Clarke CA 500, 4500480 User guide

DIGITAL ENGINE ANALYSER

DIGITAL ENGINE ANALYSER

Model No. CA500

Part No. 45010480

OPERATING & MAINTENANCE

INSTRUCTIONS

0501

Thank you for purchasing this CLARKE Digital Engine Analyser, designed for use by automotive
technicians both professional and DIY alike.

Please read this leaflet thoroughly and follow the instructions carefully, in doing so you will
ensure the safety of yourself and that of others around you, and you can look forward to
the Analyser giving you long and satisfactory service.

GUARANTEE

This CLARKE product is guaranteed against faulty manufacture for a period of 12 months
from the date of purchase. Please keep your receipt as proof of purchase.

This guarantee is invalid if the product is found to have been abused or tampered with in
any way, or not used for the purpose for which it was intended. Faulty goods should be
returned to their place of purchase, no product can be returned to us without prior
permission. This guarantee does not effect your statutory rights.

NOTE: Only use this function on engines with conventional ignition systems. DO NOT use on
engines with electronic ignition systems.

Typical internal type Contact Breaker Adjustments

Fig. 5

INTRODUCTION

The purpose of this instruction manual is to provide the information necessary to service
and carry out adjustments to keep an engine in peak running condition. Once understood,
the complexities of car engine tune-up become relatively simple.

The few basic tools required are available through your local CLARKE dealer. The
specifications contained in the owner’s handbook are indispensable for a safe and
satisfactory tune-up, and should be used in conjunction with this manual.

SAFETY PRECAUTIONS

(Before Starting the engine)

1. When working on an engine, always wear appropriate clothing. Ideally, long sleeves securely
buttoned. Long hair should be contained, and all jewellery - rings bracelets etc., removed.

2. Ensure that all electrical leads are secured well away from moving parts, or hot parts
of the engine.

3. Ensure that all tools have been removed from the area, and they are not left in a
place where it is possible for them to drop into the engine bay, due to engine vibration.

4. When employing an assistant to start the engine, ensure they are aware of the dangers
of starting before being told to do so.

5. When starting, stand well clear until the engine is running smoothly.

6. Take great care to avoid touching the exhaust, and keep hands well clear of moving parts.

7. Take care to ensure that any disconnected HT leads are well away from fuel lines, and
that they cannot be accidentally touched.

Please Note: A remote Starter Switch is available from your local CLARKE dealer, Part No. 4500450.

PREPARATION BEFORE USING THE ANALYSER

1. The engine must be warm, i.e. at normal working temperature.

2. The distributor points must be in good condition and properly adjusted according to
the manufacturers specifications..

3. The spark plugs must be clean and properly gapped.

4. Engine idling speed must be set according to the manufacturers specifications.

Testing Distributor Cam Wear

I. Connect the meter as described above and start the engine. Note the dwell angle

at idling speed.

2. Increase engine speed to about 2000 RPM whilst observing the dwell angle. If the
dwell angle varies more than the amount specified by the manufacturer (usually 3O),
the cam is worn out or the distributor shaft is bent. Repair or replace as necessary.

MAINTENANCE

The analyser requires no specific maintenance, except for the occasional battery change.
This is accomplished by removing the two screws from the rear of the unit, and gently
prizing off the front cover. Unclip and replace the battery, and reassemble. It should be
noted that when the meter is not in use, the function switch should always be in the OFF
position Ensure the Analyser is kept in a cool, dry location, and not at risk of damage from
other tools or machinery.

ACCESSORIES

1 Test leads with probes. .......................................... Part No. CN50001

2. Test Leads with Clips.............................................. Part No. CN50002

When disposing of this product, do not dispose of with general waste. It must be disposed of according to the laws
governing Waste Electrical and Electronic equipment, at a recognised disposal facility.

PARTS AND SERVICE CONTACTS

For Spare Parts and Service, please contact your nearest dealer,

or CLARKE International, on one of the following numbers.

PARTS & SERVICE TEL: [phone]

PARTS & SERVICE FAX: [phone]

or e-mail as follows:

PARTS: [e-mail]

SERVICE: [e-mail]

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B. Testing Air Fuel Mixture

1. Remove the air filter assembly.

2. Whilst observing the RPM reading, slowly block the air intake of the carburettor with a
piece of cardboard.

3. If the air/fuel mixture is correct, the engine speed should not change until the intake is
almost completely blocked up. If it increases, the mixture is lean, if it decreases, the
mixture is rich. Readjust the idle mixture screw accordingly.

If adjustments are made during the course of this test, check the slow running speed
once again.

C.Testing Centrifugal Advance

1. Slacken off the distributor securing bolt, or clamp bolt depending upon design.

2. Rotate the distributor in either direction, to obtain the fastest possible engine speed,
and hold in this position.

3. Increase engine speed to 1000RPM, and try to obtain a further increase by again
rotating the distributor in either direction.

If the speed can be increased by 100RPM or more, the centrifugal advance and
retard mechanism is faulty, and should be serviced or replaced as necessary.

D.Positive Crankcase Ventilator (PCV) Test

1. Remove the engine ventilator hose and block the valve with a finger to stop all air flow.

2. Check that the idle speed drops by 50 RPM or more. If the idle speed does not drop, or
drops less than 50 RPM, the ventilator valve must be cleaned or replaced.

5. DWELL ANGLE MEASUREMENT

Dwell angle refers to the degrees, or time, during which the contact breaker points are
closed in every rotation of the distributor cam . The closed points serve as a path for current
flow from the battery to the ignition coil, so that energy can be built up to give a spark. If
the dwell angle is too small, the points gap is too wide, resulting in a weak spark, giving
poor acceleration or high speed performance. If the dwell angle is too large, the points
gap is too narrow and often causes rapid deterioration of the points.

A.Adjusting the Dwell Angle, or Contact Breaker Adjustment

1. Connect the RED test lead should be connected to the “ ” input terminal,
and BLACK test lead to “COM” input terminal.

2. Set the function switch to the number of cylinders for the desired test on the ‘DWELL’ range.

3. Connect the RED test probe to the (-) terminal of the ignition coil, and the BLACK test
probe to the negative (-) terminal of the battery, as shown in fig. 4.

4. Run the engine to normal working temperature, then stop the engine.

5. Remove the distributor cap and rotor. Remove the king lead from the distributor cap
and earth it.

6. Slacken off the CB points locking screw (see figure 5).

7. Turn the engine on the starter motor, whilst turning the CB points adjustment screw until
the proper dwell angle is obtained. Tighten the locking screw.

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FRONT PANEL - DESCRIPTION

A.Function and Range Switch

This control is located in the centre of the front panel and it combines the operations of
selecting the function and desired range as well as having on “OFF position. To extend the
life of the battery, the switch should be in the ‘OFF position when the instrument is not in use.

B. Display

3-1/2 digit, 7 segment, 18mm high LCD.

C.Input Terminals

Input Terminals comprise three jacks.

1. “COM” - Common Jack

Plug in connection for black (negative) test lead.

2. “ ” Jack

Plug in connection for red (positive) test lead for
all VOLTAGE, RESISTANCE, DWELL ANGLE and RPM
(TACH) measurements.

3. “1OA” Jack.

Plug in connection for red (positive) test
lead for current measurements.

Fig.1

SPECIFICATIONS

1. General Specifications

Display: 18mm (0.7’) LCD (Liquid Crystal Display), 3-1/2 digits. Max. indication ±1999.
Measurement: 24 ranges covering: DCV, RPM, DWELL ANGLE, OHMS, DIODE and AUDIBLE CONTINUITY.

Polarity: Automatic Switching, “-” indicates negative polarity.

Zero Adjustment: Automatic

Over-input: Display shows “1” or “-i”

Sampling Time: Approx. 0.4 second.

Operating Temp:0OC to 50OC

Operating Humidity: Max. 80% RH

Power Supply: One 9V battery.

Low Batt. Indication: Sign “BAT” on the left top of LCD display

Dimensions: 150x70x35mm

Weight: Approx. 200g (including battery)

Test Leads: 2 Sets (1x probe attachment, 1x clip attachment)

2. Electrical Specification

Accuracies: ± (%reading +No. of digits) guaranteed for 1 year

Temperature:23OC±5O C

Relative Humidity: <75%

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DC VOLTAGE

RANGE ACCURACY RESOLUTION

200mV 100µV

2V 1 mV

20V 10mV

200V 100mV

500V ±(0.8% reading + 1 digit) 1V

Input impedance: l0MΩ on all ranges

Overload protection: 250V rms AC for 200mV range, 500V DC or 750V rms AC

±(0.5% reading + 1 digit)

for other ranges

RESISTANCE

RANGE ACCURACY RESOLUTION

200Ω ±(1.0% reading + 2 digits) 0.1Ω

2KΩ 1Ω

20KΩ 10Ω

200KΩ ± (0.8% reading +2 digits) 100Ω

2MΩ 1 kΩ

20MΩ ±(1.2% reading + 2 digits) 10kΩ

Overload protection: 250V rms

DC CURRENT

RANGE ACCURACY RESOLUTION

10A ±(2% reading + 3 digits) 10mA

Overload circuit protection: Unfused

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4. TACHOMETER (RPM) MEASUREMENT

1. For all tests, the RED test lead should be connected to the “ ” input terminal,
and BLACK test lead to “COM” input terminal.

2. Set the function switch to the number of cylinders for the desired test on the ‘TACH’ range.

3. Connect the RED test probe to the (-) terminal of the ignition coil, and the BLACK test
probe to the negative (-) terminal of the battery, as shown in Fig. 4.

4. When the engine is started, the display will indicate the engine RPM.

NOTE: Only use this function on engines with conventional ignition systems. DO NOT use on engines
with electronic ignition systems. The tachometer may be used for several function tests, as follows:

A. Carburettor Idling Slow Running Adjustment

1. Remove the air filter.

2. Screw ‘in’ the idling mixture screw until it is lightly
seated, then screw it out three full turns.

3. Restart the engine, and allow it to idle for at
least one minute.

4. Adjust the idling speed screw to obtain the idling
speed specified by the manufacturer.

5. Adjust idling mixture by turning the idling mixture
screw, in or out, to obtain an increase in engine
speed. Readjust the idling speed screw to the
correct idling speed.

6. Repeat these steps until no further increase in
engine speed is obtainable.

7. Replace the air filter whilst observing the RPM
reading, and check that the engine speed
does not drop. If it does, the air filter may be
dirty and needs to be cleaned or replaced.

IMPORTANT.

a. When making any mixture adjustment, only

turn the mixture screw 1/8 of a turn at a
time to prevent engine stalling.

b. Between adjustments, allow about 30

seconds for the engine speed to stabilise.

c. On vehicles with emission control systems,

air injection pumps and positive crankcase
ventilation, refer to the manufacturers
instructions for idle adjustment procedures.

NOTE:

1) Specialised equipment is required to carry out CO2 emission tests . Refer to the relevant
handbook, as certain engine adjustments may need to be carried out prior to its use.

2) 2-Stroke engines produce twice as many ignition sparks as 4-stroke engines. Thus,
when testing 2-stroke engines, the indicated tachometer reading must be divided by 2
to determine the correct engine speed.

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Fig. 4

3. RESISTANCE MEASUREMENT

1. For all tests, connect the RED test lead to the “ “input terminal, and BLACK
test lead to ‘COM” input terminal.

2. Determine highest anticipated resistance (200Ω, 2kΩ, 20kΩ, 200kW, 2MW or 20MΩ)
and set the “Function Switch”, to the corresponding position. If in doubt, select the
highest value, and work down.

3. If the resistance to be measured is connected to a circuit, turn off the power to the
circuit and discharge all capacitors.

A.TESTING THE CONTINUITY OF A CIRCUIT:

Connect the test probes across the component under test, and observe reading:

• If the reading is very low, i.e. the needle moves across the scale, then continuity exists.

• If the reading is very high, i.e. the needle fails to move, or hardly moves at all, then

the component has an open circuit.

If the function switch is set to “ ”, and the resistance value is less than approx. 30Ω, a
beeper will sound from within the meter.

DWELL ANGLE

CYLINDER RANGE ACCURACY RESOLUTION

3Cyl 0-120

4Cyl 0-90

5Cyl 0-72

6Cyl 0-60

8Cyl 0-45

O

O

O

O

O

± (1 .2%

reading + 0.1

2 digits)

TACHOMETER

O

B. TESTING THE IGNITION COIL

1. Connect one test lead to the negative (-) terminal of the
ignition coil, the other to the HT terminal at the centre of
the coil. If the reading is very low, the coil is short circuited.
If it is very high, typically above 20K, the coil is open
circuited. In both cases it needs to be replaced.

2. Repeat the same test between the centre terminal and
the positive terminal to test the primary coil resistance.
The typical good value is 1 - 5 Ohms for a coil requiring a
ballast resistor. Check manufacturers spec’s for actual values.

C.DIODE TEST

NOTE: For a correct functional test, the diode must be disconnected from the circuit.

1. Set the function switch to the position.

2. When connected with polarity as shown in fig. C1 (below), a forward current flow is
established, and the approx. diode forward voltage (VF) will be displayed.

A reading of “000” or near “000” indicates a short circuit, and the diode under test is
good A reading of “1”, indicates a high resistance, and the diode is defective.

3. When connected in reverse, with polarity as shown in fig. C2, a reverse current is
established. A reading of “000” or near “000” indicates a short circuit, and the diode
under test is defective. A reading of “1”, indicates a high resistance, and the diode is
good.

Proper diode testing should include both forward and reverse checks.

Fig. Cl

Fig.C2

CYLINDER RANGE ACCURACY RESOLUTION

3Cyl

4Cyl 500 - ± (1.2%

5Cyl 10,000 RPM reading + 10RPM

6Cyl 2 digits)

8Cyl

DIODE and AUDIBLE CONTINUITY TEST

RANGE DESCRIPTION TEST CONDITION

Display the approxi-

mate forward voltage

of Diode

Built in buzzer

sounds if continuity

is present

Open circuit voltage
is 2.8V max.

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1. VOLTAGE MEASUREMENTS

For all tests, the RED test lead should be connected to the “ ” input terminal, and
BLACK test lead to “COM” input terminal.

Determine highest anticipated voltage (200mV, 2V, 20V, 200V or 500V) and set the “Function
Switch”, to the corresponding position. If in doubt, select the highest value, and work down.
Proceed to test the various functions as follows:

A. CIRCUIT BREAKER POINTS: (Used the 2V DC range)

1) Disconnect the main, centre HT lead (“King Lead”) from distribution cap, and

earth it by taping to a bare metal surface.

2) Connect RED test probe to the “-” terminal of ignition coil, and the BLACK test

probe to earth.

3) Turn ignition switch ON. If the voltage displayed is lower than 0.2V, then the contact

resistance of the CB points is normal. Any higher than this, and the points should
be +cleaned, by filing with a smooth file, or replaced.

B. BATTERY LEAKAGE: (Used the 2V DC range)

1) Connect BLACK test probe to the negative (-) battery terminal, and the RED test

probe to various spots on the surface of the battery.

2) If a value is displayed, then there is battery leakage. Clean any electrolyte or dirt

from area around battery, and wash with bicarbonate of soda and water

solution, ensure the area is wiped dry.

C. BATTERY UNDER LIGHT LOAD: (Use the 200V or 20V DC range)

1) Connect the BLACK test probe to the negative (-) battery terminal, and the RED

test probe to the positive (+) battery terminal.

2) Turn on headlights and all electrical accessories. Observe the meter for 2 minutes. If the

reading is less than 11.5V on 12-volt systems, or 5.7V on 6 volt systems, the battery is
insufficiently charged. Charge the battery and re-test. If reading is still low, replace battery.

3) Do not continue this procedures for more than 2 minutes.

D. BATTERY UNDER HEAVY LOAD: (Use the 20V or 200V DC range)

1) Disconnect the King Lead from the distributor cap, and earth it by taping to bare

metal. This ensures the engine cannot start.

2) Connect the BLACK test probe to the negative (-) battery terminal, and the RED

probe to the positive terminal.

3) Crank the engine on the starter for 15 seconds and note the voltage. If the reading

is less than 9.5V on 12-volt system or 5.7V on 6-volt system, check the starter circuit
for loose/dirty connections. If this is OK, recharge the battery and re-test. If the
reading is still low, replace the battery.

• If voltage is above the specified value or fluctuates erratically, the regulator is defective.

• If the voltage is below the specified value, the regulator or alternator might be defective,

proceed as follows:
a. Disconnect the negative (-ve)

cable from the battery.

b. Remove the wire from the

field (F) terminal of the
alternator, do not allow it to
be earthed.

c. Use a jumper wire to connect

the field (F) terminal of the
alternator, to its output (BAT)
terminal. Refer to the owner’s
manual for more specific
information.

d. Reconnect the negative battery cable, start the engine and slowly increase

engine speed whilst watching the meter. If the voltage is now above 13.5V,
the regulator is defective.

Fig. 2

• If the voltage is still low, the alternator is defective.

Caution: Perform this test as quickly as possible and do not exceed I7V.

F. TESTING THE STARTER CIRCUIT:

1. Remove the king lead from the distributor cap and earth it.

2. Connect the BLACK test probe to the battery negative (-ve) post.

3. Connect the RED probe to the starter motor housing, ensuring a good electrical contact
is made.

4. Crank the engine on the starter, whilst observing the meter. If it reads 2 volts or more,
the starter motor is poorly earthed. Repair as necessary.

5. Connect the RED test probe to the battery positive (+ve) post, and the black probe to
the insulated terminal of the starter motor

6. Crank the engine on the starter If the reading is 2 volts or more, check for loose or dirty
connections and repair as necessary

2. CURRENT MEASUREMENTS

1) For all tests, connect the RED test lead to the “10A” input terminal, and the BLACK test
lead to the “COM” input terminal.

2) Set the function switch to the 10A position.

3) With the ignition switched OFF, open the circuit to be tested, and connect the test
probes in series with the open ends of the circuit. Switch on the ignition, and take
readings.

E. CHARGING SYSTEM CHECK:

Run the engine, and gradually increase the speed whilst observing the meter:

• if the pointer climbs steadily to between 13.5 V and 15.5 V or to the value specified

by the manufacturer, the charging system is operating satisfactorily.

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IMPORTANT:

If the reading is from I0A to 20A, DO NOT exceed 15 seconds continuous
operation. DO NOT exceed 20 Amps, as this will damage the instrument.

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