Disassembly
Loosen the nut on the lower contact bolt of the traction relay and disconnect the stator winding terminal from it. Loosen the nuts securing the traction relay and remove it. Loosen the screw securing the clamping protective tape on the cover 10 (see fig. 235) from the collector side and remove tape 9 with the gasket. Unscrew the screws securing the brush terminals and remove the latter. For starter 35.3708, remove the lock washer from the rear end of the shaft.
Unscrew the nuts of the tie rods 15, unscrew the rods and remove the cover 1 on the drive side together with the anchor 16. Disconnect the cover 10 on the collector 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 remove the drive from the anchor, remove the retaining ring from under the stop ring 34 (see fig. 232). The drive is disassembled after removing the retaining ring from the coupling hub. After disassembling, blow the parts with compressed air and wipe.
Technical condition check and repair
Anchor
Check with a megohmmeter or a lamp powered by 220 V to see if the armature winding is shorted to ground. Voltage is supplied through the lamp to the collector plates and to the armature core. The megohmmeter should not show a resistance of less than 10 kOhm. Replace the armature that has a short to ground.
Use a special device to check whether there are short circuits between the armature winding sections or the collector plates, and whether there are breaks where the winding section leads are soldered to the collector plates.
Inspect the working surface of the collector and check its runout relative to the shaft journals. Clean the contaminated or burnt surface with sandpaper of 10-M40 grain. If the surface damage is significant or its runout is greater than 0.06 mm, turn the collector on a lathe, removing as little metal as possible. The minimum diameter to which the collector can be turned is 36 mm. After turning, grind the collector with fine-grained sandpaper.
Check the runout of the core relative to the shaft journals. If it is more than 0.8 mm, replace the anchor. Check the condition of the surfaces of the splines and journals of the anchor shaft. They should not have visible burrs, nicks or wear. If yellow marks from the gear bushing appear on the shaft surface, remove them with 10-M40 grit sandpaper.
Drive
There should be no chips or crumbling on the gear teeth. If there are nicks on the entry part of the teeth, grind them off with a small diameter grinding wheel with a grain size of 10-16. The gear should easily rotate relative to the clutch hub, but only in the direction of rotation of the anchor when starting the engine. If the drive parts are damaged or significantly worn, replace the drive with a new one.
Stator
Check with a megohmmeter or a lamp powered by 220 V to see if the stator winding is shorted to ground. The voltage is supplied through the lamp to the common terminal of the winding and to the starter housing. If the lamp lights up or the megohmmeter shows a resistance of less than 10 kOhm, and also if the winding shows signs of overheating (blackening of insulation), replace the winding.
To replace the stator winding coils, remove the poles. Before removing the poles, make marks on the body and poles so that they can be put back in their original position during assembly. It is recommended to heat the winding to about 50°C before installation to make it flexible and make it easier to lay on the poles. Tighten the poles with screws until they stop so that the air gap between the anchor and the poles is maintained at the original dimensions - 0.38 mm when checked with a feeler gauge.
After assembly, check the internal diameter between the poles, which should be 67.80-67.97 mm. In addition, use a 0 67.66 mm plug gauge to check the concentricity of the housing and poles. The gauge should freely enter and rotate between the poles when seated on the inner surface of the housing. If this does not happen, repeat the assembly. Boring of the poles is not allowed.
Lids
Check for cracks on the caps. If there are any, replace the caps with new ones. Check the condition of the cap bushings. If they are worn, replace the caps as a whole or just the bushings. After pressing in, unfold the new bushings to about 12.015+0,015 mm. To replace the bushing in the cover on the manifold side, first remove the plug, and after pressing the bushing, install the plug in place and punch it at three points.
Check the reliability of the brush holders fastening on the cover from the collector side. The brush holders of the positive brushes must not have a short circuit with the ground.
Traction relay
Check the ease of movement of the relay anchor and the condition of the contacts. If the contacts are burnt, clean them with sandpaper or a flat velvet file. If the contact bolts are significantly damaged at the point of contact with the contact plate, they can be turned 180°.
Check the resistance of the relay winding, the reliability of the connection of its terminals with the "50" plug and ground, as well as the absence of traces of winding overheating. Replace the damaged relay with a new one.
Assembling the starter
Before assembly, lubricate the helical splines of the armature shaft and the overrunning clutch hub, the bushings of both covers and the gear with engine oil, and lubricate the drive ring with Litol-24 consistent grease.
Before assembly, check the axial free play of the anchor shaft by first assembling the covers and anchor together and tightening the nuts of the tie rods. In this case, the anchor may be without a drive, and the cover 1 (see fig. 235) — without a lever. The axial free play of the shaft should be within 0.07-0.7 mm. The change in the free play value is achieved by selecting the number and thickness of the adjusting washers 20. In the starter 35.3708, the adjusting washers are located on both sides of the cover 10 on the collector side.
Having selected the adjusting washers, proceed to assembly, which is performed in the reverse order of disassembly. After assembly, check the starter on the stand.