Execution order
1. Clean all starter parts.
2. Check the condition of the stator winding. Apply alternating current of 220 V to one contact of the test 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 terminals of the stator winding. The lamp should not light.
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. Inspect the anchor. If the commutator is dirty or has marks, scratches, etc., polish the commutator with fine glass paper. If the commutator is significantly rough or mica protrudes between its plates, turn the commutator on a lathe and then polish it with fine glass paper.
6. The minimum permissible diameter of the collector for the EF 12V 095 kW starter is 33.6 mm, for the DW 12V 1.1 kW starter – 31.2 mm. If the diameter of the collector is less than specified as a result of turning, replace the anchor. The maximum permissible runout of the collector relative to the shaft journals is 0.03 mm.
7. If you find yellow deposits from the bearing on the armature shaft, remove them with fine sandpaper, as this may cause the gear to jam on the shaft.
8. Check the reliability of the soldering of the anchor winding terminals to the collector plates. Inspect the winding at the ends of the anchor, the winding diameter should be less than the anchor iron package, otherwise replace the anchor.
9. Check the condition of the anchor winding using a lamp. Apply alternating current of 220 V to one contact of the lamp.
10. Connect the other contact of the lamp to the body. Connect the second wire from the current source to the collector plate and the anchor core. The lamp should not burn.
11. If the lamp lights up, then there is a short circuit in the anchor winding or the collector plate to ground. In this case, replace the anchor.
12. Place the starter drive on the armature shaft; it should move freely along the armature shaft splines without jamming. Holding the armature, turn the starter gear in both directions. The gear should rotate freely clockwise, but should not rotate counterclockwise. Otherwise, replace the drive.
13. The traction relay anchor must move freely in the housing, without jamming. Inspect the contact bolts. Clean the burnt bolt heads with fine sandpaper.
14. If the heads are heavily burnt, turn the bolts 180° so that they are pressed against the contact disk with the unburnt side. If the surface of the contact disk is heavily 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 brush holders, the holders should not dangle. The holders of insulated brushes should not short-circuit to "ground" (check with a test lamp).
17. The ends of the springs must press on the middle of the brush. Brushes worn to a height of 11.5 mm in the EF 12V 095 kW starter and 8.0 mm in the DW 12V 1.1 kW starter must be replaced.
18. Inspect the starter covers. If cracks are found on them, the covers must be replaced. If the bushings in the covers on which the anchor shaft rotates are worn or have burrs, cavities, etc., replace the covers with defective bushings.
19. Inspect the gearbox of the DW 12V 1.1 kW starter. If the gear teeth are worn or broken or the gearbox makes noise during operation, it must be replaced.
The original version of the article is posted on the website AUDImanual.ru