Order of execution
1. Clean all starter parts.
2. Check the condition of the stator winding. Apply 220 V alternating current to one contact of the control lamp.
3. Connect the other contact of the lamp to the stator housing. Connect the second wire from the current source to one of the stator winding terminals. In this case, the lamp should not light up.
4. If the lamp is on, the winding insulation is damaged. In this case, replace the winding or stator. Also check the second winding.
5. Examine the anchor. If the collector is dirty or there are marks, scratches, etc. on it, sand the collector with fine glass sand. With a significant roughness of the collector or protrusion of mica between its plates, machine the collector on a lathe and then grind it with fine glass sandpaper.
6. The minimum allowable collector diameter for the EF 12V 095kW starter is 33.6 mm, for the DW 12V 1.1kW starter it is 31.2 mm. If as a result of turning the diameter of the collector is less than the specified one, replace the anchor. The maximum allowable runout of the collector relative to the pins of the shaft is 0.03 mm.
7. If a yellow coating from the bearing is found on the armature shaft, remove it with fine sandpaper, as this can lead to gear seizing on the shaft.
8. Check the reliability of the soldering of the armature winding leads to the collector plates. Inspect the winding at the ends of the armature, the diameter of the winding should be less than the iron package of the armature, otherwise the armature should be replaced.
9. Check the condition of the armature winding with a lamp. Apply 220 V alternating current to one contact of the lamp.
10. Connect the other contact of the lamp to the housing. Connect the second wire from the current source to the collector plate and armature core. The lamp should not light up.
11. If the lamp is on, then there is a short circuit in the armature winding or collector plate on «mass». In this case, replace the anchor.
12. Put the starter drive on the armature shaft, it should move freely, without jamming, along the splines of the armature shaft. While holding the anchor, turn the starter gear in both directions. Clockwise, the gear should rotate freely, and counterclockwise, it should not rotate. Otherwise, replace the drive.
13. The armature of the traction relay must move freely in the housing, without jamming. Check contact bolts. Clean the burnt heads of the bolts with a fine sandpaper.
14. In case of severe burn-out of the heads, turn the bolts by 180°so that they are pressed against the contact disk with the unburned side. If the surface of the contact disk is badly worn, it can be turned with the unworn side towards the contact bolts.
15. Check the movement of the brushes in the brush holder. They should move easily, without jamming.
16. Check the reliability of the fastening of the brush holders, the holders should not dangle. Holders of insulated brushes must not be shorted to «mass» (check with test light).
17. The ends of the springs should press on the middle of the brush. Replace brushes worn to a height of 11.5 mm in the EF 12V 095kW starter and 8.0 mm in the DW 12V 1.1kW starter.
18. Inspect starter covers. If cracks are found on them, the covers must be replaced. If the bushings in the covers, on which the armature shaft rotates, are worn out or they have scuffs, shells, etc., replace the covers with defective bushings.
19. At the starter DW 12V 1.1kW, inspect the gearbox. If the gear teeth are worn or broken or the gearbox makes noise during operation, it must be replaced.
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