When rebuilding the starter, the five sub-assemblies must first be reassembled:
1. Core Assembly
2. Rear Housing Assembly
3. Trip Housing Assembly
4. Body Assembly
5. Mounting Bracket Assembly
Component lubrication :
General lubrication use Shell Nerita Grease HV or equivalent.
Specialist lubrication use Rocol Anti-Scuffing paste or local equivalent. Use as recommended.
* Take the main shaft
and lubricate the main two start threads. Lubricate the inside threads of the
drive nut. Place the cage over the shaft, covering the two start threads,
with the shoulder towards the shoulder on the shaft. Insert 16 of 5/16"
ball bearings into the hole in the cage, then carefully screw the drive nut
onto the ball bearings, with drive lugs towards the shoulder on the shaft.
* Stand the drive gear assembly, gear end face down on the bench. Lubricate
legs with Rocol anti-scuffing paste, lubricate the concave and the convex surface
of each spring by smearing with Rocol anti-scuffing paste. Then place
the drive spring over the sleeve in the same order as fig.
10. Place drive ring on top of spring pack, groove side up. (fig.6)
Take main shaft, complete with drive nut and insert into the centre of drive
gear assembly so that the lugs on the drive nut rest in the groove of the drive
ring.
* Take hold of the complete core pack and place it on the press with the shaft
end into base of press. Place press tool into top of drive gear and compress.
Lubricate ball races and insert ten of 8mm ball bearings in to the ball-race,
check that the ball bearings have dropped in correctly and can move free in
the race. Release pressure and remove press tool. Remove assembly from
press. See core press diagrams
* Place core assembly onto bench. Lubricate five start thread area of
the shaft with the recommended grease. Place circlip over end of
shaft up against shaft shoulder. Place drive ratchet onto shaft five lobe
end towards shaft shoulder . Lubricate inside of bore of drive pinion
and outer rear area. Assemble spring locating washers and return spring
onto pinion. Slide pinion onto shaft until the five start threads are
visible through the holes in the rear of the pinion. Insert five 7mm diameter
ball bearings, then pull ratchet forward over ball bearings until circlip groove
in the rear of the pinion is uncovered. Replace circlip, to hold unit
onto shaft. Check for a smooth operation of pinion by sliding forward
and backward along the shaft also that when the front locating washer is
held the drive pinion is forced into the rear position by the return spring.
2. Rear Housing Assembly
Input Shaft Assembly:-
* First assemble input shaft and input adapter. Place one friction
washer over threaded end of input shaft, onto its shoulder, followed by
input ratchet ensuring that it is the right way up. The ratchet is designed
to fit in one way only. (Note: When in operation ratchet rotates in a clockwise
direction.) Place second friction washer onto ratchet. Screw input adapter
onto shaft so that it compresses the two thrust washers and ratchet.
* Lubricate lower input shaft (i.e. bearing surfaces) with ROCOL anti-scuffing
paste. Slide thrust washer up the shaft and insert shaft into the rear
housing sliding the input gear onto the shaft. Fit securing "E"
clip into the groove at the base of the shaft. This will secure the input
gear and shaft in the rear housing.
* Lubricate main bearing in rear housing. Place rear housing on its back
on the bench. Lift complete core assembly and place on top of the rear housing
main bearing so that the input gear and drive gear assembly mesh. Hold
the core assembly to keep it upright on the rear housing, and rotate the input
adapter. This will cause the core assembly to rotate. Check that
the movement is smooth and not "notchy". If movement is not
smooth, add shims on top of the main bearing to lift the core pack until the
operation is smooth and a gear backlash of approximately 0.2mm is achieved.
Remove core assembly from rear housing, and put this to one side with the shims.
* Take rear housing
and lubricate lower part of support plate studs. Lubricate both catches
and place on studs checking for the correct operation of the ratchet.
Place catch springs over studs to secure catches against input ratchet.
Lubricate ground surface of input adapter with Rocol anti-scuffing paste.
Place support plate over adapter and onto studs, sealing the joint between casting
and support plate with HYLOMAR sealant. Place locking washers on studs
and tighten nuts, locking over tabs. Turn rear housing around and push
plastic plug into hole in casting.
* First assemble link by placing lower link and spring into link body. Lubricate and screw in upper link. Place link assembly into lock and push in lock pin from countersunk side, as shown. Lubricate rear hole in lock. Place lock-link assembly in trip housing and insert swivel pin. Place return spring on release shaft and lubricate. Insert shaft into trip housing, engaging end of shaft in upper link. Once shaft is in place, screw in lock stop screw.
* Lock Height Setting.
For starters where Mounting Bracket and Trip Housing are separate
bolt assemblies together using two short bolts (Not necessary for one piece
Mounting Bracket). Insert lock height gauge into bush, in Mounting Bracket,
through centre of Trip Housing and rotate. The "go" pin should
clear the lock, while the "no go" pin should not. If this is
not the case, remove the release shaft, and rotate the upper link so that it
screws to the height required. This operation may have to be repeated
to get the lock height correct.
Fig. 14
* Lubricate and refit the reset mechanism which is a straight forward operation
You are now ready to reassemble the sub-assemblies.
* Take the mounting
bracket, trip housing and body and reassemble in the required, marked position
using the front fixing screws.
* Take the core assembly and stand on end with gear face down. Lubricate
the front stub and place the thrust washer and Belleville washer in place. With
the release lever in its tripped position lower the complete body, trip housing
and mounting bracket assembly over the core until the stub at the end
of the main shaft is located in the bush in the mounting bracket.
* Place the assembly on its side. Lubricate the drive gear assembly and
insert the shims at the rear of the drive gear. Take the rear housing
and push into the rear of the body. Stand the starter on end,
with the rear housing on the bench. Make sure that the body is tight against
the shoulder on the rear housing and check the distance between the mounting
flange face and the front edge of the drive pinion. This dimension should match
the dimension shown in table for
the particular starter type. If this dimension is found to be incorrect shims
should be added between the Body and Trip Housing. Once this dimension is correct
check that the Belleville washer is free to rotate. The clearance between
thrust washer and Belleville washer or Main Shaft end float is 0.05 mm to 0.25
mm. If the clearance is found to be too great shims should be added between
the thrust washer and Belleville washer. Repeat this until the correct
clearance is achieved. When all the operating clearances have been achieved
remove the mounting bracket and Trip housing assembly and seal all joint with
Hylomar sealing compound. Assemble the starter using the required Assembly
Code or the marks placed on the body before dismantling. The front fixing screws
should be tightened to a torque of 12-14 Nm, the rear radial fixing screws
should be tightened to a torque of 6-8 Nm. The starter is now complete.
Fig.15
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Final Check Before Returning to Engine
Rotate the
input adapter by hand. The drive pinion should move forward to its front
position. Do not carry on winding, as this will begin to charge the starter.
Instead, operate the release lever, returning the drive pinion to its rear position.
If this does not happen, the starter should be stripped down and the fault located.
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