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Hudson 480-490 Series Service Manual

480-490 series
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  • Page 2 This manual provided by HET Club member Drew Meyer...
  • Page 3 The Hudson Service sign is designed to identify your place of business as an authorized Hudson service station and will not only create confidence in the minds of the owners but will guide transient owners and new customers to your door.
  • Page 4 INTRODUCTION The series 480 and 490 Hudson is built of a completely new principal and design, and is not just another motor car. The "Monobilt" body and frame construction differs greatly from the conventional motor car employing separate body and frame units. Naturally being so totally different, a new approach to the repair of body damage is necessary.
  • Page 5 INDEX Page Page Adjustment, door striker 27,60 Door lock lubrication folding top Door straightening hood Door trim panel - Convertible . radio Door window regulator hydraulic 75-77 weather control convertible door window cylinder windshield wiper arms Elastic metal top control rod Electrical system checks - convertible Alignment, body 48,62-64...
  • Page 6 Page Page Lubrication, body Spindle pin inclination 1, 41-42 hydraulic cylinder 75, 77 Splash guard 22, 23 lock Spot weld positions 13-15 Metal finishing 47-58 Springs, front 2 43 Model designations rear Monobuilt body II, 10 window regulator 69, 75, 76 Motor, pump 68, 69,70-72, 90 Starter switch...

  • Page 7: Technical Information

    BODY MANUAL MODEL DESIGNATIONS AND SERIAL NUMBERS The new Hudson models are produced in the Super and Commodore Series and carry the following designations: Hudson Super Six Series - Model 481 - 491 BODY TYPES STARTING SERIAL NO’S Brougham 481101 - 491101 and up...
  • Page 8 BODY MANUAL FRONT SPRINGS SIX CYLINDER EIGHT CYLINDER Type Coil Coil Free Height 16-5/16" 16-5/16" Height under curb weight 9-9/16" 9-9/16" REAR SPRINGS Type Semi-elliptic Semi-elliptic Covered Covered Uncovered Uncovered Metal Metal Covers 54" - 1-3/4" 54" - 1-3/4" Length and Width Number leaves Silent "U"...
  • Page 9 Always use the charts furnished herein and be sure that every repair order including paints has the complete, detailed information. Hudson body colors are pure virgin lacquers. For the maintenance and protection of these high quality finishes refer to Page 45 of this manual under the heading "Paint - care of finish."...
  • Page 10 BODY MANUAL CHART No. 1 1949 HUDSON BODY COLORS Standard Single Body Colors Option Special Two-Tone Combinations Option Brigantine Blue** Upper Body Color Jersey Blue Lower Body Color JB** Glowing Gray Upper Body Color Queenstown Gray Lower Body Color Piedmont Green**...
  • Page 11 1949 BODY COLOR OPTION INFORMATION It will be noted that the 490 Series Hudson has two methods of paint option identification. On approximately the first 100,000 490 Series cars an ALPHABETICAL paint option was stamped into the right hand front door upper hinge, body half. (See 1949 Body Color Chart No.
  • Page 12 From this list, which includes the proper car IDENTIFICATION NUMBER taken from the car serial number plate, the Hudson parts manager will be able to arrive at an estimate of the cost of the job, from which a definite de- cision can be made before ordering the necessary parts.
  • Page 13 ORDERING TRIM MATERIAL The following chart on the Hudson upholstery options in relation to paint options will prove helpful when the need arises to order upholstery material. The paint option chart is also included and will serve to clarify the alphabetical paint code stamping on the upper hinge of the right hand front door and as a cross reference guide when ordering upholstery materials.
  • Page 14 Optional Hudson upholstery materials are of the finest broadcloth and Bedford Cord available, however, this fact does not create immunity to spots and stains. For details on the removal of spots and stains, please refer to Page 44 of this...
  • Page 15 BODY MANUAL CHART No. 5 ROOF BOW COLOR GUIDE Part Up to and Part Serial No. Number Including Color Number and upward Color Serial No. 4 DOOR SEDAN 210761 483115172 Black 216220 48311517* Black 210762 " Light Gray 216221 " Light Green 210763 "...
  • Page 16 BODY MANUAL...
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  • Page 22 BODY MANUAL Figure 13...
  • Page 23 BODY MANUAL...
  • Page 24 BODY MANUAL REFERENCE Source of Date Subject Information...

  • Page 25: Installation

    BODY MANUAL REMOVAL AND CARE OF 8. Remove rear bumper extension at side of fender. PARTS 9. Pry off fender panel lower moulding. With most damaged bodies, there are parts that 10. Remove the two self tapping screws attaching rear have to be removed to facilitate the repair of the fender panel and moulding retainers to the rocker panel.
  • Page 26 20 BODY MANUAL 2. Attach all upper bolts at quarter panel flange before 9. Remove moulding and 4 self-tapping screws attaching fender to rocker panel. DO NOT TIGHTEN. attaching fender and moulding clips to front rocker panel. 10. Remove kick pad in the front seat compartment at the dash panel.
  • Page 27 BODY MANUAL FIGURE 17 1. Front fender ornament. 22. Radiator grille moulding (center L.H.) 2. Hood louver (R.H.) 23. Radiator grille baffle (center L.H. 3. Radiator grille baffle side support (R.H.) 24. Radiator grille moulding (lower L.H.) 4. Front splash guard moulding 25.
  • Page 28 22 BODY MANUAL separately. RADIATOR REMOVAL: 1. Remove complete front bumper assembly. 2. Remove three bolts at each side attaching splash 1. Drain radiator and disconnect hoses. guard to radiator grille panel. 2. Remove two sheet metal screws attaching deflector shield 3.

  • Page 29: Engine Hood

    BODY MANUAL FENDER AND GRILLE SIDE SUPPORT (Right or Left Hand) REMOVAL: 1. Remove the screws attaching the radiator grille baffles to side and center support. Remove baffles. 2. Remove five bolts under fender attaching the side panel to fender. 3.
  • Page 30 24 BODY MANUAL FENDER TIE PANEL AND HOOD LOCK LOWER SUPPORT REMOVAL: 1. Raise hood and disconnect hood lock control wire. 2. Remove two bolts (each side) attaching fender tie panel and hood lock support to fender bracket. 3. Remove two bolts attaching the fender tie panel and hood lock support to radiator mounting channel.
  • Page 31 BODY MANUAL 2. Remove headlining from glazier's points around upper wind- Replace upholsterer's tacks in rear window opening. shield opening., Use a screwdriver to pry open these glazier's Trim surplus material from around rear window open- points to facilitate installation of new headlining. ing.
  • Page 32 26 BODY MANUAL 4. Using a dull putty knife, Figure 22, pry between the REPLACING BROKEN rubber weatherstrip and the chrome reveal moulding to WINDSHIELD loosen and remove the windshield glass and weatherstrip. NOTE: On radio equipped cars it is necessary to NOTE: Glass is removed from the inside.

  • Page 33: Front Door Lock Cylinder

    The retainers will then slide down into position when tightened. 6. Remove masking from upholstery and install all trim and radio parts removed prior to removing windshield. 7. Carefully remove all excess sealer with Hudson fabric cleaner. FIGURE 25 DOOR STRIKER PLATE...

  • Page 34: Door Trim Panel

    28 BODY MANUAL 6. If door opens easily without pushing the handle button, 3. Install pocket trimboard. loosen screws as in step one and rotate bottom of striker 4. Install valance by inserting lower flange between door plate inward. (C). Tighten screws and re-check. and pocket trimboard;...

  • Page 35: Door Lock

    BODY MANUAL 4. Remove 4 screws (A) holding regulator to door inner panel. 5. Lower window to bottom of door and release regulator from glass channel. 6. Remove regulator through opening at bottom of door. INSTALLATION: Reverse procedure of removal and repair damage to door inner liner with Mystik tape.
  • Page 36 30 BODY MANUAL in bottom of door inner panel. INSTALLATION: Reverse procedure of removal and repair door inner liner with Mystik tape. DOOR VENTILATOR WING (Commodore) REMOVAL: 1. Remove safety lock knob and garnish moulding. 2. Remove ventilator regulator handle and valance. 3.

  • Page 37: Door Glass

    BODY MANUAL 3. Remove garnish moulding. DOOR GLASS 4. On Commodore models remove valance. (Front) 5. Remove two screws from under side of arm rest and REMOVAL: remove arm rest. 1. Remove safety lock knob and garnish moulding. 6. Remove pocket trim panel and lower trim panel, at- 2.

  • Page 38: Rear Window Glass

    Clean off all 2. Remove four sheet metal screws attaching glass frame excess sealer carefully with Hudson fabric cleaner. to window opening and remove glass and 3. Remove nut And spring from friction pivot.

  • Page 39: Cigar Lighter

    BODY MANUAL FIGURE 32 INSTALLATION: 2. Loosen Allen set screw in control knob and remove knob (36). Reverse procedure of removal. Keep battery disconnected 3. Using a suitable spanner, remove escutcheon nut and until operation is completed. escutcheon. 4. Remove wiper control from panel and pull control wire INSTRUMENT PANEL LAMP through dash.
  • Page 40 34 BODY MANUAL INSTRUMENT SWITCH PANEL INSTRUMENT FINISH PANEL (Left) REMOVAL: REMOVAL: 1. Remove ornamental trim. 1. Remove starter switch (3), Figure 32. 2. Remove locker box and glove compartment door bum- 2. Remove left half of chrome finish strip at steering pers.

  • Page 41: Fuel Gauge

    BODY MANUAL 4. Remove gauge (10) from back of cluster. FUEL GAUGE INSTALLATION: REMOVAL: Reverse procedure of removal. 1. Remove instrument finish panel (A), Figure 32. 2. Remove four screws attaching instrument cluster to TEMPERATURE GAUGE instrument panel and pull out cluster. 3.

  • Page 42: Installation Instructions

    36 BODY MANUAL with a windshield washer attachment. ADJUSTMENT: REMOVAL: Windshield wiper cable tension is set at the factory but 1. Disconnect cables at the wiper motor and lift free of the requires adjustment whenever an over-travel of the tension assemblies. blade occurs at high speed or a reduction of travel 2.
  • Page 43 BODY MANUAL FIGURE 34 9. Before locking the receiver securely in position, place the rear mounting bracket. Replace instrument finish the instrument finish panel into position over the clock panel and fasten securely. and note whether or not the radio and trim panel are 10.

  • Page 44: Automatic Tuning

    38 BODY MANUAL FIGURE 36 18. IMPORTANT: Turn the receiver on and allow it to If the positions have not been previously adjusted, pro- operate for approximately fifteen minutes in order for ceed as follows: it to reach normal operating temperature. Tune in a 1.
  • Page 45 1. Remove the mounting screw of the voltage regulator and under this screw mount a condenser. Connect the lead The Hudson "Weather Control" system is partially built to the voltage regulator "A" terminal. (Figure 37). into every Monobilt body. With the addition of the acces- sory subunit, a new kind of living comfort is experienced within the automobile.
  • Page 46 The thermostatic WEATHER CONTROL control valve remains wide open until the temperature The proper use of the Hudson Weather Control is some- rises to the regulated setting; therefore, moving* the con- thing that everyone who works on Hudson automobiles trol lever will not increase the delivery of heat.

  • Page 47: Circuit Breakers

    BODY MANUAL is controlled by the switch knob (No.3), Figure 40, on the CAUTION: When installing the front floor mat, be front of the heater. The fan should then be turned off after sure that enough clearance is allowed so that this the windows are clear.
  • Page 48 42 BODY MANUAL FIGURE 42 PIVOT PIN INCLINATION: WHEN CHECKING THE CASTER THE WHEELS SHOULD BE TURNED ON THEIR BEARINGS TO Pivot Pin Inclination is the inward tilt of the steering BRING THE HIGH SPOT, OR THAT PORTION OF spindle pivot pin at the top. The correct degree of THE TIRE WITH THE GREATEST RUNOUT, TO- pivot pin inclination is 3°36' .
  • Page 49 BODY MANUAL When camber is increased, pivot pin inclination is de- RIDING HEIGHT AND COIL creased. Decreasing camber increases pivot pin inclina- SPRING SAG tion. When the car does not seem to be level, and a check of the TOE -IN: coil spring height is desired, place the car so that the front end is level crosswise and then rock the car sidewise Toe-in is the drawing together of the front wheels at the...
  • Page 50 44 BODY MANUAL GREASE AND OIL STAINS: GENERAL INFORMATION ON APPEARANCE Use reliable cleaning fluid. If the fabric is saturated with oil, pour the fluid directly on the spot and soak it up by pressing a white blotter against the spot before cleaning CLEANING UPHOLSTERY: with a cloth dampened with the fluid.
  • Page 51 Finish by rubbing dry with a clean cloth. The gloss finish of the For the removal of rust, when it occurs, use Hudson Rust leather may disappear during the first application. How-...
  • Page 52 46 BODY MANUAL REFERENCE Source of Date Subject Information...
  • Page 53 BODY MANUAL BODY REPAIR AND METAL FINISHING One characteristic of sheet metal is its elasticity; that is, the ability of the metal to spring back to its original shape after having been bent. Each type of sheet metal has a definite "limit of elasticity" de- pending upon its chemical composition, method of manufacture, and heat treatment.
  • Page 54 48 BODY MANUAL forced into their original position by the aligning and roughing operation. FIGURE 50 FIGURE 48 The standard practice in beginning to reshape a damaged body is to remove the dents and buckles in a reverse sequence to A true "oil can"...
  • Page 55 BODY MANUAL The stiff slopes are corrected at the same time with the valleys and ridges. The dent is in stages A to B to C to D. TOOL EQUIPMENT The proper alignment and repair of doors, cowls, tops, luggage compartments, and inner body construction can- not be accomplished without a complete, modern set of the proper body repair tools for reaching all of the open and closed areas in the modern automobile body.

  • Page 56: Body Construction

    50 BODY MANUAL A maximum spread of 15 1/2" may be obtained with the Pushing against a buckle in an open panel which is being arms full open. One arm may be fitted with a hinged dolly held in by a stiff reinforcement serves only to stretch the which follows changing contours and allows the spreader panel at the jack head and buckle the panel where it is to be used in connection with both spring and direct...
  • Page 57 BODY MANUAL Stiffer buckles can be removed by laying the face of a broad spoon against the ridge or valley and striking the spoon with a hammer. The face of the spoon spreads the force of the hammer blow. This application is commonly known as ''Spring Hammering,'' because no backing up tool is used.
  • Page 58 52 BODY MANUAL BUMPING Bumping consists of reshaping each panel to its original contour. FIGURE 67 Often a single body jack will provide sufficient pressure over a small area of damage, Figure 67. FIGURE 70 This is accomplished by holding a dolly block (of the same original contour of the panel being bumped out) against the LOW spot and striking the HIGH spot with a hammer.
  • Page 59 BODY MANUAL Bumping is started from the edges toward the center of a buckled area. Use the undamaged area of a panel as a pattern for reshaping the damaged metal. The damaged metal, hav- ing been reshaped, becomes the pattern for reshaping the damaged metal beyond it.
  • Page 60 54 BODY MANUAL PULLING OUT DENTS: To further prevent buckling due to expansion, quench the soldered area with a wet sponge as soon as the solder has Occasionally the body mechanic encounters small dents hardened. or depressions which cannot be pushed out from behind unless considerable time is spent in the removal of inte- The flux usually employed in soldering is muriatic rior trim panels and trim.
  • Page 61 BODY MANUAL FIGURE 77 FIGURE 79 depressions a soldering iron will perform best, Figure 77. HEAT SHRINKING Before painting a surface that has been solder filled, neutralize any traces of acid flux by washing with a Excess metal may accumulate in a hump, Figure 79, after solution of baking soda and water.
  • Page 62 56 BODY MANUAL Keep the torch moving around in a rotary motion to heat evenly. As the spot is heated, it will rise in a peak. FIGURE 83 After water quenching, the remaining irregularities in the FIGURE 81 shrunken area are smoothed out by bumping with a body hammer and dolly block, Figure 83.
  • Page 63 BODY MANUAL Heat shrinking may be done without using a dolly block painting. It is not advisable to file the bead because this at all, simply by heating, upsetting, and quenching; but it weakens the weld. The welded seam may be smoothed by is better to bump the upsets smooth as the work progresses.
  • Page 64 58 BODY MANUAL SANDING: The use of sand paper is generally restricted to removing old paint and to provide a finished smoothness to all surfaces. Use an open grain type of sandpaper for remov- ing paint, as it will reduce clogging. To prevent gouging of solder filled areas, the sand paper should be wrapped around a wood block or a file, Figure 86.
  • Page 65 BODY MANUAL application of pressure to the misaligned door frame and roughing out of the buckles. Check the repaired door by mounting it into the door opening of an undamaged body of the same year and model as the car from which it came. DOOR STRAIGHTENING SUGGESTIONS A door header rail that is found to be too low can be...

  • Page 66: Checking Body Door Openings

    60 BODY MANUAL 2. If door is away from the pillar at the lock side of door, move the striker plate inward according to instructions on Page 27. 3. A door that is out of alignment at the top or bottom may be adjusted by loosening the screws attaching the hinge to the hinge pillar and moving the hinges in or out as required.
  • Page 67 BODY MANUAL...
  • Page 68 62 BODY MANUAL FIGURE 93 is of telescopic construction that permits adjustment to the BODY ALIGNING AND desired length. A convenient thumb screw is used to lock TRAMMING the tram exactly on the marks and in the position at which MEASURING: the first or opposite ,measurement was taken.
  • Page 69 BODY MANUAL between the two center body pillars at marks which are the same distance from the sill. These measurements are used in checking the correct distance or spacing between the body pillars for proper and true openings. FIGURE 94 HORIZONTAL MEASUREMENTS: Horizontal measurements are taken on a level at the FIGURE 96...

  • Page 70: Final Check Of Body Repair

    64 BODY MANUAL 2. Set one end of the tram on the top vertical marking of Check the body alignment to be certain that the repair the right front body pillar and adjust the other end of the work has not caused any distortion. Check the squareness tram to contact a fixed location at the bottom of the left of the top at the front section.
  • Page 71 BODY MANUAL RESEALING AFTER REPAIR REPLACING INSULATING MATERIAL After the body has been repaired and before the trim ma- On the underside of the roof panel and on the body floor terials are installed, the body should be thoroughly in- panel and rear wheel house, heavy insulating pads are spected and resealed to prevent leakage of air, dust, and used as sound deadeners.
  • Page 72 66 BODY MANUAL REFERENCE Source of Date Subject Information...

  • Page 73: Folding Top

    The 480-490 Hudson Commodore Convertible Brougham has as standard equipment, the Hydro-Lectric power system for raising and lowering the folding top and the windows. The 480-490 Hudson Super Convertible Brougham features only the hydraulically operated folding top with manually operated windows.
  • Page 74 68 BODY MANUAL...
  • Page 75 BODY MANUAL...
  • Page 76 2. Hydraulic pump rubber and mounted in a well behind the rear seat in the 3. Pump reservoir 480-490 series Hudsons. Flexible rubber tubing connects 4. Spring wire bail the pump to the metal hydraulic tubing to prevent any 5. Solenoid loosening of connections or breaking of tubing from 6.

  • Page 77: Removal And Installation

    MAJOR HYDRAULIC UNITS, the system. Top must be moved slowly and steadily to 480-490 SERIES prevent excess strain on top parts or top operating cylinders. When all fluid is out of the system, empty the reservoir and REMOVAL AND INSTALLATION: replace it on the pump.

  • Page 78: Motor And Pump Assembly

    72 BODY MANUAL FIGURE 105 motor and pump assembly to the top or bottom of the double action top operating cylinders, depending on the position of the control knob on the instrument panel. Operation of the valve is controlled by a push- pull knob at the left of the steering column.
  • Page 79 BODY MANUAL VALVE AND SWITCH ASSEMBLY REMOVAL: 1. Loosen set screw (E), Figure 109, and remove control rod (F) from cap of valve (G). 2. Remove wires from valve cover (A) and valve body (B). 3. Disconnect four hydraulic inlet and outlet tubes (C) from valve body.
  • Page 80 74 BODY MANUAL FIGURE 111 The lower casting forms a yoke which, together with a FOLDING TOP CONTROL ROD clevis pin, provides secure anchorage to the floor bracket. ADJUSTMENT Proper adjustment of the folding top control rod is very important to insure full and complete operation of the folding top to either the up or down positions.

  • Page 81: Door Window

    BODY MANUAL and felt. These parts are held in place by metal washers and a snap ring. The piston rod is chrome plated and contains at its inner end an assembly of metal and synthetic rubber washers which seal the inner piston chamber against a by-pass of fluid during the raising or lowering operation, Figure 113.
  • Page 82 76 BODY MANUAL from upward movement by a hardened steel roller, which For this reason pump pressure must not be raised above fits over a hardened bushing, riveted in place. 260 P.S.I. With any higher pressure the expansion arm would be moved downward in normal operation, allowing no movement of the expansion arm in event the fluid became heated.
  • Page 83 BODY MANUAL by a crimped-in formed cup which houses a saturated DOOR WINDOW AND GLASS felt. This felt prevents the entry of dirt or water to the FRAME ASSEMBLY upper portion of the cylinder and lubricates the piston REMOVAL: rod. The upper end of the piston rod (2) is mushroom shaped and fits into a formed seat on the cross arm.
  • Page 84 78 BODY MANUAL 2. Remove two hex head bolts (E), Figure 119, from wing mounting bracket. 3. Remove wing pivot to regulator screw (F). 4. Remove Phillips head screws (G and H) and lift door wing assembly up and out of door. INSTALLATION: 1.
  • Page 85 BODY MANUAL 5. Remove quarter window pivot bolt (D) and three (3) hex head cap screws (E) from quarter window regulator. Disconnect hydraulic inlet-outlet tube (F) and solenoid lead wire and lift window and regulator assembly up and out of top of quarter panel. NOTE: Manually operated regulator may be removed without removing quarter inner panel.

  • Page 86: Multiple Switch Units

    80 BODY MANUAL Spring clips at either end of the switch housing serve to hold the switch together, and to provide snap locks for holding the switch in position when mounted. FIGURE 124 Figure 124 shows the knob in the window lowering position. FIGURE 127 To remove a switch from its mounting, a special tool, KMO-685, is available.
  • Page 87 BODY MANUAL 4. Remove two screws from under side of arm rest and remove arm rest. 5. Remove window regulator switch (electric) using tool KMO-685, Figure 127. NOTE: The door trim can be removed at the left door without disconnecting wires from the switch by tipping the switch sideways and pushing the switch through the panel opening.

  • Page 88: Quarter Trim Panel

    82 BODY MANUAL 6. Install valance panel by inserting lower flange between 6. Raise rear corner of trim panel facing and remove door and pocket trimboard with slots in line with the screws (F) and (G). trimboard clips. Force down into position and install 7.

  • Page 89: Door Lock Cylinder

    2. Remove three screws (E), Figure 132, from triangular before replacement. Special Hudson "Lock Ease" lubri- bracket (F) at the handle end of remote control arm. cant should be used to insure operation in cold weather.
  • Page 90 84 BODY MANUAL 1,2,3,4 and items 7,8, and 9. Top and rear curtain installation includes items 1 thru 11. Top decking only includes items 3 thru 11. FIGURE 133 CONVERTIBLE TOP AND REAR FIGURE 134 CURTAIN REMOVAL: Rear curtain removal includes items thru 6. Top and rear curtain removal includes items 1 thru 8.
  • Page 91 BODY MANUAL 1. Install two rear curtain alignment gauges with the slotted ends 5. Insert stiff top retaining flaps into retainers at side engaging the rear bow and the tapered end (with the metal belt line, and at rear quarter windows. At this point, retaining strap on) braced against the rear belt line of the body, move forward and pull top material into position at one on each side, 19"...

  • Page 92: Top Adjustment

    86 BODY MANUAL FIGURE 138 before water test. Wet top thoroughly and allow to dry 3. Back out the side rail adjusting screw at A, Figures 138 completely in a warm room. This will shrink out any and 139. This screw must not be making contact inside of minor wrinkles which may have occurred due to the top the side rail hinge when starting a major top adjustment.
  • Page 93 BODY MANUAL 5. Loosen the hex head bolts attaching top pivot bracket 8. If, after these adjustments have been carefully made, the top support to rear pillar to wheelhouse brace at (C) and (D). side rails are not level with the top of the door window, adjust Bolt holes at (C) are slotted.

  • Page 94: Quarter Window

    88 BODY MANUAL of the door window travel to assure full contact with the WINDOW ADJUSTMENTS side rail weatherstrip. QUARTER WINDOW: Before attempting any door window adjustments, the quarter window must be properly positioned as follows: 1. Loosen screws (R) Figure 138, to obtain the proper forward adjustment.
  • Page 95 Since the The operation of the hydraulic top and window units in hydraulic fluid is inflammable, any accidental sparks the Hudson Convertible Brougham is accomplished may ignite spilled fluid. through the use of a electrically operated hydraulic pump,...

  • Page 96: Electrical System

    90 BODY MANUAL NOTE: It is not necessary to lower the top to check terminal of 20 ampere, circuit breaker and "BAT" terminal fluid level. Since the top operating cylinders are dou- of 30 ampere circuit breaker. ble action cylinders, the amount of fluid in the cylin- When the test lamp lights from the rear terminal of the 30 ders remains constant.
  • Page 97 BODY MANUAL...

  • Page 98: Motor Solenoid Switch

    92 BODY MANUAL FIGURE 149 retaining nut on the instrument panel. See Figure 149. Current should reach the switch (center) terminal of the The pump motor should operate when the top operating motor solenoid when window switches are moved up or knob is pulled out or pushed in.

  • Page 99: Cylinder

    BODY MANUAL When the window control switch operates satisfactorily, under the head of the plug to allow for necessary adjust- remove the trim panel to expose the window operating ment or variation in pressure. The addition of washers cylinder. The solenoid valve can frequently be freed by reduces the pressure while the removal of washers in- several sharp taps on the base of the cylinder.

  • Page 100: Fluid Level

    94 BODY MANUAL be indicated by a discharge of fluid from the valve port. 3. Remove reservoir and refill as necessary to fluid Such discharge indicates a defective valve and replace- level line. Operate all windows several times to expel ment should be made.

  • Page 101: Troubleshooting

    BODY MANUAL TROUBLE SHOOTING Condition Hydraulic Electrical Mechanical 1. Top will operate in one (A) Top control valve shaft and (A) Top control valve switch con- (A) Top valve control rod improp- direction only. rotor not assembled properly. tacts at one point only. erly adjusted.
  • Page 102 96 BODY MANUAL TROUBLE SHOOTING Condition Hydraulic Electrical Mechanical 7. Window lifts operate upward (A) Pump pressure relief valve (A) Low battery (A) Top control rod improperly ad- slowly. stuck. (B) Ollite bear- justed. Internal leak in top oper- ing on top (B) Units possibly binding.

This manual is also suitable for:

480 series490 series

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