Land Rover Defender 90 110 Workshop Book 5 Rover

							ELECTRICAL 1861 
r..z:.. ,... .._. . . . .,.. . . . .. .. ,, ,.... AMPLIFIER MODULE 
22. Before fitting the module,  apply MS4 Silicone 
grease or equivalent  heat - conducting  compound 
to  the  amplifier  module backplate,  the seating face 
on  distributor  body and both  faces 
of the heatsink 
casting. 
?U,. v.: I ., ..  ~ 
IGNITION TIMING 
Adjust 
1. It 
is essential  that thc following  procedures  are 
adhered  to. Inaccurate  timing  can  lead to serious 
engine  damage  and  additionally 
crcate failure to 
comply  with the emission  regulations  applying  to 
the  country  of destination.  If the  engine  is being 
checked 
in thc vehicle  and is fitted  with an air 
conditioning  unit the compressor  must be isolated. 
2. On initial  engine  build, or if the distributor  has  been  disturbed  for  any  reason, the ignition  timing 
must  be set  statically  to 
6 B.T.D.C. 
(This sequence  is to  give  only an  approximation in 
order that the engine  may be started) ON  NO 
ACCOUNT  MUST  THE ENGINE  BE STARTED 
BEFORE THIS OPERATION 
IS CARRIED  OUT. 
T ..:: ;I ., . .. ,.. . , I, .. . 
LUCAS  CONSTANT  ENERGY  IGNITION SYSTEM 
35DLM8 PRELIMINARY  CHECKS 
Inspect  battcry  cables  and conncctions to ensure they 
are clcan and  tight.  Check battery state of charge if in 
doubt as to its  condition. 
Inspect 
all LT connections to ensure that they are  clean 
and  tight.  Check 
the HI leads are corrcctly positioncd 
and not shorting  to earth  against  any cnginc 
components.  The wiring  harness  and  individual  cables 
should  be firmly  fastened  to prevent  chafing. 
PICK-UP AIR  GAP 
Check  air gap  with a non-ferrous  feeler gauge. 
NOTE:  The  gap  is  set  initially at the  factory  and will 
only  require  adjusting  if tampered  with or when the 
pick-up module is replaced. 
TEST 
1: 
Check HT Sparking 
Equipment required 
Calibrated  Tachometer 
Stroboscopic  lamp  start  er. 
Remove 
coil/distributor HT lead 
from distributor  cover 
and  hold  approximately 
6 mm (0.25 in) from  the 
engine  block. Switch 
thc ignition  on  and operate thc 
If regular sparking  occurs,  proceed  to Test 6. If no sparking proceed to Test 2. 3. Couple stroboscopic timing lamp and tachometer 
to engine  following  the manufacturers  instructions. 
4. Disconnect thc vacuum  pipes from  the distributor. 
5. Start  engine, with no load and not exceeding 
3,000 rpm,  run  engine  until normal  operating 
temperature  is reached. (Thermostat  open). Check 
that  the  normal  idling  speed falls  within  the 
tolerance  specified 
in the data  section. 
6. Idle  speed for timing  purposes  must not exceed 
750rpm, and this speed  should  bc achieved  by 
removing  a breather  hose 
NOT BY ADJUSTING 
IDLE SETTING  SCREWS. 
7. With  the distributor  clamping bolt slackened  turn 
distributor  until  the timing  flash coincides  with the 
timing  pointer and  the  correct timing  mark  on  the 
rim 
of the  torsional  vibration  damper as shown  in 
the engine tuning section. 
8. Retighten  the distributor  clamping  bolt  securely. 
Recheck timing in the event  that  retightening  has 
disturbed  the distributor  position. 
.:. , . ... ... ..i 
... .. .. 
EA2262 
9. Refit vacuum pipes. 
10. Disconnect stroboscopic  timing lamp and 
tachometer  from engine. 
17  
						

							186 I ELECTRICAL 
1 2 3 4 
L V d V 
TEST 2: 
SUSPECT 
Discharged  battery 
TEST 3: 
V V L V 
% V H 
L. T. Voltage 
Coil or amplifier 
Amplificrearth 
Switch 
the ignition 
on 
(a)  Connect  voltmeter  to points in the  circuit  indicated 
by  the  arrow  heads  and make  a note  of the  voltage 
readings. 
(b)  Compare 
voltages obtained  with the specified 
values  listed below: 
EXPECTED READINGS 
V1. More  than 11.5 volts 
V2. 
1 volt max below  volts at point  1 in test circuit 
V3. 
1 volt max  below volts  at point  1 in test circuit 
v4. 
0 volt -0.1 volt 
(c)  If all  readings  are correct proceed  to 
Tcst 3. 
(d)  Check  incorrect 
reading(s) with  chart  to identify 
area 
of possiblc faults,  i.e.  faults  listed  under 
heading  Suspect. 
(e) 
If coil or amplifier  is suspected,  disconnect LT lead 
at 
coil, repeat  V3. If voltage is still incorrect, fit 
new  coil. If voltage  is  now correct,  check LT lead, 
if satisfactory fit new amplifier. 
(f) If engine will not start proceed to Tcst 3. 
V L L V I Ign. switch and/orwirin I 
Check Amplifier Switching 
Connect  the voltmcter between  battery  positive (+ ve) 
terminal and FIT coil negative (- ve)  tcrminal:  the 
voltmeter should  register zero volts. 
Switch  the ignition 
on and  crank  the engine. Thc 
voltmeter  reading  should  increase just above  zero, in 
which case proceed  with Test 5. 
If there  is no increase in voltage  during cranking 
proceed  to Test 
4. 
TO DfSTRlBUTOR - 
CRANK 
TO AMPLIFIER 
TO IGN TO  STARTER 
SWITCH 
c ? RR2264E 
TEST 4: 
Pick-up Coil Resistance. 
Disconnect  the pick-up leads at  the harncss  connector. 
Connect  the ohmmeter  lcads 
to the two pick-up lcads in 
the plug. 
The  ohmmeter  should 
registcr between 2k and  5k ohms 
if pick-up  is satisfactory.  If the ohmmcter reading  is 
correct,  check all connections  between pick
-up  and 
amplificr, if satisfactory, fit new amplifier. If the engine 
still  does  not start  carry  out Test 
5. 
Change thc pick-up if ohmmeter  reading is incorrect. If 
the  engine  still does  not start  proceed  to Test 5. 
18  
						

							ELECTRICAL 186 I 
Coil H1 Sparking 
Remove existing coil/distributor HT lcad and fit test 
HT lead to coil  tower.  Using suitable  insulated  pliers, 
hold  free  end  about 
6 mm (0.25 in) from  the  engine 
block  and crank 
the engine. There should  be a good FIT 
spark. 
If weak or no sparking, fit new coil,  rcpeat test. 
HT sparking good, repeat  test with  original  HT lead. If 
sparking  is good,  carry out Test 6. 
If weak or no sparking, fit new  HT lead, if engine will 
not start carry  out Test 6. 
CRANK # 
TEST 6: 
Rotor Arm 
Remove  distributor  cover. Disconnect  coil HT lead 
from 
covcr and using insulatcd pliers,  hold about 3 mm 
(0.13 in)  above  rotor arm electrode and crank  the 
engine.  There should  be 
no HT sparking bctwecn rotor 
and 
HT lead. If satisfactory  carry out Test 7. 
If HT  sparking  occurs, an  earth fault on the rotor arm  is 
indicated. 
Fit new  rotor arm. 
If engine will not start  carry out Test 7. 
TEST 7: 
Visual  and HT Cable  Checks 
Examine:  Should bc: 
1. Distributor Cover  Clean, dry, no tracking marks 
2. CoilTop Clean, dry, no tracking marks 
3. HT  Cable Insulation  Must not be cracked  chafed or 
perished 
4. HT Cable Continuity  Must not  be open  circuit 
5. Sparking  Plugs  Clean,  dry,  and set to correct 
gap. NOTE: 
1.  Reluctor  Must not foul  pick
-up or leads 
2. Rotor and Flash  Must not be cracked or show 
Shield 
signs of tracking  marks. 
R R 2 2 6 7 E 
I. , . .. . 
19  
						

							86 
ALTERNATOR OVERHAUL - Lucas A115-3 and 
A115-45 
ELECTRICAL EQUIPMENT- ALTERNATOR 
DISMANTLE 
1. Remove the alternator  from the engine. 
2. Remove  the  cover  retaining  screws and lift off the 
cover. 
Removing  the surge  protection  diode 
3. Withdraw  the screw  securing  the  diode to the slip 
4. Disconnect  the lead  from  the rectifier  assembly  and 
ring 
end bracket. 
remove 
the diode. 
Removing  the regulator (Note  arrangement  of the 
brush  box  connections) 
5. Disconnect  the regulator  leads. 
6. Remove  the  screw securing the regulator to the 
brush  box and  withdraw  the regulator.  Note  that 
this  screw  also  secures 
the inner brush  mounting 
plate 
in position. 
% 
Removing  brush box assembly 
7. Remove  the screw  retaining  the  outer  brush 
8. Withdraw both brushcs. 
9. Remove  the  two  screws securing  the brush  box to 
the slip ring  end bracket  and lift off the  brush box. 
mounting 
plate. 
Removing  the rectifier  assembly 
10. 
11. 
Securely  clamp the alternator  and release the stator 
winding  cable ends from 
the rectifier  by applying a 
hot  soldering  iron to the  tcrminal  tags of the 
rectifier.  When the solder  melts prise out the cable 
end.  Remove  the two  remaining  screws securing  the 
rectifier  assembly  to the  slip  ring  end bracket  and 
lift off the rectifier. 
NOTE:  Further  dismantling of the rectifier  is not 
required. 
Removing  the slip  ring  end bracket 
12. Sccurely clamp  the alternator  and remove the thrce 
13. Lift off the bracket. If necessary  tap under  each 
fixing 
bolts. 
fixing  bolt 
with a soft  mallet. 
Removing  stator assembly 
14. Note the position  of the stator output  leads relative 
to  the  alternator  fixing 
lugs and then lift the stator 
from  the drive  end bracket. 
15. 
16. 
17. 
18. 
Separating  drive end bracket  and rotor 
Remove  the shaft  nut washers  from  the  pulley, 
woodruff 
kcy and spacers. 
Use a  press  to remove  the rotor  shaft  from  the 
drive  end bearing. 
Check 
all components  as  detailed under bench 
testing  and renew  any parts that arc  unsatisfactory. 
If  necessary  the slip  rings  and 
or thc slip ring  end 
bearing  on the  rotor  shaft can bc 
rcplaced. To 
renew the bearing, both  slip rings  must  be rcmoved 
as follows: 
Unsolder  outer slip  ring  connection  and gently 
prise  the slip ring  off 
the shaft. 
Unsolder  inner slip  ring 
conncction and gently 
prise 
the slip ring  off the shaft. 
Whilst  carrying  out the above  two 
imtructions take care 
not  to damage 
the insulation  covering  the winding 
leads. 
ELECTRICAL  TEST OF COMPONENlS 
The illustrations  for  the following tcsts show  the 
Components 
scparated from the altcrnator, for  clarity. 
Rotor  field winding 
19. Chcck field  winding  continuity and resistance 
simultaneously,  by connecting  either 
a battery- 
operated  ohmmeter  (illustration A) or a 12 volt 
battery  and moving  coil  ammeter (illustration 
B) 
between  the slip  rings. The ohmmetcr should 
indicate  the  appropriate  resistance given 
in the 
data, 
or it should  indicate a current approximate  to 
the  figure  obtained  by dividing  the appropriate 
resistance  of the  rotor into the  battery voltage. 
A 
ST!282??! 
20  
						

							ELECTRICAL EQUIPMENT - ALTERNATOR 
ST 1280M 
86 
10 
I 9 
1. Cover 
2. Regulator 
3. Rectifier 
4. Drive-end bracket 
5. End bearing kit 
6. Rotor assembly 
7. Slip ring  end bearing 
8. Slip rings 
6 7 
14 
KEY TO ALTERNATOR 
9. Slip  ring end bracket 
10. Stator 
11. Brush box 
12. Brushset 
13. Fixing bolt -slip ring  end bracket  to drive-end bracket 
14.  Suppression capacitor 
15. Surge  protection  diode 
21  
						

							I86 I ELECTRICAL EQUIPMENT - ALTERNATOR 
19 
/ 
11ov - 
I 12 I 
ST1283M 
20. Check for satisfactory  field winding  insulation  by 
connecting  a 110 
V A.C.  15-watt test lamp betwcen 
either of the slip  rings  and the rotor  body.  The 
lamp  should  not light. 
ST1284M 
Stator winding 
21. Due  to the  very  low resistance  of the  stator 
windings,  a practical  test 
to determine  the presence 
of  short
-circuited  turns cannot  be carried  out 
without  the 
usc of special  instruments.  However, in 
practice  inter
-winding  short-circuiting is usually 
indicated  by obvious  signs of burning 
of the 
insulating  varnish covering  the windings.  If this  is 
the  case,  renew 
the stator  assembly  without the 
need  for further  testing. 
22. Check  continuity  of stator  windings,  by first 
connecting  any two  of the  three  stator winding 
connecting 
cables in scries with a 12 V battery- 
operated tcst lamp,  of not less than  36 watts.  The 
test  lamp  should  light. 
If not, renew the stator 
assembly.  Providing 
the first part  of the  test  is 
satisfactory,  transfer one of the  test  lamp  leads  to 
the other  (third)  cable. Again  the test  lamp  should 
light.  If 
so, proceed to insulation  test. 
23.  Check  insulation 
of stator windings,  by connecting 
a 110 V A.C.  15-watt test lamp  between the stator 
laminations  and any one  of 
the three  connecting 
cables. 
The lamp  should not light. 
I 
ST1285M 
Rectifier  diodes 
24. Test each  of the nine diodes  separately, as follows. e?.. 
g - Connect  a 12 V battery and a 1.5 watt bulb in series 
with  one of the  diodes,  one test lead  being  applied 
to the diode  connecting  pin and  the other  to the 
particular  heat sink plate 
in which the diode 
undergoing  test is soldered.  Note whether  lamp 
lights,  then reverse  the test  lead  connections.  The 
lamp  should  light during 
one half of the test  only. If 
any  one  diode  test is unsatisfactory,  renew the 
rectifier  assembly. 
Regulator 
25. Individual  testing of the  regulator  can only  be 
carried  out with  special  test equipment  and unless 
this  is available  the regulator  must be proved  by 
substitution. 
ASSEMBLE 
Reassembly of the  alternator  is a reversal of the 
dismantling  procedure. However the following  points 
should  be observed. 
26.  Take  care not to damage 
the insulation  covering 
the  winding  leads when  renewing  the slip  rings. 
27.  A build  up 
of solder  must not occur on the upper 
face  of the  inner  slip ring. 
28.  Use  resin  cored  solder  only. 
29.  Pack  the bearings  with a suitable  high melting  point 
30.  Ensure  that 
the brushes  move freely in the brush 
31.  If 
the slip  rings  are not  renewed  the existing  ones 
32.  Tighten  fixings to 
the torque  figures  quoted. 
-2 
grease. 
box. 
must  be clean  and smooth. 
continued 
22  
						

							ELECTRICAL EQUIPMENT- ALTERNATOR 
ST1286M 
TIGHTENING TORQUES 
Through bolts ..................................................... 
Rectifier fixing bolts ............................................. 
SRE Cover ...................................................... 
Brush  Box ....................................................... 
Surge Diode .................................................... 
Brush  and Regulator  fixing ................................. 
D/E Bearing Plate ............................................. 
Reg ‘IND’ Lead ................................................ 
Main output  terminal.. ....................................... 
‘IND’ terminal  nuts ........................................... 
Shaft nut ............................................................ 
Sundry screws: 
Capacitor.. 
...................................................... 
NUTS:  4.5 
- 6.2 Nm (3.3 - 4.6 
Ibf it) 
27.2 - 47.5 Nm (20.0 - 35.0  Ibf ft) 
3.4 
- 3.96 Nm (2.5 - 2.9  Ibf ft) 
1.7-2.25” (1.3- 1.7Ibfft) 
3.4 - 3.96 Nm (2.5 - 2.9 Ibf ft) 
3.4 - 3.96 Nm (2.5 - 2.9  Ibf ft) 
3.61 
- 4.74 Nm (2.7 - 3.5  Ibf ft) 
1.7 
- 2.25 Nm (1.3 - 1.7  Ibf ft) 
4.7 - 5.7 Nm (3.5 - 4.2  Ibf ft) 
1.1 - 1.36 Nm (9.7 - 12.0 lbf in) 
3.96 - 5.08 Nm (2.9 - 3.7  Ibf ft) 
3.61 
- 4.74 Nm (2.7 - 3.5  Ibf ft) 
.:... .. .... .I/ , 
.. ..:: .. .:.a ... 
23  
						

							86 
ALTERNATOR OVERHAUL - Lucas A12745 
ELECTRICAL EQUIPMENT- ALTERNATOR 
Description 
The model A127 alternator is a three  phase,  field 
sensed  unit, the rotor  and stator  windings  generate 
three  phase  alternating  current (AC) which  is rectified 
to  direct  current 
(DC). The electronic  voltage regulator 
unit  controls  the alternator  output voltage  by high 
frequency  switching 
of the rotor  field circuit. 
It 
is essential  that good  electrical  connections  are 
maintained  at all  times. 
Of particular  importance  are 
those  in the  charging  circuit (including  those at the 
battery)  which should  be occasionally  inspected 
to see 
that  they  are clean  and tight. 
In this way  any significant 
increase 
in circuit  resistance  can be prevented. 
Do not disconnect  battery cables while the engine  is 
running 
or damages to the  semi-conductor  devices may 
occur.  It is also  inadvisable  to break  or make  any 
connections 
in the  alternator  charging and control 
circuits  while the engine  is running. 
The model 21TR electronic  voltage regulator  employs 
micro-circuit  techniques resulting 
in improved 
performance  under difficult  service conditions. 
The 
whole assembly  is encapsulated in silicone  rubber and 
housed 
in an  aluminium  heat sink,  ensuring  complete 
protection  against the adverse  effects 
of temperature, 
dust,  and moisture  etc. 
The  brushbox  assembly 
is incorporated  in the regulator 
unit. 
Surge protection is incorporated in the regulator  unit. 
The  regulating  voltage is set  during  manufacture 
to give 
the  required  regulating  voltage range 
of 13.6 to 
14.4 volts, and no adjustment  is necessary. The only 
maintenance  needed is the  occasional  check on 
terminal connections  and wiping  with a clean  dry cloth. 
The  alternator  system provides  for direct  connection 
of 
a charge  (ignition)  indicator warning light. and 
eliminates 
the need  for a field  switching  relay or 
warning  light control  unit. 
As the warning  lamp is 
connected in the charging  circuit, lamp failure  will 
cause 
loss of charge.  Lamp should  be checked  regularly 
and  a spare  carried.  When 
using rapid charge  equipment 
to re-charge  the a 
battery, the battery  must be disconnected  from the 
vehicle. .-- 
NOTE: Alternator  charging circuit - The ignition 
warning  light is connected  in series  with the alternator 
tield circuit.  Bulb failure  would prevent  the alternator 
charging,  except at very  high  engine speed, therefore, 
the 
bulb should  be checked before suspecting an 
alternator  failure. 
Precautions 
Battery  polarity  is NEGATIVE  EARTH, which must 
be  maintained  at all  times. 
No separate  control unit is fitted;  instead  a voltage 
regulator 
of micro-circuit  construction is mounted  on 
the  slip  ring  end bracket. 
Battery  voltage is applied 
to thc alternator  output cable 
even  when 
the ignition  is switchcd off, the battery  must 
be  disconnected  before commencing  any work 
on the 
alternator.  The battery  must also be disconnected  when 
repairs  to the  body  structure  arc being 
done by arc 
we I ci i ng . 
4, ?? 
-. -. 
DISMANTLE 
1. 
2. 
3. 
4. 
5. 
Withdraw  the connectors  from the alternator. 
Re 
m o vc; the a I t e  r n a  tor . 
Remove the nuts  from the through  bolts, 
disconnect  the connectors  and remove  two 
suppression  capacitors. 
Remove  three screws,  disconnect 
one lead and 
withdraw  the regulator  and brushbox  assembly. 
Check  the brush  lengths  by measuring  length 
of 
protrusion from moulding. If dimension A is 5mm 
(0.20in) or less,  change thc assembly. s: -d 
RR2218M 
s-. .... 
24  
						

							ELECTRICAL EQUTPMENT- ALTERNATOR 186 
ill* . . -2G ALTERNATOR - LUCAS A 127-65 .- . 
.. .. .. 
Service parts 
1. Suppression capacitors - 2 off 
2. Regula t or/Brus h box assembly 
3. Through bolts 
4.  Slip ring  end 
(SRE) bracket 
5. Stator 
6. Rectifier 
7. Drive end bracket (DRE)/bearing assembly 
8. noior 
9. Slip ring  end bearing 
25  
						

							186 I ELECTRICAL EQUIPMENT - ALTERNATOR 
6. Check brush  spring  pressure using a push  type 
spring 
guage. Gauge  should  register 136 to 279 g (5 
to 10 02) when brush  is pressed  until face is flush 
with  housing. 
If reading is outside  these  limits, 
renew  assembly. 
7. Mark the  relative positions  of the end  brackets  and 
stator.  Remove  through bolts and withdraw  slip 
ring  end bracket and  stator assembly. Carefully  tap 
the mounting  lugs with a mallet 
if necessary. 
8. Remove  nuts, washers  and insulators  from  stud 
terminals  noting  their  position  for  reassembly. 
Remove  two  screws  and insulation  cover  and 
withdraw  rectifier and stator  from slip  ring  end 
bracket. 
RR22 19M w 
Y 
9. Release  the stator  winding  cable  ends from the 
rectifier  by applying  a hot  soldering  iron to the 
terminal  tags 
of the rectifier.  Prise out the cable 
ends  when 
the solder  melts,  and  separate  the 
rectifier  and  stator. Further  dismantling 
of the 
rectifier  is not  required. 
10. Check the diodes.  Connect  the test  equipment as 
shown  and test  each  diode in turn,  note  whether 
lamp  lights,  then reverse  test lead  connections. 
Thc 
lamp  should  light in one direction  only. Rencw thc 
rectifier asscmbly if a faulty  diode is diagnosed. 
11. Visually  inspect  the stator  windings  for signs of 
damage or burning.  Check  the stator  insulation 
using  a suitable 
110 volt  test lamp. Connect the  test 
leads 
to the  laminated  yoke and to each of thc 
three  leads in turn. If test  lamp  lights,  fit a ncw 
iZ 
1.5W Max 
13. Clean  surfaces  of slip  rings  using  a solvent 
moistened  cloth. 
14. Inspect slip ring  surfaces for signs of burning, 
remove  burn marks  using extra  fine glasspaper. 
On 
no account should  emery cloth or similar abrasives 
bc used, or any attcmpt made  to  machine the slip 
rings. 
15. Check  the insulation of the rotor field  windings, 
using 
a suitablc 110 volt  test lamp connccted 
betwccn one of the slip  rings  and onc of the  rotor 
poles.  If the  test  lamp  lights,  the rotor  must bc 
rcncwed. 
e I 
RR222 1 M 
16. Check  the resistance/continuity of the  rotor  field 
windings  by connecting  an ohmmeter  to the  slip 
rings  as shown. 
A reading  of 3.2 ohms should be 
obtained. 
17. Check  condition of bearings.  If signs of rubbing 
between  rotor Doles  and stator  is evident,  both 
stator. 
Kemove the fan and puiiey asscmbly. Piish oiit ihc 
rotor  shaft from the bearing  using a  suitable prcss 
and remove the spacer from the shaft.  bearings 
are excessively  worn,  and  must  be 
renewed. 18. Use  a suitable  press, applying  pressure  from the 
rear  of the  slip  ring  end bracket,  to withdraw  or 
refit  the bearing.  Note that  the  drive end oracket 
and  bearing  are only  supplied as a 
unit. gf---; 7’ -y/ 
26