SERVICIO NACIONAL DE ADIESTRAMIENTO EN TRABAJO INDUSTRIAL

OCUPACIÓN:

ELECTRICISTA AUTOMOTRIZ

MANUAL DE APRENDIZAJE

INGLÉS TÉCNICO PARA

ELECTRICISTA AUTOMOTRIZ

Técnico de Nivel Operativo

 MATERIAL DIDÁCTICO ESCRITO

FAMILIA OCUPACIONAL MECÁNICA AUTOMOTRIZ

OCUPACIÓN ELECTRICISTA AUTOMOTRIZ

NIVEL TÉCNICO OPERATIVO

Con la finalidad de facilitar el aprendizaje en el desarrollo de la formación y capacitación en la

ocupación de ELECTRICISTA AUTOMOTRIZ a nivel nacional y dejando la posibilidad de un
mejoramiento y actualización permanente, se autoriza la APLICACIÓN Y DIFUSIÓN de material
didáctico escrito referido a INGLÉS TÉCNICO PARA ELECTRICISTA AUTOMOTRIZ

Los Directores Zonales y Jefes de Unidades Operativas son los responsables de su difusión y
aplicación oportuna.

DOCUMENTO APROBADO POR EL

GERENTE TÉCNICO DEL SENATI

N° de Página……74

Firma ……………………………………..
Nombre: Jorge Saavedra Gamón

Fecha: ………05 – 02 - 14…………….

 TABLE OF CONTENTS

FOREWORD
UNIT ONE .- ENGINE TUNE UP
Fan – belt inspection
Air cleaner element inspection
Air cleaner precautions
Review

UNIT TWO .- ENGINE TUNE UP

Battery inspection
Review

UNIT THREE .- ENGINE TUNE UP

Spark plug inspection
Gap adjustment
Review

UNIT FOUR .- ENGINE TUNE UP

Distributor inspection
Resistive cord inspection
Review

UNIT FIVE .- CHARGING SYSTEM

Alternator
Review

UNIT SIX .- CHARGING SYSTEM ( Alternator )

Trouble shooting
Review

UNIT SEVEN .- CHARGING SYSTEM ( Alternator )

Inspection in car (Part I )
Review

UNIT EIGHT .- CHARGING SYSTEM ( Alternator )

Inspection in car ( Part II )
Review

2
UNIT NINE .- CHARGING SYSTEM
Alternator regulator
Review

UNIT TEN .- CHARGING SYSTEM

Alternator regulator ( Part II )
Review

UNIT ELEVEN .- CHARGING SYSTEM

Check with the alternator checker
How to use the alternator checker
Review

UNIT TWELVE .- CHARGING SYSTEM

Battery
Review

UNIT THIRTEEN .- STARTING SYSTEM

Starter
Construction
Operation
Specification
Review

UNIT FOURTEEN .- STARTING SYSTEM

Starter ( Part II )
Trouble shooting
Review

UNIT FIFTEEN .- STARTING SYSTEM

Starter ( Part III )
Removal
Review

UNIT SIXTEEN .- STARTING SYSTEM

Starter ( Part IV )
Assembly

UNIT SEVENTEEN .- IGNITION SYSTEM

Distributor
Components
Secional view

3
UNIT EIGHTEEN .- IGNITION SYSTEM
Distributor
Removal
Disassembly
Inspection
Review

UNIT NINETEEN .- IGNITION SYSTEM

Distributor
Assembly
Adjustment and test
Review

UNIT TWENTY .- IGNITION SYSTEM

High tension wires
Spark plugs
Review

4
 FOREWORD

This book is one of a series of texts , intended to introduce students of English as

a foreign language to the terminology of an specific field.

This book serves two purposes: to give the English student an English
introduction to the language of a particular vocational area and to improve his or her use
of this language.

Those who use this Special English Book for careers, should be acquainted with
most of the structural patterns of the language.

Their principal goals should be mastering specialized vocabulary, using the

language patterns in a normal mixture, and improving their ability to communicate
effectively in English.

Much successful language learning comes from interest and experience which is
not altogether conscious. In offering this book it hoped that the students’ involvement in
this career will increase their ability to communicate in this language.

5
 ENGINE TUNE UP
UNIT 1
I.- FAN-BELT INSPECTION

A.- Visual check:

There should be no defects such as listed below:
1.- Look at the list:
a) Cracked
b) Deteriorated,
c) Stretched, or
d) Worn belt.

Note: Do not examine only the outside. Also examine the inside.

Fig 1.- Belt and Pulley inpection

2.- Adherence of oil of grease.
Oil or grease on the belt will cause slipping.
3.- Improper contacting of belt against the pulley. The pulley is driven by the frictional
force will be reduced and the belt will start to slip.
4.- Pulley centers not on same plane.
Unless the pulley centers lie on the same plane, the belt will be twisted and result in
early wear.
5.- Belt tension check and adjustment .
When the belt is pressed down with specified force ( generally about 10 kg ( 22 lb)
force) the belt should deflect the specified amount. If the belt is tensioned too
strongly, early damage in the various bearings will tend to occur. It tensioned too
weakly, slippage will develop.
Tension:
8 - 12 mm ( 0.31 - 10.47”) at 10kg (22lb)

6
 Fig 2.- Cheacking Fan Belt Tension

II- AIR CLEANER ELEMENT INSPECTION

1.- In removig the air cleaner or element, and after removal, use care not to drop dirt
and dust down into carburetor.

2.- In cleaning the element, blow air from the inner side first, then from the outer side,
and finish by blowing again from the inner side.

3.- In case the element is torn or excessively dirty, replace with new element. If the
element should become choked with dirt, the airintake resistance will increase,
causing drop in power output and rise in fuel consumption.

Fig 3.- Air Cleaner Element Cleaning

7
III.- Air cleaner precautions

¾ Check air cleaner to carburetor gasket to see if deformed or damaged.

¾ Make sure that air cleaner case gasket is fitted properly into the groove.
¾ When installing the air cleaner cap, be sure to align the marks.
REVIEW

A.- Mark each of the following statements true or false.

1.- ______ The adherence of oil or grease will not cause slipping.

2.- ______ When you check Fan-belt, there should be defects such as cracked or

deteriorated belt.

3.- ______ In cleaning the element, blow air from the inner side first.

4.- ______ If the element is excessively dirty, you must replace it with new one.

5.- ______ In the precautions, you make sure that air cleaner case gasket is not fitted

properly into the groove.

6.- ______ In the visual check, there should be not improper contacting of belt

against the pulley.

7.- ______ In the air cleaner element inspection at the end of the process, we must

blow again from the inner side.

8.- ______ In the Fan-belt inspection, pulley center should not be on same plane.

9.- ______ The tension in the belt is important to avoid damages.

10.- _____ When you make inspection in the air cleaner to carburetor gasket to see if

deformed or damaged.

8
 ENGINE TUNE UP

UNIT 2
I.- BATTERY INSPECTION

A.- Visual checking

¾ If very dirty, remove and clean before checking.

¾ There should be no defects such as listed below:

1.- Rusted battery mounting hardware.

2.- Damage or leakage in battery.

3.- Loose connection, rusting deterioration, or corrosion of battery to started cable and

battery to ground strap terminals ( both ends).

Note: If the terminals are dirty, wash off the dirt with warm water and polish with
sandpaper.

B.- Fluid level check and replenishment

1.- The head and plug of each cell should be free from cracks and damages, and the
vent hole unclogged.

2.- The fluid level should be up to the upper level. If low, add distilled water ( or
purified water).

Note:
1.- If water is added above the upper level, there will be danger of the
electrolyte overflowing when charging due to the fluid temperature rising
and gases being formed.

2.- Water from wells and city mains contain impurities which if allowed to get
on the battery plates will cause self discharge, resulting in lowering the
battery performance.

9
C.- Specific gravity measurement

After replenishing water, start the engine and charge the battery with alternator
(or generator).
Then measure the specific gravity.

1.- Hold the hydrometer such that the float will not contact against the cylinder wall and
read the graduation by the method shown in Fig. 4

FIG. 4 How to Read Hydrometer

2.- The specific gravity differences between cells should not exceed 0.025.

3.- The electrolyteshould not be turbid.

The electrolyte in a battery after long service and lowered performance will be of
reddish color.

4.- Securely tighten all cell caps.

Electrolyte Specific Gravity and Discharged Amount ( Fluid temp. 20°C)

Specific Gravity Discharged Amount Charging Requirement

Above 1.230 Less than 25% Charging not requiered

1.190 - 1.230 25% Quick charging sufficient

Below 1.190 More than 50% Bench charging requiered

Specific gravity at 20°C ( 70°F) : 1.250 1.260

10
D.- Voltage measurement

1.- When using battery tester.

Set the tester resistance so that the ammeter will show current reading three times
that of battery capacity ( for examples, 120A when battery capacity is 40Ah). After
allowing this current to flow for about 5 seconds, the voltmeter should indicate at
least 9.6V.

Note: Measurement should be made within 5 seconds and not repeated more
times than necessary.

2.- When using voltmeter

After warming up the engine, pull out the ignition cord from the ignition coil, turn on
the headlamps, and turn the engine with the started. The voltmeter at this time
should indicate more 9.6V.

Note: Measurement should be made within 5 seconds and not repeated more
times than necessary.

E.- CHARGING

Charging is performed when specific gravity or voltage measurement shows it to

be necessary.
Note:
¾ In case the battery is to be charged on vehicle, be sure to disconnect the
battery positive terminal because of the danger of high voltage being
impressed on the alternator and damaging the diodes.

¾ Have all cell plugs removed due to formation of gases during charge. Use
extra care to keep open flames away from the battery since the gases

( hydrogen and oxygen) formed are highly flammable.

¾ If the battery electrolyte temperature rises above 45°C while charging, stop
charging and allow the electrolyte to cool down before starting to charge once
more.
If the temperature rises excessively, there will danger of battery becoming
damaged due to internal short.

¾ Before clamping on the terminals after charging, clean the battery posts and
terminals to ensure good contact and then clamp on securely.

¾ When fitting on the terminals, avoid driving them on with hammer.

11
REVIEW

A.- Mark each of the following statements true or false.

1.- _______ To start the visual check in the battery inspection, we must clean the
battery first.

2.- _______ When you check fluid level in a battery the vent holes should be
unclogged.

3.- _______ Water from cities contain impurities that cause in the batteries self
discharge.

4.- _______ In the specific gravity measurement, the specific gravity differences
between cells should not exceed 0.025.

5.- _______ For voltage measurement, the measurement should be mad within 6
seconds.

6.- _______ When you charge the battery, you must disconnect the battery positive
terminal.

7.- _______ About fluid level check, if the fluid level is low, you must add distilled water.

8.- _______ You can measure the voltage using voltmeter.

9.- _______ Before measure the specific gravity you must start the engine and charge
the battery with alternator.

10.- ______ In a standard battery, the fluid level should be up to the upper level.

12
 ENGINE TUNE UP

UNIT 3
I.- SPARK PLUG INSPECTION

A.- REMOVAL

1.- In removing the spark plug, use care not to tilt the plug wrench or allowing it to slip
as there will be danger of damaging the plug insulator.

2.- After removing the spark plug, make sure that the gasket on the cylinder head has
also been removal.

3.- Be careful not to drop dirt or other matter down through the plug hole in the cylinder
head.

Note: If the spark plug had been difficult to remove, examine the threads on both
the spark plug and the cylinder head after removal.
B.- INSTALLATION

1.- First screw the spark plug tightly into the cylinder head by hand, and then tighten
securely with spark plug wrench.

2.- If the cylinder head in made of aluminum alloy, use care not to damage the threads.

3.- If the wok includes distributor inspection, install the spark plug after completing the
inspection and adjustment of the distributor.

C.- VISUAL CHECK

Condition is good if none of the following defects are present:
1.- Cracks or damages in the threads or insulator.

2.- Gas leakage in the clamped part between the insulator and plug housing.

3.- Wear in the electrodes.

4.- Damaged or deteriorated gaskets.

5.- Burnt condition of electrode ans amount of carbon deposit.

13
Determination by burnt (color) condition:
A Ligh Brown ......... Engine condition good, spark plug heat range correct.

B While .................. Engine tends to overheat, air-fuel mixture too lean, spark plug

heat range too low.

C Black ( wet ) .............. Oil entering into combustion chamber (oil rising up

through cylinders or sucked down through cylinder head).

D Black ( dry ) ............. Air-fuel mixture too rich, intake air extremely small,

misfiring, spark plug heat range too high.

D.- CLEANING:

1.- Do not use spark plug cleaner longer than necessary.

Long use of plug cleaner will erode the insulator and electrodes.

2.- Blow off cleaning compound and carbon on the threads thoroughly with air.

3.- Clean off the dirt from the outer surface of insulator.

II.- GAP ADJUSTMENT

Check the plug gap with plug gap gauge. If not to specified value, adjust by bending the
ground (outer) electrode.

Adjustment 0.8 mm ( 0.031”)

Fig. 5.- Adjusting Plug Gap

Note: When using new spark park for replacement, check the gap to make sure
that it is correct.

14
REVIEW

A.- Mark each of the following statements true or false.

1.- _______ When you remove a spark plug, you must be sure the cylinder head has
been removal.

2.- _______ The condition of a spark plug is good when it shows cracks or damages.

3.- _______ The black color of a spark plug means engine tends to over heat.

4.- _______ When you clean a spark plug you can use a spark plug cleaner longer
than necessary.

5.- _______ We use a plug gap gause for cleaning a spark plug.

6.- _______ If a spark plug presents damage, it has a good condition.

7.- _______ For a good condition in a spark plug, we must clean off the dirt from outer
surface of insulator.

8.- _______ We always must check the gap in a new spark park for replacement.

9.- _______ If a spark plug has a ligh brown color, the engine condition is good.

10.- ______ Spark plug inspection include removal, visual check, cleaning and
installation activities.

15
 ENGINE TUNE UP

UNIT 4
I.- DISTRIBUTOR INSPECTION
1.- Clean the distributor cap and the rotor, and inspect for crack, carbon track, and
burnt or corroded terminals.
Replace them if defective.
2.- Clean the breaker points with a point file if necessary, and thoroughly clean after
filing.
If the points are excessively burnt or pitted replace the breaker points, and it is
recommended that the condenser capacity be checked.

Fig. 6 .- Point Alignment

The condenser capacity is within 0.20 - 0.24 microfarad. Adjust the breaker point
gap to 0.4 0.5 mm ( 0.016 - 0.020”), and the dwell angle should be within 50 - 54º.

Fig.- 7.- Adjusting Point Gap

16
3.- Raise the engine speed while observing the timing mark in disconnected vacuum
sensing hose. If advance takes place with rising speed, the distributor governor is
operating properly.
4.- Disconnect the distributor vacuum sensing hoses from vacuum switching valve and
suck hose respectively with mouth while the engine is idling. Check if timing
advances when advance side is sucked and if riming retards when retard side is
sucked.
Replace the distributor if it fails to work properly.

5.- Lubricate the distributor cam lobes, breaker arm rubbing block, arm pivot and the
distributor shaft hollow portion with Molybdenum Grease.

II.- RESISTIVE CORD INSPECTION

A.- Resistance check

Using circuit tester, measure the resistance between the resistive cord terminals.
If resistance measured exceeds the limit, replace the cord as there is open circuit.

Limit 25 K ohm per meter

Standard 16 K ohm per meter

Fig. 8.- Checking Resistive Cord Resistance

Note: While measuring , check the continuity condition of the cord by attaching
the circuit tester lead wires on the cord terminals and shaking the center
part of the cord by hand.
The tester pointer should not fluctuate when the cord is shaken.

17
B.- INSTALLATION

1.- If the cord is loose when inserted , correct with pliers before installing.

2.- Check the primary cord to see that it is installed properly on the distributor and
ignition coil.
REVIEW

A,. Mark each of the following statements true or false.

1.- _______ We must replace the terminals of a distributor if them are defective.

2.- _______ Breaker point gap in a condenser should be 0.8 a 0.9 mm.

3.- _______ We can lubricate the distributor cam lobes with molybdenum grease.

4.- _______ For measuring the resistive cord terminals we use a circuit tester.

5.- _______ We must correct loose cards with a screwdriver.

6.- _______ We can check the continuity condition of the cord using hands.

7.- _______ When you check the resistance in cord terminals, you can replace them if

the resistance measured exceeds the limit.

8.- _______ The first step in distributor inspection is lubricate the distributor cam lobes.

9.- _______ The condenser capacity is within 0.40 a 0.44 microfarad.

10.- ______ In the resistive cord inspection, when the cord is shaken , the tester

pointer should not fluctuate.

18
 CHARGING SYSTEM

UNIT 5
I.- ALTERNATOR

A.- DESCRIPTION

The alternator generates the three-phase alternating current. This three-phase

alternating current is completely rectified into the direct current by the three positive
and three negative rectifiers ( silicone diodes) which are installed within the
rectifier end frame.

Also, as the alternator has a self-limiting characteristic in regulating the maximum

output current, the current limiter is not required. By utilizing the silicone diodes as
rectifiers, the current control such as the cut-out relay is also not required.

Fig. 9.- Alternator Cross Sectional View

19
B.- OPERATION

The alternator generating circuit is as illustrated in figure 13 .

When the ignition switch is closed, the current flows from the battery to the
voltage relay points “Po” and “P1”, through the charge warning light resulting the
charge warning light to glow , and at the same time, the exciting current from the
battery flows to the rotor coil through the fuse, voltage regulator points causing the
rotor to magnetize.
In these conditions when the engine is started and the rotor is rotated, the three-
phase alternating current is generated within the stator coil, and the alternating
current is fully rectified into direct current by the six rectifiers. This direct current
voltage is actuated between the “B” terminal and the “E” terminal.
At the same time, the output voltage of the stator coil neutral point becomes
higher, the pull-in force of the pressure coil in the voltage relay increases, and the
point “Po” contacts the point “P2” side, which results the charge warning light to go
out.
When the alternator output voltage becomes higher than the battery voltage, the
current will flow to the load or into the battery.

Fig.10.- Alternator Generating Circuit

The reserve current flow from the battery to the stator coil is prevented by the
rectifiers.

20
 When the stator coil revolution increases further, the coil has a feature to prevent
the flow of excess current, therefore, it does not require the use of a regulator
incorporated with a cut-out relay and current limiter as for the direct current generator.
Only the voltage should be controlled.

As the generated voltage of the alternator varies in relation with the revolution of
the alternator, a voltage regulator is utilized for necessity not to exceed the alternator
“B” terminal voltage for correct charging of the battery.

When the “B” terminal voltage increases, also the actuated voltage of the
regulator “IG” terminal increases.
Due to this , the points “Plo” opens from the low speed point “PL1” due to the
increase of the pull-in force of the regulator voltage coil.
As the point opens, the exciting current to the rotor has to flow through the
control resistance “Rf” which decreases the current flowing through the rotor coil,
resulting to reduce the output voltage at “B” terminal.
Under light load at high revolution, the point “Plo” contacts the high speed point
“PL2”, and the exciting current is further decreased to control the “B” terminal voltage to
specified voltage.

C.- SPECIFICATION:

Rating voltage 12 volts

Maximum output current 40 amperes

Ground Negative

Direction of revolution Clockwise as seen from pulley

Stator coil connection Three-phase, Y shape

Rectification Full wave rectification by six integral silicone

diodes

Pulley ratio 2.0.......................6R,7R,8R,8R-C model

engines
1.62.....................6R-B,7R-B,8R-C model
engines

No-load characteristic at normal temperature 14.0 volts,zero ampere at 800+-

150 rpm

Load characteristic at normal temperature 14.0 volts,40 amperes at 3,500

rpm

21
REVIEW

A.- Mark each of the following statements true or false.

1.- ______ An alternator produce two – phase alternating current.

2.- _______ When the ignition switch is opened, the current flows from the battery to
the voltage relay poits “P0” and “P1”.

3.- _______ A slip ning is a part of the alternator.

4.- _______ Rectifiers are important because prevent the reverse current flow from
battery to the stator coil.

5.- _______ In a specifications, the rating voltage is about 12 volts.

22
 CHARGING SYSTEM ( Alternator )

UNIT 6

I.- TROUBLE SHOOTING:

1.- Battery discharges

a.- Loose fan belt

b.- Stator coil shorted or opened
c.- Rotor coil opened
d.- Defective contact of brushes and slip rings
e.- Defective alternator rectifier/s
f.- Regulator voltage adjusted too low
g.- Regulator low speed points defective contact
h.- Regulator high speed points melted
i.- Battery electrolyte insufficient or defective
j.- Shorted battery plates
k.- Defective connection of battery terminals
l.- opened or defective connection of wiring between ignition switch and regulator
“IG” terminal
m.- Opened or defective connection of wiring between regulator “F” terminal and
alternator “F” terminal .
n.- Excessive current load
2.- Battery over charges:

a.- Regulator “E” terminal defective ground

b.- Opened pressure coil of voltage regulator
c.- Regulator low speed points melted
d.- Regulator high speed points defective contact
e.- Regulator voltage adjusted too high
f.- Opened or defective connection of wiring between alternator “N” terminal and
regulator “N” terminal

23
3.- Defective actuation of charges warning light :

a.- Loose fan belt

b.- Loose wiring connections
c.- Defective operation of regulator points

4.- Alternator noisy

a.- Defective bearing/s

b.- Mulfunction of rectifier/s
c.- Stator coil grounded or shorted

REVIEW

A.- Mark each of the following statements true or false.

1.- _______ The problems about battery discharges can be caused by loose fan belts.

2.- _______ Battery over charges can be caused by defective alternator rectifiers.

3.- _______ A loose fan belt can cause problems on warning light.

4.- _______ Excessive current load can cause problems with the alternator.

5.- _______ Battery over charges can be caused by loose wiring connections.

6.- _______ Defective actuation of charge warning light can be caused by defective
operation of regulator points.

7.- _______ Alternator noisy can be caused by defective bearings.

8.- _______ Trouble shooting includes the specific gravity measurements.

9.- _______ Battery electrolyte insufficientor defective can cause a battery over
charges.

10.- ______ Regulator voltage adjusted too low can cause battery discharges.

24
 CHARGING SYSTEM ( Alternator )

UNIT 7
INSPECTION IN CAR

PART I:

1.- Precautions for operation with the alternator :

a.- Take care when connecting any test equipment onto the alternator as
the alternator output “B” terminal is connected to the battery at all times, and
if the ignition switch closes, the voltage of the “F” terminal is also the same .

b.- Always pay attention to the polarity of the battery, not to connect it onto the
alternator oppositely.
If connected oppositely, large current flows from the battery to the alternator
so that the rectifiers are damaged, and sometimes the flasher unit will burn
out.

c.- For quick charging the battery , make sure to disconnect the battery to starter
cable . If not, the rectifier will be damaged .

d.- Never rotate the engine at high speed with the “B” terminal lead wire
disconnected .
If disconnected, the voltage regulator cannot operate and the voltage of the
“N” terminal increases abnormally so that the voltage relay burns.
If it is necessary to open the “B” terminal, disconnect the connector plug for
the “F” terminal at the same time .

e.- For adjustment of the regulator, make sure to disconnect the regulator
connector plug.
If not, the points may be melted and the fuse may be burnt.

f.- Never connect a condenser onto the “F” terminal. The regulator points will be
pitted

g.- Take care not to wet the alternator rectifier diodes with water or steam when
washing the car, as this will result in damaging the rectifiers .

25
2.- Pre-check of this inspection

a.-Inspect the installation of the alternator for looseness .

b.- Check the fan belt tension.

c.- Inspect the turn-signal fuse within the fuse block for installing condition and for
burnout .

d.- Inspect the alternator and regulator wirings for connection .

e.- Check the alternator noisy during engine operation.

REVIEW

A.- Mark each of the following statements true or false.

1.- _______ About precautions for operation with the alternator, we must pay attention
to the polarity of the battery.

2.- _______ The first precaution is the adjustment of the regulator.

3.- _______ we must check the fan belt tension in the pre – check in the inspection in a
car.

4.- _______ For quick charging the battery, make sure to connect the battery to starter
cable.

5.- _______ When we washing the car, we must avoid to wet the alternator rectifier
diodes.

6.- _______ The pre – check in the inspection in a car include inspect the alternator
and regulator wirings for connection.

7.- _______ When the rectifier is damaged we can´t do a quick charging the battery.

8.- _______ We must disconnect the regulator connector plug.

9.- _______ In the precaution for operation with the alternator, always must pay
attention to the polarity of the battery.
10.- ______ We must not take care when the connecting any test equipment onto the
alternator.

26
 CHARGING SYSTEM ( Alternator )

UNIT 8
INSPECTION IN CAR
PART II:

(After to read Unit 7 we must continue with this Unit)

3.- Inspection of adjusted voltage and current.

a.- Inspect the operation of the alternator and regulator with an alternator tester.
The test circuit is as illustrated in figure 11.

Fig. 11.- Test Circuit

b.- Start the engine and increase the engine revolution gradually to
600 – 2,000 rpm, and read the “B” terminal voltage which should be 13.8 to
14.8 volts with the current of less than 10 amperes
(See Fig. 12)

Fig. 12.- Adjust Voltage and Current Inspection

27
c.- If the current reading of the tester is over 10 amperes, it indicates following
causes. (See Fig. 13).
• The battery is discharged
• Shorted within the battery

Fig. 13.- Current too high

d.- If the voltage tester needle is not steady, it indicates following causes. (Fig.
14)
• Regulator points dirty or melted
• Defective contact of “F” terminal

Fig. 14.- Voltage Unsteady

28
 e.- If the voltage tester reading is too high, it indicates following causes. (Fig 15)
• Regulator low speed point gap too wide.
• High speed point gap too wide.
• High speed point resistance too high.
• Regulator coil and voltage relay coil opened .
• Regulator “N” terminal and “B” terminal opened .
• Low speed point contact tension too strong.
• Defective ground of regulator.

Fig. 15.- Adjust Voltage Too High

4.-Inspect the voltage between the “F” and “E” terminals in the following procedures.
Stop the engine , disconnect the alternator wiring connection, and utilize only the
ignition switch at closed position. The voltage should be 12 volts. If the voltage of the
voltmeter is zero voltage or low voltage than the specified voltage, it indicates the
following symtoms. (Fig 16 )

Fig. 16.- Voltaje Inspection Between E and F Terminals

29
 • Opened or defective contact of fuse, regulator “IG” terminal wire or “F”
terminal wire.
• Regulator high speed points melted.

5.- Disconnect the regulator connector plug, and check the resistance between the
regulator “IG” and “F” terminals with a circuit tester.
There should be no resistance. If there is any resistance , it indicates that the
voltage regulator low speed points contact poorly. ( Fig. 17 )

Fig. 17.- Checking Resistance Between “ IG” and “ F ”

6.- Perform the load test in the following manner.

a.-Make the same connection as shown in figure 11, and start the engine, and
run it at approximately 1,100 rpm with all lights and accessories turned on.
The ammeter reading should be over 30 amperes with the voltage of 13.8 –
14.8 volts.
If the battery is in fully charged state and the amperage reading is less than
the specified amperage, it is recommended that the battery should be
discharged by rotating the engine with the ignition coil high tension lead
disconnected for about 5 – 10 seconds.

b.- If the ammeter reading is less than 30 amperes , it indicates following

causes. (Fig . 18):

• Opened rectifiers
• Shorted rectifiers
• Stator coil opened or shorted

30
 Fig. 18.- Insufficient Current at Load

7.- Inspection with Auto Radio

Tune in to the near broadcasting station, and adjust the volume.

In this condition , start the engine, and gradually increase the engine revolution
from 600 – 2000 rpm.

If a humming sound is heard from the speaker, the rectifier is shorted or opened (
Fig. 19 ).

Fig. 19.- Rectifier Inspection

31
REVIEW

A.- Mark each of the following statements true or false.

1.- _______ We must revise the operation of the alternator and regulator with an
alternator tester to finish the inspection of adjusted voltage and current.

2.- _______ When you read the current of a tester, if the reading is over 10 amperes,
this is caused by discharged battery.

3.- _______ If the voltage tester reading is too high, it indicates following cause:
shorted within the battery.

4.- _______ To check the resistance between the regulator “IG” and “F” terminals with
a circuit tester, you must connect the regulator connector plug.

5.- _______ If the ammeter reading is less than 30 amperes, it indicates following
cause: opened rectifiers.

6.- _______ The cause “ high speed point gap too wide” is shown as a voltage tester
reading too high.

7.- _______ When the voltage tester needle is not steady, it indicates following cause:
Defective contact of “F” terminal.

8.- _______ When you make a inspection with Auto Radio, if a humming sound is
heard from the speaker, the rectifier is shorted or opened .

9.- _______ When the stator coil is opened or shorted, the ammeter reading is more
than 30 amperes.

10.- ______ Shorted within the battery can cause a current reading tester over 10
amperes.

32
 CHARGING SYSTEM

UNIT 9
ALTERNATOR REGULATOR

A.- Description:

The alternator output varies in relation with the rotor revolution and exciting current
which flows into the rotor. But, as the rotor revolution varies together with the engine
revolution, the alternator output must be adjusted by controlling the exciting current to
the rotor. This exciting current control is automatically done by the alternator regulator.

The alternator regulator consists of two main elements: voltage regulator which perform
the exciting current control above mentioned and voltage relay which regulates the
current to the voltage coil.

B.- Removal

1.- Disconnect the battery to ground cable from the battery.

2.- Disconnect the regulator wiring harness connector plug, and remove the
regulator assembly.

C.-Electrical adjustment

If the alternator regulator does not actuate properly in accordance with the electrical
adjustment, check the resistance of the regulator circuits. If defective, repair the
defective portion, and repeat the electrical adjustment after performing the mechanical
adjustment. Always use a fully charged battery to perform the electrical adjustment.
1.- Voltage Relay

• Make the test circuit as shown in figure 20

• Operate the variable motor, and turn on the switch (S).
• Next, increase the Alternator revolution gradually, and read the voltage relay
operating voltage when the test lamp goes out. This voltage relay operating
voltage should be 4.5 – 5.8 volts.
• If the voltage is not within the specified voltage, adjust it by bending the adjusting
arm of the voltage relay.

33
 Fig. 20.- Voltage Relay Test Circuit

2.- Voltage regulator

• Make the test circuit as shown in figure 21
• Operate the variable motor, and turn on the switch “S”.
• Check the voltage and amperage by varying the alternator revolution
gradually , and note their value at the time when the ammeter needle
registers maximum. Increase the alternator revolution further, and read the
voltage at the time when the ammeter needle registers one-half of
maximum amperage reading.
• Also increase the revolution until it reaches 3,000 rpm, and read the
voltage. The regulated output voltage should be within 13.8 – 14.8 volts
both at one-half of maximum amperage and at 3,000 rpm of alternator
revolution.
• If the voltage is not within the specified voltage, adjust it by bending the
adjusting arm of the voltage regulator.

Fig. 21.- Voltage Regulator Test Circuit

34
REVIEW

A.- Mark each of the following statements true or false.

1.- _______ The kind of alternator varies in relation with the rotor revolution and

exciting current which flows into the rotor.

2.- _______ The principal elements in an alternator regulator are the voltage regulator

and the voltage relay.

3.- _______ The voltage regulator is in charge of exciting current control.

4.- _______ To remove the alternator regulator we must connect the battery to ground

cable from the battery.

5.- _______ If the alternator doesn`t work according with the electrical adjustment, we

must check the resistance of the regulator circuits.

6.- _______ To make the electrical adjustment we must use a fully charged battery.

7.- _______ We must disconnect the regulator wiring harness connector plug for

removing the alternator regulator.

8.- _______ Voltage relay is responsible for regulating the current to the voltage coil.

9.- _______ In the voltage regulator, if the voltage is not within the specified voltage,

we can adjust it by bending the adjusting arm of the voltage regulator.

10.- ______ An alternator regulator we must follow two steps.

35
 CHARGING SYSTEM

UNIT 10
ALTERNATOR REGULATOR - PART II

I.- MECHANICAL ADJUSTMENT

A.- Voltage Relay

1.-Press down the armature, and check the contact spring deflection with the
feeler gauge.
This deflection should be 0.20 – 0.45 mm. (0.008 – 0.018”). If necessary,
adjust it by bending the point holder “P2”.

2.-Check the point gap with the feeler gauge.

This point gap should be 0.4 – 1.2 mm (0.016 – 0.047”) . If necessary, adjust
the gap .

B.- Voltage Regulator

1.-Check the armature gap with the feeler gauge.

This gap should be more than 0.30 mm ( 0.012”).
If necessary, adjust the gap by bending the low speed point holder “PL1”.

2.- Check the point gap with the feeler gauge.This point gap should be
0.25 – 0.45 mm (0.010 – 0.018”). If necessary, adjust the gap by bending the
high speed point holder “PL2”.

3.- Press down the armature, and check the contact spring deflection with the
feeler gauge. This deflection should be 0.2 – 0.6 mm (0.008 – 0.024”).
If not, replace the regulator assembly.

4.- Press down the armature, and check the angle gap with the feeler gauge.
This angle gap should be more than 0.2 mm (over 0.008”).
If not, replace the regulator assembly.

II.- INSTALLATION OF THE ALTERNATOR REGULATOR

Follow the removal procedures in the reverse order.

36
REVIEW

A.- Mark each of the following statements true or false.

1.- _______ To make the mechanical adjustment we must see voltage relay and the

voltage regulator.

2.- _______ To make the installation of the alternator regulator we must follow the

removal procedures in the reverse order.

3.- _______ In the voltage regulator, when you check the armature gap with the feeler

gauge, it should be less than 0.30 mm.

4.- _______ In the voltage regulator, we check the angle gap with the feeler gauge.

5.- _______ In the voltage relay we check the point gap with the feeler gauge.

6.- _______ For checking the angle gap in a voltage regulator, we must press down the

armature.

7.- _______ We also use the feeler gauge to check the contact spring deflection.

8.- _______ In a voltage relay, the point gap should be 0.4 – 1.8 mm.

9.- _______ The mechanical adjustment include to revise the contact spring deflection

and the point gap.

10.- ______ If the angle gap is not more than 0.2 mm, we must replace the regulator

assembly.

37
 CHARGING SYSTEM

UNIT 11
CHECK WITH THE ALTERNATOR CHECKER

I.- CHECK WITH ALTERNATOR CHECKER

1.- Condition of the charging system can be checked with surprising speed.

• Check has been made to allow easy connection into vehicle.

• Anyone can make accurate determination of the condition.

2.- Alternator diodes can be measured to determine if in normal condition, if (+)

diodes are defective, or if (-) diodes are defective.

3.- Generator regulator can be easily checked to see if operating properly.

4.- Test probes have been provided to allow use of 12V , 24V voltmeter and
enable easy checking of open dircuit or other faults in the wiring.

5.- Checked made to allow operation with one hand. Push button switch system
adopted.

II.- HOW TO USE THE ALTERNATOR CHECKER

A.- Pre-Inspection and connections

1.- Check the checker meter needle to see if at zero. If not adjust to zero.

2.- Pull out the alternator and regulator 6-pole connector from the vehicle to be
tested and insert the checker connectors after matching the shapes. ( Fig. 22
).

Fig. 22.- Connecting The Checker

38
B.- Checking Method

1.- Start the engine

2.-Push the checker blue meter switch and the (B) check switch. Speed up the
engine gradually from idling to 2,300 rpm. If the needle stays within the meter
(B) green marks, the condition is good. ( Regulator operation and regulated
voltage are normal).

Standard regulated voltage : 13.8 – 14.8V

Note:
At high speed and high temperature, the voltage may rise higher, but
up to 15.5 V is allowable in such case. (Fig. 23)

Fig. 23.- Checking Regulating Voltage ( B Voltage )

3.- Hold the engine speed at 1,000 – 2,000 rpm and push the (N) check the
switch. If the needle is within the meter (N) blue marks, the condition is good.
( Fig. 24 )

Note:
If the indicated N voltage (neutral voltage) is about one – halt of the B
voltage, the alternator output is normal.

Standard neutral voltage : 6.9 – 7.4 V

Note:
• If more than standard voltage is indicated, the (+) diode is
defective.
• If less than standard voltage is indicated, the (-) diode is defective.

39
 Fig. 24.- Checking Neutral Voltage ( N Voltage )

4.- Push the checker (F) check switch. Speed up the engine gradually from 600
rpm to 2,300 rpm.

If the meter indicated voltage fluctuates by small amounts, changing from

about 12 – 7 V or 4 – 6 V or 1 – 3 V, the regulator operation is good. (
Fig. 25 )

Note:
If the engine is idling at specified speed, the indicated F voltage will
already be unstable at 12 – 7 V.
In such a case, the regulator low speed points are operating normally.

Fig. 25.- Checking Regulator Operation

( F Voltage )

40
REVIEW

A.- Mark each of the following statements true or false.

1.- _______ For checking the condition of the charging system, we can use a surprising

speed.

2.- _______ We can measure alternator diodes to check the condition.

3.- _______ It is very easy to check the generator regulator to see operating.

4.- _______ Before to use the checker, we must check the checker meyter needle.

5.- _______ To use the checker, we must start the engine.

6.- _______ When the needle is within the meter ( N ) blue marks, the condition is bad.

7.- _______ The regulator operation is good if the meter indicate voltage fluctuates by

small amounts.

8.- _______ We must follow four steps in the checking method.

9.- _______ The standard neutral voltage is about 7.0 v.

10.- ______ The standard regulated voltage is about 10 v.

41
 CHARGING SYSTEM

UNIT 12
BATTERY

A.- REMOVAL

1.- Disconnect the battery ground cable first and then started to battery cable.

2.-Remove the battery hold-down clamps and remove the battery.

B.- INSPECTION & ADJUSTMENT

1.- Check the electrolyte level in each cell. Add sufficient electrolyte up to the
level line.
Always use distilled water to replenish the battery.

2.- Check the specific gravity of the electrolyte with a hydrometer. If the specific
gravity reading is below 1.200, and the difference between each cell is more
than 0.025, the battery should be recharged. Electrolyte specific gravity of a
fully charged battery should be 1.250 – 1.270 at 20oC (68oF).

The specific gravity of acid solution to be used as electrolyte, varies

according to its temperatures. It is necessary before adjusting the specific
gravity that it is converted accordingly to standard temperature reading of
20oC (68oF). For conversion of temperature. ( Fig. 26 ).

Fig. 26.- Battery Sp. Gr. Measurement

42
 3.- Precaution before charging

a.- Before charging the battery with a charger, clean the battery terminals,
check the electrolyte level, and replenish with distilled water as
necessary.

b.- Remove all filler caps while charging, and do not allow the battery
electrolyte temperature to rise 45oC (113oF).

c.- Hydrogen and oxygen gases are produced during normal battery
charging operation. This gas mixture can explode if flames or sparks
are brought near the vent opening of the battery.

d.- The sulphuric acid in the battery electrolyte can cause a serious burn if
spilled on the skin or spattered in the eyes. It should be flushed away
with large quantities of clear water.

e.- For quick charge, make sure to disconnect the battery to started cable.
If not disconnected, the alternator rectifier will be damaged.

C.- INSTALLATION

Follow the removal procedures in the reverse order.

43
REVIEW

A.- Mark each of the following statements true or false.

1.- _______ For removing the battery we must disconnect the battery ground cable

first.

2.- _______ We can use the common water for replesnishing the battery.

3.- _______ For checking the specific gravity of the electrolyte we can use a

hydrometer.

4.- _______ We must recharge a battery when the specific gravity is above 1,200.

5.- _______ The specific gravity of acid solution to be used as electrolyte, no change

with the temperature.

6.- _______ Before charging the battery we must not clean the terminals.

7.- _______ For installation a battery we must follow the removal procedures in the

reverse order.

8.- _______ The sulphuric acid is very dangerous for health.

9.- _______ The normal battery charging operation produces oxigen gases.

10.- ______ We must not permit the battery electrolyte temperature to rise 45°C ( 113

°F).

44
 STARTING SYSTEM

UNIT 13
STARTER

A.- CONSTRUCTION

The principal components of the starter consist of the armature, starter clutch,
pinion drive lever, magnetic switch, field coil, drive end frame, yoke, commutator
end frame, brushes.

B.- OPERATION

The figure 27 shows the starter construction and the starter circuit . The following is
the description on the operation of the starter.

Fig. 27.- Starter Circuit

45
 When the starter switch is closed, the battery current flows into the hold – in
coil and also to the armature coil through the pull – in coil, field coil and the brushes.

Then, the moving core is pulled in by the magnetic force of the pull – in coil and
the hold - in coil , and the stater clutch is slided on the armature shaft splines with the
drive lever through the drive spring to engage the starter pinion with the ring gear.
At this time, as the current flow being slight, the rotation of the armature is very
slow, thus the starter pinion meshes with the ring gear smoothly .

When the starter pinion is meshed with the ring gear , the main terminals are
closed by the contact plate , and a large current will flow directly from the battery to the
field coil and the armature.

For this reason , the armature is energized to create a large torque to crank up
the engine.

As the magnetic switch is closed, the current does not flow to the pull – in coil,
and the contact plate is retained at the closed position by the hold – in coil.

As soon as the engine starts , the armature will be rotated by the ring gear ,
causing the clutch to rotate freely to protect the armature from excessive rotation.

When the starter switch is opened, the current does not flow into the hold – in
coil, resulting with no pulling force.

For this reason , the moving core, drive lever and the starter clutch are returned
to the original position by the spring tension.
When the starter clutch returns, the armature brake contact surface contacts the
brush holder and the armature brake is applied.
Then , the armature quickly stops, and becomes ready for the starter re–
operation.
C.- SPECIFICATION:

Motor type Direct current, series wound

Rating voltage 12 volts

Rating output power 1.0 KW ( 1.4PS)

0.9 KW RN12L

Rating time 30 seconds

Direction of revolution Clockwise as seen from pinion side.

Number of pinion teeth 9

46
Number of poles 4

Rotational ratio with crank pulley 9: 115

Suitable battery 40 – 70 Amp.-Hours

No-load characteristics: Voltage at 11volts

Amperage Less than 45 amperes
Revolution More than 6,000 rpm

Locked characteristic: Voltage at 7.0 volts

Amperage Less than 550-amperes
Torque More than 1.4 m-kg (10 ft-lb)

47
REVIEW

A.- Mark each of the following statements true or false.

1.- _______ Brushes is one of the components of the starter.

2.- _______ The battery current flows in the hold – in – coil when the starter switch is

closed.

3.- _______ When the starter switch is opened, the current does not flow into the hold

– in- coil, resulting with no pulling force.

4.- _______ The rating voltage in a starter is 11 volts.

5.- _______ When the starter pinion is meshed with the ring gear, the main terminals

are open by the contact plate.

6.- _______ The spring tension cause the moving core, drive level and the starter

clutch return to the original position.

7.- _______ Inside the specification in a starter, the rating time is 30 seconds.

8.- _______ The biggest part in a starter is the armature according to the circuit picture.

48
 STARTING SYSTEM
UNIT 14
STARTER ( Part II )
A.- TROUBLE SHOOTING
1.- Starter does not turn on turns too slow, and does not crank the engine.

a.- Defective contact of ignition switch contact points.

b.- Defective ignition switch wiring connection.

c.- Defective magnetic switch 50 terminal connection.

d.- Broken wiring between ignition switch to magnetic switch 50 terminal.

e.- Defective ground of battery ground cable.

f.- Defective contact of battery terminals.

g.- Low voltage due to battery discharge.

h.- Insufficient voltage due to defective battery.

i.- Magnetic switch contact plate burnt or defective contact.

j.- Open magnetic switch pull-in coil circuit.

k.- Open magnetic switch hold-in coil circuit.

l.- Defective contact of brushes.

m.- Burnt commutator.

n.- Commutator mica too high.

o.- Shorted field coil.

p.- Shorted armature.

q.- Weak brush spring tension.

r.- Poor soldering of field coil.

s.- Worn bushings.

49
2.- Starter turns, but pinion does not mesh with ring gear.

a.- Starter clutch pinion gear worn.

b.- Starter clutch spins.

c.- Defective starter clutch drive spring

d.- Starter clutch will not turn to over-running side.

e.- Poor movement of clutch on splines.

f.- Worn starter clutch bushing.

g.- Poor starter clutch pinion travel.

h.- Starter drive lever securing bolt lost.

i.- Ring gear worn.

3.- Starter motor keeps running .

a.- Melted magnetic switch contact plate.

b.- Shorted magnetic switch coil.

c.- Ignition switch returns poorly.

50
REVIEW

A.- Mark each of the following statements true or false.

1.- _______ We know three principal trouble shooting in a starter.

2.- _______ Defective contact of ignition switch contact points cause starter turn, but

pinion does not mesh with ring gear.

3.- _______ Melted magnetic switch contact plate cause starter does not turn or turns

too slow.

4.- _______ Starter clutch pinion gear worn cause starter turns, but pinion does not

mesh with ring gear.

5.- _______ Shorted field coil cause starter motor keeps running.

6.- _______ Poor movement of clutch on splines cause motor keeps running.

7.- _______ Shorted armature cause starter does not turn or turns too slow, and does

not crank the engine.

8.- _______ Starter drive lever securing bolt lost cause starter turns, but pinion does

not mesh with ring gear.

9.- _______ Open magnetic switch pull – in – coil circuit cause starter does not turn or

turns too slow.

10.- ______ Ignition switch returns poorly.

51
 STARTING SYSTEM

UNIT 15
STARTER ( Part III )

A.- REMOVAL

1.- Disconnect the battery ground cable from the battery terminal.

2.- Disconnect the battery to starter cable and the starter wires from the magnetic
switch terminals.

3.- Remove the starter retaining nuts, and remove the starter.

II.- DISASSEMBLY

1.- Disconnect the field coil wire from the magnetic switch main terminal.

2.- Remove the two magnetic switch retaining screws and remove the magnetic
switch by moving the switch toward the arrow mark to unhook the moving
stud from the drive lever spring.

3.- Remove the bearing cover, and pull out the armature shaft look plate, plate
washer, seal washer and the brake spring.

4.- Remove the two through bolts, and remove the commutator end frame

5.- Pull out the brushes from the brush holder, and remove the brush holder
from the armature shaft.

6.- Remove the yoke from the drive housing.

7.- Remove the drive lever set bolt, and remove the rubber piece and the plate
from the drive housing.

8.- Remove the armature and the drive lever from the drive housing.

9.- Remove the clutch stopper collar from the armature shaft end, and remove
the starter clutch.
To remove the clutch stopper collar, make a similar tool as shown in the
illustration ( Fig 28 ).

Drive out the clutch stopper collar towards the starter clutch side first using
the tool.

52
Fig. 28.- Removing Starter Clutch

53
REVIEW

A.- Mark each of the following statements true or false.

1.- _______ To remove a starter we must connect the battery ground cable.

2.- _______ First step in disassembly of a starter is remove the two magnetic switch

retaining screws.

3.- _______ To remove the magnetic switch we must move the switch toward the

arrow mark.

4.- _______ To remove the commutator end frame , we must remove the two through

bolts.

5.- _______ To remove the brush holder from the armature shaft we must remove the

bearing cover.

6.- _______ To remove the starter clutch we must remove the clutch stopper collar

from the armature shaft end.

7.- _______ The last step for removing a starter is remove the starter retaining nuts.

8.- _______ We must make nine steps for removing starter.

9.- _______ We take out the yoke from the drive housing.

10.- ______ We use a thin large tool for removing the clutch stopper collar.

54
 STARTING SYSTEM

UNIT 16
STARTER ( Part IV )

A.- ASSEMBLY

Upon assembling, always coat the sliding surface or moving portion of the
armature shaft splines, starter clutch bushing, end frame bushings, drive lever and the
moving stud with multipurpose grease.

1.- Assemble the clutch assembly (2) onto the armature (1).

2.- After installing the clutch stop collar (3) and the snap ring (4) onto the
armature shaft, lock the snap ring by calking the collar at two places. ( Fig.
29 ) .

Fig. 29.- Installing Starter Clutch

3.- Assemble the drive lever (2) onto the clutch (1) as follows.}

a.- Always install the drive lever as shown in the illustration. If the installation
is incorrect, the pinion meshing with the ring gear will be improper.

b.- Always install the steel washer (3) towards the clutch side.

55
 c.- Always apply mulpurpose grease onto the contacting surfaces of the clutch
drive lever, drive lever set bolt and the starter clutch.

4.- Install the armature onto the drive end frame and install the drive lever set
bolt.
Always apply mutipurpose grease onto the drive end frame bushing.

5.- Install the plate and the rubber piece onto the drive housing, then assemble
the yoke onto the drive end frame.

6.- Install the brush holder onto the armature , and install the brushes into the
brush holder.

7.- Install the commutator end frame, then tighten the through bolts. Coat the end
frame bushing with multipurpose grease before installing.

8.- Inspect the thrust clearance of the armature shaft. If the clearance exceeds
0.8 mm (0.03”), use additional washers. The specified clearance should be
0.05-0.35 mm (0.002-0.014”).

9.- Install the seal washer, brake spring, plate washer and the lock plate.

10.- Pack the bearing cover with multipurpose grease, and install it onto the end
frame.
After assembling, turn the pinion in the rotational direction , and confirn that
the pinion rotates smoothly with the armature.

11.-Install the magnetic switch onto the drive housing. Always hook the moving
stud joint onto the drive spring from underneath of the spring as illustrated.
Also inspect the drive lever installed direction.

12.- Check the clearance between the starter clutch pinion and the clutch stopper
collar by rotating the starter without load. This clearance should be 1-4mm
(0.04-0.16”).
If the clearance is not within the specified limit, adjust the moving stud length.

56
REVIEW

A.- Mark each of the following statements true or false.

1.- _______ For assembly a starter, we must follow twelve steps.

2.- _______ We start the assembly putting the clutch assembly onto the armature.

3.- _______ We can lock the snap ring by calking the collar at two places.

4.- _______ We must follow four steps for assembly the drive lever onto the clutch.

5.- _______ We must apply multipurpose grease onto the drive end frame bushing

before installing the armature onto the drive end frame.

6.- _______ At the end of the assembly, we must check the clearance between the

starter clutch pinion and the clutch stopper collar.

7.- _______ When we check the clearance of the armature shaft, if the clearance

exceeds 0.8 mm , we must use additional washers.

8.- _______ After installed the commutator end frame, we must tight the bolts.

57
 IGNITION SYSTEM
UNIT 17
DISTRIBUTOR

I.- DISTRIBUTOR COMPONENT PARTS.- ( FIG. 30 )

1. Clamp, distributor
2. Terminal sudassembly, distributor
3. Condenser, distributor
4. Spring sudassembly, housing cap,B
5. Spring, governor,B
6. Washer,snap
7. Weight,governor
8. Cap, adjuster
9. Washer, rubber
10. Pin
11. Gear,spiral
12. Ring, “O”
13. Housing subassembly, distributor
14. Washer, steel
15. Shaft and plate, governor
16. Spring , governor , B
17. Weight, governor
18. Cam subassembly, distributor
19. Advance subassembly, distributor
20. Plate subassembly, breaker
21. Kit, distributor
22. Wire, earth
23. Spring subassembly, housing cap A
24. Spring, damping
25. Cover, dustproof
26. Rotor subassembly, distributor
27.Cap subassembly, distributor

58
Fig. 30.- Distributor Component Parts

59
II.-DISTRIBUTOR SECTIONAL VIEW ( Fig. 31)

1. Rotor terminal

2. Cam

3. Cap spring

4. Contact point

5. Breaker plate

6. Governor weight

7. Housing

8. Pin

9. Gear

10. Cap

11. Rotor

12. Vacuum advancer

13. Damping spring

14. Condenser

15. Ball bearing

60
Fig. 31.- Distributor Sectional View

61
 IGNITION SYSTEM

UNIT 18

DISTRIBUTOR

I.- REMOVAL

1.-Disconnect the spark plug cords from the spark plugs.

2.- Disconnect the distributor primary cord.
3.- Disconnect the vacuum pipe from the vacuum advancer.
4.- Remove the set bolt and pull out the distributor.

II.- DISASSEMBLY

1. Remove the distributor cap and adjuster cap,

2. Remove the rotor and dustproof cover
3. Remove the distributor breaker arm and contact point.
4. Loosen the vacuum advancer screw and remove the vacuum advancer.
5. Disconnect the distributor terminal and remove the condenser.
6. Remove the cap spring holder set screws (2 screws) and remove the breaker
plate.
7. Remove the governor springs.
8. Remove the screws from the end of governor shaft and plate assembly, and
remove the distributor cam.
9. Remove the snap washers and take off the governor weights.
10. Remove the spiral gear pin and take out spiral gear.
Caution: The pin is peened on both ends. File off the peened part and
remove with a pin punch.
11.Remove the governor shaft and plate
Caution. Keep track of number and size of shims during
disassembly.

62
III.- INSPECTION
Wash and inspect all parts. Repair or replace any parts found defective.

Caution: Do not wash the vacuum advancer diaphragm and condenser in

gasoline or similar solvents.

A.- Cap

Inspect the distributor cap and rotor to see if cracked, damaged, rusted, or
corroded.

B.- Governor shaft

1. Inspect the shaft for wear and for fit with the housing.
2. Inspect the shaft for bending. If bent more than 0.05 mm (0.002”), replace the
shaft.
3. Inspect the governor weight and pin contacting parts and the governor spring
installation parts for damage.
4. Insert the shaft in the housing and after installing the washer and spiral
gear, measure the shaft thrust clearance.

Thrust clearance 0.15 – 0.50 mm

(0.006” – 0.020”)

If the thrust clearance is greater than 0.50 mm (0.020”), select suitable thickness
steel washer when installing the shaft.

Washer thickness 2.5 mm (0.098”)

2.7 mm (0.106”)
2.9 mm (0.114”)

C.- Breaker plate

If the resistance at the breaker plate sliding part exceeds the limit,oil or replace
the plate.

Sliding resistance limit 1kg (2.2 lbs)

63
D.- Others

1. Inspect condition of breaker arm the point.

2. Inspect the cam for wear, damage on cam surface, and fit between cam and
shaft.
3. Inspect the condenser for damage and capacity.
4. Inspect the vacuum advancer diaphragm for damage.
5. Inspect the “O” ring for damage.

64
REVIEW

A.- Mark each of the following statements true or false.

1.- _______ To remove a distributor we must follow four steps.

2.- _______ The first step is disconnect the spark plug cords from the spark plugs.

3.- _______ In the disassembly of a distributor we must remove first the distributor cap

and the adjuster cap.

4.- _______ To remove the vacuum advancer we must loosen the vacuum advancer

screw.

5.- _______ When we remove the governor shaft and plate we must keep track of

number and size of shims during disassembly.

6.- _______ We must not use gasoline or similar solvents with the vacuum advancer

diaphragm and condenser.

7.- _______ In the inspection we must wash the all parts except the vacuum advancer

diaphragm and condenser.

8.- _______ In the inspection we must inspect condition of breaker arm and point.

9.- _______ Another step to remove the distributor is disconnect the distributor primary

cord.

10.- ______ We must disconnect the vacuum pipe from the vacuum advancer.

65
 IGNITION SYSTEM

UNIT 19
DISTRIBUTOR
I.- ASSEMBLY

1. Install the governor weight (2) and snap washer (3) to the governor shaft and
plate (1).

2. Insert the cam (4) over the governor shaft (1) and install the springs (5) . (
Fig. 32 )

Caution : Grease the shaft sliding part and cam inside surface, using
Molybdenum grease.

Fig. 32.- Governor Weight Installation

3. Insert the steel washer (2) over the governor shaft and plate (1), and install
the shaft to housing.

Caution : Oil the shaft before installing.

4.- Install the spiral gear (3) and peen the pin (4).

Caution : Adjust the shaft thrust clearance with steel washer before
peening.
Thrust clearance 0.15 – 0.50 mm
(0.0006” – 0.020”)

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 5.-Install the breaker plate assembly (2) to the housing (1). Install the cap spring
(3), screwing together the earth wire (4) at the terminal side.

Caution:
• Install by fitting the four clips on the breaker plate assembly to
the respective slots in the housing.
• Install the cap spring without the cap position locator to the
terminal side.

6. Install the terminal insulator (7) and bolt, together with the condenser (6)
terminal,and screw on the nut finger-tight.

7. Install the contact poit (5), screwing on together the earth wire (4) at the arm
side.

Caution: Apply a small amount of Molybdenum grease to the sliding

portion and damping spring heel.

8. Install the vacuum advancer (2) to the housing (1) and the screw together the
condensor (4).

9. Set the octane selector to the standard position and install the adjust cap (3).

II.- ADJUSTMENT AND TEST

1. Point Gap

Turn the distributor shaft until the breaker arm heel rides on the highest part of
cam lobe and the point gap is at the widest opening. Check the point gap with
thickness gauge.

Point gap 0.4 - 0.5 mm (0.016” – 0.020”)

Caution: When checking and adjusting the point gap, check damping
spring gap at the same time.
Damping spring gap 0.1 – 0.4 mm
(0.004” – 0.016”)
2.-Breaker Arm Contacting Pressure
Measure the breaker arm tension, using spring tension tester.
Point contact pressure
500 – 700 grams (17.6 – 24.7 oz)
Caution: Pull the breaker arm point at right angle direction and read the
scale gauge just when the points begin to open. If the spring
pressure is lower than specified value, replace the breaker arm
and point.

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 3.- Dwell Angle
Measure the dwell angle with distributor tester.
Adjust Value 50 – 54º
Correct by adjusting the point gap

4.- Condenser Capacity

Measure with distributor tester and replace if outside the specified value.
Standard capacity 0.20 – 0.24 Uf

Caution: Insufficient or excessive capacity will cause the secondary

voltage to drop and result in sparking and burning of contact
points.
Insufficient capacity will cause projections to form on the plus
(arm) side and excessive capacity will cause it to form at the
minus side. ( Fig. 33 )

Fig. 33.- Condenser Capacity

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Purpose of Condenser

The inductance of ignition coil causes spark to form at contact point

when the current is broken and allows the current to continue flowing.
The purpose of the condenser is to absorb this spark suitably and
obtain high secondary voltage. When the spark forms at the instant
the points open, If it was not for the condenser, the breaking of the
ignition coil primary current would be delayed and since the current
would die down slowly, the voltage induced in the secondary side
would be low.

Fig. 34.- Condenser

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REVIEW

A.- Mark each of the following statements true or false.

1.- _______ In the assembly we must oil the shaft before installing.

2.- _______ We must check the point gap with thickness gauge.

3.- _______ The purpose of the condenser is to absorb the spark and obtain high

secondary voltage.

4.- _______ For measuring the breaker arm tension, we use the spring tension tester.

5.- _______ We measure the dwell angel with distributor tester.

6.- _______ In the breaker arm contacting pressure, if the spring pressure is lower than

specified value, we must replace the breaker arm and point.

7.- _______ For assembly of the distributor we must install the governor weights and

snap washer to the governor shaft and plate.

8.- _______ When we install the spiral gear and peen the pin, we must adjust the shaft

thrust clearance with steel washer.

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 IGNITION SYSTEM

UNIT 20
HIGH TENSION WIRES – SPARK PLUGS

I.- HIGH TENSION WIRES

A.-Description

Internal resistance type spark plugs and ignition coil wires are installed on the
engine high tension circuit. These wires are of a radio resistance type which the core is
carbon-impregnated linen.

These are designed to eliminate the high frequency electrical impulses that are
the source of ignition noise interference, but are also superior in resistance to cross-fire.

The resistive wires,however,are most easily damaged by careless handling than

copper cored wires.

For this reason, care must be taken that the wires are removed by pulling on the
wire insulating fittings rather than on the wire insulation .

B.- Removal
To disconnect the high tension wires, pull only on the end insulating fitting.
Do not pull or jerk the wire, because pulling on the wire might cause damage of
the conducting core of the wire.

C.- Inspection

1. Check the resistance value of each wire between both ends. The resistance value
should be less than 25,000 ohms per unit, and if it exceeds the specified value,
replace the wire.

2. Wipe the high tension wires with a cloth moistened with cleaning solvent, and wipe
them to dry. Bend the wires to check for brittle and cracks or loose connection.

3. Check the condition of the wire terminal.

If any terminal is corroded, clean it, and if it is broken or distorted, replace the wire.
Never try to alter the length of the wire, and do not make a sharp bend in the wire.

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D.- Installation

Insert the wire securely as it was installed before, and do not allow the wire to
contact any metal surface.

II.- SPARK PLUGS

A.- Description

The temperature of the electrode portion must be within the specific range called
“Self-Cleaning Temperature” to obtain the engine performances sufficiently.

If the temperature is maintained under 500º C (930º F), such as the engine is
operated for long period in slow speed at part throttle opening, the plug tends to foul
that the insulator tip and the electrodes will become covered with carbon and other
products of combustion, and this will result missing or roughness because of their lower
resistance.

On the other hand, if the temperature exceeds 500º C (930º F), the carbon or
other products is burnt and dispersed. However, it is not necessarily good condition that
the temperature of the electrodes exceed over 500º C (930º F).
If it exceeds 870º C (1,600º F), for instance, the engine is operated for long
period under approximately at full load conditions, the mixture will occur pre-ignition and
detonation, and the engine performances decrease.
It is therefore, advisable to always maintain the temperature of the electrodes
within 500 – 800º C (930 – 1,600º F) by utilizing the proper plug with heat range based
on average driving condition.

B.- Removal

Disconnect the high tension wires from the spark plugs, and remove the spark
plug using the Spark Plug Wrench.

C.-Inspection & Adjustment

Inspect and adjust the spark plug referring to the Engine Tune-up section. (Fig.36
)
Specification
Type NIPPONDENSO W20EP (For all model engines )

NGK BP-6ES (For all model engines)

Plug size & reach 14mm x 19mm (0.551 x 0.748”)
Plug gap 0.7 – 0.8 mm (0.028 – 0.031”)

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 Fig. 36 .- Spark Plug Burned State

Fig. 37.- Point Gap Adjustment

D.-Installation
Follow removal procedures in the reverse order. The specified spark plug
tightening torque is 1.5 – 2.1 m-kg (11 – 15 ft-lb).

73
REVIEW

A.- Mark each of the following statements true or false.

1.- _______ In the high tension wires , in the removal, for disconnecting the high

tension wires, we must pull only on the end insulating fitting.

2.- _______ In the spark plugs, to obtain the engine performance, the temperature

must be within the specific range.

3.- _______ We called testing to obtain the engine performance.

4.- _______ In the inspection, we must not check the resistance value of each wire

between both ends.

5.- _______ We must check the condition of the wire terminal in the inspection of the

high tension wires.

6.- _______ For removing the spark plugs, we must disconnect the high tension wires

from the spark plugs and use the spark plug wrench.

7.- _______ To inspect and adjust the spark plugs, we must not referring to the engine

tune up section.

8.- _______ The temperature of the electrodes exceed over 500°C ( 930 °F) in spark

plugs.

9.- _______ The electrodes will become covered with carbon if the temperature is

maintained under 500°C ( 930°F).

10.- ______ There are three description about spark plug burned state.

74
 PROPIEDAD INTELECTUAL DEL SENATI PROHIBIDA
SU REPRODUCCIÓN Y VENTA SIN LA AUTORIZACIÓN
CORRESPONDIENTE

CÓDIGO DE MATERIAL EDICIÓN

0441 FEBRERO 2005