service manual a10 & a12 ee

7/26/2019 Service Manual A10 & A12 EE

1/32

SECTION

MODEL

A 1 0

& A 1 2

EltGt1{E

ENGINE

ELECTRICAL

SYSTEM

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NISSAN

vIOTORO., TD.

TOKYO,

JAPAN


2/32

Eng ne

Electr ical

ystem

S T A R T I \ C

C I R C U I T

BATTERY

V I S U A L

N S P F C T I O N . . . , .

INSPECTION F BATTERY

F I F C T R O L Y T T

Ct .1AR

NC

S I A B T I N G V ] O T O R

STARTING

CIRCUIT

The starting circuit

consists

essen-

tially

of a

battery, ignit ion

switch,

stading

motor

and solenoid,

as shown

in Figure

EE-1.

BATTERY

VISUAL

lNSPECTlOltl

l . Check for corroded erminals

r

broken cables.

Clean or replace,

as

necessary.

2. Checkcase or cracks

r leaks. f

necessary,

eplace.

3.

Check cell connectors

or cracks,

and check or

missing ell connectors.

Check vents for clogging

or leaks.

Clean r replace,

s

necessary.

4. Check for

corroded,broken,

or

loose fitt ings. Clean, replaceor re-

tighten,

snecessary.

Notes:

a. Always keep battery top

and sides

clean and

dry

to prevent

cunent

leak.

b. Keep battery

terminals clean.

After

connecting cables o

terminals, ap-

ply

a

thin

coating of vaseline

o

battery terminals

and top surfaces

of

cable

erminals o

prevent

orma-

tion

of corrosion.

INSPECTIONOF

BATTERY ELECTROLYTE

Electrolyte

level

Check

electrolyte

evel n eachbat-

tery cellat least nce

a month.

l . Remove

ix

vent p lugs

ar rd n-

spect electrolyte evel in

each cell.

Level can be

quickly

determined y

Blancing

nto cellopening.

C O N S T R U C T I O N

. . . . . .

E E -4

D

S A S S E | \ , I B

Y

. . . . . . . .

E E -5

C L E A N I N G

N D I N S P E C T I O N

. . . E E - 5

A S S E I , 4 B L Y . . . . . . . . . . . E E .

r l s r

. . .

. . . E E -

S E R V I C E A T A

A N D S P E C I F I C A T I O N S

. . . . E E -9

T R O U B L E

D I A G N O S E SN D

C O R R E C T I O N S

E E - 1 0

Ring

gear

Shift lever

guide

Armature

Battery

Field coil

Stat ionary

ontact

Movable

contact

Shunt oil

Plunger

Ignition

switch

Series oil

Torsion

spring

Shift lever

Pinion

F ig .EE-1

E

E 4 0 1

Startingcircuit

STARTING

YSTEM

CONTENTS

2

2

2

2

4

4

2. If electrolyte

erel :

rcunc rr

': e

low, add

d is t j i l ed r r : : :

l o . ' , - i

. . : : i

unti l

ievel ises

o approxinar:;1

10 ro

20

mm

(0.394

o 0 . -S-

in t a r l r ie

op

of

plates.

For a

battery \ ' i th

elecirolrre

uide

l ines

n i rswa l l .

he ;k L r r e ie .

ro ly re

level s

between

pper

ald lo*er l ines.

Note:

Do not overf

l. Overfilling

will

cause

oss

of electrolvre.

esult ing

in poor performanceand short life.

Specif ic

gravity

of

electrolyte

Specif ic

graviry

of battery electro-

l y te i s tes ted

,vr th

a hydrometer .

Observe

he follorving:

1.

When

measuring pecif ic

gravity,

place

your

eyes n l ine

with scale o

read

rhe h ighesr

eve lo i e le . t ro ly re

(electrolyte

ises

t edge ue o

surface

tension).

eeFigureEE-2.

I

Thermometer

2

Hydrometer

E E O O l

EE-2

Fig.

EE-2

Checking

specific

grauit!


3/32


4/32

Eng

ne Electr ical

ystem

CHARGING

If electrolyte

level is satisfactory,

battery must be

chargedwhen electro-

lyte

gravity

reading falls below 1.200

corrected

o 20oc

(68oF).

If battery

still mounted

on car is

quick-charged

to

bring

it up to

full

charge,

the

operationshould be carriedout with

negativecable

emoved.

Prior to charging,corroded

battry

terminals

should be cleaned

with a

brush and common

baking-soda olu-

STARTINGMOTOR

coNsrRucrtol{

I Magnetic witch ssembly

2 Dustcover

adjust ing

ashef)

3 Torsion pring

4

Shift

ever

5 Dustcover

6 Dustcover

packing)

7 E ring

8

Thrust

washer

9 Rerrcover

metal

l0 Through

ol t

I

I Rear over

l2 Brush

holder assenrbly

13 Brush

-)

tion. [n

addition, the following

should

be

observed

while ballery

is being

charged:

l . Be sure

hat e lec l ro ly te

eve l s

above op of each

late.

2. Keep

removed

plugs in a safe

place.

3.

Do nol alJow

lectrolyte

empera.

ture o

go

over45oC

l

l30F).

4. After

charging, check

to

be

certain

that specific

gravity does not

exceed 1.260 corrected

to 20oC

(68oF).

Correction can

be made

by

adding

distilled

wate! into

cells as

necessary.

5.

After all

vent

plugs

have

been

tightened,

clean all sprayed

electrolyte

off upper aceof battery.

Caution: Keep

battery away

from

open flame while

it is being

charg-

ed .

9

N

v{

,a\

Y

f \ 9

,ht^l

e(/d

14

Brushsprins

1T

15

Brush

+)

l6

Yoke

l7

l;ield

coil xssemblt

l8

Arm|ture

assemblY

t9

Center

late

20

Pinion assembly

2l Pinion

topper

22

Dust

cover

23 Stopper l ip

24 Gelr

clrse

25 Gear

xsemetal

EE.4

Fig.

EE-6 Exploded

oiew of starting

notor


5/32

Engne

E ectr ica

SVStem

DISASSEMBLY

l . Disconnect onnecting

late

ro m

"M"

terminal of magnetic

switch.

Remove wo

screws ecuringmagnetic

switch and remov e magnetic

switch

assembly.

2. Remove dust

cover, E-ring and

thrustwasher(s).

\?,/

I

Dust

cover

2

Packing

3 E

ring

4 Thrustwasher

E E 4 O 2

Fig. EE-7

Remouing

dust

couer,

E-ring

and

thrust

uasherlsl

3.

Remove two through

bolts

an d

rear

covet.

4. Remove brushes from

their

holders by

moving each brush spring

away from

brush

with

a hook. Remove

brush

holder.

5.

Remove

oke

assembly

ndwith-

draw armature

assembly

and

shift

lever.

6. Remove

pinion

stopper ocated

at

end of

armature shaft. To remove

stopper, first

move stopper toward

p in ion

nd

af rer emovingropper

l ip .

remove

stopper with

overrunning

clutch assembly rom armature

shaft.

CLEANINGAND

INSPECTION

Cleanall

disassembledarts,

but do

not use greasedissolvingsolvents for

cleaning verrunning

lutch, armature

assembly,

magnetic

switch assemoly

and field

coils since

such a solve nt

would

dissolve

rease

acked

n

clutch

mechanism

nd would

damage oils

or

other nsulators.

Check them

for excessive

anage

or wear,

nd eplace

f necessary.

Terminal

Check

terminal for

damage and

wear,

and replace

magnetic switch

assemblyf

necessary.

Field

coil

Check field

coil for insulation.

[f

insulation

of coil

is damaged

or

worn

it should be replaced.

Testing ield coil for

continuity:

Connect

probe

of a circuit ester

r

an ohmmeter to field

coil

positive

terminal

and

posit ive

rushholder.

I f testershowsno continuity, ield

circuitor

coil

s open.

Testing

field

coil for

ground:

Place

one

probe

of

circuit teste

onto

yoke

and other

onto field

coil

lead

posit ive

erminal).

If very

little resistance

s read,

ield

coil

is

grounded.

E E O 1

FiE. EE-10 Testing

field

coil

for

ground

Brushes and brush

lead wire

Check surfacecondition

of brush

cLrnract nd rvearof brush. f a loose

crrntacts bund, t shouldbe replaced

If brush s worn so hat its ength s

less han 12 mm(0.472 n), replace.

Check

connection f lead clip and

leadwire.

Check

brush holders

and spring clip

to see f they are not deformed or

bent,

and will

properly

hold brushes

against ommutator.

If brushesor brush holders are

dirty, they shouldbe cleaned.

Brush spring tension

Check brush spring

tension by a

spring

cale s shown n FigureEE-l .

Reading hould be

1.4 to 1.8kg

(3.1

to 4.0 1b). Replacespring l tension is

lower than the

specification.

Fig. EE-8 RemoL'ihg

pinion

stopper

\ ( (

n-f i

\

^ffi?

6

d J

FE. EB-g

Testing

ietd

coit

E E O 1 6

for

continuity

Pinion topper

EE-5


6/32

Engine

Electr ical

ystem

0.5

o

0.8

nm

(0 . 0197

o

0 0315

n)

Armatura

assembly

Check

external

ppearancef arma-

ture and commutator.

1. Inspect ommutator. f

commuta-

tor su rface s rough, t mustbe

sanded

lightly

with a

No.

500 emerycloth. f

depth of

insulating

mica is less han

0.2 mm (0.0079 n) from commutator

surface, nsulating mica should also be

undercut o that ts depth s

0.5 to 0.8

mm

0.0197

o 0 .0315 n) .

Wear imit of commutator ia meter

is 2 mm

(0.0787

in). If diameter

of

commutator

s less han

3l mm

(l.22

in), replace

rmature ssembly.

2.

Inspect soldered

connection of

armature

lead and

commutator- If

loose connection s

found, solder

t

using osin lux.

E E O l A

Fig. EE-11 Inspecting

brush

spring

tension

Incorrect

EE 0 2 I

Fig, EE-12

Undercutting

insulating

mi.a

3.

Armature est or

ground

Usinga

circuit ester,

lace

ne est

probe

onto armature halt and

other

onto each ommutator

ar .

lf

tester shows continuity,

arma-

ture s

grounded

nd nrustbe replaced.

Fig. EE-t3 Testing armature

for

ground

4. Checkarmature

or short

by

plac-

ing it on

armature ester

(growler)

with a

piece

of iron over

armature

core, rotating

armature. If

plate

vibrates,

rmatures shorted.

Metalplate

EE403

FE,

EE-14

Testing

artnoture

for

5.

Checkarmatureor continuityby

placing robes f testeron two seg-

mentssideby side. f testgr hows o

continuity, ircuit s

open.

Overrunnlng clutch assembly

lnspect inion

assemblyndscrew

sleeve.

crew leeve

ustslide reely

along armature

shaft

splines. f

danrages found

or resistances felt

*hen

s l id ing. t nrustbe repaired,

Insp3.t in ion eeth.f excess iveub-

bing is

.found

on teeth,

replace.

Fl l

! r - 'e

- r rq

sear

lso

mustbe in-

spected

I

l

3

Pinion

5!eErbl l

Pin ion

iropDer

Cl i !

Ee404

FE. EE'15 Overrunninglutch

assembl!

Brush

holder

t3t tor

grosnd

L sing

a circuit ester, lace

ne est

probe

onto negative

side

ol brush

holder

and another

onto

posit ive

ide.

If

tester

shows continuity,

brush

holder

is shorted

o

ground.

Replace

brush

holder,

EE.6


7/32

Engine Electrical

System

EE.rO5

Fig. EE-17

Circuit of no-lood test

Bcarlng

metal

Inspect

bearingmetal for

wear or

side

play.

Replace

etal f required.

Magnetic awitch assembly

1. Using circuit ester, heck onti-

nuity between

S"

terminal

of mag-

netic

switchand

switchbody metal.

f

continuitydoes

not exist,shunt

coil s

open.

Replace

witchassembly.

2. In the same

manneras above,

check continuity

between erminals

"S"

and

"M".

If continuity does

not

exist,

sries

coil is open. Replace

switch

assembly.

ASSEMBLY

Reassemblesta ing

motor

in

re-

verse

sequence f disassembly,

When

assembling, e sure to apply

grease

to

gear

case and rear

cover

bearing metal, and apply oil lightly

to

pinion.

TEST

Pcrformance test

Starting motor should be

subjected

to

a

'no-load"

test whenever.it

has

been

overhauled to ensure that

its

performance

will be

satisfactorywhen

installed on engine.

Starting motor

should also

be subjected o test when

causeof abnormal opention

is to be

determined.

A

brief outline

ofthe test

is

given

below.

No-load

test

Connect starting

motor in

setes

with

specified

battety

(12

volts)

and

an ammeter

capable of indicaLing

1,000 amperes.

Specified

current draw and revolu-

tion

in these tests, are

shown in

ServiceData and

Specifications.

EE-7


8/32

Engine

Electr ical

ystem

Test diagnosis

Condition

Low speedwith

no-load and high current draw.

Failure

o operate ith highcurrent

draw.

low current

draw and ow noload speed.

High speedwith no-load and high current dravt.

Starting motor does not

operate and current

draw.

ilagnetic

switch

assembly

test

Test magneticswitch assembly fter

performance

est.

l. Connect

startingmotor

in series

with battery and switch asshown n

FigureEE-l8.

2. Make sure

that

pinion

assemblys

quickly pushed

out by meansof mag-

netic switch when switch

(described

n

step I above) s turned

"ON".

3. With switch on,

push pinion

back

to remove all slack

and measure the

elearance

,L"

between

pinion

ftont

edgeand

pinion

stopper.The clearance

should be held

within 0.3 to 1.5

mm

(0.012

o 0.059 n). See

FigureEE-18.

If necessary, djust it by changingor

adding adjusting washer(s).Adjusting

washers

are available into two dif-

ferent sizes,0.5 mm

(0:020

in) and 0.8

mm

(0.032

n).

'' '

Probable ause

Tight,

dirty or worn bearings.

Bent armatureshaft

or loose

ield

probe.

Shorted rmature.

A grounded rmalure r f ield coil.

A

grounded

r open ield coil.

Armature

coil doesnot operate.

Burned

out commutalor ar.

l.oose connections,

amfred

mutator.

t

t

a

a

a

t

a

lead or dirty com-

doesno t

r Shorted ield coil.

o

Shorted

armatureand

field

coil.

. Shorted brush

eads.

. Dity commutator.

r Failure of brush-to-commutator

ontact.

Starting

motor

0.3

ro

1.5mm

(0.012

o

0.059 n)

EE4O6

FE. EE-18 Circurtof magneticsuitch o'Fembly est

EE-8


9/32

Engine.

Electrica,l:.System

Starting, motor

Type . . . . . . . . . .. . . . . . . . . .

Sl14-160

annlierr ennine mnzr"r Al2 for B2l0

'

andBl20

s1 4 .161

A10 nd l2

for F

0

1 2

Less

han60

More han

7,000

1 2

0.324

0.694

sr

14-

63

Al2 for B2l0

(Option)

System oltage

No-load:

Current

Revolution

Terminal

oltage

Magnetic

witch

Sedes

oil resistance

Shunt coil resistance

Gapbetween

inion

and

pinion

stopper

Outerdiameter f cornmutator

.

-

. -

' :

Brush ength

Brush pringension

mm

(in)

rnm

(in)

mn

(in)

kcb)

0.3 o

1.5

0.012

o 0.059)

More han3l

(1.22)

More han12

0.47)

1.4 o 1.8

3.1

o 4.0)

EE-9


10/32

.: s

Engine

Electrical

System

TROUBLE

DIAGNOSES

Al{D

CORRECTIOI{S

Condition

Probable

ause

Corrective ctlon

Startingmotor

will

not

operate.

Discharged

attery.

Broken

magnetic witch.

Loose rminal

onnections.

Worn

brushes.

Inoperative

tartingmotor.

Charge r replace.

Repair r replace.

Clean nd ighten

ermlnal.

Replace.

Remove

nd

est.

Noisy

tarting otor.

Loose

ecuring olt.

Wornpiniongear.

Poor

ubrication.

Worn

commutator.

Worn

brushes.

Tighten.

Replace.

Add oil.

Disassemble

otor.

KePlace.

Startingmotor

cranks

lowly.

Discharged

attery.

lrose terminal

onnection.

Worn

brushes.

Locked

brushes.

Dirty

worn commutator.

Armature

ubs

ield

coil.

Broken

magnetic witch.

Charge

r replace.

Clean

nd ighten.

Replace.

Inspect

brush

spring ensionor

repairbrusl

holder.

Clean

nd epair.

Replace

sembly.

Repair

r replace.

Starting

motor

operatesut does

ot

crankengine.

Wom pinion.

Lockedpinionguide.

Worn ing

gear.

Replace.

Repair-

Replace.

Sta ing motor

will

not disengage

hen

ignition

switch s

turnedoff.

Broken

magnetic

witch.

Broken

ear

eeth.

Repairor replace.

Replace roken

ear.

E

E-10


11/32

Engine

Electr ical

ystem

C O N S T R U C T I O N. .

DISASSEVBLY

INSPECTION

ND REPAB

CHARGING

YSTEM

CONTENTS

E E - i l

EE.12

EE.12

E E - 1 2

EE- 12 '

E E . 1 5

E E - 1 6

E E - 1 6

engine nto electrical

nergy

which s

used o operate

ll electrical

nitsand

to keep he

battery ully

charged.

Figure

EE-19

showsa charging

circuit

when gnition

$/itch is turned

Voltage

eBulator

D E S C R I P T I O N

I\iIEASU

EI\4ENT

F

REGULATOR

VOLTAGE

ADJUSTMENT

S E R V I C E A T AA N D S P E C I F I C A T I O N S

. . . .

TROUBLE

IAGNOSESND

COBBECTIONS

EE.i

E E - ] 7

EE, ]

EE.21

EE-22

A S S E N , I B L Y . . . . . . . .

ALTERNATOR

TEST

CHARGING

CIRGUIT

The

charging

circuit consists

of the

battery,

alternator,

regulator

and

necesgfy

wiring to

connect

these

pans.

The function

of this

system s to

convert

mechanical energy

from the

T - - - - - - - -

- - - - - -

to

"ON".

Figure EE-20

showswhat

happens

when

alternatorspeed s in-

creased r voltage

tarts o riseexces-

sively.

Stator

(almatulei coil

Roro.

(rieH)

cdl

9

I

-=

r- Battery

I

-.:_

T,a

I

I

I

I

-I

L _ _

_ _ _ _ _ _ _ _ _ _ _ _ _

Altemator

E E O 2 9

Fig.

EE-19

Charging circuit

(l )

EE-11


12/32

Engine

Electrical

ystem

Stator

amlature)

oi l

Rotor

(icld)

cojl

t

ALTERNATOR

corsTRucTtol{

- - - - _

_ _ _

- - - - - _ J

Voltage

regulator

'=-

T

_.I_

I

I

I

__-L

'

Q

EEO3O

FE.

EE-20

Chorging cicuit

(

)

Pulley

assembly

Front bearing

Rotor

Rear

bearing

Stator

Brushassembly

Rearcover

Diode

(setplate)

assembly

Diode

cover

Throughbolts

EE345

FE. EE-21 Exploded uieu of alternator

K

q'?-

w

@

@.

b

rrt'

+?

\

3 \

o

I

2

3

5

6

7

8

9

t 0

EE.12


13/32

Engne

Electr ical

ystem

DISASSEMBLY

1.

Remove pulley

nut and

pulley

assembly.

@#

@ o o

Fig. EE-22 Remouing

pulley

ond

fan

2.

Remove

brush

holder

fxmg

screws,

and

remoye

brush

holder

cover.

Pull

brush

holder

orward-

an d

remove

brushes

together

with

brusn

ho lder .

Note:

Do

not

disconnect

N

terminal

from

stator

coil

lead

wire-

6.

Remove

diode

cover ixing

screw

and

remove

diode

cover.

Disconnec

three

stator

coil lead

wires

rom

diode

terminal

with

a soldering

ron.

7.

Remove

A terminal

nut

and diode

installation

nut,

and remove

diode

assembly.

E E 0 3 5

Fig. EE-24

Separcting

ront

couer

uith

rotor

from

rcar

couer

4.

Remove

three

set screws

from

bearing

retainer,

and

separate

rotor

from

front

cover.

r

@ o

Fig.

EE-25

Remouing

rotor

5. Pull

rear

bearing

out

from

rotor

assembly

with

a

press

or bearing

puller.

E

E O 3 7

Fig. EE-26

PuIIing out

of

rear

bearing

fV::\ I

fl/ .'.ry aue

\ l:l--/ A-- \

\ilq

i{

,"+

6n^

li:l*'

D'ode asqembly

-c^

\ j /

Diode cover

'oe

EEo39

FE. EE.27

RemoDing

diode

ossembly

,o

Note:

Do not

apply undue stress

o

diode

assembly

when handling.

INSPECTIOI{

A]{D

REPAIR

Remove alternator

from

car and

connect

a circuit tester

between

F

terminal

and E t erminal.

When resistance

s approximately

5 f ) , b rush

and f ie ld co i l cond i l i on

s

satisfactory. henno

continuityexists

in brush

or f ield coil, or when re-

sistance differs

significantly between

those parts,

disassemble

nd inspect.

E 0 4 0

E

E346

"N"

terminal

Brushholder

Brushholder

cover

Fig, EE-23

Removing

brush

3. Remove through bolts.

Separate

front

cover with rotor from rear cover

with stator

by

lightly tapping

front

bracketwith a woodenmallet.

E

E-i 3

Fig. EE-28

Inspecting alternator


14/32

Engine

Electr ical

ystem

Rotor

inspection

1. Continuity

estof rotor coil.

Apply tester between slip rings of

rotor as

shown

in Figure EE-29. lf

there

is no continuity, rotor coil

(field

coil) is open.

Replace otor assembly.

Fig.

EE-29 Continuity test

of rotor

coil

2. Ground estof rotor coil

Check on t inu i t y e rween

l ip ing

and rotor core,

I f

continuity exists,

replace otor

assembly, ecaus otor

coil or

slip

ing may be

grounded.

Fig. EE-30

Testing rotor coil

for

ground

Inspection

of statol

l .

Cont inu i t y

est

Sta lo r

i s normal

when

there s

continuity

between

ndividual

stator

coil

terminals.

When here

s no contr-

nuity

between

individual

ternrinals,

cable

s broken.

Replace ith statorassernblY.

EEO43

Ftg.EE-31

Testingstator

for

continuity

2.

Ground est

If each lead

wire of

stator

coil

(including

neutralwire)

s not conduc'

t ive with

stator core,

condition

is

satisfactory. lf there is contiluity,

statorcoil s

grounded.

EEO44

Fig.

EE-32

Testingstator

for

ground

Inspection of diode

Perform a continuity

test on diodes

in both directions,using an

ohmmeter.

A

total of six diodes are

used; three

are mounted

on

positive

@

plate, and

the other three are on negative

O

plate.

The continuity

test should

be

performed

on each diode,

between

terminal nd

plate.

Conductive

+

@

I (+) plate

2

(

)

plate

3 Diode

EEO45

Fig.

EE-33

Conducliue

direct ion

of

diode

Diode installed on

@

plate

is a

positive

diode which allows current

flowing from terminal

to

O

plate

only. n other

words, urrent oes ot

flow

from

@

plate

o terminal.

I

(+)

plate

) Terminal

FE. EE-34 Inspecting

positiue

diode

Diode installed on

Q

plate is

a

negative

diode which

allows current

flowing

from

e

phte

to terminal

only. In other words,currentdoes ol

f low from

terminal o

O

plate.

I

( - J

p l a l e

2 Terminal E E O 4 7

Fig. EE-35

Inspecting

negatiue d.iode

lf current

l-Io,.\'s n both

positive

and negative

irections, iode s

short-

circuited. f cunent

flows n one

direc-

t ion

only.

diode s in

good

condition.

If anv diode is

faulty, replace

all

diodes

(six

diodes) as an

assembly.

(See table below.) Thesediodesar e

unserviceable.

E E - 1 4


15/32

EngineElectr ical

ystem

TestDrobe

f a

circuit ester

Conduction

X)

U

o

terminal

@

plate

x

@

plate terminal

terminal

O

plate

Q

plate terminal

X

O

plate

@

plate

X

@

plate

O

plate

lnspection of bruah

Check movement

ofbrush. lf

brush

does not slide smoothly, check brush

holder and clean f necessary.

Check brush

for

wear. If it is

worn

down to less than specified limit,

replacebrush assembly.

Check brush

pE

tail and, if damag-

ed, eplace.

Bru!h

wear imiting

ine

E E 1 2 7

Fig.

EE-36 Bru4oear limit

Spring

pre3sure

test

With

brush projected

approd-

mately 2 mm

(0.079

n) from

brush

holder, measure

rushspring

pressure

by a

springbalance.

Normally,

ated

pressure

f a new

brushspring

s 255

to 345

gt (9.0

o 12.2

oz\.

When

brush s worn,

pressure

e-

creases pproximately

0

gr

(0.7

oz)

per

mm

0.0394

n)

wear.

ASSEMBLY

Reassemblelternatorn the reverse

sequence of disassembly

noting the

following:

l.

When

soldering

each

stator

coil

lead wire to diode assembly erminal,

carry out operation as fast as

possible.

2. When nstalling diode A

terminal,

install nsulatingbush correctly.

EO49

Fig. EE-37 Measuring pring

pressure

3.

Tighten

pulley

nut with t ighten-

ing

torquc of 3.5 to 4.0 kg-nr

25.3

o

19,0

ft ' lb). When pulley

is t ightened.

makesure hat deflectionol V-groove

is ess han0.-? im

(0.01

8 iu).

I

:

+

5

In\uhting bush

' 'A"

tc rmi ia l

bolt

Diodr

cover

Diode rsscnlb lv

E E 3 4 7

Fig. EE-38 Sectional uieu of d,iode

and A terminal

2

mm

(0.079

n)

EE-15

Fig. EE-39 Tightening

puller

nut


16/32

Eng ne Electr ical

ystem

ALTERNATORTEST

Before conducting an alternator

test, make sure that battery is fully

charged.

REGULATOR

DESCRIPTION

The regulator consists asically of a

voltage regulator and a charge relay.

The

voltage regulator

has two sets of

contact points,

a lower

set and

an

uppr set,

to control alternatorvolt-

age.An armatureplate placed

between

the two setsof

contactsmovesupward

or downward

or

vibrates.

The

lower

sontacts,when

closed,complete he

A

30-volt

voltmeter and suitable

test

probes

re

necessary

or this test .

Sel

up

a lest circuit as shown n

Fig. EE-40

Testing

alternotor

f ield

circuit direct to

ground;and

th e

upper contacts, hen

closed, omplete

the field circuit to

ground

through a

resistance

(field

coil), and

produce

alternator utput.

When he upper

contacts reclosed,

charge arning amp

goes

n.

The charge relay is similar in

construction to the voltage regulator.

Figure EE-40

and test

alternator n the

manner indicated in the

flow chart

below:

Notes:

a.

Do not

run engineat

a speed

of

more

han

1.100 pm while

est

s

being

onducted

n alternator.

b, Do not

raceengine.

I Charge

elay

2

VoltaSe

egulatot

EE396

Fig. EE-41

External

uieu of

regulator

1. Discornect onncctors t alternator.

2. Connect

A"

terminal o

"F"

terminal.

3. Connectone test

probe

rom

voltmeter

posit ive

enninal

o

"A"

terlninal.

Connect he other est

probe

o

ground.

Makesure hat _ oltmeter egisters

attery

voltage

4. Turn on headlights nd

switch o High Beam.

5.

Star t

ng ine .

6. Increase ngirre peed

radually

nti l

i t is approxintately ,100 pm, and

take

voltmeter eading.

Measured alue: Over 12.5Volts

Alternator s n

good

condition.

Measured

alue: Below 12.5Volts

Alternator

is

in trouble. Remove

and check.

Voltmeter

E E . 1 6


17/32

EngineElectr ical

ystem

1 Connectingpring

2 Yoke

ga p

3

Armature

4 Core

ga p

5 Low speed

ontact

6

Poirt

ga p

? Highspeed ontact

8 Contacl

et

9 3mnr

0.1

8 iD)dia.screw

l0

4mm

0. 157

n)d i r .

s c rew

I I Coil

l 2

Lock

nut

l3 Adjustingscrew

l4 Adjust ing pring

15 Yoke

I Point

ga p

2 Chargeelay

ontact

3 Core

ga p

5 Connecti 'tg

pring

6

Yoke

ga p

8 Adjust ing pring

EE397

9 Adjust ing

crew

l0 Locknut

I

I Coil

l 2

4mm

0-157

n)d ia .

c rew

l3 3rnm

0.118

n)

dia.screw

14

Contact et

15 Voltage

egulator

ontact

Fig. EE-42

Structurcl uiew

Voltmeter

30V)

Voltage

regula.or

MEASUREMEI{T

Of

REGULATORVOLTIGE

Regulator voltage

s

rneasurecwrth

regulator

assembled with

ahernaror.

When

measuring oltage

wirh

regulator

mounted

on

car, it

is

necessar).

o

rotate

engine

at

high

speed.

Connect

a DC

yoltmerer

(15-30V),

DC

ammeter

(15-30A),

battery

and

0.25Q

resistor

(rated

at

25W)

wirh

cablesas

shown.

l. Check to

be sure hat

all electrical

loads such as lamps,air conditioner.

radioetc.are urned

off.

2.

Beforestartingengine,

sure o

make

short circuit with

a cable

be-

tween fuse

side terminal of

lesistor

(0.25Q)

and negative

ide erminal

of

ammeter. Failure to follow

this pre-

cautionwill causeneedle

of ammeter

to

swingviolently,

esult ing n

a dam-

aged mmeter.

3,

Refer

to the following chart to

determine

if

regulator and relative

parts

are

n

good

condition:

Charge elay

Ammeter

( l 0A )

E E 0 5 5

Fig. EE-43 Measuring regulator

voltage with regulator on

car

Regulator

Resistor

ot measurcment

fuse

ide

eminal

and

)

terminal

of

ammeter)

beforc

EE.17


18/32

Engine

Electr ical

ystem

l.

Startengine.

2. Rotate

ngine t 2,500

pm or

several inutes.

After racing

for

several

minutes,

ammeter

eading-

below5A .

After

racing

or

several

minutes,

ammeter

reading-over

A.

Fully

charged

battery

available.

l.

Replace

ith

fully

charged

attery.

2.

Check

o

see fcurrent

falls

below

54.

Fully

charged

battery

not

available.

l. Connect

a

0,25 ohm

resistor

n series.

Current alls

below5A .

Current

doesnot

fall

below 5A,.

Recharge atteryand see f current allsbelow

5A.

Reduce

enginespeed o

idling and then

raise

r

ro

l._iOO pm while

observing

needle

of voltmeter.

Needle

of

voltmeter

held

within limits

shoiln in rhe

rable

below.

Regulatorunctioningproperly.

Needle

of voltmeter

out of l imits

shown n

the following

chart.

Adjustor replace egulator.

Voltage V

Temperature

oC

(o

F)

- 1 0

( 14 )

0

(32)

r0

s0)

20

(68)

30

86 )

40

104)

T1'peRQ82220B

ftlitsubishi)

speed.

c.

Voltage

may be approximately

0.3

V higher than mted

for two

to

three

minutes after

engine is start-

ed,

or

more specifically,

when regu-

lator

becomesself-heated.

Measure-

ments should

then

be made within

one

minute after

startingengine,or

when regulator

s cold.

d. The regulator

is of a temperature-

compensating

type. Before meas-

uring voltage,

be sure to measure

surrounding

temperatute and cor-

rect measuremenls

ccording

o

the

table

at lef t .

14.75

o l5;15

14.60o 15.60

14.45

o 15.45

14.30

o 15.30

1 4 . 1 5

o 1 5 . 1 5

14.00

o 15.00

14.15a

15.25

14.60o

15.10

14.45o

14.95

14.30o

14.80

14.15o 14.65

14.00o 14.50

Notes:

a. Do not measure

oltage mmediate-

ly after

driving.

Do this

while

regulator

s cold.

b. To

measure

voltage,

aise engine

speed

gradually

rom idling to rated

E E . 1 8


19/32

Engine

Electr ical

ystem

ADJUSTMENT

Voltage regulator

When

regulating voltage,

as meas-

ured above,deviates

rom

ratedvalue,

adjust regulator

n accordance

with

the

following

instructions.

l. Inspect contact surface,and if

rough,

lightly

polish

with fine

emery

paper

(f,500

or

600).

2. Measure

each

gap,

and adjust

if

necessary.

Adjust

core

gap

and

point

gap

in

that order.

No

adjustment s

required or

yoke

gap.

3. Adjusting

ore

gap.

Loosen

screw

[4

mm

(0.157

in )

diameter]

which

is used

to

secure

contact set

on

yoke,

and

move

contact

upward

or downward

properly.

See

Figure

EE-.14.

4.

Adjusting

oint

gap

l,oosen

crew

3

mm

(0.118

n)

diameter]

used o

secure

pper

con-

tact, andmoveuppercontactupward

or downward

snecessary.

eeFigure

EE-45.

5.

Adjusting

voltage

Adjust

regulating

voltage

as

follows:

Loosen

lock

nut

securingadjusting

screw.

Turn

this screw

clockwise

to

increase,

or

counterclockwise

to de-

crease,

egulating

voltage.

Se

Figure

EE-46.

Charge relay

Normal relay

operating

voltage

s

8

to lov

as measured

t

alternator

"A"

terminal.

Relay itself,

however,

operates t

4 to

5 V.

Use a DC voltmeter,

and set up

a

circuitasshown

n FigureEE-47.

Adjust charge elay

in the same

manneras that for voltage

egulato!.

I

2

3

4

Contact

et

Thickness auge

4 mm

(0.157

n)

dia.

scrcw

Crosshead

crewdriver

t

2

3

4

Thickness

auge

3

mm

(0.1l8

n)

dia.

Ciosshead crewdriver

Upper contact

I

Wrench

2

Crossheadscrewdriver

3 Adjustingscrew

4 Locknu t

0.6 o 1-0

mm

(0.0236

o

0.0394 n)

0.7 o

1.3mm

(0.0276

o

0.0512

n)

0.3 o

0.4mm

(0 . 01 l8

o

0 . 0157

n)

0.3 o

0.45mm

(0.0118

o

0.0177

n)

E E , 1 9


20/32

Engine ElectricalSystem

EE4O7

Fig. EE-47 festing charye ela!

EE.2O


21/32

Engine Electfical System

SERVICE

DATA

AND SPEC|fICATIOIIS

Applied

engine

model

Nominal ating

Ground

polarity

Minimum

revolution

under no

load

When

4 voltsareapplieQ

Fn

.....................

Outputcuuent

Pulley atio

Brush

Length

Spring

pressure

Outer

diameterof dip

riq

LTl35. l3B

A10

andAl2

l2-35

Negative

Less

han 1,000

2812,sDO

3sls,000

2.25

More han7.5(0.30)

255 o 345

9.0

o 12.2)

More han30

1.18)

LTl50-12

Al2

for

82l0

(Option)

l2-s0

Negativ

Less han

,000

37

512,5N

s0/s,000

2.25

More han7.5(0.30)

255 o 345

(9.0

o 12.2)

More han30

1.18)

v-A

Regulator

Voltage egulator

Type TLIZ.57

*

14.3o 15.3

at 20oC

68eF)

10.5

t 20oC

68oF)

1 0

3 1

0.6 o 1.0

(0.0236

o 0.0394)

0.3 o 0.4

(0.01

8 to 0.0157)

4.2 o 5.2at

"N "

terminal

37.8 t 20oC

58oF)

0.8 o

l 0

(0.0315

o 0.0394)

0.4 o 0.6

(0.0157

o

0.0236)

+

Standardemperature

RQ8222OB

*

14.3o 15.3

at 20oC

680F)

23.6

at 20oC

680F)

1 0

38

0.7 o 1.3

(0.0276.to

.0512)

0.3 o 0.45

(0.0118

o 0.0177)

4.2 o 5.2at

"N"

terminal

23.6

ar 20oC

680

F)

0.9 o 1.4

(0.03s4

o 0.0ss)

0.7 o l . l

(0.0275

o 0.0433)

gradient

0.015

V/oC

Reguheg tirbF"

Voltage

coil rc6b

Rotorcot@'

resistance

-

:.

Voltage

cf,ll -ri!3

Y

o

resistec

Core

grp

Point grp

Chargeelay

mt(in)

nqGtr)

Release

dte3c

Voltagecoil rci@;

Core

ga!

Point

gap

o

nm

(in)


22/32

Engine

Electr ical

ystem

TROUBLE

DIAGNOSESAND CORRE TIONS

Condition

Probablecause

Corrective

ction

Nooutput

Sticking rushes.

Dirty

brushesand

slip rings.

l.ooseconnectionsor broken leads.

Openstatorwinding.

Open otor

winding.

Opendiodes.

Shorted otor.

Shorted tator.

Grounded

A"

terminal.

Broken an

belt .

Correct

or replace

rushes

nd brush

springs.

Clean.

Retighten r solder onnections.

Replace eads

f necessary.

Repair

or replace

tator.

Replace

otor.

Replace.

Replace

otor.

Repair

or

replace,

Replacensulator.

Replace.

Excessiveutput

Broken neutral wire (color of wire is yellow.)

Voltage

regulator breakdown.

Poor

grounding

of alternator

and voltage

regulator

E"

terminal.

Broken

ground

wire

(color

of wire is

black.)

Replace.

Check regulator

operation

and repair or

replace s e quired.

Retighten erminal

connection.

Replace.

Low

output

Loose

r

worn

an

belt.

Sticking rushes.

Lowbrush pringension.

Voltage egulator reakdown.

Dirtyslip ings.

Partial

short,

ground,

or

open in staror

winding.

Partially

horted r

grounded

otorwinding.

Open r damaged

iode.

Retighten

r

replace.

Corrector replace

rushes nd springsf

necessary.

Replace rush prings.

Check regulator perationand repairor

replaces equired.

Clean.

Replace tator.

Replaceotor.

Replace

iode.

Noisya l te rna tor

Loose

mounting,

Loose

drive

pulley.

Brokenball bearing.

Improperly

eated rushes.

Retighten

olts.

Retighten.

Replace.

Seat orrectly.

EE.22


23/32

Engine

Electrical

System

IGNITION

YSTEM

CONTENTS

EE-23

EE-24

EE.24

EE-24

EE-25

EE.27

ignition

coil, distributor,

spark

plugs Figure

EE-48.

and

connecting

wires, as shown

n

Ignit ion

witch

To

starting

motor

S P A R K

L U G

. . .

. . . . . . .

E E - 2

I N S P E C T I O N

. . . . . . . . . . . . . . . . . .

E E - 2

C L E A N I N GN D B E G A P . . . . . . , . E E . 2

SERVICE

ATAAND SPECIFICATIONS

. . . .

EE-29

TROUBLE

IAGNOSESND

C O R R E C T I O N S

. . . . . . . . .

E E - 3

I G N I T I O N

I R C U I T

t c N t l o N

o t L

. . . : . . . . .

. : : . .

D I S T R I B U T O R

CONSTRUCTION

C H E C K I N G

N DA D J U S T M E N T . . . . . . . . , . .

ASSEMBLY

lcl{lTroN

ctRcutT

The ignition

ckcuit

consists

es"

sentially

of a battery,

ignition

switch,

Model

B21O

and

B12O

kdti@

coil

Secondarywinding

B.eake!

point

Model FlO

Primaty

Ignitior

coil

Secondarywindlng

Bleake.point

(J

L)

To starting

motor

Rotor

head

Spark

plug

Ignition switch

Distlibutor

EE.23

Rotor

head


24/32

EngineElectr ical ystem

tcl{lTloN

coll

The

ignition coil

is an oil-filled

type. The

ignition

coil case s

filled

with oil

which has

good

nsulatingand

heat-radiating

haracteristics.

In

the

ignition coil,

there is a

greater

atio

between

he

primary

and

secondary windings to step uP the

battery

voltage

to a higher

voltage so

as to cause

tronger

sparks

o

jump

the

spark

plug

gap.

The

cap is made

of alkyd

resin

which

offers

increased

nsulation and

high

resistance

o electric arc.

The

ignition coil and

external resis-

tor

should be

handledas a

matched

set.

DISTRIBUTOR

CONSTRUCTION

The distributor consists

of a break-

er

plate

with contact

points,

centrif-

ugal advancemechanism,

acuum con-

troller, distributor shaft

and rotor.

I

High

voltage

erminal

2

Primary

erminal

3

lnsulation

oil

4 Core

nsulating

mateial

5

Coie

6

Pdmary

coil

? Secondary

oil

8

Case

9

Scondary

erminal

E Eutog

FiE. EE-49

Cross-sectional

view of ignition

coil

I

Cap assembly

2

Capclamp

set

3 Dustseal

4

Carbon

point

assembly

5

Rotor

head

6

Contact

set

7

Breaker

plate

8

Earth wire

9

Camset assembly

l0 Governor

weight

I I Govemorspring

l2 Shalt assembly

13

Thrust washer

14 Housing

15

Leadwire

16 Terminal assembly

17 Condenser

ssembly

l8

Vacuum control assembly

19

Fixing

plate

20

Pinion

set

EE 4 1 O

FE. EE-50

Exploded uiea

of dhtributor

@

EE.24


25/32

Engine

Electr ical

ystem

GHECKING

AND

ADJUSTMENT

Gap

and rotor

head

Cap and rotor

head

should

be rn-

spected

periodically

as

specified

n the

"Maintenance

Schedule". Remove

cap

and clean all dust

and carbon

deposits

from cap

and rotor. If

cap is

cracked

or is eaking,

eplace.

Contact

point

Standard

point

gap

is 0.45

to 0.55

mm

(0.0177

o

0.021'7

n). In

case

rze

is off

the

standard,

adjustment

s

made

by loosening

point

screws.

Gap

gauge

is required or adjustment.

When point

surface

s rough,

take

off

any irregularities

with fine

sand

paper

of No. 500

or

600 or with

oil

stone.

When

wear

on contact

points

is

noticeable,

rcplace points

togther

with

contact

arm.

To replace,proceed

as ollows:

Advance

mechanbm3

Advance

characteristics

E E 4 1 1

Fig. EE-52 Adiusting

point

gap

Screw

Adjuster

Primary

ead

ern1inal

Earth

ead

wire

Set screw

Fig.

EE-51 Bresher

First

turn

set screws

out I to

1.5

turns

at contact

arm and primary

lead

wue

connection

just

enough to pull

primary

lead

erminal

out.

Referring

o Figure

EE-51, unscrew

two

contact

set fixing

screws

and

remoye ead

wire.

While holding contact arm by

fingers,

pull

contact

set out

toward

you

by raising

it slightly.

Contact

point

and arm

can then be removed

as

an assembly.

Install

new contact point

and arm

assembly

n

reverse

sequence

of re-

moval.

Coat

cam with

a light coating

of

grease.

Gondenser

Satisfactory

performance

of con-

denser

epends n capacity

nd

degree

of

insulation.

equiring

ttention o

be

sure

that terminals

are

clean and set

screws re ight.

Checking f condensers

madeby

a

condenser

ester.

I

2

3

4

5

20

l 5

l 0

210

{

9 .5-

300 ?.

,W

I

9 1 0

< 5

0

500 1,000

1,500

2,000

2,500 3,000

Distributor

perating

peed

rpm)

r00

150 200

250

300

350

40 0

(3 .94)

(5 .91) (1_87) (9 .84)

(11 .81)

13. r8 )

15 .75

Vacuum

mmHg

inHg)

E E 4 1 2

Fig. EE-53

Aduance characteristics

(Type

D411-89)

2,400

10.5

EE.25


26/32

EngineElectr ical ystem

l )

"9

3

< 5

l )

- t o

5

l 5

< 5

e

x

10.5

s00 r,000 1,s00

2,000 2,500

Distributor

peratingpeed

ryrn)

500 1,000 1,500 2,000

2,500

3,000

Distributor peratingpeed

rpm)

300 7.5

150 200 250 300

3s0

(s .91) (7 .87) (9 .84)

( l

r .8 r )

( l3 .78)

Vacuum mmHg

-inHg)

E E 4 1 3

FE.

EE-'4 Ad.uance harccte.i.stbs

Tfpe

D411'97)

0

100

(3.93)

20

0

27

0 x 9 . 5

3O0x7.5

.W

Vacuum

advance

mechanical

Parts

If

vacuum advancemechanism

ails

to

operate

properly, check for the

following and correct malfunction as

required.

l.

Check

vacuum inlet for signs of

leakage

at connection.

lf necessary,

retighten

or replace.

2. Check

vacuum

diaphragm

or air

leak.

If leak is

found, replace vacuum

control

assembly.

3.

lnspect breaker

plate

for smooth

100

(3.93)

movement.

If

plate

does not move smoothly,

this condition could

be due to sticky

steel

balls or

piyot.

Apply

grease

o

steel balls

or, if necessary, replace

breaker.plateassembly.

Centrifugal advance

mechanical

parts

Whencause f

enginemalfunction

is traced to

centrifugal advance

mechanical

ad,

usedistributor ester

to check ts characteristic.

150

200 250 300

350

40 0

(5 .91) (7 . 87) (9 .84)

( l1 .81)

(13 .78)

r5 .75)

Vacuum -mmHg (-inHg)

EE414

Fig, EE-55

Aduance choracteristbs

Tfpe

D413-67)

See

he

specifications

bove.

When

nothing is wrong with its

characteristic,

conceivable

causesare

break-down,

bnormal

wearof driving

part,

or others-

So

do not disassemble

lt.

In case of improper

characteristic,

remove contact breaker assemblyand

check clmely

cam assembly,

overnor

weight, shaft and

governor

spring,etc,

In case entrifugal

advancemechan-

ical

part

is

.reassembled,

e sure to

check advance characteristic with a

distributor tester.

2,000

l 4

2,O00

12

/

"%

EE.26


27/32

Eng ne

Electrical

System

aq

w

Disassembly

To disassemble,

ollow the

below

procedure.

l. Remove

cap and disconnect

otor

head.

2. Remove vacuum

conttol as-

sembly.

3. Removecontact

set.

E E 0 7 1

Fig.

EE-56 Remouingwcuum control

ossembly

nd contact

set

FE. EE-57

Remouingbreaher

lote

4. When

breaker

plate

is removed,

be

careful not to

lose steel

balls

between

breaker spring

and

breaker

p1ate.

5.

Pull knock

pin

out

and discon-

nect

pinion

to remove

he entire

otat-

ing

parts.

EE 2 0 1

E E 3 2 6

Ftg.EE-59 Remouing

ctation

parts

6.

Remove

packing

from top

of cam

assembly

and

unscrew otor

shaft

set-

screw.

Put match

mark across

am and

shaft so that

original

combination can

be

restored

at

assembly.

Fig. EE-60 Remouing

cam

7. When

governor

weight

and spring

are

disconnected,

be

careful not

to

stretch or

deform

governor

spring.

After disassembling,

pply

grease

o

governor

weights.

ASSEMBLY

To assemble,

everse

rderof

disas-

sembly.

Carefully

observe he

follow-

ing instructions.

l. Align

match marks

so that

parts

are assembled

o their

original

posl-

trons.

2.

Apply

grease

o top

of cam as-

sembly

as required.

3.

Check

operation

of

governor

be -

fore installing

distributor

on engine.

4. Adjust

ignition

timing

after dis-

tributor is

installed

on engine.

SPARK

PLUG

tNSPECTtOl{

The inspection

and

cleaning

should

be

made

every

suitable

maintenance

period.

If necessary,

eplace.

l. Remove

spark plug wire by

pulling

on boot,

not on wire itself.

2. Remove

spark

plugs.

3.

Check electrodes

and

inner

and

outer

porcelains

of

plugs,

noting the

type

of deposits

and the

degree

of

electrode

erosion.

Refer to

Figure

EE-61.

Normal:

Brown

to

grayish-tan

de-

posits

and

slight

electrode wear

indicat

correct

spark

plug

heat

range.

Carbon fouled:

Dry fluffy

carbon

deposits

on the insulator

and

electrode are

usually

caused by

slow speeddriving

in city, weak

ign i l i on .

too

r i ch fue l

m ix tu re ,

dirty

air

cleaner, tc.

It is advisable

o replacewith plugs

having

otterheat ange.

Oil fouled: Wet

black

deposits ndi-

cate excessive

il entrance nto

combustion

hamber hrough

worn

rings

and

pistons

or excessive

lear,

ance

between valve guides

an d

stems. f the same condition re -

mains

after repair,

use a hotter

plu8.

Overheating:

White

or l ight

gray

in -

sulator

with

black or

gray

brown

spots

and bluish

burnt electrodes

indicate

engine

overheating.

ore-

over, the

appearance

esults

from

incorrect ignition

timing,

loose

spark

plugs,

low fuel

pump

pres-

sure, wrong

selection

of fuel,

a

hotter

plug,

etc.

It is advisable

o replacewith ptugs

having

colder heat

range.

Fig. EE-58

Removing

hnoch

pin

EE.27


28/32

Engine

Electr ical

ystem

Normal

Carbon

ouled

Result

ol overheating

Fig, EE-Gl Appearance of

fifing

end

4. After cleaning,

dress

electrodes

with

a small

ine file to

flatten surfaces

of both

cenlerand

side

electrodesn

parallel.

Set spark

pluggap

o specif ic-

atlon.

5. lnstall spark

plugs

and

torque

each

plug

o

1.5 o 2.0 kg-m

1

to 15

ft. lb).

6. Connectsparkplug wires.

Note:

All

spark

plugs installed on an

engine must

be of

the samebrand

and the

samenumber

of heat

range.

CLEANING

AND REGAP

Cleanspark

plugs

n a s and blast

type cleaner.

Avoid excessive lasting.

Clean and

remove carbon or

oxide

deposits, but do not wear away

porcelain.

f deposits

re oo stubborn,

discard

lugs.

After cleaning

spark

plugs, renew

firing

surface of

electrodes with

file

mentioned

above. Then

gap spark

plugs

to

the specif ication

using

a

round wire

feeler

gauge.

Al1

sPark

plugs,

new

or used, should

have he

gap

checked

and

reset

bY bending

electrode.

Fig. EE'62 lleasuring

sparh

plug

gap

park

plug

gap

0.7 o

0. 8

(0.028

o 0.031)

0.8 o 0.9

(0.031

o 0.035)

EE.28


29/32

Engine

Electrical

System

SERVICE

DATA

AND

SPEGIFICATIONS

lgnitaon

coil

Type

Primary

voltage

Sparkgap

Extemal

esistance

Distributor

m m ( i n ) . . . . . . . . .

c6R-205

1 2

More

han

7

(0.2756)

HPs-l3El1

t2

More

han

7

(0.2756)

1.6

Type

Applied

engine

model

1.6

D411-89

Al2

for

Fl0

and 2 l0

t.3-4-2

Counterclockwise

49 to 55

0.45

o 0.55

(0.0177

o

0.0217)

0.50 o

0.65

( l . l

to

1.4)

0.20 o 0.24

5

50

50

12

0.472)

D41)'97

412 for

Bl2O

1-3.4-2

Counterclockwise

49 to

55

0.45

o 0.55

(0.0177

o

0.0217)

0.50

o

0.65

( 1 . 1

o

4 )

0.20 o

0.24

5

50

50

12 (0.472)

D413.67

Al0

for

Fl0

1-3-4-2

Counterclockwise

49 ro

55

0.45

o 0.55

(0.0177

o O.0217)

0.50

o

0.65

(1. I

o

1.4)

0.2Q

o 0.24

5

50

50

12

0.472\

Firing

order

Rotating

direction

Dwell angle

Point gap

Point pressure

Condenser

capacity

Condenser

nsrlatim

rBistance

Cap

insulation

resistem

Qstol

hsld

insrbtim

resistnce

Cap carbongoint

Spark

plug

Model

Applied

engine

model

Gap

Tightening

orque

L46W,

BsES,

RsES

A l0

0.7 o

0.8

0.028

o

0.031)

1.5

o

2.0

11

o 14)

L46PW,

BPsES,

PRsES

At2

0.8 o

0.9

0.031

o

0.035)

1.5

o 2.0

1

to 14)

degree

..........

mm

(in)

..........

ke

0b)

..

.......

mm

(in)

.......

pF

MO

MO

MQ

mn

(in)

........

kg-m

ft-lb)

....

EE.29


30/32

Engine ElectricalSystem

TROUBLE

DIAGNOSESAND

CORREGTIONS

l. Engine

oes ot start.

detaching spark

lug

wire

rom

spark

tween

spark

plug

wire and

spark

plug

If there s no

malfunction

n

fuel

__plug,

starting engine

and

observing

terminal.

After checking

his, ePair s

system,

ignition

system

should

be

condition of

spark that

occurs

be-

necessary,

checked.

his can

be easily

done bY

Condition

Location

Probable

ause Correct ive

ctiorl

No sparks t

al l Distributor

lgnit ion coil

High

tension

cable

Damaged

nsulation

f condenser.

Breakage f lead-wireon low

tensionrside.

Damaged

nsulation fcap and

rotor head.

Point doesnot open

or close.

Wre

breakageor shorl circuit of coil.

Wire coming

off.

Damagednsulation.

Replace.

Repair.

Replace.

Repair.

Replace.

Repair.

Replact.

Spark

ength

t to

2 mm

0.01

to 0.0787

n) or

irregular.

Distributor

Poini

gap

oo wide.

Oilsticking

n point.

Point

urnt

oo

much.

Correct.

Clean.

Replace.

More

han6

mm

(0.2362

n)

Spark

phrgs

Spark

plug

gaP

oo

wide'

Too

much carbon.

Broken

neckof

insulator.

Expiry of

plug ife.

Correct

ol replace.

Clean

or replace.

Replace-

Replace.

EE.30


31/32

Engine

Electrical

System

-

2'

When

engine

otates

ut

does ot

resulting

rom the

gnition

system

nd

tion

of the

gnition

system

hould irs

run smoothly.

other

engin

onditions

ot related

o

be

carried

u1.

In this

case,here

are

many

causes

ignition.

Therefore,

complete

nspec-

Condition

Locat on

Probable

cause

Corrective

ct ion

Clean.

Correct.

Repair

or

replace.

Replace.

Oil

shaft.

Replace

ssembly.

Replace.

Replace

assembly.

Replace

ssembly.

Replace.

Replace.

CIean.

Repair

or replace.

Correct fitting.

Correct

or replace.

Replace.

Replace.

Correct itting.

Replace

ssembly.

Clean.

Correct.

Clean.

Engine isses Distr ibutor

Ignition coil

H[h tension

cord

Spart

ph4s

Drty points.

Improper

ointgap.

Leak

of electricity

rom

capand

otor head.

Damaged

ondensernsulation.

Malfunctioning

rm.

Damaged

rm

spring-

Broken

ead

wire.

Worn

ut or

shaky reaker late.

Worn

out.or

shakydistributor

haft

liyer shortcircuitor nferiorqualitycoil.

Deterioration

f insulation

and

consequent

leak

of electricity.

Fouled.

kak

of

electricity

at upper

porcelain

lnsulator .

Engine krnc*s

very

often

Dtlributor

Spark ph4gs

Improperly

dvanced

iming.

Displaced

r

broken

overnor

pring.

Worn

pin

or hole n

governor

ortion.

Excessively

urnt.

Engine

oes

no t

deliver enough

Ilowcr

Distributor

spark plugs

Improperly

etarded

iming.

Malfunctioningovernor.

Dirty points.

Point ap

oo

narrow.

Fouled.

EE.31


32/32

EngineElectr ical

System

ENGINE

OOLING

YSTEM

F1O

SERIES

ONLY)

FAN MOTOR

Fan motor

specifications are as

follows:

SPECIFICATIONS

Voltage

Wattage

Revolution

w

rpm

12

95

I 1 ( O t o I 6 i O

THERMOMETER

SWITCH

tnsPEcrloN

Carry

out conduction

test as

follows:

l. Submerge

temPerature

sensing

unit of themometer

switch

nto water

as

shown in Figure

EE-63. Gradually

heat

water

to 90oC

(194oF). Never

boil water.

2.

Make

sure that

thermometer

switch

comes

on in

the temperaturc

rang

specified

n the chart.

3. Stop heatingwater and make sure

that

switch

goes

out

outside

specihed

temperature

mnge.

4. Replace

hermometer

switch if it

doesnot function

properly.

SPEClFlcATlol{s

Water emperature

83 to 87oC

181

o 189"F)

79.5

o 80.5oC

175

o 177oF)

Thermometer

witch

Fig. EE-63

Inspecting thermometer switch

service manual a10 & a12 ee

Documents