2. Clean the block from dirt.
Checking the traction relay - all types
3. Before checking the traction relay, disconnect the battery and engine wires from the traction relay terminals and disconnect the switch wire from the flat clamp.
4. Using a multimeter (in resistance measurement mode) or battery and lamp, check the traction relay as follows.
5. Ring connection between flat clamp "S" traction relay and relay body, between the terminals "S" And "M". If there is no resistance, the windings are defective and the traction relay must be replaced.
6. To check the operation of the traction relay, connect the battery (12 V) and an 18-21 W lamp between the traction relay motor and the battery pole; there should be no short circuit. Connect the wiring between the positive battery terminal and the relay terminal. The traction relay should operate and the lamp should light up; if not, the relay contacts are bad and it must be replaced.
7. To replace the relay, disconnect the wires, unscrew the screws, remove it, disconnect the relay or plunger from the drive lever.
8. When installing, lubricate all contact points between the relay plunger and the actuator arm. Install the relay by connecting the plunger to the actuator lever and the spring, and tighten the screws.
Hitachi S114-390A and 391A
Pic. 12.4. Starter - Hitachi S114-390A and 391A: 1. Anti-dust cap; 2. Anchor; 3. Yoke and field winding assembly; 4. Positive brush; 5. Screw; 6. Elements of the back cover; 7. Bushing; 8. Brush holder elements; 9. Negative brush; 10. Brush spring; 11. Thrust washer and C-bracket; 12. Drive gear assembly; 13. Bearing and snap ring; 14. Elements of the front cover; 15. Bushing; 16. Drive lever and spring; 17. Traction relay; 18. Adjustment plates; 19. Pinch bolt; 20. Anti-dust cap; 21. Screw; 22. Screw
9. Remove the traction relay as described above.
10. Remove the dust cap from the rear cover.
11. Remove the C-bracket and thrust washers.
12. Unscrew the tightening bolts and screws securing the brush holder to the back cover, remove the back cover.
13. Remove the springs, release the two positive brushes and remove the brush holder from the armature.
14. Remove the yoke, anchor and drive lever.
15. If the starter motor is removed, lower the gear stop bearing down the shaft, remove the retaining ring, stop bearing, and disconnect the engine assembly from the armature shaft.
16. Check all components, replace if necessary.
17. The armature can be checked with an ohmmeter by connecting probes on adjacent contacts around the commutator (Pic. 12.5). If there is a gap between any pair, the armature must be replaced.
Pic. 12.5. Checking armature windings
18. Now check for short circuit between each contact of the commutator and the armature shaft. If there is a short circuit, the armature must be replaced.
19. Check brush wear. If they are worn to the specified minimum length or less they must be replaced.
20. The field windings can be checked with an ohmmeter; it is between (+) field winding clamp and positive brush (Pic. 12.6). If there is a break, replace the field winding.
Pic. 12.6 Checking the field windings
21. Now check for short circuit between the positive terminal of the field winding and the yoke. If a short exists, then the field windings must be replaced.
22. Check the drive gear clutch for proper operation. It should jam when rotating against the engine rotation and rotate freely in the opposite direction.
23. Assembly is carried out in the reverse order.
24. The backlash between the gear and the stop bearing must be certain. For adjustment, use plates of different thicknesses installed between the relay and the front cover. Connect the wiring to the clamp "M".
Mitsubishi M3T33981, M3T33981H and M3T30581
25. These blocks are very similar to the Hitachi engines described above, the only significant difference being that the thrust washers and C-bracket are not installed.
26. According to Fig. 12.7 and the information given in the Specifications, proceed as described in the paragraphs above.
Pic. 12.7. Starter - Mitsubishi M3T33981, M3T33981H and MZTZ0581: 1. Screw; 2. Anchor; 3. Yoke and field winding assembly; 4. Positive brush; 5. Elements of the back cover; 6. Bushing; 7. Brush holder elements; 8. Negative brush; 9. Brush spring; 10. Thrust washer elements; 11. Drive gear; 12. Bearing, bracket and thrust washer; 13. Elements of the front cover; 14. Bushing; 15. Elements of the drive lever; 16. Pinch bolt; 17. Traction relay; 18. Screw
Hitachi S114-392 and 393
Pic. 12.8. Starter - Hitachi S114-392 and 393: 1. Clamp nut; 2. Anchor and bearings; 3. Rear bearing; 4. Front bearing; 5. Yoke and field winding assembly; 6. Screw; 7. Positive brush; 8. Back cover; 9. Brush holder elements; 10. Brush spring; 11. Negative brush; 12. Gear and coupling assembly; 13. Gear shaft; 14. Bearing, bracket and spring; 15. Assembling the coupling; 16. Front bearing; 17. Rear bearing; 18. Front cover; 19. Drive lever and spring; 20. Traction relay; 21. Adjustment plates and dust cap; 22. Bearing retainer; 23. O-ring; 24. Pinch bolt; 25. Clamp cover; 26. Screw; 27. Screw; 28. Gasket
27. Mark the alignment of the yoke, front and back covers relative to each other.
28. Unscrew the tightening bolts and remove the back cover.
29.Disconnect the yoke, armature and brush holder from the front cover.
30. Separate the two positive brushes and remove the brush holder.
31. Remove the anchor from the yoke.
32. Remove the drive lever and dust caps.
33. Unscrew the bearing retainer, remove the coupling assembly and shaft from the front cover. Disassemble the assembly if required as described above.
34. Check all components as described above.
35. Assembly is carried out in the reverse order.
36. Check the clearance between the drive gear and the bearing. Measure the height from the front end of the gear to the front cover of the starter, pull the gear by hand until it contacts the bearing, measure the height again. If the difference is outside the specified tolerance, select the adjustment plates and adjust the installation.
Mitsubishi М2Т53781 and М2Т53785
Pic. 12.9. Starter - Mitsubishi М2Т53781 and М2Т53785: 1. Screw; 2. Anchor and bearings; 3. Front bearing; 4. Rear bearing; 5. Yoke and field winding assembly; 6. Drive gear elements; 7. Assembling the gear and shaft; 8. Reduction gear; 9. Gear shaft and coupling; 10. Thrust washer, gasket and cover; 11. Gear elements; 12. Bearing and bracket; 13. Brush holder elements; 14. Brush spring; 15. Back cover; 16. Front cover and bearing; 17. Central suspension; 18. Drive lever; 19. Spring elements; 20. Traction relay; 21. Pinch bolt; 22. Screw; 23. Screw
37. Remove the relay.
38. Mark the location of the front cover, center hanger, yoke and back cover in relation to each other.
39. Unscrew the tightening bolts and screws securing the brush holder to the rear cover, remove the rear cover.
40. Remove the positive brushes from the brush holder by pressing the spring back, then remove the brush holder. If any of the brushes are worn to the specified minimum length, the brush holder assembly must be replaced.
41. Disconnect the yoke and armature from the front cover and center suspension assembly.
42. Replace armature bearings if necessary.
43. Check field windings if required.
44. Remove the rear gear shaft cover.
45. Remove the screw and separate the center hanger from the front cover.
46. Remove the bracket from the front crankshaft gear, remove the bearing, gear and (where available) spring.
47. Disconnect the drive arm, reduction gear, and pinion shaft assembly from the front cover.
48. Check all components as described above.
49. Assembly is carried out in the reverse order.
50. When installing the reduction gear and gear shaft assembly, install thrust washers, central hanger, and gasket. Press the gear shaft as far as possible and measure the axial pressure gap. If the gap is greater than a certain amount, adjust it with thrust washers.
Lucas/Magneti Marelli M78R
Pic. 12.10. Starter - Lucas/Magneti Marelli M78R: 1. Relay and plunger; 2. Commutator suspension and brush holder assembly; 3. Brush; 4. Brush spring; 5. Anchor; 6. Thrust ring; 7. Start lever and sealing ring; 8. Gear shaft and reduction mechanism; 9. Assembling the drive gear; 10. Bushing; 11. Bushing; 12. Bushing; 13. Drive suspension; 14. Tightening bolts; 15. Intermediate suspension; 16. Yoke and field winding assembly; 17. Switch suspension
51. Remove the traction relay and plunger as described above.
52. Unscrew the two nuts and remove the commutator end hanger.
53. Remove the rubber sealing ring from the yoke, remove the brush holder assembly with brushes.
54. Disconnect the yoke from the drive suspension and armature.
55. Remove the anchor from the step-down block. Then the armature drive.
56. Remove the reduction block, including the lever and drive assembly from the drive side hanger.
57. Remove the ring from the shaft. Remove the drive gear assembly and thrust ring.
58. Check the condition of the brushes and spring tension.
59. Check the condition of the armature, field windings and drive gear assembly as described above. The armature and gear shaft bushings can be replaced separately (regardless).
60. Assembly is carried out in the reverse order. Check the play of the gear jump ring.