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    Bedford TK Petrol Instruction Book 1971

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
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    2K views47 pages

    Bedford TK Petrol Instruction Book 1971 PDF

    Uploaded by

    Next2normal NZ
    Bedford TK Petrol Instruction Book 1971

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
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    of 47
    INSTRUCTION BOOK BEDFORD TK PETROL ENGINED MODELS sane T.S.1053 issued August 1971 : 2H | BEDFORD VAUXHALL MOTORS LIMITED, LUTON, ENGLAND “e aig. Ox Se eS Ag Say = fa INSTRUCTION BOOK BEDFORD TK PETROL ENGINED MODELS VAUXHALL MOTORS LIMITED, LUTON, ENGLAND FOREWORD DETAILED instructions are given in this handbook for the operating, ‘adjustment and general maintenance of the Bedford models listed on pages 3 and 4. In accordance with the Vauxhall policy of progressive improvement, rightis reserved to alter any details of specification and equipment without notice Conscientious attention to the routine and general maintenance described in the following pages is essential. Providing the instructions are carried out regularly and thoroughly, the parts will be protected from unnecessary wear, the vehicle will continue to function efficiently for longer periods, and fewer repairs and replacements will be necessary. The nation-wide “ Bedford Guardian Maintenance Scheme” sponsored by Vauxhall Motors and operated by Bedford dealers is available for all Bedford owners resident in the United Kingdom. Full particulars of the scheme are given on page 29. ‘As a general guide, the information given in this booklet is confined to operation, care and general maintenance. obviously wise, however, to entrust overhauls and repairs to authorised Bedford dealers, who possess the specialised equipment and technical knowledge necessary to ensure skilled and efficient workmanship. A booklet giving their names and addresses is included in the same package as this instruction book. One other point. Owners sometimes ask whether it is possible for maintenance and repair work on their vehicles to be carried out at the Vauxhall factory. The answer must, unfortunately, be “no.” The service station at the factory is fully employed in attending to the company’s own fleet of vehicles. Finally, a word to the driver. The vehicle with which you are entrusted was built to stand up to hard work. It will stand up to hard work if you play Your part in looking after it. Make it your business to learn all you can about it.’ Drive it as you would want someone else to drive it if it belonged to you. Don’t neglect to do any of the things you know are necessary to keep it in good BEDFORD MODELS Covered by this Handbook _ The information given in this handbook coyers all the petrol- engined Bedford vehicles in the TK (E000000) range. are shown below. Each basic serie: into individual models. In general, however, only the basic series references, shown in the centre headings below, are used in this book. KB SERIES (EDG0000) Model KBZ (EDGOBZO) Chassis only 115 in. (2:92 m.) Model KBC (EDGOBCO) Chassis with cab wheelbase KC SERIES (EDL0000) Model KCC (EDLOBCO) ith cab 3-429 m.) wheelbase KDS SERIES (EFM0000) Model KDSC (EDM2BCO) Chassis with cab 135 in. (3-429 m.) wheelbase KDL SERIES (EFM0000) Model KDLC (EDM3BCO) Chassis with cab 151 in. (3-835 m.) wheelbase KEL SERIES (EFNO0000) Model KELZ (EFN3BZO) Chassis only 1SLin, (3835 Model KELC (EDN3BCO) Chassis with cab tt m.) Model KELC (EFN3BCO) Chassis with cab J Wnee'ase KGE SERIES (EFR0000) Model KGEC (EFR4BCO) — Chassis with cab 193 in. (4-90 m.) wheelbase KGL SERIES (EFR0000) Model KGLC (EFR3BCO) — Chassis with cab 167 in. (4-242 m.) wheelbase KGM SERIES (EFR0000) Model KGMC (EFRABCO) Chassis with cab (3-50 m.) wheelbase KGS SERIES Model KGSC (EFRIBCO) Ch 3-835 m.) wheelbase Model KGTC (EFR6BCO) 120 in. (3-048 m.) wheelbase ENGINE IDENTIFICATION GENERAL DATA In cach of the model designations the second letter indicates the type of engine fitted to a particular vehicle. letters is: D E The code for these Bedford 214 cu. in. Petrol engine Bedford 300 cu. in. Petrol engine Note: For location of model, chassis and engine number see page 12. Engine Oil 214 cu. IN. ENGINE: Refill with filter element change otal. . 300 cu. IN. ENGINE: Refill with filter element change PrOtald ot ‘ Rear Axle (single speed): Models KB, KC, KD All other models Rear Axle (two-speed): Bedford axle. . Eaton axle .. Cooling System: Models with 214 cu. in. engine 300 cu. in. engine Fuel Tank: Models KB .. All Models except KB MAXIMUM GROSS VEHICLE PLATED WEIGHTS DOMESTIC All Bedford TK petrol-engined models, produced for use in the United Kingdom, are now fitted with a Vehicle Weight Specification Plate which gives the Maximum Gross Vehicle Weight and Gross Train Weight together with the vehicle maximum front and rear axle weights. seat support. The plate is located on to CAPACITIES p of the wheelarch inside the left-hand cab door, but on a drive-away chassis, the plate will be on the driver's 124 pints (7-1 litres) 14 pints (7-9 litres) 15} pints (8-95 litres) 17 pints (9-7 litres) 63 pints (3-7 litres) 9 pints (5-11 litres) 10 pints (5-68 litres) 4 pints (2-3 litres) 6 pints (3-4 litres) 15 pints (8:5 litres) 20 pints (11-4 litres) 31 pints (17-6 litres) 364 pints (20-7 litres) 12 Imp. galls. (54 litres) 14-4 U.S. galls.” 26 Imp. galls. (118 litres) 31-2 US. galls. GENERAL DATA GENERAL DATA Track—Rear: MAXIMUM GROSS VEHICLE WEIGHTS EXPORT pans — —— Models KB, KC, KDS, KDL -- 64-60 in. (1-641 m.) FRONT | REAR | Models KEL, KGE, KGM, KGS, MODEL, | AXLE AXLE | GVW. KGT oF 67-12 in. (1-705 m.) EDGOBCO [ 4032 Ib. 8512 Ib. 11760 Ib. Overall Width: | (1828 kg.) | 3861 kg.) (5334 kg.) Model KB 2-088 m.) OBCO | 5152 1b. | 11200 1b. 15904 Ib. Model KC .. 2-098 m.) gee | (2337 kg.) | (5080 kg.) (7214 kg.) Moses KDL nf 2-111 m.) el 15 Se pie) fa (2:177 m.) EDLOBCO ane eae oa, (Gore) Models KGS, KGL,KGT 87-32 in. (2.218 m.) — e Sede | Models KGE,KGM —...— 88:22 in. (2:240 m.) EFM2B00 6272 Ib. 13440 Ib. 18144 Ib, EFM3BOO, (3845 kg.) | (6096 kg.) (8230 ke.) Overall Length: MIGdcWAIB) oot es) Op -somna(soee Tas) EFN3BCO 8288 Ib. pons ee Models KC, KDS .. .. 245-36 in. (6-232 m.) ae Sete le Models KDL, KEL t 268-9 in. (6830 m.) EFR3BCO 8288 Ib. 19040 Ib. 26096 Ib. Model KFL .. eA DE + 294-2 in. (7-473 m.) EFR4BCO (3759 kg.) (8637 kg.) (11837 kg.) Model KGE ist Ye -. 339-23 in. (8-616 m.) Enrca Model KGM. aa) ii .. 249-73 in. (6-343 m.) i | Model KGS .. ed a .. 270-16 in. (6-862 m.) - ci cues src ens eae a Model KGT s. ses. 19956 in. (5-069 m.) Note: In some overseas countries the Gross Vehicle Weight may vary according to local regulations andor operating conditions. Groand Clearance: Models KB, KC... ay .. 7:50 in. (201 mm.) Models KDS, KDL ay -. 7-60 in. (193 mm.) Models KEL “i i -- 9:90 in. (251 mm.) LEADING DIMENSIONS Models KGE, KGM +. 10-00 in. (254 mm.) Overall dimensions are for chassis equipped with standard tyres Models KGS, KGL, KGT s «» 10-70 in. (272 mm.) . Turning Circle Diameter: Wheelbase: : Model KGT 40 ft. (1219 m) | Model KB... ae Br +. 115 in. (292 m.) Model KB... = a +. 41 ft. (12-50 m.) Models KC, KDS .. ++ 135 in. (3-429 m.) Models KC, KDS .... ~—«.- 44 ft. (13-41 m.) Models KDL, KEL, KGS.. +» 151 in, (3-835 m.) Model KDL hai te .. 49 ft. (14-93 m.) Model KGL.. . . +» 167 in. (4:242 m.) Model KEL .. es a ++ 46:5 ft. (14:17 m.) Model KGT a ot oeelag: in. (3-048 m.) Model KGL Pe _ re) Seb ott (16:91 may) Model KGE a8 . per leauhe (4-90 m.) Model KGS .. a aN +» 49-3 ft. (15-08 m.) Model KGM ca Sle 138 in. (3-50 m.) Track—Front: Model KB .. a re -» 7414 in, (1-882 m.) Model KC .. a ++ 74:18 in. tees m.) Models KDS, KDL od +» 74:28 in, (1-886 m.) Model KEL . +» 72-30 in. (1-836 m.) Models KGS, KGL, KaT.. soo) CLS) Nie Models KGE, KGM. +» 71-26 in, (1-810 m.) GENERAL DATA BRIEF SPECIFICATION OF THE CHASSIS 214 CU, IN. ENGINE ‘Type ee . Stroke 0.1. os Piston Displacement Compression Ratio Brake Horse Power: Gross... - Brake Torque: Gross .. Valve Clearances (Hot) Ignition. cn Firing Order en Spark Plugs. Carburetter : Petrol Feed Lf Radiator and Cooling System Six cylinder in-line type with push rod operated overhead valves in detachable cylinder head. Engine mounted in the frame at three points, all on rubber insulators. 3-375 in. (85-72 mm.) 4 in, (101-6 mm.) 214-7 cu. in. (3519 c.c.) 6-75:1 100 at 3,600 r.p.m. 184 Ib/ft. at 1,200 r.p.m. Inlet valves -010 in. Exhaust valves -013 in. AC distributor driven from the cam- shaft spiral gear. Contact breaker point gap 019 in. to-O21in. AC Delco oil-filled ignition coil. Ignition timing 5° before top centre as indicated by steel ball in flywheel. Maximum permitted setting 9° before top centre. pon Ones. AC type 44, 14 mm. thread. Gap +028 in. to -032 in. Zenith, type 37 VNR with engine speed governor. Combined oil bath air cleaner and flame arrester fitted to air intake. By AC fuel pump driven by camshaft. Pressurized cooling system. Header tank filler cap located under the left- hand engine access panel. Coolant circulation by a centrifugal impeller type pump driven by “V” belts. Thermostat incorporated in cooling system. Air flow assisted by fan and cowl. (See Important Safety Note on page 60.) 8 GENERAL DATA 300 CU. IN. ENGINE ‘Type bs Sh . Six cylinder in-line type with push rod operated valves in detachable cylinder head. Engine mounted in the frame at three points, all on rubber insulators. Bore ce <= +» 3-875 (98-42 mm.) Stroke... sits +. 425 in. (107-95 mm.) Piston Displacement ++ 300-7 cu. in. (4927 c.c.) Compression Ratio per iat Brake Horse Power: Gross .. eo 9 Brake Torque: Gross .. o Valve Clearances (Hot) .. Ignition .. oa oe ing Order... Spark Plugs Carburetter ss oi Petrol Feed : d: Radiator and Cooling System 133 at 3,400 r.p.m. 267 Ib/ft. at 1,200 r.p.m. Inlet valves -010 in. Exhaust valves -010 in. AC distributor, driven from the camshaft spiral gear. Contact breaker point gap -019 in. to -021in. AC Delco oil-filled ignition coil. Ignition timing 5° before top centre as indicated by steel ball in flywheel. Maximum permitted setting 9° before top centre. 155; BiGores A AC, Type 44, 14 mm. thread. Gap +028 in. to -032 in. Zenith, Type 48 VIR, with engine speed governor. Carburetter air intake protected by an oil bath air cleaner and silencer. By AC fuel pump driven by camshaft. Pressurized cooling system. Header tank filler cap located under the left- hand engine access panel. Coolant circulation by a centrifugal impeller type pump driven by “V” belts. Thermo- stat incorporated in cooling system. Air flow assisted by fan and cowl. (See Important Safety Note on page 60 for full draining instructions). 9 GENERAL DATA GENERAL DATA ELECTRICAL SYSTEM Teak Sad Gain apeed)s Alternator... .._ Lueas or AC-Delco. Models KB, KC and RD Soaers ~ Fully-floating rear axle with final drive peemaed NES eel le saad a by spiral bevel gears. Taper roller hub attery: 214 cu. in. engine Exide, 12 volt, 60 amp. hour capacity at 20 hour rate. bearings. Detachable inspection cover with combined filler and level plug. All other models .. Final drive by hypoid gears, otherwise 300 cu. in. engine... of similar construction to KC, KD type. Exide 12 volt, 75 amp. hour capacity at 20 hour rate. Two-speed Bedford Rear Axle (where fitted) .. TRANSMISSION The Bedford two-speed axle incor- porates a conventional hypoid gear and Clutch .. =... Single dry-plate with spring-loaded pinion with an epicyclic reduction gear centre. Pedal adjustment to com- mounted between the hypoid gear and pensate for wear. Radial type clutch the differential which enables the axle throw-out bearing. to operate with a high and low gear ratio. The change of ratio is made by a push-pull control attached to the Gearbox: gearbox change speed lever. 4-speed .. Bo .. Four forward speeds and one reverse, with synchromesh operation on top, Two-Speed Eaton Rear third and second gears. A standard Axle (where fitted) .. The full-floating two-speed rear axle 6 bolt S.A.E. power take-off facing provides a normal single reduction is provided at the left side of the through a bevel pinion and crown- gearbox casing. of planetary sareea) | ee ect ecapesie etal Suter eae NerSeo mnt HS RETO CIES NSE cee ‘The change of ratio is made by a push- ongitep fourth, ‘third andimseeond pull control attached to the gearbox gears. A standard six bolt S.A.E. change speed lever. power take-off facing is provided at i both sides of the gearbox casing. FRONT AXLE AND STEERING Universal Joints: A Front Axle 5 .. Drop forging of “I” section beam. Type ++ ++ Needle roller bearing. Stub axle load taken by thrust Numbei bearings. Steering knuckles fitted with Models: KB, KC, lead-bronze steel-backed bushes. KDS, KGT Two All other models... Three Steering Gear. . .. Semi-irreversible worm and _ sector. Hotchkiss type. Drive and torque taken through rear springs. Single open propeller shaft on Models KB, KC, KDS, KGT. Two open propeller shafis in tandem on all other models. 10 Front Wheel Alignment: Drop arm shaft straddle-mounted in gearcase. Self-adjusting steering joints on tie-rod and steering connecting rod. (See page 7 for turning circle diameters.) 0 to + in. (0 to 1-6 mm.) BT GENERAL DATA BRAKES ck eo -- Hydraulic system, incorporating tan- dem master cylinder operating on all wheels. Operation on KB models assisted by vacuum servo motor. On KC, KD, KE models operation assisted by air pressure servo. On KG models hydraulic system is air pressure oper- ated. All models except KB have an engine driven compressor. On all models parking brake operates rear brakes only; mechanical system on KB model air operated on all other models. On all models parking brake lever is at the outer side of the drivers seat. WHEELS Type os ae .. Detachable steel disc wheels with wide base rims. Wheel studs and nuts screwed left-hand on left side of vehicle and right-hand on right side of vehicle. FRAME Type os re .. Pressed steel channel section. Side- members and crossmembers riveted together by cold squeeze process. Towing eyes fitted to the front of the frame sidemembers on all models. On Model KGT only, rear towing eyes are an integral part of the rear spring hangers. LOCATION OF MODEL, CHASSIS AND ENGINE NUMBER Bedford TK petrol models intended for use in the United Kingdom are now fitted with a Vehicle Weight Specification plate, this plate also carries the Chassis and Model numbers. The plate is mounted on the left-hand front wheelarch, inside the cab adjacent to the door. Bedford TK petrol models are also fitted with a Service Parts Identification plate which carries the chassis number and all the code numbers for any particular model, therefore when ordering replace- ment parts all details on this plate, together with the engine number should be quoted to ensure correct replacement parts being obtained. The plate is mounted on the left-hand sidemember just forward of the engine rear cross-member support bracket. The chassis number is 12 GENERAL DATA also stamped on the left-hand sidemember in the vicinity of the rear spring front hanger. The engine number is stamped on a pad on the engine crankcase on the right-hand side. THE CONTROLS _ COMBINED IGNITION AND STARTER SWITCH. This switch is located on the engine compartment top panel, which is in the centre of the cab floor, adjacent to the driver’s seat. It is operated by a “ Union” key and the first movement of the switch turns on the ignition circuits. Further rotation of the switch—against the pressure of a spring—operates the starter. When the switch is released it returns automatically to the running position, A spare key is provided, and the number should be noted in a diary or pocket book. If a key is lost a new one can be obtained by quoting the number, through your Bedford dealer. COMBINED LIGHTING SWITCH AND HORN PUSH. This combination switch is attached to the steering column and points toward the right-hand side of the vehicle. The lighting Fig. 1. Controls 1. Combined ignition and starter switch. 2. Choke control. 3. Gear lever. 4. Parking Brake lever (model KB). 5. Brake pedal. 6. Accelerator Pedal. 7. Clutch pedal. 8. Ventilation control lever. 9. Instrument cluster panel. 10. Turn signal switch lever. « Combined lighting switch and horn push. 12. No-draught ventilator catch. 13. Door inside handle. 14. Window winder. 15. Windscreen washer control. 16. Windscreen wiper switch lever. 17. Seat adjuster height control. 18. Panel lamp switch. 19. Brake ‘ir pressure or vacuum gauge. 14 THE CONTROLS All lights off. Side and tail lights. Side and tail lights, with headlight in dipped position. Side and tail lights, with headlight beam in the straight ahead position. switch is lever operated and has four positions which are marked on the switch body. These are given in the diagram above. A blue warning light, incorporated in the top of the speedometer, glows when the headlight beams are in the straight-ahead position. The horn-push is located on the end face of the switch. TURN SIGNALS. The flashing turn signal lamps are fitted each side, at the front and rear of the vehicle. The switch is on the left-hand side of the steering column. Anti-clockwise movement of the lever switches on the left-hand turn signal, signalling a left-hand turn. Clockwise movement of the lever correspondingly indicates a right-hand turn. Whenever the turn signal lights are in use, a small green lamp adjacent to the main beam warning lamp is illuminated, and the flasher unit emits a “clicking” sound. These two devices serve as a warning should any failure occur in the system, and the cause of trouble can be diagnosed as follows. Failure of one or both turn signal lamps—No light from warning light and no audible clicks. Failure of warning light—Audible clicks normal, front and rear turn signal lamps working correctly. CAB ROOF LAMP (WHERE FITTED). The switch con- trolling the roof lamp is incorporated in the lamp body. Full instructions for changing the bulb are given on page 65. ALTERNATOR WARNING LAMP. This is the small red lamp which glows when the ignition is switched on. It should go out as soon as the voltage output of the alternator rises above the battery terminal voltage. The lamp acts as a warning if for any reason the alternator ceases to charge the battery; it also serves as a 15 THE CONTROLS Fig. 2. Instrument panel. 1. Panel lamp switch. 2. Brake reservoir warning light. 3. Temperature gauge. 4. Alternator warning light. 5. Speedometer. 6. Turn signal warning light. 7. Main beam warning light. 8. Oil pressure warning light. 9. Fuel gauge. 10. Windscreen wiper switch. reminder not to leave the ignition switched on when the engine is not running. OIL PRESSURE WARNING LAMP. _ This is the small orange lamp which glows when the ignition is switched on. It should go out when the engine is started and should remain out all the time the engine is running. The lamp is operated by oil pressure through an automatic switch on the engine crankcase and will, therefore, light up as soon as the oil pressure falls below the safety limits. TEMPERATURE GAUGE. The temperature gauge shows whether the engine is operating at the correct temperature or not. Under normal conditions the needle should lie around the 80°C. mark. If the needle approaches the 130°C. mark it will be an indication that the temperature of the cooling system is approaching boiling point, and a stop should be made so that the level in the cooling system expansion tank in the engine compartment can be checked. Due allowance, however, should be made for travelling in extremely hilly country and in hot weather with a following wind. Should the temperature gauge show that the cooling system is 16 THE CONTROLS consistently operating at too low a temperature, the vehicle should be taken to a Bedford dealer to ascertain the efficiency of the thermo- stat. Note: Before removing the radiator filler cap read the Important Safety Note on page 60. PETROL GAUGE. The petrol gauge is electrically operated and functions only when the ignition is turned to the “on” position. INSTRUMENT PANEL LIGHTING. Illumination of the instruments is provided by concealed lamps mounted at the rear. They are controlled by a switch at the left-hand side of the instrument cluster panel and the wiring is so arranged that the lamps cannot be switched on until the side and tail lamps are also switched on. Note: The interconnection of the panel light wiring with the tail light wiring means that if the panel lights fail to operate this will be an indication that the tail lights may also not be in operation, and the bulbs and wiring should be checked. CHOKE CONTROL. The choke control is the knob next to the combined ignition and starter switch. It should be pulled right out when starting the engine from cold and pushed in again as soon as the engine will continue to run without the choke. Running with the control pulled out longer than is necessary will result in liquid petrol being drawn into the engine. This will cause excessive wear by washing the lubricant from the cylinder walls and diluting the oil in the sump. ACCELERATOR PEDAL, This is of the lever type and is situated on the extreme right-hand side of the toe panel. When starting the engine, do not pump this pedal (see page 23). BRAKES. On KB models the brakes are of the vacuum servo type, on models KC, KD, KE, the brakes are of the air pressure servo type. On model KG, the brake system is of the air/hydraulic type, the brakes being applied by means of an air pressure operated combined dual master cylinder and actuator. The parking brake on KB models is of the horizontal mechanical pull-up type and is at the outside of the drivers seat. On all other models the parking brake is air controlled by a control valve at the outside of the drivers seat. To apply the parking brake raise the finger lift and slide the valve lever up the quadrant to the PARK position. Release the finger lift to secure the valve lever. On model KB when the engine is running and the parking brake applied, the brake stop lights are illuminated. When the vehicle is parked the stop lights are automatically extinguished when the ignition switch is turned off. 17 THE CONTROLS BRAKE WARNING DEVICES. If there is insufficient pres- sure or vacuum in the brake system a yellow warning lamp on all models, plus an alarm buzzer on air pressure systems, will come into operation as soon as the ignition switch is turned on. Both warning devices will remain in operation until the engine has been run sufficiently to restore the air pressure or vacuum in the respective systems. Should the pressure or vacuum at any time fall below the safe minimum limit the buzzer and/or warning light will come into operation giving immediate visual and audible warning to the driver. On all models in addition to the warning light and buzzer a vacuum gauge or a dual air pressure gauge is provided. The normal reading on the yacuum gauge should be between 15 to 20 in. Hg. (38 to 51 cm. Hg.). The dual air pressure gauge should normally read between 103-120 Ib./in.2 (7:24-8-4 kg./cm.2) on both scales. Note: On all models except KB it will not be possible to release the parking brake if pressure in the reservoirs has dropped. In these circumstances air pressure must be restored by running the engine before the parking brake can be released. (See page 25.) WINDSCREEN WIPERS. Dual, parallel action windscreen wipers are operated by a single speed, heavy duty, electric motor. The switch is just to the right of the instrument cluster panel. WINDSCREEN WASH. The knob for operating the screen- wash is on the instrument panel. To clean the screen push the knob in and two jets of water will be directed on to the area of the screen swept by the wiper blades. The reservoir for the screen-wash is under the instrument panel. SEATS. The driver’s seat incorporates provision for 2 in. (50 mm.) height adjustment as well as fore and aft movement. The seat is moved, fore and aft, after moving the small lever which is just below the front edge of the seat. To alter the height just turn the handle at the front of the seat, to the right to raise the seat, and to the left to lower it. On models fitted with a de-luxe cab there is a further adjustment provided at the back of the drivers seat squab. To expose the adjusting bolt open the zip fastener in the back of the squab cover and turn the bolt clockwise to increase spring pressure. The passenger seat is not adjustable. CAB DOOR LOCKS. On all vehicles fitted with the standard cab, the left-hand door can be locked by moving the door inside handle downwards. The other door being locked from the outside with the ignition key. WINDOW CONTROLS. No-draught-ventilator windows are incorporated in the front portion of each door. They are retained in the closed position by a small catch on the bottom of the window 18 THE CONTROLS frame. To open a window, release the catch and push the rear of the window outwards. This allows air to circulate without causing strong draughts. The rear portion of each front door has a window which can be raised or lowered by turning the handle on the door inside panel. REAR VIEW MIRROR ADJUSTMENT. The rear view mirror is mounted on an arm that swivels horizontally through 180° on a spring-loaded pivot. The arm may be moved close to the cab when desired and will yield on impact. It can afterwards be easily returned to its former position. Minor adjustments to the mirror can be effected by slackening the mirror bracket clamp nut and turning the mirror on its cup joint. Should this not be sufficient, further adjustment may be obtained by altering the setting of the mirror arm pivot. This can be achieved as follows: (a) Remove the plastic cap (J) enclosing the tension- ing mechanism. (b) Bear down on the mirror arm (2) to force it through the bracket (3) against the pressure of the spring (4). (c) Rotate the toothed collar (5) so that its upper seg- ment aligns with the next 5) 3 Rear view mirror adjustment set of holes in the base getaiis. The numbered arrows are referred of the bracket. to in the text. (d) Release the pressure on the mirror arm and check the mirror position. Repeat the adjusting operation until a satisfactory mirror position is obtained. CAB VENTILATION. Air, from an entry at the front of the vehicle, is ducted to a distribution outlet in the centre of the cab floor. Control of the entry of air is by a lever at the side of the distribution box. The ventilation system is designed to take the heating and demisting equipment available as an accessory. HEATER (WHERE FITTED). The heater is designed to operate in conjunction with the cab fresh air ventilation system. In addition to heating the cab interior, the heater is also used for 19 THE CONTROLS demisting and de-icing the windscreen, air being diverted for this purpose through a duct at each side. An electrically-operated air booster fan, controlled by a 3-position switch, is incorporated in the heater; move the switch lever to the right for fast speed, and to the left for slow speed. The system is operated as follows: No Ventilation or Heating Move the floor mounted air control lever to its rearward position. Heat control lever to the left. Close the three air flaps on the sides and front of the heater. Cab Cooling Heat control lever to the left. Move the floor mounted air control lever to its forward position. Oren air flaps on both sides and front of heater. Air flow can be increased by operating the heater fan, fast or slow as required. Cold Air Demisting Heat control lever to the left. Open floor ventilation flap by moving the control lever to its forward position. Close air flaps on both sides and front of heater. Air flow can be increased by operating the heater fan. Cab Heating Heat control lever to the right. Open floor ventilation flap by moving the control lever to its forward position. Open air flaps on both sides and front of heater. Air flow can be increased by operating the heater fan. Hot Air Demisting and De-icing Heat control lever to the right. Open floor ventilation flap by moving the control lever to its forward position. Close all air flaps on both sides and front of the heater. Air flow can be increased by operating the heater fan. ENGINE EXHAUST GAS CAUTION (CARBON MON- OXIDE). Avoid inhaling exhaust gases because they contain carbon monoxide, which by itself is colourless and odourless. Carbon monoxide is a dangerous gas that can cause unconsciousness and is potentially lethal. The best protection against carbon monoxide entry into the driving compartment is a properly maintained engine exhaust system. If you notice a change in the sound of the exhaust system, if exhaust fumes are smelled or detected in any other way inside the vehicle, or if the exhaust system on the underside or rear of the vehicle is damaged, have your Bedford dealer inspect the complete exhaust system and nearby body areas for broken, damaged, missing or mispositioned parts, open seams, holes, or loose connections, or other deterioration which could permit exhaust fumes to seep into 20 THE CONTROLS the driving compartment. Dust or water in the vehicle may be an indication of a problem in one of these areas. Remember to keep outside ventilators clear of snow or other obstructions at all times, also ensure cargo does not block inside vent holes to allow proper operation of the ventilation system. It is recommended that the vehicle be inspected as outlined in the previous paragraphs each time the vehicle is raised for lubrication or oil change. If at any time you suspect that exhaust fumes are entering the driving compartment have the cause determined and corrected as soon as possible. If you must drive under these conditions, drive only with all windows fully open. Use genuine Bedford parts recommended for your vehicle for any repairs which may be necessary. SITTING IN A PARKED VEHICLE WITH ENGINE RUN- NING FOR AN EXTENDED PERIOD IS NOT RECOMMENDED Do not run the engine in confined areas such as garages any more than needed to move the vehicle in or out of the area. When the vehicle is stopped in an unconfined area with the engine running for more than a short period, the following precautions should be observed. Adjust the heating or ventilation system to force outside air into the vehicle with the booster fan (where fitted) set at high speed and the controls set in any position except “OFF”. On a van type of vehicle the rear doors should be closed while driving to help prevent inadvertently drawing exhaust gases into the yehicle. It is unwise to drive at high speed for long durations with the rear doors open. However, if for some reason the rear doors must remain open for a period while driving the following pre- cautions should be observed. Close all windows and adjust the heating or ventilation system to force outside air into the vehicle with the booster fan (where fitted) set at high speed and the controls set at any position except “OFF”. On vehicles with outside air vents in or under the instrument panel open the vents fully. ENGINE ACCESS PANELS. A hinged panel beneath the quarter light on each side of the cab is fitted with a quick action slam-type lock and an outside-handle. A self-locking stay retains it in the open position. On Models KB, KC and KD the hinged panels are of greater depth to match the deeper section front wings. Note: Twin lamps, with built-in switches, are fitted in the engine compartment to provide illumination when working on the engine. 21 THE CONTROLS HAZARD WARNING DEVICE. The four-way hazard warning device is available as an accessory from your Bedford dealer. In the event of an emergency stop on the road, operation of the switch on the instrument panel inboard of the cluster panel, will cause all four signal lights to flash simultaneously, thereby warning all other road users that your vehicle is a traffic hazard. The switch knob is illuminated when the hazard warning lights are switched on. The hazard warning device can be operated with the ignition switch in the off position, thus allowing the vehicle to be locked while assistance is sought. If the vehicle has to be left under these circumstances every endeavour should be made to leave it in as safe a position as possible. 22 DRIVING STARTING THE ENGINE. Always adopt the following procedure when starting the engine from cold. 1. Switch on the ignition. Immediately, the red alternator warning lamp and the orange oil warning lamp should glow (see note). 2. Pull out the choke knob as far as it will go, 3. Make sure that the gear lever is in neutral. 4. Operate the starter control. 5. Push the choke control in as soon as the engine will run without it. Note: Before starting the engine switch on the ignition switch. Unless the brake warning lamp lights up and the buzzer operates, depress ihe brake pedal several times to lower the vacuum or air pressure in the reservoir. As the reservoir is exhausted the lamp should glow and the buzzer should operate (see page 18—Brake Warning Devices for more details). The yehicle should not be taken on the road until all devices are operating satisfactorily. Finally, start the engine and in a few seconds the warning light should go out and the buzzer cease to operate and shortly afterwards the gauge(s) should indicate that the safe working pressure or vacuum has been reached. The same instructions apply when starting an engine which has already been warmed up, except that the choke should not be used. If the engine fails to start at the first application of the starter, do not make a second attempt until both the starter motor and the engine are at rest again. It is important not to “ pump” the accelerator pedal while starting, as this practice produces an excessively rich mixture and makes starting more difficult. If the engine fails to start after several attempts, proceed as follows: Push the choke control right in. Press the accelerator pedal slowly down to the floorboards and keep it there. Operate the starter. The first few revolutions will clear away excess petrol sucked in by the repeated attempts at starting and the engine should fire as soon as the mixture is just right. (See also under “If the Engine Fails to Start” on page 50). WHEN ENGINE STARTS. When the engine is running, the alternator and oil warning lamps will go out. The alternator warning lamp may glow now and again when the engine is idling (ie. when the idling speed is not fast enough for the output voltage to rise above the battery terminal voltage), but the oil warning lamp should remain out all the time the engine is running (see page 15). Important. Always push the choke control right home as soon as possible after starting. 23 DRIVING WARMING UP. Do not allow the engine to “tick over” after a cold start. It is best to drive away immediately after starting and get into top gear as soon as possible. Speed should be moderate until the engine is fully warmed up. ENGAGING GEARS (FOUR-SPEED AND FIVE-SPEED). The gear positions, shown below, are also marked upon the knob on top of the gear lever. These gearboxes have synchromesh operation on all forward gears except Ist gear. On four-speed boxes, to prevent any risk of reverse gear being accidentally engaged while the vehicle is moving forward, the resistance of a stiff spring must be overcome before the gear can Or O © © @ ) N) ® @ A) BD oi). 4B) Fig. 4. Gear change diagrams. 4-speed gearbox 5-speed gearbox be engaged. The easiest method is to give the gear lever a sharp tap with the palm of the hand. This will overcome the resistance and the lever can then be moved into the reverse position. Excepting when changing into Ist gear, gear changes can be made, cither up or down, by merely depressing the clutch pedal and moving the gear lever firmly into the required position. On steep hills, or when baulked by traffic when climbing, it may be necessary to change down to Ist gear. It will then be advisable to use the double-declutching method of changing gear. DESCENDING HILLS. Whenever possible use your engine as a brake when coming to a traffic stop or when descending a long hill. When going down hill use the same gearbox ratio you would use when climbing the hill, but do not let the engine over-rev. USE OF BRAKES. Do not use any more force on the pedal than is necessary to bring the vehicle to rest in the desired distance. Heavy application of the brakes means increased tyre wear. On 24 DRIVING all models the brake action is either vacuum or air pressure assisted, therefore continuous operation is only possible when the engine is running. Do not “coast” with or without the engine switched off. On all models the parking brake operates the rear brakes only. On KB models they are operated mechanically by a horizontal pull-up lever at the REURASE le of the drivers seat. Fig. 5 Parking brake control. On all other models the parking brake is air-controlled, by a valve mounted at the side of the drivers seat. To apply the brake slide the lever of the valve up to the end of the quadrant to the PARK position. Release the finger lift to secure the lever. Note: On vehicles fitted with an air controlled parking brake if pressure in the reservoir has dropped the parking brake cannot be released until normal pressure has been restored by running the engine. However, if for any reason the engine driven compressor cannot be utilised, normal pressure can be restored by connecting an independent air supply to the “ Schrader type” valve fitted to the front of the condensing tank. TWO-SPEED AXLE (WHERE FITTED). On vehicles fitted with a two-speed rear axle, high or low ratio is selected by means of the push-pull control fitted to the normal gearbox change speed lever. Two types of axles are fitted, namely, the Bedford 2-speed axle or the Eaton 2-speed axle; but with both axles, lift the control knob for the high ratio and push it down for the low ratio. To Change Into Low Speed Ratio (Both Axles). 1. Keep the accelerator pedal down and push the control button down. 2. To complete the change, disengage and re-engage the clutch as quicklyas possible, still holding the accelerator pedal down. To Change Into High Speed R: (Both Axles). 1. Keep the accelerator pedal down and pull the control button up. 2. To complete the change, release the accelerator and pause until the change is completed Depress the accelerator pedal. To Change Gearbox ard Axle Ratio Together (Bedford 2-Speed Axle). Hicu to Low: Make the gearbox change in the normal manner and then push the control knob down before engaging clutch. 25 DRIVING Low To Hicu: First pull up the control knob and then make the gearbox change in the normal way. To Change Gearbox and Axle Ratio Together (Eaton 2-Speed Axle). To change to the next higher gear in the gearbox and at the same time change from “ High” to ‘* Low” speed axle, make the gearbox change in the normal manner but just before engaging the clutch push the axle change speed control right down. _ To change to the next lower gear in the gearbox and at the same time change from ‘** Low” to “ High” speed axle, pull the axle change speed control upwards, then make the gearbox change in the usual manner. On models with a 2-speed rear axle and a 5-speed overdrive top gearbox the downchange sequence is: Sth high to 4th high; 4th high to Sth low; Sth low to 4th low and thereafter normally. This sequence is reversed on upward changes. As the 4th high ratio splits the 5th high and Sth low ratios it can generally be omitted from the change sequence. However, it can be used to advantage in particular circumstances—such as long steady hauls—as an alternative to Sth high. Important: Always keep the accelerator down when moving the axle change speed knob. Always park and start the vehicle with the axle in the low speed ratio. RUNNING-IN. The working parts of a new vehicle are always made slightly on the tight side to allow for a perfect fit after an initial running-in period. Long trouble-free life, particularly of engine, rear axle and brakes, depends on this careful running-in, which can only be achieved by restraint on the part of those who drive the vehicle during this critical period. During the running-in process these parts gradually develop a highly polished surface which will be extremely resistant to wear and thus ensure long life. By restraint is meant driving gently during the first 1,000 miles (1500 km.). Treat the vehicle considerately. Avoid full throttle operation, high engine speeds and heavy braking. To ensure that no harm was done to the engine during its early fe we used to ask the driver of a new vehicle to keep the speed of the vehicle down to certain specified figures, with the result that the running-in period was rather a trying time. Modern engineering practice has changed this considerably. Precision manufacturing methods used in the production of current Bedfords ensure that, so long as high speed or full throttle work is not maintained for appreciable periods during the early life of the engine, no harm will be done by an occasional burst of speed. Of course, in the United Kingdom, the speed must not exceed the statutory limit for the particular vehicle. In fact, the running-in 26 DRIVING period will be lengthened by restricting the vehicle to low speeds for very long periods. Please remember, though, that this does not mean that we suggest the vehicle is driven really hard right away. To get the best results later it is important to treat the engine eng during the first 1,000 miles (1500 km.). In your own interests we ask you not to maintain high engine speeds (in any gear) and to refrain from “‘ foot hard down ” driving during this period. Bedford engines are designed to give extremely long life between overhauls, and this must inevitably prolong the process of bedding down the pistons and the rings to the cylinder bores. Normal good oil consumption will not be obtained until this process is completed, which may take some thousands of miles according to driving conditions. Intelligent driving technique can shorten this time whilst avoiding a risk of damage associated with over-driving a new engine. Therefore, as you build up mileage during the first 1,000 miles (1500 km.) or so of the vehicle’s life, you may steadily exceed those figures previously associated with the somewhat tedious job of running-in, and hold them for progressively longer periods. However, for the first one or two thousand miles (1500 to 3000 km.) your engine will resent abuse, and at the slightest sign of distress, the speed and load must be reduced. AFTER THE FIRST 500 MILES. A general check-over is necessary after the first 500 miles or 750 km., when most of the working parts will have settled down. Details of the checks and adjustments to be carried out at this stage are given on page 28. PETROL CONSUMPTION. Good petrol consumption depends on observing these instructions: Keep the engine in efficient “ tune,” with correct ignition setting and valve clearances and properly adjusted petrol feed system. Avoid overloading. Check tyre pressures weekly (low pressures increase “‘drag”). Make sure the brakes are not rubbing. Use the correct grades of oil. Drive as smoothly as you can. Sudden acceleration and sudden braking are expensive in tyres and brake- linings as well as in petrol. Switch off promptly whenever you pull up, except in traffic. Idling when you start up wastes petrol and is also bad for the engine. Don’t keep the choke control out longer than necessary. In cold weather blank off the lower part of the radiator to maintain the temperature in the engine compartment. These are all simple things. But it is by observing simple things that petrol can be saved. AFTER THE FIRST 500 MILES During the early life of the vehicle, the working parts tend to “settle down,” with the result that various clearances and adjust- ments need to be corrected. A general check-over should therefore be carried out as soon as possible after completing 500 miles, but before 650 miles. If you live in the United Kingdom you will have received a Guardian Maintenance Booklet which includes a 500-mile coupon covering the operations necessary. All you need do is present this coupon to the Bedford dealer who supplied the vehicle. He will carry out the check-over free of charge, except, of course, that any materials used will be charged for. If you are likely to be away from your home town when the 500- mile service falls due, see that your dealer has filled in and signed your Owner Service certificate on the inside front cover of the Guardian Maintenance Booklet. This will serve as an introduction toany Bedford dealer in the United Kingdom or, elsewhere, a General Motors dealer (preferably handling Vauxhall products), who will then carry out the service, unless there are legal restrictions which prevent it. To suit local conditions in overseas territories it may be that the check-over is scheduled to be carried out at a different mileage to that specified for the United Kingdom. At the appropriate mileage your dealer will carry out the check-over for you if you are able to run the vehicle into his service station. However, for the benefit of those owners who live some distance from the nearest dealer point, here is a complete list of the items which need attention during this check-over. Detailed instructions for carrying out the various operations are given in the Routine Maintenance Sections Lubricate high pressure Tighten wheel nuts. nipples. Tighten steeri Change engine oil. (Clean mae en, iestane, crap eer 214 cu. in. engine crank- case oil strainer.) Check for fuel, oil and econ CS aU a athe Adjust fan belts. Tabreate brake linkage Gleanipetolenareiniien clevis joints, ae R Top-up radiator and wind- eee distributor contact screen wash. aa er gap and ignition Check tyre pressures, ues TaeMIR Eat ee electrolyte. Adjust valve clearances. Adjust clutch free travel. Adjust engine idling speed. Check steering axle wheel alignment and adjust if Adjust brakes. Remove labels from wind- Tighten front and rear screen. spring U-bolts. Road test vehicle. 28 ROUTINE MAINTENANCE Instructions are given in the following pages for carrying out all the lubrication and general maintenance jobs which need regular attention. They apply to all models unless otherwise stated. It is vitally important that each and every item be attended to conscientiously, as no motor vehicle can give of its best, either in performance or long life, unless it is properly maintained. All engine components are fully accessible after raising the engine access panels—one each side—at the rear of the cab. The periods under which the various items are listed are intended to apply to vehicles engaged on normal main road transport. More frequent attention will be necessary to vehicles working under adverse conditions such as sand and gravel pit work, or under the severe terrain and adverse conditions existing in certain overseas territories. The routine maintenance periods, therefore, should be adjusted to suit the local conditions and the type of work being done. Under very dusty conditions it is advisable to check and, if necessary, service the carburetter air cleaner every month, fortnight or even weekly according to the severity of the operating conditions. It will be seen that for most items of maintenance the frequency is based on mileage, but in a few instances it is necessary to use a time basis. However, it is important that where vehicle usage involves low mileage, the interval between items normally governed by mileage should not be allowed to exceed a time period of three months. The frequency of routine checks for vehicles operating in countries where the metric system is used is indicated throughout the text of this book as a guide. The figures quoted are not direct conversions for the relative mileage figures. Included in the same pack as the instruction book is the Guardian Maintenance booklet which contains the Guardian Main- tenance, and Inspection Schedules, listing all the lubrication, inspection and maintenance items for the vehicle. There are three separate services on each schedule, headed A, B and C, listing the items needing attention at intervals of 6, 12 and 24,000 miles respectively and corresponding to the schedules given in this instruction book. A black square on the schedule indi- cates that work does not have to be carried out at that particular mileage. The open squares should be filled in according to the instructions given at the top of each schedule. A separate schedule is to be used for each service and sufficient schedules are provided to cover the maintenance up to 120,000 miles. Single vehicle owners or small fleet operators will find it more convenient and economic to have their vehicles maintained at their local Bedford dealer’s premises, and the presentation of the schedule 29 ROUTINE MAINTENANCE ROUTINE MAINTENANCE endorsed with the type of service required will ensure that the dealer has his full instructions. Any work required in addition to the service items can be written on the back of the schedule. Larger fleet operators with well-equipped and staffed mainten- ance shops who may prefer to carry out their own servicing of vehicles can use these schedules as work sheets or job cards, and as part of their vehicle maintenance records system. The scheme enables the dealer carrying out the service to let you know if there are any items in need of attention. This keeps the owner informed of the condition of the vehicle and of any additional work which may be necessary. Continuous use of the scheme not only ensures that the vehicle is maintained in first-class condition but provides visual evidence of it. When the time comes to exchange it for a new Bedford, the coupon counterfoils, stamped by the dealer, provide evidence of the efficient maintenance of the vehicle and thus enhance its trad value. Chassis Lubrication and Front Hubs Esso Multi- purpose Grease H Gulfiex A Marfak All purpose Retinax A’ Energrease 12 ZEALAND commendations Fina Marson HTL2 MMENDATIONS APPLICABLE NEW Your Dealer for Local Re Gear Oil 90 Mobilube GX 90 Hypoy Hypoid 90 Esso Gear ‘Steering Box Oil GX 90/140 SAE 90 EP Castrol Thio- Hypoy FD or 2-speed Axles: Multi-purpose Fina Pontonic XP SAE 90/140 Single speed Axles: Multi-gear Lubricant 90 BP Gear Oil THESE RECO) NOT Refer NOTES ON LUBRICATION There are few things more important to the modern commercial vehicle than correct lubrication. Correct lubrication entails the use of lubricants of the right grade and the highest possible quality. Inferior and unsuitable lubricants cause excessive wear in an unduly short time. Always use approved lubricants of the correct grade, as listed on page 31. An engine in good condition uses comparatively little oil. In other words, the additional cost of using a good oil is negligible compared with the dangers of relying on so-called cheap oils, which seldom prove to be so cheap in the long run. Experience has proved, over and over again, that good quality lubricants are the surest safeguard of efficiency and performance. They reduce carbon deposit, make starting easier (thereby avoiding undue load on the battery), prevent unnecessary wear, and eliminate some of the causes and the expense of mechanical breakdown. The lubrication points which need regular attention are listed in the following pages. They are also shown on the lubrication chart at the end of this handbook. Make a point of always wiping nipples clean before applying the lubricant gun. When lubricating the steering box always use the oil recommended for the rear axle for the particular model. It is essential to use ‘‘ Hypoid’’ oil for the rear axle on all models except KB, KC and KD. If the rear axle (except those fitted to Models KB, KC and KD) has to be drained before completing 10,000 miles (15000 km.), or new hypoid gears have to be fitted, use only Castrol Thio-Hypoy FD when refilling the axle. Transmission Oil 90 Mobilube C90 Pontonic WA. SAE 90 ! Esso Gear Oil GX 90/140 Dentax 90 Castrol ST SG 90 Gear Oil RECOMMENDED BRANDED LUBRICANTS. Essolube HDX 20/20W Gulflube Motor Oil HD 20/20W Delvac 1120 Fina Delta Motor Oil SAE 20W/20 URSA SI SAE 20/20W Rotella T20/20W Vanellus 20W Castrol CR1 20 or Deusol CRI SAE 20 "NOL Diesel HD 20/1, Manufacturer See special instructions for engine oil lubricants given under Notes on Lubrication page 30. Petrofina Duckhams 30 ROUTINE MAINTENANCE LUBRICANTS RECOMMENDED FOR OVERSEAS USERS S.A.E. Viscosity No. Specification No. Temperature Ranges ofthe appropriate viscosity MIL—L—2104B Below -23° C. for long periods | 12° C. to -23° C. GEARBOX Above 32°C... 32°C. to O° C. .. 0° C, to -12° C. ENGINE _G.M.4753-M. Without EP additives Above 0° C. 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