Friday, 5 January 2018

Three DKWs Across India - 1935 Hartlmaier Expedition

I am very pleased to be able to publish here a very rare English edition of the 1935 Hartlmaier Expedition to India and the Himalayas, 'With Three 20hp DKWs through India.' In 1935, Peter Hartlmaier and team took the DKW F5s - a two seater and four seater sedan and a delivery wagon on an 18 month journey across India. All the cars performed fantastically. The booklet, published by DKW is extremely rare in German, let alone English. I have to thank Peter Thorogood from the Historic German Vehicle Register of Australia for sharing his copy with me. Enjoy!
















Sunday, 31 December 2017

DKW F89P New Meisterklasse driver manual


This is my translation of a 15 page French drivers guide for the New Meisterklasse. Some of my translations may not be exactly correct but I think I have captured the general gist. Unfortunately English language documents for the New Meisterklasse are quite rare.

Your new Auto-Union DKW

So simple to use it requires only minimal maintenance. If you follow these instructions your car will always be ready to serve and will retain its value. It is therefore in your interest to follow the advice in this manual and perform the few, simple instructions.

Our wide range of offices - there are in all major cities - are always at your disposal to advise you wisely. Please contact the official DKW Auto-Union agent, which are recognizable by the cover badge, to benefit from the advantages offered by our periodic maintenance services.

The DKW repair shops are run by skilled men. Specialist mechanics, having taken technical courses in our factories, will carry out your work. Only in these workshops will you find the special DKW tooling and original spare parts that make it possible to complete any repairs fast, effectively and with the minimum of fuss.

Before starting your new car:
1. Fill the fuel tank (32 litre capacity)
2. Fill the radiator
3. Check the pressure in the tyres

Instrument Panel


Running in:

The great advantage of the DKW two-stroke engine is its simplicity in running-in. The motor and speed is not restricted or limited during the running-in period and care needs only be taken to maintain engine temperature within the 80-90 degree range. Do not run the car at full acceleration for more than:
½ to 1 minute for the first 500 kilometres.
2 to 3 minutes for the next 1500 kilometres.
The most suitable running in speed is between 60 and 80 kilometres an hour.

These indications are also valid on cruises of long duration or if the speed, in spite of the full acceleration, falls below 50 – 60 kilometres per hour. We advise you to play with the accelerator and not to drive too slowly.

During the running-in period use the freewheel as much as possible to reduce strain on the engine.

Fuel and Lubricants
The two-stroke engine that the Auto-Union DKW plants have constantly perfected for more than thirty years is a pinnacle of efficiency. The secret of its longevity, of its trouble-free ignition in the cold, and its ability to drive at full acceleration is that its fed by a mixture of fuel and oil.

Use only branded petrol and oils and in no case use gasoline with alcoholic ingredients. Regular lubrication must also be carried out as indicated in the "lubrication plan."

The ratio of oil to gasoline remains the same in all circumstances and in all seasons, i.e. one liter of oil per 25 liters of gasoline.

Radiator

The radiator is over-pressurized. Do not be alarmed if the water temperature reaches 100c. The water begins to boil only over 110c. Radiator temperature is indicated by the instrument panel thermometer. The best performance of the car in terms of speed and consumption is at a temperature of 80-85.

During winter a good antifreeze should be added to the radiator (special DKW available under reference number 401 249/0).

Starting hints
The fuel is fed by a fuel pump from the reservoir - which is located at the rear - to the carburetor. A petrol tap does not exist. Place the shift lever at the neutral position (i.e., lever in the vertical position) and leave in that position. Switch on the ignition and the red control lamp will illuminate. Pull out the starter knob only when the engine is absolutely cold (position 1). Actuate starter button on the floor without touching the accelerator.

As soon as the motor turns, push the starter knob in half way. When the engine is cold, let the engine run for a few minutes with the starter half closed. Push it back in entirely when the engine is running regularly.

Do not use the starter knob when the engine is already hot but start by giving full acceleration, but remember, never touch the accelerator when starting with the starter.

To ensure that all energy is available for the Dynastarter, switch off all electrical accessories when you activate the ignition. The suction pipe of the air filter must be placed in the summer or in hot conditions towards the radiator in the rear and in winter or in cold weather, downwards into the exhaust port, to suck air heated by the exhaust manifold.

Clutch, gears and accelerator
The gear control lever in the centre of the dashboard is pulled forward by a spring in the direction of travel. To engage the reverse gear, first depress the clutch fully. Move the lever to the center point (position between the second and third gear) then pull it towards you and push to the right.

Do not use the reverse gear until the car has stopped completely.

Always accelerate gradually and when the desired speed has been reached, remove the accelerator foot as much as possible while maintaining this speed. By doing so a great saving in fuel is achieved.

Freewheel
A free wheel device is located between the motor and the clutch. Its use will save you fuel.

A lever on the left of the steering column allows the freewheel to be set or removed. To engage, pull the lever upwards until it locks into a stop. The freewheel can be locked at any time and operated, for example, in a descent to use engine braking. Simply remove the freewheel latch from its locking catch and push it downwards. Disengaging the freewheel is recommended when driving on an ice-covered or steeply descending road.

Brakes
The car is equipped with hydraulic brakes which act on the 4 wheels according to the principle servo and duo servo. Always try the brakes before setting off in the car. If by actuating the brakes your car pulls on one side, or if you actuate them you are forced to push the pedal of the brakes to the floor, immediately have your brakes checked at your local DKW service centre. Don’t forget that by slamming on the brakes you will lock up the wheels. This effect could become dangerous both for you, for other road users and for your car. You should always pay attention to the road condition and slow down before braking.

By pulling the lever shown on figure X on page 4 the heating and defrosting of the windscreen is controlled. The temperature inside the car can be easily adjusted by means of various notches on the lever.

Care and Maintenance
Always consult your DKW service agent. He alone knows thoroughly the construction of DKW, has the special tools and the original parts to carry out servicing quickly and efficiently. Exemplary service forms the basis of his reputation and that of the company, and he has the greatest interest in preserving it. and the necessary spare parts.

A regular maintenance will give you the advantage of always having a vehicle in perfect working order. This is of the utmost importance. Many of these steps can be undertaken by yourself easily, if you have the time.

Periodic maintenance before driving
  • Check there is water in the radiator;
  • The brakes are working correctly;
  • The correct air pressure is in the tyres;
  • Horn and lights are working;

At 300 kilometres

Clean the air filter with gasoline and then soak it with a few drops of engine oil;
Pay attention to the correct positioning of the rubber seals between the silencer and the carburetor;
Clean the fuel filter;

Clean the spark plugs and check the spacing of the electrodes (0.5mm);
Check the condition of the battery, grease the terminals, top up the battery with distilled water.

At 6000 kilometres
Check the fixing of the steering column and the housing;
Check the tightness of the telescopic shock absorbers before topping up the oil in the rear shock absorbers, according to the lubrication plan;
Replace dampers that are not waterproof;
Check the contacts of the ignition switches and their adjustment. Lubricate the channel of the insulation blocks of the breaker. Distance between contacts - Ignition point; 4.5mm before the top half-point, the automatic counterweights being fully open.
Check the play of the clutch pedal it must be about 10mm;

Check the operation of the gas pump and clean it if necessary. The diaphragm operates automatically, without mechanical control by pressure changes in the motor housing. The flow rate of the pump must be such that the glass receptacle of the filter and the connection of the inlet pipe is empty after 25 seconds of starting of the engine;
Pay attention to the sealing of the pipes and the connection of the fuel pump and the crankcase. Seizures and a lower fuel yield may be caused if there is a leak;
Check the level of the brake fluid in the reservoir and refill if necessary.

After 12000 kilometres
Check the tightening of all bolts and nuts, especially those of the front hubs;

Have your carburetor serviced by a DKW agent (remove the lid, float and jets, clean thoroughly and reassemble it as per factory specifications). Nothing should be changed to the settings otherwise the consumption of fuel will increase or performance will be impacted. It is always preferable to have this work carried out by a DKW workshop, except for the cleaning of the nozzle or a possible adjustment of the idle.

A few tips for tyre maintenance

Like the engine, the tyres require care to ensure a long service life. It is not only their exact pressure that plays a role but also the speed at which one is driving.
Carefully check the tyres, ensuring that the inner tube is not pinched between the tyre bead and the rims.
Rotate the tyres every 4000 km including the spare wheel.
Avoid pinching and slack in the steering components and inadequately greased hinges as they cause uneven and abnormal tyre wear.
Do not forget that oil and grease are rubber's enemies.


Care of the bodywork
Clean bodywork will give your car the best appearance, retain it its value and avoid neglect. Depending on the weather and the correct use of the car, wash the whole car under a slight jet of water. Gently use a sponge to remove mud and dust and dry with a chamois leather.
From time to time put a drop of oil on the door hinges.
Clean the chassis every year. Remove the grease and repaint it with special chassis paint.

Never use gasoline or similar products to remove stains from a convertible top, it damages the rubber layer between the exterior and interior fabrics. A top must never be folded in wet or frozen condition.
Make sure that it is always well folded in order to avoid friction wear while driving. Brush it with a soft brush only in one direction.

The Gillet mixing funnel was designed to facilitate the efficient mixing of the oil with the petrol. This very useful instrument is available to purchase as No 09492/0.

The fuel consumption of all two-stroke engines depends primarily on how the car is driven. It goes without saying that consumption increases with speed. If you want to drive with a minimum of fuel consumption, slowly press the accelerator and only as much as necessary to maintain the desired speed. The most economical speed is about 65 kph.



Troubleshooting
1.The starter motor does not work
The battery is not charged or is defective – recharge or replace the battery;
The electrical circuit has been interrupted – check the connections from the battery to the starter motor;
The Dynastart is defective – check the armature and clean any carbon from the contact points.

2. The engine does not work
Check the fuel system;
Check to ensure that the fuel is reaching the carburetor;
Clean the carburetor, float and jets;
Check the fuel line;
Clean the fuel filter;
Check that there is fuel in the tank;
Check the cables;
Bad contact to the coils;
Condenser is defective.

Accessing the engine

The hood lock is positioned in the upper aeration vane gap. Easily accessible to you, it remains ignored of others.

Spark plugs – Bosch M175T1 or Beru K175 b1/17
Gap = 0.5mm