Content .. 141 142 143 144 ..

Defender 90 / 110 / 130. Manual - part 143

ELECTRICAL

DIESEL ENGINE

STARTER MOTOR

TECHNICAL DATA

. .

Starter performance
Minimum battery requirement

................................

Ah (20 hr rate) battery

at least

70%

charged.

........................................................

940

A max at 6.5 V min

Lock torque

39.4
4.0

29.0

f t

.........................................

540 A max at

8.0 V min

Torque at 1000

14.9
1.5

11.0 ft

Light running current ............................................

100 A max at 5,000

7,500

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

.................................................

brush

...................................................

22.2

in)

0.50

(0.020 in)

in)

Armature end-float
Cast

aluminium intermediate bracket .......................

Pressed steel intermediate bracket ...........................

1.4

-0.056 in)

0.03

1.55

(0.001

0.061 in)

Commutator
Commutator minimum diameter .............................

(1.5 in)

...

TIGHTENING TORQUES

Solenoid main

‘BAT’ terminal

fixing nut

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

(2.9

ft)

3.5

(2.6

ft)

2.82

(2.1

ft)

(4.5

ft)

(5.0

ft)

(4.5

ft)

40.68

(30 ft)

10.84

ft)

(15.0

ft)

ELECTRICAL EQUIPMENT- ENGINE STARTER MOTOR

ENGINE STARTER MOTOR

DISMANTLE TEST AND OVERHAUL

DISMANTLE

1. Remove the starter motor.

2. Remove the connecting link between the starter

and t h e solenoid terminal

‘STA’.

Remove the solenoid from the drive end bracket.

4. Grasp t h e solenoid plunger and lift the front end to

release

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

t h e

retaining ring to be removed.

7.
8.

10.
11.
12.
13.

14.

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

Check that the clutch gives instantaneous take-up

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

sealed in a rolled

steel cover and cannot be dismantled.

18. Lubricate all clutch moving parts with Shell

2628

for cold and temperate climates or

Shell Retinax

‘A’

for hot climates.

Brushes

19. Check that the brushes move freely in the brush

box moulding. Rectify sticking brushes by wiping %--

with a petrol-moistened cloth.

Fit new brushes if they are damaged or worn to
approximately

(0.375 in).

21.

Using a push-type spring gauge, check the brush
spring pressure. With new brushes pushed

until

the top

of the brush protrudes about

(0.065 in) from the brush box moulding, dimension

the spring pressure reading should bc 1,0 kgf

(36 ozf).

continued

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

t h e

springs

turn. The lamp should not light.

Armature

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

a finished surface

obtained

without reducing the thickness of the commutator
copper below

3,5

(0.140 in), otherwise a

armature must

be fitted. Do not undercut the

insulation slots.

KEY

TO STAKTER

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

Yoke and field coil assembly

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

starter and solenoid

17.

Intermediate bracket and seals

18. Field coil brushes

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,

f i t

a new armature.

Field coil insulation

ELECTRICAL EQUIPMENT - ENGINE STARTER MOTOR

So I en o i d

27.

28.

30.

Disconnect the end

of the field winding where it is

riveted to

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.

W test lamp between t h e

disconnected end of the winding and a clean part

the yoke.
Ensure that the brushes

or bare parts of

flexibles arc not touching the yoke during the test.
The lamp should not light; if

does light, fit a new

field coil assembly.
Re-secure the end

of the field winding to the yoke.

33.

34.

35.

Disconnect all cables from the solenoid terminals

and connectors.
Connect a 12

battery and a

W test lamp

between the solenoid main terminals. T h e 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,

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'

Field coil continuity

31. Connect a

12 V battery-operated test lamp

between each of the brushes in turn and a clean
part

yoke.

32. The lamp should not light; if

does light, fit a new

field coil assembly.

ASSEMBLE

37.

38.

39.
40.
41.
42.

43.
44.

45.

46.

Fit

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
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

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

the correct torque.

Fit

sintcrcd bearing bush.

continued

Content .. 141 142 143 144 ..