Land Rover Defender 90 110 Workshop 1984 Rover Manual

							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  
						

							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