ELECTRICAL SYSTEM 4 D INSTRUMENTATION

Transcription

1 ELECTRICAL SYSTEM 4 D INSTRUMENTATION

2 Tle of Contents Pge Identifition D-1 Speil Informtion D-1 Lighting Options D-1 Commodore nd Interntionl Series.. 4D-1 QSI Series D-2 Guges D-2 Oil, Fuel nd Temperture D-2 Testing D-2 Bttery Guge D-3 Testing D-3 Cruiselog Meter D-4 Testing D-4 Vuum Guge D-4 Testing D-4 Speedometer D-4 Testing D-4 Clirtion Chrt D-4 Thometer D-4 Testing D-4 Guge Replement D-5 Senders D-5 Oil Pressure D-5 Dul Sttion Sender Identifition D-5 Testing D-5 Wter Temperture D-6 Dul Sttion Sender identifition D-6 Pge Removl D-6 Testing D-6 Instlltion D-7 Fuel Tnk Sender D-7 Flnge Type D-7 Cpsule Type D-8 Swithes D-9 Ignition Key Swith D-9 Testing D-9 Lnyrd Stop Swithes D-10 Testing D-10 Strt/Stop Swith D-11 Testing D-11 Audio Wrning System D-11 Buzzer D-11 Testing D-11 Oil Pressure Swith D-12 Testing D-12 Wter Temperture Swith D-12 Removl D-12 Testing D-13 Instlltion D-15 Trnsmission Fluid Temperture Swith D-15 Removl D-15 Testing D-15 Instlltion D-17 NOTICE For informtion nd proedures on trouleshooting, refer to Setion 1C. NOTICE For informtion nd proedures on Fuel Injetion Engines, refer to Setion 5C. 4D-0 - INSTRUMENTATION

3 Identifition NOTE: One of three distint lines (Series) of Quiksilver guges my e instlled (if equipped with Quiksilver guges). Aside from different guge fe ppernes nd styling, the k of the guges nd wiring onnetions re different s shown. Speil Informtion Lighting Options COMMODORE AND INTERNATIONAL SERIES These guges my e wired so tht the illumintion lighting is provided from the ignition swith or seprte instrumenttion lighting swith. By removing ontt strip I from etween + terminl nd the srew s shown following, nd supplying seprte +12 V power supply to the srew onnetion, illumintion lights n e operted independent of ignition swith Bk of Commodore nd Interntionl Series Guge - Typil Ignition Swith Lighting Ciruit - Positive (+) 12 Volt Power Supply From Ignition Swith - Contt Strip I - Srew Connetion Bk of QSI Series Guge - Typil Seprte Instrumenttion Lighting Ciruit Wiring - Positive (+) 12 Volt Power Supply From Ignition Swith - Contt Strip I - Srew Connetion INSTRUMENTATION - 4D-1

4 QSI SERIES These guges re equipped with optionl illumintion lighting. Light ul soket n e removed nd ontts n e ligned to e used with ignition swith lighting iruit +12 V or seprte instrumenttion lighting iruit LT. IMPORTANT: Light soket must e removed from guge nd turned ounterlokwise (fing k of guge) when djusting to desired setting. Turning soket while still instlled in guge ould result in dmge to guge or soket. NOTE: For different lighting effets, olored sleeves re ville through the Quiksilver Aessories nd n e ssemled to the ul. Guges Oil, Fuel nd Temperture IMPORTANT: If testing proves guge to e defetive, it must e repled s there is no repir ville. 1. Turn ignition swith to OFF. 2. Remove wire from terminl S (SEND). Ignition Swith Lighting Ciruit Position - Positive (+) 12 Volt Power Supply From Ignition Swith Typil - Terminl S (SEND) 3. Turn ignition swith to RUN. Guge eing tested must e t position A Seprte Instrumenttion Lighting Ciruit Position - Positive (+) 12 Volt Power Supply From Ignition - Positive (+) 12 Volt Power Supply From Seprte Instrumenttion Lighting Ciruit Typil Position A Turn ignition swith to OFF. 4D-2 - INSTRUMENTATION

5 5. Connet jumper wire from terminl G (GND) to terminl S (SEND). Bttery Guge 1. Remove les from ttery nd fully hrge ttery. 2. Connet negtive ( ) jumper led from ttery to guge terminl G (GND). 3. Connet positive (+) jumper led from ttery to guge terminl I or +12 V Typil 6. Turn ignition swith to RUN. 7. Inditor needle of guge eing tested must red t position B. If not, reple guge Typil 4. Chek guge reding; if not s shown reple guge. Position B Typil Typil INSTRUMENTATION - 4D-3

6 Cruiselog Meter 1. Connet jumper wire from negtive ( ) ttery terminl to negtive ( ) guge terminl. 2. Connet jumper wire from positive (+) ttery terminl to positive (+) guge terminl. Vuum Guge 1. Disonnet vuum hose from engine. Connet servie vuum guge to engine nd reord engine vuum redings t idle, 1000, 2000 nd 3000 RPM. Reonnet vuum hose nd ompre vuum guge redings (t speified RPM) with servie guge redings. Redings should e within 3 inhes of vuum of eh other. IMPORTANT: Mke sure tht vuum hose etween guge nd engine is not leking nd tht ll onnetions re tight. Speedometer Oserve guge run inditor. If inditor is turning, guge is operle; if not, reple guge. IMPORTANT: When testing speedometer guge for ury, the ir supply used for the test must e regulted to the speified ir pressure. Do not pply exessive ir pressure to speedometer guge. 1. Apply ir pressure diretly to speedometer guge (speified in hrt) nd note guge reding. Light tpping of pressure guge is required during ury hek. 2. If guge redings re not within speifitions, guge is defetive CALIBRATION CHART Air Pressure Guge PSI Speedometer Guge MPH (km/hr) ±2 (32±1.6) ±1 (72±1.6) Thometer - Inditor 1. Connet servie thometer to engine nd ompre redings. 2. Reple if not within speifitions. Thometer Allowne 6000 RPM ± 150 RPM 8000 RPM ± 200 RPM 4D-4 - INSTRUMENTATION

7 Guge Replement 1. Disonnet ttery les from ttery. 2. Remove wires from k of guge. 3. Remove hoses (vuum, speedometer guge). 4. Disonnet light soket. 5. Remove holding strp nd remove guge. 6. Position guge ssemly in pproprite mounting hole. 7. Instll holding strp nd nuts. Tighten nuts evenly nd seurely. IMPORTANT: Do not distort se or rket y over-tightening. 8. Connet ground (BLACK) wire to ground terminl, if guge is not mounted in metl pnel. 9. Connet other wires to guge s shown in Setion 4F. 10. Connet hoses (vuum, speedometer guges). 11. Instll guge light soket. 12. Cot ll terminls with Quiksilver Liquid Neoprene. 13. Reonnet ttery les to ttery. Senders Oil Pressure DUAL STATION SENDER IDENTIFICATION Sender will hve 353-AM stmped on hex of sender. IMPORTANT: Use following test proedure for heking ury of oil pressure sender only. If oil pressure guge indites zero oil pressure, refer to Setion 1C - Trouleshooting. 1. Remove wire from sender terminl. 2. Connet ohmmeter etween sender terminl nd sender se. Chek ohms reding without engine running (zero pressure), then hek reding with engine running. Compre oil pressure nd ohms redings s shown in following hrt: d Positive Led - Negtive Led - Wire Removed d - Oil Pressure Sender Oil Pressure (PSI) Ohms Reding Single Dul INSTRUMENTATION - 4D-5

8 Wter Temperture DUAL STATION SENDER IDENTIFICATION Sender will hve 362-BC stmped on hex. REMOVAL 1. Drin oolnt from losed ooling system into suitle ontiner s outlined in Setion 6B. 2. Remove TAN wire from temperture sender. Typil Wter Temperture Sender - TAN Wire - Wter Temperture Sender NOTE: Hoses re shown removed for lrity. 3. Remove temperture sender ! WARNING The following test involves the use of intense het. Filure to follow pproprite proedures or wrnings n use urns whih n result in severe personl injury. While performing the following test, oserve these generl preutions: Wer personl protetive lothing suh s ruer gloves, non-flmmle pron, nd eye protetion - preferly full fe shield or sfety glsses. The pproprite het soure should only e eletri. Het soure should e operted y qulified person. Be sure to follow ll instrutions of the mnufturer of the het soure. The het soure should e heked eh time it is used to e sure it is funtioning properly. The thermometer used in the test should e high-temperture thermometer with mximum reding of t lest 300 F (150 C). Under no irumstnes should the opertor llow tempertures to exeed test speifitions. Perform test only in well ventilted re. Use suitle ontiner, suh s metl, to hold the wter. Avoid use of glss ontiners unless the opertor first onfirms for himself/ herself tht the glss ontiner is n pproprite high-temperture vessel. Beuse the omponents will reh high tempertures DO NOT hndle mterils or omponents until COMPLETELY ooled. 1. Connet n ohmmeter etween temperture sender terminl (+) nd hex (se) for ground ( ) s shown Ohmmeter Leds - Wter Temperture Sender 4D-6 - INSTRUMENTATION

9 2. Follow these instrutions:. With ohmmeter onneted s outlined nd using suitle ontiner, thermometer nd het soure, suspend sender with tip in wter.. Het wter nd oserve thermometer.. As temperture rises ohmmeter redings must e within the rnges speified for eh temperture (see hrt elow). d. Turn het soure off. Allow wter nd omponents to ool. NOTE: While wter ools you my rehek ohmmeter redings. INSTALLATION 1. Apply Lotite Pipe Selnt with Teflon to threds of temperture sender. 2. Instll sender in thermostt housing nd tighten seurely. 3. Connet tn wire nd ot with Liquid Neoprene. e d Typil Wter Temperture Sender - TAN Wire - Wter Temperture Sender Refill losed ooling system with pproved oolnt s outlined in Setion 6B. - Suitle Continer - Thermometer - Het Soure d - Wter Temperture e - Ohmmeter Leds Wter Temperture Ohms Reding 140 F (60 C) F (90 C) F (100 C) Reple sender if ohmmeter redings re other thn s shown for eh temperture. Fuel Tnk Sender FLANGE TYPE Testing 1. Disonnet wire from terminl on sending unit nd ground wire from sending unit mounting srew. 2. Remove sending unit from fuel tnk. 3. Connet ohmmeter etween sending unit terminl nd sending unit housing INSTRUMENTATION - 4D-7

10 4. With flot rm in FULL position (rm horizontl), ohmmeter should red 30 ohms (+ 5 ohms). CAPSULE TYPE Testing 1. Disonnet wire from terminl on fuel tnk psule. 2. Remove two srews nd remove psule ssemly. 3. Ple mgnet under fuel psule. 4. Connet ohmmeter etween fuel psule terminl nd metl portion of psule housing. - Ohmmeter Leds - Vertil Flot Arm With flot rm in EMPTY position (rm vertil) meter should red 240 ohms (+ 5 ohms). Sender is defetive if not within speifitions. - Ohmmeter Leds - Cpsule Assemly - Mgnet Turn mgnet ounterlokwise until fuel psule inditor reds EMPTY. Ohmmeter should red 240 ohms (+ 5 ohms). - Ohmmeter Leds - Vertil Flot Arm Cpsule Reding Empty D-8 - INSTRUMENTATION

11 6. Turn mgnet lokwise until fuel psule inditor reds FULL. Ohmmeter should red 30 ohms (+ 5 ohms). Fuel psule is defetive if not within speifitions. - Cpsule Reding Full Swithes With key swith in OFF position, there should e no ontinuity etween swith terminls. 4. With key swith in RUN position, ontinuity will exist etween swith terminls B to I. There should no ontinuity etween terminl S nd ny other terminls. 5. With key swith in START, ontinuity will exist etween terminls B to I nd B to S. 6. Terminls re to mke ontt t ngles shown nd to sty in ontt ondition s swith is rotted towrd START. 7. If ignition key swith tests d, unsolder wire onnetions nd remove swith. Test swith gin, s in Steps 2-5, preeding. If swith tests good, wiring in hrness is d, There should e no ontinuity etween ny hrness wires with key swith removed. f e d Ignition Key Swith! CAUTION Disonnet ttery les from ttery efore testing ignition key swith with wires still onneted to swith. 1. Disonnet ttery les, if testing ignition key swith with wires onneted to swith. 2. Before testing key swith, hek ll fuses nd/or iruit rekers in eletril iruit whih ould prevent opertion of strter. Key View - Key - Off - Continuity, B to I Terminls d - Run e - Continuity B to S Terminls f - Strt B S I Bk View INSTRUMENTATION - 4D-9

12 Lnyrd Stop Swithes NOTICE For repir proedures on MPI / EFI Engines, refer to Setion 5C Remote Control Mounted Style Swith - Crureted Engines - Swith Leds - Leds (PUR) 1. Disonnet swith leds Remote Control Mounted Style Swith - Eletroni Fuel Injetion (EFI) Engines - Swith Lnyrd - Leds (BLK/YEL) 2. Test swith s follows.. Connet n ohmmeter to leds.. There should e ontinuity with swith lnyrd onneted nd no ontinuity with swith lnyrd disonneted. 1. Disonnet swith leds. 2. Test swith s follows.. Connet n ohmmeter to leds.. There should e no ontinuity with swith lnyrd onneted nd ontinuity with swith lnyrd disonneted Toggle Style Swith - Swith Cp - Swith 4D-10 - INSTRUMENTATION

13 IMPORTANT: The BLK/YEL led is not used. It should e well insulted nd tped to hrness. 1. Disonnet swith leds. 2. Connet n ohmmeter to swith leds. 3. Swith should hve ontinuity with toggle in the RUN position nd no ontinuity with toggle in the OFF position. Strt/Stop Swith! WARNING Disonnet ttery leds t ttery efore testing. 1. Disonnet ttery leds. 2. Chek for ontinuity etween the terminls on the strt swith with ontinuity meter. 6. If ontinuity exists when in the OPEN (not depressed) stte, reple pnel utton. Audio Wrning System NOTICE For repir proedures on Fuel Injetion Engines, refer to Setion 5C. Buzzer! WARNING The following test involves the use of eletriity. Filure to follow pproprite proedures n use urns or shok whih n result in severe personl injury or deth. 1. Turn key to RUN position (engine off). 2. Wit 7 to 14 seonds for horn to sound. 3. If horn does not sound:. Connet jumper wires s shown.. If horn does not sound, reple it. 4. If horn worked in Step 3:. Connet jumper wires s shown.. Repet Step No ontinuity should exist. 4. Depress swith utton nd ontinuity should exist. 5. Chek stop swith in the sme mnner INSTRUMENTATION - 4D-11

14 . If horn sounds, prolem is in tn/lue wire k to engine or swithes on engine. e f Oil Pressure Swith 1. Remove wire from sender terminl. 2. Connet ontinuity meter etween sender terminl nd sender hex. (Sender shown removed for lrity.) + g d Buzzer For 1994 Model And Older Crureted Engines - Jumper Wire To 12 Volt (+) Step 3 - Jumper Wire To Negtive ( ) Step 3 - Jumper Wire To 12 Volt (+) Step 4 d - Jumper Wire To Negtive ( ) Step 4 e - PURPLE Wire f - RED Wire g - TAN/BLUE Wire With engine not running, meter should indite full ontinuity. 4. Strt engine. With engine running nd engine oil pressure ove 6 PSI (41 kp), meter should indite NO ontinuity. Wter Temperture Swith REMOVAL 1. Drin oolnt from losed ooling system into suitle ontiner s outlined in Setion 6B. 2. Remove tn/lue wire from temperture swith Buzzer For EFI nd 1995 Model And Newer Crureted Engines (No Timer Ciruit) - TAN/BLUE Wire - Wter Temperture Swith D-12 - INSTRUMENTATION

15 NOTE: Coolnt hoses shown removed for lrity. 3. Remove swith. 1. Connet n ohmmeter etween wter temperture swith terminl (+) nd hex (se) for ground ( ) s shown. - Ohmmeter Leds - Wter Temperture Swith 2. Swith should red no ontinuity ! WARNING The following test involves the use of intense het. Filure to follow pproprite proedures or wrnings n use urns whih n result in severe personl injury. While performing the following test, oserve these generl preutions: Wer personl protetive lothing suh s ruer gloves, non-flmmle pron, nd eye protetion - preferly full fe shield or sfety glsses. The pproprite het soure should only e eletri. Het soure should e operted y qulified person. Be sure to follow ll instrutions of the mnufturer of the het soure. The het soure should e heked eh time it is used to e sure it is funtioning properly. The thermometer used in the test should e high-temperture thermometer with mximum reding of t lest 300 F (150 C). Under no irumstnes should the opertor llow tempertures to exeed test speifitions. Perform test only in well ventilted re. Use suitle ontiner, suh s metl, to hold the snd. Avoid use of glss ontiners unless the opertor first onfirms for himself/ herself tht the glss ontiner is n pproprite high-temperture vessel. Beuse the omponents will reh high tempertures DO NOT hndle mterils or omponents until COMPLETELY ooled INSTRUMENTATION - 4D-13

16 ! WARNING Use only len, dry snd suh s used for generl sndlsting purposes. Use of snd ontining ontminnts ould result in hzrds suh s fire, short iruiting, hot-spots, or other hzrds. 3. Follow these instrutions:. With n ohmmeter onneted s outlined nd using suitle ontiner, thermometer nd het soure, suspend sender with tip in snd.. Het snd nd oserve temperture on thermometer.. As temperture rises, swith will lose nd ohmmeter will indite ontinuity. Refer to hrt elow for speifitions Swith Opens F (60-77 C) Closes F (88-93 C) Swith Opens F (60-77 C) Closes F (88-93 C) e d Suitle Continer - Thermometer - Het Soure d - Wter Temperture Swith e - Ohmmeter Leds Swith Identifition Swith With Red Mylr Sleeve Swith With Blk Mylr Sleeve 4. Turn het soure off. Allow snd to ool. Note thermometer reding to ensure swith opens up t speified temperture. 5. Reple swith if swith fils to either open or lose within the speified tempertures. 4D-14 - INSTRUMENTATION

17 INSTALLATION 1. Apply Lotite Pipe Selnt with Teflon to threds of wter temperture swith. 2. Instll swith in thermostt housing nd tighten seurely. 3. Connet tn/lue wire nd ot onnetion with Liquid Neoprene. REMOVAL 1. Disonnet hrness wires t swith. 2. Remove swith nd seling wsher Trnsmission (Typil) - Trnsmission Fluid Temperture Swith With Seling Wsher - Hrness Wires - TAN / BLUE Wire - Wter Temperture Swith 4. Refill losed ooling system with pproved oolnt s outlined in Setion 6B. 1. Connet one led of n ohmmeter to one terminl of trnsmission swith. Connet the other led of ohmmeter to other terminl. Trnsmission Fluid Temperture Swith Swith is loted on trnsmission. Swith is normlly open. This swith is used on ll MIE engines, if so equipped Swith Opens F (82-93 C) Closes F ( C) Ohmmeter Leds - Trnsmission Fluid Temperture Swith 2. Swith should red no ontinuity INSTRUMENTATION - 4D-15

18 ! WARNING The following test involves the use of intense het. Filure to follow pproprite proedures or wrnings n use urns whih n result in severe personl injury. While performing the following test, oserve these generl preutions: Wer personl protetive lothing suh s ruer gloves, non-flmmle pron, nd eye protetion - preferly full fe shield or sfety glsses. The pproprite het soure should only e eletri. Het soure should e operted y qulified person. Be sure to follow ll instrutions of the mnufturer of the het soure. The het soure should e heked eh time it is used to e sure it is funtioning properly. The thermometer used in the test should e high-temperture thermometer with mximum reding of t lest 300 F (150 C). Under no irumstnes should the opertor llow tempertures to exeed test speifitions. Perform test only in well ventilted re. Use suitle ontiner, suh s metl, to hold the snd. Avoid use of glss ontiners unless the opertor first onfirms for himself/ herself tht the glss ontiner is n pproprite high-temperture vessel. Beuse the omponents will reh high tempertures DO NOT hndle mterils or omponents until COMPLETELY ooled.! WARNING Use only len, dry snd suh s used for generl sndlsting purposes. Use of snd ontining ontminnts ould result in hzrds suh s fire, short iruiting, hot-spots, or other hzrds. 3. Follow these instrutions:. With n ohmmeter onneted s outlined nd using suitle ontiner, thermometer nd het soure, suspend sender with tip in snd.. Het snd nd oserve thermometer. - Sutile Continer - Thermometer - Het Soure d - Trnsmisson Fluid Temperture Swith e - Ohmmeter Leds d e As temperture rises, swith will lose nd ohmmeter will indite ontinuity. Refer to hrt elow for speifitions. Swith Condition Temperture Opens F (82-93 C) Closes F ( C) 4. Turn het soure off. Allow snd to ool. Note thermometer reding to ensure swith opens up t speified temperture. 5. Reple swith if swith fils to either open or lose within the speified temperture. 4D-16 - INSTRUMENTATION

19 INSTALLATION 1. Apply Lotite Pipe Selnt with Teflon to threds of trnsmission fluid temperture swith. 2. Instll swith with seling wsher in trnsmission nd tighten seurely. 3. Reonnet hrness wires nd ot with Liquid Neoprene Trnsmission (Typil) - Trnsmission Fluid Temperture Swith With Seling Wsher - Hrness Wires 4. Chek trnsmission fluid level INSTRUMENTATION - 4D-17

20 THIS PAGE IS INTENTIONALLY BLANK TO ALLOW FOR CORRECTIONS OR ADDITIONS AT A LATER DATE 4D-18 - INSTRUMENTATION