SEARS 161.214230 (01) PDF MANUAL

SEARS 161.214230 (01) PDF SUMMARY:

What should I do before starting the engine?

Before starting the engine, set the parking brake and place the gear selector in neutral on a standard transmission or park on an automatic transmission.

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What safety precautions should I take regarding exhaust gas?

The carbon monoxide in exhaust gas is highly toxic. To avoid asphyxiation, always operate the vehicle in a well-ventilated area. If the vehicle is in an enclosed area, the exhaust should be routed directly to the outside via a leakproof exhaust hose.

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When operating any test instrument from an auxiliary battery, what connection is needed and where should the battery be located?

When operating any test instrument from an auxiliary battery, connect a jumper wire between the negative terminal of the auxiliary battery and the ground on the vehicle under test. When working in a garage or other enclosed area, the auxiliary battery should be located at least 18 inches above the floor to minimize the possibility of igniting gasoline vapors.

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What precautions should I take when working near the battery?

An automobile battery is capable of producing very high currents. Therefore, exercise reasonable care when working near the battery to avoid electrical connections through tools or a wristwatch. Avoid contact with battery electrolyte, which can eat holes in clothing, burn skin, and cause permanent damage to eyes. Always wear splash-proof safety goggles when working around the battery. If battery electrolyte is splashed in the eyes or on skin, immediately flush the affected area for 15 minutes with large quantities of clean water. In the case of eye contact, seek medical aid.

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What safety precautions should I take when a battery is charging?

The gases generated by a charging battery are highly explosive. Do not smoke or permit flame or spark to occur near a battery at any time, particularly when it is charging. Any room or compartment containing charging batteries should be well-ventilated to prevent the accumulation of explosive gases. To avoid sparks, do not disturb the battery charger connections while the battery is charging, and always turn the charger off before disconnecting the battery clips. When removing or reconnecting battery cables, make sure the ignition switch and all accessories are turned off.

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Is it okay to add acid to a battery after it has been placed in service?

Never add acid to a battery once the battery has been placed in service. Doing so may result in dangerous spattering of electrolyte.

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What precautions should I take to prevent entanglement with engine parts?

Keep hands, hair, necktie, loose clothing, and test leads well away from the fan blade, fan belt, power steering belt, air conditioner belt, and other moving engine parts, as serious injury could result from entanglement.

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What should I avoid touching on a running engine?

Do not touch the hot exhaust manifold, radiator, or high-voltage spark plug and coil terminals. Spark voltages are not normally lethal, but an involuntary jerk of the hands or arms caused by electrical shock may result in injury.

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Is it safe to look directly into the carburetor throat while the engine is running?

Never look directly into the carburetor throat while the engine is cranking or running. A sudden backfire can cause serious burns.

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What precautions should I take to avoid a flash fire?

To avoid the possibility of a flash fire, do not smoke or permit flame or spark to occur near the carburetor, fuel line, fuel filter, fuel pump, or other potential sources of spilled gasoline or gasoline vapors.

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Is it safe to remove the radiator cap while the engine is hot?

Never remove the radiator cap while the engine is hot. Hot coolant escaping under pressure can cause serious burns.

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When should I use the jack supplied with the vehicle?

The jack supplied with the vehicle should be used only for changing wheels. Never crawl under the car or run the engine while the vehicle is on a jack.

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What does the meter on the front panel provide?

The meter provides the following scales: 0-500,000 OHMS with 5000 center scale, 0-1200 and 6000 RPM, 0-16 volts, 4-6-8 cylinder dwell, 0-100 AMPS, and a 3.2-volt point condition scale.

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What does the zero adjuster do?

If the meter pointer is not at the zero mark, slowly rotate the plastic slotted screw until the pointer is at zero.

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Which socket should I use for Amp tests?

Insert the RED Shunt lead plug into the AMPS/OHMS socket for Amps tests.

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Which socket should I use for Ohms tests?

Insert the WHITE Ohms lead plug into the AMPS/OHMS socket for Ohms tests.

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Which socket should I use for the RPM lead plug?

Insert the BLUE RPM lead plug in the RPM PICK-UP socket.

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Which socket should I use for Dwell or Volts tests?

Insert the BLACK Dwell/Volts lead plug in the DWELL/VOLTS socket for dwell or volts tests.

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What is the purpose of the RPM range selector?

The RPM Range Selector is used to select either the 0-1200 RPM or 0-6000 RPM scales.

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What are the positions of the Function Selector Switch and what does each position do?

The Function Selector Switch positions are:

• POINTS: Provides point condition reading on a 3.2-volt scale. This test is also used to indicate voltage losses in the electrical starting and charging system.
• VOLTS: Used to test the electrical and charging systems on vehicles with 12-volt systems. Read the 16-volt scale.
• RPM: Permits reading the engine RPM on either the 0-1200 or 0-6000 RPM scale, depending on the RPM Range Selector.
• DWELL: Used to check Breaker Point Dwell Angle. Read either the 4, 6, or 8 cylinder scale corresponding to the number of cylinders on the engine. Read the 90, 60, or 45-degree scale.
• AMPS: Used to measure the alternator charging system output.
• OHMS X 1000: Used to measure electrical resistance (ignition cables, resistors, coils). Multiply the OHMS scale reading by 1000.

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What is the purpose of the Ford Adapter?

The Ford Adapter is used to provide easy hook-up on ignition systems with insulated coil primary connections.

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What is the purpose of the G.M. Diagnostic Connector Adapter?

The G.M. Diagnostic Connector Adapter is used to make tests on G.M. cars equipped with the diagnostic connector.

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What is the purpose of the H.E.I. Adapter?

The H.E.I. Adapter is used to provide Dwell connection on G.M. HEI systems.

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What is the purpose of the Jumper Lead?

The Jumper Lead is used in electrical system tests and OHMS cable tests.

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What is the purpose of the Alternator Field Terminal Connector?

The Alternator Field Terminal Connector is used for field connections.

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How do I connect the test leads to the tester?

Insert all test leads into matching color sockets on the panel, except for Ohms. The Ohms (WHITE) lead connects to the Red socket on the panel when making tests. The plugs and sockets are polarized to ensure correct attachment. The socket has a groove on each top edge and the plug has a mating ridge on the inside of the top corners.

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Where do I connect the red clip?

Connect the red clip to the battery’s positive (+) terminal.

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Where do I connect the black clip?

Connect the black clip to the battery’s negative (-) GRD terminal.

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Where do I connect the green clip on breaker point ignition systems?

Connect the green clip to the distributor terminal of the ignition coil primary on breaker point ignition systems only.

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Where do I attach the RPM induction pickup?

Attach the RPM induction pickup to a spark plug cable as close to the distributor cap as possible. The jaws must be fully closed.

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Where do I connect the ammeter shunt?

Connect the ammeter shunt to the alternator output terminal.

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What condition should the engine be in before testing?

The engine must be at operating temperature before testing.

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How do I connect test leads for electronic ignition systems?

Connect the test leads as illustrated, but do not connect the green clip on electronic systems.

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When testing electronic ignition systems, what tests should be omitted?

When testing electronic ignition systems, omit Test No. 1 – Point Resistance and Test No. 4 – Dwell Test.

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How do I perform the Point Resistance Test (Test No. 1) on breaker point ignition systems?

1. Place the function switch in the POINTS position.
2. Disable the engine to prevent starting by removing the coil secondary lead from the distributor and connecting it to a good engine ground with a jumper lead.
3. Turn the ignition switch to the START position momentarily to crank the engine slowly until the points are closed, as indicated by the lowest meter reading.
4. Points are in good condition if the reading is 0.3 volts or less. Replace the points if the reading is out of the OK zone or over 0.3 volts.
5. When the reading exceeds 0.3 volts, check the distributor primary lead to the coil for breaks or misaligned contacts.
6. When new points are installed, always clean and lubricate the cam, check for contact alignment, and check again for contact resistance. Set the point gap to the manufacturer’s specifications.
7. If the point resistance is satisfactory, proceed to the Battery-Starter Load Voltage Test No. 2. New points may give a high reading until operated for a few minutes.

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How do I perform the Battery-Starter Load Voltage Test (Test No. 2)?

1. Place the function switch in the VOLTS position. The engine must be disabled to prevent starting for this test. On electronic ignition, disconnect the battery cable at the coil or unplug the pickup coil connector at the distributor, or ground the HT secondary lead on any external coil system.
2. Place the ignition switch in the START position and operate the starter for 15 seconds. Observe the battery voltage reading with the starter operation load.
3. A battery in good, fully charged condition should read 9 volts or more.
4. If the battery voltage reads below 9 volts, recharge the battery to a full charge condition.
5. Excessive fluctuating voltage reading (over 1 volt) can be caused by a starter in poor condition due to worn bearings, a dirty commutator, a defective battery, or corroded starter cables.
6. To check starter cable voltage loss, remove the tester red clip from the battery’s positive terminal and check the voltage at the starter solenoid on both the BATTERY and STARTER terminals.
7. Readings below 8 volts (with a fully charged battery) at the starter usually indicate a defective starter cable or burned solenoid contacts. Replace defective parts as required for good starter performance.
8. If the battery-starter test is normal (a steady reading over 9 volts), proceed to the Battery Charging System Test No. 3.

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How do I perform the Battery Charging System Test (Test No. 3)?

1. Place the function switch in the VOLTS position.
2. Start the engine and operate at a fast idle (approximately 1500 RPM). Note the charging battery voltage. The meter should read over 12 volts and slowly rise to the regulated voltage in a few minutes (15 1/2 volts maximum).
3. Place the function switch to the AMPS position during the above charging period and note the alternator charging rate. Shortly after starting, an alternator in good condition should charge from 50% to 80% of its rated capacity and slowly decrease as the battery regains its charge. The charging voltage will slowly rise as the ampere rate decreases and the maximum regulated voltage is obtained.
4. Place the function switch to the VOLTS position again and operate the engine at fast idle until the charging voltage stops increasing. Note the voltage and compare it to vehicle specifications.
5. If the charging voltage exceeds 15 1/2 volts or as specified, replace or adjust the voltage regulator.
6. If the charging voltage does not slowly increase, this usually indicates no charging amperes. Check in AMPS position.
7. If a zero or low charging amps reading is indicated, check the alternator output under full field conditions by removing voltage regulator control action. Refer to the vehicle specifications to determine type A or B system for proper bypass field connections.

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How do I test the alternator output under full field conditions?

To perform this test, it is necessary to ground the field in a Type A circuit or remove the regulator from the charging system and energize the field in a Type B circuit. This provides full field operation, and the alternator will charge at its maximum rated capacity.

• Type A Circuit (Electronic Voltage Regulator): Remove the field lead (green wire) from the alternator field terminal. Connect a jumper wire from the alternator field terminal to ground.
• Type B Circuit (External Voltage Regulator): On some vehicles, it may be inconvenient to connect the jumper wire at the alternator. In such a situation, remove the regulator connector from the voltage regulator and connect a jumper wire as illustrated. Remove the field lead from the field terminal. Connect a jumper wire from the positive terminal of the battery to the field lead.

If the meter reading is the specified minimum or higher, the alternator output is satisfactory. If the meter reading is less than specified, check for a loose or worn alternator drive belt, a faulty field or battery wire to the alternator, or a poorly grounded or defective alternator. If the meter reading is to the left of zero, a broken field wire or a defective alternator is indicated. When the test is completed, shut off the engine, disconnect the jumper lead, and reconnect the wiring harness plug, connector, or field wire to the regulator for normal operation.

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How do I perform the Dwell Test (Test No. 4)?

1. Place the function switch in the DWELL position.
2. Consult the vehicle manufacturer’s service manual as to what vacuum hoses should be disconnected and plugged while setting dwell.
3. Operate the engine at the manufacturer’s specified idle speed and note the dwell reading on the proper 4, 6, or 8-cylinder scale corresponding to the engine under test.
4. Compare the reading to vehicle specifications and adjust to the correct dwell if required.
5. Dwell Variation Test: Operate the engine at idle, note the dwell reading, then increase the speed to fast idle (approximately 1500 RPM); note the reading and return to idle. Dwell variation should not exceed 3 degrees. When a variation of over 3 degrees is indicated, the distributor should be replaced or rebuilt. Variation may be caused by a worn shaft, bushing, worn or loose breaker plate, or worn cam lobes.
6. Dual Point Systems: Stop the engine and block one set of points with clean insulating material (cardboard). Operate the engine on each set of points, one at a time, read the dwell, and finally on both points. Refer to vehicle specifications for specified dwell and limits. Adjust as required.
7. Proceed to the ignition timing test when the dwell test is within normal specified limits.
8. When necessary to adjust point dwell, refer to the adjustment procedures.

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How do I adjust dwell on engines with a sliding window in the distributor cap?

1. Operate the engine at the specified idle.
2. Raise the window and insert a 1/8" Allen wrench into the adjustment screw.
3. Turn the adjustment screw until the correct dwell is indicated on the Dwell scale.

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How do I adjust dwell on engines with non-window type distributors?

1. Stop the engine and remove the coil wire from the center tower of the distributor cap.
2. Connect a jumper wire between the coil wire and engine ground to prevent arcing while cranking the engine.
3. Remove the distributor cap and rotor.
4. Connect a remote starter switch to test the vehicle or have an assistant crank the engine for you with the ignition switch.
5. Turn the ignition switch on, and while the engine is cranking, observe the reading on the Dwell scale.
6. To adjust dwell, loosen the locking screw slightly and adjust the point gap by turning the adjustment screw or by inserting a screwdriver in the slotted hole and turning the tool slightly left or right to obtain the specified point dwell reading.
7. Tighten the locking screw and recheck the dwell while cranking the engine. Repeat the procedure if necessary.
8. Reassemble the distributor and recheck the dwell reading with the engine operating at the specified idle.

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What is important to do every time the dwell is adjusted?

It is important to recheck the ignition timing every time the dwell is adjusted. A one-degree change in dwell causes a one-degree change in timing.

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How do I perform the Ignition Timing Test (Test No. 5)?

1. Connect a timing light to the battery and #1 spark plug cable.
2. Place the function switch to the RPM position and set the RPM range switch to Lo-1200 RPM for idle speeds and Hi-6000 RPM for hi-speed tests.
3. Locate the timing mark on the flywheel and the degree indicator plate. Clean both surfaces and apply a white chalk mark on the flywheel mark for good visibility.
4. Consult the vehicle manufacturer’s service manual as to what vacuum hoses should be disconnected and plugged while setting the timing.
5. Start the engine and operate at the speed specified by the Tune-Up decal under the hood or service manual for timing adjustment.
6. Operate the timing light and aim it at the timing mark. Note the position of the flywheel mark in relation to the degree indicator. Compare to the specified basic timing. If not within specifications, readjust the distributor as required.
7. Timing Adjustment: To change the timing, loosen the distributor hold-down screw or bolt and rotate the distributor body until the proper timing is indicated.
8. Centrifugal Advance: With the vacuum hose from the distributor vacuum advance unit disconnected and plugged, bring the engine to normal operating temperature at hot engine idle speed and note the position of the timing mark. Increase the engine speed slowly and observe the movement of the timing mark. It should move smoothly and without jerking in the opposite direction to the flywheel rotation up to about 2000 RPM. Decrease the speed, and the mark should return smoothly to its original position.
9. Vacuum Advance Test: Operate the engine at 1500 RPM and connect the rubber hose to the distributor vacuum control and observe the movement of the timing mark. The mark should move opposite to the flywheel rotation with a normal operating vacuum control.
10. Note: The emission control system of many vehicles prevents the operation of timing advance systems. Before tampering with your distributor’s advance systems, consult the vehicles service manual for further information.

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How do I perform the RPM – Carburetor Adjustment (Test No. 6)?

1. Place the function switch in the RPM position.
2. Idle Speed Adjust: The engine must be at normal operating temperature before setting the idle screw. Refer to the vehicle specifications for the idle RPM range. Check for variations in RPM with the air conditioner on and any other specified idle range requirements.
3. Emission Control Systems: Carburetors on late-model vehicles usually have sealing caps on idle mixture screws, which prohibit or restrict carburetor adjustment. These are factory calibration seals. Refer to the vehicle manufacturer’s service manual for idle screw adjustment procedures.
4. Idle Mixture Adjustment: It is advisable to use the idle mixture adjustment procedure as outlined in the manufacturer’s service manual whenever possible. However, the following procedure should work well on those vehicles without emission control systems. Turn the idle mixture screw in (lean) until the idle RPM starts to decrease and the engine begins to idle rough. When this point is reached, slowly back the idle mixture screw out (rich) until the maximum steady RPM is obtained. When making any mixture adjustment, only turn the mixture screw 1/8 of a turn at a time. Between adjustments, allow about 30 seconds for the engine speed to stabilize.
5. Multi-Barrel Carburetors: Repeat this procedure on EACH mixture screw until the smoothest maximum RPM is obtained. Turn each screw 1/8 of a turn at a time to prevent the engine from stalling. If the final idle RPM is now higher than specified, readjust the THROTTLE idle screw back to the normal specified RPM and readjust mixture screws again until no further increase is possible.
6. Note: On vehicles with emission control systems, air injection pumps, and positive crankcase ventilation, refer to the vehicle decal in the engine compartment for idle adjustment procedures.
7. Operate the engine at various speeds and return to idle. If the idle returns to normal each time, the carburetor is normal.

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How do I perform the Voltage Loss Test (Test No. 7)?

1. Disconnect all tester leads. Use only the BLACK PLUG battery-dwell lead for this test. Use the black and green test clips for voltage loss tests.
2. Place the function switch in the POINTS position and read the 2.5-volt points scale. Each division is 0.1 volt.
3. Disable the engine to prevent starting by grounding the HV lead of the coil. On HEI or electronic systems, disconnect the battery lead at the coil or unplug the distributor pickup coil connector.
4. Refer to the starter system and connect the green and black clips across each section of the circuit. Operate the starter for each test and observe the reading.
5. All readings must read 0.2 volts (2 divisions) or less for normal conditions. Reverse test leads if the meter reads backwards.
6. High readings will be caused by corroded or loose connections at battery terminals, cables, or a worn solenoid.
7. Remove and clean battery terminal and cable terminals with a water solution with baking soda to dissolve corrosion. Tighten the nuts on starter solenoid terminals.
8. Replace worn or corroded cables as required to correct the condition.
9. Do not crank for more than 15 seconds at a time. Allow the starter motor to cool off for 30 seconds between tests.
10. When the tests are completed, reconnect the coil for normal starting.

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How do I perform the Ohms Test (Test No. 8)?

1. The tester does not require any internal dry cell batteries. The ohmmeter test is powered from the vehicle’s 12-volt battery. No zero calibration is required by the operator. Place the function switch in the OHMS X 1000 position.
2. Connections: Insert the BLACK Plug (Other Tests) into the BLACK Socket and the WHITE Plug (Ohms) into the RED Socket. Connect the black and red clips to the vehicle’s 12-volt battery in the correct polarity.
3. The OHMS test is always made between the RED OHMS clip and the BLACK Ohms clip.
4. Important Caution: Always disconnect all leads from any electrical part to be tested on the vehicle. Failure to observe this caution may result in damage to the tester.
5. Refer to the manufacturer’s specifications for the normal resistance value of any part being tested – ignition cables, ballast resistors, coil windings, etc.

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How do I order repair parts for the Automotive Engine Analyzer?

To order repair parts or service for the Automotive Engine Analyzer, contact any Sears Service Center or most Sears, Roebuck and Co. stores. Provide all pertinent facts when you call or visit. The model number can be found on the front of the instrument. When ordering repair parts, always provide the part number, model number, part description, and name of the item. All parts listed may be ordered from any Sears Service Center and most Sears stores. If the parts are not stocked locally, your order will be electronically transmitted to a Sears Repair Parts Distribution Center for handling.