressure Running 3 5 Idling 0 5 4 0 kg kg cm em SO 7 lb sq 57 lb sq in in at oil temp 70 SOoC Sump capacity Oil 5 3 litres 1 4 gal U S A S A E MS No 20 For temperature No 62 30 above 300C MS 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 FILTER OIL 6 2 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 packing considered The tightl y and to gasket place and in are used if leak the oil capacity of be checked every engine oil should day The oil capacity is measured by vided at the pr side of cylinder The oil level the oil level gauge right 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 63 Fig 6 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 0 6 64 7 5 kg cm 2 5 kg m opening pressure SERV E NEWS REFERE CE NO DATE CONTENTS OF SERVICE JOURNAL AND BULLETIN 65 SERV E NEWS REFERENCE NO DATE CONTENTS OF SERVICE JOURNAL AND BULLETIN 66 SECTION COOLING 7 SYSTEM 2 I 3 Radiator 2 Fan 3 Thermostat 4 Water pump S Cylinder 6 Cylinder block head Fig 7 1 WATER PUMP FAN a FAN I 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 15 1 BELT 14 11 16 2 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 9 Fig 2 10 4 Sectional View of Water Pump 67 17 DATA Water pump type Centrifugal Pulley 1 28 ratio to 1 Fan blade Number 4 Diameter 476 Thickness 1 6mm mm 18 7 In Fan belt Type Lengtb Angle of V 40 degrees 1175 1181 mm 46 250 46 500 in V outer Deflection tensioo 25 adjustment Fig 2 7 REPAIR OF WATER mm 1 in 3 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 In case of the pump shaft 1 Disa88emblll of Water Pump 1 Remove fan blade from the 2 Move the generator toward the engine after generator and take off the fan belt 3 Remove the 4 water pump pulley removing the eight loosening bolts holding by pass rubber hose at water outlet spacer Remove three bolts which hold the water pump body to the 68 cylinder screws the block 5 Draw out washer 6 cotter Pull pin in the castle nut on the pump shaft and remove nut and out pump pulley from the shaft using a puller and remove woodruff key Remove four bolts 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 7 8 9 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 2 rear seal plate bearing felt Ner C plate and felt seal from Auemblg of Water Pump In order to assemble tIle parts after having finished invert the order of disassembling work mentiooed above care is to be taken in handling 1 washer body necessary repair works However the follOWing 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 4 2 1Sj VI ttfi See that the rubber seal fits on the shafl with proper tighteness J T i il F t t if I t 9 The proper tighteness is deter by the rubber seal sliding mined em the shaft when with 3 After having assembled assembly with i pushed lightly fingers retainer seal seal system water seal retainer e t tg the vane spring rubber seal seal r bakelite check snap ring whether the unit is In proper The unit is in working order good shape If the bakelite seal vane ff snaps back to its proper place when depressed with a thumb and freed If the seal does not return instantly and without drag it i t due to weakness of the seal re tainer spring or too i of the rubber seal Remove such a seal and inspect the bore of the C i seal and if found blamable for fitting rebore Until it properly On the cemtrary stiff cause new 0 A Wi fits if the is found in weak seal re tainer 4 spring replace spring t it with a g 7 Fig assembly to set it to the shaft stall the shaft the pump Yc j r r 1 5 Cover the felt seal with sufficient grease and cover plate and rear seal plate Then in shim washer front seal plate and snap spring body spacer l t together with felt bearing i fo Jii F In order to assemble shaft first insert the bearing etc vane ff tight fitting 4 to F Jt Jiil t 1 f1 2 f Fig 6 70 l 4 r 1 r t 5 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 6 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 7 In runs 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 Water 3 smoothly assembling Pump Ordinary Troubles and Remedies troubles in the waler pump are water leakage vibration noises Causes of waler I Rubber seal in bad b Bakelite seal in bad shape Retainer spring fatigued shape d Friction surfaces of pump body and bakelile seal e Body g Wrong h Worn Anyone have be to leakage 2 vane gasket shaft bearings or bent shaft of the above will cause water replaced and loose have to be wabbling and a Worn b Bent vane assembly shaft Loose pump body screws or leakage and damaged or worn out parts tightened up in order to SlOP the surface of the pump body can be reground screws The wear of the friction Causes of vibration c noises burnt ball bearing Of the above burnt ball bearing is caused from poor Replace it with a new one and feed grease sufficiently ting in the pump supply of oil through lubricator fit body Periodical supply of chassis grease to kilometre run 4 worn in poor shape or loose screws of the pump cover or loose screws of the pump body or cover f Wrong and leakage a c wabbling A4justmellt water pump is to be made for each 1 000 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 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 the bolt belt Fasten the bolts wear bearing If the belt is in to would be damaged 71 Fig 7 RADIATOR 7 Adjustment of Fan Belt THERMOSTAT a HEAT INDICATOR DATA RADIA TOR Water tube Type Pressurized 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 REPAIR OF 1 Cleaning Pellet 71 50 86 50 74 50C 89 50C 1600 1870 l660F 1930P RADIATOR of 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 Neglect impure I wster Drain the cooling water by opening the drain cock at the bottom of tbe radiator 2 Loosen the clamps of radiator inlet hose and the outlet hose of radiator and disconnect them from the engine 72 at the sides 3 Plug up the Inlet hose opening that connects with cylinder water outlet of proper diameter and securing it in place with the using a wootl block clamp 4 5 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 6 First remove radiator from the chassis 7 Plug 8 Heat the soldered up the outlet port of radiator tubes that they are Is empty at 9 If other wlse Scrape off completly a water up to the top of radiator core and upper tank With a burner so Never heat the soldered when the radiator sean seam separated radiator tubes and will the bottom of radiator and fill the heat will melt away the soldered parts of the cause leakage the scales and other impurities in the water tubes with thin stick and flash the insides of water tube and lower tank with clean waler 10 After finishing the above operation assemble the core and upper tank by soldering Care 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 Water Cooling Cooling water must be filled always up to the overflow pipe at the top of radiator 2 Hard water cooling or water cootaining alkali substance is to be avoided for use of 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 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 must be taken In the time of not to let color would be affected 4 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 keep late the 5 the engine is stopped before feeding cold water and will have undesirable effect the cold winter or whenever is liable to freeze During waler from the radiator and engine Be sure to rear it will not circu water right never fail open both drain cocks at the bottom of the radiator and side of the engine to completely drain the water 74 to drain at the SERvreE NEWS REFERENCE NO DATE CONTENTS OF SERVICE JOURNAL AND BULLETIN 75 SERV E NEWS REFERENCE NO DATE CONTENTS OF SERVICE JOURNAL AND BULLETIN 76 SECTION FUEL 8 1 8 SYSTEM FUEL 2 PUMP 3 4 1 I Upper body 2 Valve retainer 3 4 S 6 Cap Diaphragm Valve Coonector Rocker ann Rocker arm spring Rocker arm pin Lever Hand primer pin 7 8 7 q to 11 12 13 14 Packing cap Diaphragm spring Lower body 14 9 15 16 8 Fig 1 Valve Diaphragm Fuel Pump DATA Type Diaphragm spring Free length Fitted length I tload Mechanical diaphragm 60 4 mm 22 arm 9 5 mm at 21 Rocker 61 6 pump 2 3779 2 4251 in 10 5 kg 0 8661 in at 23 lb spring Free length 29 5 30 5 7 05 7 1 1614 in mm 1 2007 in Valve spring Free length Valve thickness 15 mm l5mm 0 2776 0 2815 in 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 Max outlet pressure suction vacuum 220 Max Hand primer output 400 250 mm 15 7 in Approximate 10 strokes 77 hg 8 mm hg 200 cc 66 9 84 in or over 12 2 cu in hg OF 2 REPAIR 8 FUEL PUMP Measurement of Rocker Arm 1 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 2 Fig 2 Construction of Fuel Pump and Measurement of Rocker Arm Wear of Ports Inspection air before Wash and clean the parts wilh gasoline and blow tith compressed attended items should be Undermentioned specially making the inspeclion 1 Whether phragm 2 Whether phragm 3 or not gasoline is infillrating due to the wear or there is any crack or wear in the shaft and link Whether or not or not lhe conlacting surfaces are worn 78 at rocker damage of connecting part arm cam dia of dia and the link 4 5 6 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 COllses and Repairs Poor fuel supply This will happen when gasoline leaks 1 due to crack 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 damage or fatigue of disphragm 2 In 3 of case In case the 5 be be re and two inch replaced check csp bolts for tighteness In case fuel or air leaks If this does 4 a new one must for inner through cap gasket not stop the leakage gasket is to be replaced wash it with gasoline screen is clogged with dusts 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 place When the conlact surfaces of valve eat and valve are 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 remove not smooth polish the valve lightly em a glass plate Slandard thickness of valve is 1 16 inch 6 coated with fine emery If worn beyond the 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 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 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 arm by part the surface with file phragm 8 9 a exygen simpler repair can be done by using paper dia in 4 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 as Also is 29 5 30 5 mm Over Flow of Gasoline from Carburetor I 2 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 3 gasoline leaks damaged or worn out In case the cause will either the Replace If the ventilation hole of the lower leak into the engine oil pan diaphragm is cracked it with a new one body resulting 79 is clogged in diluted with dirts engine oil gasoline will 5 Attention for I Assembling the Pump Don t tamper the 3 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 4 After 2 assembling check the air 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 valve action is not spring seats In 5 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 assembling lower body and phragm it sure that the help diaphragm 6 making diaphragm move does not up and down wrinkle freely alemg its and insure edge a long This life care will Inspection When the is finished assembling the following items are to be checked before installing 1 2 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 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 burelor functions idling 80 car DATA Hilachi VC42 IA for Model 680 VC42 4 for Model 4W73 and 60 series VC42 5A Type FR40 Downdraft throttle and choke valve linked 42 mm I6535 in 36 x 17 x 10 mm I417 in Throat diameler Venturi diameter x 669 in x 0 393 in 143 for Model 680 Model 4W73 and 60 Main jet No Main air bleed jet No No 70 55 Slow air bleed No 210 Power No Slow Slow jet by pass 4 hole Needle valve diameter C dimension Accelerating pump bore Imm 2 0 19 m 0 7480 in 0 ff787 in Choke valve Fuel level height Poppet 20 stroke accel pump Pressure em fuel Functioning valve 22 mm 0 7874 O 8661 in 4 3307 in 1I0mm hg II full choke Output in mm 2 0 mm Power valve start open Degree throttle valve open 1 110 0 1575 in xO 0394 0 ff787 in 7 8mm 0 3070 in x Idler hole diameter at No 135 for I8 cc 0 1098 cu in 0 3 kg cm2 4 26 lb sq in 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 3 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 the air neously Functioning 2 lion Speed Carburetting System This system operates for lhe slow speeds the throttle valve is opened only slightly is low Ccmsequently for lhe slow the main speed operation developed below as the Slow o carburetting is created lhe throttle valve The idling During slow speed opera and the air flow rate of course system is inactive principally by functieming The mixture the of negative pressure the slow speed system is follows The fuel in the floal cham by passed al the main jet Power valve Piston ber is 10 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 of a lengthwise slot and a Imm hole snd delivers lhe mixture for slow speed when the open ing of the throttle valve is ex tremely small However as the throttle valve the opens gradually mixture is ejected from the hole snd the transi tion from speed slow to inter mediate speed is made smooth ly without irregularities such as pauses in the ction Throule valve shaft Fig 3 Functioning o the Accelerating Pump 4 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 is 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 82 provides the necessary acceleration Pump injector If the accelerator is depressed further the throttle valve will open further Then which its opening becomes 110 mm Hg from the fully closed position the end of power valve roo moves down together with descent of the connecter to push down the valve Simultaneously a new fuel passage is formed between the float chamber and main and the fuel of the float chamber through the fuel port is metered by jet enlers the power jet goes oul of the end of lhe main jet and is ejected from the injection nozzie together with fuel of the main carburetting system As a result and is extremely righ mixture supplied Air check bowl 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 Fig 5 Choke valve Fig 6 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 it smaller will make the mixture leaner If an air bleed is made large if it is made smaller the mixture will become the mixture will become ieaner richer 83 4 ADJUSTMENT 8 OF CARBURETOR The slow 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 and lhe siow h 7 I y t l I t i f C I Fig I First set the by 2 7 engine speed approximately al slow speed of 350 10 400 rpm of the throttle valve means Next c adjust the slow adjusting screw speed adjusting screw so that the engine rotates smoolhly 3 Needle Then adjusl the rOlating speed pre cisely with the throttle valve adjusting screw If lhe slow speed adjusting screw in with too much force its tip will be damaged and become the causes of improper operation screwing be careful in even when this screw in a certain amount is still 100 rich that the slow not clogged high not 100 therefore it in If is screwed Float the mixture check to see speed air bleed is that the fuel level is and that lhe seating of the floal needle valve is good 84 Fig 8 valve 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 when the engine adjustments are adjusted correctly to be made Otherwise chamber must first be the fuel level in lhe float correcl adjustment cannot be made Without special equipment the correctness of the fuel level cannol be determined Ordinarily the following method will produce lhe correct level directly 2 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 3 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 I 4 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 5 If holding pin plate as shown extract the float not angle 9 of the contact making this adjustment be broken off from headed because the float lhe float and adjust the Be careful in photograph bending is forced the arm may remove in the if the Also because the needle valve is be careful not to let it drop 85 out togelher with its not spring Fig 6 10 Check the seating of the needle valve replace the needle valve assembly to the valve If seat 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 As described previously valve becomes 110 high side adjustment the if it is on the functioning will be hastened 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 For correct 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 totally closed the opening degree throttle valve will stand at Connecting rod Setscrew of Rod 11 Side groove Fig 86 11 post 5 8 AIR Cleaning of CLEANER Air Cleaner The air cleaner serves to clean the air before it is suctioned into the cylinder 1 If the cleaner has been in service for considerable length of lime withoul having been cleaned the accumulated a dusts within the cleaner interferes free This will of the air passage a re sult in poor engine performance and As any increased fuel consumption for Model 4W73 and 60 dust particle mature wear in the air will cause pre of cylinder wall air cleaner should not be dispensed with kept clean aU the time by periodical inspection and cleaning and it should be unscrew the To clean the apparatus nut on top of the cap and remove wing the Take out the steel wires and 2 b for Model 680 cap gasoline Filllhe bowl oil up to the specified level engine ReinstaU the wires after having been dried and soaked with oil clean them in Fig 3 12 Air CleaneT with 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 STRAINER GASOLINE j 2 s lj lSjr 1 i I r li c f J@ 8D 1 Fig 13 Q f ii J ii I i i Ik h f l 1 Jr 264t2 I CD Bowl jClamp nut @Srrajner element Gasoline Strainer Ass y 87 of Gasoline Repair Instructions for 1 1 Strainer To remove the bowl from the wire to a side 3 of Gasoline Slrainer loosen the strainer body nut nut and remove lhe and washer from the wire and remove screen 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 4 Assembly Take off the bolt gasket and bowl 2 and Disassembly tight alloy Strainer body is made of aluminum Take good care not to break threads of each connection 5 Pay attention not to bowl 6 When installing sufficiently air 2 Poor the strainer nut so tighten excessively that the gasket and broken are the strainer bracket should be cleaned plug from keeping assembly the strainer Dust and dirt em the bracket surface prevent tight Feeding of Fuel Causes of this trouble are as follows When the Air leaks from the bowl 3 Air leaks from strainer nut screen is with dirls 1 2 clogged gasket strainer connector or plug as the result of imperfect tightening 3 Disorder of Nem relurn Valve This is caused from either corrosion to open or or wear of valve seat which makes it hard shut In this case replace a new valve and flatten the seat Somelimes the troubles in non relurn valve will discontinue feeding gasoline the engine when the lalter is over heated to Inspection 1 Cleaning of the Screen screen become clogged with dust After ioug run dust and water in its bottom and will result in poor 2 Check depositted with straining efficiency Periodically In case of dust and dirts are up and the bowl is completely with gasoline and deposilted therein compressed S8 air remove bowl and screen clean 8 7 GASOLINE GASOLINE TANK a GAUGE 2 1 CVResistance wire OOTerminal iFloat Fig Gasoline Gauge Tank Unit and Dash Unit 14 Fuel tank capacity Model 680 110 1 of Gasoline Tank Troubles of Gasoline Tank 1 50 ltrs 13 U S Gal 100 26 4 29 Repair 60 4W73 Gasoline Gauge and 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 The gasoline pipe of tank unit of lank and clean inside of tank 2 Fuel does not come into the a This gasoline pipe happens when the ventilation hole in the filler cap is clogged with dust 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 b 3 Fuel Leaks from the Gasoline Tank a First fuel b locate the leaking spot and mark it with com a chalk and drain the pletel y Blow the compressed air into the tank and expel therein Get it dried completely 89 out lhe stagnant gas c 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 Failure to explosion patched lhereto the gas at the time of expel stsying in lhe lank will induce a dangerous Good care is invited to wilding operation this matter 2 Trouble and Check of Gasoline Gauge The trouble in unri and poor wirings 1 2 gauge is attributable Check them as follows gasoline 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 running from the wiring moves the back of dash unit to tank unit is no If the indicator good 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 4 the trouble in lank unil Remove the terminal of tank unit wire 3 to In case of no Defective dash unit should be replaced is seen when the wiring from the battery is spark it indicates the lrouble is in wiring 90 grounded SERV E NEWS REFERENCE NO DATE CONTENTS OF SERVICE JOURNAL AND BULLETIN 91 SERV E NEWS REFERENCE NO DATE CONTENTS OF SERVICE JOURNAL AND BULLETIN 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 1 Ignition System Circuit DATA IGNITION COIL Hitachi CIZ Ol Type Primary voltage Primary coil resistance 12 volt 3 95 n Insulation resistance 10M Current consumption approx 200C 680P SOOC 1760P st n at Running 1 4 Amp distributor lS00 rpm Slall 2 0 93 Amp o t l 11 T 0 o Fig 2 94 DISTRIBUTOR Hitachi 060S 01 Type water 100 B T D C and Ignition timing Automatic advance system Advance angle characlerislic Advance start at Max advance engine angle Centrifugal 340 at 3600 rpm crankshaft 45 0 55 mm 0 018 0 021 in 350 400 at point gap O 5 mm 0 point gap Dowel angle Condenser vacuum lOoorpm rpm Breaker Contact arm D608 02 proof spring capacity O 020 in 500 600 gr tension 17 6 21 1 O 24 Micro farad O 20 Insulation resistance oz 5M n or over Clearance distributor shaft and 0 015 bushing O 035mm 0 0006 0 0014 in SPARK PLUG Model 9 1 1 B 54E or B 6E Size of thread 14 ffim Gap o 6 CHECK Ignition a O 7 mm REPAIR Coil When the ignition coil is found unreliable test it by comparing with a new ooe I 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 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 4 If the ammeter indicates a flow of current over six amperes it suggests If it regislers no CUrrent flowing lhrough that lhe coil is short circuited the circuit it is because the coil wire is broken and a new coil should be used 2 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 a To 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 lhe stud washer and b 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 c Before grounding assembling supply three the center of earn Check the grease cup or four drops of engine oil to the Celt at d and make sure the distribulor shaft in sufficienlly lubricated 2 Trouble a Burning of the When lhe point points are defeclive condenser burnt due to remove long service the breaker arm improper point gap and Redress the contacling surface of the poinl with b a or contact arm fine file and adjust their gap after installalion Adjustment of point gap Loosen the lock screw Turn the adjusting screw until poinl gap arm riding em a lobe of cam is 0 020 inch with the heel of contact Tighten lock screw recheck gap c Wear of heel of contact arm and wear of cam 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 Short circuit contact arm and arm inspection 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 3 tension of contact arm Improper spring e D When the tension of contact arm 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 twenty at the two ounces measured contacting point just before it starts to open When replacing arm scrape the hole of contact so as it can be easily in arm a new contact stalled and freely work on the When it is plate pin breaker @ not working easily the regular spring tension will not be strong enough to and will speed f work cause on the Fig cootact arm misfiring at Q Governor iPlt wei @ Governor spring high spring in lhe case of weak as Distributor Governor 4 Short circuit Df distributor cap There will be a short circuit when distributor cap has cracks and it will cause misfiring Replace with a new g cap Distributor rotor h 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 Condenser troubles L 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 by comparing i 2 Using a are weak the condenser is suspecled of trouble test lighting tester touch one of the tester terminal to the lead wire of condenser and the olher end to tbe bracket of condenser the tester il with a new roe bulb lights If it indicates the condenser is short circuiled 98 3 Flow for just native a momenl 200 volts current either of direct or alter After a minule lead wire and body of lhe condenser through approach the end of the body of condenser or lWO from is assumed to be O K heated when the current 3 If a sprak jumps 16 inch distance lhe condenser the gap On the contrary if lhe condenser becomes is supplied as described above or if there spark when the lead is probably defeClive is no ser lead wire to about 1 wire is 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 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 pipe phragm Fig 4 5 Spark Plug The spark plug used 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 is fourteen millimeter spark ap is 0 6 O 7 mm g a 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 99 there is any damage on the porcelain After that 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 When side electlcxie which is in the b b Diagnosing Engine I If the inside of of the core center Condition through by Spark Plug spark plug a is well dry and brown colour without any carron element making a satisfactory combustioo Accumulalion of carbon in lhe spark plug indicates that the engine is supplied with too rich mixture and lherefore ilS combustion is imperfect b When the spark plug is found b 3 4 wet with gasoline it means the spark plug missing When there is 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 wet with oil an it indicates the whenever it is removed sibly 1 porcelain is in light cylinder is assumed to be b 2 is 9 2 ilS white this fairly accurate diagnosis of the cylinder is pos made ADJUSTMENT Test of Distributor Efficiency 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 follows Fig 6 100 set the ignition timing as 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 comes near to in line with a and set the indicalor to 0 the top of poinler and on the tighten the screw screw at the bottom of the distributor Remove the cap and adjust the contact point gap to O 020 ness gauge Loosen the Cemnect one of the wires of the distributor and connect is turned to the right unlil the is lightly pushed with a finger Connecl No ing lhe is firing When 1 facing tester to the primary wire of lhe other wire to earth Turn ignition switch on Adjust the distribulor so rotor arm liming lamp measured with thick the timing lamp is lighted when the distributor body point begins to open and lhe lamp is off when the poinl as wire to the dislributor al its terminal to which the and connect other wires in counter clockwise order and follow spark plug order of 1 5 3 6 2 4 lamp tester is not available Pull out lhe high tension wire at the a proceed as follows cap and hold it 1 8 inch away from the en gine block Fig 7 Turn 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 Connect the spark plug wires Finally tighten all the terminals and connections 101 high tention SER CE NEWS REFERENCE NO DATE CONTENTS OF SERVICE JOURNAL AND BULLETIN lO2 SECTION 10 GENERATING SYSTEM DGenerSCOT OOVoltage regulator Ammeter @ @Ba ery @ Fig 10 1 1 Generating System GENERA TOR D Frame j Terminal @Terminal @ Commut8cor @ Brush spring @ Field coil Armature @ Ball bearing @ Fan pulley @ Throw bolt Fig 2 Sectional View of Generator 103 Fig 3 Generator DATA Type HITACHI G1l5 09 Voltage Output amp Pulley ratio x Shaft limil runout 12 volt 200W 13V Volt 1 84 Wear limit 2 0 Out of round limit Irregular wear limit O 05 mm 0 002 in 0 3 mm 0 012 in 16 mm 0 630 in Brush length Amendment limit Brush spring tension 4 in 0 433 in 700 gr 17 6 0 3 mm 0 012 in core clearance Field coil pole core screws FOR 6 7kg HANDLING Keep always clean the inside and m 44 24 6 armature In case of assembling And when assembling After assembling bearing feed oz 51Ib ft GENERATOR outside of the generator wash the pans with gasoline When the generator is disassembled the field coil and 3 0 0079 II mm Armature 2 CAUTIONS 10 m 500 Torque wrench setting 1 l5A Not to exceed O I mm 0 004 in 37 mm 1 4567 in Conlnlutalor diameter 2 x I excepting coil blow away the dirl and dust by make sure all cemnections are eight 10 ten drqJs 104 the compressed air tightened securely of engine oil 10 lhe armature shaft s 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 6 generator If the generstor will be burnt The terminal of circuit must be tightly fastened 7 3 10 not ground CARBON PILE REGULATOR TYPE and kept clean VOLTAGE qPiIe preS ure @Csrbon pile @Pile holder screw @Moving core @Compre6sion spring @Yolce VMagnet l coil jFlux adjusting Fig screw 4 DATA Hitachi R 115 02 Caron pile Type Voltage adjustment No load voltage setting Flux screw locating voltage CuI out relay point gap Armature air gap CUI in voltsge point 15 8 16 volt generator 2500 rpm 10 volt generator 2500 rpm 0 7 O 9mm 0 028 0 035 in 0 25 0 45 mm 0 010 O 18 in closed 12 5 13 5 volt 1300 rpm generator 5 ampere 45 Reverse current Number of carbon The carbon crease pile system piles is so applied field coil in series conlrol the plate spring sure The 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 designed higher pressure is applied With this function lhe carbon when pressure higher voltage produced by and therefore more resistance the lower the generator will exert less pres voltage will induce more pressure 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 sult of iI the pile I voltage and reduce field current of the generator will be reduce 105 As the re Fig On the very low contrary the carbon 5 when the VoUage Regulator voltage pile system in Model4W73 of the electric current from generator drops will functiem in inverse order as described above and raise 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 Thus the tage so thaI it will not exceed a limit Note The 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 carbon 104 pile type has no contact lhe points point which may cause TROUBLE AND REMEDY AND REGULATOR sparks OF at However the this trouble 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 c 2 When the lerminal is loosened Troubles in the tighten securely 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 repair the When the wire of the c If the contact d is with the inside electric circuit contacting cover b points replace the opening regulator regulator is broken or shorted of the cut out cut out When the face of conlact relay replace or remedy found unstably closing and are relay points of cut oul relay are pitted or rough dress them down with a fine file or emery cloth e In case the the cut out relay coil of the cut out voltage f When the current coil of cut out broken g replace 3 replace plale of plate regulator relay relay lhe automatic is found broken or aboUl to be is found dam voltage regulator the If there is any broken tage i the cut out When the carbon aged replace h is shorted or broken relay shorted wire in the or replace magnetic ooil for the vol lhe part If the resistance coil of the voltage regulator is shorted broken replace the coil or its wire Troubles of generator a If the brushes are found making poor contacl remedy or replace the brush Weak or refective c When the surface of commutator is found d should be repaired b spring If there is any short or it damaged on or rough replaced turn the armature coil down on a lathe repair or re place e If any broken or shorted wiring is located in the generator replace or repair 4 Over Charging If the ammeter generated voltage Check I regislers anbormal high charged condition high it means that the is too causes as follows 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 2 Troubles of Repair the exposed wires or replace 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 a 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 b c with d 3 4 a new one If lhe resister for or shoned replace lhe coil Troubles of the battery happens that the actual reading of the volt meter rate the the trouble is located in the Cut out relay ing current is than battery defective registers a discharge while the is engine running at a charg relay of the the cause of trouble is no doubt in defective cut put Check as follows regulator 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 b charge speed voltage a of always higher If it so If the ammeter the closing voltage to the rated value 12 5 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 coil is broken pile GENERATOR Test Motoring Have a OF fully charged battery and a 30 amperes ammelers ready for the use of test Build up a 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 to of current in this manner I If the ammeler locate the inside trouble of the generator indicates a discharging rate of less than five amperes and slight sound and it should if the generator keeps running amoothly with a be regarded as perfect condition 2 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 located in defective in good shape Usually If the generator lurns in the above test there must be a short circuit internally 3 If the be a ammeter lhe internallrouble is armature shows poorly contacing a discharging or highly rale but if the ammeter needle vibrates of below four amperes there must resistance parI in the internal circuit 2 Internal Troubles of Generator By the above test a idea of the location of trouble go into the detail it is recommended to make test If the tester is not available an armature growler 110 However 10 obtained universal electric tester can on a Fig 6 can be used 1 Low Current Charging When the ammeter keeps registering unreasonably low If it is found in good order on rate check first the ammeter and remedy in the following order current 1 charging Troubles of External wiring a b 2 of locate the trouble If any wire is broken worn or replace When any terminal is found loose Troubles of or tighten securely regulator a When there is any shorted or broken wire b Check the cut out dress with c repair a and if the contact relay replace points or are repair dirty pitted or fine file or emery cloth When the adjusted voltage adjusting screw is too low turn counter clock wise the and increase the vollage for variable flux d Check the resister for pile coil e Check the magnetic coil If it is burnt and shorted If any part of the coil is shorted replace or broken replaced 3 Troubles in Generator a When the surface of commutator is remedy the b c dirty Check commutator brushes If their redress the brush surface replace Check coil of any or extremely rough polish or surface armature or and of field broken part is disclosed contact as replace with commutator well or as wiring repair is poor 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 above 1 Troubles in external wiring a If any wire is broken b Check the insulation of wire generator c 2 replace Check terminals or or about to break it replact If it is broken and grounded to the body of repair If found detached or 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 If then Note a ground remarkable the other spark occures to the generator body wilh the generator is in good a light bouch 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 a Check the wirings inside the generalor be b c 3 replaced or repaired Check the armature coil and field coil shorted replace the complete parI parts If the surface of dress e Check the brush holder commutator Troubles of voltage If tbe regulator is found extremely scored replace If it is shorted due to poor insulation or re repair regulalor cover is found repair the in a short circuit b If their wires are hroken or If they are found worn and not contacting Check commutator brushes with the commutator or if the spring is found broken replace lhese d a Broken or shorted wire should In case any wire in the making contacl with the resulting wiring cover regulator is shorted or broken replace or re pair c If the contact points of cut out relay do not close when pushed Wilh a Make adjust moving plate are stuck it is because the core and finger men In Note making Next lhis test be sure to have the hook up a voltmeter fifteen volt battery disconnecling to Band E terminal of the 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 d e f 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 coil may be broken current or If so shorted replace cut out relay complete When the cut out closing voltage g In relay is O K ed and lhe volt meter the trruble will be in or zero reading voltage is low raise up the voltage by turning lhe for variable flux to the counter clock wise case screw h In i When the case place 3 Fluctuation of wear or damage magnetic coil of of carbon is below voltage regulator adjusling replace it and adjusl again voltage regulator is broken or s hurled re pile it of Charging Current When the ammeter needle surges check lhe following showing a charge unless the trouble is in the ammeler I Cisorder of external wiring be aboul to he broken a Wiring may b In case the insulation of or correct v replace ire is Orn and is it 108 it grounded to the body replace 1 Test of field coil connect Dis grounding 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 is illuminated the field coil has a short circuit If does not light the field coil is in In the dormer case good condition replace the coil 2 Lead wire test Contact the two wires of the growler both ends of the lead wire and if the lamp lights the wire is O K to If not 3 the wire is defective Test of Fg and should be 6 A Tma tUTe G TOW IeT replaced 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 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 growler ment placed 5 Short circuit of armature Place the 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 a hand 10 6 WIRING OF GENERATOR VOLTAGE REGULATOR AND OUT PUT ADJUSTMENT 1 Wiring I Connection of wire c f Fig 7 Be sure each wires is connected to its regulator Also each wire should be grounded to the terminal E the lerminal be minimized Regulalor A right place on both the generator and tightly in place especially the one Make it also sure that eleclricsl resistance by clean light connection to Generator A terminal 8 to Ammeler to battery F to Generator F E to E lerminal III terminal to body al 2 Size of wires The following sizes are to be selected for different wirings A 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 From S gauge No 8 S gauge No 16 w 611 @ I otQJ Wi ifJ J J J C tt 1 t 1 L Q mI Iif I Fig 2 7 Wiring Diagram A Ammeter D C M Motor B Battery V Volt speed R meter O C O 15V Variable resistance 0 0 2 ohm 30 Amp S Switch volt r O 15A I HP Variable on f 2 J Fig 8 Universal Electric Tester 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 I 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 equal to I volt The adjusting screw voltage Each quarter of a turn of lhe screw is for pile be utilized for pressure may ment 112 voltage adjust F ScreW Fig it is used However only Adjusting 9 when the carbon In this case repair work Screw for Variable Flux pile has been reassembled after the screw clockwise will raise lhe As the ammount of current is automalically turning voltage and lhe vice versa regulated to specified limils this type of the regulator is not provided with a current limitter 2 Adjuslment of Cut oul Connect the volt reading the of lhe cut meter to meter oUt realy the gradually A terminal of the regulator increase the generator and while speed until the poinl relay starts to close The voltage at lhat shown by the voltmeter momenl should he 12 5 10 13 5 volts If it is found higher push down the arm to spring on P Screw adjusting decrease the tension If the contrary the closing voltage lower is raise arm up 10 increase the sprIng tension The points will open when lhe ge nerator is slowed down and ilS Fig out 113 10 put is reduced to three amperes or less SERV E NEWS REFERENCE NO DATE CONTENTS OF SERVICE AND JOURNAL BULLETIN 114 SECTION 11 MOTOR STARTOR DATA Type Hitachi S114 20 4W Series S114 2l E690 S114 22 L4W Series S114 23 680 690 60 Voltage 12 volt Starling Less than 420 amp 9 5 volt Over 1 8 kgm 130 ft lb voltage current Lock torque Pinion gear type Pinion gear number of leelh Flywheel gear Sliding bushing 146 16 2 14 O 1 Irregular wear limit mm 3 0 mm 0 3 mm wear limit 0 559 in 0 004 in 0 003 0 0012 in 0 1181 in 0 0118 in O 05 mm 0 002 in 16 3mm 0 6417 in 11 3 mm 0 4448 in Oul of round limit Brush length Amendment limit Brush spring tension O 9 kg 1 98 lb REPAIR 11 1 2 I 2 mm 0 076 0 030 mm O 2 mm 0 008 in 34 mm 1 3386 in clearance Amendment wear limil Commutator diameter Amendment running clutch number of Gear ratio Pinion shaft diameter Amendment wear limit Shaft and over 9 teeth 1 1 4 HP 1 0 KW Power Removal 1 Remove the startor 2 Loosen two through pedal and remove startor motor from screws bearing and pull 3 Remove armature shaft center 4 Remove shift lever from head cover 5 6 Remove pinion and clutch Remove fOOl switch Inspection Inspect engine and remove head cover out armature assembly of parts each parts after cleaning parts should be amended and judge if il be reusable or not Reusable if necessary and amend commutator out of round by lather I Check distorted 2 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 armature 115 it and the armature with a hand revolving Brush which is worn to a 3 placed InSpeCl pinion gear for 4 Polish outside of length of less than half inches should be a re crack armalure and inside of core if they are and coot rusty with oil 5 6 7 8 3 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 and Assembly i bushing if excessively worn testing Coat all friction surfaces with reverse 2 head cover order of Carefully lighten engine oil and assemble lhe parts in the disassembly the terminals of each wire and be sure lhey well are insulated 3 the Adjust length Wilh the cutton of switch button so as the shift lever will make contact instantly 4 ring gear Tesl performance 5 Starting 6 torque of about eight carburetor closed ing the engine 4 Inspection I Poor engaged with flywheel fully charged haltery pounds on engine it should ordinally be over eleven feel crank the engine at a check the flywheel ring gear for provable trouble shooting Power a Check the specific gravily of electrolyte in the battery over I 270 b Check battery cable ground cable and each connections for tighteness Check foot switch for perfect contact c 2 is revolutions per minutes with the throttle valve of And if unusual noise is heard when the motor is crank and trouble Cranking pinion gear with must When motor is tested speed after the and see it is When motor does nol revolve a Stem of foot SWilCh buttem is adjusted too short and fails 10 make contact Screw b 3 In out button until the length of stem Poor connection of hattery cables Disconnect the terminal and clean and case pinion gear does not become enough to act tightly connect again mesh with flywheel ring gear when armature is revolving a b 4 Stem of fO In gear teeth are case the ring gear has occurred shift the transmission into high and jerk the car back and forth lhen gears will be released lhis lrouble Remove motor from wear long Adjusl it excessively worn Replace too pinion gear and flywheel ring gear bind speed gear b switch buttem is Flywheel ring In case lhe a t and check check gears engine armalure or head cover shaft for distortion necessary 116 Amend bushing for or replace if c lt j r 1 ii 1 5 In case of excessive noise in replace check the revolving flywheel ring gear and if gear teeth are worn out e J c c H T f t t J 117 i l t t flit j id 1 SERV E NEWS REFERENCE NO DATE CONTENTS OF SERVICE JOURNAL AND BULLETIN 118 SECTION 12 BATTERY DATA Model 2SMC Voltage Capacity 60AH 20H 12 Plate per cell SPecific gravity of eleclrolyte Electrolyte level Initial charging current Ground earth term inal 12 1 1 19 1 270 positive 3 5 Weight dry Approx OF 9 1 280 3 8 in above plate 10 amp Electrolyte capacity HANDLING rale 10 3 6 ltr 20 kg 0 92 O 95 U S Gal 44 lb 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 1 Hydrometer 119 2 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 3 not be allowed beyood the Check the volume of the level as 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 high be as low as to as also will result in much the liquid If the decreasing efficiency electrolyte is found to be too is liable to overflow from the case with the result of corrosion of metal parts 4 Discharging should to the battery specific gravity minimum Keep the regular height of causing 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 judge the crndition of charge by the drop of voltage at the time of heavy discharge to In using this tester cemtact the arms to both terminals of each cell for length of time as specified More than 1 75 volt at 1 em enain aa the tester Fig 200 specific Charge 2 Ex cell Tester and specific gravity good gravity Less than 1 75 volt less than 1 200 Fully discharged specific gravity Less than 1 75 volt more 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 weather specific gravity is low Therefore case must specific gravity Inside trouble the Keeping the battery fully charged is liable to freeze in cold let the specific gravity drops electrolyte be taken not to in winter seasem Freezing of electrolyte Freezing point unexpected troubles such as the damage of the cell of electrolyte at different specific gravity are under causes Specific gravity l5OC Freezing temperature 7 70C 1 100 1 ISO l4 4OC 270C 1 200 1 2SO 1 275 520C 65OC 120 6 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 7 A 8 To prevent 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 leakage of Be Sure electrolyte keep the vent pluge tight plug is kept allowing free passage of gas small ventilation hole in the the from the cell 9 When electrolyte soluliem to is overflowed on the outside of a neutralize the acid and keep it dry battery wipe it with alkali all the time 10 On 11 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 Nissan vehicles the positive 121 pole is grounded SERV E NEWS REFERENCE NO DATE CONTENTS OF SERVICE JOURNAL AND BULLETIN IZZ