7.4.3. Repair

You carry out dismantling of a starter in the following order:

Fig. 279. Starter 42.3708: 1 – a cover from the drive; 2 – flood ring; 3 – persistent ring; 4 – castle ring; 5 – drive; 6 – anchor; 7 – case; 8 – brush; 9 – traverse; 10 – persistent washer; 11 – adjusting washer; 12 – lock washer; 13 – a cover from a collector; 14 – contact bolt; 15 – contact plate; 16 – relay cover; 17 – returnable spring; 18 – rod; 19 – relay anchor; 20 – the compensating spring; 21 – buffer spring;
22 – gear wheel; 23 – M5x14 screw; 24 – nut of a coupling hairpin; 25 – M6x16 screw; 26 – M8 nut; 27 – input of coils of the relay; 28 – M6x30 screw; 29 – lever; 30 – M8 nut; 31 – lever axis


1. Turn off a nut 26 (see fig. 279) and disconnect a conclusion from a contact bolt 14.
2. Unscrew screws 28 of fastening of the traction relay to a cover from the drive and remove the relay.
3. Turn off nuts 24 on coupling hairpins.
4. Unscrew two screws 25 and take off a cap.
5. Remove lock 12 and adjusting the 11th washers.
6. Uncover 13 from a collector.
7. Take out brushes 8 of brush holders and remove to a traverse 9.
8. Remove the case 7.
9. Turn off a nut, the fixing lever axis, turn out an axis of the lever 31 and take out the lever 29.
10. Take out an anchor 6 with the drive assembled from a cover from the drive.
11. Remove a persistent ring 3 to the left, remove a castle ring 4, and then a persistent ring and the drive 5 from a shaft.
12. For survey of contacts of the traction relay unscrew two screws 23, unsolder two inputs 27 and uncover 16 relays.
Carefully clear details of dirt. Examine and check details and knots of a starter. Replace the damaged details.
 Case. By means of the special device or a control lamp about-verte whether there is no short circuit of coils of a winding of excitement on the case.

Fig. 281. Check of short circuit of coils of a winding of excitement on the case


When checking by a control lamp connect it to the case and a conclusion located on the case (fig. 281). If the lamp burns, then it indicates damage of isolation of coils of a winding of excitement. In this case number poles of coils, unscrew screws of fastening of poles and remove excitement winding coils. Wind the damaged places of isolation with an insulating tape. After this pole and the coil establish into place. Screws of poles zakernite.

Fig. 282. Check of short circuit of the isolated brush holders on the case


 Cover from the party of a collector. By means of the special device or a control lamp check whether there is no short circuit of the isolated brush holders traverses on the case (fig. 282). In case of short circuit replace insulating laying and the plug of rivets of the brush holder. Brushes in brush holders have to move freely, without jamming. Check a condition of the plug of the bearing in a cover and in case of wear replace. Diameter of an opening of the new plug after a press fitting and development has to be 12,5+0,035 mm with a surface roughness on the 8th class. With a height of brushes less than 6-7 mm replace them.
 Cover from the party of the drive. Pro-verte a condition of the plug (bearing) in a cover and in case of wear replace the plug. Diameter of an opening of the new plug after a press fitting and development has to be 12,5+0,035 mm with a surface roughness on the 8th class.

Fig. 283. Check of short circuit of a winding of a rotor on a rotor iron package


 Rotor. Check by means of the special device or a control lamp whether there is no short circuit of a winding of a rotor on "weight". For this purpose connect one end to any of rotor lamels, and another – to a rotor iron package. Thus the lamp should not burn (fig. 283).
Attentively examine a rotor. The Pe-redny part of a winding of a rotor on diameter has to be less package of iron. The increased diameter of a forward part of a winding indicates winding "rating". Replace such rotor. The ends of wires of windings have to be reliably soldered to collector plugs.
Check whether there are no short circuits between rotor rounds. In case of detection of short circuit replace a rotor.
 The collector of a rotor has to be pure. In case of a considerable roughness of a collector or a vystupaniye of mica pierce it on the turning or special machine. After protochki grind a collector a glass skin granularity 100 to a surface roughness on the 7th class.
The collector beating concerning pins of a shaft should not exceed 0,05 mm.
The rotor iron package beating concerning pins of a shaft should not exceed 0,25 mm. At the same time check whether there is no shaft deflection as the deflection can be the reason of jamming of the drive on a shlitsevy part of a shaft. If on a rotor shaft in that place where the starter gear wheel rotates, the yellow raid from the bearing is found, then it should be removed with a small skin. Existence of a yellow raid often leads to jamming of a gear wheel on a shaft after launch of the engine and to rotor winding shift.
 Drive. Examine the starter drive outside and check whether is not present probuksovki. The drive has to freely, without jammings to move by a shlitsevy part of a shaft. At strong wear of plugs (bearings) of the drive replace them.
At deduction of a rotor the gear wheel has to rotate freely clockwise to an arrow. Against an hour arrow the gear wheel has to rotate only together with a rotor. On probuksovku you carry out an inspection of the coupling of a free wheeling at the stand at test of a starter for full braking.
 Traction relay. Serviceability of the involving and holding windings about-veryayte measurement of resistance by means of an ohmmeter or use of the voltmeter and ampermeter. In case of malfunction of windings replace the traction relay. Smooth out contacts on klemmovy bolts, and at their strong burning out turn bolts on 180 ° around an axis. At strong wear of a contact disk turn it not worn-out party to contacts.
 The anchor of the traction relay has to move freely in the case.
You carry out assembly of a starter in an order, the return to dismantling, taking into account the following:
1. Grease before assembly bearings, pins and a shlitsevy part of a shaft motor oil.
2. Collect starter rotor knot for what put on a shaft of a rotor the intermediate bearing, the drive 5 (see fig. 279) and the persistent knot consisting from persistent 3 and castle 4 rings. Apply a mandrel to convenience of installation of a castle ring.
3. Establish on a rotor from the party of a collector a persistent washer 10.
4. At a final inhaling of nuts of coupling hairpins of the case combine pins and grooves on covers and the case.
5. Check the size of an axial gap of a rotor which has to be about 0,8 mm.
After assembly check and adjust a starter.

Adjustment of a starter

Fig. 284. Scheme of adjustment of provision of a gear wheel of the drive of a starter: 1 – a conclusion to the relay; 2 – a conclusion to the rechargeable battery; 3 – axis eccentric drive lever


Installation of a gear wheel in the switched-off situation has to be such that the size from privalochnoy the starter flange planes to an end face of a gear wheel was no more than 34 mm (fig. 284). Check a full speed of a gear wheel at the switched-on traction relay. The distance between an end face of a gear wheel and an emphasis has to be (4±1) mm. This gap adjust turn of an eccentric axis 3 levers of turning on of the drive.
After adjustment tighten an axis nut.

Control check of a starter
Are necessary for check of a starter the low-voltage unit (or completely charged battery), the voltmeter of a direct current with a scale from 0 to 30 V, the ampermeter of a direct current with the shunt to 1000 A, a tachometer with a scale to 10 000 min.-1 and a dynamometer.
The scheme of inclusion of a starter for check is shown in fig. 285. You carry out an inspection at the special stand. At lack of the special stand strengthen a starter in a vice and connect it to the accumulator battery (a clip of a starter connect via the ampermeter with positive, and the starter case – to the negative plug of the battery). Apply wires with cross-sectional area to connection of a starter with the battery not less than 25-35 mm2. Idling measure the current and frequency of rotation of a rotor at test through 30 from later inclusion of a starter.
The starter is considered sustained test if at a voltage of 12 V it consumes current no more than 75 And yes not less than 5000 min.-1 develop rotation frequency.
At hard rotation of a rotor which usually is caused by distortions in result of the wrong assembly of a starter or a rotor zadevaniye for poles and also at short circuit of a winding of a rotor on "weight" or at mezhvitkovy short circuit of a winding of a rotor the starter consumes current of bigger force, and the frequency of rotation of a rotor is less than specified. The small consumed current and the lowered rotation frequency at a normal tension on clips of a starter demonstrate bad contact in connections of wires or weak pressing of springs brushes.

Fig. 285. The scheme of inclusion of a starter for check: 1 – lever; 2 – dynamometer; 3 – starter; 4 – traction relay of a starter; 5 – switch;
6 – voltmeter; 7 – ampermeter; 8 – ampermeter shunt; 9 – accumulator battery


For check of a starter at full braking fix on a drive gear wheel the lever 1 (see fig. 285) connected to a dynamometer 2 (the hydraulic dynamometer is more preferable). The brake moment is determined by a formula M=PL,
where M – the brake moment, N · m (kgf · l);
      P – indication of a dynamometer, N (kgf);
     L – length of the lever, m.
In order to avoid a starter overheat you carry out test during short time. If at the slowed-down gear wheel the rotor rotates, replace the drive.

Note
When conducting this check observe care as at the time of inclusion of a starter there will be a strong breakthrough of the lever strengthened on a gear wheel.

The serviceable starter when using of completely charged battery consumes current no more than 520 And at a voltage no more than 7 V and develops the moment equal to about 15,7 N · m (1,6 kgfs · м). If the consumed current more than 520 And, and the brake moment less than 15,7 N · m (1,6 kgfs · l), it indicates malfunction of a winding of a ro-tor or winding of excitement. If the size of the brake moment and force of the consumed current of less normal, then it (at a normal tension on starter clips) indicates bad contacts in a starter or weak pressing of springs brushes. Tension on starter clips indicates less than 7 V bad contacts in wires or on malfunction of the battery.
The additional relay of a starter in operation of special service does not demand.

Fig. 286. The scheme of turning on of the additional relay of a starter for check and adjustment:
1 – accumulator battery; 2 – rheostat;
3 – control lamp; 4 – additional relay of a starter; 5 – switch; 6 – voltmeter; "30", "85", "86", "87", "87B" – relay conclusions


You carry out an inspection of the relay according to the scheme specified fig. 286. Smooth movement of a cursor of a rheostat 2 increase tension until turning on of the relay 4 (thus the control lamp 3 lights up).
Moving of a cursor to the opposite party reduce tension until switching off of the relay (the lamp dies away). The relay is considered serviceable if it turns on at a voltage of 5,5-8,5 V, and switching off at a voltage of 2-4,5 V.
The gap between an anchor and the core at the closed contacts has to be not less than 0,15 mm, and a gap between contacts in the opened state – not less than 1,0 mm.