SECTION

ENGINE
ELECTRICAL
SYSTEM

MODEL
A10& A12
EltGt1{E

. . . ..Et.2
STARTilGSYSTtit
CI|ARGII{G
SYSTEiI. ... . . ..tt-lI
........ .. tt.23
101{lll01{
SYSItlil.
E1{0lllE
C00tll{G
SYSTIl'l
rt-rr
(t10stRtts0ilLY)

-,

lNrssANl
---NISSANIvIOTOR
CO.,[TD.
TOKYO, JAPAN

Engine ElectricalSystem

STARTINGSYSTEM
CONTENTS
S T A R T I \ CC I R C U I T
BATTERY
V I S U A LI N S P F C T I O N . . . , .
INSPECTION
OF BATTERY
FI FCTROLYTT
C t . 1 AC
RI N C
SIABTINGIV]OTOR
,

2
2
2

CONSTRUCTION
. . . . . . E E -4
D I S A S S E |L\ ,YI B
. . . . . . . . E E -5
CLEANING
AND INSPECTION
... EE-5
ASSEI,4BLY
. . . . . . . . . . . E E .1
rlsr....
. . . E E -7
S E R V I C ED A T A A N D S P E C I F I C A T I O N. S
. ... EE-9
T R O U B L ED I A G N O S E A
S N D C O R R E C T I O N.S E E - 1 0

2
4
4

STARTINGCIRCUIT
Ring gear
Shift leverguide
Armature
Battery
Field coil
Stationarycontact
Movablecontact
Shuntcoil
Plunger
Ignition switch
Seriescoil
Torsion spring
Shift lever
Pinion

The starting circuit consistsessentially of a battery, ignition switch,

stading motor and solenoid, as shown
in FigureEE-1.

BATTERY
VISUAL lNSPECTlOltl

J*
t

l. Check for corrodedterminalsor

broken cables. Clean or replace,as
necessary.
2. Checkcasefor cracksor leaks.If
necessary,
replace.
3. Check cell connectorsfor cracks,
and check for missingcell connectors.
Check vents for clogging or leaks.
Cleanor replace,asnecessary.
4. Check for corroded,broken, or
loose fittings. Clean, replace or retighten,asnecessary.
Notes:
a. Always keep battery top and sides
clean and dry to prevent cunent
leak.
b. Keep battery terminals clean.After
connecting cables to terminals, apply a thin coating of vaseline to
battery terminals and top surfaces
of cable terminalsto prevent formation of corrosion.

EE 4 0 1

F i g .E E - 1 Starting circuit

2. If electrolytelerel i: rcunc rr ':e

l o w , a d d d i s t j i l e dr r r : : : l o . ' , - i . . : : i
until ievelrisesto approxinar:;1 10 ro
2 0 m m ( 0 . 3 9 4t o 0 . - S - i n t a r l r i e i o p
of plates.
For a battery\\'ith elecirolrreeuide
l i n e so n i r sw a l l .; h e ; k i L r r e i e .t r o l y r e
levelis betweenupperald lo*er lines.
Note: Do not overf l. Overfilling will
causeloss of electrolvre.resulting
in poor performanceand short life.

INSPECTIONOF
BATTERY ELECTROLYTE

Specif ic gravity
of electrolyte

Electrolyte level

Specificgraviry of battery electrolyte is tested ',vrtha hydrometer.

Observethe follorving:
1. When measuringspecificgravity,
place your eyes in line with scaleto
r e a d r h e h i g h e s rl e v e lo i e l e . t r o l y r e
(electrolyterisesat edgedue to surface
tension).SeeFigureEE-2.

Checkelectrolytelevelin eachbattery cell at leastoncea month.

l . R e m o v es i x v e n t p l u g s a r r d i n spect electrolyte level in each cell.
Level can be quickly determinedby
into cell opening.
Blancing

EE-2

I Thermometer
2 Hydrometer
EEOOl

Fig. EE-2 Checking specific grauit!

Engine ElectricalSystem

r2ro
'?.o

,.?oo

;
>
'S

!.,&
r,ra0
r.r.o
rrro

c-

I
'6

|2lo

Chargingcondition (7o)
EEOO2

Fig. EE-' Relation betueen specific grauity and charging

condition

- 1 0 - 5 0 5 r 0
( - 1 4 ) ( 2 3 ) ( 3 2( )4 1 )( s 0 )(

2. A fully chargedbattery will have

a specificgravity readingof approximately 1.260at an electrolytetemperatureof 20oC(68oF).
Battery must be rechargedor battery acid concentrationmust be adjustedif:
a. Battery chargingcondition is below
60% of its normal capacity, or
b. Specific gravity reading is below
1.200 as conectedto 20oc (68"F).
3. If electrolyte temperatureis above or below 20oc (68oF), additions
or subtractionsof gravity points must
be made in order to obtain a hydrometer reading corrected to the 2OoC
(68oF) standard.
The gravity of electrolyte changes
0.0007 for every loC (33.8oF) temperaturechange.
To obtain specific gravity reading
corrected to 20oC (680F), add or
substract the value determined by
chart (along vertical axis) in Figure
EE-4, for measuredspecificgravity.
Examples:
l) When electrolyte tempenture is
30oC (86oF) and measured
specific gravity is 1.240, specific
gravity correctedto 20oC (68oF)
is deterrninedby:
1.24O+ 0.007= 1.247
2) When electrolyte remperatureis
lOoC (50oF) and measured
specific grayity is 1.240, specific
gravity correctedto 20oC (68oF)
is determinedby:
|.240 - 0.007= 1.233

( 6 8 )( 7 7 ,( 8 6 )( 9 5 X 1 0 4t X
I JJ(122)

EE415
Fig. EE-4 Changes of specific groL)ity in response to electrolyte
temperature change

Electrolyte

freezing

The electrolyte freezing point depends on the acid concentration and

its specific gravity. If specific gravity
of electrolyte falls below 1.200 as
corrected to 20oC (68oF), batter),
must be recharged.

\ote: Since freezing may ruin batter-v.alrra],sbe extremely careful to

piotect battery against freezing by
keeping it in a chargedcondition.

n /1)\

W.N-

_ln/141

C)

-30e22)

I
E
i

-4ot 4ol

-50(-58)

-60( 76)

,a

7 0/ - 9 4 l

%A

lt

{tt

-Rnr- |1)l

1 . 0 01 . 0 41 . 0 81 . 1 2L l 6 1 . 2 0t . 2 4 1 . 2 8t . 3 2

EEOO4

S p e c i f i c g r a v i t y o f c l e c t r o l yl e
Fig. EE-s

EE-3

Freezing poinl of eleclrolyle

Engine ElectricalSystem
CHARGING
If electrolyte level is satisfactory,
battery must be chargedwhen electrolyte gravity reading falls below 1.200
correctedto 20oc (68oF). If battery
still mounted on car is quick-charged
to bring it up to full charge, the
operation should be carriedout with
negativecableremoved.
Prior to charging,corroded battry
terminals should be cleaned with a
brush and common baking-sodasolu-

tion. [n addition, the following should

be observedwhile ballery is being
charged:
l.
B e s u r e t h a t e l e c l r o l y t el e v e l i s
abovetop of eachplate.
2. Keep removed plugs in a safe
place.
3. Do nol alJowelectrolytetempera.
ture to 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 sprayedelectrolyte
off upperfaceof battery.
Caution: Keep battery away from
open flame while it is being charged.

STARTINGMOTOR
coNsrRucrtol{

v{

I.
I
2
3
4
5
6
7
8
9
l0
II
l2
13

Magneticswitchassembly
Dustcover(adjusting
washef)
Torsionspring
Shift lever
Dustcover
Dustcover(packing)
E ri ng
Thrustwasher
Rerr covermetal
Throughbolt
Rearcover
Brushholder assenrbly
Brush(-)

14
15
l6
l7
l8
t9
20
2l
22
23
24
25

Brushsprins
Brush(+)
Yoke
l;ield coil xssemblt
Arm|ture assemblY
Centerplate
Pinion assembly
Pinionstopper
Dustcover
Stopperclip
Gelr clrse
Gearcxsemetal

,a\

f\9

,ht^l

e(/d

1T

Fig. EE-6 Exploded oiew of starting notor

EE.4

Engine ElectricaI SVStem

DISASSEMBLY

Testingfield coil for

continuity:

l.
Disconnectconnectingplate from
"M"
terminal of magnetic switch.
Removetwo screwssecuringmagnetic
switch and remove magnetic switch
assembly.
2. Remove dust cover, E-ring and
thrustwasher(s).

^ffi?
@

n-fi

I
2
3
4

Dustcover
Packing
E ring
Thrustwasher

Pinionstopper

Fig. EE-8 RemoL'ihg pinion stopper

\((

6 d J

Connectprobe of a circuit testeror

an ohmmeter to field coil positive
terminaland positivebrushholder.
If testershowsno continuity, field
circuit or coil is open.

Testing field coil for ground:

Place one probe of circuit tester
onto yoke and other onto field coil
lead(positiveterminal).
If very little resistanceis read, field
coil is grounded.

\?,/

CLEANINGAND
INSPECTION
EE4O2

Fig. EE-7 Remouingdust couer,

E-ring and thrust uasherlsl

3. Remove two through bolts and

rearcovet.
4. Remove brushes from their
holders by moving each brush spring
away from brush with a hook. Remove
brushholder.
5. Removeyoke assemblyandwithdraw armature assembly and shift
lever.
6. Remove pinion stopper located at
end of armature shaft. To remove
stopper, first move stopper toward
p i n i o na n da f r e rr e m o v i n sgr o p p ecr l i p .
remove stopper with overrunning
clutch assemblyfrom armature shaft.

Cleanall disassembled
parts,but do
not use greasedissolving solvents for
cleaningoverrunningclutch, armature
assembly,magnetic switch assemoly
and field coils since such a solvent
would dissolvegreasepackedin clutch
mechanismand would damagecoilsor
other insulators.
Check them for excessivedanage
or wear,and replaceif necessary.

EEO17
FiE. EE-10 Testing field coil
for ground

Terminal
Check terminal for damage and
wear, and replace magnetic switch
assemblyif necessary.
Field coil

Brushes and brush

Check field coil for insulation. [f

insulation of coil is damagedor worn
it should be replaced.

Check surfacecondition of brush

cLrnractand rvearof brush.If a loose
crrntactis lbund, it shouldbe replaced.
If brush is worn so that its lengthis
lessthan 12 mm(0.472 in), replace.
Check connectionof lead clip and
leadwire.
Check brush holders and spring clip
to see if they are not deformed or
bent, and will properly hold brushes
againstcommutator.
If brushes or brush holders are
dirty, they shouldbe cleaned.
Brush spring

EEO16

FE. EB-g Testingfietd coit for continuity

EE-5

lead wire

tension

Check brush spring tension by a

springscaleas shownin FigureEE-l l.
Readingshould be 1.4 to 1.8 kg (3.1
to 4.0 1b). Replacespring il tension is
lower than the specification.

EngineElectricalSystem
4. Checkarmaturefor shortby placing it on armaturetester (growler)
with a piece of iron over armature
core, rotating armature. If plate
vibrates,armatureis shorted.

Metal plate

EEOlA

Fig. EE-11 Inspecting brushspring tension

EE403
FE, EE-14 Testing artnoture for

5. Checkarmaturefor continuityby
placingprobesof testeron two segmentssideby side.If testgrshowsno
continuity,circuitis open.

0.5 to 0.8 rnm

( 0 . 0 1 9 7l o 0 0 3 1 5i n )

Overrunnlng clutch assembly

Incorrect
EE 0 2 I

Fig, EE-12

Armatura

Undercutting

insulating

mi.a

lnspectpinionassembly
andscrew
sleeve.
Screwsleevemustslidefreely
along armature shaft splines. [f
danrage
is found or resistance
is felt
* h e n s l i d i n g .i t n r u s tb e r e p a i r e d ,
I n s p 3 . pt i n i o nt e e t hI.f e x c e s s irvueb bing is .found on teeth, replace.
F l l * ! r - ' e - r r q s e a rr l s o m u s tb e i n spected

assembly

Checkexternalappearance
of armature and commutator.
1. Inspectcommutator.[f commutator surfaceis rough,it must be sanded
lightly with a No. 500 emery cloth. If
depth of insulatingmica is lessthan
0.2 mm (0.0079 in) from commutator
surface,insulating mica should also be
undercutso that its depthis 0.5 to 0.8
m m ( 0 . 0 1 9 7t o 0 . 0 3 1 5i n ) .
Wearlimit of commutatordiameter
is 2 mm (0.0787 in). If diameterof
commutatoris lessthan 3l mm (l.22
in), replacearmatureassembly.
2. Inspect soldered connection of
armature lead and commutator- If
loose connection is found, solder it
usingrosinflux.

3.

Armaturetest for ground

Usinga circuit tester,placeone test
probe onto armatureshalt and other
onto eachcommutatorbar.
lf tester shows continuity, armature is groundedand nrustbe replaced.

I
l

Pinion 5!eErbll
Pinion iropDer
Cli!

Ee404

FE. EE'15 Overrunning

clutch
assembl!

Brush holder t3t tor grosnd

Fig. EE-t3

Testing armature for ground

EE.6

L singa circuit tester,placeone test

probe onto negativeside ol brush
holderand anotheronto positiveside.
If tester shows continuity, brush
holder is shortedto ground. Replace
brushholder,

Engine ElectricalSystem
Bcarlng metal
Inspectbearingmetal for wear or
sideplay. Replace
metalif required.

Magnetic awitch assembly

1. Usinga circuittester,checkcontinuity between"S" terminal of magnetic switchand switchbody metal.If
continuitydoesnot exist,shuntcoil is
open.Replaceswitchassembly.
2. In the samemanneras above,
check continuity between terminals
"S" and "M". If continuity does
not
exist, sries coil is open. Replace
switchassembly.

ASSEMBLY
Reassemblesta ing motor in reversesequenceof disassembly,
When assembling,be 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
performancewill be satisfactorywhen
installed on engine. Starting motor
should also be subjectedto test when
causeof abnormal opention is to be
determined. A brief outline ofthe test
is given below.
No-load test

E E.rO5

Fig. EE-17 Circuit of no-lood test

Connect starting motor in setes

with specified battety (12 volts) and
an ammeter capable of indicaLing
1,000 amperes.
Specified current draw and revolution in these tests, are shown in
ServiceData and Specifications.

J
L

EE-7

tl ! ,/

ll

EngineElectricalSystem
Test diagnosis
Probablecause

Condition
Low speedwith no-load and high current draw.

Tight, dirty or worn bearings.

Bent armatureshaft or loose field probe.
a Shortedarmature.
a A groundedarmalureor field coil.
t
t

Failureto operatewith high currentdraw.

a A groundedor openfield coil.

t Armature coil doesnot operate.
a Burnedout commutalorbar.

l.oose connections,damfred lead or dirty commutator.

low current draw and low noload speed.

High speedwith no-load and high current dravt.

Shorted field coil.

Starting motor does not operate and current does not

draw.

o
.
.
r

Shorted armatureand field coil.

Shorted brush leads.
Dity commutator.
Failure of brush-to-commutatorcontact.

ilagnetic switch
assembly test
Test magneticswitch assemblyafter
performancetest.
l.
Connect starting motor in series
with battery and switch as shown in
FigureEE-l8.
2. Make sure that pinion assemblyis
quickly pushed out by meansof magnetic switch when switch (describedin
"ON".
step I above)is turned
3. With switch on, push pinion back
to remove all slack and measure the
",L"
elearance
between pinion ftont
edgeand pinion stopper.The clearance
should be held within 0.3 to 1.5 mm
(0.012 to 0.059 in). SeeFigureEE-18.
If necessary,adjust it by changingor
adding adjusting washer(s).Adjusting
washers are available into two different sizes,0.5 mm (0:020 in) and 0.8
mm (0.032 in). '''

Startingmotor

0.3 ro 1.5mm
(0.012to 0.059in)
EE4O6

FE. EE-18 Circurt of magneticsuitch o'Femblytest

EE-8

Engine.rElectrica,l:.System

Starting, motor
Type.....................
annlierr ennine mnzr"r

s 11 4 . 1 6 1

sr14163

Al2 for B2l0

A10andAl2

andBl20

for F l0

Al2 for B2l0

(Option)

Sl14-160
'

Systemvoltage

12

No-load:
Current

Lessthan60

Revolution

Morethan7,000

Terminalvoltage

12

Magneticswitch
Sedescoil resistance

0.324

Shunt coil resistance

0.694

Gapbetweenpinion
andpinionstopper

mm (in)

0.3to 1.5(0.012to 0.059)

Outerdiameterof cornmutatorrnm (in)

':
- ..
Brushlength
mn (in)
Brushspringtension

Morethan3l (1.22)
Morethan 12 (0.47)

kcb)

1 . 4t o 1 . 8( 3 . 1t o 4 . 0 )

EE-9

.:5YfslF

Engine ElectricalSystem

TROUBLE DIAGNOSESAl{D CORRECTIOI{S

Condition

Startingmotorwill not
operate.

Noisystarting
motor.

Startingmotor
cranksslowly.

Startingmotor
operates
but doesnot
crankengine.

Sta ing motor will

not disengage
when
ignitionswitchis
turnedoff.

Probablecause

Correctiveactlon

Discharged
battery.

Chargeor replace.

Brokenmagneticswitch.

Repairor replace.

Loosetrminalconnections.

Cleanandtightentermlnal.

Wornbrushes.

Replace.

Inoperative
startingmotor.

Removeand test.

Loosesecuring
bolt.

Tighten.

Wornpiniongear.

Replace.

Poorlubrication.

Add oil.

Worncommutator.

Disassemble
motor.

Wornbrushes.

KePlace.

Discharged
battery.

Chargeor replace.

lrose terminalconnection.

Cleanand tighten.

Wornbrushes.

Replace.

Lockedbrushes.

Inspectbrushspringtensionor repairbruslr
holder.

Dirty worn commutator.

Cleanandrepair.

Armaturerubsfield coil.

Replaceasembly.

Brokenmagneticswitch.

Repairor replace.

Wom pinion.

Replace.

Lockedpinionguide.

Repair-

Wornringgear.

Replace.

Brokenmagneticswitch.

Repairor replace.

Brokengearteeth.

Replacebrokengear.

EE-10

EngineElectricalSystem

CHARGING
SYSTEM
CONTENTS
EE-il
EE.12
EE.12
EE-12
EE-12'
EE.15
EE-16
EE-16

C O N S T R U C T I.O
. .N
DISASSEVBLY
I N S P E C T I OANN D RE P AI B
ASSEN,IBLY........
A L T E R N A T O RT E S T

DESCRIPTION
E E .6
i
I\iIEASU
REI\4ENTOF REGULATOR
VOLTAGE
EE-]7
ADJUSTMENT
E E , 9]
SERVICE
D A T A A N D S P E C I F I C A T I O. N
. .S
. . EE.21
T R O U B L ED I A G N O S EASN D
COBBECTIONS
EE-22

CHARGINGCIRGUIT
The chargingcircuit consistsof the
battery, alternator, regulator and
necesgfy wiring to connect these
pans. The function of this systemis to
convert mechanical energy from the

T--------

engineinto electricalenergywhich is
usedto operateall electricalunitsand
to keepthe batteryfully charged.
Figure EE-19 shows a charging
circuit when ignition $/itch is turned

to "ON". Figure EE-20showswhat

happenswhen alternatorspeedis increasedor voltagestartsto riseexcessively.

- -----

Stator (almatulei coil

-=

r- Battery
I

-.:_

T,a

Roro. (rieH) cdl

I
II

L__ _ ___ _ ____

Altemator

I
-I

____

VoltagereBulator
EEO29
Fig. EE-19

EE-11

Charging circuit

(l)

EngineElectricalSystem

Stator(amlature)coil

'=T

'

_.I_

Rotor (icld) cojl

- -

--_

___

----

I
I
I
__-L

-_J

Voltage regulator
EEO3O

FE. EE-20 Chorging cicuit ( )

ALTERNATOR
corsTRucTtol{

@.

q'?-

rrt'

+?
c \

3 \

wK
@

I
2
3
5
6
7
8
9
t0

Pulley assembly
Front bearing
Rotor
Rear bearing
Stator
Brush assembly
Rearcover
Diode (set plate) assembly
Diode cover
Throughbolts
EE345

FE. EE-21 Exploded uieu of alternator

EE.12

Engine ElectricalSystem
DISASSEMBLY

6. Remove diode cover fixing screw,

and remove diode cover. Disconnect
three stator coil lead wires from diode
terminal with a solderingiron.
7. RemoveA terminalnut and diode
installation nut, and remove diode
assembly.

1. Remove pulley nut and pulley

assembly.

@#

EE035

Fig. EE-24 Separctingfront couer

uith rotor from rcar couer

@oo
Fig. EE-22 Remouing pulley ond fan

4. Remove three set screws from

bearing retainer, and separate rotor
from front cover.

fV::\

A--

fl/ .'.ry \ aue

l:l--/

\ilq

FE. EE.27

2. Remove brush holder fxmg

screws, and remoye brush holder
cover. Pull brush holder forward-and
remove brushes together with brusn
holder.
Note: Do not disconnect N terminal
from stator coil lead wire-

'oe

li:l*'
\j/

EEo39

RemoDing diode ossembly

Note: Do not apply undue stressto

diode assemblywhen handling.

r @o
Fig. EE-25 Remouing rotor

5. Pull rear bearingout from rotor

assembly with a press or bearing
puller.

,o
"N" terminal
Brushholder
Brush holder cover

i{" ,"+

6n^
-c^

D'ode asqembly
Diode cover

INSPECTIOI{A]{D
REPAIR
Remove alternator from car and
connect a circuit tester between F
terminaland E terminal.
When resistanceis approximately
5 f ) , b r u s ha n d f i e l d c o i l c o n d i l i o ni s
satisfactory.
Whenno continuityexists
in brush or field coil, or when resistance differs significantly between
those parts, disassemble
and inspect.

E E346

EE O 3 7

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.

E040

Fig. EE-26 PuIIing out of rear bearing

EE-i 3

Fig. EE-28 Inspecting alternator

EngineElectricalSystem
Rotor inspection

2.

Continuitytestof 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.
Replacerotor assembly.
1.

Groundtest
If each lead wire of stator coil
(includingneutralwire) is not conduc'
tive with stator core, condition is
satisfactory. lf there is contiluity,
statorcoil is grounded.

I (+) plate
) Terminal
FE. EE-34 Inspecting positiue diode

EEO44

Fig. EE-29 Continuity test of rotor

coil
Groundtest of rotor coil
C h e c kc o n t i n u i t yb e r w e e ns l i p r i n g
and rotor core, If continuity exists,
replacerotor assembly,becausrotor
coil or slip ring may be grounded.

Fig. EE-32 Testingstator for

ground

2.

lr

I
i

Inspection

of diode

Diode installed on Q plate is a

negative diode which allows current
flowing from e
phte to terminal
only. In other words,currentdoesnol
flow from terminalto O plate.

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
terminaland plate.
I (-J plale
2 Terminal

Fig. EE-30 Testing rotor coil for

ground

Inspection

of statol

C o n t i n u i t yt e s t
Stalor is normal when there is
continuity between individual stator
coil terminals.When there is no contrnuity between individual ternrinals,
cableis broken.
Replacewith statorassernblY.

Fig. EE-35 Inspecting negatiue d.iode

Conductive

+
lf current l-Io,.\'sin both positive
and negativedirections,diode is shortcircuited.If cunent flows in one direction only. diode is in good condition.
If anv diode is faulty, replace all
diodes (six diodes) as an assembly.
(See table below.) These diodes are
unserviceable.

l.

@
I (+) plate
2 ( ) plate
3 Diode
EEO45
Fig. EE-33 Conducliue direction
of diode

EEO43

Ftg. EE-31 Testingstator for

continuity

EEO47

Diode installed on @ plate is a

positive diode which allows current
flowing from terminal to O plate
only.In otherwords,currentdoesnot
flow from @ plateto terminal.
EE-14

EngineElectricalSystem
TestDrobeof a circuit tester

lnspection

Conduction(X)

terminal

@ plate

@ plate

terminal

terminal

O plate

Q plate

terminal

O plate

@ plate

@ plate

O plate

ASSEMBLY

2 mm (0.079in)

of bruah

Check movement ofbrush. lf brush

does not slide smoothly, check brush
holder and cleanif necessary.
Check brush for wear. If it is worn
down to less than specified limit,
replacebrush assembly.
Check brush pE tail and, if damaged, replace.

EEO49

Reassemble
alternatorin the reverse
sequence of disassemblynoting the
following:
When soldering each stator coil
l.
lead wire to diode assemblyterminal,
carry out operation as fast aspossible.
2. When installing diode A terminal,
install insulatingbush correctly.

Fig. EE-37 Measuringspringpressure

Bru!hwearlimitingline

:
+
5

EE127

Fig. EE-36 Bru4oear

limit

Spring pre3sure test

With brush projected approdmately 2 mm (0.079 in) from brush
holder, measurebrushspringpressure
by a springbalance.Normally,rated
pressureof a new brushspringis 255
to 345gt (9.0 to 12.2oz\.
Whenbrush is worn, pressuredecreasesapproximately20 gr (0.7 oz)
per I mm (0.0394in) wear.

In\uhting bush
''A"
tcrmiial bolt
Diodr cover
D i o d e r s s c n l b l' v

EE347

Fig. EE-38 Sectional uieu of d,iode and A terminal

3. Tighten pulley nut with tightening torquc of 3.5 to 4.0 kg-nr(25.3 to

19,0 ft'lb). When pulley is tightened.
make sure that deflectionol V-groove
is lessthan0.-?nim (0.01l8 iu).

Fig. EE-39 Tighteningpuller nut

EE-15

Engine ElectricalSystem
ALTERNATORTEST
Before conducting an alternator
test, make sure that battery is fully
charged.

A 30-volt voltmeter and suitable

test probesare necessary
for this test.
Sel up a lest circuit as shown in

Figure EE-40 and test alternator in the

manner indicated in the flow chart
below:

1. Discornectconncctorsat alternator.
2. Connect"A" terminalto "F" terminal.
3. Connectone testprobefrom voltmeterpositivetenninalto "A" terlninal.Connectthe other testprobeto ground.
Makesurethat_voltmeterregisters
batteryvoltage
4. Turn on headlightsand switchto High Beam.
5 . S t a r te n g i n e .
6. Increaseengirrespeedgraduallyuntil it is approxintately1,100rpm, and takevoltmeterreading.

Measuredvalue: Below 12.5Volts

Alternator is in trouble. Removeand check.

Measuredvalue: Over 12.5Volts

Alternatoris in good condition.

Notes:
a. Do not run engineat a speedof
more than 1.100rpm while test is
beingconductedon alternator.
b, Do not raceengine.

Voltmeter
Fig. EE-40 Testing alternotor

REGULATOR
DESCRIPTION
The regulator consistsbasically 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 alternatorvoltage.An armature plate placed between
the two setsof contacts movesupward
or downward or vibrates. The lower
sontacts,when closed,complete the

field circuit direct to ground;and the

upper contacts,when closed,complete
the field circuit to ground through a
resistance (field coil), and produce
alternatoroutput.
Whenthe upper contactsare closed,
chargewarninglamp goeson.
The charge relay is similar in
construction to the voltage regulator.

I Chargerelay
2 VoltaSeregulatot

EE396

Fig. EE-41 External uieu of regulator

EE.16

EngineElectricalSystem

EE397
1
2
3
4
5
6
?
8

Connecting
spring
Yoke gap
Armature
Coregap
Low speedcontact
Poirt gap
High speedcontact
Contaclset

9
l0
II
l2
l3
l4
15

3mnr(0.1l8 iD)dia.screw
4 m m ( 0 . 1 5 7i n ) d i r . s c r e w
Coil
L o c kn u t
Adjustingscrew
Adjustingspring
Yoke

I Pointgap
2 Chargerelaycontact
3 Coregap

9
l0
II
l2
l3
14
15

5 Connecti'tg
spring
6 Yokegap

Adjustingscrew
L o c kn u t
Coil
4 m m ( 0 - 1 5 7i n ) d i a .s c r e w
3rnm(0.118in) dia. screw
Contactset
Voltageregulatorcontact

8 Adjustingspring

Voltage regula.or

Chargerelay

Fig. EE-42 Structurcl uiew

Regulator

MEASUREMEI{T Of
REGULATORVOLTIGE
Regulator voltageis rneasurecwrth
regulator assembled with ahernaror.
When measuringvoltagewirh regulator
mounted on car, it is necessar).to
rotate engineat 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 that all electrical
loads such as lamps, air conditioner.
radio etc. are turnedoff.
2. Before startingengine,b sure to
make short circuit with a cable between fuse side terminal of lesistor
(0.25Q) and negativeside terminal of
ammeter. Failure to follow this precaution will causeneedleof ammeter
to swingviolently,resultingin a damagedammeter.
3, Refer to the following chart to
determine if regulator and relative
partsare in good condition:

fusesideteminal and ( )
terminal of ammeter)beforc

Resistorfot measurcment
Ammeter
(l0A)

Voltmeter(30V)

EE055
Fig. EE-43

EE.17

Measuring

regulator

voltage with regulator

on car

EngineElectricalSystem
l.
2.

Startengine.
Rotateengineat 2,500rpm for several
minutes.

After racing for severalminutes, ammeter readingbelow 5A.

After racing for severalminutes,ammeter

reading-over
5A.

Fully chargedbattery available.

l.
Replacewith fully chargedbattery.
2. Check to seeifcurrent falls below 54.

Fully chargedbattery not available.

l.
Connect a 0,25 ohm resistorin series.

Currentfallsbelow 5A.

Current does not fall below 5A,.

Rechargebattery and seeif current falls below

5A.

Reduceengine speedto idling and then raiseir ro l._iOOrpm while observingneedleof voltmeter.

Needle of voltmeter held within limits shoiln in rhe rable

below.
Regulatorfunctioningproperly.

Needleof voltmeter out of limits shownin

the following chart.
Adjustor replaceregulator.

Voltage V

T1'peRQ82220B
ftlitsubishi)

TemperatureoC (o F)

-10 (14)

14.75to l5;15

14.15ta 15.25

0 (32)

14.60to 15.60

1 4 . 6 0t o 1 5 . 1 0

r0(s0)

14.45to 15.45

14.45to 14.95

20 (68)

1 4 . 3 0t o 1 5 . 3 0

1 4 . 3 0t o 1 4 . 8 0

30 (86)

1 4 . 1 t5o 1 5 . 1 5

1 4 . 1 5t o 1 4 . 6 5

4 0( 1 0 4 )

1 4 . 0 0t o 1 5 . 0 0

1 4 . 0 0t o 1 4 . 5 0

Notes:
a. Do not measurevoltageimmediately after driving. Do this while

regulator is cold.
b. To measure voltage, raise engine
speedgradually from idling to rated

EE.18

speed.
c. Voltage may be approximately
0.3 V higher than mted for two to
three minutes after engine is started, or more specifically,when regulator becomesself-heated.Measurements should then be made within
one minute after starting engine,or
when regulator is cold.
d. The regulator is of a temperaturecompensating type. Before measuring voltage, be sure to measure
surrounding temperatute and correct measuremenlsaccordingto the
tableat left.

EngineElectricalSystem
ADJUSTMENT

Charge relay

Voltage regulator

Normal relay operating voltage is 8

to lov as measuredat alternator "A"
terminal. Relay itself, however,
operatesat 4 to 5 V.

When regulating voltage, as measured above,deviatesfrom rated value,

adjust regulator in accordancewith 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 adjustmentis
required for yoke gap.
3. Adjustingcoregap.
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.

Contactset

2 Thicknessgauge
3 4 mm (0.157in) dia.scrcw
4

Crosshead
screwdriver

0.6 to 1-0mm
(0.0236to 0.0394in)
0.7 to 1.3mm
(0.0276to 0.0512in)

4.

Adjustingpoint gap
l,oosenscrew [3 mm (0.118 in)
diameter] used to secureupper contact, and moveuppercontactupward
or downwardasnecessary.
SeeFigure
EE-45.

t Thicknessgauge
2 3 mm (0.1l8 in) dia.
3 Ciossheadscrewdriver
4 Upper contact

0.3 to 0.4 mm
( 0 . 0 1 l 8t o 0 . 0 1 5 7i n )
0.3 to 0.45 mm
(0.0118to 0.0177in)

5.

Adjusting voltage
Adjust
regulating voltage as
follows:
Loosen lock nut securingadjusting
screw. Turn this screw clockwise to
increase, or counterclockwise to decrease,regulating voltage. Se Figure

EE-46.

I
2
3
4

Wrench
Crossheadscrewdriver
Adjustingscrew
Lock nut

EE,19

Use a DC voltmeter,and set up a

circuitasshownin FigureEE-47.
Adjust chargerelay in the same
manneras that for voltageregulato!.

Engine ElectricalSystem

EE4O7

Fig. EE-47 festing charyerela!

EE.2O

Engine Electfical System

SERVICEDATAAND SPEC|fICATIOIIS

LTl35.l3B

LTl50-12

A 1 0a n dA l 2

Al2 for 82l0 (Option)

l2-35

l2-s0

Groundpolarity

Negative

Negativ

Minimum revolutionunder no
load(Whenl4 voltsareapplieQrFn .....................

Lessthan 1,000

Lessthan I ,000

2812,sDO

3sls,000

37.512,5N
s0/s,000

2.25

2.25

Length

Morethan7.5 (0.30)

Morethan7.5 (0.30)

Springpressure

255Io 345(9.0 to 12.2) 255to 345 (9.0 to 12.2)

Appliedenginemodel

v-A

Nominalrating

Outputcuuent
Pulleyratio
Brush

Outer diameterof dip riq

Morethan30 (1.18)

Morethan30 (1.18)

RQ8222OB
* 1 4 . 3t o 1 5 . 3
at 20oC(680F)

Regulator
Voltageregulator
Type
Reguheg tirbF"

TLIZ.57
* 1 4 . 3t o 1 5 . 3
at 20oC(68eF)

Voltagecoil rc6b

10.5at 20oC(68oF)

23.6at 20oC(680F)

10

10

31

38

Rotorcot@'
resistance

- :.

Voltagecf,ll -ri!3
resistec
Coregrp

mt(in)

0.6to 1.0
(0.0236to 0.0394)

0 . 7t o 1 . 3
(0.0276.to
0.0512)

Point grp

nqGtr)

0.3to 0.4
(0.01l8 to 0.0157)

0.3to 0.45
( 0 . 0 1 1 t8o 0 . 0 1 7 7 )

4.2to 5.2at "N"

terminal

4.2 to 5.2at "N"

terminal

Chargerelay
Releasevdte3c
Voltagecoil rci@;

37.8at 20oC(58oF)

23.6ar 20oC(680F)

Corega!

nm (in)

0 . 8t o l 0
(0.0315to 0.0394)

0.9to 1.4
(0.03s4to 0.0ssl)

0.4 to 0.6
(0.0157to 0.0236)

0 . 7t o l . l
(0.0275to 0.0433)

Point gap

+ Standardtemperature
gradient- 0.015V/oC

EngineElectricalSystem

TROUBLE DIAGNOSESAND CORRE TIONS

Condition

Nooutput

Excessive
output

Low output

N o i s ya l t e r n a t o r

Probable cause

Correctiveaction

Stickingbrushes.

Corrector replacebrushesand brushsprings.

Dirty brushesand slip rings.

Clean.

l.oose connectionsor broken leads.

Retightenor solderconnections.
Replaceleadsif necessary.

Open statorwinding.

Repairor replacestator.

Open rotor winding.

Replacerotor.

Open diodes.

Replace.

Shortedrotor.

Replacerotor.

Shortedstator.
Grounded"A" terminal.

Repair or replace,
Replaceinsulator.

Brokenfan belt.

Replace.

Broken neutral wire (color of wire is yellow.)

Replace.

Voltage regulator breakdown.

Check regulator operation and repair or

replaceas required.

Poor grounding of alternator and voltage

regulator"E" terminal.

Retightenterminalconnection.

Broken ground wire (color of wire is black.)

Replace.

Looseor wornfanbelt.

Retightenor replace.

Stickingbrushes.

Corrector replacebrushesand springsif

necessary.

Low brushspringtension.

Replacebrushsprings.

Voltageregulatorbreakdown.

Check regulatoroperationand repair or

replace
asrequired.

Dirty sliprings.

Clean.

Partial short, ground,or open in staror

winding.

Replacestator.

Partiallyshortedor grounded
rotorwinding.

Replace
rotor.

Openor damaged
diode.

Replace
diode.

Loosemounting,

Retightenbolts.

Loose drive pulley.

Retighten.

Brokenball bearing.

Replace.

Improperlyseatedbrushes.

Seatcorrectly.

EE.22

l
Engine ElectricalSystem

IGNITION
SYSTEM
CONTENTS
IGNITION
CIRCUIT
EE-23
t c N t l o Nc o t L . . .
. : . . . . . : . : : . . . EE-24
DISTRIBUTOR
EE.24
CONSTRUCTION
EE-24
C H E C K I NAG
N D A D J U S T M E N T . . . . . . . .EE-25
,..
ASSEMBLY
EE.27

PLUG
SPARK
... .......
INSPECTION
..................
C L E A N I NAGN D B E G A P
......,.
S E R V I C ED A T A A N D S P E C I F I C A T I O N
. . S. . .
T R O U B L ED I A G N O S EASN D
CORRECTIONS
.........

lcl{lTroNctRcutT
The ignition ckcuit consists es"
sentially of a battery, ignition switch,

ignition coil, distributor,spark plugs

and connectingwires, as shown in

FigureEE-48.

Model B21O and B12O

Ignitionswitch
To startingmotor

kdti@

coil

Secondarywinding
B.eake!point
Rotor head
(J

Spark plug

Model FlO

Primaty
Ignition switch
To startingmotor
Ignitior coil

Secondarywindlng
Bleake.point

Rotor head
L)

Distlibutor

EE.23

EE-27
EE-27
EE.28
EE-29
EE-30

EngineElectricalSystem

tcl{lTloN coll
The ignition coil is an oil-filled
type. The ignition coil case is filled
with oil which hasgood insulatingand
heat-radiatingcharacteristics.
In the ignition coil, there is a
greater ratio between the primary and
secondary windings to step uP the
battery voltage to a higher voltage so
as to causestrongersparksto jump the
spark plug gap.
The cap is made of alkyd resin
which offers increasedinsulation and
high resistanceto electric arc.
The ignition coil and external resistor should be handled as a matched
set.

I High voltageterminal
2 Primary terminal
3 lnsulation oil
4 Core insulatingmateial
5 Coie
6 Pdmary coil
? Secondarycoil
8 Case
9 Scondaryterminal

DISTRIBUTOR
CONSTRUCTION
The distributor consistsof a breaker plate with contact points, centrifugal advancemechanism,vacuum controller, distributor shaft and rotor.

E Eutog
FiE. EE-49

Cross-sectional

coil

view of ignition

tt,

I
2
3
4
5
6
7
8
9
l0
II
l2
13
14
15
16
17
l8
19
20

Cap assembly
Cap clamp set
Dustseal
Carbonpoint assembly
Rotor head
Contact set
Breakerplate
Earth wire
Cam set assembly
Governorweight
Govemorspring
Shalt assembly
Thrust washer
Housing
Leadwire
Terminal assembly
Condenserassembly
Vacuum control assembly
Fixingplate
Pinion set

EE 4 1 O

FE. EE-50 Exploded uiea of dhtributor

EE.24

EngineElectricalSystem
GHECKINGAND
ADJUSTMENT
Gap and rotor head
Cap and rotor head should be rnspectedperiodically as specifiedin the
"Maintenance
Schedule". Remove cap
and clean all dust and carbon deposits
from cap and rotor. If cap is cracked
or is leaking, replace.

Contact point
Standard point gap is 0.45 to 0.55
mm (0.0177Io 0.021'7in). In casesrze
is off the standard,adjustmentis made
by loosening point screws.Gap gauge
is required for adjustment.
When point surface is 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
asfollows:

Screw
Adjuster
Primaryleadtern1inal
Earthleadwire
Set screw

2
3
4
5

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 terminal out.
Referring to Figure EE-51, unscrew
two contact set fixing screws and
remoyelead wire.
While holding contact arm by
fingers, pull contact set out toward
you by raising it slightly. Contact
point and arm can then be removedas
an assembly.
Install new contact point and arm
assembly in reverse sequence of removal. Coat cam with a light coating
of grease.

Gondenser
Satisfactory performanceof condenserdependson capacityand degree
of insulation.requiringattentionto be
sure that terminals are clean and set
screwsare tight.
Checkingof condenseris madeby a
condenser
tester.

EE411

Fig. EE-52 Adiusting point gap

Advance mechanbm3
Advance characteristics
20

l5

910

2,400x 10.5

210{ 9 . 5 -

l0

I
300x ?.

< 5

,W

500
1,000 1,500 2,000 2,500 3,000
Distributoroperating
speed(rpm)

0
r00
250
150
200
300
350 400
( 3 . 9 4 ) ( 5 . 9 1 ) ( 1 _ 8 7 ) ( 9 . 8 4 ) ( 1 1 . 8 1 )( 1 3 . r 8()1 5 . 7 5 )
Vacuum-mmHg( inHg)
Fig. EE-53

EE.25

Aduance

characteristics

EE412
(Type D411-89)

EngineElectricalSystem

l)

"9

x 10.5

3
300x 7.5

< 5

0
3s0
100
150
200
250
300
(3.93) ( s . 9 1 ) ( 7 . 8 7 ) ( 9 . 8 4 ) ( l r . 8 r ) ( l 3 . 7 8 )
Vacuum mmHg(-inHg)

s00
r,000 1,s00 2,000 2,500
speed(ryrn)
Distributoroperating

EE413

FE. EE-'4 Ad.uancecharccte.i.stbs(Tfpe D411'97)

20

20

2,000 l 4

l5

l)

2,O00x 12

-to

270 x 9 . 5
3 O 0 x 7.5

< 5

"%
500

1,000 1,500 2,000 2,500 3,000

Distributoroperating
speed(rpm)

.W

0
350
200
250
300
100
150
400
(3.93) ( 5 . 9 1 ) ( 7 . 8 7 ) ( 9 . 8 4 ) ( l 1 . 8 1 ) ( 1 3 . 7 8()r 5 . 7 5 )
Vacuum -mmHg (-inHg)
EE414

Fig, EE-55 Aduance choracteristbs(Tfpe D413-67)

Vacuum advancemechanical
Parts
If vacuum advancemechanismfails
to operate properly, check for the
following and correct malfunction as
required.
Check vacuum inlet for signs of
l.
leakage at connection. lf necessary,
retighten or replace.
2. Check vacuumdiaphragmfor air
leak.
If leak is found, replace vacuum
control assembly.
3. lnspect breaker plate for smooth

movement.
If plate does not move smoothly,
this condition could be due to sticky
steel balls or piyot. Apply greaseto
steel balls or, if necessary, replace
breaker.plateassembly.

Centrifugal advance
mechanicalparts
Whencauseof enginemalfunction
is traced to centrifugal advance
mechanicalpad, usedistributortester
to checkits characteristic.

EE.26

Seethe specificationsabove.
When nothing is wrong with its
characteristic, conceivable causesare
break-down,abnormalwear of driving
part, or others- So do not disassemble
lt.
In case of improper characteristic,
remove contact breaker assemblyand
check clmely cam assembly,governor
weight, shaft and governor spring,etc,
In casecentrifugal advancemechanical part is .reassembled,be sure to
check advance characteristic with a
distributor tester.

Engine ElectricalSystem

SPARK PLUG

Disassembly
To disassemble,follow the below
procedure.
l.
Remove cap and disconnectrotor
head.
2. Remove vacuum conttol assembly.
3.

tNSPECTtOl{
The inspection and cleaningshould
be made every suitable maintenance
period. If necessary,replace.

Removecontact set.
EE326

aq

Ftg.EE-59 Remouingrctation parts

6. Remove packing from top of cam

assemblyand unscrew rotor shaft setscrew. Put match mark acrosscam and
shaft so that original combination can
be restoredat assembly.

EE071

Fig. EE-56 Remouingwcuum control

ossemblyand contact set

Fig. EE-60 Remouingcam

FE. EE-57 Remouing breaherplote

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 disconnect pinion to removethe entirerotating parts.

7. When governor weight and spring

are disconnected, be careful not to
stretch or deform governorspring.
After disassembling,
apply greaseto
governorweights.

ASSEMBLY
To assemble,
reverse
orderof disas-

EE 2 0 1

Fig. EE-58 Removing hnoch pin

sembly. Carefully observe the following instructions.

l.
Align match marks so that parts
are assembledto their original posltrons.
2. Apply greaseto top of cam assembly as required.
3. Check operationof governorbefore installing distributor on engine.
4. Adjust ignition timing after distributor is installedon engine.

EE.27

l.
Remove spark plug wire by
pulling on boot, not on wire itself.
2. Removespark 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 deposits 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 speed driving in city, weak
ignilion. too rich fuel mixture,
dirty air cleaner,etc.
It is advisableto replacewith plugs
havinghotter heat range.
Oil fouled: Wet black depositsindicate excessiveoil entrance into
combustionchamberthroughworn
ringsand pistonsor excessive
clear,
ance between valve guides and
stems. lf the same condition remains after repair, use a hotter
plu8.
Overheating:White or light gray insulator with black or gray brown
spots and bluish burnt electrodes
indicate engine overheating.Moreover, the appearanceresults from
incorrect ignition timing, loose
spark plugs, low fuel pump pressure, wrong selection of fuel, a
hotter plug,etc.
It is advisableto replacewith ptugs
havingcolder heat range.

EngineElectricalSystem

Carbonfouled

Normal

Result ol overheating
Fig, EE-Gl Appearance of fifing end

4. After cleaning,dress electrodes

with a small fine file to flatten surfaces
of both cenler and side electrodesin
parallel.Set spark pluggap lo specificatlon.
5. lnstall spark plugs and torque
eachplug to 1.5 to 2.0 kg-m(1 I to 15
ft.lb).
6. Connect spark plug wires.
Note: All spark plugs installed on an
engine must be of the samebrand
and the samenumber of heat range.

CLEANING AND REGAP

Clean spark plugs in a sand blast
type cleaner.Avoid excessiveblasting.
Clean and remove carbon or oxide
deposits, but do not wear away
porcelain.If depositsare too stubborn,
discardplugs.

After cleaning spark plugs, renew

firing surface of electrodes with file
mentioned above. Then gap spark
plugs to the specificationusing a
round wire feeler gauge. Al1 sPark
plugs, new or used, should have the
gap checked and reset bY bending
electrode.

Fig. EE'62 lleasuring sparh plug

gap

Spark plug gap

0.7to 0.8
(0.028to 0.031)

0.8to 0.9
(0.031to 0.035)

EE.28

Engine ElectricalSystem

SERVICE DATA AND SPEGIFICATIONS

lgnitaon coil
Type
Primaryvoltage
Sparkgap

mm(in).........

Extemalresistance

c6R-205

HPs-l3El1

12
Morethan7 (0.2756)

t2
Morethan7 (0.2756)

1.6

1.6

Distributor
Type

D411-89

Applied enginemodel

D41)'97

D413.67

A l 2 f o r F l 0 a n d8 2 l 0

412 for Bl2O

t.3-4-2

1-3.4-2

1-3-4-2

Counterclockwise

Counterclockwise

Firing order
Rotating direction

Counterclockwise

Al0 forFl0

Dwell angle

degree...........

Point gap

0.45to 0.55
mm (in) ..........
(0.0177to 0.0217)

Point pressure

ke0b)...........

0.50to 0.65
(l.l to 1.4)

0.50to 0.65
( 1 . 1t o l 4 )

0.50to 0.65
(1.Ito 1.4)

Condenser capacity

pF

0.20to 0.24

0.20to 0.24

0.2Qto 0.24

Condenser insrlatim rBistance

MO

Cap insulation resistem

MO

50

50

50

Qstol hsld insrbtim

MQ

50

50

50

12(0.472)

12 (0.472)

12 (0.472\

resistnce

Cap carbongoint

mm (in) .......

49 to 55

49 to 55

49 ro 55

0.45to 0.55
(0.0177to 0.0217)

0.45to 0.55
(0.0177ro O.0217)

Spark plug
Model

Appliedenginemodel
Gap
Tighteningtorque

L46W,BsES,BRsES
Al0
mn (in) ........ 0.7to 0.8(0.028to 0.031)
kg-m(ft-lb) ....
1 . 5t o 2 . 0( 1 1t o 1 4 )

EE.29

L46PW,BPsES,BPRsES
At2
0.8 to 0.9 (0.031to 0.035)
1.5to 2.0(1I to 14)

Engine ElectricalSystem

TROUBLE DIAGNOSESAND CORREGTIONS

Enginedoesnot start.
detachinga sparkplugwire from spark
If there is no malfunctionin fuel __plug, starting engine and observing
system, ignition system should be
condition of spark that occurs bechecked.This can be easilydone bY
l.

Condition
No sparksat all

Location

tweensparkplug wire and sparkplug

terminal.After checkingthis,rePairas
necessary,

Probablecause

Correctiveactiorl

Damagedinsulationof condenser.

Replace.

Breakageof lead-wireon low tensionrside.

Repair.

Damagedinsulationofcap and rotor head.

Replace.

Point does not open or close.

Repair.

lgnition coil

Wre breakageor shorl circuit of coil.

Replace.

High tension cable

Wire coming off.

Repair.

Damagedinsulation.

Replact.

Poinigaptoo wide.

Correct.

Oil stickingon point.

Clean.

Pointburnttoo much.

Replace.

Spark plug gaPtoo wide'

Correct ol replace.

Too much carbon.

Cleanor replace.

Brokenneck of insulator.

Replace-

Expiry of plug life.

Replace.

Distributor

Sparklength
t to 2 mm(0.01
to 0.0787in) or
irregular.

Distributor

Morethan6 mm
(0.2362in)

Sparkphrgs

EE.30

Engine ElectricalSystem
-

2' Whenenginerotatesbut doesnot

run smoothly.
In this case,thereare manycauses

Condition

Enginemisses

Engine krnc*s
very often

Enginedoesnot
deliver enough

resultingfrom the ignition systemand

other enginconditionsnot relatedto
ignition.Therefore,a completeinspec-

Location

Distributor

tion of the ignitionsystemshouldfirst

be carriedou1.

Probablecause

Correctiveaction

Drty points.

Clean.

Improperpointgap.

Correct.

Leakof electricityfrom capandrotor head.

Repair or replace.

Damaged
condenser
insulation.

Replace.

Malfunctioning
arm.

Oil shaft.

Damaged
armspring-

Replaceassembly.

Brokenleadwire.

Replace.

Wornout or shakybreaker
plate.

Replaceassembly.

Wornout.or shakydistributorshaft

Replaceassembly.

Ignition coil

liyer shortcircuitor inferiorqualitycoil.

Replace.

H[h tension cord

Deteriorationof insulationand consequent

leakof electricity.

Replace.

Spart ph4s

Fouled.

CIean.

kak of electricity at upper porcelain

lnsulator.

Repairor replace.

Improperlyadvanced
timing.
Displaced
or brokengovernor
spring.

Correct fitting.
Corrector replace.

Wornpin or holein governorportion.

Replace.

Sparkph4gs

Excessively
burnt.

Replace.

Distributor

Improperlyretardedtiming.

Correct fitting.

Malfunctioning
governor.

Replaceassembly.

Dirty points.

Clean.

Pointgaptoo narrow.

Correct.

Fouled.

Clean.

Dtlributor

Ilowcr

spark plugs

EE.31

EngineElectricalSystem

SYSTEM(F1OSERIESONLY)
ENGINECOOLING
FAN MOTOR
Fan motor specifications are as
follows:

SPECIFICATIONS
12

Voltage
Wattage

95

Revolution

rpm

I 1(O to I 6iO

THERMOMETERSWITCH
tnsPEcrloN
Carry out conduction test as
follows:
l.
Submerge temPerature sensing
unit of themometer switch into 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
rangspecifiedin the chart.
3. Stop heatingwater and make sure
that switch goesout outside specihed
temperaturemnge.
4. Replace thermometer switch if it
doesnot function properly.

Watertemperature
8 3 t o 8 7 o C( 1 8 1 r o 1 8 9 " F )

( 1 7 5r o 1 7 7 o F )
7 9 . 5t o 8 0 . 5 o C

Thermometerswitch

Fig. EE-63 Inspecting thermometer switch

SPEClFlcATlol{s
Voltage
Amperage
Thermometerswitchtightening
torque

l8)