Disassembly
Unscrew the nut on the lower contact bolt of the traction relay and disconnect the stator winding output from it. Turn away nuts of fastening of the traction relay and remove it. Loosen the screw that secures the clamping protective tape on the cover 10 (see fig. 235) from the collector side and remove the tape 9 with the gasket. Turn out screws of fastening of conclusions of brushes and remove the last. Starter 35.3708 remove the lock washer from the rear end of the shaft.
Unscrew the nuts of the tie rods 15, unscrew the studs and remove the cover 1 from the drive side together with the armature 16. Disconnect the cover 10 from the manifold side from the housing. Remove the rubber plug 2 of the lever from the cover 1, unpin and remove the axle of the lever 3 of the starter drive; remove the lever and anchor from the cover.
To disarm the drive, remove the circlip from under the stop ring 34 (see fig. 232). The drive is disassembled after removing the retaining ring from the coupling hub. After disassembly, blow the parts with compressed air and wipe clean.
Checking the technical condition and repair
Anchor
Check with a megger or with a lamp powered by 220 V for a short circuit of the armature winding to ground. Voltage through the lamp is supplied to the collector plates and to the armature core. The megohmmeter should not show resistance less than 10 kOhm. Replace the anchor that has a short to ground.
Using a special device, check for short circuits between the armature winding sections or collector plates, and for breaks at the soldering point of the winding section leads to the collector plates.
Inspect the working surface of the collector and check its runout relative to the shaft trunnions. Clean the contaminated or burnt surface with sandpaper, grit size 10-M40. If the surface damage is significant or the runout is greater than 0.06 mm, turn the manifold on a lathe, removing as little metal as possible. The minimum diameter to which the collector can be machined is 36 mm. After the groove, the collector is polished with a fine-grained sandpaper.
Check core runout against shaft trunnions. If it is more than 0.8 mm, replace the anchor. Check the condition of the surfaces of the splines and trunnions of the armature shaft. They should not be visible scoring, nicks and wear. If there are yellow marks from the gear bushing on the surface of the shaft, remove them with sanding paper, grit 10-M40.
Drive unit
There should be no chips or chips on the gear teeth. If there are nicks on the lead-in of the teeth, then grind them off with a grinding wheel of small diameter and grit 10-16. The gear should turn easily relative to the clutch hub, but only in the direction of rotation of the armature when starting the engine. If the drive parts are damaged or significantly worn, replace the drive with a new one.
Stator
Check with a megger or with a lamp powered by 220 V for a short to ground in the stator winding. The voltage through the lamp is supplied to the common terminal of the winding and to the starter housing. If the lamp is on or the megger shows a resistance of less than 10 kOhm, and also if the winding has signs of overheating (insulation blackening), replace the winding.
To replace the stator winding coils, remove the poles. Before removing the poles, make marks on the body and poles in order to put them in their original position during assembly. It is recommended to preheat the winding to about 50°C before installation in order to make it flexible and to facilitate laying on the poles. Tighten the poles with screws to failure so that the air gap between the armature and the poles is maintained in the original dimensions - 0.38 mm when checking with a probe.
Upon completion of assembly, check the inner diameter between the poles, which should be 67.80-67.97 mm. In addition, check the concentricity of the body and poles with a plug gauge Ø 67.66 mm. The gauge must freely enter and rotate between the poles when landing on the inner surface of the housing. If this does not happen, then repeat the assembly. Pole boring is not allowed.
Lids
Check the covers for cracks. If there are, replace the caps with new ones. Check the condition of the cover bushings. If worn, replace cap assemblies or bushings only. New bushings after pressing, expand to about 12.015+0,015 mm. To replace the bushing in the cover on the collector side, first remove the plug, and after pressing the bushing, put the plug back in place and drill out at three points.
Check the reliability of the fastening of the brush holders on the cover from the side of the collector. Brush holders of positive brushes must not have a short circuit with ground.
Traction relay
Check the ease of movement of the relay armature and the condition of the contacts. If the contacts are burnt, clean them with sandpaper or a flat velvet file. In case of significant damage to the contact bolts at the point of contact with the contact plate, they can be turned by 180°.
Check the resistance of the relay winding, the reliability of the connection of its terminals with the plug «50» and mass, as well as the absence of traces of overheating of the winding. Replace the damaged relay with a new one.
Starter Assembly
Before assembly, lubricate the screw splines of the armature shaft and the overrunning clutch hubs, the bushings of both covers and the gear with engine oil, and lubricate the driving ring of the drive with Litol-24 grease.
Prior to assembly, check the axial free play of the armature shaft by first assembling the caps and armature together and tightening the tie rod nuts. In this case, the anchor can be without a drive, and the cover 1 (see fig. 235) - no lever. The axial free play of the shaft should be within 0.07-0.7 mm. Changing the amount of free play is achieved by selecting the number and thickness of shims 20. Starter 35.3708 has shims located on both sides of the cover 10 on the manifold side.
Having picked up the adjusting washers, proceed with the assembly, which is performed in the reverse order of disassembly. After assembly, check the starter on the stand.