SKODA 120 LSE 1980 Workshop Manual
Manufacturer: SKODA, Model Year: 1980, Model line: 120 LSE, Model: SKODA 120 LSE 1980Pages: 238, PDF Size: 47.09 MB
Page 171 of 238
junction
with the olternoto,r occording to
Chop-
ier 13.3 ond mointoining
o constont voltoge of
tlre power
supply set within the
entire ronge
of
service speeds.
Tlre voltoge regulotor
is instolled orr the body
cross beorer, to
the right of the engine ond
beside the ignition coil.
To focilitote hondling
of its leods' especiolly
the occess to their
connections, it
is recom-
rrrended to remove the regulotor fostening
screws. For disconnecting procedures,
see
Chopter 13.3 "Alternotor
lnstollotion ond Gen-
erol lnstructions".
DK 1565
Fig.13.411- Internol
Wiring Diogrom of
Alternotol with
Voltoge Regulotor ond
Outer
Connections
Altenrotor: B, R, M -
olternotor outlets
f -
olternotor phose
windings
m -
olternotor field winding
D1,2,3, 4, 5, 6 -
moin diodes
D7, 8,9 -
olternotor ouxiliory diodes
D10 -
olternotor choking diode
Voltoge regulotor:
R, M, 15/54 -
regulotor outlets
reg -
regulotor tension winding
Rk -
boloncing resistor
Ro -
protective resistor
Rr -
odiustoble resistor
Kr -
regulotor contocts
Outer connections: K -
worning lomp (1.5
W)
S -
switch (switch
box)
B -
bottery
Checking Voltoge Regulotor
on Cor
The regulotor operotion con be offected by
loosened connections ond on imperfect eorth- ing.
lf the wsrning lomp does not go
o.ut when
driving, i. e., if it glows
ot increosed engine
speed brightly or dimly,
or if it does not stort
glowing ofter stopping
the engine ond
o new
iurning of the ignition key in
the switch box,
the voitoge regulotor
is probobly
foulty. Another
symptom of o regulotor
foilure is
o poor
chorg-
irrg of tlre bottery or its
overchorging.. lf there
is nothing wrong with the regulotor, check the
reguloted voltoge over the regulotor which
slrould reod 13.2 volts ot the
minimum ond 14.8
volts ot the moximunr. This check
in the
cor
is only tentotive ond only
o check on
the test
bench'con be considered os definite ond
bind'
i ng.
Electricol Adiustment
The voltoge regulotot- should be tested
ond
odjusted only on o test bench
in o connection
slrown in Fig. 13.412.
At o lood of some
2
onrperes, the checked
voltoge should correspond to
volues specified
in the column "Checking".
lf the checked volt-
oge is within the specified ronge, do
not odiust
the regulotor. Othenwise odiust it to the volues
specified in the column "Adiustment".
lf woter
evoporotes obnormolly from the bottery, odiust
the voltoge regulotor to the bosic volues of
"Adiustment" utilizing the lower section of
the
toleronce zone.
Fig.13.al2 -
Wiring Diogrom of
Regulotor Tested
ond Adiusted on
o
G -
olternotor
REG -
voltoge regulotor
A -
ommeter
V -
voltmeter
S -
switch
R -
lood resistor
B -
bottery DK
1566
Voltoge Test Bench
178
Page 172 of 238
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Page 173 of 238
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Fig. 13.5i3 -
Vocuum Control Course -
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Vocuum Control Course -
opplicoble to both
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Fig. 13.5i3 -
Vocuum Control Course -
opplicoble to both
regulotor models
copscrew fostening the distributor brocket to
the support on the engine (do
not loosen the
brocket clomping bolt).
Refit the distributor on the engine by
re-
versing this procedure. The
coupling on
tlre
shoft is osymmetricol ond it hos to engoge into
the heod of the drive shoft in the engine. To
seot properly
o new distributor
or o distributor,
the brocket of which hos
been loosened, refer
to Chopter 2.3, por.25
to 27.
Distributor Disossembly ond Reossembly
This should be done in speciolizedworkshops,
especiolly with regord
to the checking of the
mechonicol condition or o repoir
of the dis-
tributor. lt is recommended
to use o suitoble
holder for doing the moiority of the required
iobs in
o verticol position.
When reossembling
the distributor, lubricote
the sliding points
oc-
cording to Chopter 15.3
but bewore of over-
lubricotion.
Remove olso the copscrew
on the bottom of
the distributor housing ond drip some low-pour
point oil into the hole to increose the oil reserve
of the shoft
sel-lubricoting beoring -
see Chop-
ter 15.2 "Speciol
Oils".
Disossembly 1. Remove the distributor cop ond the breoker
orm.
2. Remove the coupling from the shoft (note
the relotive position
of the eccentric dogs ond
the breoker
orm).
3. Remove
the circlip from
the pivot
ond litt
owoy the breoker orm.
4. Remove
the subossembly
of the terminol
"1" (current supply to distributor).
5. Screw off the copocitor. 6. Screw
off
the retoining springs.
7. Lilt owoy the vocuum chomber (do
19t
open it, o chonge of the curve is on.improboble
d'efect; do not chonge the screw-in depth
of the
pull-rod).
' 8. Lift owoy the contoct breoker
bose plote
with pocking piece from
the housing.
g. Litt owoy the shoft with the
centrifugol
governor. -
10. lf necessory, disossemble further
the sub'
ossembly of the shoft with the centrif
ugol
governor (odvonce mechonism) ond
com.
l?;h.',0, ReossemblY
1. Reossemble the centrifugol governor
(the
weights must be free
to rotote on the pins).
2. lnstoll the reossembled shoft
with the res'
pective woshers into
the distributor housing.
3. Fit the contoct breoker bose plote
with the
f ixed contoct holder ond pocking
piece into the
housing. 4. Fit the pull-rod on
the pin
ond lock it in
position, screw down the vocuum chiomber with
the copocitor. Check the
ignition odvonce po-
sition for the first cYlinder.
5. Screw down
the retoining springs
with
shims (the
spring with
the dog opposite to
the
terminol "1"i;
the bose plote must
rotote freely
in the distributor housing.
6. Reosemble the terminol "1".
7. Fit the breoker orm
on
the pivot
ond lock
it in position. Adiust the contoct breoker point
gop (lift) ond check the
contoct
Pressure'
"
if. 'Stip
woshers on
the shoft in
the originol
sequence, slip on the coupling ond
lock
it in
position^ 9. Fit the lubricoting felt
into the hole of
the
com ond instoll the breoker orm.
10. Fit the distributor cop
in position.
11. Check the distributor operotion.
Checking A def inite indicotion of the condition of
the
distributor (during on operotionol check
os
well
os ofter o
repoir) con be obtoined by testing
the distributor on
o test stond with
o circulor
spork gop.
After o preliminory
odiustment of
the
contoc-t breoker point gop,
the stond is
used for
check i ng:
1. The contoct point
contoct ongle.
2. The spork ongulor distribution (with o
tol-
eronce of -+45
ongle minutes within
the entire
operotionol ronge).
3. The rongJ ond course of the
centrifugol
ond vocuum control. 4. The
operotion ot
moximum speed (length
of spork on spork goP -
4 mm) for o
brief period
(obout 2 minutes).
180
t
5
2tD zsa !l!
F llti
rc
Page 174 of 238
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Page 175 of 238
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R
L D
v Ir
1' 2
3
orotely
(
screen the other one) . With lef t
directionol heodlomps,
the borderline deviotes
towords the other
side.
lf the heodlomps ore neorer to the woll thon
the soid
5 metres, decreose the meosure indi-
coting the
deviotion of the light ond
dorkness
bordeiline from the
height of the heodlomps
obove the ground in the
direct proportion to
the
decreose of
tfre distonce, for
exomple when
plocing the cor 2.5 metres
from the woll, de-
creose the deviotion bY holf.
Light proiections "A"
ond "B"
correspond to
the spocing of heodlomPs on
the cor ond they
hove the following dimensions:
Heodlomps, dio. 160
mm 1,030
mm
Duol heodlomps, dio.
130 mm 1,114
mm
Auxiliory heodlomps, dio.
130 mm 790 mm
When odjusting the heodlomps, the cor must
be empty ond the
tyres must be correctly in-
floted. Hologen heodlomps should
not be left
switched on for too long o period os they build
up heot if not cooled by heod-on
oir blost when
driving. For lhe odiustment of
heodlomPs ore intended
screws in their fromes. The screws
ore occess'
ible ofter the removol of the side ports
of the
grille. Remove the copscrews of the corners
ond push
the grille
oside.
Heodlomp Assembly
o) The fundomentol fostening
Port of
circulor
heodlomps is the
so-colled support plote
(rec-
tongulor plote)
ottoched to the bodywork by
copscrews with lock woshers. The
heodlomp
housing is bolted to this suPPort plote by bolts
with nuts ond lock woshers. One of the bolts holds
down olso the
lug of the eorthing coble-
The inner frome,
forming the
odiusting element
of the heodlomp insert, is ottoched
to the
hous'
ing by two speciol odiusting screws
ond two
tension springs. The heodlomp insert
is ot'
toched to
the bezel by
three copscrews.
There is one left-hond ond
one right-hond
support plote.
Both should
be mounted with the
oriow ond the word "TOP"
upwords. With
the
exception of the ouxiliory heodlomps, the
heod'
lomp inserts ore different for
the left-hond ond
the right-hond troffic. The leods
enter the hous-
ing through o
rubber grommet.
When r-eplocing the insert, remove
the bezel
copscrews. After
hoving fitted o new insert, it
is necessory to reodiust the
heodlomps.
Front Direction Indicotors
The right-hond ond
left-hond direction indi-
cotors ore undisossembloble units
(the
lomp
fostening sockets (locks) ore
mounted in the
direction towords the cor longitudinol centre
line). They ore fostened to their brockets in the
bumper with o nut ond o ploin ond
o lock
wosher.
Toil Lomp Cluster
The lomp cluster is on undisossembloble unit
fostened to
the bodywork by
nuts with ploin
woshers ond the
respective bolts.
Scrope off
the enomel ot the
top bolt used for holding
down the eorthing coble.
For the sequence
of the individuol lomps ond
their bulbs see Fig. 13.111 ond the respective
porogroph on bulbs.
Fig. 13.812 -
Adiusting ond
Fastening Screws of Right-hond Heodlomps -
their locotion
on
left-hond he-odlomps is their
mirror ref lection
1 -
Sidewoys odiusting screw
2 -
Height odiusting screw
3 -
Fostening screws
182
Page 176 of 238
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Page 177 of 238
1 3.9-1
3.10
13.9 HORN
It is situoted behind
the left'hond port of
the
front bumper. To
remove it, disconnect the
leods ond remove the
fostening screw. heor
the ormoture being ottrocted (o
cleor ond
loud click). Now continue to
switch the bottery
on ond off
while rototing
corefully ond
sloryly
the screw "1"
onticlockwGe till
the
horn sounds'
iune it by rototing the odiusting.:cr9ry slightly
clockwise or
bock.-After hoving
odiusted (tuned)
ih" honn, secure
oll
odiusting ports with
o
dob
of point.
12
volts
4 omperes
Operoting
voltoge
Moximum current demond
Horn Adiustment
Before odiusting (tuning) the
horn, clomp it
firmly by th'e brocket ond
tighten thoroughly
oll screws "4"
ioining the
horn cover
with the
housing ond the dioPhrogm.
1. The horn is "hoorse"
- Using o screwdriver
rotote slowly the screw "1"
clockwise to odiust
the current demond
till the tone is cleor.
2. The horn sounds weokly -
Using o screw-
driver, rotote the screw "1"
slowly onticlockwise
to decreose the current demond
till the tone is
loud ond cleor.
3. The horn does not sound ot oll-Proceeding
through the operture in the front cover, loosen
the nut "2"
using o socket
sPonner. Then
insert
o screwdriver ond rotote
the odiusting screw
clockwise till it
beors lightly on the core. Then
bock off the screw by 1lz
or moximolly 3/a
of
o turn to odiust the distonce
of the ormoture
from the core. Hold the screw in this position
with the screwdriver ond
tighten firmly the nut
by rototing it clockwise. After hoving
connected
the bottery (of
the specified voltoge), you
will Fig.
13.9/1 -
Sectionol View
of Horn ond
o View
of Reor
Adiusting Screw
13.10 STARTER MOTOR
This is o series motor for
intermittent oper-
otion with on
electromogneticolly engoged
pinion. -@
c@c
Specif icotions
TyPe Roted outputStorting torqueSpeed for roted output
Voltoge ocross terminol
No-lood storting current
Direction of rototion
Number of pinion
teeth/modulus .
Contoct spring pressure PAL-Mogneton
12 V/0.8
h.
p. -
443'115'142'070
0.66 kw (0.e h.
P.)
12.25 Nm (1.25
kgm)
'1,000 r. p.
m. moximum
9.5 V moximum
65 A moximum
onticlockwise (left'hond)
912.5
e.3 N (0.ss0 ks) +100/6
"30"
of roted output
Mointenonce The mointenonce consists of periodicol
in'
spections ond repoirs or replocement of foulty
ports:
o) brushes
b) brush springs
c) commutotord) storter pinion ond idler
e) self-lubricoting beorings The brushes
must
be sufficiently long
ond
they must slide
freely in
their-cells, their
press-
ure springs must hove o
sufficient thrust,
the
commutotor must not
show ony
domoge, ond
it
must be
free of dust ond dirt.
Cleon the
commu-
totor with olcohol, petrol or
trichloroethylene,
ond let it dry before closing it
ond switching
on the storter motor. A
burnt or mechonicolly
domoged commutotor must
be repoired or
re'
ploceJ immediotely. A commutotor in
good con'
dition hos o brownish red
hue.
184
Page 178 of 238
'(ecuanbas
reql purtx
u; deal
)
lrod angip
lrDqs eql
lo sreqsoM
tlo dlls 'l
'ple!qs Pue e^lrp aql
uro.r; uolu;d eql qllM
eJnJDurro oql e^oueu '9
'ple!qs pue
e^lJp aql lo lno urd eql a^!rp
puo
u;d:ane; 6u1
-6o6ue-e.rd aql
lo raqsDM
lcol aq]
e^oueu 'g
'q31!,!\S
eql rlnDJPq]!M puD 'uolsuedsns
llol eql uorl
ernlouro r]c]!Ms eql aerl 'plelqs
pue e^!rp aql
uo r1cllMs aq1 6u1p1oq srr,rarcsdoc elorrlag "t
uelDl aq
louuoc l!) '{1rodo
lolols aq] a^oulau 't
'(s.raqsom sq] ]o
6utrrtl lo reuuDru
aql puD
acuanbas eql pulul
ul
deel) a)Drq aql lo sraqsDM eql
qllM
.raq1a6ol
plelqs pue rolDlntuuo" aq] Iorrto
Ull 'Z
'sraploq Ple!qs
aql u! seLlsnrq eql
ll!l 'slloq
6uldtuo;c aql puD
JaAOC plelqs
pue
JolDlntuuroc aql e^ourad '[
,t;qtuassoss!O Jolol
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esJeAeU'lorvro l! 11
l puo
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orll puD qo]lMs
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eql
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'(;ou rur
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'pJDoq Jooll lueul:oduoc e6o66n1 aql
u! srenoc
qloq enorreJ
PUD'lDLu eql
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lDas
roer eql d11 'xoq:oa6
aq1 1o epls
puDq-q6!r
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.roe.r aqt
Jo
rooll aql JePun
PellDlsu! s! rolotu reuDls
eq1
6u;g;1eX puD
lDAouraU rolo!\l reuDls
'Jolout JauDls orll
]o
Ilqtuassosgp eqt q11m
6u11oap qdo.r6orod
aql
ot elou aql ees 'sBu1:oaq
6u;1oc1.rqn;-llas JoJ
'lelp! eql qllM
elalduoc euo Meu
o q1;m
(q1ae1
paDouop rll!t*) uo!u1d pe6oruop
eql acoldex
a^rnC tndtno
puD f Dolrlcelf rolot
,l reuols -
ZIOL'1L'6lJ
981
rolonl reUDtrS jo
Metn
lDuollcos -
L/01'eL '6!J
LgL ilt}
W t\
t
0t'€t
Page 179 of 238
(
1
z
Strike the
slip-over ring off the circlip
(towords the motor windlng). Open the circlip
ond pull
it off the shoft together with the re-
leosed ports.
8. lf necessory, re-turn the commutotor ond
scrope or mill out the insulotion between the
lominotions. "Mikonit"
should be 0.4 to 0.8 mm
below the octive surfoce.
Note: The
switch connot be further token
opat. lf
defective, lt hcs to be reploced with
o new one. When cleoning ports
of the storter
motor, do not dip the ormoture or the pinion
with the idler into petrol
or onother degreosing
ogent.The some opplles to the end shieldswith
beorings. By dipping them in o degreosing
ogent, the beorings become procticolly
worth-
less"
Storter Motor Reossembly 1. Lubricote the hellx of the ormoture shoft
with greose -
see Chopter 15.2 'Lubriconts
of
foreing mokeu ond fit the pinion
with the idler
ond the slip-over ring in posltion.
Fit the
circlip
into the groove
in the shoft, ond drive the slip-
on ring over it. The pinion
with the idler must
move freely olong the shoft.
2. Slip the respective
woshers on the shoft in
their originol sequence (corrier
ring, distonce
ring, fibre ring, distonce ring) ond insert the
ormoture with the engoging lever
into the drive
end shield. 3. Suspend the switch
ormoture into the
pre-engoging lever ond bolt down the switch
lightly. Fit the lever pin
into the drive
end
shield ond lock it in position
with the retoiner.
4. Tighten the copscrews of the switch
ond
fit the stotor on the drive
end shield.
5. Instoll the respective
woshers into
the
commutotor end shield in
their originol se-
quence (the dished wosher with its centre
focing the shield, then the ploin
wosher, the
toothed wosher, ond the drive wosher).
6. Fit the commutotor end shield with lifted
brushes on the shoft (in
the position
occording
to the recess
for the excitotion outlet ond the
notch) ond screw in the clomping bolts.
7. Instoll the brush interconnecting strip ond
bolt it down together with the field winding
outlets to the positive
brush holders, lower the
brushes. 8. Fit the Insuloting strip in position
ond bolt
down the cover. 9. Test the storter mottr.
Diognosing Storter Motor Defects in Cor
o) lf the storter motor refuses
to operote, look
first for on interrupted connection between
the bottery ond
the storter
motor, the engine
eorthing ond the storter
motor, or the engine
eorthing ond the bottery. lf these connec-
tions ore in order (current
flows to the ter' DK
1575
Fig. 13.10/3 -
Storter Motor Testlng Connection
minols u30"
ond "50"
with switched on
ignition), stort looking for o foilure of the
storter motor switch. Even in this instonce,
the couse con be o fully dischorged or foulty
bottery.
b) lf the storter motor
continues running
even
ofter the ignition key hos been switched in
the switch box from the position "START",
it hos to be stopped without ony deloy by
disconnecting the bottery (using
its eorthed
pole).
c) lf the storter motor hos no power
to cronk
the engine, stort with switched-on heod-
lights. A
morked dimming indicotes c poorly
chorged bottery.
Tentotive Checking of
Storter Motor
Outside Cor
Connect the terminol "30'of
the storter
motor to o properly
chorged bottery ond incor'
porote on ommeter with o wide
meosuring ronge
into the circuit -
see Fig. 13.10/3.
Stort the
engine (feed
current to the terminol "50").
The
volue of the current ot idling speed must
not
exceed 65 omperes (not
considering the peok
ot
the first momentous deflection).
The storter motor must run noiselessly,
smoothly, ond the pinion
must move smoothly
into ond out of the rest position
(engoge
ond
diesengoge). The engoged pinion
must not ro-
tote direct on the foce of the slip-on ring. The
run-out of the storter motor must not lost longer
thon 8 seconds ofter the disconnection of the
switch from the current supply.
Inspect the brush pressure
springs. The
brushes must
beor on the commutotor by ot
leost two thirds of their surfoce ond they must
move freely in their cells.
The ormoture should hove o noticeoble oxiol
cleoronce (ploy)
not exceeding 0.7 mm.
At
o slight rototion of the pinion
in the direction
of the storter motor rototion,
the idlor must
slip
freely.
186
Page 180 of 238
L8r
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ree6 6urr 6urgl;ru uorurd 'luaura6e6us
olu!
(6uruun.r en.rl rol geqs
lceqc)
Ueqs uo
rnq
onourar '6ur:eeq
uorurd eceldeg
'qclr/v\s elelduoc
ro (aDpuq
lceluoc 6urpnlcur) slurod ece;dag
'xoq qcy^ s ece;deg ol
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1rren10 u*o,o tyrp!"frliiilii'ff
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slurod qclr^As
lurng 't
(put1
lueragtp) alqnorl
lecrueqcalN
' s6uueeq ur (pezraslo)esoo;
alnleuuv
(eurbue uo) e6ue11 uo
asool rolor-u reuels
rolou reuels Asrol;
' (6ursec
laaq/tir aa:;
paOeueg
tueueq pabreqcs16
eq ueo roloru reuels
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