1934 Workshop manual for HERCULES Söderström's Motor Workshop Kil – Wermland - Sweden Machine Translated by Google “This has been done to the best of my ability, only the best is good enough” Söderström - HERCULES 1934 P. Söderström 3 Straight 16-Cylinder Introduction Machine Translated by Google A story about building a car that would be like one from the 30s, with a very long hood. On several occasions I have tried to calm myself down and at least settle for 12 cylinders, but every time I came to the same conclusion: I have to do this..! Introduction For me, this journey began eons ago with the advent calendar Herkules Jonsson's Great Works. As a technically interested 12-year-old, I was fascinated by the kid tinkering with an old car and countless hours, and countless projects later, I have built... a completely unreasonably long automobile engine. I have also chosen to use the name "Söderströms Motor Werkstad" solely because it amuses me, and because it gives a resonance of what it might have been called 80 years ago. So I have built the world's first and only straight 16- I hope that the manual you hold in your hand will be of use to you when repairing and maintaining the engine. My ambition is that the content will reflect as much as possible of the knowledge I have gained during the course of the project, long after I have taken my hand off it. This has been the project of my life. cylinder automobile engine. There has never been such an engine before. As a basis I have used four engine blocks from a Volvo B20, but I have not "put four engines together", I have built an engine from its parts. Construction of the engine started in August 2012. Straight 16-Cylinder In the model name HERKULES 1934 one might be tempted to assume that it would be an engine from the year model –34. It has also been my intention to let people draw that conclusion for themselves, since the idea is that the engine could have been built at this time. With the exception of certain electronic components. Kil 2015 Pelle Soderstrom 4 Söderström - HERCULES 1934 1 Introduction - Hercules 1934 Machine Translated by Google Hercules 1934 – Specification: 2.1 Repair – Knowledge level 2.2 2 General information Söderström - HERCULES 1934 Rack • Number of carburetors, Make • Cylinder volume, Liters Ethanol/Gasoline 4 / Zenith Stromberg 2 xxx Kilogram 7 Straight 16-Cylinder • Fuel Cubicity This manual is not complete in the sense of attributing to a novice knowledge of the noble art of engine restoration. A large measure of basic knowledge is necessary for the work to be carried out in a reliable manner. However, more information is attributed in this manual regarding the special mechanical components which cannot be derived from general engine knowledge. General information 494 16 Starters, Carburetors, Coolant and Lubricating oil • Length: Pressure Plate – Front Pulley 2464 mm • Number of cylinders 8,1 • Engine Type • Number of Distributors • Weight: Incl. Cooling fan, Dynamo, Flywheel, Machine Translated by Google 2.3 Repair – Working methods Söderström - HERCULES 1934 General information 8 I have taken the liberty here to quote selected passages from Reparationsteknik för Motorcyklar, Teknografiska Institutet 1955, in revised form . In cases where the author has used the words "motorcycles" and the like, I have chosen to replace them with a more appropriate term in this context. The main guiding principle in repair work is accuracy. Temporary, makeshift repairs are part of the road and can certainly be interesting and test imagination and dexterity. However, their only purpose is to help the driver and his vehicle get home so that the repair can then be carried out in a reliable manner. In the long run, accuracy and care still pay off for the owner. One requirement that cannot be stressed enough is cleanliness. Do not disassemble any parts until the machine has been thoroughly cleaned. The basic cleaning should be done in a place that is separate from the assembly workshop, so that it can later be kept impeccably clean. Also store clean, dismantled parts in a safe way so that they do not get dirty or damaged. Of course, there are quite a few parts and details on a machine that can tolerate a little dirt, and which do not really need to be given that much care. However, dirt has an incredible ability to spread to places where it is not desirable, for example via such simple means of transport as the assembler's hands. Cleanliness must therefore be general. In addition, cleanliness gives the work a better "finish" and a greater guarantee of quality. It also provides significantly more pleasant working conditions and therefore increases the feeling of satisfaction with the work, a factor whose indirect importance for the work result cannot be valued in numbers but which is certainly very large. "Although repair work can be carried out with relatively modest resources, great demands are made on the quality and care of the work and on the judgment with which it is carried out. Service work is for the most part purely manual work, and the result therefore depends above all on the hand and the brain, to a much greater extent than on the equipment. The virtue that the repairman should primarily strive for is therefore the ability to use ordinary simple hand tools and assembly tools in a sensible and sometimes ingenious way. In its most beautiful form, service can thus be said to be an art and craft, where individual performance has great potential to leave its mark on the final result. Straight 16-Cylinder C. Borgenstam Machine Translated by Google 2.4 Labeling of components Söderström - HERCULES 1934 The marking follows the following system: • A number of parts are marked from the front and end after the number of parts that are included. Examples include Steering pins Straight 16-Cylinder • Engine blocks are marked from the front with the first block as 1-4, the second between Block and Trough, which are eight in number, and consequently marked 1 to 8 starting from the front. Valve parts can therefore, to the extent that they are marked, be engraved from 1 to 32. • Parts belonging to the Tilt Arm Bridges are marked PLE, LSE etc. with the associated serial number starting from the front. They can of course be re-marked with serial numbers 1 to 32 if desired. • Some components are marked L for left and H for right. They are intended to be seen as the engine is positioned in the car and thus as from the driver's field of vision. For some components, such as the main bearings, the fitter stands facing the opposite direction, which can easily cause some confusion as to which is Right and which is Left. However, the components are always marked from the engine's Right/Left, not the fitter's. 9 General information the block as 5-8 etc. referring to the cylinder number. A large part of the engine's components are marked with an electric engraving pen to ensure correct assembly. Some of the markings are not very visible, but can be detected if the part is held so that light falls on the surface. • The cylinders are counted from the front of the engine with cylinder 1, towards the rear end where they end with cylinder 16. • The engine blocks also have letter abbreviations which refer to the places they originally came from. (1-4/PLE, 5-8/LSE, 9-12/ANL, 13-16/TRE Machine Translated by Google Screws should always be locked with some form of locking device or locking fluid. Straight 16-Cylinder . For Herkules 1934 there are several different alternatives in the form of folding washers, castle nuts, locking nuts, etc. Other screw connections should, unless otherwise stated, be locked with LocTite medium and LocTite weak. The latter applies to screws that are exposed to less stress. The information described in the manual, such as wear, measured values, etc., refers to the time the engine was built and thus shows the current status of the various components and values at that time. This has nothing to do with the service and wear values, etc. recommended by, for example, Volvo, unless this is stated. General information NOTE! There are very good souls who want these boxes to be respected, as there is a lot of experience and a lot of thought behind their creation. Major engine damage can be at stake! The choice of screw quality has been made with regard to its length, yield strength and the machine element that the screw is to fasten. On several occasions, the choice of a screw with lower strength has been made solely in order to be able to stretch the screw sufficiently to obtain a good preload. 10 On most pages concerning the actual assembly, there are warning and information boxes with yellow text. Söderström - HERCULES 1934 Information – Wear etc. 2.5 Screws – Strength class Important points in the Workshop Manual 2.7 2.8 2.6 Screws – Locking Machine Translated by Google 11 Bar = 100 kPa Kpm = 9,807 = 98,07 Some of the units shown are primarily: kPa Newer unit 1 Kilopondmeter General information Straight 16-Cylinder 1 Atmosphere overpressure Atm = 1.013 - Older device 1 Kg/cm2 kiloPascal Newtonmeter Nm kiloPascal Kilopond meter (kpm) is often also written kilogram meter (kgm). a mixture of the older system and the newer ISO system. Many values are shown with older values, all to reflect the time the engine is thought to have been built. An example of this is the engine plate, which, among other things, shows torque in Kilopond meters (Kpm), instead of Newton meters. Bar 1 Kilogram meters Bar 1 Bar The Units used to measure quantities in this manual are a Newtonmeter Nm For technical specifications and measurements, such as volumes, tightening torques and the like, see the respective sections. Kgm = 9,807 Söderström - HERCULES 1934 Units 2.9 2.10 Technical specifications – Measurement values Machine Translated by Google 60------------------------------------------------------------------------- 100hk--------------------------------------------------------------------- 80------------------------------------------------------------------------- 40------------------------------------------------------------------------- 20hk---------------------------------------------------------------------- Kpm The above curves are taken from Volvo's manual. They show the difference at which rpm the increased power is extracted for the two models. Engine power - Torque Straight 16-Cylinder Power-Torque curves for B20A 12 Power-Torque curves for B20B Söderström - HERCULES 1934 3 Engine power – Torque 3.1 Effect cure Machine Translated by Google develop about 105 horsepower. Torque x RPM = horsepower • Double Distributors of 50kV and IRIDIUM Spark Plugs 420 horsepower at 4800 rpm The relationship between torque and power: 16,5kpm x 2800 = 64 hk 4x 105 = • Intake valves such as B20B, i.e. Ø44mm (Isf Ø42mm) Adoption: 17kpm x 2800 = 66 horsepower Furthermore, by studying the above torque curves, it can be assumed that the torque is approximately 17 kilopound meters at 2800 revolutions per minute. 716,2 As can be seen from the above specifications, the B20A engine in the original version developed 90hp SAE. The following changes were made to the 1934 Herkules: = = 264 horsepower at 2800 rpm Straight 16-Cylinder 68 kilopound meters at 2800 rpm 13 716,2 4x 17 • Thinner Cylinder Head Gasket Engine power - Torque 4 x 66 Thus, Hercules in 1934 would develop: An assumption can therefore be made that each Engine Block • Flattened top of Engine Block 716,2 • Flattened underside of Cylinder Head Söderström - HERCULES 1934 3.2 Hercules 1934 – Effect: Machine Translated by Google 3.3 Power / Torque curve B20 A Söderström - HERCULES 1934 Engine power - Torque Straight 16-Cylinder 14 Machine Translated by Google 4.1 Welded Trough – Frame 4 Bottom frame – Trough / Frame Söderström - HERCULES 1934 Bottenram – Stomme Straight 16-Cylinder - 4.1.1 At the bottom of the Trough there are a number of plugs mounted seemingly for no reason. Their task is to seal the sweaty compartments after each compartment has been filled with sound-absorbing polyurethane foam. This in the form of wood glue. The trough is made of bent 8mm sheet metal whose yield strength corresponds to 35 kp/mm². Laser cutting and bending were carried out by Kils Verkstads AB. The trough has been welded, among other things, to partitions, double bottoms and reinforcements. On the top there are two square irons 30x30mm (24 kp/ mm²). The square irons are flattened after welding, also by Kils Verkstads AB. Other work: welding, drilling, reaming, threading etc. was carried out by Söderströms Motor Werkstad. 15 Trough – General information Machine Translated by Google Bottenram – Stomme Straight 16-Cylinder For your own notes: 16 Söderström - HERCULES 1934 Machine Translated by Google 5 Engine components Söderström - HERCULES 1934 General information Straight 16-Cylinder The basis, the four Blocks, are taken from the Volvo B20 from the late 60s. 5.1.1 The B20 engine is based on the 1.8-liter B18 engine, but with a larger bore, 88.9 mm, which together with the retained stroke of 80 mm gives the engine a displacement of 2.0 liters (1986 cm3 ). The B20 made its debut in 1969 in the Amazon, Volvo P1800 and Volvo 140 models and was installed in the Volvo 240 series until 1976. The design is a pushrod engine with a block and cylinder head made of cast iron. The B20 is known for its high quality and reliability. It is considered by many to be one of the most durable engines ever manufactured. One of the designers of the B18 engine was honorary doctor Per Gillbrand. 17 Engine components early 70s. 5.1 Volvo B20 engine block - Information Machine Translated by Google Hercules engine block 1934 - Information 5.2 Söderström - HERCULES 1934 • The above engine work was carried out at LJ-trim AB Hammarö by the owner Jan “Biss” Eriksson and Tommy Johannesson. Other work was carried out by Söderströms Motor Werkstad. • Camshaft bearings replaced, Manufact. DURA-BOND. Straight 16-Cylinder • Gearbox mounts including starter motor mounts cut away. • The threaded holes that the trays are normally screwed into from below have been reamed and grinding has been carried out so that the blocks can be screwed from above into the supporting frame manufactured by Söderströms Motor Werkstad , the so-called Tray. • Hole where the dipstick was previously located has been drilled and threaded M12 x 1.25 • Note: Volvo's older B20 engine blocks almost exclusively have inch threads. UNC (Unified Coarse) and UNF (Unified Fine) 18 • The blocks have been drilled to Volvo's 3rd oversize (Ø89.66-Ø89.67mm) • Crank and frame bearings replaced, Manufact. GLYCO. Engine components • The top sides of the blocks, i.e. towards the cylinder head, have been leveled on all blocks to the same height measured from the frame bearing position. • Main bearing positions have been line honed. and equipped with pistons from Mahle. Machine Translated by Google Diameter ca 50mm ner Measured Cylinder Dimensions Difference Engine components Below is a table with the cylinder dimensions measured after machining at the time of the engine's construction. The bore is made to Volvo's third oversize 0.75mm / 0.030". Pistons from Mahle specify nominal cylinder diameter to 89.670mm Diameter ca 90mm ner The measurement was performed with a Cylinder Indicator purchased from Biltema AB. The indicator has been reference checked against a measurement ring which was provided on loan from Mykå AB. According to the older Volvo manuals, the nominal measurement is 89.66 – 89.67 CYLINDER Straight 16-Cylinder Diameter ca 10mm ner 19 5.2.1 Söderström - HERCULES 1934 Cylinder dimensions HERKULES 1934 89,685 Cyl 13 89,67 89,665 0,015 89,68 89,675 0,02 0,005 89,68 89,67 89,685 0,01 89,68 89,665 89,675 89,675 89,68 Cyl 3 Cyl 15 0,01 Cyl 11 89,67 89,675 0,015 Cyl 7 89,675 89,66 Cyl 10 89,665 89,68 0,005 89,68 89,675 Cyl 2 0,01 89,68 89,675 Cyl 5 89,68 Cyl 1 Cyl 8 89,67 89,68 89,675 89,68 89,67 0,01 Cyl 12 Cyl 16 Cyl 9 89,68 89,675 89,675 89,67 0,02 89,67 89,66 89,675 0,02 89,67 89,69 Cyl 6 89,68 89,685 89,675 89,67 0,02 89,69 0,01 0,01 Cyl 14 89,675 89,665 Cyl 4 89,68 0,02 89,68 0,005 89,665 Machine Translated by Google Engine components Straight 16-Cylinder For your own notes: 20 Söderström - HERCULES 1934 Machine Translated by Google Inspect the engine block and cylinder head sealing surfaces carefully and clean if necessary before starting the assembly work. The cylinder head and cylinder head gasket are then centered during assembly using guide pins in two of the screw holes. Also ensure before assembly that the oil channel for lubricating the rocker arms is not blocked due to a faulty or incorrectly installed cylinder head gasket. Then lubricate the cylinder head screws with engine oil, install them in the holes and first tighten them lightly so that the guide pins can be removed. After all screws are in place, the cylinder head can then be tightened in the specified order as shown in the picture. Guide pins for Gasket and Cylinder Head Straight 16-Cylinder 21 next page view. 5.3.2 The cylinder heads for the B20 models have two sizes of intake valves. The early models (B20A) have Ø42mm intake valves, while the later ones (B20B) have Ø44mm intake valves. Cylinder head – General information Make sure the oil channel is clear. 5.3.1 Herkules 1934 has the latter type of cylinder head with Ø44mm intake valves. The cylinder heads are flattened by LJ-Trim and fitted with recessed, hard, valve seats for the exhaust valves , which means that the engine can be run on unleaded petrol. Cylinder head – Tightening Oil channel Engine components Cylinderlock The exhaust valves are the same size for both models. Valve guides (loose, as a spare part) and valve seats (directly in the cylinder head) are made of cast iron. The combustion chambers are machined. Steering sticks for Söderström - HERCULES 1934 5.3 Cylinderlock Machine Translated by Google Söderström - HERCULES 1934 • 1st draw, according to the order described below Cylinder Head Gaskets – General Information Straight 16-Cylinder Tightening sequence for cylinder head bolts 5.3.3 The cylinder head gaskets for the B20 models have been of different thicknesses over the years (2 - 1.4 - 1.2 - 0.8mm). The earlier B20A models had 2mm, the B20B 1.4mm and the later ones down to 0.8mm. 6kpm +/-0.5kpm 22 Engine components In the original version there were rubber seals between the Cylinder Head and Water Pump, where in our case there are now Intermediate Parts. In the case of the Herkules 1934, these surfaces (i.e. between the Cylinder Head and Intermediate Parts) are sealed with engine silicone iff rubber seals. This applies to both the main cooling loop and the loop which is activated when the engine is cold. 9kpm +/-0.5kpm • 3rd draw, . • 2nd draw, 3kpm +/-0.5kpm Tightening the Cylinder Head should be done in three steps as follows: Retightening of Cylinder Head When starting the engine with a new cylinder head gasket, the engine should be run for about 10 minutes, then shut off. After cooling down, the cylinder head should be retightened. Loosen each screw only slightly to overcome the resting friction before final tightening according to the specification above. Machine Translated by Google Söderström - HERCULES 1934 Tilting boom bridges – General information Straight 16-Cylinder Measured rocker arm play for all rocker arms was approximately 0.07mm during engine build. Cylinder Head Gaskets – Herkules 1934: Note! • Seal between Cylinder Head and Intermediate Piece – LocTite SI 5910 5.3.4 • Cylinderlockspackning 1,2mm – KG-Trim Complete rocker arm bridges are taken from 4 different engines whose running time has been approximately the same. Allowed play according to Volvo's instruction manual 0.10mm but this is probably not critical. Vipparmsbryggor Engine components After grinding the valve lifter, check that the rocker arm's profile matches the adjacent picture. 23