..

AUSTIN GI .PSY

{; 4 M I 0 \.~ G 4 l\t1 I 5

VEHICLES

.\ K () 3999 . \

f)RIVER,S HA N DB~OOK

' ' I

DRIVER'S HANDBOOK

for the

AUSTIN GIPS Y

G4 M lO & G4 M15

VEHICLES

1\ copy of this Driver's Handbook is sent out with c'ay G 4 M 10 a nd G 4 M I 5 ve hicle. 1\dditional copies a rc obta inable only from your Austin Dis ­tnhutor, ;md Part No. t\KD 399<) A s hould be

q uotcd "hc.:n ordcri ng

THE AUSTIN MOTOR COMPANY LIMITED LONG BRIDGE

;c lliRMI GHAM ENGLAND

THE AUSTCN 4 x 4 GIPSY G4 MIO SOFT TOP

0. ::::> . ~ u 0:::

I "' I

I ::E "<t 0

>< en 0..

(J

"<t ,. "<t

z f: en ::::> < Ul :r: f-

4

FOREWORD

I' prm\ucing this llllllk the o bjec t has been to confine the contents to informa­tion essent ia l to the p roper running and o peration o f the vehicle. Nen:rt hc­k:ss. the opera tor wi ll find ;til the g uidance necessary to maintain the vehicle

in lirs t-dass condition and to ensure troubk -frec service. r\·cry vehicle leaving I he ! "at:tory is t:apable of g i\ ing a bsolute ~al isfac tion if the maintena nco: ins truc­tiPn ~ d o: ta ikd in the fo llowing pages arc carefu lly carried out.

lh ·member that an .-\ ut hori to:d Dis tributor/ Dealer is bo:ttcr equ ipped 10

prll\ idc ro utine a nd n:pair senice tha n ;Jny o ther operator; he is at your sen ico: ;md should be consulted if you encounter trouble. When emergency \\Or~ has been tiiHkrtaken by o ther than a Franchise holder the vc hich.: should he su bm itted to ;t D is tributor Dealer for chec king.

All Warrant) wor~ must be carried o u t by a D ist ributort D<.:a ler.

When communicatin~ \lith your Distributor or Ut•alcr a lways <fUOtc the chas\ iS and cn~inc numhcrs; the rc~istration numlwr i ~ of no usc and is not required.

For those fl'IJuiring information of a mor<• detailed a nd technical nature than is contained in thi~ Handbook a Workshop :\lanual is amilable a t a reasonable price from your Distrihutor or Dea ler .

IGNITION SWITCH KE\"

l-or securit ~ re:tsons. the key numhers :trc no lo nger sta mped o n the face o f the ig.nition l o~-:1-.s. This will ma ke it more \lillicu\1 for unauthorizl:ll person~ to dri,·c your ve hic le .

The number is stampc~l on the key only. anll owners are advised to rccnrd the numnc r for rckrencc s hould the key be lost.

IDENTIFICATION

\'chicle number. Located on a plate mounted inside the locker compartment o f the dash panel.

Engine number. Sta mped o n a meta l plate fixed to the rig ht -ha nd s ide o f the cy linde r block and a lso to ano the r p la te fixed to the left -hand dash panel.

Gcarhox number. S tamped on to p o f the gearbox a t the rea r o f the top cover.

l; ront ax le number. Stamped o n the to p face of the left-hand axle tu be.

Rear axle number. Stamped on the top face of the le ft -hand a xle tu be . . -r

Chassis number. Stamped o n a plate on the c hass is, adjacen t to the engine right-ha nd fro nt mo un ting.

5

IMPORTANT Your a llcnt ion is dra,,n to the fo ll'''' lng poin t ~ . compl ianc..: wit h ''luch, we

su ggest, will p rove m utuall y bcndicial.

I. WARRANTY DOCU 1E~T R etention of the docume nt . signed by the Distribu to r or Vendor. in a s afe

place in the ' 'chicle (by qui~.: J...I y esta bl ish ing the date of ~ale) will help " ' ex­pedite a ny adjus tments under Warranty if suc h adj ustments a rc required t(l be u rried ou t by a Dis tnhutur ur Dcakr othe r than the supplier of your \ ch ide.

2 . CLAIMS UNDER W AlmANTY C la ims fo r the rcplaccnh.:nt o f materia l o r parts unde r \Varrant y mu~t alwa) ~

be submillcd to the s uppl ytng Distri bu tor o r Dealer, or \\ hen this is no t pth~i bk to the nearest Dis tributor or Dealer. informing the m o f the Vendor 's name and address.

Except in cases of cmergcm:y. Wa rrant y \\Ork sho uld a lw;tys be carried out by a franc hise ho lder, since th is cn~urcs that no doubt can a r i<>c in connection with circumstances o f the vchick hi~tory when cla ims are p ut fnrw;ml.

3. PRt::VENTIYE MAINTENANCt:: A Passport to Service eontaining Service Vo uchers (a ppl ieablc ·in the Unit..:d

Kingdom o nly) is provided with e,·cry new vehide and the regular usc o f the Vo uchers in sequence is the bes t safegua rd against the possibili ty of abnormal repa ir bills a t a later date. Rcplal·emcn t Passpo rt to Serv ice Books arc obtainabh: free of charge from Dis tr ibutors and Deale rs.

Pn•\'1'111 ra ther than cun·. R egula r servic ing, proved hy the presentatio n o f com pleted vnucher coun ter­

fo ils, could well enha nce the value of your veh icle in the eyes of a prospccti'e buyer.

4. REPLACEMENT J>AIHS Wht·n Srrvicr Parts an· n·<1uin·d iu~i~t nn B.M.C. GENUII\E PAin'S a\ thest•

arc dl·signt'd and trstcd for ~·uur H·hide <tnd in addition \\arra ntl•tl fur 12 nwnth' by the British Motor Curpuratiun. ONL\ \\'HI-:1\ GJ-:Nl ' l:'\1-: J>:\RTS A RE L'SEI> CAN 11.:\l.C. ACCEPT tn:SPOI\SIBILITY.

W E SUPPLY ONLY

BMC GENUINE PARTS

\\ hen purchasing replacement parts o r ha\ ing rep.tir-. donc O\\ tter:. are requcsl\:d to sec t hat a label simi l;tr to tho.: o ne illus tra ted here is attat.:hed to the itwo ice rendered . These label~ arc i s~ucd by B.M .C. S..:rvicc Ltd. :111d en ~ t llu t c a g ua rant..:c tha t II. !.C. (iL·nu inc Parts arc supplied.

Our world-wid..: network of D i~tributors a nd Dealers is at your -;~:n icc .

B.M.C. SLRYICE LIM IT ED

C OW LI ' Y · <>XH)RD · F NG Li\1\;J)

I ,·/,•t• ' o1w: Oxfo rd 77777 li'l<·..:mm .: BMCSER \ '. l'ckx <h f'.,rd 1i ·ln : 11 1\lC'SI R \ '. Oxford !U I-15 and S., l-1 6

{) ,·~'~' "'" ' C11hln · 11 \oiCSI R \' . O xfPrd . England

CONTENTS

I OR I \\'O R IJ

1.\ II'ORTA . T

(j l :'\I:RAL D :\ I :\

C O ;\.'T ROLS .\ 'D S\\' ITC I JI ·S

.\ li SCE U _,\ :'--. 1 O l S I Ol ' IP ,\11 :'\1

R L':'\N i l\:G 10- S I R L'Cl iOI\S

COOLI:'\G S YSTI.I\1

ICi:" ITI ON l.Q U IP.\ lLNT ( Pe tm l Model-, )

I LJ LL SYSTI 1\ 1 ( l'c trol Modcb)

I l ' I· L SYSTI \ I ( D iesel f odcls)

C l UTCII

BR AKES

I LECTR ICA L EQU IPM ENT

ROAD WH EI-.LS AND T Y R ES

\!AI NTENANCE ATTENTIONS

BODY ATTENTIONS

MA I NTENA~CE SUM M A RY

LU BRICATIO~ C_~RT (~trol . . .\;

L U BRI CATION C IIART ( Diesel

Models) -- \

M odels)

Page

5

6

8

II

16

17

Ill

21

26

37

41

59

60

65

6')

GENERAL DATA Petrol engine

Type.: . . Number o f cylinde rs llor.: . . St roke C apacity Ma.,illllllll to rque Compression ratio Firing order .. Valve rockc.:r clea ra nc.: (hot o r cold) Contac t b reaker gap Static ignition timing Sparking plugs Plug gap Oil pressure:

Idling Normal running

Diesel engine T ype.: . . N umber o r cylinders Maximum to rque Bor~ .. Stroke Capacity Valve rocker cle<Hance (ho t or cold) Comprc.:ssion ratio .. Injectio n ordc.:r Static injc.:~o:t i on timing Oi l pressure :

Id ling Norma l run ni ng

Cooling system T yp..: C irc ulat io n . . Nnrm;tl npc.:rating t..:mp..:ra t111 c.:

Fuel system (petrol models) J>um p

X

Air cleaner Carburettc r

M ode l C hoke Main j.:t By-pass j..:t Full throlll c hl cc.:d Slow-running jet

Pump jc.:t

22NA 4 3· 125 in . (79-4 111111 . )

4 ·375 in. (1 11· 1 nun. ) 134 · 1 cu. in. (2 199 c.c.) (( (l lb . f"l. ( 15·5 h!;. Ill. ) a t I .80() l". ' l .l ll.

6·8: I l, J, 4, 2 ·012 in . ( · 30 111111 .)

·014 to ·016 in . (·36 to -4 1 mm.) 6\ ' B.T.D.C. C-hampion XN8 ·025 in. (-64 mm. )

15 lb./ sq. in. ( 1·055 J.. g. :c1n.") 50 lb ./ sq . in. (3 ·5 15 J..g. c111.')

22U ,\ 4 89 lb. fl. ( 12·3 kg. 111 .) at 2,800 r.p.m. 3·25 in. (82·6 mm.) 4 ·0 in. (I 0 1 ·6 mm.) 132 ·7 cu. in. (2 17ll c.~:.) ·012 in. ( ·30 111111.)

20: I I , 3. 4. 2 2X B.T.IJ.C.

15 lb.; sq . in. ( 1·055 kg. <.:111. ' ) 45 to 50 lb .fsq. in . (3 ·16-l tu 3·5 15

kg-'<.:m.' )

l' reso;uri;ed to 7 lb . o;q. in. ( ·5 kg. c n1. '1 Pum p, ra n, ;lnd thcrnHlStat n c. <16-l 1·. 1

S. U. electric Oil bath type.: Zenith downd raugh t 42YN J(, 145 110 xo 60 5ll 60

Fuel system (di('sd models)

l ·ucl injection pump Fuel lift pump I ue l injector 1101 ;lc I ucl injecto r nn11 k ho lders r·ucl li l t~o:r I !ca ter p lugs ;\ ir cleaner

c ·rutch

Type

Ge:1 rbox

T ype . . Gear ratios:

First Second Third Fourth Reverse

Transfer box Ratios:

Hig h Low

Front and rl'ar axles T ype .. Axle gear ratio Overa ll gear ra tios:

High gear . . Low gear

S tc<'ring

T ype .. Rat io .. Track toe-in . . Adjus tmen t

Brakes

Make Foot brake

Drum d iameter (G-l M 10 ) .. G4 MIS Hand brake . .

GEI\ERAL DATA

C.A.V. T ype DI'A 324J760c\ S.C. dccrric C.I\ .Y. l' intaux BD:'\ .12.S I'C62'Jll CAY. HK B.35.S5 136 C. ,\ .\'. Type FS5836020 l.odg<.: D IS. 1·2 V .. or C ha mpil'n .-\Ci-l

O il h;11h cypc

Borg & Beck , s ingle dry plate, hy­dr;wlic;llly opcr;llcd

4-$pced :;ynchromesh

4 ·05: I 2 35 : I I ·37 : I I : I 5·7 : I

I : I (two- or fo ur-wheel dri ve) 2·02 : I (fou r-wheel d r ive only)

Hypoid bevel 5·125: l

5 125 , 7 ·02 1, 12·043. 20·756 : I 10·352, 14 ·182, 24·326, 41·927: I

Cam and lever 16: I ;'i in. (2 ·38 mm.) Screw and shim

G ir ling ' · ll ydraulically opera ted wit h twu k ad ing

s hoes o n front wheels I 0 in . (25 em.) I I in. (27 ·94 em.) Mechanica l on rea r wheels only

GENERAL DATA

T~·re sizes a nd pressure' -- i

" (II/I/ Normal roa CrO.\ \·COI/IIIr,\' (' I For lootls in exct'"

CllltiitiOII~ of 560 lb. (254 hf<.) Tyre si::e F'rtmt Rear Front

lh. j.lq. hf<. / /h . >If. kg. / lb. I sq. kg. in. nn. '

6·00 16 25 6·50 16 .. 25 7·00- 16 20 7·50- 16 20

Principa l dimensions

Length overa ll. (G4 M 10)

Le ngth overall (G4 M 15)

Wid th overall

H eight overall (unladen)

G ro und clearance

Capacities

1·76 1·76 1·41 1·4 1

Diesel sum p (including fil ter)

Petro l sum p ( includ ing fi lte r)

II.

3 2 2 2

0 5 0 0

C/11. " ill. em. ' ---

2· 11 25 1·76 1·76 25 1·76 1-4 1 20 1·4 1 1·4 1 20 1-41

142~ in. (3·62R m .)

163 ~ in. (4 · 162 m .)

66~ in . ( 1·695 in .)

741 in. ( 1·886 in. ) 81 in. (-222 m .)

9} pin ts (5 ·25 litn:s)

11 1 pints (6· 38 litres) Fi lter capac ity I ~ pints ('7 lit re)

Cooling system (excluding hea ter) 2 1 pints ( 12 li trcs) 1ain gea rbox

M a in gearbox (with lyre pump)

Trans fe r gearbox

Front ax le

Rear axle

F ro nt hub and swivel hous ing

Steeri ng-box ..

Fuel tank

10

4 pints (2 ·2 lit res)

41 pints (2 ·4 lit n.:s)

3\ pints (2 ·0 l itre~ )

3 pints ( 1·73 lit rcs)

2 ~ pin ts (I· 5 lit rcs)

I pint ( ·57 lit res)

~ pint ('5 litre)

12 gallons (54· 5 lit res)

Rear

lh. jsq. /,g, ill. ('Ill.'

--30 2· 11 30 2· 11 30 2·11 25 1·76

CONTROLS AND SWITCHES Gear ~:hange le1·er

The gear change lc1er is central ly oO'set and ~:omcs read ily to h;md. T he posi tions to which the lever is to be moved to obtain the gears a rc shown in the itlu!>trations. L ift the lel'cr to engage reverse.

Peda l controls T he pedals a~e a rranged in the o rthodox posi tions- namely, the clutch

pedal, brake pedal, a nd accelerator pedal, read ing from left to right.

(f3)

}y@ f='=C·~~~::::\l.t.~::::=.::::~r;;~~. ~ I ®

3

/ . I

;l!Jfll © I fs') 6 7 8 ) c 14 12.

The contro/s- R./1 . D. models

I . Vcmilatl>r cont rol. X. Clu tch rcd;-~ 1. 2. Di rection i ndic:~ tor contn'l. 3. Gear k1<:r. 4. Four-\\ heel-drive indicator plate.

9. Brake peda l. 10. Accelerntl>r [JCdal. II. l-l cadla m p drp ~\\llch.

5. Four-wheel-d rive (low ratio) leva. 12. llorn but ton. 6. Four-wheel-drive (high ratio) 1<:1 cr. 13. Windscreen wiper control. 7. H :~nd brake. 14. \'cnlllawr control.

Ha nd bra ke A pull-up-type lever pro t rudes from under the front sea t and operate~

r~1echanica ll y on the rea r wheels only. '

Choke contro l (petro l engine) Pull out the contro l marked 'C' to its lim it when s ta rt ing the engine fn .. .,

cold. Push in the con t ro l full y as soon as the engine wi ll run without it s usc

CONTROLS AND SWITCHES

Ignition/master and starter switch ( Jx.•tro l models)

The switch is o perated by a remo vable key. When the key is turned in a d ock­wise directio n to the firs t positio n the bauc ry a nd d yna mo arc bro ug ht into c irc uit. Further movement in the same d irectio n w ill opera te the starter mo:or. Relea se the key immedia te ly the engine s ta r ts. If the e ngi ne fa il s to sta n tirst t ime wai t until it has come to rc~t h.:fore o p.:rat ing t he sta rte r S\\i tc h agai n. T he co ntinued usc of the sw rter "hen tht• engine fa il~ to s ta rt will no t o nly disdurg.: the ba tte ry but also damage the ~tarter . If the pinio n fails to disengage" hen thc engine starts . the starter \\i ll emi t a h igh-pi tc h.:d whine a nd the .:ng inc m ust bc s topred immediately. The S\1 it ch mus t no t b.: left o n "hen t he engine is not runn ing o r the battery will disch;trge it s.: lf thro ug h the co il sho uld the con tact breake r points be c losed .

The controls I . Ventilator contro l. 2. Directi on indicator colllrol. 3. G ea r lever. 4. Fo ur-wheel-dri ve indicator plate. 5. Four-wheel-d rive (low ratio) lever. 6. Four-wheel-drive (high ratio) lever. 7. Ha nd bra ke.

L./1.0 . models X. C lutch pedal. <J. Drake pedal.

10. Accelerator pedal. II . Head lamp dip switch. 12. 1-lorn. l .l. Windscreen wiper switch. 14. Vent ilato r contro l.

1aster , heater plug, and starter swilch (diesel models)

For no rma l starting de press full y the accele ra to r pedal. turn the key clock\\ ise to the firs t s to p (which turns o n the elec tric a uxiliaries), then further movement in the same d irectio n to connect the sta rter. Release the accclerato r pedal and the key when the e ng ine is running.

12

CONTROLS AND SWITCHES

For cold s tan ing tu rn the key anti-clm:k" ise to the firs t s to p a nd ho ld it in this posi1io n fo r a period of be tween 15 and JO seconds to allow the hea ter p lugs to warm up , depress fu lly t he acce lera10r pedal . the n move the key to t he second ~lop tl' o pe rate t ho.: start..: r. Release the acc.:lc ra to r pedal a nd thc key whe n the .:ngin.:: is running. Turn the key clOl.:k" i ~e to th.: firs t s to p to swit.::h o n the auxilia r ies.

EnJ.(ine stop control (diesel models) Pull the cont rol I.. nob fully o u t to cut o rr the fuel supply to the injection p ump,

when the engine will cease firi ng. R etu rn t he knob to the fu lly closed posit io n befo re o pera t ing t he starter contro l.

Side/ tail and J)l llld la mp s witches M ove the ma in ligh ting switc h do" nwards to the half-wa y posit ion to b ri ng

the s ide lamps a nd ta il la m ps into o peration. a nd into the fully do\\·n position f()r t he headlamps. The panel la m p swi tch \\ill only ill umi na te the panel lamps when bo th S\\itchcs ar.: o perated.

Four-whecl-dri\e (low ratio) lever Located o n the r ight side o f t he gea rbox cover. Move the le ver fo rwa rds to

engage four-wheel d ri ve ( low rat io) and backwa rds to e ngage rear-wheel drive. The cent ral positio n is neut ra l and di sengages the dri ve to all wheels.

The four-wlwel·dril'l' /el'er positions

I . Rear-wheel drive (high ratio). 4. Front-wheel d rive (high ratio). 2. Four-wheel d ri ve (high ratio). 5. Ncul ra l positio n fo r power takc-3. Fo ur-wheel drive (low ratio). olf.

Four-wheel-drive (high ra tio) lever This is a two-position lever loca ted immediately to t he righ t of the low-ratio

lever. Move both h igh- and low-ratio levers backwa rds to e ngage fo u r-wheel drive in hig h ra tio. T o regain rea r-wheel d rive mo ve the hig h-ra tio leve r for­wards to its ne utral position.

Usc of the four-wheel drive Four-whee l drive in high rat io may be engaged or d isengaged whe n the

, ·ch icle is moving and sho uld be t rea ted as a normal sync hromesh gea r c hange. To c ngage four-wheel d r ivt: in low ra tio when the vehic le is mov ing, it is ad­' isablc to employ do uble-declutc h ing and to keep the vehic le s pee d to a bout 15 m. p.h . (24 km.p.h. ).

Fo ur-wheel drive s l:\o u ld be used o n s lippery surfaces suc h a s s now or 1rl m ud. on ro ug h stony surfaces, and o n exceptio nally severe grad ients.

It shou ld not be used o n normal smoot h and reasona bly firm surfaces, suc h usc is o f no benefi t to the vehicle's pe rfo rmance and it wi ll result in 1

wear o f the drive shafts, axle components. and the tyres. · -13

CONTROLS AND SWITCHES

Direction indicators To operat~. m ove the swi tch to the l~ft or right . acc.:on.ling to 11 h ic.:h.:n:r

indic.:ato r is required . A warning light flashes green for as long a s th.: imlic.:a tors a rc in usc.

Air control A supply o f unheated a ir can be admitted to the body interior for 1cntila t ion

purposes by lifting the lever mounted c.:cntra lly j u~t above thc instrument panel.

Windscreen wiper The windscreen wiper is started by pulling ou t the handle and turning it to

the right to d isengage it from the swi tch. Then move the switch to the left. To sto p the wipe r m ove the s11i tch to the right. pull out the handh:: to discng;1gc the wiper blade from the gears, and turn th.: end of the handle into the top of the s witch c.:ontrol.

I lorn hutton Mo untcd o n the right-ham! side o r the s tc.:ring-n>lumn a nd ~:an b..: opera ted

'' he n the ignitio n s11 itch is o iL

Dip switd1 Located in the ho rn butto n hody and consists o f a small liiO-P••s it ion k 1cr

fo r dipping t he headlight beams.

T!te instm1ncn1s-R.H.D. models

I. Pan ..:I la mp 5\1 it.:h. 2. Spccd,)mcter. J. Temperature gauge. 4. O il pressure gauge. 5. Main lighting switch. 6. Ignition o r master switch.

Oil pressure gauge

7. Fuel gauge. ll. Direction indicator \laming

light. 9 . No-charge warning lighl.

10. Main-heam warning ligh1. II . Choke or sto p contro l.

The gauge indicates the pressure (in lb./sq. in.) of oi l being delivered l)y the pump. The gauge should register within 30 seconds o f starting the engine.

14

CO;\JTROLS A:'\:D SWITCHES

l· ucl gauge

T h.: ~;auge will indic.:atc the qua ntit) of fuel tn the ta n!-. when the igni tion mast.:r s11 itch is operated.

\Yater ll·mperature gauge T he gauge 11 ill indica te the temperature (lf t he t:tH>Iing 11atcr 111 the engine

11 hen the ignit ion. m;tstcr switch is ope rated .

SJ)ccdumcter T h.: meter indic.:atcs the speed o f the vchi~:le and the tota l d istance t ra v.:lled .

P:uwl lamp T he lamp is o pera ted by a togg le s11 itd 1 positioned on the fas~: ia panel

and will only opcrate when the s ide a nd ta il l;1m ps a r.: swi tched on .

lgnitiun 'master !-.1\itdt. flashing indicator. and main-hcam warning lamps

T he igni tio n mast.: r switch, flashing ind icator, and main-beam warning lamps ;1re posi tioned in the base of the speedometer d ial.

The instm/111'11/s- L.H. D. mut!ds

I. 1':1 n.: l lamp S\1 itch 2. Spe.:d•>metcr. J. T.:mpcratu rc gauge. 4 . Oil pressure gauge. 5. Main lighting switch. 6. lgniti'"' ••r mast.:r swi tch.

7. F u..:l gauge. 8. Di rection ind i.:atnr \\arning

light. 9. o-chargc wa rn ing lighl.

10. 1ain-bcam wa rni ng light. I I. Choi-.: or ~top ..:ontrol.

T he igni tion, master switch warning lam r !$lows red when switc hed on, bu t 11 ill go o ut to indicate that the dynamo is charg ing as the engine speed is incn:ascd .

While the flashing unit is ope ra ting, the wa rning la m p g lows gree n inter­lll it tcnt ly.

T he main-beam wa rning lamp glows blue w hen the headlamp beams arc rais.:d and wi ll go ou t when they arc lowered.

15

MISCELLANEOUS EQUIPMENT Windscrcl'n (soft top mock!~)

l f desired. the 11 ind. cre..:n .:a n h.: hing..:d forward Ill lie horiwnta ll) on top ol the bonnet. Simply rcka~e the 11 ingnut-headed holt s :11 <.:~1ch end of the 11 ind ­scre..:n and lower it until the r..:st in th..: centre of the 11indscreen engage.; in the rub ber rest o n the bonnet.

Fuel fillcr

The fuel t;1 nk Iiiier cap 1' po,itHHlcd at the ~ide of th..: whick and i' ,..:akd 11 ith a bayonet-type fixi ng. l lnsc re11 the cap in an an ti-dod.wis..: direction to remove it.

Considerable loss o f fu.:l C lll occur as a res ult of filling the tank unt il fuel is visible in the filler tu be. If th is as done and the vehicle is left in the sun, expansion due to heat wi ll cause leakage. 11 ith Cllll'\equ..:n t los~ of and dang..:r from expos..:d fue l.

'vVhen filling up therefore :

(I) A void filling the ta n!.. until fuel is visibk in the Iiiier tub.:.

(2) If the ta nk is inadverll'nth ollcrli lk d . tal..: c 1re to p;trl. tho: 1<.:hick in the shade and with the Iiiier ;h lugh ;" po~~iblc.

RUNNING INSTRUCTIONS Huuning-in speed

The t rea tment gi1·en to a new 1ch icle 11ill ha1e an importalll bearinl.! on its subsequent life and engine s peeds during this early period mu~ he limit~d . The follo11 ing instructions must be s trict ly adhered to.

During the fi rst 500 miles (llOO kn1. ) or 25 hour~ running -

UO NOT exceed 21\ m.p.h. (45 km .p.h.).

UO ~OT operate a t full throttle in any gea r.

1.)0 NOT alltlll th..: engine to la bour in ~my gear.

\\'arming up

. Res..:a rch has prtlled th;t l the practice of 11anning up an engine by allo11ing at to id le slowly i ~ ddinitcly harmful. Tho: correct procedure is to let the engine ru n fair ly f~1s t. a t ~1pproxirnatc ly 1.000 r.p.m .. so that it attains its correct 11 orking ll'mperature as q uid ly as possible . 1\l lo11 ing the ..:ngine to work slowly in a cold state leads to ..:.xccssi1·c cylinder 11car. and far kss damage is d one by driving th..: , ·chicle str~tight on the road from cold than hy lett ing tho: engine idle slowly unt il wa rm.

\\' l 'l hra kc:~

After the 1<:hiclc has been washed or d rwcn through water the brake linings m;r) hcl:orne 11ct. To dry them, apply the br;IKl'S scv.:ra l times with the vehicle mo1 int; s lllll ly. 1- mcrgcncy brak ing 11 ith 11e1 bra!..:~ is e'\tremcly dangerous and r~ tn he avoided a t a ll co~ls.

17

CO()LING SYSl'EM ( ·ooling sy~tt•m

,\ pr..:ssurizcd cooli ng sy>.to.:m is used and tho: pr..:s"ur..: must b.: rdea<;o.:d gradually \\hen remo\·ing tho: radi ;ll<lr IIIIer cap wh..:n tho: system is hot. It i-; advis;tblc to protect tho: h;1nds ;tgai ns t escaping s to.:;tnt ;1 nd then turn the ctp slcl\\ ly in an anti-clockwis..: dirt·ction until tho: r..:sistance or the s;tfet ~ stnp i, felt. Leave the cap in thi-; i'"~ it ion until ;til pres-;ur..: is rekas..:d. Pres-; t he ctp dO\\·nwards against the sprin t: l<> ck.1r tho: saf.:ty st<>p-; and C\>11linue tur11ing unti l it cut he lifted oil'.

Tlte rlllliaror tlrai11 Wfl.

Tum i11 tire direction of tire mTou· ro open

Frost precautions

'~ -

Rotlioto r /i, ·tuf,T tmd, 1111.1 t,{{,•r, 1111

-~=--=:==- ;;___--;.; -~ = cl~.~, ~~

\Vater expands when it rr..:o.t·s and 11' prectutions arc not taken th..:rc is <.:o n­sidcrablc risk of bursting tho: radlatt> r, cylinde r block, or hea ter (wh..:re fitted). Such damage may be a void.:d by draining the cooling system when the vehicle is left for any le ngth o r time in fn1sty \\'t'ather, or by adding an an t i-freeze solution to the water. \Vhcn a he;ltcr is til ted ;ut anti-freeze sol ut ion must he used as no provisio11 is mad<.: f,u· dr;nni1lg the unit.

COOLI NG SYSTEM

l:kfore adding ;tit ;1111i-frccze solu t ion the cooling system must be drained and flushed through h) insert ing a hose in the fi lling orifice and a llowi ng water to flow through unti l c lc;111. The taps should be dosed after a llowing a ll the wa ter ttl drai n away and the system filled with an anti-freeze solution to the correct lc\ cl.

Tn a\'tlid w;hl;tge by mcrflow. add s ullicient coobnt to coYer the bottom of the header tank . T hen run the engine until it is hot and bring the coolant to the CP ITe<.:t \\'orking k:\·el. i.e. about I in . (~·5 em.) from the top of the tank .

Tire cl'/irrda hlocl. drairr lllfl is locaft•d in tire rit:/11-11111111 side of tfte />lock

(petrol nrotfd,)

I. Clo,cd po,itinn .

2. Op.:n "'"itinn . ~'' '-\\\\\"

Tlte crli111h·r hloc/, drairr lap

is lo cat('(l orr t!te rt/.:ltt-lwllll .1idc of tlw crrgirrc· 111111 i> .1111>11 '11 itt tftc clov,·tf position

(dine! lll<>de/s )

T he Ct,oling svst..:m is u l· the sc;tlcd l)J1e and rclat i\cl~ high temperat ures are dc\clopcd in th..: radiator upper tank.- l:or this reason anti-freeze solutions h;1\·ing ;tn ;tlcolwl base arc unsuil ;Jbk: ()\\ing to t heir high evaporat ion rate p n,duc in!; ;t r;tpid loss o f coolant and ;t consequent interruption of circubtiun .

Only anti -freeze solutions o f th ..: eth ~ lcne glycol type incorporating the correct type or corros ion inh ibitor a re suiu ble and O\\'ncrs are recommended to usc Bluccol. \\'c al so apprm ·c t11c usc l'f ;ul$· an ti-freeze solution which conform-; to Specilicllion B.S .3 151 <>r B.S.3 1 5~ . -'

19

COOLING SYSTEM

NOTE : Sho uld anti-freeze be retained in the cooling system for more than one year the specific gravity of the coolant must be checked a nd addit iona l anti­freeze solutio n added to ensure adequa te protect ion against frost. A fter a second winter the system sho uld be d ra ined and refi lled with clean water and the appropria te quantity of an ti-freeze solution added when required.

The correct quant ities of a nt i-f reeze solution for differen t degrees of frost res is tance a re given in the fo llowing ta ble.

Amount of Anti-freeze required

Absolute Witll heater Without heater Commences Saf e

j i·eezin" Limit us uS I Sulution1 __ --:_o_

1 __ ...,...... __

1 • • ••

o; Pints Pints Litres Pints Pints Litres 1 o ''C. • F. •c. F.

20

25

30

9 16

13 9

- 16 3 I

19 3

26 15

33 28

-----:--6 - 4!--5-·1 2-4 4& 5! •

6 3 · I 5} 6! 3·0

8 3·8 I 7~ 3 ·7

A ll new vehicles leaving the Fac to ry during the w inter months a re pro tected down to - 19° C. ( - 3° F.).

Draining the cooling system

T he cooling system is provided with two d ra in ta ps both of which must be opened when dra inin g the cooling system . O ne tap is located o n th~ under side of the radia tor bottom ta nk nnd the o the r is located on the cylinder block. The radia tor filler cap must a lso be removed .

IGNITION EQUIPMENT (Petrol Models)

tgnition adjustment

Adjustment is provided for the ignition point to enable the best setting to be ttta ined to suit va rying fuels. The adjusting nut is indica ted by the letter ( E) n the illustra tion, and turning the nut in a clockwise directio n re ta rds the gnit ion. Turning it in an a nti-clockwise direction advances the ignit ion.

The barrel o f the screwed spindle has graduations to indica te the settings.

The distributor A . Cam. ll. Adjusting slot. r. Contact locking screw. o . Lubricating point. E. Adjusting nut. r. Lubricating point. G . Lubricating point.

Static ignition selling

T he normal static igni tiOQ..liCHing is with the spark tak ing place a t 6t • B.T.D.C. T he ign ition point can'bc-reset if necessary by adjusting the knurled nut on the d ist ributo r body. Each gradua tion on the barre l is equal to ap proxima tely 5" o f t iming movement a nd one gradua tio n is equa l to 55 clicks o n the knu rled nut. Do not disturb the pinch clip a t the base of the distri buto r un less absolutely necessary.

21

FUEL SYSTEM (Petrol Models)

Carburetter slow-running adjustment

After the lirs t 500 mik' ( ~00 j..m_) or 25 hours runn1n~. when the engine i, fu lly run in , the slow-runn ing adj ustment m ay need a little a ttention. The adj ustme nts should be made on ly a fter the eng ine has reached its no rmal runni ng temperature.

Wea k mixture is recogni1.ed by ir regu la r behavio ur of the eng ine and the tendency to s tall. Ric h mix tu re wi ll cause the engine to ' hunt' and tend to stall when the ' hunt' becomes ex~.:ess i \\; .

T wo screws have to be turned to elkct an adjustment- the thro ttle stop screw and the vo lume co ntrol scn:w.

The thrott le stop screw l im 11 ~ the dos ing o f the throttle and thus fixes the idl ing speed of the engine . Turn the ~crew in a clockwise d irect ion to increase the eng ine speed and in an a n ti dod.w i~e direc tilln to decrease the speed.

The carburi'UI!r

I . Volume control 'c r~" -

2. Throllk ~top ~ere\\ .

The volume cont ro l screw 1s p1 '> \ 1dn l to va ry the s low-ru nn ing mixture. \Vhen unscrewed it e nriches the mi .~ t111 e and \\hl.'n sc rewed in it weakens it.

Set the thro ttle stop screw so th.tt the eng ine speed is s light ly (ln the high side . Adjust the vo lume control ~ne\\ un til the engine runs evenly, fir ing on a ll cy linders regular ly. This operatio n will gene1a ll} :1lter the engine speed and will perm it readjus tment o f the thrott k ' top '<.:' e\\.

C heck the adjus tment hy speeding up the engine m o menta rily and releas ing the accelerator quickly. If the engine ~t all ~ . the s low-runn ing adjustment has been overdone and the idling s peed ~hou l d be increased s ligh tly by screwing in t he thro tt le s to p screw o r e nr id ted :1 lill ie by unscrewing the vol ume control screw.

22

FUEL SYSTEM (Diesel Models)

Eliminating a ir from the fuel system (bleedin~)

Failure to start or erra t ic engine accelerat ion ca n be the r.:su lt of a ir in the fu~l s~st~m . _This can be . caused by a lkl\\ ing the fue l tan k to become em pty, b~ ·' lc.d,tngJOtnt . o r by thsmant lmg any pa rt of the fue l system. If this condi tio n ts suspected , and ;tf'ter every occasion when part of the fue l sys tem has been dt smantlecl , the fuel syste m must be bled of air as fo llows:

( I) Slacke n the unio n nut a t the Iiller end tlf the injection pump reed pi pe . ~)p.:r;lte t ilL' h it pump and when the rud pass ing the union threads is free lrom ai r huhhks. t igh ten the union nut.

l .oca t io11 11/ the· 11/clill }iwl / iltN a ir h/,•,·cl f}(}illfl'

Two air bleed t•tdt•es are filled 011 the fuel i11jection

pump

(2 ) Unscre\\ t he blank ing pl ug in lh<.: unu~ed o ut let connection in the lil ter heatl su ll icien_tl_y to al low fud at lift pump pressure to pass th.: thread,. Operate _ th~ hf~ pump a nd \\hen t he fuel issuing from a round the plug th reads IS lree lrom ;ur bubbles. tighten the plug. -

23

FUEL SYSTEM (Diesel Models)

(3) Slacken the two a ir bleed valve on the fuel 111Ject ion pump. One bleed va lve is located on the governor housing, while the other is incorpo rated in the hydraulic head lock ing screw situated immediately above the pump nameplate. O perate the lift pump and when the fuel issuing from bo th valves is free from air bubbles, tighten the bleed valves.

(4) Slacken the union nuts at the injector end of any two high-pressure pipes. Ensure that the stop con tro l is in the ·run· position. a nd set the accelerator in the fully open position. Crank the engine unt il the fuel flowing from both pi pes is free from air bubbles , then tighten the pi pe unio n nuts.

(5) Start the engine and allow it to run until it is fi ring on all cylinders.

After renewing the main fuel fil ter clement. providing the engine is not cranked during this operation, it i only necessary to bleed the fuel filter as described in operations ( I) and (2) before s tarting the engine.

WARNING.- Lubrication of the injection pump mechanism is effected by fuel oil under pres~'Ure, therefore, no attempt should be made to bleed the fuel system by towing the vehicle in gear as this may result in serious da mage to thr injection pump.

Roadside injection adjustment

On no account should the injectors o r a ny part o f the injection pump be dis­mantled at the roadside. It is recommended that a spare injector is carried, and renewing an injector is the only servicing of this nature that should be carried out a t the roadside.

It is often possible to locate an injecto r which is no t working correctly by slackening the feed pipe union nut of the suspect injector and a llowing the fuel to leak past the union whilst the engine is running slowly. If there is no change in the engine performance or if a fa ulty condition, such as a smoky exhaust , has disappeared, it is reasonable to assume that the injector nozzle is faulty.

To renew a faulty injector disconnect the high-pressure feed pipe from the injector nozzle holder and the lcak-o iT pipe from all the injector cap nuts, noting the seal washers located on C<lCh side of the pipe banjo-type unions.

Remove the two nuts securing the fa ulty injecto r to the cylinder hea d and withdraw the injecto r. In cases o l' difliculty Service tool 18G 491 A should be used to draw the injector from the cylinder hea d .

Ensure that the injecto r in the cylinder head is in good condition and wilf make a gas-tight jo int.

Place the new injector in posit ion and tighten the securing nuts evenly half < turn at a time to ensure even seating. A torque wrench set to 121b. ft. (1·6 kg. m.: should be used whenever possible.

Reconnect the fuel pressure pipe and leak-off unions, ensuring that the join. washers are fitted on each side of the leak-off pipe banjo unions.

24

CLUTCH To bleed air from the hydraulic system

Bleeding t~e system is not a routine maintenance operation, and should only be necessary 1f some component of the hydra ulic system has been disconnected or the fluid drai ned off.

Unlike the hydraulic fluid, air is compressible, and its effect when present in the system is to give a 'spongy' feel on the pedal a nd produce excessive travel making gear selection difficult. '

During the bleeding operation maintain the fluid level in the reservoir to within t in. ( 13 mm.) below the bottom of the filler neck and ensure that a ll union and pipe connections are tight a nd leakproof. '

The clutch sla ve cylinder bleed nipple

The slave cylinder provides the only bleeding point, as shown in the illustra tion. Clean o n· a ll dirt from a nd around the bleeder screw, a ttach the bleeder tube to ~he bleeder. screw nipple, a llowing the other end of the tube to ha ng into a glass Jar filled with suffictent hydraulic fluid to immerse the end of the tu be. Slacken th.e screw one complete turn. Instruct an assista nt to depress the clutch pedal with ~ s low ~ull st~oke a nd a llow the pedal to return unass isted , repeating this pumpmg actton with a pause before each depression o f the pedal. Watch the How of fluid into !he glass jar and when a ll bubbles cease to a ppear, tighten the bleeder screw durmg a down stro ke of the peda l. Remove the tube a nd jar.

NOTE.-Ciean fluid bled from the system should be alJowed to stand until it is clear of all air bubbles before being used again. Used fluid, if not contaminated, may be filtered and used again.

25

BRAKES To bleed air from the hydraulic system

Bleeding the system is not a routine mai ntenance operation and s ho uld only be necessary if some component o f the hydraulic system has been d isconnected o r the fluid drained ofT.

Unlike the hydraulic fluid, a ir is compressible, and its effec t when present in the system is to give a 'spongy' feel on the pedal a nd produce excessive travel.

During the bleeding o pera tion maintain the fluid level in the reservoir to wi thin ! in. (13 mm.) below the bo ttom of the fi ller neck , and ensure tha t a ll union a nd pipe connections arc tight and leakproof.

Showing the rear brake bleed nipple

Bleeding the frollf brakes

NOTE.-Pressure bleeding nl(' llwd a rc not suitable for G irling systems and are not recommended. For pressun· hlccding lo be successful it must be accompanied by manual bleeding.

To bleed air from tbe system, ('Ontinucd

Rear Scotch the wheels a nd rclca~o the ha nd brake fu lly. Check tha t the wheel

cylinder is free to slide, a nd tum the adjuster clockwise unti l the shoes are fully locked on the d rum. The wheel cycl indcr pisto ns will then be pushed into the bore with the minimum of air to be expelled.

Front Slacken off the adjusters to a llow the shoe springs to push the pistons into the

wheel cylinder bore leaving the minimum amount of space for a ir or fluid .

26

BRAKES Commence bleeding on the rea r brake s ta rting with the wheel cylinder

farthes t away from the master cylinder. Clean orr all d irt fro m around the bleed nipple and remove the protecti ve rubbe r ca p. Fit the bleed tube over the nipple and immerse the free end in a clean jar contain ing a little fluid . Unscrew the nipple a bout three-quarters o f a turn, and commence bleeding with a fairly fast ful l st roke of the brake pedal, a llowing the pedal to fly back unassisted. Repeat th is procedure unti l it is apparen t that all ai r has been excluded, closing the nipple during the last slo w pedal application. A t no time during the bleeding operation must the fluid level fa ll to a point where a ir may be drawn into the system.

Repeat with each wheel cylinder in turn , finishing wi th the cylinder s ituated nearest the maste r cylinder.

If the bleeding of any cylinder continues without clea ring the ai r bubbles, it may be tha t air is being d rawn in to the system via the bleed nipple threads. In this case the bleed nipple should be tightened a t the end of a downward s tro ke, a llowing the pedal to retu rn before re-opening.

Never use fluid which has just been bled fro m the system for to pping up the supply tank. It '' ill most certa inly be aerated and must be a llowed to stand for at least 24 hours before re-use. Contaminated flu id must be discarded.

Replace the rubber cap on all bleed n ipples.

NOTE.- Ciean fluid bled from the system should be a llowed to stand until it is clear of a ll air bubbles before being used again. Used fluid, if not contaminated, may be filtered and used again.

Readjust the brakes if necessa ry to obtain the correct shoe-to-drum clearance.

Drake adjustment Front

Jack up the front o f the vehicle until the wheels a re free to rotate. F ully release the two adjusters on the o utside of the backplate by turning them in an anti-clock­wise d irect ion wi th an o pen-ended spanner. T urn one of the adjuster bo lts in a clockwise dirc~..:tion unti l the bra ke s hoe concerned touches the bra ke d rum, then turn back the adjuste r unt il the shoe is free o f the drum. Repeat this opera tion for the second adjuster and shoe. Spin the '' heel to ensure tha t the brake shoes arc quite free o f the drum. Adjust the other front brake in a s imila r manner and then release the jack.

Rf'ar Jack up the rear of the vehicle so that the wheels arc free to rotate '' ith the

hand brake fully released. Us ing an open-ended spanner. turn the squared end of the wedge-type adjuster in a clock\\ ise direct ion unti l resistance is fe lt, i.e. both brake shoes touching the brake drum. T urn back the adjuster two 'cl icks', which can be felt or heard , when the wheel should rotate freely. It should be noted that only one adjuster is provided for both s hoes. A pply the foot brake to centralize the shoes and check tha t tffc wheel is free to rotate when the pedal pressure is relieved. Carry out the same ope ration fo r the other rear wheel apply the hand brake, and release the jack. '

NOTE.- O n no account must the brake-rods be used as a means of taking up bra ke lining or drum wear as they arc correclly set at the Works on erection. All hand brake adjustment is automatically dealt with by the rear brake shoe adjustment described in the foregoing instructions.

27

ELECTRICAL EQUIPMENT Fuses

The fuse holder is located on the engine bulkhead and is readily accessible after raising the bonnet.

The fuse between 'I' and '2' pro tects the accessories which operate irrespec­tive of whether the ignition/master switch is off or on. The fuse between '3' and '4' protects the accessories which operate only when the ignition/master swi tch is on.

Two spare fuses are provided, and it is important that only the correct replace­ment fuses a re used.

If a new fuse blows immediately on replacement trace the fault before inserting a nother one of the same fusing value (marked inside the fuse tube).

Tile fuse holder with the spare/uses arrowed. A blown fuse must be immediately

renewed

The units which are protected by the fuses can readily be identified on the wiring diagra m. A blown fuse is indicated by the failure of the units protected by it, and is confirmed by examination of the fuse when withdrawn. Before renewing a blo'-'!'n fuse inspect the wiring of the units that have failed for evidence of a short-circuit or other fault. Remedy the cause of the trouble before fitting a new fuse.

Voltage control box

The cut-out and regulator arc accurotely set before leaving the Works a nd they must not be tampered with .

Headlamps (except European 1111d senh . .'d-bcam type)

To reach the headlamp bulb remove the rim after extracting the reta ining screw from the under side, push the lamp reflector and glass assembly inwards against the springs, turn it in an anti-clockwise direction until the locating screws r~gister with the enlarged ends of the slots, and withdraw the light unit. Depress the back-shell and turn it to release the bulb. When replacing the bulb ensure that the slot in the bulb flange engages the keyway in the holder.

28

ELECTRICAL EQUIPMENT

To replace the back-shell push it home against the spring pressure and turn it to engage the bayonet attachment.

Refi t the lamp unit by positioning it so that the heads of the adjusting screws pass through the slotted holes in the flange, press the unit inwards, and turn it in a clockwise direction as far as it will go.

Refi t the front rim, locking it in pos ition with the reta ining screw.

The head/amp unit removed. Inset, altemative bulb filling

Headlamps (European type)

Tire sealed beam head/amp showing:

I . Retaining plate screw. 2. Horizontal adjustment

screws. 3. Vertical adjustment screws.

These headlamps are fitted with special front lenses and bulbs giVIng an asym~etrical light beam. Ace~ to tht bulb is achieved in the same manner as descn bed above, but the bulb ts released from the reflector by withdrawing the three-pin socket and pinching the two ends of the wire retaining clip to clear the bulb flange.

When replacing the bulb care must be taken to see that the rectangular pip on the bulb flange engages the slot in the reflector seating for the bulb.

Replace the spring clip with its coils resting in the base of the bulb flange and engaging the two retaining lugs on the reflector seating.

29

ELECTRICAL EQlllPI\IENT

1-ieadlamps (~ea led-bcam I)IH'- :\orth .-\merka)

To gain access to the se;tkd -bcam light unit rcmo1e the rim reta ining ~ere'' and lift the rim ofr the locating htg' at the tPp of the he:tdlamp she ll. Slacken the three screws securing the lantp unit retaining plate, t urn the plate and rcmon: i t from the lamp unit. Withdr; t\1 the l;tmp rrom the sh ell and disengage the plug.

llcadlamps (s(•alcd-hcam l)'lll'- llornl' \ larkl-1)

To ren JO\'e a ligh t unit pr<>L"L'Cd a\\\ ith t he ~orth :\ meric;t n I) pc u r ~cakd­beam headlamp but compkt ,·lv tcnu"e the three -.cr,·"' to reka~c the ligh t unit retaining p late.

Setting hcadlarnps

Tlte lll<' flt,l// o( st•rring rite IU'atfla111p hclll/1.\

I. \ 'nt ical " "t ti ng ;tdju,ting ~CIT\\:-..

l t,,rilllnta l ,,·tting '"litr ' ­tin!! ...,cn.:w .... .

T he lamps shou ld b e se t S•' tll.tt the tt t:ttrt dtt\lttt~ hcam~ arc parallel \l i th t he road su r face or in accordance " itll tll c loc;tl reg ulations . I f adjust n11.:nt ts requi red rcmmc the rim as dc~c1 thcd nt t p:q..:..: 2.'\.

Vertica l :llljust ment is ma d..: hy turtllll )'. tltc 'crt.:\\ at t lte top llf the lamp.

H o rizontal :ldjustmen t can h..: n t:tdc h 1· t u rnin g th..: ~cre" s on each sid..: of tlte lamp unit. A n1id se tting the m ai n hc·atl l'> :thm·..: lwri;onul : th<.:) "i ll da711c o ncoming trallk and give inkrior J<>.td tll tttlti n :ttilHl.

It is r ..:comtnendcd that h L·:tdl:t lll l' ht· .un 'ol"tting ~ IHiuld be chcd .cd at the hc'ginning (1f the winter pniod .

S idclamps

R em ove the ch romium h..:;rcl fto lll the l:tt np b y peeling b;lck t he rubber nange and inserting a sma ll sn ..:wdi i\'L'r behind the bezel. Run the s..: r..:wdriYer round the lamp and the bc;L·I tna y h o.: "J thdr:l\1 11. R emo1·e the lamp glass in a si m ilar manner .

Front flasher lamps

Adopt the procedure given ahmc fnr ~ idt.:lamps.

:w

ELECTRICAL EQUIPMENT

Tail a nd s top lamps

A ccess to the lam p bulb can be gained b y rem oving the re ta ining screws and withdrawing the la mp lens . The bulb is of the bayon e t-fixing type, having a s ingle filam..:nt , and m;1y be fitted either way rou nd .

Rear flasher lamps

,\ d opt the pn1ced ure given for s idcht mps.

Showing access ro bulb.1·

I. Tail nnd stop l;unp.

2. Flashe r lamp.

., ncar number-plate illumination lamp

The rem· 1111111ber-plate lamp bulb

The cover is secured by a s ing le screw which , when removed, allows access t o the bulb for rep lacement purposes.

Warning lamps and panel lamps

The warning and panel lamp b ulbs arc accessible fro m behind the fascia panel.

:I I

ELECTRICAL EQUIPMENT

.. 'IJ I"' ' I~ .,

' t i

;!

t

.. , . ' ... .~ . II :

A •

.

,,

,, : '

' ;I ' ,. .

(, ,

,,

r.•

·"'

. 1 . .

tit 1\..H ! . I .. '1 : " t.• !'l 1:

,,..I I ti l • 111 1

W I II . , . , 1 1 I

I II·: ~ .~. I I ' "I I' ~ I ' ~- I .

,(.w; 'I,

' ~ ; j

\0 , I •

,, . . , .. ..

fi e ., , ..

1'{• ,

. '·'

'

'" •

<.u.

~l I , • . ,

..

. I "' ] ! ,,,

. (..•' .l'l

t .I

>ol

Wiring ditiJ:NIIII ( pl'lrol models)

32

•.

...

- ~

1\'o.

I.

2.

3.

4 .

5 .

6.

7 .

8.

9.

10.

II.

12.

13.

14.

15.

16.

17.

I H.

19 .

23.

25.

ELECTRICAL EQUIPMENT

KEY TO WIRING DIAGRAM (PETROL MODELS)

IJn<Tiptiotr

Dynamo.

Control box.

Battery.

Starler solenoid switch.

Starter motor.

Lighting switch.

Main-beam dipping switch and born-button.

R.H. hcadlamp.

L.H. headlamp.

Main-beam warning lamp.

R.H. sidelamp.

L.H. sidelamp.

Panel lamps switch.

Panel illumination lamps.

Number-plate lamp.

R.H. t<til and stop lamp.

L.H. t<til and stop lamp.

Stop lamp swih.:h .

Fuse un it.

llo rn.

F lasher unit.

.\lo. Descriptiotr

26. Flasher switch.

27.

28.

29.

Flasher warning lamp.

R. H. front flasher lamp.

L. H. front flasher lamp.

JO. R.H. rear flasher lamp.

31. L.ll. rear flasher lamp.

32. Heater switch.

33. Heater.

34. Fu~l gauge.

35. Fuel gauge tank unit.

37. Windscreen wiper.

3H. Starterjignition switch .

39. Ignition coil.

40. Distributor.

41. Fuel pump.

43. Oil pressure gauge.

44. Ignition warning lamp .

45. Speedometer.

46. Temperature gauge .

47. Temperature transmitter.

48. Ammeter .

95. Revolution indicator.

CAIII.E COLOUR CODE

B. Dlack. U . Blue.

N. Brown.

G. Green. R. Red. LG . Lil:il< Green. W. While. 1'. Purple. Y. Yellow.

When a cable has two colour code letters the first dcnote3the ma1n colour and the second denotes the tracer colour.

33

ELECTRICAL EQUIPMENT

No.

I.

2.

3.

4. I ' t <" r=>

,•i») 5.

~l ,, t r·············•·········· ·· rJ··=#=:::! ; r············-······· j:

H ii ll ::

6.

7.

8.

9.

10.

II.

12.

13.

14.

15.

16.

17.

18.

19.

23.

25.

Wiri111: din~:r·nm (diesel models)

34

ELECTRICAL EQUIPMENT

KEY TO WIRING DIAGRAM (DIESEL MODELS)

Descriplion No. Description

Dynamo. 26. Flasher light switch.

Control box. 27. Flasher warning lamp.

Batteries. 28. R.H. fro nt flasher lamp.

Starter solenoid switch. 29. L.l-1. front flasher lamp.

Swrtcr motor. 30. R.H. rear flasher lamp.

Lighting switch . 3 1. L.H. rear flasher lamp.

Main-beam dipping switch and 32. Heater switch. horn-button.

33. Heater. R.H . hcadlamp.

34. Fuel gauge. L.H . hcadlamp.

35. Fuel gauge tank unit. Main-beam warning light.

37. Wi ndscreen wiper. R .H . sidelamp.

L.H . sidclamp. 38. Master/starter switch.

Panel lamps switch. 39. Ballast resistor.

Panel illu mi nation lamps. 40. Heater plugs.

Number-plate la mp. 41. Fuel pump.

R .H . tai l and stop lamp. 43. Oil pressure gauge.

L. H. tai l and stop lamp. 44. No-charge warning light.

Stop lamp switch. 45. Speedometer.

Fuse u nit. 46. Temperature gauge.

Ho rn. 47. Temperature transmitte r.

F lasher unit. 48. Ammeter .

CABLE COLO UR CODE

B. Black. G . Gree n. R. Red. u. Blue. LG. Light Green. w. White.

N. Drown. P. Purple. ' Y. Yellow.

W hen a cable has two colour code letters the first deno1es the main colour and the second denotes the tracer colour.

3:-

ELECTRICAL"EQUJPMENT

Each bulb is secured in posuio n by a push-fit holder. T o rep lace a bulb pull o ut the holder from the rear o f the fascia panel and

unscrew the bulb from the holder. Sc rew in a new bulb a nd push the holder back in positio n.

Windscreen wiper

The wiper is contro lled by a switch on the wiper motor. No adjustment o r lubrication is necessary. Should it be necessary to reposit ion

the wiper a rm on its spindle, slacken the colle t nut o n the spindle and tu rn the a rm to the Tequired posit ion.

The blade is removed fro m the arm by swivell ing t he blade upwards and away from the ann a fter first removing the rubber stop.

Replacement bulbs Headlamps, left dip (all R . l-1 .0 . c ccpl Sweden)

Headlamps, vertical d ip (all L. l l.l). h11 op , except F rance)

Headlamps, vertical dip (Franc~.: o nly yellow) . . Headla mps, vertical dip (Sweden w •ly) .. Headlamps, right dip (aU L.ll.l) . cM.:cJ) I · urope

and U.S.A.) Sidelamps Flashing di rectio n indicators Tai l and stop lamps

Rear number-pla te lamp Panel lamps Direction indicator warning lamp . .

Ignition/master swi tch warning lamp Main-beam warning la mp ..

The windscreen wiper blade can be removed aft er first withdrawing the rubber stop

B.M.C. Watts Part No.

50/40 BFS 4 14

45/40 BFS 4 10

45/40 BFS 41 1

45/40 BFS 4 10

50/40 BFS 4 15

6 BFS 207 2 1 BFS 382

2 1/6 BFS 380

6 BFS 989 2·2 BFS 987 2·2 BFS 987 2·2 BFS 987 2·2 BFS 987

ROAD WHEELS AND" TYRES Removal and replacement of a road wheel

A pply the hand brake and scotch one o f the wheels. P rise off the hub cover using the fla ttened end of the wheel spanner in one of the recesses formed in the wheel. D o not lever the cover from the wheel centre but give a sideways twist. Slacken the wheel nuts ha lf a turn , i.e. turn anti-clockwise to loosen the nuts on the right-hand wheels a nd clockwise o n the left-hand wheels. Jack up under the axle tube sufficiently to enable a wheel with a fully infla ted tyrc to be removed. Remove the wheel nuts and lift off the wheel.

/

30 I I

...._,_

" \ Q 4

I ' I \ I

P~ --o; .... Order of tightening the whee/nuts

When replacing the wheel, first lighlly screw on the nuts, ensuring that the ir con ical faces sca t correctly in the recesses of the wheel stud holes. Lower the jack and fu lly tighten the wheel nuts in the order shown in the illustrat ion. A to rque wrench set to 100 lb. ft. (13·8 kg. m.) should be used to tighten the wheel nuts whenever possible. Place the rim of the hub cover over two of the studs on the wheel centre a nd give the outer face o f it a sharp blow of the fist over the third stud. Remove the jack a nd sco tches.

Tyre pressures

The recommended tyre pressures a re given in 'GENERAL DATA' on page 10. Maintain the correct pressures by checking with an accurate tyre gauge, and infla ting if necessary.

Any unusual pressure loss should be investigated . l.Jnder-infla tion causes rapid tyre wear, and even more serious is the possible damage to the cords of the fabric owing to excessive bending or flex ing of the cover wa lls.

Vehicles leaving the Factory do so with a reduced tyre pressure, which should be corrected before the vehicle is put into service. The only correct method of •

ROAD WHEELS A~D TYRES

arriving a t the approx imate pn:ssun: is by weighing the front axle and rear a.xk separately when the v..:hiclc is lad..:n to th..: maximum load it is expected to carry and adjusli ng the pressures in ;H.:cordance wilh the table gi i'L'Il on page 10.

Tyrc cx;lminalion

Flints and other s harp objeo,;ts should be removed with a screwdriver or similar tool. If they arc neglec ted tho.:y may work through the cover and dama ge the cords.

Pcnelratio n docs no! ;d ways n:s ull in dc:Oation and the lyre s hould be ins pected a nd removed fo r vulcanizing if ncc:c:ss;try .

Any o il o r grease which may gc.:l onto !he lyres should be <.:lea ned otr by us ing po.:tro l sparingly. Do r11ll u~~.: p;trallin, which has a dclrimcntal ell'c:ct on t·uhber.

With the /)('ad of' th• · ,,.,, . /,./,/in rfl, · hmc· of !IIi' rim, insert a lc·t·c·l ,·/u" ' lo till' •·o/!·,· 111111 fill tlw

t )' l 't' !lt'tld ,,.,.,. ,,,. ,.,.,

Tyn: remo,'a l and replacement

'When removing or replacing a ty rc 11 " He ll to IL'IIlembcr !hat the usc oJ' fo rce is unnccc:ssa ry and can be dango.: rntls, a ' 11 mc rdy !ends to damag..: th..: co 1·o.:r beads. The usc o f wa ter on th~.: l Yil' ln<' l ~ n•n ~idcr; thly e;tso.:s the litting and removing or the beads .

Rcmo1·c the wheel as prc:viDu~Jy tlL''L'Jii>n l and dc:Jblc lhc ly re. if not already detlatc:d . 1-'r..:c both tyrc beads fro111 tho.: 11 111 "·:; 11 ~.

Commence to remove the head 011 till' l'a ln : side of thc COI'L'r by inserting a Jc ,·..:r at the valve posi tion. and wluk pttlli n~ nn this k,·cr push th..: bead in to thc well of the rim diametrically llflflll, th: tho.: v;dve . lns..:rt a scc,mJ lever about 2 in. (5 e rn.) away fro m !he lirs t and Kt .tduall v pri st: th..: b..:;td over the rim !lange. Continue round the rim. pris in,.: I he head m ·o,; r !he: r im '' ith one k v..:r while holding the removed po rtion or the hc.1d '' irlt tho.: o ther.

With o ne bead thus freo.:d rrum Jh,· 11 ho.:cl rilll th..: tu b..: can be withdrawn.

JH

ROAD WHEELS AND TYRES

:'\ext, s ta nd the cove r upright with the frc..:J bead ne;trcs t the opera tor, t hen insert a leve r fro m the front between 1hc second bead a nd !he flange. Pu ll the cover back o ver the llangc. Should !he o pera lion prove d in1cult, keep the st rain t ll l the lever and tap the tyrc ofT w ith a rubber mallet.

In fitting a tyrc. fi rst p l;tCC the cover on top of the wheel and push as much as poss ible o f the lower bead, by hand, into t he we ll of the rim . U sing a tyrc lever , pr isc the rem;tining portion of the lowo.:r bo.:ad over the rim tlang..:.

With rite head uf the f. t 'I'C in the hase of the ri111, the Uflfll'r fllll 'f of til<' f.J ·re ca11 be /e1 ·ered oj(

the H·lteel

N o w slightly innate the tuhc: until it just begins to ro und ou t and insert it in the coYo.:r, making sure that the' alvc:, which is fitted in the s ide of the tube, is on the correct s ide o l' the rim and properly entered into the ho le pro vided.

Commence to fi t the second bo.:ad by pushing it into the well of t he rim di;tmc t rically opposite the va lve. Lo.:\..: r the bead over the !lange, starti ng at either side of th is pos ition a nd finish ing a t the \alve.

Ease the valve in the r im ho le and push upwards by hand to enable the heads to seat correctly, then pull the val\'<: li rml y back in to position.

Finally, inlla1c the ly re 10 the correct pressure, ensuring in the rrnco.:-;s tha t the beads arc seated evenly rou nd the r im, a factor wh ich rn;ty he c:hed.cd by the line on the: cover.

.N

ROAD WHEELS AND TYRES

Valves and caps

Valves may be tested by removing the valve cap and immersing the exposed end of the valve in water. If the sea ting is faulty, shown by air bubbles, the valve interior should be renewed.

Ensure t hat the va lve caps arc s~ re11 cd down firmly by hand. The cap prevents the entry o f d irt into the valve mechan ism and fo rms an add itional sea l o n the valve, preventing any leakage if the va lve interior is damaged .

With the l yre bend /wid in the base of the rim opposite the m h•t•, tilt' finn/ /iuing can he carried

out ll'ithout mu/111' fo rcr

Changing posit ion of lyres

To obtain the best lyre servicc and 111 supprcss thc dcvelopmcnt o f irreguln r wea r it is essent ial tha t the wheel~ be ll lterdla nged cvcry .1.000 m iles (5Q(X} k m.J o r J mo nths (sec page 6 1 ).

Impact fractures

Excessive local distortion as a rc~ult ul' ~ ~ rit.. ing a ke rb. a loose brick. a deep po t-hole. etc., may cause the casin tt cnrd , to frac turc. Every ell'o rt should be made to avo id such obstacles.

40

MAINTENANCE ATTENTIONS DAILY l~adiator

C heck the level of water in the radiator : to p up if necessary.

Chrcking engine oil lrvd

Check the oillevl.'l with the veh icle on level ground aml t he engine swi td1cJ off. Maintain the level a t the 'MAX' mark on the dipst ick and never a llow it to

fa ll below the 'M IN' mark .

nu· petrol engine oil ll'l'el dipstick

~

Filling up with engine oil

The diesel engine oil Jerel dipstick

The oil fille r is on the top of the valve rocker cover. and the quantity for filling the engine sump is given in 'GENERAL DATA' o n page 10.

Clean, fresh oil is essent ial and the use of an engine oil to Ref. A is recom­mended.

41

WEEKLY

Battery

Remove the filler plug from eac h of the ce lls and exa mi n..: the leve l of the e lectrolyte in each. If necessary. add di ~tillcd water until the perforated scpar:ttor guard is _just covered . Topping up may he ncccssar) more frequently in ho t climate~ or if long daily runs a rc tll:tdc. Do not o,·er till. , c,·cr u~c ta p-\latcr. and do not u~e a naked light when ~·"tllltning the cond it ion of the l:clls. \V ipc :1\\a~ all d irt and mois ture from the lop of the bat ter~.

T yre Jlrl·ssures

C heck :.~11 tyrc pressures with :1 ga ug..: and if n..:cess:.~ry, infl:tte to the recom­mended pressures to be found on pag..: 10. Ensure th:.~t the vah·es :1re filled wi th screw caps, and insrcct tit ..: !) res for possible damag..:. \Vip..: olr any oil or grease.

For a compll•tc summa ry of th1· att1·ntion-; to he gi \·cn weekly ~l·e a l'in page 60.

EVERY 3,000 MILES (SHHH Km.)

Dra ining the engine oil sump (di(•sd III4 Hids)

r:n~:inc (11/(/ f.:l't ll'hox drain plll/,!:i

I. 1:nginc oi l ~ump dra in p lug . ., Gearbox <•il drain plug.

The oil in the sump should he dt atncd to d..:ar the sump of any impurities that may have accumul:.lted a nd tltcn tcfilkd with the appropriate grade of lubricant. This operat ion is best can ted o ut when th..: oil is warm.

Remova l o f the hexagon-hc;Hicd d rain plug will release the contents of the sump. After ca refully clean ing the drai n p lug it sho uld be rep laced and screwed up lirmly.

Rc lillthe sump with fresh o il tu l{cf. A .

42

EVERY 3,000 M ILES (5000 Km.)

\lain gcarbo :~.

Check the llil k,·el. and tor up if necessa ry. Al:cess to the combi ned dipstick and Iiller is g: ti ned by removing the rubbe r g rommet on the lo p of the ge:trbox <.:0\<::r. Th.: ctlrrect oil k\el is to the ' I JI (il J" m:trk on t h..: di pstick.

The usc o f :1n oi l Ill Ref. B is recommended. Rerlace the dirst ick .

Tran~f(•r gearhm:

Check the llil Jc,cJ. and wp up if n..:ce~~ary. To gain a...:ccs~ to tin: lilkr and k\l:l plugs remm c the centre seat cushion and rai~c the h inged panel. T he corrcct Jc,d is to the hnlltHll of the Je,·eJ plug aperture .

T he usc of a 11 lli l to Ref. B is recomm..:ndcd . Replace the plug~.

I .

(,", ·,n /oo~t .J, 1ttil1

:\l.o11o ,., ·" ""' l tlkr plug .tnd d1Jhll• k Sl td tt t)' ' 1'11111' II IJ' J'k

~ . l l ll t \\' 1 ':" It IIIII l l tppl, ·

I t.t tt ,kt J,,, ltl k t plttf!.

~ .tttd (, ll. tt td ht.th· k\CI Pill Ill~ J' l IIIII\ Jo.ttt, J.-o J,, , ~,:,,·lplu;; .

Front and r l'ar axles

711<' /rolll ' " 1,· oil jilla ll/1(1 drain plugs

1. O il drain plug. O il fil kr 'k:vt:l pl ug.

Check the oi l levels, and top up ir necessa ry. The combined filler and lc' cl plugs arc s itua ted on the dilrcrent ial ca~e~. T he correct oi l level is loth..: bollt>n l of the fil ler plug apertures.

The usc of an oi l to Ref. H is recommended .

43

EVERY 3,000 MILES (5000 Km.)

Rear axle propeller shaft universal joint lubricating

nipple

44

Throttle linkage

I, 2, 3, and 4 are oiling points on the throttle linkage.

Note.- No lubrication re­quired at points I a nd 3 when

nylon jo ints are fitted .

Hand brake and propeller shaft oiling points

1, 2, and 3. Hand brake lever oi li ng points.

4. Sl iding spline nipple. 5. Universal joint n ipple.

Transfer box details

I , 2, and 3. Four-wheel-drive control oiling po ints.

4. Sliding spline ni pple. 5. Universal join t nipple.

The drag/ink and track-rod lubricating nipples

Front axle propeller shaft universal joillllubricating

nipple

45

EVERY 3,000 MILES (5000 Km.)

Swivel housings

Check the oi l level, and top up if necessary. The combined filler and level plug is situated a t the front of the right-hand swivel housing and at the rear of the left-hand swivel housing. The correct level is to the bottom of the filler plug a perture.

NOTE.- The front bub bearings arc lubricated by oil from the swivel housings.

The steering gearbox filler/ level plug

Steering-box

Swivel housing

I. Oil fi ller/level plug. 2. Oil drain plug.

Check the oil level, and top up if necessary. Access to the steering-box fi ller plug on the top of the box is from underneath the front grille.

The correct oil level is to the bo ttom of the filler plug hole. Take care to ensure that no dirt o r grit enters the steering-box when removing or replacing the plug.

46

EVERY 3,000 MILES (5000 Km.)

Oil filter clement (diesel models) The external oil filter should be dismantled, the filter bowl cleaned internally,

and the filter element renewed. Release the filter bowl by unscrewing the centre-fixing bolt securing the bowl

to the filter head. Remove a nd discard the filter element, wash the filter bowl in pet rol, and allow to dry. Install a new element in the filter. bowl, ensure_ ~hat the joint washer in the filter head is positioned correctly and 111 good condttJOn, and reassemble the filter. Start the engine, ensure that the oil pressure gauge registers within 30 seconds, allow the engine to warm up thoroughly, and then check the filter fo r oi l leaks.

Brake and clutch fluid

l

""' j

Brake and clutch flu id reser­roirs

I. Brake reservoir. 2. Clutch reservoir.

Check the level of fluid in the hydraulic brake and clutch master cylinder reservoirs, and replenish if necessary with Girling Brake and Clutch F luid or a fluid which conforms to Specification S.A.E. 70.R3.

Maintain the fluid level to within t in. (13 mm.) below the bottom of the fi ller neck . Replace the cap securely.

47

EVERY 3,000 MILES (5000 Km.)

Lubrication points

Lubricating nipples are situated at the points listed below and should receive th.ree or four strokes from a gun fi lled with a lubricant to Ref. C unless other­WISe stated.

(I) Steering draglink joints (one nipple each end).

(2) Steering track-rod joints (one nipple each end).

(3) Propeller shaft universal jo ints (one nipple each). (4) Propeller shaft splines (one nipple each).

The front brakes are pro­vided with two leading shoes which require independent

adjustment

Brake adjustment

From brakes

The rear brakes have a single adjuster

Firmly chock one of the wheels and then jack the vehicle until the front wheel to ~ adjusted is clear of the ground. Fully release both the hexagon­headed adJuster bolts on the brake backplate by turn ing them in an anti-clock-

48

EVERY 3,000 MILES (5000 Km.)

wise direction. Then turn one of the adjuster bolts in a clockwise direction un til the brake-shoe concerned rubs against the drum. Release the adjuster one notch, or until the brake-shoe is just free of the drum, and then repeat the procedure fo r the second adj uster, as on the front brake assembly a separate adjuster is provided for each shoe. Repeat the adjustment for the other front wheel.

The adjusters opera te snail-type cams which bear against the shoes. These cams are notched in order to hold them in position and thus require no locking device.

Rear brakes Adjustment is made by turning the squa re-ended adjuster on each rear brake

backplate in a clockwise direct ion as fa r as it will go. The brake-shoes are then hard on, and the adjuster should be turned back two full notches to give the shoes the correct clearance from the drum.

The adjuster can be turned a notch at a time, and the engagement, which can be heard and felt, is caused by the Hat sides of the cone on the inner end of the adjuster engaging with the plungers supporting the ends of the shoes.

One common adjuster is provided for both shoes in the rear brake assembly and the adjustment for both rear wheels is identical. After adjustment the brake pedal should be applied hard two or three times to centra lize the brake-shoes in their drums.

The running positions of the tyres should be changed at the recommended intervals so as to regularize lyre wear.

Tyrcs- running position

Change the running position of the tyres as shown in the il lustra tion. Th is will equalize the tyre wear of the front and rea r wheels and prolong the life of the tyres.

Check the tyre pressures after ... the wheels have been changed round (see page 10).

Inspect the lyres frequently and remove any pieces of flint , stone, or glass which have become embedded in the covers.

For a complete summary of the attentions to be given every 3,000 miles (5000 km.) sec also page 60.

49

EVERY 6,000 MILES (10000 Km.)

External oil filter (petrol models)

The external oil filter is of the renewable-element type and is located on the right-hand side of the cylinder block. Unscrew the central casing bolt, remove the casing, a nd discard the filter element. Wash out the casing with petrol and dry it before replacing it with a new element.

Start the engine, ensure that the o il pressure gauge registers within 30 seconds, allow the engine to warm up thoroughly, and then check the filter for oil leaks.

Air cleaner

I . Gauze mesh. 2. Oillevcl. 3. Oil reservoir.

Air cleaner

The petrol engine oil filter centre-fix ing bolt and head

joint washer

The air c leaner is mounted on the right-hand side of the engine and is con­nected to the. carburctter or venturi adaptor by a corrugated hose. Servicing must be earned out at the recommended intervals, or more often if excessively dusty conditions arc experienced.

Remove the oil bath air cleaner and detach the oil bath from the gauze container. Swill the gauze in petrol, clean out the oil bath, and refill with clean engine oil. Keep the air cleaner in a vertical position whilst removing or replacing to avoid oil spillage.

50

EVERY 6,000 MILES (10000 Km.)

Sparking plugs (petrol models) To save fuel and facilitate starting, plugs should be cleaned and tested,

preferably by a service garage with a s~cial ' air-blast' service. uni_t. The gap between the points should be set at ·025 111. (·64 mm.). When adjustmg the gap move the side wire, never bend the centre elect rode.

A combined setting tool and gauge can be obtained from the Champion Sparking Plug Co. or from your Distri butor or Dea ler.

Adjust the plug gap by bending the side electrode

only

Battery

The correct use of the hydro­meter, which may also be used for topping-up purposes

Remove the filler plug from each c f the cells and ascertain the s tate qf the battery by taking hydrometer readings. If necessary, top up with distilled water to bring the electrolyte just above the top of the separators. Do not overfill.

EVERY 6,000 MILES (10000 Km.) Dyna mo

A lubricating ho le is provided for the dynamo end bearing on the commutator end bracket. Apply two or th ree d rops of oil to Ref. A at the recommended intervals. Do not over-oil.

54

Lubricate the dynamo tltrouglt tlte !tole indi­cated (diesel models)

Lubricate tlte dynamo through the hole indi­cated (petrol models)

71w dynamo .l'i'curin!{ bo/15 ami nuts (diesi'l engine')

Fan and dynamo belt

EVERY 6,000 MILES (10000 Km.)

The dynamo securing bolts and nuts (petrol engine)

The tension of the belt is controlled by the location of the dynamo. To increase the belt tension slacken the two bolts securing the dynamo s lotted link and the two bolts on which the dynamo pivots. Using only hand pressure, draw the dynamo outwards to tension the belt . Avoid overt ightening as this will place undue stra in on the dynamo bearings. Ret ighten the bolts securely.

For a complete summary of the attentions to be given every 6,000 miles ( 10000 km.) sec also page 6 1.

55

EVERY 12,000 1\11 LES (200()0 Km.)

1\Jain grarhox

Drain tho.; oi l from tho.: gca rbo.\ wh~.:n th ~.: 1>il i~ \\arm ;tnd r~.:lil l to the ' lll(ill ' mark o n the dipstick with fresh oil to R..:L B.

Transf<•r gearbox

D rain the oil from t h.: t ra nsfer gc;1rlw\ wh..:n the oi l is \\arm and rdill to t h..: bottom of th..: lc\d plug apcrturl' "ith fr..:~h oil to Rd. ll.

Hear tt.r!t• dc ·rails

I. l> rai n plug. Oil lilkr ami kH:I pl ug.

Front and rear axl<·~

( ;curhox ami I raw.kr }:l'arho.\ drain plug.,

I. ( ;.:ar h,,, drain plug. 2. Tra rhf.:r c.:arhux drain

plug. -

Drain the o il from the fwnt and' ''·" ,1\k' '' hen the oi l is \\arm and rcli ll to the Iiller p lug apert ures ''ith frc.: sh ""'"Rd. B.

1:\IPOHTANT.- ln the case of thl' n ·ar a\k the oi l le \·rl in the n •ntn' tase mus t he ma inll1inr d, otherwise sullil'il'lll oil 11ill no! n •adt the huh hea rings, this h1·in:.: the only means of thrir luhrka tiuu .

EVERY 12,000 MILES (20000 Km.)

\lain fud lilt<·r (dit·~rl models)

The main fud lil ter e lement, which is 1>1' the p;tper typ..: a nd not int..: ndcd to be ckancd , s hould be r.: nC\\Cd. This intcn·al o f ckmen t r~.:nC\\;tl is for engines opcr;tl ing under no rmal condi tions and using clean, fi ltered ftH.:I. If. howcq:r, the engine mis lircs or runs erratic;tl ly, O\\ ing to fuel s tar\atillll due to a clwkcd m;tin fud filtcr. th..: clement mus t be rcnC\\cd irr.:specti\'l? of the di~tancc con:rcd .

The fi lter.'' hich is fitted at the front of the engine. is a CA. V. bu,\1-less typc, the clement being d;uHp<:d bet\\CCn the liltcr hc;td and bas.: castings.

To rene'' the clcm~.:n t. suppo rt th..: has~: ami unscrC\\ th..: r..:ta ining bolt lo..:a tcd in the cen tre o f the head casting. D..:tach the base casting and, using at\\ isting moYement. separa te the clement from th..: h..:a d casting. R cnwvc the three se;tling rings from their locat ions in th .: head and base castings.

Culllflllllellls of rlw 11111i11 jiwl jiliN (c!iest•l IIWcll'ls)

Thorough ly wash the basr casting in p.:trol, and when dry n:mllY<.: any residu..:.

Reassemble, using a n..:w dcmcnt and sca ling rings . fitting the clemcnt with its strengthened rim u ppermost.

Bleed the fucl system as dcs~:ri bcd on pagc ::!3 .

Fuel injectors

Remove thc fuel injectors from the cy linder hea d. clca n a nd adjust t hcm and t..:s t them for correct spray .

Owing to the varyi ng cond itions undcr which .:ngincs o p..: ra te more frcqu..:n t ;lltention ma y be necessary . This is indicated b~ loss of engine po\\cr. hlad. exhaust fumes and inc reased fu c.: l consumpt ion.

Strrring bo x

Chc.:ck thc stc.:e r ing box for play. and adjust to eliminate all p..:rcq>tibk cnd play. Thi, \\ork should be entrusted to an Authorized Dea ler.

57

EVERY 12,000 MILES (20000 Km.)

Sparking 11lugs

Fit a new set of sparking plug~ ,,r the make and ty pe ren1 n1men ded.

Check the plug gap before insta ll1ng the new plugs a nd adju't the p(linh I< '

the gap setting g iven under 'GI-:1\1·: 1~ .\1. D.YL\ ·.if 11L·,·~.·~s; 1 n.

The 1\'ater pump /uhricating plug (diesel models)

Water pump

Jhe n·atcr f1UIII{IIuhricotinr: plug (pl'trol 11/0tlels) •

Remove the plug on the watcr pump c;1sing and add a sm a ll quantit y of greas<.: to Ref. C. The g reas ing of the pump must be don<.: , ·cry sparing ly o ther­Wise grease will leak past the bearings and ther<.:by impair eflieicncy.

For a complete summar.\· of tlw ath·ntions 1<1 he gin·n c\·ery 12.000 miles (2HIHIO km.) sec also pag<' 61.

BODY ATTENTIONS ( 'uachwork

Regular c1rc nf the body finish is necessary if the new appearance o f the vehi.:le extcriur is til be maintained against the ctreets o f air polution . rain. and mud.

Wash the body11t1rf.. frequently . using a ~<Jft sp<mge and ple nty of 11ater con­ta ining a mild dell.:rgent. Large dcposits of mud must bc softcned 11 ith 11;11n bdon: us ing thc sponge. Smears shou ld be rcnw1·ed by a sc~.:ond ll'ash in clc;1n ll';t te r. and with the SPl'ngc if necessary. When dry. dean the surfa~.:e of the ~chick ll'ith a damp ~.:hamois- kathcr. In addition to the regular maintcnan~.:e. s;,c~.:ial :1ttention i-; req uired if the vehicle is dri,·en in ext reme conditions such ;tS sea 'pray. or lln s;dtl·d roads. In thcsc l·ond itions and 11 ith othn fo rms o f ~cvcre conlamin;llil'n an add iti o nal 11ashing operation is neccs~ary 11hich shou ld includc undc r- lwdy hosing. Any da nl;tgcd ;ucas s lwuld be immcdiat ..:h <.:m cr..:d with paint and :t completc repair ell'e~.:ted as sonn a s poss iblc . 13cforc !(luch ing-in light scrat~.:hes a nd abras ions wit h p;1in t tiHH'<'IIghl y dean thc surf:1cc. Us~.· pctrol, " hitc spir it tgas(d ine/ hydrnc lrh<•n S< >i vent ) tn r..:movc spo ts ,,f g reasc or Ltr.

The appl1c;1ti(ln <.If B.M.C. Car l'o lish is :d l th ;1! is requ ired to remo\'C traflie lilm and lo ,·n surc the rctentitlll ni' the nc11· ;tppcarancc.

Bri~ht trim

i\cv..:r usc an abr;t~ivc llll \ l:linkss. chn>111ium. ;duminium, or plast ic br ight p :1 rts and o n no at.:Cllunt dean them with lll<.'lal polish. Remove spo ts of grease <>r tar w it h petrol/ whit<.' sp irit ( g:tsoline, hydwcar:bon solvent) and wa sh frequentl y 11 ith water cl..-1.la in i~ild detcr~ent. When the dirt has been removed polish \\ ith a dry cloth oii"81 ; 11110i.;-lcath~r until bright. i\ny slight tarni sh fo und o n ~tainkss o r plated c;o mplln..:n ts w hich have not rec:e i1ed regular wa~hing may be rl·nwvcd with B. t\1.< ·. < 'hrome C leaner . i\n occas i,,n;tl application or min~· r;d ligh t oi l lll' grease wi ll he lp to prescrve the lini~ h . pa ni~.:ul a r ly during winter whe n ,aJt ma y be used on tiK'-- roads . but thc~c protecti .. ·cs mus t no t be applicd to p la , tic lini shcs.

\ \'indsncl'll

If windscreen smearing h;t' nccu rred it can be re moved w ith ll .t\l .C. Sere.:n Cleaner.

A razor blade w ill rc movc transfe rs fro m the 11 indo-.•: gl:l';s .

The ll .'vl.C. apprt1vcd products mentioned ab.J\1.' arc obtainabk fmm you r () ~, tributor or Dealer.

59

MAINTENANCE SUMMARY Periodic servicing-vehicles in usc

The servicing instructio ns given in the fol lowing table show in a clearly a rra nged a nd concise manner the attent ions required to maintain the vehicle in a n effic ient condit ion under normal condit ions of work a nd c lima te.

Extreme climatic conditions may, however, necessita te altera tions to the inte rva ls at which some of the atte nt io ns a re g iven, and it must be left, therefore, to the discretion of operators on the spot to vary these interva ls to suit lo ca l condit ions.

Where the actua l distance run in a given period is small it may be a d visable to apply the instructions on a 'time' ins tead of on a 'distance' basis .

When c hecking nuts which a re s plit-pinned or secured by ta b washers exa m ine fo r s igns o f movement o r leakage before attempting to tighten them wi th a spa nner. Only hand pressure sho uld be used when checking fo r tightness w ith a spanner, a nd a torque wre nc h used when called fo r in the ins tructions. Do not overtighten.

Daily service

C heck the o il level in the engine sump, a nd top up if necessary. C heck the water level in the radia tor. and top up if necessa ry.

Weekly service

C heck the battery electrolyte lcv~o: l , ami fi ll up if ncccssary. C heck the tyre pressures, a nd correc t if necessary .

3,000 miles (5000 km.) or 3 months service

I. Clurch C heck the fluid level in the reservoir, and top up if necessary.

2. Brakes C hec k the pedal and hand brake travel, and adj us t the brakes if necessary Make a visual inspectio n of the pipe lines. C heck the fluid level in the rese rvo ir, and to p up if necessa ry.

3. Radiator C heck the water level. and to p up if necessary.

4. Elecrrical C heck the battery electrolyte leve l and to p up if necessa ry.

5. Lubricarion C ha nge the engine o il (Diese l). C ha nge o il in petrol engines if us ing mo nograde o r s ingle-viscosity con­

ve ntional lubricants. Fi t a new element to engine o il llltcr ( Diese l). C heck the o il level in the gearbox, a les. s teering-box. a nd sw ivel ho usings .

a nd top up if necessary. Lubr ica te a ll chassis nipples . hand brake and peda l linkages.

6. Wheels and lyres C heck the tyre pressures. C hange the road wheels round diagona lly to regularize tyre wear.

60

MAINTENANCE SUMMARY

6,000 miles (10000 km.) or 6 months scnice

I . Engine C lean and rc-oil the a ir cleaner. Tighten t he fa n belt. if necessary. C heck the va lve clearances. a nd adjus t if necessary (Petrol and Diese l).

2. /gnirion (Pi' fm/) C heck the func tioning o f the aut omatic advance a nd reta rd mechan ism . C heck , a nd adjust if necessary, the dis tributor contact po ints. Lubricate a ll parts as necessary. Clean a nd adjust the sparking plugs.

3 . Clutch C heck Lhc fluid level in t he reservo ir. and top up if necessary.

4. S teering heck the track , and adjust if necessary. heck nil co nnectio ns and stifl'eners, a nd adj us t or ti ghten a s necessary.

5. Oro!.. 1',\

hec k thr p •tlu l und hand bra ke trave l, and adj us t the bra kes if necessary Make u vi<,ual i n ~pection o f pipe li nes.

hec k the thud I vel in the reservoir, and top up if necessary.

6. Rtuliorm heel.. th · wa ter level. a nd top up if necessary.

7. CNII'I (1/ hcd. tl nd tighten the nuts o n the engine. gearboxes, ax les, ' U ' bolts, uni c rsal join ts, spring shack les (where appl icable), fuel tank , e xhaust pir>c , a nd s pa re wheel ca rrier.

ll . l:'ll't fricol heck the specific gravity o f the battery e lectro lyte, a nd top up if necessa ry. hec k the ba ttery connections. heck the operation of all instruments, lamps, etc .

9. Lubricar ion C hange the engine o il (Petro l a nd Diesel). Fit a new element to the engine o il filter (Petro l and Diesel). C heck the oi l level in tie ea rboxes, axles, stee ring box, and swivel hous ings.

a nd top up if neces ' . Lubricate a ll c hass is ni ~les, hand brake a nd pedal linkages. Lubrica te the dynamo bearjngs .

10. Wheels and lyres C heck the tyre pressures. C hange the road wheels ro u nd diagonall y to regu larize tyre wea r.

9,000 miles (15000 km.) or 9 months service

Carry out the 3,000 miles (5000 km.) or 3 months service.

61

'1AINTENANCE SUMMAR\'

12,000 miles (20000 km.) or 12 months sl·rvicc

I . Lngill<' Ckan and rc-oil the air ckaner. Tighten the fan belt , if necessary. Chec k the va lve clearances. ;1nd adjust if necessary I Petrlll and Diesel). ( · ~~:an the fuel lift pump filll'r (Petrol). R enew the main filte r clement (Diesel). R emove, clean . and test the injectors for spray.

fr.:nirion ( P,·rrof) C heck the futH.:tioning o f the ;lll tnmatic ;tdv;tnce ;tnd rcwrd mechanism. Check. and adjust if nccessan. the distrihutnr contact points. Lubrica te all parts as necessa r}. Fit ne\\ ~parking plugs.

.1. ( 'lill i'lt Check the lluid level in thc rc-;L·noir , and top up if necessa ry.

4. .<.;fl. ,•ring Check the track. a nd adjust 11' IIL'L"L'Ssa ry. <"heck all connections and st1 lknL·rs. and adjust or ti gh ten a s ncccss<t ry. <'heck the s teering-box for pLI \'.

5. /Jml-c•.' Check the pcdal anti hand hrak ~· tr;l\cl. and ad.JUSt the br;1kc~ if ncccssar} \lake a\ isual inspcctil'll of tilt· pip..: lin..:s. ( "heck the iluid in the resnvoir. allll lop up if n..:c..:ss;try.

6. 1<{/(li(/f(!J"

7.

k ' .

Check t h..: \\·atcr le vel, and top up i l' necess<~r~ .

G('!{('rol <"heck and ti ghten the nut s n11 tile engine. g..:a rh<lxt.:s . a, Jcs. ·u· bolts.

uni ve rsal joints. sp ring shad .. k ' (\\her..: applic;lbkJ. fuel tanks. exhau st pip..: , and spare whcd ca rrin .

/Jod_t· T ighten the screws on th..: door lock s. c:1tches. striker plates and hinges. a nd

lubricate as nl!eessary.

9. Ef1'c/ r i ca/ C h..:ck the s pecifi c gravity of the battery electrolyte. and top up if necess<~ry .

( 'heck the battery connections. Check the operatio n o f all instrun1cnts. lamp-;, etc .

I 0 . f_uhri{'(lfion Change the eng ine o il (Petrol and Diesel). l-it a new clement to the eng im· oi l filter (Petro l and Diesel) . c ·hang..: the oil in gearboxes. a , J..:,, ~tcering-box, and swivel ho us ing. 01nd

top up if necessary. Lubricate all chass is nipples, hand bra ke and pedal linkagl!s . Lubricate d ) namo bearings. l .ubricatc \Vate r pump.

iVlAI~TEl'A'\jCE SUi\lMARY

I I . II "h<'dt ond fi n·.' ( 'heck t} rc prcs~u n:-;.

Change road "heels rnund di;tgonall} to regulari;e t} 1-c \\Ca r . <"heck the h uh hc;t ri n~s for pLt).

12. T"'' Road test tiK' \C hich: and rcpt)rt.

I 5.0011 miles (2SOtiO km.) or 15 munths s(•nin·

( ·arry o ut tilL' _,_oun miles (5000 km.) ur 3 months sl•nin•.

18.000 milt•s (.\OOIHl km.) ur IH months sl•nkl•

Carry out tl1c (>,()()()miles (10000 km.) or 6 months Sl'nil'l'.

21.000 mih-~ ( .,SOOO km.) ur 21 nwnths scn·ice

Ctrry <111t tilt- .\,IIIlO mill'S (5000 k ru .) or 3 months ~enil'l'.

2-t.OOCI milt·~ (-ttlllUCI km.) or 2-t nwnths scnit' l'

C'<~rry out till' (o,UilOmik' (SUIICI km.) or 6 months senkt•.

63

NOTES

LUBRICATION CHART

PETROL MODELS

KEY TO LUBR ICATIO~ CHART

(Petrol Models)

D:\II. Y

I I l I i"(i i NI'. < "hed, I he <>il k'd .. <nd i< >p u p if 11<:~'<.:" ;11·) \\ it h o il to R<:L ·\ .

E\"1-. I~ Y J.nnn "II.ES (5UOU 1-\rn.) OH J \10'-.TIIS

C l \I :\ I :-.l A I' D T R A N S I I R <d A RIIO:\ I· S. Check lh<: ,,11 k' cl-; , ;t nd lop up if ne<.:c:s,il l"\ \\ t! lt ••il h > Rd. ll . .

!.;1 I I{ON I :\ :-.JD REAR A .\ I I S . ( hc:c l, <he: n il ~.;,·c:Js . and lop trp ir n,.,.,.";'r~ "i1 h oi l tn RL•f. 11 .

I-ll SW I \ 11 . I IO I JS INGS. <lt,·,k l l ~c· <>il k , ,·l . a nd lop up if nee.·"·" , "i l h <>il lo l{c:f. II.

I ) ) S II I IU N(i (iEARBOX . (Ill·, k lite: P il k\ <.:1 . a nd lop up if n<·u·, ' a ry "i<h o il tn R ef. B.

I(>) ()1{,\(ii.I N J.: J\ I"RA< "K-ROD

JOINTS.

17 ) I'RO PI. I.I.FR S II A IT JO I N f S AND SPI INFS.

D l Gi\'c lh ' '"' or four

I s tro l,, ,

(' of the: gun

ti lled "lllo I lubricanl

) It> Ref. < ·

ll\J COI"TROI.I.I NKAGES. Wi1h ;11> <•ikan lubricate the throlllc:. hand h ra kc. a nd ft>ur -wheel-dri\c lc' n lin kage join ts.

l '>l 1- N (i i N I· . Change engi ne oil II u"n!! . lll<Hh>g radc o r s ingk -, . , ~<.:os11y C<Hl\l'n tiona l lubrica n h .

1-:\THY o.Uiltl \lii.ES (IUOOO 1-\m. J <m (, 1\ IOI"I IIS

I'JJ l.i\(i i N I· . D1 ;o!n ••fl" t hc:old o il ;ond r,·lill \\ ilh nc" n il It> Ref. A .

1101 I '\I I.R N AI . Oli.I · II.TUC< k ;u> lh<: "'"'' a nd fil a new clc:m <:lll .

1111 011 -lli\T II - IYI'I ,\ IR ('I.J ,\ ;'>. ­! J{ . D rain a nd ,· k a n 1hc: h, '" I .111d l'it'll lc'll l. a nd refill " il h nt'\\ ••il to Rd'. A .

I I :1 I) I ~ I IU Ill I OR . I ubri~·;! l c: the 11111 ing l'< Hll r<~l . c t ll l hc:;tring . <:<•Il­Iad hr<:;1kc:r , ·;un . a 11d pi\ <ll "i1h <> II Ill lh·f. :\ .

11-' l D YNA.\ 10 . ,\pp l-. '"'' o r lhrcc· dn'p~ ,, f nil ' " Ref. :\ . t<> th,· d ) namn bea ring ft: h .

E\'1\H\' 12.0()0 .\III.ES (.WUUO 1\rn. ) OH T\\ EI .VI·: i\10:\TI IS

1141 \ 1 i\ IN A N J) TR A NS I· J: R ( ii ·A RBOX J-.S. Drain nil' lht: ,, Jd <•i l a nd rdill w i1h nc:\\ nil h> Rd . B.

I 15 ) I· RO NT AND Rl' i\R AX I.LS. Drain <>l r I he t>ld oil a nd refill "ilh nc:w o i l to R d . B.

1161 WATFR I'UMP. Ci i,t: tlm:c or f<>ur ~lrnk t:s of lhe \!lin lillt:d wi1 h luhric;lllt to Rd. c'.

( I ) I

(9)

~)

(2) (~)

(8 I

LUBRICATIOl\i CH ART (Petrol Models)

. / 7 ' , \..

-{j)

.... x

s

KEY TO RECOMMENDED LUBRICA:\TS (Petrol Models)

Component

( limali< condition~

ESSO

A

E11~ t nr. ,\ l r l lc,tncr , J nd Od .. :.nl

All l<mporalur<•s a bo>e I H C. (0 F)

E)30 E)r. tra M otor Oil 20\V Jo•

8 \I Jtll ant! I r.Ul'-l c.:r (rc:c rl~~ \\~' .- 1

s \\·~ ~~~ri 111t~lJ:~~{~~1.'·.~~ht l 1-r\'ll t .tnJ R l.'., .. r ,, ,~c;,

All t <-mpt.•r aturl''

do"'n to I! \.

( 10 F . )

E s!'<o l-c.-tr O il

U .P . ~0

ll'niiJCraturL' ' lwlo" 12 c.

( 10 F. J

E )30 (.;e.lr 011 ( o.l' . so

_________ , ------------ ______ , __ :'\IOBIL \lvbilml Src-••'

BP UP Encrgt)l \ ,,,·n·,t..tlh.:

-------S II EI.L Sh<l l X 100 ~l uhi~r.to.!c 10\\ .'ol

-·--------FILTRATE Fill r..ttc 10\\' 30 \l u l ll~rall~o.·

---·---- --- --------STER!'\OL S tcrm,J Multip li(

\l oblluN: \I ,· ~ h:~e

G ' ~\.) (, ' ' II

Energ,,l !> A .E. 40 .

E.P. I

- ---, ~hell

I Spira' 90

E.P. - - ----·

. F thratc I II ~ pOid G~·H OtllJU

...\ mbroh.·wn E.P . 90

-----t- ner~t'~l

:> \I' M l [. I' .

~hell Sp1r.t\ 1\0

f .P.

I lltr.ttc II ~ p~u t.J

( ,c,u 0 11 ~0

..\mhr~ · h:ttlll f .l' . Sll

I -------1 Dl'CI\H .nrs Ou.:l Q. 5500

ch:tm' s H ypo;d 90

lltK lh.tm'" If ~ J'tHJ :-\(1

CASTROL ca~trolllc:"' Cas1rol 1-fypn)

(.aqn.,l It ~ I''" L1~h1

c \\ :ncr l' ll:np

.tnJ Lt thrt\."altnb

;..., p pk'

\II Cl}ndJ t ion 'IO

L:-.'\o \1ult ipurro~c

Gre.t~e H

\t c•r'l. l :r\.'.t't' \ I p

l· ncrc: r.:.t ' C L.-~

S~1cll Rt.' l trl,s\ .\

I d tJ ,Ih.' S uper l. lth JU rn

(irt':t'"-'

AmhrPimt.• .

1

I..H .l . CJr ... ·.t~c ---D ud .. h.tm · ~

L.H. Ill ( lfC::l"'C

ca~troka~c L. \I.

D

l I'Pc:r (_ ' l u~J .. : r

I utlncJtion

-\ II r• •ndt tiun'

l:.!\~('1 Lppcr t.\ lmdcr LUbricant

\l ,, bd li'Pl'rluh:

[nt..·r ~(l l

L'.l l.

Shdl l ' rr'"~r <.. \ hndc.·r I ,;hncJ nt

f tllr .th: 1'~11 t 1\ lc

Sll~rnt d \l.t~ l i..P~ I

Ou~kham's ·\d\.'IJUJ L l\tUIJ

('~ 401 Ttl l h.'

Ar'IPnwal is <tho gi,en to nuck ha nl' :, Q. ~0.50 oil. UP , .,.,,·o · .. l:lt H: LonghiC l \11. :md It) 1111\n(lgr<~lk <H , jn~le·\i l.:ti'JI~ ..:l \ f1\l.'llli l ll1 ,d lubl t\.: .mt ~ 'ut'rlicd hv companie' l i,tcU JbO\C . • h lr temperature~ bC)O\\ I :! c . ( IU •·. ) U ~l' t he s .,\ .l. 10\\ ,HI t: l.u.k OJ!. T Ju, '" ,.n.lll.ibk Ill 11\.lllCh \\here :- m:h Il l\\ ll'lll PI..' I.tltlll'' 1' " .'\ .td

~ L

0 = - ::c ~ -00 n ~ , r- ~ --~ 0 0 z ~ n ~ :t r-00 >

~ ~

KEY TO LUBRICATION CHART

(Diesel Models)

DAILY

I I) ENG INF. Ch~.:k th.: oi l lew I. and lop up if necessary with ••il tn R~f. A.

E\"ERY ~.non :\IlLES (5000 Km.l < m 3 1\10:'\TIIS

12) I:NGINI- . Drain niT the: <>ld n il and relill \\ith new tlil LP Rd :\ .

CJ) EXTERNAl. O IL FII .TI ' R. < · ~c·: u> I he b''" I and lit a n.:w clement.

(4) MAIN :\ N D T RANS I I R GEARBOXES. Ch~.:k th<· .. 11 lewis. and t<>P up iflll'l.·es,ar~ \\ ll h oi l t•> Ref. B.

15) FRONT AND REAR AXIl S. ( heck lhe <>il 1.:: \·cls. and top up 1f necessa ry wit h uil tu Ref. B.

(6) SWIVI'L HOUSINGS. Check the oil lcH'i . and lop up if IK'I."C\\:I I"Y wil h nil I<> Ref. B.

(7) STLERI N(i GF.ARROX. < ·h,·,·J.. I he oi l level. and top up if m.'l.:<"";u v wil h oil lo Ref. 13.

TRA< X-ROD or four (8) DRACiLINK AND l Give tlu·,."

JOINTS. slrokcs

lof the ~un (<J) PROI'EI.I.t:R filled with

SHi\ I·T JOINTS luhricanl AN D SI'I.INFS. ) to Ref. <·.

110) CONTROI . I.INKAGES. Wirh an oikan lu brit:atc th.: thwttle, hand 11raJ..c. and f<>ur-wheel-drivc l,·wr linkage jt>ints.

70

EVERY 6,000 1\IIU:S (10000 1\m.) OR (, 1\10:'\THS

t.l l ) OIL-BATII-TYI'J: A IR C LEAN­FR . D ra in ami clean the h.>wl ami dement. and l"l' lill wilh new o il Ill Rei'. A.

112} DYNAMO . Apply two or lhrct' drops of <>i l to Ref. A. lo lhc ~~~ nam,, hearing.

E\"ERY 12.1HIO MILES (20000 Km.) on 12 :\IOj'I;TIIS

Cl .') MAIN A N I) TR ANSFER Cii :AR BOXLS. Drain oiT the old •>i l and refill 1\ ith Ill'\\" oil lo Ref. B.

114) FRONT AND RLAR AX LES. Drain oil" the <>ld o il and rctill wilh new oi l to Ref. B.

t l5) WATER PUMP. (ii vc three or four stroke~ of the gun tilled with lub ricant to Rd. C.

MULTIGRADE MOTOR OILS

In additi(m to 1 he recommentled luhri..:anls we approve lhc usc of the oils lis1ed hclow for a ll d imali<: conditions u nless the engine is <>ld and in poor mechanical Cl>ndition. Mobi l ..

Shdl

Ill'

l'iltrate ..

Sterno I Dudh:11n·s

Mohiloil Special or Oclva.: Spedal.

Ro lclla Multigrade IOW/JO.

Encrg,>l Mulligrad<.:.

10\V/JO Multigrade. Minx 10/30 S. l. Multigradl· Diesel

f:nl!inc Oil l·I.D. IOW,'JO.

< ·. R. :!OWi.ltl

(I~

( I) I (~

(9-·----·-

~-·---_

©·-

LUBRICATION CHART (Diesel 1\'Iodcls)

--(i '.

---®

·- - --®

' I

\

\

I

71

-..J N

.. !! z .. " " " "' z

" ,.. > .. " " < j ; z ~ .. ;; ,.. " :i .. 1: .. i ~ 5' 8 ~ " ;< 0

" a "' ?

~ .... .... v: ;:;: 00

"' f .._, 8

-KEY TO RECOMMENDED LUBRICANTS (Diesel Models)

A I B " c i\·fain and T r;.msfcr Gcarbo:\t:S,

St~enns Gearbox \\'atcr Pump

Component Engine, A ir Cleaner. and Oelcan S" i'el Housing. and and Lubricating t- ront and Rc:1r A.\les i': ipplc~

All condit ion~ Arctic 32" C. (90 F.) down to consistently

Oimacic Abo' • 32 C. do"n to Bclo,. 12 c. - 12" c. below - 12' C. All conditions (90' F.) - 12 c. <ro• F.> (10 F.) ( to• F.> <to• r .> conditions

Essofleet Essofleet Essofleet Esso Esso Esso ESSO H.D. 30 H.D. 20 H.D.IOW Geor Ool G e.tr Ool Mulllpurposc

G.P.90 G .r .so Goc•>e H

Deh11e 0elv3e Dehne 1\fobolube ~1 obolube 1\1 obi! grease MOBIL Ool930 O ol920 Uil 910 G.X. \10 G .X. 80 M.P.

Energol Encriol Energol Energol Enersol Energrease BP D 30 D 20W D lOW S.A.E. 90 S.A .E. 80 L.2

E.P. E.P. - -

Rotella Rotella Rotella Shell Shell Shell SHELL 30 20/20\V lOW Spor.n 90 Spira' SO R~l103X A

E.P. E. I'. -

Filtrate Filtrate Fihrdte Filtrate Foltrate Foltrnte FILTRATE Ooesel 30 Diesel 20 Doesel lOW Hypood Hypood Suptr Li thium

Gear 90 Gear 80 Gre.:tse

Auto Deso Auto De.so Auto Dc~o Ambrolcum A mbrolcum Ambrol tnC' STERNOL H.D. 30 H.D. 20 H.D. tO E.P. 90 E. P. SO L.H .T. G rease

i D uckh•m's Duckhnm's Duck hom's Duekhnm's Duck ham's Duck hom's I DUCKHA~'l'S NOL D iesel NOL Diesel NOL Diesel Hypoid 90 Hypoid 80 LB. 10 Grease

Thirty T wenty Ten

Castro! Castro! Castro! Castro! Castro! Castro lease CASTROL C.R. 30 C.R . 20 C. R. 10 Hypoy Hypoy

Light L.M.