PRINT CONTENTS ZOOM ZOOM ALTERNATOR TEST - PEM M.

FIX ENGINE START MARELLI NOTE: Before checking the starter, you have to check that the result of insuffic ient torque is not due to low battery. REMOVAL To remove the starter simply remove the screws that secure the gear change after disconnecting the power cables. To remove the starter, proceed as follows: Loosen the nut (1) and decouple the c able (2) of the electromagnet (3). Remove the screws (4) that secure the electro magnet (3) to the old firmware (5). Remove the belt (6) Brushes protection. Remo ve the nuts (7) and remove the screws that attach the front bracket (5) in the c entral part (8) and holder brush holder (9). Separate the different elements and untie the fork (10) of the anterior support (5) and rotor (11). CONTROLS Subjecting the starter components to the following tests: Rotor: continuity test , short circuit and ground isolation. Stator: continuity test and insulation to ground. Support brush holder: isolation mass. Electromagnet: continuity test and insulation to ground. NOTE: The hub (12) should be replaced every time the starter gear to make noise at boot time. 29 PRINT CONTENTS ZOOM ZOOM ALTERNATOR TEST - PEM BOSCH STARTER MOTOR WITH REDUCER EPICLOIDAL This engine can have a great power despite its low weight. This advantage is ach ieved by combining an armature of small dimensions that can reach a high number of rpm, with an epicyclic gearbox able to multiply the torque developed. 30 PRINT CONTENTS ZOOM ZOOM

ALTERNATOR TEST - PEM Epicyclic reduction unit 1. 2. 3. 4. 5. 6. 7. 8. Pinion to freewheel. Planet carrier shaft. Stator (internal gear). Rotor. Housin g with windings and brushes. Support. Coupling coil. Support. The drive gear is located at the end of the rotor and is coupled with 3 satellit e, mounted on three planet carrier shaft bolts on the end is installed connectin g the pinion to start the engine. At the same time the satellites are coupled wi th a gear of annular stator fixed to the motor. The reaction of the stator cause s the planet carrier shaft rotate around the shaft of the motor at low speed to that of the rotor. The total transmitted rpm spins become speed of each satellit e on its axis and rotation of the planet carrier shaft on the motor shaft. NOTE: To replace just the brushes must be broken with a hammer or vise, then be soldered with tin the terminals of the windings replacement brushes. Bosch starter motor connection diagrams 31 PRINT CONTENTS ZOOM ZOOM ALTERNATOR TEST - PEM BANK TO FIX SCREWS FIXING SIDE SUPPORTS REMOVAL Remove the nut fastening the stator windings terminal contactor. REMOVING THE COVER AND AXIAL ROTOR SUPPORT WASHER 32 PRINT CONTENTS ZOOM ZOOM ALTERNATOR TEST - PEM INDUCED-INDUCTOR UNIT REMOVAL 1. Epicyclic gear system driver rpm reduction, fixed to the rotor. REMOVAL OF CONTROL step relay pinion 33 PRINT

CONTENTS ZOOM ZOOM ALTERNATOR TEST - PEM STATOR REMOVAL OF TEETH GEAR INTERIOR, FROM THE CABINET ( ) Court reference and fixing gear. REMOVING RETAINING RING GEAR SET FREE-WHEEL 1. Planet carrier shaft, fixed to the pinion. 2. Sprocket freewheel coupling. 34 PRINT CONTENTS ZOOM ZOOM ALTERNATOR TEST - PEM FITTING BRUSHES and brush holders (WITH THE SPRING) Push the brush holder in alojammiento to insert the cap in the cavity. NOTE: For installation, reverse the operations that have been made for removal. 35 PRINT CONTENTS ZOOM ZOOM ALTERNATOR TEST - PEM M. STARTER MARELLI with planetary reduction gears This engine can have a great power despite its low weight. This advantage is ach ieved by combining an armature of small dimensions, which can reach a high numbe r of rpm, with an epicyclic gearbox able to multiply the torque developed. REVISION TO THE BANK NOTE: Before checking the starter control that the cause of insufficient torque is not due to the battery is discharged. REMOVING THE REAR FRAME FIXING SCREWS.

36 PRINT CONTENTS ZOOM ZOOM ALTERNATOR TEST - PEM REMOVING THE SCREW FIXING PLATE SUPPORT REAR Brush Holders REMOVING SECURING BRUSHES SPRINGS 1-button fastening spring brushes (number: 4). 37 PRINT CONTENTS ZOOM ZOOM ALTERNATOR TEST - PEM SUPPORT FOR REMOVAL holders and 2.Holder. 3. Mounting Plate holders. 4. Brush (Quantity: 4). NOTE: To replace just the brushes must be broken with a hammer or vise, then sol der to tin the terminals of the windings replacement brushes. INSULATION TEST Brush Holders Connect one end of the tester to the support plate holders and the second on a p ositive brush holder, make sure the tester does not indicate electrical continui ty. Repeat the test for the positive brush holder. In case of lack of insulation board to replace the holders. Verify that the negative brush holders are proper ly grounded. 38 PRINT CONTENTS ZOOM ZOOM ALTERNATOR TEST - PEM BRUSH WEAR CONTROL To control the brushes, brush holders disengage the respective plate. Verify tha t the length of the brushes have the required values and are not damaged, otherw ise, replace the brush holder plate full.

Brush minimum length L = 8 mm Also, check that the springs that push the brush are not relaxed and thus its ri gidity does not ensure good contact of the brushes on the commutator. 39 PRINT CONTENTS ZOOM ZOOM ALTERNATOR TEST - PEM REMOVING SCREWS FIXING TO SUPPORT FORMER Electromagnet Remove the terminal nut stator windings of the electromagnet. Electromagnet: making the continuity test and insulation to ground. CONTINUITY TEST Electromagnet winding 1. Electromagnet. 2. Test leads. 3. Tester. Connect one end of the tester on the terminal 50 of the electromagnet and the ot her on the metal casing (ground) and verify that the electrical continuity teste r notes. In the absence of electrical continuity replace the electromagnet. 40 PRINT CONTENTS ZOOM ZOOM ALTERNATOR TEST - PEM ISOLATION TEST OF FIXED CONTACTS Electromagnet 1. Electromagnet. 2. Fixed contacts. 3. Test Leads Connect one end of the tester alternately on the metal casing of the electromagn et and the other on the fixed contacts (terminal 30) and verify that the tester does not indicate electrical continuity. Otherwise replace the electromagnet. . 41 PRINT CONTENTS ZOOM ZOOM

ALTERNATOR TEST - PEM REMOVAL OF SUPPORT FROM PREVIOUS STATOR HOUSING Stator: testing continuity and insulation to ground. Rotor: continuity test, sho rt circuit and ground isolation. ISOLATION TEST INDUCED (ROTOR) 1. Electromagnet. 2. Fixed contacts. 3. Test leads. Connect one end of the tester on the collector and the other on the rotor or the shaft and check that says no electrical continuity tester. In the event of insu lation failure (short circuit) replace the armature repeat these tests on all th e commutator segments. 42 PRINT CONTENTS ZOOM ZOOM ALTERNATOR TEST - PEM CONTINUITY TEST COLLECTOR Connect the ends of the tester on the commutator segments and check the electric al continuity tester notes. In the absence of electrical continuity replace the armature. Repeat the above tests for all pairs of commutator segments. 43 PRINT CONTENTS ZOOM ZOOM ALTERNATOR TEST - PEM ECCENTRICITY COLLECTOR CONTROL Pair of parallel V-based magnetic comparator Check the collector efficiency by controlling the eventual collapse ovalization or a commutator. Run, if necessary, turning the collector. Insulator cleaning operation between the commutator segments by manual utensil Clean the insulation between the commutator segments by manual utensil. In this case it is necessary, on, verify that no short circuits exist between the segmen ts and reduce the insulator interposed between commutator and commutator. 44

PRINT CONTENTS ZOOM ZOOM ALTERNATOR TEST - PEM ISOLATION TEST stator windings (coils in series ONLY) 1. 2. 3. 4. Tester. Cables to run the test. Housing. Terminal stator winding. Connect one end of the tester on the terminal of the stator winding in series (l arge section) and the other on the case and verify that the tester does not indi cate electrical continuity. In the event of insulation failure (short circuit) r eplace the stator winding. 45 PRINT CONTENTS ZOOM ZOOM ALTERNATOR TEST - PEM CONTINUITY TEST stator winding 1. Tester. 2. Test leads. 3. Stator winding terminals. Connect the ends of the terminals of the stator winding in series (large section ) and verify that the electrical continuity tester notes. In the absence of elec trical continuity replace the stator winding. With stator winding shunt (paralle l small section)€tester having terminals at the ends of the said winding, contr olled the resistance value is the insulation continuity. The absence of any indi cation of resistance indicate that the winding is interrupted. A resistance valu e does not conform to the manufacturer's data indicate a short circuit. 46 PRINT CONTENTS ZOOM ZOOM ALTERNATOR TEST - PEM REMOVING THE FRONT LINE OF UNION TO SUPPORT AND SECURING POST REDUCER

Epicyclic reduction gear UNIT REMOVAL 1. Epicyclic reduction unit. NOTE: The epicyclic gear is supplied with spare as it is not checked, must be re placed each time there are malfunctions (noise, jamming etc.). 47 PRINT CONTENTS ZOOM ZOOM ALTERNATOR TEST - PEM REMOVING THE FORK LOCK PIN GEAR COUPLING EXTRACTION WITH FREE WHEEL GEAR-SHAFT 48 PRINT CONTENTS ZOOM ZOOM ALTERNATOR TEST - PEM FREEWHEEL GEAR-REMOVAL FROM SHAFT 1. Axis. 2. Free wheel sprocket. 3. Fork advancing sprocket. NOTE: The pinion pulley (2) must be changed every time the starter gear to make noise when starting. 1. 2. 3. 4. 5. 6. 7. 8. 9. Anterior support. Housing with stator windings. Holders. Coupling coil. Free whe el sprocket. Axis. Epicyclic reduction unit. Rotor. Posterior support. View of the elements of the starter motor M. Marelli with epicyclic gearbox NOTE: To reassemble reverse timely sequence of disassembly. 49 PRINT CONTENTS ZOOM ZOOM ALTERNATOR TEST - PEM

OPERATING CONTROLS We need to make functional tests and checks on the electrical characteristics th at must correspond to the values given for each type of engine (see the values o n the manual). About the bank: Before mounting the starter should be checked on car that is efficient. Connecte d to a battery for an absorption test in vacuum. About the car: Place the cable clamp on the battery-starter. Remove power to the ignition syste m. Make an attempt to start for a few seconds and read the current value (higher value read by the instrument during startup). The values of voltage and current at a temperature of 20 ° C, are evidenced in the manual (section 00 technical data). 50 PRINT CONTENTS ZOOM ZOOM ALTERNATOR TEST - PEM DIAGNOSIS OF THE DISADVANTAGES OF OPERATION OF STARTER 1. The engine will not run cause may be: the battery terminals and respective te rminals corroded. Terminal battery - starter loose. Terminals bypass wiring boar d disconnected. Completely discharged battery. Lack of contact of the brushes wi th the collector or short circuit of one or both brushes. Start switch contacts corroded, frayed or cut off by bringing cuttings. Induced or inductor to ground. Induced or spin manifold. 2. The engine runs very slowly The cause may be: Brushes and bayonets worn colle ctor. Some turns of the inductor winding or armature shorted. Battery terminals and respective terminals corroded. Charging the battery very low, or one or more items damaged. 3. Excessive noise at startup The cause may be: Mechanism worn freewheel sprocke t. Misalignment between starter and flywheel crown. Some teeth of the flywheel c rown worn excessively on the side link. Speed reducer defective or excessively w orn. 51