og ees The Source for Power... Worldwide™ VSG-41 1/413 ENGINE DISTRIBUTORLESS IGNITION SYSTEM28.09 Ignition System 28.09 eB nse = i Re=O0000C a awa Eeersec \VSG DISTRIBUTORLESS IGNITION SYSTEM (015) WIRING DIAGRAM REFERENCE (E8dL-124200-AC) [UESC ] BASIC | STRIPE | ] Sein NO | CIRCUIT DESCRIPTION GA} cocoa | coco SPEC | T BLANK (NO WIRE) | T | (27 264 UESC To VRS = 78_| Woe _| i 1 [sass [uese To vas — 18] GREEN | | ‘| 354_| UESG TO RESISTOR 18 | BROWN | ware | 1 5 [BLANK (NO Wine) & 6 __| UESC SPARK RETARD OS2 18 BROWN. | [776 7 VESC SPARK RETARD O51 38 [BROWN r i [a7 21a [UESC TO IGN ON IGN SWITCH (SWITCHED)! 18_| YELLOW | | Lg) 57_| YESC TO BAT GROUND 18 BLACK j L410 389__| UESC TO ECTS GROUNO 18 | GREEN WHITE | [Fi¥ sso Tuese To spuce 18 | veuow | BLack | 1 12 | 852 | VESC TO SPLICE 18 | veLow | _wnIre =| 16 | DIS COIL TO BAT POWER (NOT SWITCHED)| 18 [RED ‘GREEN (T= aeea[resist0a 70 eGTs 18] sAOWN | WHITE | [F=** ssa T'SPUCE TO 01S Cont 18) YELLOW | BLACK i [=] e808] SPLIGE TO ELECTRONIC GOVERNOR OR | | TACHOMETER 1s | veuow | _siack ! = __B52A 1 SPLICE TO DIS COLE [rie vewtow "| wnire: 1 — | 8528 | SPLICE TO ELECTRONIC GOVERNOR OR 1 l | TACHOMETER sa_|_vewow | wareUO7OB/ ZULU 13289 KAR MINUTEMAN POWERBUSS: \gous/oan 28-10 ignition System 28-10 BE] ase SS RSE2O0000C a] aan ' | om rer a cme Ske SS ae ' SS. 1 Qe eee | \V80 OISTRIBUTORLESS IGNTION SYSTEM (05) WIRING OWGRAM REFERENCE (EAL '2A200-A0) Ue | NO CIRCUIT DESCRIPTION aa} ESIC | STRIPE | spec TI BLARING WR] 1 2 | asa uese 70 vas + ewer 1 3 | 265 | VESC TO VAS - 18 GREEN I 4 | a4 | UESG TO ECTS 1a [BROWN | WHE) rect BLANK (NO Wine) | t ia a Te aRown t 1 Loz fs UESC SPARK RETARD OS1 0 BROWN 1 8 | 16M_| ESC PIN 8 TO SPLICE | 8 RED GREEN | | ("3 Ts7Tuese To ear cnouno [re] aLack t (“io ase [Uese 70 ects (ie [angen ware (TT eso [uese 70 bis con 1 SAUCE [ie | vewow | etack | (Tie [ese ues 018 con 2 sPuce Tre_[vewow—|~ were | { ("= Tees con To sPuce [re Reo | GREEN | __ = __| 3544_| RESISTOR TO ECTS Lie BROWN WHITE | = et IGNITION SWITCH TO SPLICE 18 RED GREEN [S"eea5" | sPucE To ELECTRON GOVERNOR =] | TACHOMETER [ve | vewow | wre | —__| 8s2a_| SPICE TO O'S COM 2 118 YELLOW WHITE | =] Hee SALES TO ELECTRONG GOVERNOR — | | | S88 | SaChoMeTER 1 | vewow | auacx (ET mer T sete 70 81s FOU Tie | yewow [ata05/06/2010 13:35 FAX 28-05 DIAGNOSING AND TESTING DIS DIS DIAGNOSIS EQUIPMENT ‘To accurately diagnose DIS. cerain diagnostic equipment and tools are required. In addition. the suggested diagnosic equip ‘ment may make the job easier and more convenient Prior to diagnosing DIS. obtain the follow sguivalen, test equipment or ‘© DIS diagnostic hamess PPOIUI29 ot equivalent ‘* SPARK TESTER, NEON BULB TYPE CHAMPION CT 36 OR EQUIVALENT) There 5 no need to disconnect a plug wie: just place his spark ‘ester ona span plug wire to determine if spark is being provided ‘othe plug. This is especially useful for those hard to reach plug ‘© SPARK TESTER. GAP TYPE (SPECIAL SERVICE TOOL BIP-6666-A OR EQUIVALENT) Connect this eap type spark tester between any spark plug wire and engine ground fo instantly determine if spark is being pro- ‘ded othe plug. A spark plug with a broken side electrode isnot sulficient to check for spark and may lead fo incarect suis © VOLT-OHMMETER (ROTUNDA 9014-00575 OR EQUIVALENT) ‘A voltohmmeter is essential fr gathering system operating data ‘during diagnosis, testing. and engine servicing procedures. This ‘igual voltonmmetes (DVOM) can also be Used for general purpose electrical woubleshooung om conventional staring and ‘harping systems. © 12.14 VOLT TEST LAMP TIMING LIGHT (ROTUNDA 059.0006 OR EQUIVALENT ‘This timing light uses an inductive pickup for convenience and safety on 12 vat systems. This timung light includes 3 tachometer which reads from zero © 3000 RPM (Figure 11) MINUTEMAN POWERB ignition System gooasosa 28-05 DIS DIAGNOSING Identity the engine harness Ford part number and use se follow sng eleeacal harness part number sketch thax corresponds (0 the ‘engine bamess part number being ctecked. FIG. 11 Timing Lit ‘The firm check will ust the engine harness, connectors and seasors for both continuity and resistance. T Remove the 12 pia UESC harness plug from the UESC ‘module, Pins | od $ are pot used. therefore. do noc have female connector in the 12 pin harness connector plu, 2. Check the following circuits withthe volt-ohmmeter (with the seosors connected) per the following chart with reference to pages: 28-06 through 28-15 f the DIS Engine Harness checks are aot to tbe chart specifications {page 28-2). complete the following: Remove the wire harness connector 10 tbe UESC ‘© Remove each sensor oF component from the harness (© Using high impedance digital voltonmme:er (DVOM) cheek each wire for connuity or resistance (ref. 28-2\) {or wire sumbers & colors forthe harness being used. 1 If te wire harpess bas opea circuits or resistance higher ‘han specifications repair or replace the harness. (Ifthe wire barmess checks are to specificanons — reconnect cach sensor and component and complete another DIS Engine Harness check (ref. page 23+ 1 UC he same sensor or component CUCU does not test t0 specfieanons — replace that sensor oF coil (UF the engine will oe start and/or run install a new module snd make a normal start. LN Use the elecerical sketch that corresponds 10 harness part umber reference pages 28-06-2815 and fold-out page.05/06/2010 13:35 FAX MINUTEMAN POWERBOSS \go0s/o31 28-06 Ignition System 28-06 DIS ENGINE HARNESS CHECKS (UESC HARNESS CONNECTOR REMOVED ALL SENSORS CONNECTED TO HARNESS) { \ jine Harness | Harness T | [Test | £8! | VOM set] Reading Description of Circut, Wires | Wer | pG2Ag00., Genser |‘Seecion | Ohmavoc | CM4*8 | Ghecke & Creu Function | I ] T | Engine RPM & Crank Position, Wires [a [eanacao | 2s | a | cose | | Sagine REM a Crank | eteacea Sane as Test ay Teavesce Same as Test 1 [s Jeanacad | ser | a _| roseeo@ | o@ | Sagamore See wee 0 (Fs Testa L Same as Test 4 t ’ | | cauca,ce 410 10 | ss.000@ | o@ | £7g, Soctert Teme, Sensor, Wires 254) 7 | Continuity Eng. Spark Adv. Circuit, Wires 6 & {_7_| ELAS, AD Bo7 2 | 0100 Ress. No Grounds Equals S/A Set (or 87 Oct. 3 EaeeA Sa os Test 7 3p eaos, Co Same a8 Test 7 10 | eaiLacr aes | voc | v0 Ta he grton Swac “ONT — Wes 11 | EQULCA Same as Test 10 J °AD & CCAgn. Switch "ON", Wires Me [eancer ‘ame as Test 10 | See askase ter wa jeauacad | nw | a | osto | Bare ESS SOR, Bw O52A 8 ia ean Sane a Tea 3 is Lean-c8, 6 Same a8 Test 19 18 | eBiLAc cage [on [amo = 05 “Remene ie 4 Spark Pug Wires Tr teacee Sane as Te 18 a Teatca |] Sarme_as Test 16 49 | EaJL-AC [Coit Sec. 2-3 ‘Same as Test 16 1 (20 TEaca [ ‘Same as Test 16 | Ca Testes Same a Test 16 { HLT. spark plug wire resistance 9,000 to 16.000 ohms — (maximum 30,000 per wire) CODES — TEMPERATURE SENSOR CHARACTERISTICS CHART (TSCC) D Columa A coavers the sensor only resistance 10 a temperanue reading (page 28-07) Column B conver the sensor and harness resistance (0 2 temperanwe (page 25-07) D Use column A when the sensor is connected o the harsess (page 2B-07) (Harness does not have LOK resistor) D Use columa B when the sensor is connected 19 the harness (page 28-07) (Harness has 10K resistor) DECTS. brass only in 32°F ice water28-03 REMOVAL AND INSTALLATION IGNITION COIL Removal 1 Position coll assembly, secure with thee screws. 2 HT leads at col, ensuring that locking tabs snap into |. Disconnect batery ground lead. 2. Disconneet ignition coil multiply Connect banery ground lead. Start engine and check coi! ENGINE SPEED SENSOR: Removal28-04 {ignition System 28-04 ENGINE COOLANT TEMPERATURE SENSOR | i Removal 1. Disconnect batery and release cooling system pressure WARNING: When releasing system pressure, cover cap with a thick cloth fo prevent coolant scalding, 2. Place a clean drain tray below engine under radiator drain plug and remove drain plug. To assist draining remove radiator cap. 3. Remove temperature sensor multipiug. located below the in- ‘ake manifold. To remove multiplug. pull on multiplug, do not pull on winng. 4. Unscrew sensor from intake manifold Installation 1. Install sensor into inlet manifold, do not avertighten sensor. Connect muliplug, ensuring that locking tabs snap into position 2, Replace radiator drain plug and refll system with corect FIG: 8 Temperature Sensor solution. Remove rubber blanking cap on water outlet, When coolant is evident, refit blanking cap. Fill container 10 maximum” mark allowing time for air in system to bubble through. Insull radiator cap. 3. Connect battery and start engine. Allow engine to warm 10 ‘normal operating temperaure. Check. and if necessary, add coolaat.28-01 {gnition System a vos/oss 28-01 PART 2B — Ignition System — Distributorless ‘COMPONENT INDEX Page "[coMPONENT INDEX Page DESCRIPTION coves | 2808 REMOVAL AND INSTALLATION (Contd) ‘OPERATION 2801 Ignition Colt - 28.09 Igntton Col Driver 28-02 Engine Speed Sensor 28.03 Sensor Fai-Sale coe 28-02 Engine Coolant Temperature Sensor 28.04 (Cranking Mode ce | 2802 DIAGNOSIS AND TESTING 28.05 Fun Mode . : 28.02 IS Diagnosis Equipment 2805 ‘Tansient Mode 28.02 DIS Diagnosis... 28-405 Overspeed Mode : B02 DIS Engine Harness Checks oo | 28406 ‘SERVICE ADJUSTMENTS AND CHECKS ...| 28.02 Engine Coolant Sensor Characteristics 28.07 REMOVAL AND INSTALLATION 28-03 Wiring Diagrams 2848 WARNING OPERATION 1 High tension voluge produced by 2 distibutoless ignition system is higher than for a conventional ignition system, ‘¢ When carrying out service operations on an engine equipped wih siseibutorles ignition, iis important to be aware of the above point as well as all the usual safety measures (o prevent the possibility of electnc shocks DESCRIPTION ‘The purpose of an engine's ignition system is tonite the fueVair ‘mixture a the correct time and sequence based upon the input it ‘The Distributoriess Ignition System (DIS) used on the VSG 411/813 engines is a state-of-the-art ignition syste. The brain of this system is the Universal Electronic Spark Control (UESC) module. This module normally receives four inputs: 1 Crankshaft position ‘© Engine temperature © Crankshaft speed ‘© Engine vacuum (leas) From these inputs. the UESC computes spark strategy (spark savin) oon imam engine performace for comet spt ‘With this system, the electronic contol module monitors the cogive load, speed, and operating temperature and decides what Sepree of spark advance is correct for all ofthe operating cond ‘dons. This System maximizes the beoefits ofthe high compression ‘wet design. Because ming is set for life imberently inthe design ofthe engine, and tere are no moving parts inte ignition system itself, no maintenance is required except for periodic spark-plug checks. The system provides for ixed spark advance at start-up, forcold weather sartng, fixed advance for service checking, and foe“average value” default setings in case of compooent failure ‘Panicular aention has ben given to spark optimization for excel- leat fuel economy inthe warm-up made, which is coupled with improved warm-up and a new carburetor. ‘The spark plugs are paired so that one plug fires during the compression stoke and its companion piug fires during the ex- ‘aust sroke. The oext time tat coli fired, che plug that was 00 exhaust wil be 0p compression, ad the one that was on compres: sion will be on exhaust. The spark in the exhaust cylinder is wasted bur Lisle of the coil energy is lost. ‘The spac strategy is based on sensors and manifold vacuum input to the UESC madule, which include che fllowing inputs:05/06/2010 13:36 FAX MINUTEMAN POWERBOSS Boos/oa1 28-02 Ignition System 28-02 1, Engine Speed and C/S Position ‘The crankshaft postion ad speed information comes tothe UESC trom te Variable Reluctance Sensor (VRS). The VRS istiggered ty teeth cast int the engie side ofthe flywheel, The 361 teth, spaced 10" apart, ndicae to the UESC the crankshaft speed. The missing tooth indicates crankshaft postion, 2. Engine Load The capine loud information is processed into the UESC's elee- rons by 2 presure cansdvcer located within the UESC. A Vacuum Une counecs the tapsduce othe engine intake man ‘old. The capine actu is proporuonal 1 t's led. 3. Engine Temperature ‘The Engine Coolant Temperature Sensor (ECTS) sends engine semperatue informatioa 1 the UESC. The ECTS is located inthe intake manifold water jacket. 4, Fuel Octane Level Adjustment Anotber input tothe UESC (which is not usually used in he U.S.) retars the spar. ‘The UESC module outpats re: IGNITION COIL DRIVER The UESC switches two ignition cols on and off at te correct tunes to give the desired spark advance. SENSOR FAIL-SAFE lithe UESC identifies a failure of any ofits inputs, other than the engine speed/posion sensor it will substine a fixed value for that inpet une such time thatthe fault on the input is rectified. A failed tensor is defined af the instantaneous reading of a sensor being made that is either above ot below the maximum or miai- ‘mum reading as defined by the system constans below: Engine Coolant Temperature minimum -39°C eR maximim 12°C (2327) Manifold Absolute Pressure ainimum 2. KPA (6.22" Hg) ‘maximum 101 KPA (29.91" Hp) Ignition aming is adjusted constantly by tbe UESC mole, Many faetors inching all the sensors affect che final igmion seaing. RANKING MODE Cranking mode isthe area of engine operating speed within which the ignition timing is at a static postion. The staue spark advance is fixed at 10 degrees BTDC up 10 250 RPM. RUN MODE In this mode the RPM is above 250 and the spark advance is ‘calculated im thee main sections which are added together. The UESC sections are: Base Spark Advance (BSA) plas Spark Ad- vance Offset Te (SAOM plus Spark Advance Offset Detonation ECT (SAODE), ‘The final spark advance is then corrected, for propagation delays and finally the spark advance is limited by the system ranges and the spark slew rate limited. ‘The Base Spark Advance (BSA) is calculated by the UESC mod ‘le looking 2t speed and load inputs. ‘The Spark Advance Offset Temperanure (SAOT) will change ignition timing from the function of Eagine Coolant Temperarure (ECT). This allows the spark advance to be aiered during cold engine conditions to improve sarting and operation. Spatk Advance Offset Desmation ECT (SAODE) the ignition ‘ming is off o6 a femtion of Engine Coolant Temperature CECD. This allows the spark adwance to be redoced during hot engine cooditions to avoid detomation and allow base spark ad ‘vance to be calibrated near to the best performance curve. TRANSIENT MODE ‘This fimction is to provide detonation ben the engine load is increased rapily by fast opening of the throw plate Rapid increases in engine load are determined by large changes in consecutive Manifold Absolue Pressure (MAP) values to the UESC module. OVERSPEED MODE If tbe instantaneous engine speed is greater thin tbe maximum speed threabold, then the spark events are terminated until the ‘ssantaneoos eogine speed falls below 6375 RPM. During this, ‘ime all ter UESC calculations are performed as normal. SERVICE ADJUSTMENTS AND CHECKS n Each 400 hour of eagine operation remove the spark pgs and clean & adjust the electrode. 2. Clean and visually check spark plug bigh tension leads and check for secure fit, replace if necessary. 3. To retard the spark advance if the engine is operated on lower han specified fuel octane it may be necessary to reard the ‘imiag. 87 octane o higher fuel does ot require any adjustment, 4, To retard the spark advance, cut the wire loop in tbe harness ‘hat connects 0 pins number 6 and 7. For assistance, or further information, consult Ford Power Products Engineering ‘An Grounded Pin Above Ground Retarded * 7 ® 12 6 7 24 out 68 ‘The UESC module must be mounted above the intake manifold vacuum fining to prevent fuel from entering tbe UESC module chamber ‘The connecting rubber hose must be compatable with gasoline and ‘beas short as posible. Its recommended that a fel vapor tap be ‘ed inline i the counecting hoseELECTRONIC DIAGNOSIS ANO TESTING vemor system is comonsed of three maicr 2) wonents: the caroureter, actuator ana contTotes. ‘ve of this ¢ocument isto helo @ tect mgonent is crearng a proniem so ConorTion | POSSIBLE SOURCE | AGTION | [Governor | 1. Battery power isnot | Remove the connector from the controller anc with a vonmeter 1 pears | supsied te contealer | battery power across pins A & B of tha wiring narness connecicr | ee | Treatiery power isnot present. check winng (othe cantroter 2. Controle s not itthe canvolier is connected to an engine with a asinouior. ans © & D receiving ine speed | should both be connected to the negate sice of me cal. or me signal tachometer output NOTE: Tis conwoter ithe controller is connected to an engine with a DIS ignition. 9 © shaule ore Tiecanes tina | De connected to one of the two tachometer cutouts, ana pin © snouia be trem me gniion | connectes to the other tachometer ourout. The DIS ignition uLizes two | cons i | | NOTE: De not shor tne tach leaas: doing so cous garage ine soar | contrator. | Using an ohmmeter, check conunury Wom pine C & D to the termination | | points. if conunuty is not present. repair he wiring | ‘Actuator fails to | Remove the 2-pin connector at the actuator. With a DC voltmeter. check | operate. || berwean the purple wire ana chassis (battery) ground. The votmeter i |. snould read 12 voits, = 2 volts. | Tete voltage is iow, disconnect the 8-pin connector trom ine coniraller. ane | check continuity between the wiring harness pins E & F 19 iner respective | actuator terminals. If there is no continuity, cneck ior openings n ine wires, Using a volmeter, cneck tor battery voltage trom controler terminal E10 | | chassis (battery) ground. battery powers not found, replace tne controler || ancchecktne actuator and actuator wring for grounes ano sions. i | NOTE: Check wiring before reiacing controller. Bad wirng mont destroy | the new conteoler i Check continuity across actuator wires. 2 onms = § ohm snoula be measured. Check the continulty of actuator wires to ine case. The onme. measured should be 1M or greater. these values are outa! tolerance, replace actuator 1 7, incorrect engine | with tne engine running, connect natery power 10 pin H, This will sect goesnt soeed, | Fun 2, Run 2is set a nigher speed than Run 1 and the speed does not | cnange. repiace the controler. Contact OEM for soeea seings |" With the engine running, connect battery power to pin G., This wil select | Bun 3. it Run 3 is sethigher than the previous speed and the speed does |_not change, repiace the controler. Contact OEM fer speed serings. With the engine running, connect battery power to pins GAH This wil Soiact Run 4. I Run 4 s'set higher than tne previous sosed ang the speed L | does not change. reoiace the convrolier Contact OEM for speed senings. Wwusurvos36.9 ALNULEMAN FURBKBUDS: wors/ose Co ELECTRONIC DIAGNOSIS AND TESTING iContinued) CONDITION | POSSIBLE SOURCE Funeng. | mis-agiustment, Ts causes engine Mutat [ " if the engine :s not running at tne mecnar 2 Engine w misting ntagrates carburetor. Oosen tna tnree actuator fasteners arc ‘orate actuator to acnieve an oie of 600 APM. ("=e engine is governes by inear actuator. adjust he cle soeed screw 10 acrieve 600 RPM Ea ——EreVvo ywiy rotate ihe ale mixiure screw clockwse CW! unt gine soeea | Seains to oecreasr, Siomy turn me iale mixture screw counterciocnwise {CEW) unti the engine soeed begins to Jecrease, Now. turn ime vale mruxture screw clockwise 1CW) unbi maximum idle speed is acnieveo, The | ‘le mixture 15 now aguste. Cisconneet the connecior vom te controuer ang canguil ine angne reoar | manual vai —+! — — 8 — | | Calibration 512K of convent Somoatiole PC 288 mimmum win 640% RAM, c! .20 settings. as wali as other parameters. can 08 M Mo! weer WGA graonic99/06/2010 13:37 FAX MINUTEMAN POWERBOSS worz/osa Sovernor 05:10 oe71 Zooting System 74 ECTION TITLE PRGE —SECTIONTITLE pace ASIC ENGINE STARTING sySTEM os GNITION SYSTEM - DiSTRIBUTORLESS GOVERNOR asa FUEL SYSTEM COOLING SvSTEM ort SPECIFICATIONS, oe SECTION 07 — Cooling System SUBJECT PAGE © SUBJECT PAGE SCRIPTION AND OPERATION 07.4 ADJUSTMENTS ara Drive elt ona Beit Tension ora05/06/2010 13:38 FAX MINUTEMAN POWERBOSS 2 Svstem == caoiant flow is from the bortoin of the ne ion delivers io the cyinaer Block. syuner wail. Upon reacing the rear of the cyinaer k "8 coolant is orected vowata imo ‘re cyinaet naoling System ora EEE el ADJUSTMENTS: ve Belt ater curmo operation. A bet tat jee strain on the water pump ana ine generator anings ooeny tensioned dive bell minimizes noise anc also roiongs tne service lle ofthe oatt. Therelore. itis -commenaed that a belt tension gauge be uses to cneck 2n¢ aquust tne belt tension. Any belt that has been Operated for a minimum of 10 minutes is considered a used belt, and when adjusted, it must be adjusted to the used tension shown in the specifications. Belt Tension mounting anc agjusiing arm cots. Move tne ‘generator toware oF away from the engine until the correct rension is ootainea. Remove sne gauge, Tignten the eener bots. agqusting arm ana mounting Ine tension gauge ana recneck me Delt BELT Pension. 96 Ow 234 00013 VniageD Sere) avere1605/06/2010 13:38 FAX MINUTEMAN POWERBOSS: Bore /os1 Specifications 08. PAGE SECTION TITLE PAGE SIC ENGINE O11 STARTING sySTEM a (GNITION SYSTEM ~ BISTRIGUTORLESS 021 GOVERNOR 08-4 feu SYSTEM 031 COOLING SYSTEM 71 MISSION CONTROL SYSTEM o3a1 SPECIFICATIONS oot |SAGING SYSTEM oa ess SECTION 08 — Specifications SUBJECT PAGE SUBJECT CIFICATIONS 8.3 Special Service Toois Engine Model Years 199% 3 Conversion Factors Torque Soeeitleations09/06/2010 13:38 FAX MINUTEMAN POWERBOSS @ox7/031 Specifications PECIFICATIONS ENGINE MODEL YEARS 1993+ ‘i Soecitications agine Sosed — Maxmum jinaer Block er of Main Seanngs, Singer Block L ner Bore Diameter / ‘gat (Ol Pan Fail io ead Obox) fat Above Ol Pan Fail) wa 1 20a5 Soecitications Es SPECIFICATIONS (Continued) ENGINE MODEL YEARS 1993+ Piston Pin Cengin iererence Film Rogai 21°C «thang? [ 35¥6-0,048 mn -0,0006-0.0018 i Siaarance m Piston at 21°C «iL ang i 3.008-0.954 mm ‘0,0003-0.0006iny | Piston Rings Top Comoression Ring Thickness 1 1Land 1 3. e-0,05925 1) (0.08800 0885 313.087 mam 10,0008 0071 in) tom Compression Ring Thickness t 1L ang 13k 70 Compression Ring Side Clearance 1 iL and 1.3L Eotem moression Ring Sige Clearance 1 1L and) 3 rim 0.00025 Lana 7 3t i Pere a8a0 mm ‘oression Ring Side Clearance — Wear Limit Li ti tt ‘Oil Ring Sige Clearance 1 1Lana 13, L Too Comeression Ring — Stancara Bore — ‘Botom Compression Fing — Standard Bore — Bing Sap? 9.25-0.45 mm 10,010-0.017 in Si Ang — tanaare Bore — Ring Gap ® [ 920-0 40 mm 10 008-0 015 m1 Cylinder Head Viaxmom sermissibie cyinder neaa distorvor Land 1.3L: jeasured ver a aistance of 26 mm “easures over a astanca of 152 0m I sured Over ine ennre engin | vane Siem ret iLana st a vaive Seat Angie | valve Seat ingen — Exhaust, Ouse Olameter® 1 tL ana 1 3L moe Volume Felace cyirnder nead mating surlace: he folowing minimum combustion champer ceptn must be left aiter sximming — 1 1 ang 1.3L os: Conversion Factors see page 8 10 ay exceea mse soecitcanons by 0.15 mm ‘rusiee cniegia qua nitrogen or ary ceYo 08/2010 15:39 KAR MINUTEMAN POWEKBUSS: uiyus1 SPECIFICATIONS (Continued) ENGINE MODEL YEARS 1993+ Tanition System DIS 2 swan 87 Cctane Unieagea Gasounes ~Distributoriess Type _ = Siar seme Einar Resa Re Colne =a0 cb oe Tigh Tenn Labs —S Bei Terson sea-Reset Minimum 'Seq-Rlaset iMinimumi Fuel System Cana 7.3L Unieagea 1986. I Pump Delivery Pressure t ‘Starter — Current Draw Yormal Engine Cranang Vanimum Load — at Stall I No Loae i see cage 8aozoros1 284 8, Ed SPECIFICATIONS (Continued) ENGINE MODEL YEARS 1985 Cranxsnatt fain Bearing sourna: Oia} °C Stanoara lain Bearing sournal Oia veiow ‘wan Bearing Clearance 11L ‘Main Beanng Giearance 13 | Roo Beanng Joumal Da. tit tangard 40,99-41 OF mm 17.8138-1.6145 in) 40.7840.75 mom 11 8098-1 GOAT imi 3 / i £2.90-43.01 mm 13 6996-1 i $2 TEA2.TE mm B87 BER Boa Seang Ciearance }sLane 7aL 101006:0,080 rm 0,000.0 0025 m) “gayi bande 9.075-0.285 mm 0008-000 mi Camshaft | Jeumnai Diameter tat ana 130 T 3a.615.59.606 mem 1 5596.1 5605 my Teanng 1.1 thang VoL 9, 662.99,713 mm 1.50167 S005 n) | 5 seanng Clearance (Standaro Beanng) 1 and 1 SL 3.026-0.067 mm (0 007-0002 mi | Wear cent 0.0762 ram (0.005 1m 1 amenatt Thrust Plate Thiosness 1 1Land 1 Sk 3887-4508 mm (0.17540. Ena Pay 3192-0.18 rn 10.0008-0 5075 mi | Tamu ["Zamsnan iin or intake 5.70-mm 10.2249) (Eiraust B76 mm 0227 mr Dive (iu and 3 5L Chan ‘Connecting Rod ion Pin Bare 1 1L and I :90-18.010 mim(0.7088-0.7081 wr 1 [Boe Beanng Bore ti and 3 tT 43990-48010 mmi1 73184 7027 my) 1 Manmum Twist or Beno BO mm 10.004 mr i En Play | pang? aL L am 10.0085 O10 mn» | Piston 1 Diameter 17 88.670-66.700 mm 27085 8 osT "Diameter 1a “Ss00-7s ess mmiastoresem | Fision 19 Bore Clearance 3.075 .0,050 mm 0,0006.0.00191 version Factors see nage 8SPECIFICATIONS (Continued) ENGINE MODEL YEARS 1993+ valve Mechanism 3.92"-3.068 77 10.0008-0.0027 int 2.048.0.095 mm 10.0018-0.0037 in) 3.043-0.091 mm 10.0017 0.0036 m1 70-104 40 mm 13 083-4149 ins 34.30-94.60 mm 355. 28.80-28,10 mm 1 138. wos SU, nano Exhaust arom 16) Sonng Assemblea Height Pag to Retaneri Baza mm 208i) ‘Sorng Load at Assemoled Height 270 newions 160.7 1b) ‘gppet Sameter 3.081-"9.094 mm 19 5150-0, Block 8018 Sa7o13 743 mea ST8E 1 t 0.062 mm e007 30028 Searance 19 Slock Recker Shatt — Siameter (TRocrer Bore 5215.85 om 10.6209-0.6280 5.A7S.75.919 mm 10.6050-0.6264 m1 Shaft Glearance wn Rocker 0.62°5.09 mam 10,0008-0 0035 m1 Lubrication’ Type ‘Motererait Suoer Engine Ol API SG. Si Capanty | _avim Fiter#L_ 409) | Twinout Fiter oUF Raval vaive Ooane sure — Hor at 2000 fom munmmum Suter Rotor to Housing ‘nner to Outer Rotor Gan. Fig Play — Alors fo Puro Gover seenage®. Lies05/06/2010 13:39 FAX MINUTEMAN POWERBOSS o22/031 MPR' ITH MODEL “Downdraft Carburetor With Electronic Actuator ENHANCED DESIGN EQUALS HIGHER ENGINE PERFORMANCE ‘The Model 33 Carburetor wath Electronic Actuator is an integratea, electronically controlled fuel system, which maintains precise engine speed cantral with no droop over the entire power range. Adding to its imotessve features, recent design improve- ‘ments have increased this model's durability land improvea governar performance + Larger throttle shaft bearings provide improved load bearing characterstics and longer lite + Controiied throttle shaft axial movement, results in reduced friction between throttie piate and bore, + Machined throttle plate for better sealing and reauced frition. + Encapsulated accelerator check valve assembly and jet cesian improves accelerator pump output consistency.05/06/2010 13:40 FAX MINUTEMAN POWERBOSS @ozs/os1 MODEL 33 EXPLODED VIEW sorry See ane Pome se (Optic! sea ean Soapiworee (cera et Pl a ifecian Aowawre 3 Gouetassron Mange 2 Stera sharctivene 35 Seemea Son 2) Oasagreacenerator Pume (Opto Brower humo Sapnragm options 22+ Rmoly enact vale Oneanat 1 Ghar auisacceeratr Pura Duenarge (Opeana 3 eect atone a to, OMSTo preset the actuator on tne Dench + che carburetor nas been removes, use an 008 jage OF sri steck (a wire feeler worxs nell). Adjust tne actuator until the trrowle fgainst the throttle bore. Tighten the taining serews, This secung Is 2 nerminal alue, which insures thar the engine can De started for final adjustment on the engine. ‘Consult yaur owners manual for the specifies for your machine.! Adjusting the Actuator Step-By-Step: 1. Warm up the engine 2. Shut off the igeition 5 Disconnect at least one actuator wire 4 Restart the engine. 5, Insure that the choke is fully oven, 6. Loosan the three actuator retaining Agjust idle speea to specifications ov rotating the actuator Rousing (clock wise to increase speed), using care 10 avoid bending tabs 8. Adjust idle mature screw for best ide: just so that the engine speed just ars to drop from maximum wnen the ‘dle adjustments turned clockwise, Mixture ean also be set using 2 CO2 meter. (Consult your owner's manual for Correct setting.) 9, Recheck idle speed: readjust if 10, Tighten retaining screws. 11 Turn off ignition. 42, Reconnect actuator wire() 3. Insure that all hoses, connet fietings are im place. 4. Close tne engine comoarmen. ns and New-Accelerator Pump System The Mode’ 33 Carburetor now incorporates 2 revised accelerator pump system. The new system features a more positive shut-off to Drevent fuel pull-over and better sealing to prevent internal leakage. The new system contains a new pump cover assembly (40) vihieh contains the spring and protector. This repiaces the plastic protector (38) spring (38), ana spacer (57), winich are loose arts, The previous style accelerator jet has been replaced by a new accelerator jet cartridge (47)AWA oF:€T O10z/90/50 ‘SS0aMaMOd NVKELLONIN 1e0/s708)vasue/ ZULU 19:40 KAA ALNUEEMAN FUWEKISUDD tguz/v01 Celt GiD ert Service InFormation Troubleshooting & Wiring Troubleshooting Information for DYN1-10851 Controller “This govemor system is comprised of three major components; the carburetor, actuator and controller. The ‘objective of this document isto help a technician identity which component is creating a problem so itcan be fixed or replaced. Problem Cause Corrective Action |. Govemor appears dead. |. Battery power is not supplied | Remove the connector from the controller and to controller with a voltmeter check for battery power across. pins A& Bof the wiring harness connector. | If battery power is not present, check wiring to the | controller. | 4 2. Controieris net receiving the | the controller is connected to an engine with a | speed signal. distributor, pins C & D should both be connected io the negative side of the coil, or the tachometer, —NoTE— output This controller receives its [if the controller is connected to an engine with a ‘speed signal from the ignition. | DIS ignition, pin C should be connected to one of ithe two tachometer outputs, and pin D should be connected to the other tachometer output. The DIS ignition utitizes two coils. — NOTE — ‘Do not short the tach leads; doing so could damage the spark controller [Using an ohmmeter, check continuity from pins G & D to the termination points. If continuity is not resent, repair the wirin [8. Actuator fails to operate. Remove the wires connected fo the actuator. Wth | ‘a DC volmeter, check between the actuator wires to Battery (). The volimeter should read 12 vots = 2 vols. |i the voltage is low, disconnect the connector {irom the controller and check continuity between the wiring harness pins, E & F, to their respective ‘actuator terminals. ‘If there is no continuity, check {for openings in the wires. Using a volmeter, check for battery voltage from | controller terminals E & F to Battery (-). Ibattery [power is not found, replace the controller and icheck the actuator and actuator wiring for grounds [and shorts. . —NOTE— Check wiring before replacing controller. Bad | _wiring might destroy the new controller. heck continuity across actuator wires, 2 ohms +5 ohms should be measured. Check the | continuity of actuator wires to the case, The | Johms measured should be 1M or greater. tt these values are out of tolerance, replace | actuator. | LITHO INUS.A, "DYNA 187vo/yo/ 2010 19:41 KAR MINUTEMAN POWERBOSS 027/031 Installation Dimensions (For reference only) DYN1-10851 Controller plate te ite Dimensions in mm Inches in brackets []05/08/2010 13:41 FAX MINUTEMAN POWERBOSS Basic Wiring Diagram — DYN1-10851 Controller caution [AS a suoly measure, the engine should be equipped with an independent "ovorspacd.chutdown devi n tho even! ol {aro which may ‘ender the governor operative NOTE Barber Colman bates that a information provided nein ie comect and volabie and reserves tho righ to Update al any | tive: Barber-Calman dass not assume any responsi Tot is use unless therise expressly undoraken, DYNA 157 Wiring for DIS Ignition vege (| so ha i Barber-Colman Company AEROSPACE & POWER CONTROLS DIVISION DYNA Product Group | 1954 citord Avenue | Phone: 815) 637-3000 | Po Bor 200 | Toor easoa55 | Loves Park iL USA. 61132-2040 | Fax. (818)877.0169 | in Europe contact: Barber-Colman GmbH ‘Am naven Rcnatens, D-6720 Speyer, Wost Germany | Toro62%2-1203, Fax: 05252-12158, Telex: 467 627 | Ip. Jagan contact: Ranco Japan Lid Shiovaki Bldg 71,2 chomo, Hrakawa Che, Chyodts Ku Tokyo 102, Japan Tol 9261-4289, Fax: 9264-4691, Tolex’ 0252-2087 UTHOINUS.A \gozs/031ZULU 13:41 KAN MINUTEMAN PUMEKBOSS: quzy/ost Troubleshooting Information (continued) [" Probiem Cause Corrective Action ] HL Engine doesn't | 1. Incorrect engine speed. With the engine running, connect battery power to pin change speeds. H. This wil'select Run 2. it Run 2 is set at a higher ‘speed than Run 1 and the speed does not change, replace the controfer. Contact OEM for speed settings, | With the engine runing, connec battery power pin G. This willselect Run3. if Run3 is set higher than the previous speed and the speed does not | change, replace the controler. Contact OEM for | speed settings. With the engine runing, connec battery power to [pins @ & H. Ths wil selec Fun 4. I Run 4s set | higher than the previous speed and the speed does tot change, replace the convoler, Contat OEM fr | speed settings. - M. Engine is 1. Engine is misfiring due to idle | Disconnect the connector trom the controller. hunting, mixture mis-adjustment. This | The governor is now disabled and a warm engine causes engine hunt at no load | should be running at 2 mechanical idle of ap- | condition proximately 600 RPM. | m Ifthe engine is not running at the mechanical ie | | and is govemed by an integrated carburetor, loosen) the three actuator fastenors and rotate the actuator | | to achieve an idle of 600 RPM. Ifthe engine is governed by a linear actuator, adjust the idle speed serew to achieve 600 RPM. | ‘Siowly rotate the ile mixture screw clockwise (CW)} | Lunti the engine speed begins to decrease. Slowly | tum the idle mixture screw counterclockwise (CCW)| until the engine speed begins to decrease. Now, tur the idle mixture screw clockwise (CW) unt | ‘maximum idle speed is achieved. The idle mixture is now adjusted, | | 2. Engine is misfiring, Disconnect the connector from the controller and consuit the engine repair manual.UD/05/ 201 13241 KAR MINUTEMAN FUNEKBUSS qoso/uss05/06/2010 13:41 FAX Standard Features: + Faroe Bore 2 + Chane Bore: 46 mm 11 804 i) fentut iameter 2-28 mm + Flexiole a cleaner mounting: + Manual choke: Levers mav oe speciiea an ether side of the carburetor Optional Features: + Accelerator UMD: Mecnanvcal oF vacuuin operatea + Automatic electric choke + Fuel shut-off solenoia: Prevents cieseting + Agjustabie main et Provices tlexioiity + Power system: Oouizes full load performance wnile allowing calioration + PCY connection Description of Operations: The carnuretor throttle is couple to the actuator, wnich isn turn controlled by turrent from the Electronic Contro! Module (ECM). The ECM is a closed loop contrat vyhieh manipulates the throttle actuator tO ‘maintain a programmes spees in response 19 measures engine soeed Different speeds can be selected for various persting conditions, using signais from swatenes, et. The actuator can also be Operates 35 an ail-soees governor, using 8 ‘arigbie resistor connectee to the throttie rome snaft through a covonng Termes by spring cigs aetacneo to the eno of tne actuator snait. The clips mare with two rials Dn the throttie shaft. This arrangement allows fer sight misalignment betwean the Sctuator and the throttle shaft, The closed {throttie stop 1s internal to the actuater. There is no conventional throttle stop screw tor ice speed adjusting screw. The position of the actuator establishes tne closea ‘throttle position wnen no power 's supplies ro the actuator. The combination of the actuator and the ‘throttle forms a nigh precision aasitioning system. Care is required to insure prover alignment of the actuator shaft to ine throttle shaft with no lest motion between the two ang with no friction. Ball bearings are usea througnout the system to insure MINUTEMAN POWERBOSS gosi/0s1 Semoving the Actuator: Installing the Actuator: Make sure tne mauing surfaces between ne actuator ana the carburetor are clean. Make 2 triai inspection without the aust ferews ana cbs. Check tne clearance fetween tne enas of the thyomtle snaft anc the actuator snaft, insure that there about O16 inch (.4 mm) clearance with tne throttle piate closed. During this trai nstallation, make sure that the actuator is Oriented s0 tat its soring cips properly Engage with ihe flats on the enrottie snare Remove tne actuator ana install ne ven reynstall the actual ‘taining cos ana screws, (DO qot tighten ‘she screws.) Position the actuator so that ‘the wires are oriented the same way 35 Setting the Actuator on the Engine: The engine shoula be at operating temper ature for this proceaure. With the cnoke 2pen. rotate the actuator until approx: Trately 1/32 inen open, wiven can o accemollsheo visually, of by feel, Rota throttle (toward the idle mixture aaiusting screw! until resistance is felt. then rotate in the opening airection until the perionery the actuater nousing moves about 1/32 ausconnect at least one wire trom ine actuator. Start the engine ane agjust tne actuator for an ile speed slightly below formal governed idle speed. (700 to 800 RPM is 2 good default value.) Adjust tne idle mixture screw for best idle. Stoo the engine, reconnect the actuator wires), restart the engine. ana observe the idle speed, (Consult your owner's manual for the seting for your machine.) Tighten the