Content .. 142 143 144 145 ..

Defender 90 / 110 / 130. Manual - part 144

ELECTRICAL EQUIPMENT-

FOUR CYLINDER PETROL ENGINE STARTER

47. Using

suitable tube, drive

a new spire ring into

position,

as illustrated.

The position of t h e spire

ring

the armature shaft determines the armature

end-float which should be

(0.010 in)

maximum  between  the spire retaining ring and the
sintered  bearing  bush  shoulder.  Care,  therefore,
must be used when  fitting

spire ring.

Dimension A

.OO ins)

Dimension

B 19

(0.75 ins)

PETROL ENGINE

2.25 LITRE STARTER

MOTOR

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

solenoid

terminal.

3 . Remove the nuts securing the solenoid to

drive-end bracket.

Remove the solenoid unit from the drive-end

bracket.

Lift the solenoid plunger and return spring from

the engagement lever.

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.

Remove the end cap seal.

Using an engineer’s

cut through a number of

the retaining ring claws until the grip on the
armature shaft is sufficiently relieved

t o

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’.

. . .

Remove

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 y o k e from the armature and drive-
end assembly.

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

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 o r 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

and battery connected between

the armature shaft and the commutator; if the lamp
lights the armature must

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

commutator with a cloth moistened with

fuel and examine it for burns, pitting, and excessive

wear.

21. Carry

instructions

22-24

recondition

t h e

commutator.

End cap seal

22. Skim the commutator at high speed using a very

sharp tool and removing the minimum amount

metal necessary to restore the surface.

1. Nut securing connecting link to STA terminal

2. Drive-end bracket
3. Solenoid

Solenoid plunger and return spring

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

ELECTRICAL EQUIPMENT -

FOUR CYLINDER PETROL ENGINE STARTER

27.

Check the shaft for distortion;

if the shaft is bent or

distorted the armature must be renewed. D o not
attempt to straighten the shaft or machine the
armature core laminations.

Field windings

28. Connect a 12-volt battery-operated test lamp

between each of the field brushes and a clean part

of the yoke; the lamp will light

if continuity is

satisfactory between the brushes, windings, and
yoke connection.

29. Disconnect the

windings from the riveted

connection with the yoke. Using a 110-volt A.C.,

15-watt test lamp connected between each of the

brushes

in turn and the yoke, check the insulation

the field windings,

if the lamp lights the windings

must be renewed. T h e

windings may be

renewed as follows:

30. Disconnect the end of the field winding where it

riveted to

t h e

yoke.

31. Remove the four pole-shoe retaining screws using a

wheel-operated screwdriver.

32. Withdraw the field coil assembly from the yoke.
33. Clean the inside

of t h e yoke and insulating pieces

which the through-bolts locate.

34. Loosely fit the new field coil assembly with the

pole-shoes into the yoke.

35.

Fit

the pole-shoe retaining screws but do not

tighten.

36. Slide the insulating pieces between the field coils

and the yoke, positioned 90" each side of the field
coil brush connection point.

37. Tighten the pole-shoe screws evenly using a wheel-

operated screwdriver, to the correct torque.

38.

Reconnect the end

of the winding to the yoke.

Commutator end bracket

39. Check the insulation

of the brush springs by

connecting  a  110-volt  A.C.,  15-watt  test  lamp
between  a clean part of  the commutator end cover
and each of the springs in  turn; the lamp will light

the insulation is not satisfactory.

Bearings

40. If the bearings in the commutator end cover and

t h e

drive-end bracket are worn sufficiently to allow

excessive side-play

of the armature shaft. the

bearing bush must be renewed as follows;
instructions 41 and

42.

41. Support the bracket and drive out the bush using a

suitable sized mandrel.

42.

Using a polished, shouldered mandrel, the same

diameter as the shaft bearing journal, press the
new bushes into the brackets.

Roller clutch drive

43. Check the operation

of the drive clutch, it should

provide instantaneous take-up

the drive in one

direction and rotate easily and smoothly

in the

other direction.

44. Check that the drive moves freely

o n

the armature

splines without binding

or sticking.

ASSEMBLE

45. Reverse instructions 1 to 16 whilst observing the

following instructions 46 to 48, also ensure that the
dowel peg

in the drive-end bracket aligns with

matching location in t h e intermediate bracket
before offering the yoke into position.

46. When assembling the drive-end bracket use a new

engagement lever pivot pin, and splay the end.

47. Ensure that the internal thrust washer is fitted to

the commutator end of the armature shaft before
the armature end cover

fitted.

48. Using a suitable tube, drive a new spire ring into

position, as illustrated. T h e position of the spire
ring

on the armature shaft determines the armature

end-float which should be

(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.

Dimension A

in)

Dimension

B (19

(0.75

in)

BENCH

TEST

Lock torque and current

49. Clamp the starter firmly

in a vice.

Connect a starter switch, a 0-600 amp ammeter and
a 12-volt battery in series

the starter.

50. Connect a voltmeter between the solenoid two

main terminals.

51.

Secure an arm to the driving pinion, and connect a

spring balance to the free end of the arm.

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

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

11.2 to 11.8 amps should be obtained.

reading,

the solenoid.

55. Using an ohmmeter

between the small

unmarked Lucar terminal and terminal ‘STA’
check the resistance

of the closing (series) winding;

rcading differs considerably from the limits

given t h e solenoid must be rcnewed.

56. Using an ohmmeter connected between the small

unmarked Lucar terminal and a good earth

the

solenoid body,  check  the  resistance  of  the  hold-on
(shunt) winding; if  the  reading differs considerably
from  the  limits  given,  the  solenoid  must
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  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.
Clamp the solenoid in

a vice.

63. Remove

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

torque.

TECHNICAI, DATA

Brush spring tension

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

(36 oz)

Minimum brush length

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

...

Minimum commutator thickness .............................
Lock torque

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

Torque at 1,000

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

kgm (7.3

ft) with

amps

Light runningcurrent ............................................
Maximum armature end-float

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

in)

9,5

(0.375 in)
(0.140 in)

kgm (14.4

ft) with 463 amps

40 amp at 6,000

(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

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

screws

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

Solenoid base

screws

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

(4.5

ft)

(30

ft)

(1.8

ft)

Content .. 142 143 144 145 ..