10.5.4. Repair of a starter

Fig. 10.4. Details of a starter 2111.3708010-01: 1 – case; 2 – a persistent ring from a collector; 3 – anchor; 4 – permanent magnet; 5 – nut of fastening of the tire of brushes of positive polarity; 6 – traction relay; 7 – drive lever; 8 – sealing ring; 9 – coupling of a free wheeling; 10 – returnable spring; 11 – nut of a coupling hairpin; 12 – relay anchor; 13 – coupling hairpin; 14 – sealant; 15 – lever support; 16 – lever axis; 17 – screws of fastening of the traction relay; 18 – forward cover; 19 – lock ring; 20 – restrictive ring; 21 – insulator; 22 – internal brush holder; 23 – a persistent ring from the drive; 24 – "positive" brush; 25 – clamping spring; 26 – external brush holder; 27 – internal remote washers; 28 – a back cover with the plug; 29 – external remote washers; 30 – lock washer; 31 – bolt of fastening of the tire of brushes of negative polarity; 32 – anchor shaft cover; 33 – bolt of fastening of a cover of a shaft of an anchor

In fig. 10.4 starter details are shown. Before dismantling of a starter be convinced of its malfunction by the following simple checks.
1. By means of the screw-driver check ease of movement of the coupling of the drive along a shaft.
2. Turn a drive gear wheel. It has to be turned easily concerning a coupling nave in the direction of rotation of an anchor and should not be turned in an opposite direction.
3. Connect wires for "prikurivaniye" the minus plug of the rechargeable battery removed from the car to the starter case. Connect the second wire one end to the plus plug of the rechargeable battery, and the second — to a conclusion of the operating wire of the traction relay. If the traction relay is serviceable, then the click will sound and the drive coupling will start. Otherwise the traction relay is subject to replacement.
4. Disconnect a wire from the operating conclusion of the traction relay and connect to the lower contact bolt of the traction relay. The anchor of a starter has to begin to rotate with a frequency more than 5000 min.-1. Otherwise repair a starter.

It will be required to you: keys "on 8", "on 10", "on 13", the screw-driver with a flat edge, passatizh with narrow sponges, the hammer, a tester, a caliper.
1. Remove a starter from the car (see. "Removal and installation of a starter").
2. Turn off a nut of fastening of the tire to a contact bolt.
3. Disconnect the tire from a contact bolt of the traction relay.
4. Turn out two screws of fastening of the traction relay...
5.... also remove the relay.
6. Take out an anchor of the traction relay, having raised it that the loop of an anchor was removed from the lever.
7. Remove a sealing ring from the case of the traction relay...

Replace the ring which is strongly pressed out, cracked or lost elasticity new.

8.... also take a returnable spring.
9. Turn out two screws...
10.... also uncover an anchor shaft...
11.... lock washer...
12.... and remote washers.

Remember an order of installation of remote washers as they different thickness. At assembly of a starter establish washers in the same sequence.

13. Turn out two nuts of coupling hairpins...
14.... also uncover with a shaft an anchor a starter from a collector.
15. Remove two remote washers...
16.... and external brush holder.
17. Turn out a nut of fastening of brushes of negative polarity...
18.... and it is careful not to damage a brush, remove them together with clamping springs. Replace strongly pressed out or bent springs.
19. Similarly take brushes of positive polarity.

Measure height of brushes from edge of a working surface to a copper braid of wires.
If their height makes less than 4 mm, replace brushes with a set (4 pieces).

20. Remove the paper insulator of brushes of positive polarity...
21.... and internal brush holder.
22. Take out from the starter case a rotor with magnets and a forward cover.
23. Remove a persistent ring of magnets from a collector.
24. Turn out a lever axis, previously having turned off a lock-nut on the other hand...
25.... also remove an axis.
26. Uncover the party of the drive.
27. Examine starter covers, at detection of cracks replace them. If the plugs located in covers in which the anchor shaft rotates are worn-out, teases, sinks and other defects have, replace plugs or covers with defective plugs...
28.... previously having turned out coupling hairpins from a cover from the drive.
29. Remove a lever support.
30. Burst or considerably replace a worn-out support new.
31. Remove six magnets from an anchor, previously having marked or having remembered their relative positioning.

The wrong installation of magnets can lead to deceleration of power of a starter or its rotation in the opposite direction.

32. Remove a persistent ring of magnets from the drive.
33. Having established a drive shaft on wooden whetstone, accurate blows of the hammer shift on an anchor shaft a restrictive ring, as shown in a photo.
34. Having hooked the screw-driver...
35.... remove a lock ring...
36.... then restrictive ring...
37.... also remove from an anchor shaft the obgonny coupling assembled with the lever.
38. Examine an anchor. If the collector is polluted or on it risks, scratches and other defects, the collector's proshlifuyta a fine-grained skin appeared. At a considerable roughness of a collector or a vystupaniya of mica between its plates pierce a collector on the lathe and then a proshlifuyta a fine-grained glass skin. The collector beating concerning pins of a shaft should not exceed 0,05 mm. Remove the yellow raid found on an anchor shaft from the bearing with a fine-grained skin as it can become the reason of jamming of a gear wheel on a shaft. Check reliability of the soldering of conclusions of a winding of an anchor to collector plates. Examine a winding on anchor end faces. Diameter of a winding has to be less package of iron of an anchor. Otherwise replace an anchor.
39. Examine a condition of shlitsevy connection of a shaft of an anchor on absence of damage in a look забоин and roughnesses. Whenever possible remove insignificant damages with a fine-grained skin.
40. Check a condition of a winding of an anchor by means of the control lamp fed of 12 V. You bring tension to a plate of a collector and the core of an anchor — the lamp should not burn. If the lamp burns, so there is a short circuit of a winding of an anchor or plate of a collector on "weight". In this case replace an anchor.
41. Check whether the anchor of the traction relay of a starter easily moves, whether contact bolts a contact plate become isolated (by means of a tester).
42. Check the drive. Teeths of a gear wheel of the drive should not have considerable wear. The gear wheel has to be turned easily concerning a coupling nave in the direction of rotation of an anchor and should not be turned in an opposite direction. If teeths of a gear wheel are worn-out or damaged or the gear wheel is turned in both directions, replace the drive. On the lever of the drive of a starter there should not be cracks.
43. Collect a starter in the sequence, the return dismantling, taking into account the following features:
– grease a shlitsevy surface of a shaft of an anchor with siliceous General Electric CG321 lubricant or similar;

In use the coupling of the drive does not need to be greased. However it is necessary to clear it of dirt. Do not apply to cleaning of the drive of means which can wash up the lubricant put in its coupling.

– oil engine bearings (plugs) in starter covers;
– for installation of a restrictive ring use passatizha;
– before installation of the traction relay apply on its surface contacting to a starter cover from the drive, a thin layer of silicone sealant.
44. After assembly of a starter turn on the traction relay (see item 3) and measure a gap between an end face of a gear wheel and a persistent ring, it has to be 3–5 mm.
45. If the gap does not enter the specified interval of values, adjust its turn axes of the lever which body is executed in the form of the clown. For this purpose weaken a lock-nut, turn an axis and tighten a lock-nut. After final assembly it is recommended to check a starter for HUNDRED at the stand of fashion. 532M.