WP220 Starter Service Manual
Contents
1. DESCRIPITION PART NO EML PART NO Delco Remy Electricals India Limited ds2. by repair or it may indicate the need for component testing after the cranking motor is dismantled Test Procedure Connect the starter motor for the no load test as shown in fig 1 using suitable instruments battery cables and connecting wiring Note the following 1 Secure starter motor in a suitable test stand to check operations 2 Use a momentary contact push button switch in the test circuit for quick 3 release if very high current surges are encountered 4 Close the switch and observe no load values Following are the OK starter Motor values Voltage 9 9 to 11 6 Volts Current 160 Amps Max Speed 4000 RPM Min If results of the no load test are outside limits refer to table 1 trouble shooting for possible cause and corrective action TABLE 1 TROUBLE SHOOTING Starter motor does not Faulty Battery Recharge the Battery Rotate when switch is Terminals Clean internal surface of Operated Corroded connecting lugs Battery terminal posts Starter supply Check state of cable broken or in connecting battery and starter poor state Check battery earth strap Check cable connection at starter motor and battery replace battery if necessary Change master switch or rectify circuit Starter M otor Remove starter motor and Short circuited rectify Starter M otor rotates at Drive assy Replace drive assy Ensure high speed but does not meshes with proper connection of solenoid crank
3. the engine Gear but does and shift lever not drive Drive assy does not mesh with ring gear Starter motor does not Brushes worn out Change all brushes Ensure Turn or low speed Brushes jammed Free movement of brushes Low speed with normal High internal Inspect internal wiring Or low current Electrical resista electrical connections and nce caused by poo armature commutator Connections Defective leads or Dirty commutator Low speed with high a Excessive friction Inspect bearing armature Current In bearing or gear drive shaft and gear reduction Reduction unit gears Bent armature Shaft or loose pole Shoe bent drive Shaft b Armature shorted Inspect and test armature c Ground armature Inspect armature and field or field Coil assy High speed with high a Field shorted Inspect and test field coil Current Assy Starter motor cranks the b Poor functionof Replace starter switch Engine normally continu switch es when starter switch is c Short circuit in Check wiring harness released Wiring harness d Solenoid shunt Replace defective solenoid winding open Starter motor cranks noisy a Drive pinionteeth Replace defective drive assy milled b Drive clutch jam med c Ring gear teeth Replace ring gear damaged e Plastic gear inside Replace plastic gear Starter motor teet Worn out STARTER DISMANTLING TOOLS REQUIRED Spanner No 7 Span
4. Remy Delco Remy Electricals India Limited Sa WP 220 STARTER MOTOR SERVICE MANUAL WP_220 STARTER MOTOR SERVICE MANUAL General Description The WP 220 Starter Motor is a pre engaged Motor and provides high starting torque in a compact light weight package by using a high speed motor through a reduction gear unit The engine starting system includes battery starter motor and ignition switch When ignition switch is ON the solenoid is energized and moves the plunger This in turn actuates the shift lever which moves the drive forward and engages with Flywheel ring gear After full engagement of pinion to the ring gear the starter motor rotates and cranks the engine As the engine starts pinion over runs to prevent damage on the Armature assembly caused by excessive rotation speed until switch contact is opened However switch OFF the starter motor immediately after the engine starts to prevent the Armature and Drive damage The WP 220 Armature is dynamically balanced and rides in sealed ball bearing amp Bush Fiber glass banding and varnish impregnation are used for added Armature strength The molded bar commutator receives electrical power through radially positioned one piece brushes Constant pressure brush springs are used for even brush wear and long brush life On Vehicle Service To independently test the cranking motor it is necessary to remove it from the engine However before doing this checks should be m
5. ade to ensure that the problem is with the starter motor and not with the engine battery wiring or switches When the other possible problem sources have been eliminated then remove and test the starter motor Comparison of test results with the trouble shooting chart table 1 will aid isolating the problem within the starter motor to specific components This will determine the repair or repairs needed to restore the starter motor to serviceability Battery Tests Realistic testing as well as successful operations requires a fully charged battery capable of supplying the current the starting system is to test the battery Follow Vehicle or Battery manufacturers instructions Wiring amp Switches Visually inspect all wiring and switches in the starting circuit for damages and loose or corroded connections This includes all ground connections Clean and tighten connections as required Replace the damaged wiring or components Continuity check Use Voltmeter and check terminal voltage at starter motor The voltage should be normal Cranking motor removal If the battery wiring and switches are in satisfactory condition and the engine is known to be functioning properly remove the starter motor for further testing Refer to the Vehicle manufacturer s instructions for the proper removal procedure STARTER MOTOR NO LOAD TEST With the starter motor removed from the engine the no load test can reveal damage that can be corrected
6. ner NO 10 Spanner NO 13 Philips Head Screw Driver Carbon Brush Spring puller A snap ring pliers A socket to hit the Pinion Stopper Remove the starter motor from the engine Disconnect all electrical connections before removing the starter from the engine Removal of solenoid Remove the motor terminal nut Unscrew the solenoid mounting bolts and with draw solenoid Removal of C E Frame Unscrew brush holder fixing screws Unscrew through studs Remove C E Frame Removal of Brush Holder Assy Remove field coil brushes from brush holder assy then separate brush holder assy Complete dismantling Remove Yoke assy Remove Armature assy Remove gears 3 Nos Remove damper Remove drive shaft along with gear support Remove shift lever Removal of Drive assy refer fig 2 Remove pinion stopper use an adequate socket Hit the pinion stopper as shown in fig 2 STE Remove lock ring use a Snap ring pliers File smooth burrs if any on groove Remove drive assy INSPECTION AND TESTING OF INDIVDUAL PARTS 1 D E Housing assembly Inspect crack or damage Inspect bearing condition if any problem replace with new bearing 2 CE Frame Inspect crack or damage 3 Brush Holder assembly Inspect carbon brushes ware If below 11 mm replace all carbon brushes To ensure free movement of carbon b
7. rushes holder To check insulation between brush holder plate amp positive brush holders as shown in fig 3 If defective replace the brush holders with insul bushes 4 Frame amp Field Assy Check insulation between frame amp motor terminal as shown in the fig 4 5 Armature Assy Do not remove bearing from armature unless replacement is required Clean armature using fine emery paper or petrol moistened cloth Examine the commutator and ensure that it has clean surface free from pitting The commutator if pitted may be skimmed and polished ona lathe If mica insulation not under cut sufficiently further under cutting should be done as detailed in fig 5 6 amp 7 Check insulation between armature shaft and commutator with a series lamp as shown in fig 8 Check armature on growler to ensure that there in no short circuit as shown in fig 9 an IN ty Vi 6 Drive Assy Examine wear on bush and damage of pinion teeth Drive assy should slide freely on armature splines Smear shaft helix slightly with grease before assembling the drive Drive pinion should rotate in only one direction if not replace the drive Assy 7 Solenoid Assy Energize solenoid with 12 V supply Ensure plunger moves fully and freely both ways If not operative replace the solenoid 8 Gear Support Assy Gears should rotate freely in gear support Check gear support tooth wear crack or damages If abnormalitie
8. s noticed replace gear support ASSEMBLY Generally reverse of dismantling procedure sequence in dismantling should be retracted Take following precautions Lubrication during assembly Apply grease at four places Drive shaft splines Drive pinion OD Gear support inside Recommended Grease OKS Berulub KRYO TEX EP2 Lever AUNE Tightening Ensure proper tightening of all fasteners bolts amp screws Following are recommended tightening torque values 1 Thro bolt 6 0 to 9 0 Nm 2 Solenoid fixing bolt 5 6 to 8 0 Nm 3 Brush holder fixing screws 3 0 to 4 0 Nm 4 Solenoid motor terminal nut 6 0 to 9 0 Nm Sealing the Starter Ensure proper sealing of the starter as per the fig 10 with the following sealants 1 Anabond Thread locker 112 stud grade 2 Anabond AR 01 Silicon seal 3 Anabond 871 WATER SEALING ARRANGEMENT FOR PROTECTION AGAINST WATER ENTRY DELCO REMY ELECTRICALS INDIA LTD WP220 STARTER MOTOR NOSELESS APPLICATION M amp M SCORPIO e J El Fe On I SS NOSELESS A i Z T y CONSTRUCTION i SLI A e 7 i I ie N 5 Wr o o o oe APPLICATION OF SEALING COMPOUND DT 04 03 2002 Testing after repair or overhaul After repair the starter motor can be tested as specified in the starter motor No Load test
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