ESP SKODA 120 LS 1980 User Guide

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16. 17
19
q
"b 2A
Technicol
The gec
tegrol uni
Neither of
Since c,
tionolly tc
"georbox "
molly to d
respect i ve
The geo
from the c
reor oxle c
the so-coll
4.1 DtSM
PACK
The pov
tronsm issi,
plete with
Fi9.4.111.
Removql
o) Prelimir 1. Jock r
the reor wl
ond remov Droin th
see Choptt
b) Operoti
2. Prise r
of the reor
cobles ofte
3. Remo,
behind the
bottery. Re
engoge the
lever, loosr
fronr the gr
it from tht
housing to
getting int
pressed on
housing wi
4. Proce
bockrest, fr
detoch the
obsorbers, ,
c) Operotir
5. Remor
connectionr
cooling sys
see choPte
d) Operotic
6. Discol
motor.
4
2
'u., ts
I
Fbb
,w
FINAL DRIVE ASSEMBLY
I
r8
12
ik"-n
TO
13
6
q
76

Proceed
in the some woy with the
3rd- ond
4th-speed geors.
lf the morked position
of the neutrol is not
midwoy between the side morks (check
visu-
olly), remove the pinion,
mork the positions
of
the striking forks on
their rods (preferobly
on
either side), slocken the forks ond 'rnove
them
toword the required centre by
the distonce of
the deviotion of the neutrol morking. Then lock
the striking forks in position
with screws.
For the striking fork tightening torgue see
Chopter 1.8. 13. Adiust the reverse geor position
so thot
there is o gop
of obout 2
mm between its teeth
ond the odioining teeth, ond swing the striking
fork of the first ond second speed
to moke sure
thot it connot foul
the teeth.
14. Reinstoll the pinion
with its respective
woshers ond lock it in position.
Shift the strik-
ing fork rods to moke sure thot, for exomple,
o movement opposite to the required one of the
striking forks did not toke ploce,
i. e. thot the
neutrol is midwoy betvr'een the engogement
positions of the synchronizing clutches. Correct
ony error ond remove
ogoin the pinion.
Fitting Drive Geors ond Clutch Shqft
15. lnstoll the ossembled drive shoft into the
housing ond slip the splined bush on it.
Top home the seol ring with its seoling lip
pointing outwords into the guide
of the clutch
thrrowout sleeve, ond smeor it with oil. Then
threod the clutch shoft through the ring to
instoll it into the splined bush ond put
it into
the housing together with the guide provided
with o cooting of seoling compound on its cyl-
indricol bedding surfoce. Secure both the shoft
ond the sleeve with circlips.
lnstoll the sleeve guide
with its droin hole
level with the porting plone
of the housing ond
focing the pinion.
For the speciol seoling compound see the
note in Chopter 10.1.
16. Put the pinion
with geors
into the housing
ond oil oll synchronizing rings. Fit the MP 5-104
iig for
setting the crown wheel bocklosh into
the bore of the differentiol beoning ond the
fitted cover, fit the ossembled differentiol in it,
ond close the housing with the other housing
holf ofter hoving cooted the seoling surfoces
with o seoling compound.
Fit o rubber ring in the recess of the boss
beside the stud
bolt ond put
o spring wosher
under the nut. Tighten the remoining nuts
without ony woshers (the
stress of the bolts
ofter the tightening of the nuts provides
for'
their suff icient securing). Tighten the nuts
moderotely for the time being.
For the speciol seoling
compound refer to the
note in Chooter 10.'1. 17.
Proceeding through
the bore of the differ-
entiol beoring in the upper holf of the housing,
fit another
iig, the MP
5-104,
on to the differen-
tiol with flonges clomped so os to fit
into the
topered roller beoring cover, locote the cover
pocking, ond fosten
the cover by meons
of three
nuts. lf the clomping or drowing close of the
flonges of this jig
proves inodequote, it is
necessory to drow close the flonges olso of
the
first, previously
inserted
iig.
18. Drive the guide
of the clutch throwout
sleeve into the housing using the MP 3-103 drift,
top home the drive shoft, ond insert
two od-
iusting woshers under the collor of the
pinion
shoft boll beoring on both holves of the housing
ofter hoving determined their thickness by
meosuring. Using o wire needle
inserted into
the holes of
the tobs of the woshers orronge the woshers so
thot they do not overlop the porting plone
of
the housing,
then instoll the cover ond spring
woshers, ond tighten the nuts (seeChopter
1.8).
19. Fosten the housing by tightening the nuts
(see Chopter 1.8) ond lock in position
the guide
of the clutch throwout sleeve with the respect-
ive clip using the spring wosher under the
clip
nuts.
4.3 ASSEMBLING
FINAL DRIVE
Ref itting Differentiol 20. Turn the housing into the horizontol pos-
ition. Rotote the ends of the knurled hondles
of the inserted iigs MP 5-104
to move the re-
instolled differentiol (see previous porogrophs
16 ond 17) until the crown wheel withdrows
Fig. 4.311- Adiusting
1 -
MP 5-104 iig,
3 -
MP 5-106
iig,Bevel
Geor Bocklosh
2 -
MP 5-101
iig,
4 -
Screwdriver from
the
Determir
swivellin
To rotr
iig with
tiol stor
21. Ins
on the b,
rotote th
the diol
ible to th
Retoin
ogoinst 1
cover. Tl'
teeth chc
losh on t
of the ho
wheel sic
fied volut
the hond
fully its c
( preferob
wheel). I
opened f1
respectivr
of the
iigr
Now tl"
iusted on
flonges o'
topered r
This situc
trot i o n.
Fig. a3fi
for tc
1
22. Rem
side (turn
withdrow
dimension hos to be
roller beori
Measuring 23. Unscr
the toperer
locote it o
q,
ry
80

4.3-4.4
F
I
t
F
i
!
I
r
{.3-4.4
6. Remo
b) Crownwl Tools:
Settin
not le
1. Install
one of the
Glave Cylir
that the p
pendicular
2. Lock
between tl"
cover. 3. Using
back and
clearance I
teeth. This gauge, anc
wheel(see legible the
O.18mm bi
4. lnsuffi
wheel is tc
increase tl
from the nc
the equiva
This will p
increase th
Excess c
thickness
Selector Si
To worl
shims to n
(a) Bac
(b) Act
Refitting C Assembly
29. Instc
ond the rel it with nutr
-looded brc
To
(a) O.3i
(b) o.2r
lf
the shims
connot be set up exoctly to the
colculoted thickness, determine o thickness
which would result
in o prelood
due to on
overoll increose of 0.03 to 0.07 mnr of the di-
rnension of the shims.
27. Ploce the topered roller beoring on the
respective bore, bolt the other MP 5-107
iig on
the housing ond rotote
the centre bolt to press
the beoring into the housing os for os it will go.
Remove the iig, fit the shrunk-on
ring on the
stor pinion,
and lock the ring in position
using
o circlip. Lubricote the beoring with oil, f it the
respective shims on the beoring ond the gosket
on the cover, ond bolt down the cover.
Turn over the housing ond press-in
the other
beoring in the some monner (the press-fitting
iig is olreody in
position),
instoll the preporred
shims, ond bolt down the cover with its gosket.
28. Meosure how deep is tlre drive shoft
beoring below the level of tlre housing
surfoce
ond compensote the difference
with shims up
to o moximum protrrrsion
of 0. I mm -F0.05
rnnr.
Fig.4.3/4 -
Press-f itting of Differentiol Toperecl
Rollr:r Beorings
Using MP 5-107 Jig
Shims 0.1 nrm to 0.2 mm thick ore ovoiloble.
Fit the gosket
ond the ossembled cover on the
housing ond fosten it with nuts ond spring
woshers (for the cover refer
to Chopter 4.5).
Swing down the beoring
with the speedo-
meter drive geors
in the cover into engoge-
nrerrt with the pinion
drive geor
ond lock the
beoring in position
by tightening the nut of the
beoring clip.
Adjusting crownwheel Bearing
Alternative Method a) Crown Wheel Bearing Preload.
Tools Dial Test Gauge and Stand
MPs -
1OG lever Setting:
Preload O.Ob -
O.10 mm
1. Before assembling Transmission casing
remove outer crown wheel bearing races. Leave
the bearings on the
differential housing.
2. Assemble transmission. DO NOT carry out
operation 17
above.
3. Fit the outer races into casing pressing
into
place using coned cover. Do not forget to fit
gaskets. On the Selector Shaft side (side
B) of the
casing fit
approximately O.60 mm of shims
between the coned cover and outer races. Ensure
there is
backlash between crownwheel and
pinion, increase the
shim thickness if required.
4. Fit Dial test gauge
so that pointer
rests on
the differential as shown in fig. 4.3/1A.
5. Lift Crownwheel assembly to determine
clearance between bearings (a).
. . lf this exceeds
O.2O mm decrease the clearance to between O.O1
and 0.20 mm by f itting
shims to Non-selector side
of casing. (b)
. . . When the clearance is between
0.01 and0.20 mm take
a reading. Addtothis0.OS
to 0.10 mm. Make a shim pack
to this thickness
and fit to non-selector side (side
A) of transmission
casing. Check some
backlash still exists between
the Crownwheel and pinion.
Example 1st Dial reading 0.3O mm
0.20 mm
Shim fitted
on non-selector side.
2nd Dial reading 0.07mm
Shim pack
required between
0.07 +O.O5 =O.12mm
and0.O7mm *O.1Omm
= 0.17 mm
Shim sizes available.
0.08, O.14, O.2O and O.SOmm
Shim size selected O.14mm. This
will give
O.07mm preload
tension to crownwheel
beari ngs.
The Crownwheel should now
turn freely with
little drag. Fis.
4.3/1A
82

1-
in the
other groove.
Chose the ring olso with
regord to toleronces cvoiloble
in one closs of
the rings os mentioned in the previous
Pqro-
groph. Check the cleoronce of the geor with
the oid of o diol indicotor.
Then remove the geor
including the friction
ring in the second groove
of the shoft.
7. Ploce the lock of the 1st' ond 2nd'speed
synchron izing clutch on the bench with
its
teeth downword. lnstoll
springs in the clutch
core securing them with greose
ogoinst folling
out ond insert the clutclr core with the shorter
side of the inner heod on
top in the respective
geor. Locote bclls (dio. 1ir
in.) on the springs, com-
p,ress the springs with
the fingers or using
o suitoble rod, cnd fit
the complete core
itrto
the geor.
8. Hoving thus osembled the synchronizing
clutch lock, instoll the synchronizing ring
fronr
the opposite side of the geor.
Now threod the
lock on the oiled shoft
with the geor focing
owoy from the shoft.
9. Instoll in position the
previously selected
friction ring with its groove
focing owoy from
the shoft (toword
the geor)
ond insert the
synchronizing ring into the fitted lock of the
synchronizing clutch. Slip the oiled geor ond Fig.4.6la
-
Assembling 1st' ond 2nd-speed
Synchronizing Clutch -
lnstolling the Core
ond Pnessing in the Bolls
the previously
selected friction ring on
the
oiled shoft. 10. Slip on the 3rd -
speed geor
ond secure it
with on
orbitrorily chosen ring from the ronge
of friction rings in complionce with the poro-
groph 2. Meosure the oxiol cleoronce ond odiust
it to 0.1*0.07 mm by o repeoted exchonge of
the friction ring. Now remove the geor,
lubricote it,
slip it on
the oiled shoft ond lock it in position with the
ring with the oil groove
focing the geor.
11. Proceeding occording to porogroph 2,
insert on orbitrory friction ring into the lost
groove, slip on the 4th-speed geor
ond tighten
the pinion
nut over o pilot
collor replocing the
beoring (for
exomple of dimensions dio.
25.5/38x26 with edges of the inner
bore chom-
fered to 1x45o). Mork the side of
the pilot
col-
lor which will be
turned toword the
nut so thot
the side focing the geor
connot be domoged by
impression. Adiust the cleoronce of the geor
to 0.1+0.07 mm by o repeoted trying
on (ex-
chonge) of the friction rings. Then remove the
geor ond the ring from the shoft.
12. Assemble the 3rd- ond 4th-speed synchon-
izing clutch using the some method os when
hoving ossembled thot of the 1st ond 2nd
speed. lnsert the synchronizing ring
into the
clutch ond slip the clutch on the oiled shoft
with the short side of the lock first.
13. Instoll the selected friction
ring in the
locking position
into the groove with its
oil
groove focing owoy from the shoft. Push or top
home the key into the spline of the shoft so
thot it posses
through oll friction rings ond its
end is ot leost flush with the splined shoft end.
Fig.
4.6/3 -
Locking 1st-speed Geor in Position
(turning the ring with o drift) with the Pinion
Clompecl in MP 3-105 or MP 3111 Jig
86 Fig.
4.(

*
Fir
il
.-q
Fig.
6.1/4 -
Costor Angle
It is imperotive to set the
ongle with regord to
the direction of forword
trovel os indicoted
by the orrow
Fig.6.1/5-Preporing front oxle for the condition
of check lood by inserting
steel bors of 181 mm
in diometer ond obout
220 mm long
The most importont points
from the point
of
view of driving ore the
toe-in ond the comber
ongle, the odiustment of which is permitted
by
the oxle design.
Adiust first the comber
ond then the toe-in
since o chonged comber
offects the toe-in.
We refroin from describing in detoil ony
meosuring method in view
of the lorge number
of existing gouges.
Insteod,
we odvise you
to refer to
the procedures recommended
by the
monufocturers of the gouges.
The check lood con be formed by blocking the
wishbones with bors occording to
Fig. 6.1/5.
Press down the cor with the hond, insert
the
bors under the wishbones so
thot they
beor
ogoinst the oxle brocket, ond releose the cor
to
let the bors be clomped. lf
clomping of the
bors
does not toke ploce
(which con hoppen on on
older cor with weokened springs),
consider the
condition os if the bors were
clomped, i. e',
corresponding to the position of the
front oxle
ot check looding.
The words "ot
full lood" describe o vehicle
looded so thot the distonce of the rubber deod
stop from the bottom of the
lower wishbone
stop is 20 mm (see olso porogroph
18) ond the
comber ongle of the reor wheels is 1". Meosure
these volues on oll wheels (not
only one front
ond one reor wheel) ond distribute the
lood os
necessory.
Toe-in To odiust the toe-in, screw
the right-hond ond
left-hond steering rods
symmetricolly (o
chonge
up to 1 mm con be effected by
one rod) ot
check lood so thot the distonce between the
wheel rims (or
ocross them) behind the oxle
(A+o) is lorger by the toe-in volue (o)
thon the
distonce between the rims
in front of the oxle
(A). To verify steering symmetry (correct screw-
ing of steering rods during
toe-in odiusting),
check the wheel lock position ot the
20" lock
ongle of the neorside wheel -
for the respective
volues refer to Chopter 1.7.
Slocken the steering rod
nuts ond rotote the
steering rods using on
olligotor wrench (Fig.
6.1/6). In oddition to the correct inflotion
pressure
of the tyres, poy
ottention to
severol essentiol
points when checking the wheel
olignment:
o) Ploce thewheel in the stroight oheod trovel'
ling direction;
b) The
steering rod ond the trock rod
must
not
be stressed. The stress con be eliminoted by
letting the cor swing
up ond down in its
suspension under the pressure of
your
honds
(olternotely press down ond releose
the
wings)
c) Prepore the oxle os
shown in Fig.6.1/5;
d) lf
o speciol gouge with
o scole for wheel
lock ongle setting is ovoiloble, odiust
the cor'
rect length of steering rods in
occordonce with
the position
of wheels in
check lock positions.
You will find the respective volues
in Chopter
1.7 "Steering".
Set the lock ongle
of the wheel
on one
side to 20' (on
o turn-toble) ond screw
the steering
rod of the other wheel to odiust
104

Shr
C
cle,
the
1
fittr
bor
(Im(
2
wit
woI
pisl
wor
the loc<(11,
3.
obo (M(
I nst
rod
the
oil' into
4.
witt
Con
prot
Inod
On f(
Inodr
oll c(
Excer
on c(
8.3 SHOCK ABSORBERS
The shock obsorbers ore of
the hydroulic,
telescopic, double-octing type of the PAL
moke.
The domping effect depends on the speed
of the
relotive movements of the oxle ond body. Doto
required for testing ond odiusting the shock
obsorbers ore given
in the following Tobles.
Front Shock Absorber -
see Fig.8.3/1
type PT 26x110,
Ser. No.443.621-215.000
1977-74 1 978 on
Maximum stroks llO mm 110 mm
Damping torce during
down stroke (compr€s-
sion 470N
500N
Damping force
during
upward stroke (expan-
sion) loSN
1
300N
Filling capacity lOO cc1OO
cc
Reor Shock Absorber
type T 26x175; Ser. No. 443.621.247.OO1
1977-78 1 978 on Both
types of shock obsorbers ore of similor
design, only their bottom fostening
is different
(the front shock obsorber hos o fostening eye,
the reor shock obsorber hos
o bolt ond locks
the outer protective
tube). They hove
o differ-
ent stroke, domping force, ond filling
copocity.
Removing ond Refitting When removing or refitting o shock
obsorber,
retoin the piston
rod (upper
fostening) by hold-
ing the flottened end of the threod in o sponner.
In the cose of
the reor shock cbsorber, retoin
the piston
rod in the bottom port
by holding the
heod of the bolt connecting it to the shock
obsorber cylinder.
The ossembly of the rubber bushes of the
respective shock obsorber mounting
con be seen
in Fig.8.3/1.
Access to the upper mountings of 'the
front
shock obsorbers is from the luggoge boot
(under the floor). The
threod is protected
by
o cop nut. The
mountings of
the reor shock
obsorbers ore occessible from the reor luggoge
comportment behing the reor seot bockrests ofter folding owoy the upholstery on the wheel
orch. The mounting is in the cyllndricol exten-
sion piece
in the scuttle
of the reor dosh.
Shock Absorbor Dismcntling
Dismontling is o routine procedure
beginning
with screwing out the plug
(1)
ofter the pro-
tective sleeve (tube)
hos been removed. Never
dismontle the piston
volves since there is o risk
of impoiring the domping force
by mixlng up
the volves.
o
o
*)
At o
temperoture ol 25
to 30oC,
of 100 strokes per
minute, ond
100 mm. frequency
stroke of
Fig.8.3/1 -
Front Shock Absorber -
Sectionol View
Maximum stroke
175 mm
175 mm
Damping force during
down stroke (compres-
ston, 470N
500N
Damping force during
upward stroke {expan-
sronl 950N
r
200N
Filling capacity 160
cc 160 cc
130

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Broke
Shoes ond Broke Drums
When refitting
o broke shoe with o portiolly
worn lining moke sure thot it hos o thickness
sufficient to lost till the periodic
inspection
(ofter every 20,000 kilometres). The new lining
is 5 mm thick. When it is worn down to 1.5
to 'l
mm (4
to 3.5 mm when meosured
with the
shoe), the broke shoe hos to be reploced
with
o new.or
o reconditioned
shoe with glued-on
new lining. Be sure to reploce
the respective
broke shoes in both wheels to preserve
o uni-
form broking effect.
Speciol glues or cements
ond hordening ot
high temperotures
ore required when relining
the broke shoes so thot this
iob con
be done in
speciolized repoir shops
only. For informotion,
opply to the broke monufocturer -
Autobrzdy
Not. Corp., Joblonec
nod Nisou.
Broke drums are grey
cost-iron costings. Their
unequol weor
con be rectified
by mochining to
o 231 mm diometer.
No tool morks must be left
on their surfoce
which hos to be perfectly
smooth. The olignment deviotion
ond mochin-
ing toleronce should
not exceed 0.1 mm. The
moximum permissible weor is up Lo 232
mm in
diometer.
Only broke drums
with on identicol
diometer
ore permitted
to be mounted on one ond the
some oxle.
9.2 FRONT BRAKE
ASSEMBLY
Disnrontling ond Reossembly
1. Detoch
the broke fluid supply piping
from
the broke. Absolute cleonliness is o must.
Otherwise dirt ond foreign
motterwill penetrote
into the piping.
2. Renrove bolts lrolding
down the broke yoke
crnd lift owoy rlre broke
ossembly.
3. Use the MP 6-132 gouge
to set correctly
the broke (new
or repoired)
on reinstollotion.
4. Select the shims required
to fill the gop
between the end of the gouge
ond the foce of
the fostening lug.To position
correctly the
broke, insert shims
between the fostening lugs
cnd yokes. You con, however,
meosure direct
the distonce
between the fostening
lug ond the
trroke disk
ond set this distonce
in complionce
with Fig. 9.211 by odding pocking
pieces
to the
shim pock.
5. Using the respective
copscrews ond spring
'.^roshers, bolt down the yoke
to the lugs.
6. Attoch the supply hoses ond bleed
the
broke.
Replocing the Brake
Disk
A worn brol disk con be reconditioned by
grinding it to o thickness
of 7.5 mm. lf necess-
cry, reploce it with o new one 9 mm thick. The lowest
limit of thickness
of o still usoble
broke disk is 6.5 mm. The
moximum permissible
run-out of the friction surfoce is
0.15 mm.
1. After hoving lifted owoy
the broke os-
sembly, remove the wheel hub
ond then the
broke disk. 2. Reossemble the broke disk
with the wheel
hub using copscrews with spring
woshers.
3. Top
rrp or chonge the lubricont
in the
wheel
hub beorings ond reinstoll the broke ossembly
Replocing Broke Pods
The overoll thickness of o broke pod
with
new lining is 15 mm. When worn down to 7 mm
(with the lining 1.5 mm thick), the pod
is
unusoble.
Alwoys reploce
broke pods
on both ends of
the oxle of the some time so
thot their weor is
uniform. With regord to the coefficient of fric-
tion, they hove to be of the some
type ond
rnoke.
1. Suck off the hydroulic fluid from the tonk
so thot it is only holf filled.
2. Remove cotter pins
ond lift
owoy the broke
lining cover.
3. Remove the friction pod,
cleon thoroughly
the covities of the yokes, piston
ports,
ond dust
boots.
4. Fit the MP 6-134 force-off lever over the
broke disc ond drive the pistons
into the
cylinder bottoms by the presswe
of levers.
5. Ploce o new friction pod
into the broke
ossembly moking sure thot the clomp of the
thrust plote
fits into the collor of the piston
foce.
Fig.9.2l1- Front Wheel Broke Mechonism
ond Mounting (setting)
Dimensions
1 -
Broke disk
2 -
Broke
3 -
Shims
A -
Broke setting climension -
18.7+O.2
136

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t
t
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r
o cc
fold
ot the moment of
the opplicotion of the
brokes, ond led
through o rubber hose (tube)
to
the booster.
Removol ond Refitting
The broke booster is held down on the pedol
brocket by nuts ond spring
woshers. The lug of
the control volve press
button connects it with
the broke pedol,
on which it is secured by o re-
toining ring. These
mounting ports
or the con-
nections of the vocuum supply
ore to be hondl-
ed only when removing
or refitting the broke
booster.
However, we odvise you
to hove this
iob done
in o speciolized
repoir shop properly
instructed
by the broke
monufocturer. All rubber ports (in
the terms of current mointenonce,
this is
procticolly the seol of the press
button control-
ling the moster cylinder)
must be protected
from the effects of the broke fluid or other
lubriconts. Use petrol
for cleoning the rubben
ports.
Adiustment 1. Adiust the cleononce
between the broke
booster press
button ond the cylinder piston
whenever the moster
cylinder or the'broke
booster ore reploced,
or whenever there is ony
doubt concerning
the correctness
of the os-
sembly of the moster cylinder
with the broke
booster. Meosure the distonce between the
cylinder bottom recess
ond the cylinder flonge
nroting surfoce os well os the length of the
press button protruding
over the moting surfoce
of the booster.
Compore the meosurings
ond
odiust the length of the press
button by rototing
its threoded
end to obtoin o cleoronce of 0.5 to
1 mm between the press
button ond the piston.
Still better, you
can use special
tools Mp6.
'14'lA.
Fit it on the
moster cylinder, push
its spindle into the cylinder till its rounded
end
rests ogoinst
the piston,
ond lock it in this po-
sitio-n with the respective
retoining screw.
Apply
the fixture to the booster
ond rotote the boostei press
button so thot it
iust touches the
lower
flot port
of the fixture spindle.
2. lf it is necessory
to level
the broke pedol
with the clutch pedol,
odiust the length
of the
contnol volve press
button lug.
Remove the broke
booster from the pedol
brocket, slip off the collor (cup),
connect the
booster with the pedol,
ond refit it tempororily
to the brocket.
Now rotote the hexogon on the
threods of the lug till both the clutch ond broke
pedol ore level. Remove once more the booster
from the pedol
ond pedol
brocket, neinstoll the
collor (cup),
ond complete the f inol reossembly.
9.7 BRAKE FLUID TANK, PIPING AND HOSES
Tonk ond Filling Hose
The broke fluid tonk is held in position
in its
brocket by o slip-over
clomp. Speciol rubber
hoses connect it with the broke ond clutch
moster cylinders.
Hose clips ore used to secure
the hoses on the tonk outlet sockets.
Both the
side ond centre outlet of the tonk ore con-
nected to the bnoke moster cylinder, the third
outlet being connected to the clutch moster
cylinder (see Fig. 12.111).
Pressure Piping ond Hoses
The rigid port
of the hydroulic line consists
of speciol steel pipes.
Their connections with
other ports of the line ore seoled off by clomp-
ing on the conicol surfoces-
lf these conicol surfoces
become domoged,
remove them ond form new ones by floring the
pipes. To do this, use the coulking holder,
type
MP 9-151. Clomp the pipe
in the holder so thot
it is level with its upper edge ond flore the pipe
with c coulking chisel. The holder is designed
to be clomped in o vice.
The holder
hos two drilled holes of 5 ond
6 mm in diometer so thot it con be used olso for
repoirs of pipes
of the clutch line. For dio.
5 mm holes, use the MP 9-152 ond for dio. 6 mm
holes, the MP 9-153 coulking chisel.
The flexiblepqrt
of the hydroulic line consists
of speciol hoses.
When fitting them to the reor
wheel cylinders, turn them in o position
which
will prevent
their contoct with ony ports
of the
cor in both extreme positions
of the cor sus-
pension. This is why the nipples ot the reor
wheels ore inclined
downword through on
ongle of 30 degrees from
the horizontol plone.
9.8 HAND BRAKE
The hond-broke
lever between the front seots
controls the tie-rod which octuotes the rocker
(see Fig.9.8/1). Cobles connected
to the rocker
Fig. 9.612
-
Broke Booster Press
Button
Adiusting Fixture
MP6 141A tx r5?2
140

'i
iiiI 14. Fuse box
Centrol connection of conductors -
do not
seporote them from the bunch!
15. Direction indicotor switches, dip switch,
and horn switch
eight-pole terminol
boord
six-pole terminol boord
16. Porking light switch ond high beom feeder four-pole terminol boord
17. Switch box femole connectors 5.5 with symbols "15",
"30", ond '50"
to be
connected to symbols
"15u, "30', ond '50"
on the switch box
18. Instrument ponel
ten-pole terminol boord
six-pole terminol boord
eorthing coble with lug
'19. Heoter switch
four-pole terminol boord
20. Switch of disobility lights
six-pole terminol boord
21. Door switch, right-hond
green -
femole connector 5.5
22. Dome light,
right-hond
green -
femole connector 5.5
red -
femole connector 5.5
23. Stop switches
forked (yellow) -
femole connectors 5.5 .
red -
femole connector 5.5
white -
femole connector 5.5upper ond lower
switch
upper switch lower switch
24.Fuel gouge block -
femole connector 5.5
yellow -
femole connector 5.5
blue -
femole connector 5.5
to be connected to the respective pins
(blodes) of the some colour of the fuel gouge
25. Storter motor, reversing
lomp switch
conductors with lugs stater motor moin
terminol boord
storter motor
control switch
green -
femole connectors 5.5 heodlomp switch
26. Oil pressure
gouge,
thermometer, corburettor
iet seporotor
green -
femole connector 5.5 yellow
-
femole connector 5.5
green - telethermometer
primory element
femole connector 7.
corburettor
iet seporotor
27. lgnition coil, voltoge regulotor, olternotor,
tochometer
conductor with femole connector ond
bronching lug
femole connector-regulotor terminol 15/54
lug -
ignition coil terminol 15
blue -
femole connector 5.5,
symbol "R"
. regulotor terminol "R"
yellow -
femole connector 5.5,
symbol "M"
regulotor terminol "M"
blue -
connector "R"
. olternotor terminol "R"
yellow -
connector "M".
olternotor terminol "M"
lug terminol "+B"
conductor with
lug ignition coilterminol "1"
(tochometer operotion
)
28. Toil lomp cluster, right.hond
yellow -
femole connector 5.5 toil light
block -
femole connector 5.5 direction indicotors
red -
femole connector 5.5 stop light
green -
femole connector 5.5 reversing lomp
29. Licence plote light
conductors with femole connectors 5.5
30. Toil lomp cluster, left.hond
se point
28.
b) Connection
of free conductors
1. Storoge bottery
bottery coble positive
(*)
terminol -
storter motor
bottery eorthing strip negotive (-)
terminal -
bodywork (eorthing conductor)
2. Engine engine eorthing strip (fostening
lug) -
engine cross beorer (eorthing conductor)
3. Distributor speciol coble from distributor to
ignition
coil; end with interference suppressing
terminol to distributor
coble from distributor to ignition coil
terminol "1"
cylindricol
(pin)
connector
pressure gouge172

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ii Observe
strictly the following instructions:
1. Mointoin the electrolyte level ot the level
of the perforoted
inserts between the plotes
or
so thot the inserts ore
covered with the electro-
lyte to o moximum height
of 4
mm. The
bottom
limit of the electrolyte level is 3 mm below the
perforoted inserts. Use only distilled woter for
topping up the electrolyte. Add electrolyte only
if it hos been obviously spilt from
the bottery.
In such cose, its density must correspond to
the density of the electrolyte Eemoining in the
bottery. 2. Keep the bottery terminols
cleon, remove
oxides occosionolly, ond
coot the terminols
with minerol
ielly.
3. Wipe off the electrolyte spilt
over the bot-
tery surfoce since it is conductlve ond couses
dischorging of the bottery.
4. Check the
chorging of the bottery occord-
ing to
the electrolyte density or check the
voltoge drop using o voltmeter with o looding
resistor ond comporing the obtoined reoding
with on evaluotion toble or scole.
5. When chorging the bottery
outside the cor,
use chorging current volues occording to the
toble. The voltoge should be
controlloble in the
ronge from 12.6 to 16.8
volts. The fully dis-
chorged bottery is fully chorged in obout 13 to
20 hours when
o) the electrolyte ottoins o density of 1.28 in
oll cells ond does not chonge in o period
of
two hours;
b) the cell voltoge (meosured
with opplied cur-
rent) ottoins o volue of 2.6
to 21
volts ond
does not chonge within two hours
of con-
tinued chorging;
c) oll cells ore lively gossing.
6. An olreody used bottery must not be left
without electrolyte or dischorged os it is opt to
suffer from
such o condition.
7. The bottery in on unused cor must
be
removed ond chorged outside the cor
within
three months ot th-e lotest. lf the cor is under
repoir for o prolonged
period,
toke oll necessory
steps to keep the bottery in good
condition.
Bottery Chorging versus Electrolyte
Density
Specificgrovityl i Electrolyte
(density) iChorgingl freezing
g/cms I I temperoture
1.28
1.24
1.22
1.15
1.12 1oo
o/o
Toolo s0% 2oolo
0 -60
0c
-50 0c
-35 0C
-17 "C
-120C At o
20 per
cent chorging, the bottery is
considered procticol
ly dischorged.
Toble of Chorging ond Dischorging Values
Roted voltoge 12 volts
Roted copocity C 20
ot o
20-hour dischorging to 1.75
volts per
cell 37 omperehours
Normol dischorging current
for 20-hour
dischorging to
1.75 volts per
cell 1.75 omperehours
Normol uniform chorging 3.7 omperes
Two-stoge chorging:
stoge I up to 2.4 volts per
cell; gossing
beginning 4.4 omperes
stoge ll up
to f inol
morks
of fuf fychorgedcondition 2.2 omperes
Diffenent instructions, determined specificolly
by bottery monufocturers, opply to moking o
new ond empty bottery reody for
operotion or
to so-colled quick
chorging.
Sofety Precoutions ond Other Meosures
During chorging, the electrolyte temperoture
must not exceed +40oC. As soon os this
tem'
peroture is reoched, interrupt the chorging or
lower the chorging current (this
opplies es-
peciolly to so-colled quick
chorging).
During chorging, on explosive mixture of hy-
drogen with oxygen is liberoted from the elec-
trrolyte. Therefore, the oreo where the bottery is
chorged must be ventiloted, ond it is forbidden
to opprooch with o noked flome (or
spork) the
cell filling holes (even
ofter o consideroble
period of time ofter the chorging hos been
completed). When chorging the bottery, open the filling
holes of its cells to enhonce degossing.
The electrolyte is on ocid hormful to the skin
ond clothes os well os to ports
of the cor fin-
ished in
enomel. Rinse with woter immediotely
ony contominoted spots.
13.3 ALTERNATOR The olternotor is o three-phose generotorwith
o built-in semiconductor rectifier
for feeding
electricol devices ond the bottery with
direct
current.
Alternotor lnstollotion ond Generol lnstructions
They opply to both olternotor models. The
following principles
should be observed:
174