1980 SKODA 120 LS Workshop Manual

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

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0t'€t

(
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

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1 3.10-t
3.1 1
13.11 WINDSCREEN WIPER
Technicol Description
The rotory windscreen wiper consists of the
wiper motor
with o geor
cosing, o lever system
driving the wiper orms, ond two wiper orms
with wiper blodes.
The two-pole wiper motor
with permonent
mognets is o two-speed
unit with self'lubri'
coting beorings. The geor
cosing comprises onepicyclic
geor
ond on outomotic self-porking
device. The shoft runs in self'lubricoting beor'
ings, the geors
being lubricoted with greose
pocked into the geor
cosing. The lever system
(leveroge) includes self-lubricoting
ioints ond
beorings.
Windscreen wiper
tyPe -
for left-hond steering .
- for right-hond steering
Roted voltoge
Roted current PAL 443.122
-
081.071
PAL 443.122 -
076.071
-12
volts
4 omperes ot high speed,
2.5 omperes ot low speed
60 ot high speed (minimum)
20 (minimum)
to 50 (moximum)
ot low speed
15 cycles per
minute (minimum)
onticlockwise -
for left-hond steering
clockwise -
for right-hond steering
Wiping
cycles per
minute
Difference of cycles between speeds
Direction of
rototion when viewing
the output
shoft
I
i
f1
llr
fi.,
il
lr
l Removol
ond
Refitting
According to the
noture of the required re-
poir, remove either only the motor with the geor
cosing after hoving disconnected the pullrod
from the cronk, the cronk from the geor
cosing,
ond the geor
cosing from the brocket, or remove
the complete unit
ofter removing the wiper orm
beorings -
see wiper orm drive.
When ref itting
the windscreen wiper unit,
observe the
ossembly position of the
wiper
cronk -
see the following porogroph "Motor
ond
Geor Cosing". For position
of the wiper
orms
(blodes), see the porogroph 'Wiper
Arms". ln-
stoll the brocket into the body bulkheod ond
fosten it in position
with the nut, using o rub-
ber ond o flot wosher.
Cleoning ond Repoirs
When disossembling the windscreen wiper
motor, do the following jobs:
1. Reploce worn brushes ond use petrol
to
cleon motor ports
ofter blowing the dust out of
the brushes; moke sure thot the brushes move
freely in their cells. 2. lf the commutotor is
dirty, cleon it
with
petrol, if it is domoged, re-turn ond polish
it.
3. During cleoning, the self-lubricoting beor-
ings must not come into contoct with the
cleoning (degreosing)
ogent (petrol,
etc.). They
should be lubricoted
only with o low-pour-point
oil dripped into the cut-outs of the
cup retoining the boll beoring ond
the felt. Use only os much
oil os the felt con hold.
4. For the epicyclic geor
in the geor
cosing
use greoses
specif ied in Chopter 15.3 -
either
of foreign
moke or of
Czechoslovok moke -
re-
commended specificolly
for windscreen wipers.
MOTOR AND GEAR CASING
Ports of the motor
with the geor
cosing (or
geored motor) is the wiper brocket,
the pro.
tective housing, ond the driving cronk. When
instolling the wiper, put
the housing
on the
motor with the geor
cosing ond clomp it from
below. Bolt down the brocket using ploin
woshers under the bolts. Fosten the motor
eorthing coble under one
of the bolts.
Fosten the cronk in position
using o nut
ond
o spring wosher while observing its ossembly
position:
o) with wipers for left-hond steering-toword
the right-hond side
of the motor ond deflected
13o downword from
the oxis porollel
with the
centre line
of the motor;
b) with wipers for right-hond steering
toword the left-hond side of the motor ond de-
f lected 17" downword from the oxis porollel
with
the centre line
of the motor.
Dismontling the Geor Cosing 1. Remove three screws ond lift owoy the
cover.
188

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r*r 3.1 2
1. lf the wiper moves with the switch in the
OFF position
ofter its
connection to the electric
power supply, tighten (screw
down) the screw
till it begins to be litfed by the geor
com ond
till the wiper begins to be
switched off ond
broked. Screw down the screw from this po'
sition by onother holf turn.
2. Press the lid into
the cover ond seol it
with point.
WIPER ARM DRIVE
This drive consists of thewiper beoringswith
cronks, the tie-rod of the
cronks, ond
the driv-
ing tie-rod. The
drive is instolled in the cor os
o unit.
Tie-rods The tie-rods should be slipepd on
the cronk
pins in the
following sequence:
o springwosher
with its centre comber focing outword (owoy
from the pin),
o flot
wosher, the tie-rod, o flot
wosher, ond o lock
ring.
lf necessory, lubricote the ioints with
greose
- see the following section deoling with beor-
ings. Fill the cover at the point
of the tie-rod
motor cronk connection with greose
(of ony
brond) ond slip it on the tie-rod.
Beorings On one side, the beoring
is inserted into the
wiper brocket from inside the body, on the
other side, it is fitted into o speciol wosher in-
serted with its nose foremost
into the re-
spective hole in the body. Locote o seoling
wosher with corefully smoothed-out edges ond
o flot
wosher from outside, ond secure the
entire unit with the respective
nut. The
unit is
seoled off by
o rubber pocking.
Fill the unit
with greose (see
Chopter 15.3 for recommended
foreign bronds or Czechoslovok Lrronds SP 4 or
A 4) ond press
it down into the neck of the
bush.
lf it is necessory to remove
or disossemble
the beoring, prise
the lock ring out of the pin
groove under the rubber pocking.
On reossembly,
insert o spring wosher under
the bush with its
combered centre
toword the bush. Lubricote
with the specified greose.
Wiper Arms
The wiper orms fitted with o rubber
blode
con be swung owoy from
the windscreen. They
ore held down by nuts
on the grooved
topers of
the beoring pins.
After hoving fitted
the wiper orms, sproy
woter on the windscreen
ond test the run
of the
wipers. lf necessory, turn the wiper cms
on the pins.
The wipers must wipe
the lorgest
possible oreo of the windscreen without, how'
ever, touching the windscreen glozing
mould-
i ng.
13.12 RADIATOR FAN
Technicol Description
The fon is on ossembly of the fon motor ond
impeller. The
impeller is pressed
on to the
motor shoft. The motor hos permonent mognets ond
o rotor running in self-lubricoting beorlngs. The
impeller is mode of plostic.
Motor type
Roted voltoge Roted current
Roted output
Direction
of rototion PAL 443.132
-
O97.O45
12 volts
7.5 omperes
55 wotts
clockwise (right-hond) when
viewing the front end of the
shoft
Coble poles
coble with lug (blue) -
negotive pole
coble with femole connector
(red) -
positive pole
Removol ond Refitting
The fon is
occessible ofter
removing the
rodiotor to which it is fostened by meons of
o rim held down by copscrews ond sprlng
woshers. The motor rests on resilient bushes in
the rim. When refitting the fon moke sure thot
there is o spocer tube in the bush, locote the
flot ond the spring woshers, ond tighten
the
nut.
Cleoning ond
Repoirs
Refer to porogrophs
1 to 3 deoling with
cleoning ond repoirs in Chopter 13.11.
Dismontling Motor ond lmpeller
The motor con be removed (ond
dismontled)
only ofter removing the impeller. Use the puller
MP 8-102
to pull
off the fon or support the fon
hub in three points
on its circumference ond
press out the motor by opplying
Pressure on
the motor shoft. No topping or blows on the
shoft ore permitted.
1. Remove the nuts of the clomping bolts,
hold the shoft
by its grooved
end, ond lift
owoy the
commutotor end shield ond stotor.
190

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