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15-20
GROUP 15-
LIGHTING SYSTEM, HORNS AND INSTRUMENTS
if necessary.
ASSEMBLY
1. Apply grease to the centre-
drilled holes in each end of the arma-
ture shaft. Assemble the Thrust Cone
(9) to the worm end of the shaft and
the
-&"
diameter ball (18) to the
other end of the shaft.
2. Assemble brush springs (14)
and brushes (13) to the gear housing
assembly.
3.
Retract the brushes and assem-
ble the armature assembly (17) to the
gear housing assembly.
4. Apply stiff grease to the back
face of the thrust pad assembly (19)
and locate in the recess in the bottom
of the motor housing assembly (20).
5. Assemble the motor housing
assembly (20) to the gear housing
assembly (6). Ensure that the wiring
to the brushes does-not foul the motor
housing. Assemble the two screws
(15) and lockwashers (16).
6. Adjust armature shaft thrust
screw in until resistance is felt and
then back off screw a quarter turn.
7. To secure earth finger (22) to
gear housing (6), install screw (23).
8. Install terminal plate assembly
(5) to gear
housing.
Ensure that
flanges on terminal plate assembly
are located in receiving slot in
housing (6).
9. Apply No. 2 cup grease to par-
king plate and cam track (8).
10. Assemble the distance washer
(7) on the gear shaft assembly (8) and
assemble gear and shaft assembly to
the gear housing.
11. Install mounting seal (3) to
gear housing and assemble grommet
insert ( 4).
12. Connect washer lead connector
to wiper motor terminal, assemble
washer pump assembly (10), terminal
(11)
and four self-tapping screws (12).
Re-locate self-tapping screws care-
fully in existing threads to avoid
stripping and tighten screws to a
torque loading of 20-25 lbs. ins.
DISASSEMBLY WASHER PUMP
1.
Remove the four screws
(11)
attaching valve cover, remove valve
cover (7), valve seal (9), valve seat (8),
suction cap (3), trim cup
(5)
and
plunger (4).
2. Remove solenoid assembly (2),
with cover from housing assembly ( 1 ),
dismantle plunger and lever assembly
(12) and solenoid cover (6).
3. Remove bush (13) and spring
(14).
INSPECTING AND TESTING
DISASSEMBLED WASHER PUMP
1. Check operation of non-retur-
ned valves in valve assembly.
2. Check suction cap for damage
or cracks or deterioration.
3. Examine trim cap, solenoid
lever and plunger for damage or wear.
4. Check solenoid windings for
continuity or short circuit.
5.
Examine housing bush for dam-
age and excessive wear.
6. Check compression spring for
damage.
7. Examine washer housmg and
latch for cracks and distortion, ex-
amine timing gear for worn or
damaged teeth.
Note: Timing gear should rotate
only when latch is retracted.
ASSEMBLY OF WASHER PUMP
1. Apply No. 2 cup grease to latch
mechanism (1).
2. Install spring (14) and guide
bush
(13)
to housing.
3. Install plunger and lever assem-
bly (12) to solenoid assembly (2).
4. Install solenoid to housing tak-
ing care that lever engages with slot
in latch. Ensure that solenoid is
located in receiving slot in housing
and solenoid wire is correctly posi-
tioned in housing assembly.
5. Install trim cup (5) and plunger
( 4) to suction cap (3).
6. Install solenoid cover (6) to
snap fit over location pin.
7. Install suction cap assembly and
ensure that plunger is located in
guide bush.
8. Install valve seat assembly (8,
10) and valve seal (4).
9. Install valve cover (7) and secure
with four screws
(11)
tighten to a
torque loading of 10-15lbs. ins.
TESTING THE ASSEMBLED
MOTOR
1. Obtain
a
switch
assembly
ARC9DF.17A553-A, a 12 volt auto-
motive battery and an 0 to 10 amperes
Ammeter.
2. Connect the Negative terminal
of the battery to the motor earthing
terminal
(11)
and the 'E' terminal of
the switch
ass~mbly.
3.
The terminal block assembly
has four terminal blades and the
moulding has four identification
numbers 1 to 4 respectively. The
switch assembly moulding also car-
ries identification numbers.
4.
(i) Connect motor terminal
No. 1 to switch terminal
No.1.
(ii) Connect motor terminal
No. 2 to switch terminal
No.2.
(iii) Connect motor terminal
No. 3 to POSITIVE bat-
tery terminal.
(iv) Connect motor terminal
No. 4 to switch terminal
No.4.
(v) Connect washer pump ter-
minal to switch terminal
'W' ..
5. Operate switch assembly and
check for LOW speed and HIGH
speed operation. Switch to park
position two or three times and check
that the motor crank assembly stops
with a positive action in the same
pcsition.
6. Switch motor to low speed and
back-off the adjusting screw in the
gear housing at the end of the arma-
ture shaft. Adjust end play of the
armature by tightening the screw
until an ammeter in series shows a
slight rise in current. Back-off slightly
until the current is just normal,
apply 'LOCTITE-GRADE CV' to
the screw to prevent unlocking.
7. Check the current consumption
after running the motor for 30 min-
utes. The consumption should be
2
.
5 amperes maximum at 13. 5 volt
and the output speed 40 rpm LOW
and 65 rpm
HIGH.
8. Energising the solenoid of the
washer pump, the current consump-
tion should not exceed 2 amperes
over the motor consumption during
the energising period at 13
.
5 volts
±
0
.
I. Washer should complete four
discharge cycles per one revolution of
the wiper motor output gear and
12-16 discharge cycles for one wash
cycle.
LUCAS
DISASSEMBLY -
PERMANENT
MAGNET TYPE WIPER/WASHER
MOTOR
1. Remove the fixing nut, motor
crank assembly and flat washer.
CAUTION: The moulded gear-
wheel inside the gearbox must be
prevented from moving while the
crank assembly fixing nut is slackened
(or tightened on re-assembly). This
is most easily achieved by securing
the crank in a vice while the nut is
turned.
2. Remove the three screws attach-
ing the washer unit to the motor. To
completely detach the washer unit
from the motor it will be necessary
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