- Direct Drive Starter
- Lightly lubricate the toothed part of the armature shaft and the rotary support of the engagement lever. Lubricate the bearing and gear.
- Place the tide ring on the armature shaft with the larger side facing out.
- Insert a stop ring into the groove of the armature shaft and clamp the shaft with the ring in a vice. Clamp and release the vice again, turn the shaft and repeat the process until the ring fits into the groove around the entire circle (Pic. 284).
Pic. 284. After installing the retaining ring, press it into the groove in a vice
- Place the anchor with the shaft and use a screwdriver to push the tide ring down onto the retaining ring. Make sure that the tide ring fits around the retaining ring.
- Right (Pic. 274) install the switch lever.
- Insert the rubber seal into the starter housing.
- Place the brush holder on the armature shaft, use a piece of wire to pull out the brush springs and push the brushes into the brush holder. Release the springs and check that they fit well on the brushes.
- After screwing the collector bearing shield, take into account the play determined during disassembly and, if it is more than 0.10 mm, insert a compensation washer 0.5 mm thick.
- Fill the inside of the cap with grease and screw it on.
- After assembly, connect the 12 V battery in accordance with Figure 285 and 1, measure the gap between the surface of the drive gear and the drive bearing shield (Pic. 286). If it goes beyond 0.1 mm to 4.0 mm, loosen the nut of the traction relay pusher rod (To do this, remove the traction relay again) and move the pusher. If the gap is too large, the pusher is screwed in; if the gap is too small, the pusher is turned out. If you have an ammeter, you can run the starter without a load. The device readings provide information about whether the starter is working with a given amperage and, in addition, whether it turns on normally (gear jumps out). Connect the device in accordance with Figure 287. The current should be 50 A.
Pic. 285. Connecting the starter when checking the backlash of the drive gear
Pic. 286. Measuring the distance between the surface of the drive gear and the drive bearing shield
Pic. 287. Starter connection diagram when checking operation
Starter with gearbox
- Lubricate the bearings and gears of the gearbox with heat-resistant grease before assembly.
- Insert the armature into the starter housing.
- Install the brush holder. Use a screwdriver to lift the brush springs and insert four brushes into the brush holder. Release the springs on the brushes. Screw the brush wires to the terminals. Do not allow the positive brush wires to come into contact with ground.
- Secure the cover with two bolts. Install an O-ring on a 1.4 kW starter.
- Lubricate the steel ball and insert it into the shaft hole.
- Install the freewheel and gears. Their location is shown in Figures 288 and 289. First, lubricate the return spring and insert it into the hole in the traction relay. Install the idler gear and bearing on a 1.0 kW starter or the idler gear, bearing and second gear on a 1.4 kW starter.
Pic. 288. gear with starter bearing 1.0 kW 1. Reduction gear; 2. Bearing.
Pic. 289. gear with starter bearing 1.2 kW 1. Intermediate gear; 2. Bearing; 3. Fuse drive gear
- Connect the starter housing and the traction relay and tighten the two bolts.
- The rest of the work is done in reverse order. In this case, use Figure 277.