Pic. 7.53. starter mount
Adjusting the axial clearance of the drive gear
Disconnect the stator winding wire from the terminal «M» traction relay.
Pic. 7.54. Scheme for adjusting the axial clearance of the drive gear
Connect the wires from the 12V battery terminals (through the switch) to conclusions «S» (+) And «M» (–) traction relay (pic. 7.54).
Set the switch to position «On», while the starter drive gear will move forward until it stops.
Attention! This check must be carried out quickly, no more than 10 s, to prevent burnout of the starter winding.
Pic. 7.55. Checking the axial clearance of the drive gear
Using a feeler gauge, measure the axial clearance between the pinion gear and the restrictor ring. If the axial clearance does not correspond to the range of nominal values, then adjust it by installing or removing shims between the traction relay and the starter front bracket (pic. 7.55).
Nominal clearance: 0.5–2.0 mm.
Pic. 7.56. Installing a traction relay
If the axial clearance is not correct, then adjust it by installing or removing shims between the traction relay and the starter front bracket (pic. 7.56).
Checking the retracting winding of the traction relay
Disconnect the stator winding wire from the terminal «M» traction relay.
Pic. 7.57. Scheme for checking the retracting winding of the traction relay
Connect the wires from the 12 V battery terminals to the terminals «S» (+) And «M» (–) traction relay (pic. 7.57).
Attention! This check must be carried out quickly, no more than 10 s, to prevent burnout of the starter winding.
If the drive gear extends, then the retractor winding of the traction relay is working. If the drive gear does not extend, then replace the traction relay.
Checking the holding winding of the traction relay
Disconnect the stator winding wire from the terminal «M» traction relay.
Pic. 7.58. Scheme for checking the holding winding of the traction relay
Connect the wires from the 12 V battery terminals to the terminal «S» (+) and starter housing (pic. 7.58).
Attention! This check must be carried out quickly, no more than 10 s, to prevent burnout of the starter winding.
If the pinion gear, extended manually to the stop, remains in the extended position, then the holding winding is in good condition. If the gear retracts, then there is a break in the holding winding. In this case, replace the traction relay.
Checking the return of the armature of the traction relay
Disconnect the stator winding wire from the terminal «M» traction relay.
Pic. 7.59. Traction relay armature return test circuit
Connect the wires from the 12 V battery terminals to the terminal «M» and starter housing (pic. 7.59).
Attention! This check must be carried out quickly, no more than 10 s, to prevent burnout of the starter winding.
Extend the drive gear by hand and release. If the drive gear immediately returns to its original position, then the traction relay is working properly. If not, replace the traction relay.
Idle test
Pic. 7.60. Assembly diagram of an unloaded circuit for testing a starter in idle mode
Assemble the unloaded test circuit as shown in Figure 7.60.
Adjust the battery voltage with a rheostat so that the voltmeter shows a value of 11.5 V. Make sure that the maximum current consumption corresponds to the nominal value, and also that the starter armature rotates freely, without jerking or jamming.
Rated current: 60A or less.
Checking the power transistor
Pic. 7.61. Measuring the beat of a power transistor
Lay the starter anchor in the measuring prisms. Measure the beat of the power transistor (pic. 7.61).
Starter armature beating.
Nominal value: 0.05 mm.
Limit value: 0.1 mm.
Pic. 7.62. Measuring the outside diameter of a power transistor
Measure outer diameter (pic. 7.62).
Power transistor diameter:
- Nominal value: 29.4 mm.
- Limit value: 28.4 mm.
Pic. 7.63. Measuring the depth of the undercut between the lamellas of the power transistor
Measure the depth of cut between the lamellas of the power transistor (pic. 7.63).
Cut depth:
- Nominal value: 0.5 mm.
- Limit value: 0.2 mm.
Checking the brush holder
Pic. 7.64. Checking the brush holder
Check for an open circuit between the plate (a plus) brush holder and brush holder (pic. 7.64).
If the circuit is shorted, replace the brush holder assembly.
Overrunning clutch test
Pic. 7.65. Freewheel Drive Gear Check
Rotate the pinion gear while holding the freewheel housing. The gear should rotate smoothly, without binding, in one direction, and not rotate in the opposite direction (pic. 7.65).
Check the condition of the starter gear teeth. If worn or chipped teeth are present, replace the overrunning clutch assembly. Check the condition of the flywheel ring gear (or automatic transmission drive plates).
Bushings front and rear brackets
Assess the condition of the bushings. If worn or scored, replace the appropriate bracket assembly.
Installation of restrictive and retaining rings
Pic. 7.66. Installing the restrictor ring
Install the stop ring first, then the retaining ring on the front end of the starter armature shaft. Slide the restrictor ring onto the circlip as far as it will go (pic. 7.66).
Cleaning starter parts
Do not wash the armature and starter stator with solvent: the insulation of the winding wires may be damaged. Clean only with a dry cloth.
Do not wash the overrunning clutch by immersion in solvent: the clutch contains grease for the entire service life and the solvent can wash out the lubricant.
Clean the overrunning clutch with a brush soaked in solvent, immediately remove excess solvent.
Brush check
Pic. 7.67. Wear limit line
Brushes worn to the wear limit or oily should be replaced (pic. 7.67).
Remove the worn brush, being careful not to break the brush wire.
Sand the end of the brush wire with sandpaper to ensure reliable soldering.
Pic. 7.68. Checking the solder end of the brush wire
Solder the end of the brush wire (pic. 7.68).
Install the brush in place, make sure that the brush is fixed with a spring
Removing the restrictor ring and retaining ring
Pic. 7.69. Freewheel
To remove the overrunning clutch from the starter armature shaft, it is necessary to knock off the restrictive ring from the retaining (pic. 7.69).
Pic. 7.70. Removing the restrictive ring
After removing the retaining ring, the restrictive ring can be removed from the starter armature shaft (pic. 7.70).