Land Rover Defender 90 110 Workshop Book 5 Rover
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ELECTRICAL EQUIPMENT- ALTERNATOR f:::,;;:: :!, ...... ,+;sir. :.: .. Assembling ...... e,.. 19. Fit the spacer and press the rotor into the drive end bracket. Tnsert the through bolts. Fit the spacer, fan, pulley and spring washer to the shaft. Fit and tighten the pulley nut to the correct torque. 20. Fit the stator and rectifier assembly to the drive end bracket in the position previously marked. 21. Fit the slip ring end bracket in the position previously marked, locating the regulator lead through its aperture. Fit the insulation cover and tighten two rectifier securing screws. 22. Fit and tighten the through bolt nuts evenly and to the correct torque. 23. Connect the lead to the regulator, locate the brushes on the slip rings and secure the regulator/ brushbox assembly, taking care not to damage the brushes. 24. Fit both suppression capacitors. 25. Refit the alternator. * ALTERNATOR DATA Manufacturer ............................................................ Type ................................... ............................ Maximum operating speed ....................... Stator winding rcsistance .................. ....................... Regulator controlled voltage ........................................ Field winding rotor poles .............. Rotor winding resistance ............................................. Brush length - new ........................ ....................... Brush spring pressure - flush with brushbox moulding ......... Polarity ................ ............................................ Maximum DC output at 6000 rev/min ............................. Stator windings .......................................................... Regulator type .......................................................... ......................... Renew regulator/brushbox assembly at ........................... TORQUE WRENCH SETTING Nm Alternator shaft nut .................................................. 50-70 Alternator rectifier screws .......................................... 3.5 Regulator/brushbox screws ........................................ 2.5 Terminal nut - main output ......................................... 4.0 Terminal nut - phase ................................................. 4.0 Alternator through bolts ............................................ 5.5 Lucas A 127/65 Negative earth 15000 rcv/min 65 amp 3 phase 0.15 ohm/phase 21TR 13.6-1 4.4V 12 3.2 ohms 17 mm (0.67 in) From 5 mm (0.20 in) 1 moulding 1.3-2.7N (4.7-9.802) Ibf ft 4.0 2.5 2.0 3.0 3.0 37-52 27
ELECTRICAL EQUIPMENT- ALTERNATOR I ALTERNATOR FUNCTIONAL CHECK The alternator contains polarity sensitive components that could be permanently damaged if subjected to incorrect polarity. Do not connect or disconnect any part of the charging circuit - including the battery leads - while the engine is running. Run the alternator with all connections made or with the unit disconnected. This operation must be performed in two parts. Thc first to prove the alternators capacity to produce current. The sccond to prove the performance of the integral regulator. Check capacity to produce current NOTE: The stated output may be exceeded slightly when the alternator is cold. To avoid misleading results, the check should be performed with the unit as near to its normal operating temperature as possible. % 1. Check drive belt adjustment. 2. Disconnect the multi-socket connector. 3. Remove the cover and provide a suitable probe and wire to enable the field winding earth brush to be earthed direct thus by-passing the regulator. 4. Provide a test circuit as shown below. A. Alternator B. Ammeter C. 12 volt battery D. Voltmeter E. Variable resistance 5. Do not connect the variable resistor across the battery for longer than is necessary to perform the check. 6. Run the engine. 7. Gradually increase the speed. At 1550 alternator rev/min (775 engine rev/min) the light should be extinguished. 28 8. Hold the speed at approximately 6000 alternator rev/min (3000 engine rev/min). Adjust the variable resistor so that the voltmeter reads 14 volts. The ammeter reading should now be approximately equal to the nominal output given in data. 9. If the ammeter reading is not correct the indication is that the alternator requires overhaul or replacement. Check control regulator NOTE: The stated output may be exceeded slightly when the alternator is cold. To avoid misleading results, the check should be performed with the unit as near to its normal operating temperature as possible. 10. Check drive belt adjustment. 11. Disconnect multi-socket connector. 12. Provide ;I test circuit as shown. r --a---- VOLTS !- +I 13. Start the engine and gradually increase the speed. At 1550 alternator rev/min (775 engine rev/min) the light should be extinguished. rev/min (3000 engine rev/min). The voltmeter reading should now be steady at 13.6 to 14.4 volts. 15. If the voltmeter reading is not steady at the above figure - and a satisfactory check capacity to y, produce current has been performed - the indication is that the control regulator should be replaced. 14. the speed at apprcjxima;c!j: 6ggg a!:ernato; g.2
Warning Light Illuminated at stand-still. extinguished at cut-in bpeed (I ,5on revhnin) but at higher speeds becomes partially illuminated again and gets progressively brighter Not illuminated hetwceti zero at 1 ,500 rev/nun Teniperature High High ALTERNATOR DOES NOT CHARGE WEAK OR IRRF,GULAR CHARGE OVER CHARGE WORN OR SLACK BELT WORN OR DIRTY BRUSHES BROKEN OR FAULTY ROTOR WINDING BREAK IN CHARGING CIRCUIT OPEN CIRCUIT OK FAULTY FIELD DIODE FAULTY REGIJLATOR 2 OR 3 RECTIFIER DIODES OFSAME POLARITY FAULTY WORN OR SLACK BELT WORN OR DIRTY BRUSHES ONE OR MORE DEFECTIVE RECTIFIER DIODES FAULTY REGULATOR FAULTY CONNECTIONS FAULTY REGULATOR FAULTY CONNECTIONS BETWEEN ALTERNATOR AND REGULATOR OPEN OR SHORT-CIRCUITED STATOR ELECTRICAL EQUIPMENT - ALTERNATOR 186 I DIODE FAULT SYSTEM Failure of one or more of the diodes will be indicated by the output of the alternator and in some instances by an abnormally high temperature and noise level. The following fault symptom chart shows how diode failure will influence alternator test results. Noise Probable Fault (Assnciated Damage) output Higher than normal at 6,000 revimin. Approximately 40A Normal Live-side main output diode open circuit. (May damage rotor field winding and regulator, overheat, brushboxes. and fuse warning light bulb) Excessive Very low at 6.000 rev/min Approximately IOA Live-side main output diode short circuit. (May darnage associated field diode) Excessive Poor at low speed Slightly below normal at 6,000 revh in. Approximately 32A Earth -side main output diode open circuit Illwninatcd at stand-still, dims appreciably at cut-in speed (I ,500 rcv/min) and gets progrcssively dimmer or may be extinguished at higher speeds Nor ni a I Field diodc open-circuit Illuminated at stand-still. dims appreciably at cut-in speed (I ,500 reviinin) and gets progi-essivcly dimmer or may be extinguished at higher speeds Normal Lower than nornial at 6,000 rev/ min. Approximately 29A Normil I Excessive Very low at all speeds above etit- in (1.500 revhin). Illuminated at stand-still. dims iit Gut-in speed (1,500 rev/min) and remains dim, but may he zxtinguished ;it very high speeds Normal Earth -side main output diode short-circuit, or witor winding short-circuit to earth Field diode short-circuit Vcry low ;it 6.000 revhnin Approximately 7A Illuminated at stand-still, dims at :ut-in spectf ( I,500 rev/min) and remains dim. but may be Normal ALTERNATOR FAULT AND DIAGNOSIS CHART NOISY ALTERNATOR WORN BELT LOOSE PULLEY LOOSE ALTERNATOR MOUNTINGS MISALIGNMENT OF PULLEYS FAULTY BEAKING ONE OR SEVERAL RECTIFIER DTODES OPEN OR SHORT-CIRC1IITEn SHORT-CIRCUITED STATOR i CHECK EACH ITEM IN TURN AND RECTIFY IF NECESSARY BEFORE PROCEEDING TO NEXT ITEM. 29
L 86 DIESEL ENGINE STARTER MOTOR (2M113) DISMANTLE TEST AND OVERHAUL Solenoid Unit ELECTRICAL EQUIPMENT - DIESEL ENGINE STARTER MOTOR 1. Disconnect link from starter terminal. 2. Unscrew and remove solenoid securing screws and withdraw the solenoid body. 3. Remove plunger complete with seal and nylon block (if fitted) by lifting front end of plunger to release it from the top of the engagement lever. Commutator end bracket 4. Remove the two brush plate securing screws. 5. Remove the two through bolts. 6. Withdraw the commutator end bracket and seal (if fitted). Note position of the dowel pegs in the end of commutator. Yoke assembly 8. Withdraw the yoke assembly complete with field coils, brushes and seal (if fitted). Drive end bracket 9. 10. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. Remove the eccentric pivot pin. Withdraw the drive -end bracket by releasing engagement lever from drive operating collar whilst the bracket is being removed. continued KEY TO STARTER MOTOR COMPONENTS Solenoid Solenoid -starter link Bracket assembly - commutator end Brake assembly Brush box mounting plate assembly Brush springs Brush set Field coil assembly Engaging lever assembly Bracket assembly drive -end Retention assembly Drive Bracket assembly, intermediate Armature Bearing bush -set of three Yoke Brush plate assembly 7. Disengage the brushes and remove the brush plate assembly. 3 6 1 STl289M 30
ELECTRICAL EQUIPMENT - DIESEL ENGINE STARTER MOTOR El
86 ELECTRICAL EQUIPMENT- DIESEL ENGINE STARTER MOTOR i Brush box insulation 32. Connect the test lamp between a clean part of the bracket and each of the two insulated brush boxes in turn. If the test lamp lights renew the commutator end bracket assembly. Bearing bushes 33. If the armature fouls the pole shoes or side play exists between the armature shaft and bush, renew the bearing bushes using a suitable hand press mandrel. ASSEMBLE STARTER MOTOR ReGassembly is mainly a reversal of the foregoing dismantling procedure. However, the following points should be observed. Lubrication 34. Smear the drive shaft splines and the drive operating collar and bearing surface of the engagement fork with Shell Retinax ‘A’ grease. Armature 35. Ensure that the brake pin is tight and symmetrically positioned. 36. Check that the jump ring locates properly in the drive shaft groove and is covered by the thrust collar. Drive-end and intermediate brackets 37. Ensure that the dowel peg in the drive-end bracket aligns with matching location in the intermediate bracket beforc offering the yoke into position. Brush plate 38. Wedge the earth brushes in raised position with 39. Offer thc brush plate into position and fit the field 40. Release the earth brushes and position the springs. 41. Ensure that the brushes move freely in the holders. brush springs. coil brushes in the boxes. Commutator end bracket 42. Check that the earth stud is fixed secureiy. 43. Ensure that the armature brake pin and slots in the brake shoes align with each other. 44. Make sure that the fixing holes in the brush plate line up with th‘ holes in the commutator end bracket. 45. Check that the through bolts are aligned with the threaded holes in the drive-end bracket. 32 Solenoid 46. Ensure that the plunger locates properly with the operating lever. Pinion setting 47. Screw the eccentric pivot pin fully into the casing and slacken one full turn and position as illustrated with arrow on the pin in line with the arrow on casing and tighten locknut. This provides an initial setting for final adjustment. 48. Connect up the starter, as illustrated, using a 6 volt supply and operate a starter control switch so that the pinion will move into the engaged position without rotating. 49. Whilst maintaining this position press back the pinion towards the yoke. Insert a feeler gauge between the pinion end face and jump ring collar. The correct clearance should be 0,13 to 0,38 mm k-.> 50. If adjustment is required, release the locknut and turn the pivot pin as necessary to achieve the correct setting. Apply ‘gold size’ to the threads of the pivot pin and locknut and tighten thc lattcr to the correct torque. (0.005 to 0.015 in). *< *: /48 ST1292M P 48
ELECTRICAL EQUIPMENT- DIESEL ENGINE STARTER MOTOR (86 TECHNICAL DATA .. .1./ ~ Starter performance (2M113) Minimum battery requirement ................................ 12 V 178 Ah (20 hr rate) battery at least 70% charged. ........................................................ 940 A max at 6.5 V min Lock torque 39.4 Nm 4.0 Kg m 29.0 Ib ft ......................................... 540 A max at 8.0 V min Torque at 1000 rev/min 14.9 Nm 1.5 Kg m 11.0 Ib ft Light running current ............................................ 100 A max at 5,000 - 7,500 rev/min Solenoid Windings Resistance Operating winding resistance .................................. measured between small unmarked Lucar terminal and main terminal marked ‘STA’. 0.145 - 0.165 ohms * Hold-on winding resistance .................................... measured between small unmarked Lucar terminal and earth point on solenoid body. 0.46 - 0.56 ohms Brushgear New brush length ................................................. Renew brush at ................................................... 22.2 mm (Yx in) k 0.50 mm (0.020 in) 8 mm (A in) Armature end-float Cast aluminium intermediate bracket ....................... Pressed steel intermediate bracket ........................... 0.03 - 1.4 mm (0.001 -0.056 in) 0.03 - 1.55 mm (0.001 - 0.061 in) Commutator Commutator minimum diameter ............................. 38 mm (1.5 in) ... TIGHTENING TORQUES Solenoid main ‘BAT’ terminal cablc fixing nut Solenoid/starter link terminal fixing nuts ................... Solenoid end cover fixing screws .............................. Solenoid unit fixing screws ........ Brush plate fixing screws ....................................... Starter earth stud, nuts ............... Pole shoe fixing screws .......................................... Through bolts ..................................................... Eccentric pivot pin locknut ..................................... 3.9 Nm (2.9 Ib ft) 3.5 Nm (2.6 Ib ft) 2.82 Nm (2.1 Ib ft) 6 Nm (4.5 Ib ft) 7 Nm (5.0 Ib ft) 6 Nm (4.5 Ib ft) 40.68 Nm (30 Ib ft) 10.84 Nm (8 Ib ft) 20 Nm (15.0 Ib ft) 33
I86 I ELECTRICAL EQUIPMENT- V8 ENGINE STARTER MOTOR V8 ENGINE STARTER MOTOR (3MlOOPE) DISMANTLE TEST AND OVERHAUL DISMANTLE 1. Remove the starter motor. 2. Remove the connecting link between the starter and the solenoid terminal ‘STA’. 3. Remove the solenoid from the drive end bracket. 4. Grasp the solenoid plunger and lift the front end to release it from the top of the drive engagement lever. 5. Remove the end cap seal. 6. Using an engineer’s chisel, cut through a number of the retaining ring claws until the grip on the armature shaft is sufficiently relieved to allow the retaining ring to be removed. ST1293M 7. 8. 9. 10. 11. 12. 13. 14. 34 Remove the two through-bolts. Partially withdraw the commutator end cover and disengage the two field coil brushes from the brush box. Remove the commutator end cover. Withdraw the yoke and field coil assembly. Withdraw the pivot pin. Withdraw the armature. Using a suitable tube, remove the collar and jump ring from the armature shaft. Slide the thrust collar and the roller clutch drive and lever assembly off the shaft. TEST AND OVERHUAL Clutch 16. Check that the clutch gives instantaneous take-up of the drive in one direction and rotates easily and smoothly in the other direction. 17. Ensure that the clutch is free to move round and along the shaft splines without any tendency to bind. NOTE: The roller clutch drive is sealed in a rolled steel cover and cannot be dismantled. 18. Lubricate all clutch moving parts with Shell SB 2628 greasc for cold and temperate climates or Shell Retinax ‘A’ for hot climates. Brushes 19. Check that the brushes move freely in the brush 5-q box moulding. Rectify sticking brushes by wiping %-- with a petrol-moistened cloth. - :* 20. Fit new brushes if they are damaged or worn to approximately 93 mm (0.375 in). 21. Using a push-type spring gauge, check the brush spring pressure. With new brushes pushed in until the top of the brush protrudes about 1,5 mm (0.065 in) from the brush box moulding, dimension A, the spring pressure reading should bc 1,0 kgf (36 ozf). continued 21 / /
ELECTRICAL EQUIPMENT - V8 ENGINE STARTER MOTOR 22. Check the insulation of the brush springs by connecting a 110 V A.C. 15W test lamp between a clean part of the commutator end cover and each of the springs in turn. The lamp should not light. L 86 Armature - I. . 23. Check the commutator. If cleaning only is necessary, use a flat surface of very fine glass paper, and then wipe the commutator surface with a petrol -moistened cloth. 24. If necessary, the commutator may be machined providcd a finished surface can be obtained without reducing the thickness of the commutator copper below 3,5 mm (0.140 in), otherwise a new armature must be fitted. Do not undercut the insulation slots. KEY TO STAKTER MOTOR COMPONENTS 1. Solenoid 2. Solenoid plunger 3. End cap seal 4. Spire ring and bush 5. Through bolts 6. Brush plate brushes 7. Commutator end cover 8. Yoke and field coil assembly 9. Retaining ring 10. Pivotpin 11. Armature 12. Collar and jump ring 13. Thrust collar and roller clutch drive and lever assembly 14. Drive -end bracket and bush 15. Rubber block 16. Connecting link bctween starter and solenoid 17. Intermediate bracket and seals 18. Field coil brushes ll0V 25. Check the armature insulation by connecting a 110 V A.C. 15 W test lamp between any one of the commutator segments and the shaft. The lamp should not light; if it does light, fit a new armature. 35
86 Field coil insulation ELECTRICAL EQUIPMENT - V8 ENGINE STARTER MOTOR So I en o i d 26. 27. 28. 20. 30. Disconnect the end of the field winding where it is riveted to the yoke, by filing away the riveted over end of the connecting-eyelet securing rivet, sufficient to enable the rivet to be tapped out of the yoke. Connect a 110 V A.C. 15 W test lamp between the disconnected end of the winding and a clean part of the yoke. Ensure that the brushes or bare parts of thcir flexibles arc not touching the yoke during the test. The lamp should not light; if it does light, fit a new field coil assembly. Re -secure the end of the field winding to the yoke. 33. 34. 35. 36. Disconnect all cables from the solenoid terminals and connectors. Connect a 12 V battery and a 12 V 60 W test lamp between the solenoid main terminals. The lamp should not light; if it does light, fit new solenoid contacts or a new solenoid complete. Leave the test lamp connected and, using the same 12 V battery supply, energizc the solenoid by connecting 12 V between the small solenoid operating Lucar terminal blade and a good earth point on the solenoid body. The solenoid should be heard to operate and the test lamp should light with full brilliance, otherwise fit new solenoid contacts or a new solenoid complete. 27 STl297M Field coil continuity 31. Connect a 12 V battery-operated test lamp between each of the brushes in turn and a clean part of thc yoke. 32. The lamp should not light; if it does light, fit a new field coil assembly. STI 298M 36 A /31 STl299M ASSEMBLE 37. 38. 39. 40. 41. 42. 43. 44. 45. 46. Fit thc intermediatc bracket and inner seal over the armature shaft. Slide the thrust collar and the roller clutch drive and lever assembly onto the armature shaft. Fit the jump ring and collar to the armature shaft. Fit the armature. Fit the pivot pin and splay the end. Fit the yoke and field coil assembly and ensure that the dowel peg in the drive -end bracket aligns with matching location in the intermediate bracket before offering thc yoke into position. Fit the internal thrust washer to the shaft. Engage the two field coil brushes in the brush box and fit the commutator end cover. Secure the assembly with the two through bolts and tighten to the correct torque. Fit thc sintcrcd bearing bush. continued