STARTER - BOSCH
1986 Starters BOSCH
DESCRIPTION
Starter is a brush type, series wound electric motor with an overrunning clutch. Field frame is enclosed by commutator end frame and drive bushing and carries pole shoes and field coils. A spline armature shaft drive end carries drive assembly. Armature shaft is supported at both ends by sintered bronze bushings.
BOSCH STARTER APPLICATION
Model Type or Part No.
190 Series 003 151 29 01
300 Series 0 001 362 600
420 & 560 Series (1)
(1) Not available from manufacturer.
TESTING
NO LOAD TEST
With starter on test bench, take readings of starter current, voltage and RPM. Readings should be within specification.
STARTER SPECIFICATIONS
Model (1) Volts/Amps. RPM
208 xxx 11.5/35-55 6000-8000
211 xxx 11.5/30-50 6000-9000
212 xxx 11.5/35-55 6000-8000
311 xxx 11.5/30-50 5500-7500
312 xxx 11/55-85 8500-10,500
317 xxx N/A N/A
362 xxx 11.5/65-95 6500-8500
(1) First three numbers are stamped on starter. XXX equals sequential part number.
BRUSH SPECIFICATIONS
Application (1) In. (mm) Ozs. (g)
208 xxx .52 (13) 40-50 (1150-1350)
211 xxx .52 (13) 40-46 (1150-1300)
212 xxx N/A N/A
311 xxx .52 (13) 40-46 (1150-1300)
312 xxx .39 (10) 29-32 (800-900)
314 xxx .52 (13) 40-46 (1150-1300)
317 xxx N/A N/A
362 xxx .61 (15.5) 40-46 (1150-1300)
(1) First three numbers are stamped on starter. XXX equals sequential part number.
REMOVAL & INSTALLATION
STARTER MOTOR
Removal & Installation
1. Follow manufacturer's precautions prior to working on vehicle electrical system. Remove negative battery cable. Raise vehicle on hoist if necessary.
2. Mark starter wiring for reassembly. Support starter and remove starter mounting bolts. Remove starter from vehicle. To install, reverse removal procedure.
OVERHAUL
DISASSEMBLY
1. Clamp starter in vise. Remove nut and washer from solenoid main terminal connection. Remove solenoid retaining screws and unhook solenoid plunger.
2. Remove screws and end cap with rubber seal from commutator end housing. Wipe grease from armature shaft and remove "C" clip with shims.
3. Remove bolts or nuts from studs and lift off commutator end housing. Lift springs clear of brushes and slide brushes from holders. Remove brush plate from housing.
4. Separate drive end housing and armature assembly from yoke by tapping apart. Remove armature assembly from drive end housing while at the same time uncoupling actuating arm.
5. To remove actuating arm, remove rubber insert from drive end housing. Remove pivot arm screw and nut and extract actuating arm.
6. To remove drive pinion assembly from armature shaft, separate thrust collar from over "C" clip. Remove "C" clip from its groove and drive pinion assembly off armature shaft.
Fig. 1: Exploded View of Typical Bosch Starter
CLEANING & INSPECTION
Clean all parts with cleaning agent. Inspect for wear or damage. Apply thin coat of oil to running surfaces.
PARTS REPLACEMENT & TESTING
Brushes & Springs
1. Check brush spring pressure with spring scale. Check brushes for minimum length and freedom of movement in holders.
2. If necessary, replace brushes by cutting old brush leads midway between connection and old brush. Solder new brushes to original leads.
Armature
1. Check commutator-to-shaft (or core) for short circuit with 110 volt AC test light. Test light should not light (a slight glowing is okay).
2. Using an armature growler, check armature coils for short circuit between windings. Check commutator for pits, burns or rough surface.
3. If out-of-round exceeds .002" (.05 mm), or grooves or burned spots cannot be removed with fine crocus cloth, turn commutator. Undercut insulation between commutator bars to a maximum depth of .016" (.40 mm).
NOTE: Never use emery cloth or a file on commutator. Turn on a lathe only.
Bushings
1. Self-lubricating bushings should be replaced only when worn or damaged. Force out bushings with mandrel.
2. Clean hole and remove burrs. Before pressing new bushing into place, soak it in lubricant for at least 30 minutes.
Drive Assembly
Replace drive when damaged or teeth are worn. See DISASSEMBLY in this article.
Solenoid Plunger (Armature)
Plunger must move in and out of solenoid body when disconnected from pinion drive lever. If corroded, clean thoroughly before proceeding with tests.
Solenoid Pull-In Coil
Connect jumper wires between a 12 volt battery and solenoid. See Fig. 2 . Armature should pull in and return when current is removed.
Fig. 2: Typical Connections for Pull-In Test
Hold-In Coil
Connect jumper wires between a 12 volt battery and solenoid, while pressing armature into solenoid by hand. See Fig. 3. Armature should remain held in. Disconnect jumper terminal No. 50 and armature should immediately return to its outer position.
Fig. 3: Typical Connections for Hold-In Test
NOTE: Do not attempt to repair solenoid. If either test is unsatisfactory, install new solenoid.
REASSEMBLY
1. Slide drive pinion assembly and thrust washer onto armature shaft. Install "C" clip into groove in armature shaft and pull thrust washer up over clip.
2. Align fork in drive end housing and insert pivot pin. Slide armature assembly into drive end housing, coupling shift fork onto drive pinion flange.
3. Install rubber insert in drive end housing. Guide yoke assembly over armature while aligning notch with rubber insert. Tap yoke into full contact with drive end housing.
4. Install brush assembly. On models with through bolts, cut-outs in brush plate slide over through bolts. On models with screws, brush plate cut-outs align with loops in field windings.
5. Plates are properly positioned when screws are installed in commutator end housing. Install brushes and springs. Ensure field winding brush leads do not contact yoke.
6. Slide commutator end housing into position and secure with nuts and washers or screws, as necessary. Install drive end housing. Install shims onto armature shaft at commutator end to eliminate end play. Install "C" clip in groove.
7. Install bearing cap seal on commutator end housing. Lubricate end of armature shaft with lithium-based grease and install bearing cap. Lubricate plunger hook and place in position over shift fork in drive end housing.
8. Install solenoid body with return spring properly positioned. Tighten retaining screws and field connections.