SKODA 120 LSE 1980 Workshop Manual

1
1
1
1
1
1:
1r
1l
't,
1',
1:
1:
1l?
ffi{,
ll
---r---
i
fdll
100 -
Storoge botteny
101 -
Switch box
102 -
Alternotor
103 -
Voltoge regulotor
104 -
Storter motor
105 -
lgnition coil
106 -
lgnition coble
107 -
Distributor 115
113
'l7s:,!--,t
ir
rl
tl
tl
t|- -
- --
- - -- - - --- --- -l
116 i
I
I
L--_-___---__ I
Fig. 13.111 -
Wiring Diogrom
108 -
lgnition horness ond sporking plug
interference suppressing resistors
109 -
Fuses
'110 - Instrument ponel
111 -
Instrrument ponel
terminol boord
1 -
High-beom worning lomp, 2 -
Lubri-
cotion worning lomp, 3 -
Telethermometer,
4 Alternotor (chorging)
worning lomp,
169

v69
t
rolDrodas c!leuDDUorlcele
le! lollernqJDC
lq6!t alDld acuac!-l
sduol 6u1s:eneg -;r 's.roloorpu!
uoll
-cer!C -
e'slq6ll dots -
Z'slq6!l llol -
L
Puoq'1q611 'Jelsnlc
dtuo; ilo1
puorl-llal 'Jelsnlc
dtuol 11og
qcllMs duol 6u1s.rene6
Aola: 6u;qclrrts druo;poaq llo11;xny
qcllrvrs dtuolpoaq A:o1;1xny
puoq-1q61r'duo;poaq Lrolpxny
puDq-llal'druo;poaq I:o1;gxny
]q6I
6u;1ro6 -C'uDaq
Mo-l -7'uoeq
q6!H -
L
puoq-1qBr.r'druo; poe g
puDq-tlel 'duolpoeg
rlol!trts 1q6r1 dolg
qcl!MS dluo; 6urulonn ualsAs slDJg
Joloul J'alDaH
(paeds
rtol) .rolotu JelosH -
g '(peeds
q6rq) .roloru
JelDeH -
Z :Z'oN
esni rxorl u!-pDal -
L
pJDoq lDU il.ujal
qclrMS Jolorx teloeH
'slepoLu
s-l ozL puD
'1 SOL 'S
901 VCO)S eql uaaMleq
sacuerallrp
urDuec erD ereql
loql os
luer.udrnba (p.ropuols)
o!sDq Joo eql ol 6ulpuodsa::oc
spool I;uo
epnlcu! sJolcnPuoc peqcunq
lDnlcD eql 'lDsJaA
-!un sl sJolsnpuoc peqcunq
lo uotlceuuoc eql
;o uolldg.rcsap
eql puo
uorDorp ouurnrr eq1
:eloN
- zgL
- LSL
- OsL
- 6tL
- 8UL
- LVL
- gVL
- gVL
- vvL
-wL
- zvL
- LVL
- OtL
- 6tL
- 8tL
_ LI,L
puDq-
-lq6!J 'stolocrpur
uorlool!Cl -
g 'puDq-]ral
'sJolDctpu! uotlcsJ!C -
t 'laloelq
l!noJ!c
Joloolpu! uorloer!p lo Jepeel
-
t :Z'oN
esnl
l.uoJl u!-pDs-l -
Z:L 'oN
esn, uorl u!-pDel -
L
PrDog lDu!Luref -
ge
L
relc!l roloc!pu!
uorlcerlp ql1rr sgq6rl I1r;rqosrp
lo qcltMs
-
gtl
uoaq q61g -
g
'slq6!l (apts) acuo.palC -
Z 'repse1
-
L
prDoq lDulurel -
ttl
rapsel uoeq qDgq puD
r{c}rMS
1q611 6urlrod -
ttL
(,,9,, puo
'u?u 'uZ, sJolcnpuoo peqcunq) qcttrr,,S
- g puD 'V
'Z
:Z 'oN
esnl rloJl ut-pDe-l -
L
Prooq lDu!ural -
ze L Joloul
.radqlrr useJcspu!M -
Lg1
Jolou JorlsDM ueeJosput411 -
g '(,,9,,
srolcnpuoc paqcunq ) roloru
.rad14n -
g '(,,t,,
srolcnpuoc paqcunq)
.rolotu tad144 -
t '6ul
-qUD3 -
E' (
uZ, slolonpuoc peqcunq
) roloru
led;rvr uaeJcspulM -
Z'peldnccou6 -
g_
prDoq lOu!r.ureI -
0t!
sJoloru
.redgrrr puD
leqsDM ueaJcsputM
lo qcllMs
-
6ZL
JolouJ JeqsDM ueejcspulnn -
gzl
uroH -
LzL
puoq-1q61r 'tuorl 'JolDO!pu!
uorlcerlCl -
gZL
puDq-llal 'luoJ]
'rolDc!pu!
uorlcerlc -
gzL
L 'oN
esn, uoJl
u!-poel -8'uDeq
Mol -l'rrDeq
q6!H -
g
'(,9gu sJolcnpuoc paqcunq) qc11rnrsd16
- g 'puoq-lq6g.r 's.rolDclpul
uo!lcer!C -
t
'PuDq-uol 's.rolocrpur
uo!lcer!c -
e 'Jopael
ro>lcll rolDcrPu! uollcerc -
z 'uJoH
-
L
prDoq loulr-ural -
tzL
qclrrusdgp
'qc11rvrs uJoq puD
Jolocrpu! uo!lceJrC -
tZL
qcllMs druol 6u;urDM e^JasoJ 'enJ
-
ZZL
luauele A:or.u1.rd Jelellort:eq]eleI -
LZL
ilollMs dr.uo1 6u1u.rDM ernsserd
itO -
OZt
rolor.u uDl .!olo!PDU -
6LL
(qclgrvrsouraql
crloruolno) qollMs
rolour uD] rolorpDU -
8LL
qcl!/v\s
palo.redo-puorl rllrM'puoq-lq6r.r 'duol
aruo6 -
21_1-
puoq-1q61.t 'qollrn,rs
rooC -
9LL
r.l3l!MS
palo.redo-puDLl ql!r* 'puDq-itol
'druo1
auoq -
g;1_
puoq-uol 'r..lc]rMS
rooc -
tLL
alcoldaceg -
91-1-
DurquDf _
9
'releuoqcDl - g '(enlq)
a6no6 lenJ -
?
'(rrrol1ai) e6no6 lenl -
t 'Z
'oN
asnl uorl
u!-pDsl -
z'uorlDu!uinll! lueunrlsul -
L
pJDoq loururJel lauod luaunllsul -
ZLL
peldnccoun -
0L '(Dr]
-xa ;ouorldo) dtuol 6ulurorrr
duol 6o3 -
6
'druol 6ulurorvr tualsls alorE -
8 'srolo3lp
-u! uorlceJrp puoq-1q6r.r
;o dr.uo1 6utu.ro41
-1's.rolocrpur uorlcelrp puoq-lla1
1o dtuol
6u1u:o1y1 -
g'druog 6u1uror"r e^Jesal
lanl -
E 'du
'le:
'!J(

TYPE: S
105/120,12O LS, 12O GLS
Electrical Equipment 198O model
WIRING DIAGRAM
Diagram 13,1/'l A170

,LL
*
9'9 uroq -
JolDclpu! utoq
'JolDc!Pu!
uo!]caJ!P
uollcoJlc'9
'L tulod ees
sduDtpDeq ro'dulDlPDeq
puDtl'Ua'l't
I Jolceuuoc alDurel -
r*o11eA
qclltylsoutJeql uol JolD!pou't
9'g Jolcauuoc
alDuel -
>lcDlq
roloclpu! uollcerlp
PuDq-ua-l'z
lrolcouuocelouel -rrro11ei''
dtuolpoaq
A.ro11;xno
g'9 Jolceuuoc oloual -
per ' 'rq6!l(epts)
ecuoJDelc
lor.l
-
)cDlq
rolcauuoc olDuel -
lcDlq
olqDc lnoqllM -
mol1aA
olqoc tnoqll't^ -
lcDlq
eoqs
eoqs
tuoaq
q61q
ruDaq Mol
9'9 Jolcauuoc
olourel per
g'g Jolceuuoc elDuel -
ueel6
puoq-llel'lq6;1 euoq'g;
9'9 Jolceuuoc elDuel -
rrtollaA
puor{-Uel'qcl1nns rooc'ZL
qcllrrns ol
9'9 rolcauuoc elDuel -
rto;1aA
sdruo;poaq o1
g'g rolcauuoc eloual -
(alqnop) rvrogleA
sduro;poeq Aro;;;xno,o tlclltvts'LL
JOIOIU UO
,, -.,,
loquAs ol
I Jolgeuuoc
elDulal -
lvrol;eA
rolour uo
,,*,, loquls ol
I Jolsauuoc
elDulel -
peJ
loloul JstlsDtn ueolcspuln^'01
,z/r,logurts ol
g'g
Jolceuuoc alDtlal -
PeJ
,,+,, loquAs ol
g'g
lolcauuoc alDulel -
rvrol;eA
JOIOUI JelDeH',6
pJDoq lDulujJel
.radlrvr aql uo sJnoloc euDs aql
lo sJo]onpuoc
o1 allsoddo Jo p:Doq
lDulr.uro1 aql
Jo sJaq
-unu anllcedsal eql ol pelceuuoc
eq ol
,9,
puo ',t" ',2, ',,L,
sloquls qllM
sJolcnpuoC
pJDoq toulurJel redlrn ueeJcspuln1'8
g'g Jolcauuoc elDuel -
ntolge{
(,,9,, qguot'q
u1 pelo.rod.rocu!
s! elqDc eql .ro)
elcoldeceg'2
Aolel eq1
la uiu
PuD ',c,
",1,, sloqulls
ol
pal3auuoo eq ol
,t, ',tu
',L,
SloQ
-uAs ql1m g'g
sJolceuuoc alDuel -
mo;1aA
sdtuo;poeq fuo;;1xno
1o Ao;er
6u;qc1;rrng'g sduo;poeq
ro'dutolpDeq puDtl'ltl6tU't
sJolcnpuoc peqcunq
lo suollcauuo3
(o
'ssouJDq 6u1.r;rvr ulou eq]
;o 6ulqcuo.rq
e^lsseccns eql 6ulMoqs 's1q6;;
llDl eql
o1 sdtuol
-poeq aql uoJl acuanbas
1ca.l1p D u!
pelsll
erD
leql'c1e 'sloquis
lDclJerrnu lolpuD
lnoloc Jlaql
qll/v ecuopjosco u! sJolsnpuoc
lo suollceuuos
eql so!'lcads ienrns 6u1rvro11o1
eql'zlL'tL '6lJ
u! xoq esnl oql ;o tuo.r6o1p
6u1l1rrr eql 'LlL'tL
'6tJ ut uMotls s1 tuo.rDogp 6u1l1ru
llora^o aql
sSclnSc clurcsl3 Jo eNlul/![
lq6q 991 :eag
qcl!/r^s 9ol reau
/e Jo^ro3aJ
Jec
17 Aept Butqcltrns ueaq
peddt6
fie1sorlap) Mopur^
reor poleaq
Io asnJ
/1 f elsorlap)
rvroputnn leal laleeH
Ae;ar 6urqclr^ s Jolsollop Mopul^ JeaU
an;en crleubeurorlcalo loualnqleJ
1q6t1 areld
raqurnN
pueq tqBt.t 'lalsnlc
dtuel 1te1
sdue; buts.raneg -
t'eolectpul
lcslo -
e'slr{6!l do}s
-
z'srq6!l llel- -
I
'pueq-Ual 'lalsnlc due; 1te1
qclln s dtue; 6utslenag
77 sduelpeaq
fuerpxne pue
sdr.ue;peaLl
lo Ae;a: Dutqcltnng -
891
_ LgL
- 99r
- 991
- ng|
- tgt
- zgL
- tgr
- ogt
- 6nl
- Bnl
- Lnl
- gnL
L/LeL uo
se suoplsod raqlg
VL/L'EL urer6el6
6Z6r ulgorco 33Nls l^lvu9vlo 9Nlul/V\

'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

tLl
rDC u! Arellog
a6o.ro1g ,o uollDcol
LIZ'IL'6tJ
'a1l;or1ce;a 'o sorlll
Z.Z lnoqD qllM
pelltl s! Arelloq e9I '(?8"
tZ) tZ'L;o suo16a.r
1oc;do.r1 rol '(ggoZg)
gZ'L 1o l11nor6
c1;1ceds o
lo p!cD
cgrnqdlns l:a11oq s! pesn
a1A;otlcage
eqf i:a11oq pDal
lt N 9 lapou 'W
lZlA ZL
VN6)V adAt eqt
qlrm
peddlnbe
s1 rDc aql
ecuDuelu!DlN r{"raltog puo
edAl l.regog
'I:a11oq aql ol e6ourop u! puD
.ro! Iralloq eql
]o uoluols!p D
ul
llnsar ot
tdo s1
6u1ue1q6!l
a^!s
-secx3 '6u1ssells
fq6!ls D ulDlqo
o1 so os l;uo
slloq lolcD:q fua11oq sql
lo slnu
aql uelqDrg
uo!lDllDlsul
'i:eltoq aEorols 1o edil
cg;1ceds eql rol
sJeJnlcDlnuot! snolJon Iq apou alpuDq Dulnou
-er ;olceds o
ro
leels dooq ulo.t; 'elduoxe
.ro1
'apDtu slooq ssn ol papueuuloceJ
st
1! 'lonouel
st! elDyl!cDl o1 'Ara11oq
eql Aomo 1r!l puD
1.rod raddn
fua1pq aql
]o sepls rolJoqs
eql uo
suolsn:1o.rd aq1 dlrg 'rolorx
JeUDls eql ol pDel
eql lo loulullel eql
puD
duls 6ulquoe eLll
lo
loulujel aql
lcauuocs!c 'pJDoq
Jool, luat!
-1.roduoc e6o66n; eq] u! ra^oc puDq-Uel
eql
e^oueJ puo '1oru
aql f]!l 'lDes
JDoJ aq]
lo lseJ
-lcDq puDq-Ual aql d11 'luarulrodruoc
e6o66nJ
Jouelu! eql Jepun pelDcol
s! I.re11oq eql
lD^ourau puD
uollDco-l
AUIUVS feVUOtS
Z'sL
troaq q6;q 'puoq-1q611
'dLuo;poaq
- g
sdruolpoaq {lo;;1xno ldtuo; 6uluJDM uJDaq-
-qDtq puD uoeq-qBrq 'puDq-Ual
'druo;poeq
-
7
uloaq Mol 'puoq-1q6;.r
'dtuo;poaq
- g
uoeq Mol rpuDLl-Uel
'druo;poaq
- g
uo!lDu !LUn ll!
luaunrlsu! ipuoq-1q6r.r'1q611
(ap;s)
acuotoalc
:rq6!l a1o1d acuec!l lpuoq-rq6lr ,lqD1
ltDl -
? '3le 'seqcllrrrs
A.ro1;lxnD roj
louDd -
t
'elcoldeceg -
7 'penouet
pll xoq esn]-sasnl -
L
elcoldeceX isesn3 Aq
stlncrlC clrlcel3
lo uollcelo
)d -
ZIL'qL'6tJ
puDq-tlel
'1q611 (eprs) acuo.roalc :puDq-Ual 'lq6!l
l!oi -
e
.ro1o:odes lel :o11a:nq
-.toc lsduro; 6ugs:enal llolou JsrlsDM ueeJcs
-pu!M isdtuol 6ululorur uotlDcllqnl eug6ua puo
(6urBroqc) ropuro]lD idtuo; 6ururorlt
o^res
-eJ lenl puo
a6no6
len; :sJolDolpul
uo!lcar
-lp :Jolour relDeq :Jolor.x .radlnrr uealcspu!nn -
Z
durol 6ulurorrr uelsls
alDrq :roloru uD, JolDrpD.r islqBrl dols ls1q6r1
i11g1qos1p :uroq is1q6t1 euop le;coldacal -
I
g ol
I'oN
sosnJ ol socl^oc
lDcltlcelf lo uollcauuoc
'lq6rr aql ol 8
ol L tuoJl
ecuenbes
lcaJlp ut
palunoc
aJD sasn,
6u;rvro11o; eql 'llal
eql ol s!
L 'oN
asn3 'se:ad
-LuD gL .ro+ pelDl
eJD sasnl eql 's;a6ur;
eql qllr',r
poMeJcsun eq uDc pll
eql,o MeJcs
oqt 'Dt3D,
oql rspun tJel eql ot
psllDlsu!
sl xoq esnj aql
xo8 Ssnl
(1eaqs lDlerrr 6u;lroddns
duo;poeq o1 sdr-uolpoaq)
lrorrrApoq-rolour
uDl JolD!pD.!'JoloLu relDaq'lq6!l e1old
acuac!l's.ro1ocgpul uollcerp
1uo.r;'sra1snlc
duog po1'redgrrr
ueercspurlvt'sdruolpoeq
:sacl^eP lDclJlcsla Jo salJosse3cD
sD salqDc -
>g.tomApoq
- sdr.uolpoerl A.ro;;1xno
;o {o;er
6u;qclrms
MeJcs 6u1ua1so1 uJoq -
uJoll
>lrorvrlpoq -
JrolDln6er a6o11on
:alolodas -
setqDc 6u;q1roe prDpuols 't
3y'.rod'g'7 la1doq3 oos
uo!lcaur"",i":A;ij
6u11.rods o] rolnquls!p tuoJ, sseuJDq uotlruDt t
t,
z'€t-l'tt

r3.2-t 3.3
tuJ
t(A 4r
3t 2t
,tl
(
Per
lp
5
4
3
2, I
Ah re€
l
i
i
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

,LO,6ft-9t|,€,nn OZO.LLn_g ! I,tft
roletnBer
YLI Joleuralle
NOIINgVI -'lvd
qll/t^ uorlcunluoc ur salelado loleulellv
'u!u/t 0006 0008 000t o@9 0009 000, oooe ooo? ooot
o
l/n't,l'6!l ul tuelBerp
Duurnn osle aos -
uorgeledg
roleureUv .ro1 6ur.rr41 crseg -
Vg/e't I .0ll
roteuJalle oure
99roj ;
hn s'r) .
durel Ouru.rervr -y
(xoq qclr^,As) qou/r
s -S
tuaueq _g
ioleln6er e8er;on -
93g
Joleulalle -
g
L/i'eL'6ll ul uelOerp
6ur:lnn osle aas -
uorleladg
roleurollv .ro; 6ur.rr11 crseg -
Vtle'e t '6ll
slOleuelle
dute Zl pue
ge rol
{A 9't}
due; 6uru.renrr -;
(xoq qclu
s) qclt/v\s -S
tuoueq -g
rolelnbe: a6etqon -
93 g
roleulelle -
g roleu.rallV
t8 t'g lg-t LL'tftn edAl
;o uer6er6 aoueurrofed
aArne
lndlng LZL' gL1-tL;ttt
rolDurat
I V -
Z lt' t
L' 6
| J
rgst x0
ulul ow
OC
0, (vt t
aAJnc
rndlno LZO'919-SLL'ett rolDurallV
-
L19'EL'6tJ
09sl y0
ud,0oo0t V9E
v at u'o,0oool
vz, uor
oooo
v9t p33os
u.4ire4
iua/nr unu,\en
ron pa@rPMl
udrOOtZterlarnl
uor ool V LI
u,o)o0oL v9z
uorooot lon
paur?Ml
udroo9zrerusrnl re su,6aq 0u,6reqJ
a6erro^ ar,das
8i9rg-ttrl I i9'€
Enn zo99 EL t NOllN9vn lVd rP)
slapolN rec
ol pre6oH
qt!/vl
sloleuleile
lo eleo
leclul.{cel
w
@0,
ma Not
o
ot
OZ
0€
o, o9
(vl I
0 0l'
0z
'llncJ!c-uoqs D lsu!DOD ,,9+,,
PDel aql
lcolord 'JolDuJello
eql uorl
spDal
llD lcauuocs!p ol
pepusurruocsJ
s!
l! 'lrDc
aql uo sJlDdar ro; 6urp;ervr c:o 6u1sn uaq6
'sJolcnpuoc!ujos oql
Io:1sep lg1rn u1o6o
qclqm 'a6o1Jon
JolDurallD
eql lo es;.r
louo;ldocxo uD esnDc
lllrvr uol]lp
-uoc pool-ou s!rll 'paeds
6ugsoe:cug lV ',,lnt
,,
lDuluJel pelcauuoc
eql qll,vl puo
,,8+,, lDu!ul
-rel eql tuoJl pelceuuocs!p
pDel
eql ql!/v\
"e'l 'pDol-ou
lD JolDuJallo
eql
tJDls lou oc
'6uguun.r s1 eug6ua
aLll ellq'vt {re11oq eql
lcauuocs!p lou ocl
'(q 1u1od)
sJolcnpuoc!utes lo uollsnllsap
aql u! oslD
llnseJ o+
ldo eJD
qolqrlt 'slDuluJe]
Aolat lop;
-n6a.r e6o1;ol Jo lolouJello eql Je^o sl!ncJlc-
-lrot{s lDtuop!ccD 1o 41111q;ssod
eq1 a1ou1
-u!le ol tlncrlc 6u;6roqc aql
lo lueuodruoc
euos Ougco;dar ueqrvr l.re11oq aq]
lcauuocs!C
'sJolcnpuoclues eql 6u1Ao.r1sep lo lslr
oqt se^lonu!
l! sD
(uo11o.redo
roloure]lD eq]
Icaqc ot Alpedxeu! 6ulA.rl uaqrvr 'eldtuoxa
.to1) luauoLU lseto!rq aql
rol
ue^e slDu!uirel
.rololnBer ro rolDuJellD l!ncl!c-Uoqs lou oC
'ac!^ep Jolcnpuoc
-!ulos rolourallD aql Alqo;ronu1 slcn:1sep fue1
-lDq eql ol uollcauuoc
elod
]osJJocu! uD Jo
6uulrvr oql o] uorlceuuoo
elod
1ce:.rocu! uV(r
(e
(p
(c
(q (o l
l
\ald vzA
.,r4 I
I
I
l=n (u),= -
Mz v:|vvn
I I
/
/ ut-/t
0006 v99I
./
I
,tt.n PJJ.I f
t
a!u'/L 0092/VLe .t
u!,'/L 0006/vz, I
f
t
t
(t
(
I
I

L
i g)
Excitotion of the olternotor by o current
supply outside the cor is not permitted.
Agoin the semiconductors would suffer.
h) A blown chorging worning lomp must be
reploced immediotely with o new
one. Other-
wise correct excitotion of the olternotor is
not ensured. Use o new lomp of
the some
roting (or input), i.
e., 1.5
to 2 W.
i) Be sure thot there is
o perfect
electricol
connection on the connecting terminols ond
thot the olternotor
ond regulotor
ore properly
eorthed.
i) The
olternotor is oeroted, open. Therefore
toke core when woshing the cor thot woter
or cleoning ogents do not get
into it through
the venting holes.
Removing the Alternqtor
1. Disconnect the bottery.
2. Disconnect the olternotor leods. lt will be
helpful to remember the colour of one conductor
ond its connection for reinstollotion.
3. Remove oll ports
holding the olternotor on
the engine, ond lift owoy the olternotor.
Reinstolling the Alternotor
1. Cleon oll mounting surfoces.
For the olter-
notor mounting, see Chopter 2.3, por.42.
2. With the bottery
disconnected, insert the
conductors into the respective
connectors "M,,
ond "R"
(the conductors beor the some sym-
bols), ond fosten the remoining leod with o nut.
3. Reconnect the botterv. Alternotor
Disossembly -
Repoirs
1. Screw off the belt pulley
nut ond remove
the belt pulley
ond fon.
2. Lift the brushes with o hook proceeding
through the holes in the
commutotor end
shield
ond hold them in the lifted position
by wires
inserted into the shield through dio. 3 mm holes
under the terminols uM'
ond "Ru.
3. Mork the mutuol (relotive) position
of the
commutotor ond drive end shields ond seporote
the qlternotor
ofter hoving removed its clomping
bolts. The drive end shield remoins connected
with the stotor.
This disossembly will give
occess to the
brushes ond some
of the diodes. All other
iobs,
with the exception of the renewol of the beor-
ing, should be done by experts in speciolized
repcir shops -
see the note supplementing the
following porogrophs.
Alternotor Reossembly
1. Insert the circlip into the becring bore
in
the commutotor end shield.
2. Fit the drive end shield with beoring on
the rotor shoft.
3. Assemble the stotor with the rotor ond the
commutotor end shield. 4" Tighten the olternoior with clomping bolts
ond check the rotor for free rototion while
tightening the bolts.
5. Slip the spocer on to tlre shoft,
top the
key in position,
fit the fon ond belt pulley,
ond
tighten the entire ossembly using the nut with
spring wosher.
6. Pull out wires from the commutotor end
shield which hove been used to hold
brushes
in their lifted position.
Replocement of Beorings
The used beorings ore fullyclosed ond seoled,
ond they hove been filled in the foctory
with
lubricont to lost through their entire service life.
1. Pull the beoring off the rotor
using o suit-
oble puller.
When ref itting the beoring, press
it
on to beor on the shoft
collor-
2. Before removing the drive end shield
beor-
ing, f irst drill off the heods
of the flonge rivets
ond then drive the beoring out from
the outer
side of the drive end shield using o suitoble
mondrel (drift).
On reossembly,
close the beoring with the
flonge ond rivet the flonge to the shield.
Replocement of Diodes
The use of the removoble
diode block with
the individuol
corriers of the so-colled positive,
negotive, ond ouxiliory diodes, focilitotes con-
siderobly the replccement of ony defective
176
Fig.133la
-
Alternotor -
Sectionol View

LLI
-uoc u! 6u11o:ado Jolorqr^ o Allo11uasse sr
ll
'
OZO' LLV-gLL'Ctt
lopoLu'a1ou uo1au6o141
-lvd aql lo sr
pesn:o1o1n6er
a6o11on aq1
uorvln9lu 39vr10n t'tt
'.reuuDuJ urDlJec o
u! eJnpDl Auo
lsotulo o1 Aler.uou
slcoat duiol
slql 'eco;d
]srll eql
ur duo; 6u1u:onn aq] Iq
pe11ou61s st .rololn6ar e6o1;on Jo rolDulo]lD
eql
lo a.!nllD,
o 'pouollueu
Apoarlo ueaq sDr1 sV
'paads req6;q Aglq6rls
o
1o .ro
peads
6u1pt
1o Apoa.rlo
lno o6
lsnu duo;
6ururorvr 6u16roqc eq1 'paeds
aug6ua unrpeur
puo .raq61q
1o a6uor eql ul sllo^
8'0+tL lnoqo
ulq]lM ,{:on
}snu a6o1;on
paloln6el eqi ',,8+,,
lDu!tural eql ol
palceuuoc
lalau]lo^ aq] ql!nn
'paads 6u1s;.r eql ol
relaurulo .ro
dr.uo1
6u1u.ror* 6u16roqc eql
lo uorlcoar eq]
ro
e6o
-llo^ peloln6er eql
lceqc o1
]uerclllns sr
1r 'pa
-lcedsns ]ou sr
lcalep o
ueqM '1as
A;ddns :anrod
erlua eql
lo lcaqs a3!^Jas eullnor
D
lv
'6u16roqcrano iralloq eql oslD
1nq Aralloq
eql lo 6u16roqc-uou Aluo
lou esnDc uoc ,{o1a.r
rolo;n6el ro rolDurallD
aLl]
lo loelap
V :a
] o
N
'6u rql.roe Atal
-1oq .rood ro 'ernlcnJls
JD3 eql puo 'auoJl
Jolol
-n6ar a6o11ol aql 'euo.r;
JolDu,tello aql uaeM]
-eq lcoluoc rood o lla.raLu eq
uoo
loelep aq]
to asnDc aql 'JolDln6a:
a6o11on aql ul
lqDnos
eq ol sDq
lcelep aql
puD 'rePro
u1 s1 1r 's1sa1
paqlrcsaP eql
Pellsllos sDq
rolDure]lD
aq]
]l
'sllo^
t'0 uoq] .ra6:o; eq
lou lsnui
asueral'!p slql',,u,, puD
,,8+,, slDull.uJal JolDu
-rallD eql uo ecuelo]l;p a6o11on aq]
l33qc 'g
'sllo^ gL o1 dn
e6uor
eql urqllM
lsel eql
l3npuoc ol
pePueuuossj
s; 11 '(anlon
>1oed) sllo^
0Z spaocxe
a6o11on aql
loql os
pesDercur
aq
lou lsnu peads
au16ua aql
'lssl slql 6u1rn6 'uo!l!puoc
poo6 u1 {;qoqoLd
sr
rolDuJallD eql "r.u'd'-r
6ur1p; aql e^oqD 6u1s1-r,
paeds aLll qllM
sesrr relaullo^ aql
1o 6u;poor
aq1 11 'paads
aul6ua eqt AllDnPD:6 asoatcul '9
'lqnop Auo puoAaq
e^!lcalep s!
]! 'Pe]!cxa
eq
louuDc JolouJellD eqi
ll 'u8+,
loutuJel oql
o]
spuoces eaJql o] oMl Jo] ',,
l l,, puD
,,u,, sloulul
-Jal eql 01
Palceuuoc 'tolcnpuoc
A.rot;txno aul
lo spua
aq1 {lddo -
roloula}lD oql e}!cx:l 't
'paeds 6uttpt o^oqo oslr
paeds sll lel lou op
1nq au;6ua aql
uDlS 'c
'(-) auotl
rolDursllD aq]
PUD ,8*,,
loultu€l eql
ueeMlsq
Jeloutllo^ o
lcouuoc puo
Jolcnpuos AJDIIlxnD eql
tll!M ,,u,, puD
,, l^l " slDUltuJel
lseuuosJelul 'z
'I:a11oq eq] ol pel
-oeuuoc sulotleJ,,E*,,
louttural'(dn ueq]
xluJ
lou op -
auo lcolq o
"N,, loull.urel 'JolDlnsu!
poJ o sDtl ,,U, lou!ulJel) ',,t
J,, puD
,,U,, slDu!Lu
-Jel JolouJello et{} utoJ,
sPDel
}cauuocs!o '! JolcnpuoC
AJD!lrxnv
uo 6urs61 -
JDC ut
6urr;41 rolDurallV
6ur1ceq3 -
g/t'tL 'DlJ
?gst x0
'g/t'01 '6tJ
ul ruo16orp
aLil o1 6urptocco
slDu!rural rolourello aq] re^o
aDpr.rq o] sjo]
-oauuoc Lltrlra Jolcnpuoc AtorltxnD uD atoda.r6
lceleq ro1oln6eg
- JolDurellv uo
6u1sou6D!C
Jo, elnpecord
'(pe6roqc lou st i.ra11oq
aq1) druol 6u1u.ror* 6ur6.roqc
sqt Aq peplou6rs
s! .ro1o;n6a.r ro rolDuJellD
aq]
lo ]3elap
V
']leq a^rrp rolourellD
aql
lo (6uruorsual
1ca:.roc) 11nd alonbapD uo
puD 'sloul"utel
l.ral
-]Dq puo 'lo1o1n6ar
ebolJon 'tolouJellD
uo suot]
-ceuuoc clrloela 1ca;.ed '6uurrt
pe6ouuopun ero
uorlo.rado JolDuJellD ]oerroc o
Jo suotltpuoC
'Zlt'tL puD L/e'eL 'sDr3
ur
sanJnc aas -
6urpurq puo
aloJnoco paraprsuoc
eq uoc rlcuoq
tsal D uo
pDol
elqorlD^ qpnn
1nd
-]no aql
,o l3eqo o Agu6 'sasodrnd
uorlDrurolul
.to; i(|uo pesn
eq uDc
lceq3 pequcsep
eqf
roC u! rolDurellv
;o 6u1>1caqC
e^llorurolul
'scluoqoer! pelllls puo luetudlnba perlnb
-er aql e^Dq qc!qM
sdoqs llodat pazt;orcads
ol llal aq
plnoqs're!l!tcel
aql
lo A;lorcadse
's.r1ode; Jo spoqleLu ctlsou6otp alDJoqDl3
:aloN
'uorlour
-Jolu! Jol iluo pesn
eq uoc (le66aru 'raleuuqo)
slueuJnJlsug 6ulrnsoeu pasn
Agluarnc eql
,o
s6u;poeg 'lueulnrlsu!
1o;ceds D
lo esn eql
ro c!lsl
-JalcDJDqc e:aduo-11on Jleql
lo 6ut:nsoau
eql sl
poqleu 6ur.rnsoetu epo!p
a^llcalqo lluo aq1
'urelsls .r1ode.r a6uoqcxe aLll rol
lnlosn lllorcadse
senord
Isolq apolP
eqf 'epolP
',8
S;.>
t't1{'t1