© 1986 TECHLIT CO.
Printed in U.S.A.
INSTRUCTION SHEET 50-710
OFF VEHICLE CARBURETOR SERVICE
HITACHI-MODEL DCR384
ISUZU P"UP-1986
GENERAL EXPLODED VIEW DISASSEMBLY
THE GENERAL DESIGN ANO PARTS SHOWN WILL VARY TO USE THE EXPLODED VIEW AS A GUIDE. THE NUMERICAL SEQUENCE MAY GENERALLY
INOIVIDUAL UNITS COVERED ON THIS INSTRUCTION SHEET.
BE FOLLOWED TO DISASSEMBLE UNIT FAR ENOUGH TO PERMIT CLEANING ANO IN•
➔
SPECTION. MARK AND REMOVE LEADS FROM HARNESS CONNECTOR FOR EASIER
REMOVAL OF SOLENOIDS. CAUTION: ORIGINALLY CHOKE VALVE SCREWS ANO SOME
38 OTHERS HAVE LOCK TIGHT APPLIED TO THEM. TAKE EXTRA CARE IN REMOVING THEM.
USE PROPER TOOLS. DRILL OR CUT OFF POP RIVET HEADS TO REMOVE CHOKE COVER.
REMOVE STAKING FROM AIR HORN FOR EASY REMOVAL Of POWER PISTON ASSEM
BLY. NOTE SIZES OF ALL JETS AND THEIR LOCATION FOR PROPER ASSEMBI.Y. RECORO
SIZES BELOW. CAREFULLY DRILL HOLE IN PLUG COVERING IDLE ADJUSTING NEEDLE.
USING A PULLER REMOVE PLUG BEFORE REMOVING IDLE ADJUSTING NEEDLE, TURN IN
COUNTING THE NUMBER OF TURNS IT TAKES TO LIGHTLY SEAT THE NEEDLE RECORD
FOR REASSEMBLY.
NOTE: IF VENTURIS ARE REMOVED TO REPLACE 0-RING SEALS. LIGHTLY TAP VENTURI
FROM THE BOTTOM SIDE UNTIL IT IS FREE. (REMOVE STAKING ON 0-RING SIDE OF VEN
TURI IF NECESSARY.I INSTALL NEW 0-RING AND VENTURI FIRMLY IN PLACE THEN TAP
IN SPRING RETAINER. BE SURE VENTURI IS FIRMLY IN PLACE. UGHTLY RESTAKE VEN
TURI ON 0-RING SIDE.
CAUTION: DO NOT TURN THE SCREW LIKE PLUGS LOCATED IN THROTTLE BODY
0-RING HOUSING. (PRIMARY SIDE).
)o NOMENCLATURE
ffl-1 REF. REF.
NO. NO.
1. SPRING• PUMP LEVER RETURN 50. SCREW & LOCKWASHER (2)• PUMP
2. COTTER PIN • PUMP LEVER BOOT PLATE
3. E-CLIP• PUMP LEVER 51. PLATE· BOOT
4. WASHER• PUMP LEVER 52. BOOT• PUMP
5. LEVER·PUMP 53. PUMP ASSEMBLY
6. BRUSHING·PUMP LEVER 54. SPRING- PUMP RETURN
7. SPRING -THROTTLE RETURN 55. BALL• PUMP INTAKE CHECK
8. COTTER PIN- PUMP ROD !LOWER) 56. PLUG• PAI. SLOW JET
9. WASHER (2)• PUMP ROD 57. SPRING- PR!. SLOW JET
10. ROD -PUMP --=,.. __
11. SOLENOID ASSY. - BOWL VENT ;:: t��/�u���HEc i< _
(SINGLE LEAD) 60. GASKET• PLUG
12. GASKET• SOLENOID 61. SPRING• PUMP BALL WEIGHT
13. SOLENOID ASSY. • IDLE SHUT OFF 62. WEIGHT- PUMP BALL
ITWOLEADl 63. BALL· PUMP DISC CHECK
14. GASKET• SOLENOID 64. JET. SECONDARY SLOW ___
15. POP RIVET (21 - CHOKE RETAINER 65. SCREW. FILTER SET
16. SCREW TO LOi:KWASHER- CHOKE 66. GASKET• SCREW
RETAINER 6 7. NIPPLE- FUEL
17. AETAINER• CHOKE COVER 68. SCREEN. FUEl FILTEA
18. CHOKE COVER ASSY.• !ELECTRIC) 69. GASKET• NIPPLE
19. E-CLIP·SEC.DIAPHRAGM STEM 70. SCREW (3) ·RETAINER
20. SCREW & LOCKWASHER 131 • SEC. 71. RETAINER- WINDOW
DIAPHRAGM ASSY. 72. WINDOW·FUEL BOWL
21. STOP PLATE• FAST IDLE CAM 73. GASKET- WINDOW
22. SECONDARY DIAPHRAGM ASSY. 74. SLEEVE- FLOAT RETAINER
23. GASKET• sec. DIAPHRAGM ASSY 75. FLOAT ASSEMBLY
24. SPRING·SEC. THROTTLE RETURN 76. NEEDLE & SEAT ASSEMBLY
25. SCREW 12) - CHOKE VALVE 77. GASKET (SERVICE!• NEEDLE SEAT
26. VALVE- CHOKE 78. POWER VALVE ASSEMBLY
27. SCREW & LOCKWASHER - FAST IDLE 79. GASKET- POWER VALVE
LINK LEVER 80. JET. PAI. MAIN,_______
28. CHOKE SHAFT 10
,_ - "" - - - ---
29. SCREW & LOCKWASHER. CHOKE ;;: ���E��-L�K�W-ASHEA, 11-
HOUSING THROTTLE BODY IHOLLOWl
30. SCREW & LOCKWASHER- CHOKE 83. SCREW & LOCKWASHER 11l -
HOUSING THROTTLE BODY (LONG)
31. CHOKE HOUSING 84. SCREW & LOCKWASHER (2)-
32. CHOKE PULL-OFF & BRACKET ASSY. THROTTLE BODY
33. BRACKET 85. BOWL ASSEMBLY
34. SCREW & LOCKWASHER 131- PLATE 86. VENTURI PRIMARY
35. PLATE 87. O•RING- PRI. VENTURI SEAL
36. GASKET- PLATE 88. RETAINER- PAI. VENTURI
37. SPRING • PLUG 89. VENTURI • SECONDARY
38. SCREW & LOCKWASHER 121 - VENT 90. 0-R!NG- SEC. VENTURI SEAL
COVER 91. RETAINER- SEC. VENTURI
39. AIR VENT COVER 92. GASKET• THROTTLE BODY
40. SCREW & WASHER• LOCK LEVER 93. PLUG- IDLE NEEDLE
41. LOCK LEVER- FILTER SET SCREW 94. NEEDLE• IDLE ADJUSTING
42. SCREW & LOCKWASHER 14) - AIR 95. SPRING- IDLE NEEDLE
HORN (DIFF. LENGTHS! 96. WASHER- NEEDLE SEAL
43. AIR HORN ASSY. 97. SEAL- IDLE ADJUSTING NEEDLE
44. PISTON- POWER VALVE 98. SCREW & LOCKWASHER- RETAINER
45. SPRING·POWER PISTON 99. RETAINER- THROTTLE SHMT SEALS
46. JET • PRI. MAIN AIR BLEED____ 100. CUP- PRI. SHAFT SEAL
47. JET- SEC. MAIN AIR BLEED ___ 101. SEAL• PRI. SHAFT
48. JET·PRI. SLOW AIR BLEED ___ 102. CUP· sec. SHAFT SEAL
49. GASKET- AIR HORN 103. SEAL- SEC. SHAFT
l 04. THROTTLE BODY ASSEMBLY
CLEANING
CLEANING MUST SE DONE WITH CARBURE10 R DISASSEMBLED SOAK PARTS (SEE
CAUTION BELOW) LONG ENOUGH TO SOFTEN ANO REMOVE ALL FOREIGN MATERIAi..
USE A CARBURETOR CLEANER SOLVENT. MAKE CERTAIN THE THROTTLE BODY IS FREE
OF ALL CARBON DEPOSITS . WASH OfF IN SUITABLE SOLVENT. BLOW OUT ALL
PASSAGES IN CASTINGS WITH COMPRESSED AIR AND CHECK CAREFULLY TO INSURE
THOROUGH CLEANING OF OBSCURE AREAS. CAUTION: DO NOT EXTEND CLEANING
PERIOD OF PARTS WITH ATTACHED PLASTIC COMPONENTS. DO NOT SOAK AIR HORN
WITH RUBBER VENT VALVE OR PARTS SUCH AS (1 ll. 113). 118). 122). 132). 1431. (t;8).
100 (72). (75) IN ANY TYPE Of CLEANING SOLVENTS.
98 I 101
� r;:;.,,
REASSEMBLY
99 � -0@ REASSEMBLE IN REVERSE ORDER OF DISASSEMBLY NOTE SPECIAL INSTRUCTIONS
AND ADJUSTMENTS.
102 ), �
SPECIAL INSTRUCTIONS
103.,.{'�
IDLE ADJUSTING NEEDLE • TUAN NEEDLE IN UNTIL LIGHTLY SEATEO. THEN BACK OUT
NUMBER Of TURNS RECORDED ON DISASSEMBI.Y.
PUMP RETURN SPRING • INSTALL WITH CROSS WIRE TO THE BOTTOM OF PUMPS
CYLINDER AND IN SLOT.
POWER PISTON - AFTER INSTALLING LIGHTLY RESTAKE CASTING AROUND WASHER.
ADJUSTMENTS
0 FLOAT BC'NL INVERTED. RAISE FLOAT AND THEN LOWER IT SLOWLV
UNTIL FL 0,_ r SEAT MAKES CONTACT WITH STEM OF NEEDLE VALVE.
100 NOT C<:::,•RESS SPRING LOADED NEEDLEJ.
NOTE REMOVE NEEDLE
PULLCLIP TO MAKE FLOAT
0
TO AOJUST
SETTING
1.SMM
ADJUSTMENTS, THEN REPLACE. BENO FLOAT 059"
STOPPER.
0
SETTING
0
TO ADJUST
7.SMM
295" MEASURE DISTANCE BETWEEN
BENO FLOAT FLOAT SEAT ANO STEM o;
SEAT. NEEDLE VALVE.
CAUT.ON DO NOTEXERT
MEASURE DISTANCE BETWEEN
END OF fLOAT ANO 80WL.
0 FLOAT BOWL INVERTED RAISE FLOAT
PRESSURE ON RESILIENT UNTIL FLOAT STOPPER CONTACTS
NEEDLE VALVE CARBURETOR BODY.
ORY FOAT LEVEL ADJUSTMENT FIG.1 FLOAT DROP ADJUSTMENT FIG.2
0 OPEN PRIMARY THROTTLE LEVER UNTIL KICK LEVER
JUST MAKES CONTACT WITH SECONDARY RETURN
LEVER CD CHOKE COMPLETELY CLOSED, FAST IDLE SCREVI
ON HIGH STEP OF CAM
I'
SETTING ,:
11
I
6.1-7.6MM
I 11
.240"-.300"
0
TO ADJUST TURN FAST IDLE �CREW
I
II
I 11
-1-
SETTING
128-151MM
OS0"-.059"
CD MEASURE DISTANCE FROM THROTTLE
I
BORE TO TriOTTLE Pt.ATE -1
MEASURE CLEARANCE SETWEEN THROTTLE PLATE ANO BORE.
i
SECONDARY THROTTLE START TO OPEN ADJUSTMENT F I G, 3 FAST IDLE ADJUSTMENT (BENCH) FIG.4
