4-26 Starters DELCO-REMY ENCLOSED HOUSING emer “se tering Sod scn01 International Harvester DESCRIPTION 12 volt, 4 pole starters of conventional design. Storters hove solenoid pinion shaft (overrunning clutch) with entire shift ‘mechanism enclosed within drive housing, Field assembly con- fists of four series coils or combination of series coils with one ‘or more shunt coils. Bruth assemblies ore completely enclosed ‘within field frame ot commutator end so that entre starter and drive assembly is protected from dirt. Starter solenoid. is flange mounted on drive end housing ond shift lever return Spring is compression type located inside solenoid case. Starter Application Delco-Remy Part No. Application 250! "C"& "K" Models 1108744, 1108778 Ali Other Models 1108746, 1108779 292" 1108747, 1108780 350°, 400", 4541 ‘Motor Home 1108502, 1108782 Exc. Motor Home 1108748, 1108781 1108761 455° Motor Home TESTING STARTER CRANKING CIRCUIT TESTS 1), With engine at normal operoting temperature, ground dis tribvtor terminal of coil 29 engine will not stort. Connect voltmeter positive lead to motor terminal on solenoid and ‘ground negative lead, Crank engine ond read voltmeter: if Cranking speed is normal and voltage is 9 vols or more, system is stisfoctory. If cranking speed is below normal and voltage is 9 volts or greater, sorter is detective. 2) starter turns engine slow with 9 volts or las, test voltage ‘across solenoid switch contacts. Connect o 12 volt meter lead to solenoid motor terminal ond positive lead 10 terminal of switch, Crank engine and immediately turn voltmeter switch to low scale, toke reading, then turn switch Bock to high scale before stopping engine. Voltage drop must rot exceed .2 volt for contacts 0 be satisfactory SOLENOID WINDINGS TEST NOTE — Tests are performed with all leads disconnected Complete tes!s in minimum amount of time 10 prevent overheating solenaid. Hold-In Winding — Connect test equipment as shown in il lustration. Use carbon pile to decreore bottery voltage to 10 volts. Ammeter should read 14.5 to 16.5 Amps. H amperage is above 16.5 Amps., winding is shorted or grounded. Amperage. drow below 14.5 Amps, indicates excessive resistance Beth Windings In Poralel ~ Remove jumper wre trom motor terminal of solenoid ond readjust reistonce +0 oiage 10 volts, Current draw should be 40.5:475 amperes. If not within specifications replace solencia. SOLENOID WINDING TEST CONNECTIONS STARTER NO LOAD TEST To perform test, connect starter as shown in illustration, To ob toin voltage specified in Delco Remy Storter Specifications, ‘adjust corbon pile. Then read current draw and armoture speed ond compare these readings with specifications CAUTION ~ Do not apply voltage greoter than specified; excessive voltage may couse armature 10 throw windings becouse of excessive speed, Ammeter STARTER NO LOAD TEST CONNECTIONS DELCO-REMY STARTER SPECIFICATIONS: eral No toad Test —rDr,rhmrmrrCOCOC "o8s02 4595 | 750010500 | 9 "owe #80 | ‘oooesoo | 9 Moers S080 | Ssoorba00 | rosa? 3580 | 3300-6000 | oersa 8395 | 7i001bs00 | > Nowra! $595 | Zs0010800 | 9 oer Soo | 5300-10300 | Moers S080 | Ss0o.10800 | > oszeo 5500 | 300 3 "08761 3555 | zsoo1es00 | 9 howe 4595 | 730010300 | 9 ‘ipo 200 Rapa ema CampaStarters DELCO-REMY ENCLOSED HOUSING (Cont.) SPECIFICATIONS Brush Spring Tension. 35 ons Rotation. : ockewite’ ot pinion end jon-to-Housing Clearance. ‘O.010-.140" © = Between pinion and pinion stop with pinion in engaged position. OVERHAUL DISASSEMBLY 1)_ Disconnect field lead strap from solencid by toking out ter minal screw. Remove two through bolts, withdraw commutator fend frame and field frame by pulling these ports off the or mature. Remove thrust washer from commutator end of ar mature shaft 2) Pull out bruth holder pivot pin and remove two brush holders and spring as on assembly. Remove brushes by toking ‘out screws attaching leads ond brushes to holder. 3) Remove two solenoid attaching screws ond remove solenoid from drive housing. To remove solenoid cover for switch inspection, remove nuts and insulating washers from solenoid "S" and "BAT" terminals, remove cover 44) Remove shift lever fulerum bolt, remove shift lever, plunger, ‘and return spring from end housing. Withdraw armature ‘ossembly. Remove thrust collar from pinion end of armature shaft 5) To remove dive assembly from armature shoft, install piece of correct size tubing over end of shoft and against pi: hion stop retainer, tap retoiner toward armature to uncover snap ring. Remove snap ring from groove in shalt, then slide Fetainer ond drive assembly off shoft CLEANING Clean all ports by wiping with clean cloth. Do not clean ar: mature, field cols, or drive assembly in any type of grease dis: solving solvent os this will damage insulation ond wash lubri cont out of drive assembly. PARTS REPLACEMENT & TESTING Armature ~ Test ormature for shorted coils with a growler. Check for grounded coils with © 110 volt test lamp. Place one test lead on armature core or shaft, and other test lead on commutator, Lamp should not light. flomp lights, armature is grounded ond should be replaced. Inspect commutator. If commutator is worn, out of round, oF has high insulation, tn down commutator in a lathe, undercut insulation i" deep ond Squore across entire width, sand commutator lightly with 00 grade sandpaper and clean out slots caretuly CAUTION — Some starters have molded-type commutator, ‘ond insulation must not be undercut on these models os *his ‘may couse serious damage 40 commutotor. Field Coils — Check with 110 volt test light. Place one test lead on field coil terminal strap, touch other test lead to field «oil brush lead (check series coils and shunt coils separately ot ‘oppropriote terminals). Lamp should light. If lamp does not light, cols ore open. Check for grounds by placing one test leod on field armature strap, touch other lead to ormature core or shaft, CAUTION — Shunt coil ground lead mus! be disconnected ond all field terminals insulated from frame when ‘moking ths test, If lamp lights, one or more cols are ground: a, ‘ipo 0 200 a Rea Brushes, Springs, & Holders — Replace brushes if worn to one-half of original length, or if oil-soaked or pitted. Check brush spring tension and replace springs if weak or distorted Deformed or bent brush holders can be replaced by service un its which are installed with screws and nuts Drive & Pinion Assembly ~ Pinion should turn freely in overrun direction and should not slip in drive direction. Check Spring for correct tension and drive collar for wear (these parts con be removed for replacement by forcing collar toward clutch and removing lock ring from end of tube). Replace drive cossembly if pinion teeth are worn, chipped, or cracked Pivot Pin ir) cor rush Holder Support Brush Holder Spring Brush Holder (Ground) BRUSH ASSEMBLY (ONE SET SHOWN) Armature Shaft Bushings — Inspect armature shoft bear: ing surfaces and check for wear by noting sideploy with shaft inserted in bushings. Drive end bushing con be replaced. Reploce commutator end plate ossembly if bushing is worn. Pinion Clearance ~ Connect an electrical source of 6 volts between solenoid "S" terminal and ground. CAUTION — Do ot use more thon & volts or motor will operate. After tenergizing solenoid, push pinion away from stop retainer as for as possible and use feeler gouge to check clearance between pinion and retainer. If clearance is not within specifications disassemble motor and check for defects4-28 Starters DELCO-REMY ENCLOSED HOUSING ( Cont.) 1) Lubricate armoture shaft with silicone lubricant or several drops of SAE 10 engine oil install drive assembly on shal, in stall retainer with cupped side out or away from pinion, instoll lock ring in shaft groove, install thrust collar with shoulder ‘against locking. Position retainer on lack ring by using two pliers ot opposite points to squeeze retainer and thrust collor together against lock ring 2) Assemble brush holders ond instll brushes, connect field leads to proper brushes, check assemblies for free movement, 3) Assemble solenoid plunger on shift. Lubricate drive housing bushing with silicone lubricant or few drops of SAE 10 engine cil, Install armature and drive assembly in drive housing with Shift lever engaged in drive collar, install shift lever pin. Coot both tides of solenoid flange which extends down between drive housing ond field frame with suitable sealer (No. 1050026), place return spring over plunger ond install solenoid, tighten solenoid attaching screws securely. 4) Align field frame dowel with dowel hole in drive housing. Install field frame over armature and against end housing CAUTION — Lift brushes up over commutator os field frame is installed to prevent damage to brushes. Shift Lever Assembly Drive Assembly Thrust Collar Drive Housing Armature” mature shaft, Lubricate commutator end frame bushing with slicane lubricant or few drops of SAE 10 engine oil install end frame, install through bolts and tighten securely. Plunger 3co2 0 & SHIFT LEVER ASSEMBLY Return Spring Shift Lever Drive Housing Solenoid Assembly Terminal Brush Holders End Plate Brush Holder Field Coils Brush Spring Leather Washer cos DELCO-REMY ENCLOSED HOUSING STARTER ASSEMBLY ‘ipo 200 Rapa ema Campa