Land Rover Defender 90 110 Workshop Book 5 Rover
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ELECTRICAL EQUIPMENT- FOUR CYLINDER PETROL ENGINE STARTER 1861 , I, : 47. Using a suitable tube, drive a new spire ring into , .. , position, as illustrated. The position of the spire ring on the armature shaft determines the armature end -float which should be 0,25 mm (0.010 in) maximum between the spire retaining ring and the sintered bearing bush shoulder. Care, therefore, must be used when fitting the spire ring. I* . Dimension A 25,4 mm (1 .OO ins) Dimension B 19 mm (0.75 ins) PETROL ENGINE 2.25 LITRE STARTER MOTOR (2M100) LUCAS. DISMANTLE TEST AND OVERHAUL DISMANTLE 1. Remove the nut securing the (solenoid-to-starter) connecting link to the solenoid ‘STA’ terminal. 2. Pull back the connecting link from the solenoid terminal. 3. Remove the nuts securing the solenoid to the drive-end bracket. 4. Remove the solenoid unit from the drive-end bracket. 5. Lift the solenoid plunger and return spring from the engagement lever. 6. Remove the block-shaped grommet. NOTE: Before carrying out instructions 7 to 14 ensure that new retaining rings are available for the armature shaft and the engagement lever pivot pin are available for reassembly of the starter. 7. Remove the end cap seal. 8. 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. 48. Fit the end cap seal. 49. Fit the solenoid to the drive-end bracket whilst 50. Fit the connecting link between the starter and locating the drive engagement lever. solenoid terminal ‘STA’. ST1301 M . ; T: ... . , .. , :. , ,:. 9. Remove thc through-bolts. 10. Detach the commutator end cover from the yoke, disengaging the field brushes from the brush box moulding, and remove the end -cover. 11. Remove the thrust washer from the armature shaft. 12. Withdraw the yoke from the armature and drive- end assembly. 37
ELECTRICAL EQUIPMENT - FOUR CYLINDER PETROL ENGINE STARTER 13. Drive the pivot pin from the engagement lever and 14. Move the thrust collar clear of the jump ring, and 23. Polish the commutator with very fine sandpaper. 24. Using an air blast, clean any copper residue from drive -end bracket. the armature. remove the jump ring from the armature shaft. 15. Remove the thrust collar. 16. Remove the roller clutch drive and engagement IMPORTANT: The commutator segment insulators must not be undercut. lever assembly and intermediate bracket assembly from the armature shaft. Armature INSPECTION Brush gear 17. Check the brush spring tension using a spring balance; renew a spring if its tension is not within the limits given. 18. Check the brushes for wear; renew any brush worn to or approaching the minimum length. 19. To renew a brush, unsolder the flexible connection, remove the brush and re -solder the flexible connection of the new brush in place. New brushes are pre -formed and do not require bedding to the commutator. 25. Test the insulation of the armature windings with a 12 -volt test lamp and battery connected between the armature shaft and the commutator; if the lamp lights the armature must be renewed. 26. Check the windings at their connections with the commutator riser for signs of melted solder or lifted conductors. continued Commutator KEY TO STARTER MOTOR 20. Clean thc commutator with a cloth moistened with fuel and examine it for burns, pitting, and excessive wear. 21. Carry out instructions 22-24 to recondition the commutator. 6. End cap seal 22. Skim the commutator at high speed using a very sharp tool and removing the minimum amount of metal necessary to restore the surface. 1. Nut securing connecting link to STA terminal 2. Drive -end bracket 3. Solenoid 4. Solenoid plunger and return spring 5. Spirering 7. Throughbolts 8. Commutator end cover 9. Yoke 10. Field coil and brush plate brushes 11. Engagement lever 12. Pivotpin 13. Thrust collar and jump ring 14. Intermediate bracket 15. Roller clutch drive assembly 16. Bush ST1305M r7 Y 38
ELECTRICAL EQUIPMENT - FOUR CYLINDER PETROL ENGINE STARTER El $:.::;:$ .>.. .. 27. Check the shaft for distortion; if the shaft is bent or distorted the armature must be renewed. Do not attempt to straighten the shaft or machine the armature core laminations. .;:
ELECTRICAL EQUIPMENT- FOUR CYLINDER PETROL ENGINE STARTER 52. Operate the switch and note the ammeter, volt- meter, and spring balance readings. Calculate the lock torque by multiplying the reading of the spring balance in pounds by the length of the arm in feet. 53. Check the readings obtained in instruction 52 against the figures given in DATA for lock torque current and voltage. NOTE: If a constant-voltage supply is used for this test, a higher voltage may be registered on the voltmeter than the figure given. If this should occur a variable resistance must be added to the circuit and adjusted to give the required reading and the test repeated. Solenoid - Coil 54. Check the continuity of the coil windings between the terminal ‘STA’ and a good earth point on the solenoid body, using an ammeter (in series); a reading of 11.2 to 11.8 amps should be obtained. If no reading, rcnew the solenoid. 55. Using an ohmmeter connectcd between the small unmarked Lucar terminal and terminal ‘STA’ check the resistance of the closing (series) winding; if thc rcading differs considerably from the limits given the solenoid must be rcnewed. 56. Using an ohmmeter connected between the small unmarked Lucar terminal and a good earth on the solenoid body, check the resistance of the hold -on (shunt) winding; if the reading differs considerably from the limits given, the solenoid must be renewed. Solenoid contacts 57. Check the contacts for correct opening and closing by carrying out the instructions 49 to 51 plus the following instruction 58. 58. Operate the switch and note the voltmeter rcading; it should register practically zero if the solenoid is satisfactory. Alternatively the solenoid should be checked by substitution. 59. The contacts must only be rcnewed as a set, e.g. moving and fixed contacts. The fixed contacts arc an integral part of the moulded cover. Renew a set of contacts by following instructions 60 to 66. 60. Remove the screws securing the terminal and base assembly to the solenoid. 61. Unsolder the coil connections from the cover terminals. 62. Clamp the solenoid in a vice. 63. Remove the tcrminal and base assembly. 64. Assemble the new terminal and basc asscmbly. 65. Rcsoldcr the connections to the terminal and basc assembly. 66. Refit the securing screws and tighten to corrcct torque. .e- g, ;: -2“’ TECHNICAI, DATA Brush spring tension ............................................. 1,02 kg (36 oz) Minimum brush length .................................. ..._. ... Minimum commutator thickness ............................. Lock torque ........................................................ Torque at 1,000 r.p.m. .......................................... 1,02 kgm (7.3 Ib ft) with 300 amps Light runningcurrent ............................................ Maximum armature end-float ................................. 0,25 mm (0.010 in) 9,5 mm (0.375 in) 3,5 mm (0.140 in) 2,02 kgm (14.4 Ib ft) with 463 amps 40 amp at 6,000 r.p.m. (approx.) Solenoid Closing (series) winding resistance ........................... Hold on (shunt) winding resistance .......................... 0.25 to 0.27 ohm 0.76 to 0.80 ohm TIGHTENING TORQUES Drive-end bracket nuts .......................................... Through bolts ..................................................... Pole-shoe screws .................................................. Solenoid base asse! . ‘y screws ................................ 6 Nm (4.5 Ib ft) 40 Nm (30 Ib ft) 10 Nm (8 Ib ft) 2 Nm (1.8 Ib ft) c 40
ELECTRICAL EQUIPMENT STARTER MOTOR - Paris Rhone - 4 cylinder Diesel Dismantle and Test , I.. .* r. -> ‘. 5.r t 86 DISMANTLE 1. Remove starter motor from engine. 2. Disconnect field winding lead from the solenoid. 3. Remove the two nuts and withdraw the solenoid, plungcr and spring. 4. Removc the terminal strap. 5. Remove the two through-stud nuts. 6. Remove the brush plate cover. 7. Withdraw the yoke complete with brush plate assembly whilst noting the position of the yoke location plate in the reduction gear housing. 8. Remove the single socket headed screw and withdraw the armature and reduction gear housing from the drive-end bracket. 9. Remove the clutch drive and pinion assembly. * . 10. Withdraw the brushes from the holders. Inspection and test 11. Examinc all parts for condition. Check the bearings and bushes and pinion drive assembly for wear. Examine the reduction drivc pinion and drive gcar intcrnal tecth. Check the field coil and armature brushes. Armature 12. Using very fine glass paper, clean the commutator and wipe the surface with a petrol -moistened cloth. Do not undercut the insulation slots. 13. Check the armature insulation by connecting a 110 V.A.C. 15 W test lamp betwecn each commutator segment in turn and thc armaturc shaft. The lamp should not light. ST1846M .. .. ., .. . ,;: !.’ , . .. . .. Field coil insulation 14. Connect a 110 V.A.C. 15 W test lamp between the disconnected end of the winding and a clean part of the yoke, 15. Ensure that the brushes or leads do not touch the yoke during the test. 16. The lamp should not light; if it does light, fit a ncw field coil assembly. . ST1847M Field coil continuity 17. Connect a 12 V battery-opcrated test lamp 18. The lamp should light; if it does not light, fit a new between each brush in turn and a link lead. field coil assembly. STl848M Solenoid 19. Disconnect all cables from the solcnoid tcrminals and connectors. 20. Connect a 12 V battcry and a 12 V 60 W test lamp across the solcnoid main terminals. The lamp should not light; if it does light, fit a new solenoid complete. 21. Leave the test lamp connected and, using the same 12 V battery supply, energize the solenoid by connecting a 12 V supply between the small solenoid operating Lucar terminal blade and a good earth point on the solenoid body. continued 41
Battery connection Earth connection Socket headed screw Field winding to solenoid nut Through -stud nut Brush cover nuts Solenoid retaining nuts 11 NM 11 NM 7-C 1,4NM 9,5 -C 1,5 NM 8,5 k 1,5 NM 4,2 _+ 0,6 NM 3,l -C 0,4NM I86 I ELECTRICAL EQUIPMENT i 29. Fit the through-studs to the drive-end bracket. 30. Fit the brush plate cover and secure to the brush 31. Sccure the assembly with the through-stud nuts. 32. Fit the terminal strap to the through-studs and retain with the two nuts. 33. Fit the coil spring to the solenoid plunger and assemble the solenoid to the drive-end bracket and secure with the two nuts. 34. Check that the starter motor turns freely without tight spots. plate with the two nuts. U -- ST1853M 22. The solenoid should be heard to operate and the test lamp should light with full brilliance, otherwise fit a new solenoid complete. TIGHTENING TORQUES ASSEMBLE 23. Fit the round rubber pad to the drive-end bracket. 24. Fit the lever to clutch drive and pinion assembly and fit to the drive -end bracket ensuring that the two washers are in position on the shaft. 25. Check that the fibre washer is positioned on the shaft inside the reduction gear. ST1849M 26. Place the rubber pad, with plain side towards the drive -end bracket fit the ‘0’ ring seal and assemble and secure with the single socket -headed bolt. 27. Place the yoke location plate in position in the slot in the reduction gear housing and fit the yoke and brush plate to the armature. 28, Insert the brushes into their holders and release the retaining springs. Ensure that the brushes rest correctly on the commutator. the :educ!ie:: gear heusing tG the d:ive=end bracket 42
ELECTRICAL EQUIPMENT (861 - . . .. .. . .. . .. , ST1833M 1. Solenoid 2. Solenoid plunger and spring 3. Drive-end bracket and bush 4. Reduction gear pinion 5. Reduction gear 6. Rubberpad 7. 0 ring seal 8. Lever 9. Clutch drive and pinion assembly 10. Rubber pad 11. Armature KEY TO STARTER MOTOR 12. Yoke 13. Roller bearing 14. Through-studs 15. Brush plate 16. Field coil brushes 17. Armature brushes 18. Brush plate cover 19. Reduction gear housing 20. Socket-hcaded screw 21. Terminal strap 22. Yoke location key , .. . I ,: .,. . - .. . I.. . 43
186/ ELECTRICAL EQUIPMENT STARTER MOTOR - Paris Rhone, Turbo charged 2.5 Diesel engine. Removing 1. Disconnect the battery. 2. Slacken the four nuts securing the intermediate exhaust pipe heat shield and move the shield rearwards. 3. Remove the exhaust flange nuts and bolts. ST1859M // 4. Remove the bolt securing the front downpipe to the cylinder block. 5. Release the clamp securing the front downpipe to the turbo -charger elbow. 6. Remove the front downpipe. 7. Disconnect the earth straps from the starter motor. 8. Disconnect the battery, alternator and ignition leads from the starter motor. 9. Remove the starter motor fixings to the engine i.e. one nut and bolt, one nut and one bolt. 10. Remove the startcr motor. Fitting 11. Fit starter motor to engine locating it on the single stud and secure with the remaining fixings and evenly tighten to the correct torque. 12. Conncct the alternator, ignition and battery leads to the starter solenoid. 13. Connect the earth leads to the rear of the starter motor. 14. Fit the exhaust front-pipe to the intermediate system and evenly tighten the three bolts. Re - position the heatshield and tighten the four nuts. 15. Connect the front pipe to the turbo-charger elbow and secure with the clamp. 16. Secure the front pipe to the cylinder block with the single bolt. 44
I86 I ELECTRICAL Inspecting Solenoid 23. Check the continuity and resistance value of windings by connccting an ohmmeter as shown. RR1812E (a) Resistance value should be: 1.074 k 0.035 ohms (b) RR18l3E (b) Resistance value should be: 0.298 k 0.015 ohms If test results are unsatisfactory replace the solenoid. If results arc correct proceed to 24. 24. Check the contacts by connecting an ohmmeter as shown. Solenoid plunger removed, ohmmeter should read infinity. RRl814E Solenoid plunger operated by hand, ohmmeter should read zero. If test results are unsatisfactory, replace the g-x If results are correct proceed to 25. movement. solenoid. g.2 25. Check operation of spring for freedom of Brush gear 26. Check brush springs and ensurc that the brushes move freely in their holders. Clean the brushcs with a petrol moistencd cloth, if requircd. RR1815E Brush length new, Dimension A is 9 mm (0.354 in). Minimum brush length, Dimension B is 3.5 mm (0.138 in). 46