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Starter, Delco Remy 42MT Series 15.01 General Information

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Starter, Delco Remy 42MT Series 15.01 General Information Starter, Delco Remy 42MT Series 15.01 General Information General Information The brush rigging has four one-piece brushes. The commutator end cap can be removed to inspect the The Delco Remy starter ( Fig. 1) is located at the brushes. The bushing lubrication is provided in each sintered bronze bushing by an oil-saturated wick. Oil hand side of the vehicle. can be added to each wick by removing an oil reser- voir cup, which is accessible on the outside of the NOTE: The 42–MT series starters have a drive motor. housing that can be rotated for different mount- Under normal operating conditions, no maintenance ing positions. On vehicles with the Detroit Diesel will be required between engine overhaul periods. At Series 55 engine, the starter is installed on the the time of engine overhaul, replace the starter with right-hand side. a remanufactured starter. 1 2 4 12 3 4 5 4 11 6 7 10 8 8 9 9 01/07/2000 f150992 1. Solenoid 5. Drive Housing 9. O-Ring 2. Return Spring and Boot 6. Bronze Bushing 10. Thermostat (450 series only) 3. Shift Mechanism 7. Positive Engagement Drive 11. End Cap 4. Oil Wick 8. Armature Bushing Fig. 1, 42-MT Starter Motor Components The starter has a shift lever and solenoid plunger For the basic cranking circuit wiring, see Fig. 2. that are totally enclosed to protect them from expo- sure to dirt, icing conditions, and splash. The starter is equipped with a starter drive, solenoid, and a Principles of Operation positive-engagement mechanism that prevents the Turning the ignition switch to the START position starter motor from rotating unless the pinion gear is engaged with the ring gear teeth. The pinion gear is closes the magnetic switch contacts, connecting the battery to the starter solenoid. As a result, the mounted on a roller bearing one-way clutch, that al- plunger and the shift lever move, causing the pinion lows the pinion to spin when the engine has started. Columbia Workshop Manual, Supplement 0, April 2000 050/1 15.01 Starter, Delco Remy 42MT Series General Information G M B S 2 15A + 15C 1 3 9 15B 14 16 10 52 4 8 AA6 7 6 5 15A 15 15K 07/16/98 f150543a NOTE: Wire 16 connects to the alternator. 1. Battery 4. Frontwall Connector (pin E1) 7. 10-Amp Circuit Breaker 2. Cranking Motor (top view) 5. Splice Connector 8. Cab/Frontwall Power Stud 3. Magnetic Switch 6. Ignition Switch 9. Engine Power Stud Fig. 2, Cranking Circuit Wiring bad connections cause slow cranking speeds that of the stroke, the solenoid main contacts close and will overheat and damage the starter motor. the motor cranks the engine. If the pinion fails to en- The 42–MT 450 series starter is equipped with a gage the ring gear teeth, the solenoid contacts will thermal overcrank protection circuit. If overheating not close the circuit to the motor. The switch must be occurs, a thermostat opens and stops the current to released and again moved to the START position to the magnetic switch, protecting the cranking motor. attempt another start. After the motor cools, usually in 1 to 6 minutes, the When the engine starts, the pinion overruns, protect- thermostat will close and then a new start attempt ing the armature from excessive speed. When the can be made. ignition switch is returned to the normal RUN posi- tion, the solenoid spring returns the plunger and the pinion disengages from the ring gear. Never crank the motor longer than 30 seconds at a time. Stop and allow the motor to cool for at least 2 minutes before cranking again. Weak batteries or 050/2 Columbia Workshop Manual, Supplement 0, April 2000 Starter, Delco Remy 42MT Series 15.01 Starter Removal and Installation Removal Installation Before removing the starter from the vehicle for re- 1. Insert the starter nose housing through the pair, perform the checks in Troubleshooting, 300. 1. Turn off all electrical loads such as lights, igni- 2. Install the three starter mounting bolts and lock- tion, and accessories. washers. Refer to the fastener and torque values 2. Disconnect the battery negative cable(s). table in . 3. Disconnect the electrical leads attached to the NOTE: Torque values differ according to type of starter. Mark the terminals and wires for ease of engine installed. installation. 3. Connect the wires to the starter as previously NOTE: It may be difficult to gain access to the marked. Tighten the nuts 16 to 30 lbf·in (180 to starter mounting bolts. For ease of removal, 340 N·cm). straddle the front axle with your arms extended 4. Spray any exposed terminal connectors with di- around the leaf springs and use a long socket electric red enamel. See Table 1. extension. Approved Dielectric Red Enamel 4. Remove the mounting bolts and lockwashers (Fig. 1) that attach the starter to the engine. Re- Protectant Material Approved Brands move the starter. MMM 1602 IVI–Spray Sealer, Spray-On Application Red Electric Grade; order from the PDC Glyptal 1201EW– Low VOC, Red; order at Brush-On Application www.glyptal.com or 1-800- GLP-1201 Table 1, Approved Dielectric Red Enamel 5. Connect the battery negative cable(s). 1 03/23/2001 f150115a 1. Starter Mounting Bolts (with lockwashers) Fig. 1, Starter Installation Columbia Workshop Manual, Supplement 0, April 2000 100/1 Starter, Delco Remy 42MT Series 15.01 Ignition Switch Removal and Installation Removal 1. Disconnect the batteries. 2. Reach in underneath the switch housing and re- move the ignition switch from the rubber grom- met. It is not necessary to remove the switch housing. 3. Remove the electrical connector from the rear of the switch. Installation 1. Connect the electrical connector to the ignition switch. the switch points inboard, towards the steering wheel. 3. Connect the batteries. Columbia Workshop Manual, Supplement 0, April 2000 110/1 Starter, Delco Remy 42MT Series 15.01 Troubleshooting Troubleshooting Problem—Starter Cranks Slowly Or Not At All Problem—Starter Cranks Slowly Or Not At All Possible Cause Remedy The batteries are undercharged. Do a load test on the batteries. See Section 54.02, Subject 140, for instructions. Charge or replace batteries as needed. If the batteries were discharged, check the alternator voltage and output. See the troubleshooting subject in the appropriate alternator section in Group 15 for instructions. The battery cables do not deliver sufficient Check the available cranking voltage. Go to "Available Cranking Voltage Test" voltage to the starter. for instructions. The starter solenoid circuit is broken. Check the starter solenoid circuit. Go to "Starter Solenoid Circuit Test" for instructions. Make repairs as needed. Start the engine to verify the repair. The control circuit is broken. Check the starter wiring. Go to "Starter Wiring Test" for instructions. Make repairs as needed. Start the engine to verify the repair. The magnetic switch is broken. Replace the magnetic switch. Go to Section 54.03, Subject 100, for replacement instructions. The starter ring gear or pinion gear is Visually check the ring and pinion gears. Go to "Ring and Pinion Gear Test" damaged. for instructions. The starter does not stay engaged. Go to "Cold Weather Starting Test" for instructions. The starter is damaged. Replace the starter. There is a mechanical problem in the See Group 01 or the engine manufacturer’s manuals. engine. The drive belt is loose. Check the drive belt. See the drive belt subject in the appropriate engine section in Group 01 for instructions. If necessary, tighten to the Start the engine and check the alternator voltage and output. See the troubleshooting subject in the appropriate alternator section in Group 15 for instructions. The drive belt is damaged or missing. Check the drive pulleys for locked bearings. Repair or replace any damaged components. Replace the drive belt and start the engine. Check the alternator voltage and output. See the troubleshooting subject in the appropriate alternator section in Group 15 for instructions. Troubleshooting Chart Available Cranking Voltage Problem—Starter Spins, But Does Not Crank Test For troubleshooting instructions, see Fig. 1. BATTERY CABLE TEST Problem—Starter Makes Clicking Noise, But Does 1. Connect the positive lead of a carbon pile tester Not Crank (Or Cranks Intermittently) to the starter solenoid B (battery) terminal. Con- For troubleshooting instructions, see Fig. 1. nect the negative lead of the carbon pile to the starter G (ground) terminal. See Fig. 2. Columbia Workshop Manual, Supplement 0, April 2000 300/1 15.01 Starter, Delco Remy 42MT Series Troubleshooting Connect voltmeter More than 6.0 Vfrom solenoid "S" 6.0 V or less terminal to ground. Engage start switch. Symptoms continue Remove starter. Check & repair Visually check pinion. Milled pinion magnetic switch circuit. OK OK Repair or replace starter. (Do not install) Repair verified. Milled teeth Visually check ring gear. OK Replace ring gear and check flange to flywheel dimension. Reinstall starter and perform "Cranking Circuit Test." Defective Replace starter and verify repair. 02/18/97 f040314 Fig. 1, Milled Pinion Symptoms IMPORTANT: Connect the voltmeter to the 5. Turn on the carbon pile again and adjust it to a starter B terminal, not to the carbon pile clamp. 500-amp load, as before. Read and record the voltage (V2) on the voltmeter. Turn off the carbon 2. Set a digital voltmeter on the low scale (2V, 3V, pile. or 4V, depending on type of meter) and connect the positive lead to the battery positive (+) termi- NOTE: Ignore the minus (–) sign. nal. Connect the negative lead to the starter B 6. Add the positive (V1) and the negative (V2) volt- terminal.
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