+ Maintenance instruction
+ 3. Engine (two top camshafts)
+ cooling System
+ Toplevnaya and exhaust systems
- Electric chain
6.2. General description
6.3. Rules of care of the accumulator
6.4. Accumulator check
6.5. Battery charging
6.6. Storage battery
6.7. System of start-up of the engine
6.8. Diagnostics of malfunctions
6.9. Algorithm of diagnostics of malfunctions
6.10. Traction relay
6.11. Coupling of a free wheeling (MCX)
6.12. Repair of knots of a starter of 5MT and 10МТ
6.14. Diagnostics of malfunctions of the CS-121 generator
6.15. Generator dismantle
6.16. CS-130 generator repair
+ 7. Ignition system
+ 8. Electronic control unit and sensors
+ 10. Five-speed transmission and main RPO MM5 broadcast
+ 11. Automatic Transmission
+ Running gear
+ 14. Forward suspension bracket
+ 15. Drive of forward wheels
+ 16. Back suspension bracket
+ Brake system
+ Heating, ventilation
+ Electric equipment
Starter assembled (longitudinal section)
| 1. DRIVE LEVER
2. ANCHOR OF THE TRACTION RELAY
3. COUPLING OF THE FREE WHEELING
4. RETURNABLE SPRING OF THE ANCHOR
B. ELECTRIC MOTOR anchor
7. GEAR WHEEL EMPHASIS
8. WINDING OF EXCITEMENT OF STATOR
10. CONCLUSIONS OF THE TRACTION RELAY
11. CASE OF THE TRACTION RELAY
12. CONTACT DISK
Dismantling, check and starter assembly
Starter installation on the engine
| AND. CONCLUSIONS FOR FASTENING OF PLUGS OF WIRES
22. BOTTOM BOLT
23. TOP BOLT
Lever of a drive and anchor of the traction relay
Gear wheels and coupling of a free wheeling
|1. ANCHOR SHAFT
2. PERSISTENT WASHER
3. SPRING RING
5. MCX AND GEAR WHEEL ASSEMBLED
6. FIBRE WASHER
7. AVERAGE BEARING
Replacement of a shchetkoderzhatel, standard starter
|1. SHCHETKODERZHATEL (ISOLATED)
3. SHCHETKODERZHATEL'S AXIS
4. SHCHETKODERZHATEL'S ARM
5. SPRING OF THE HOLDER
6. SHCHETKODERZHATEL (NEIZOLIROVANNY)
Replacement of a shchetkoderzhatel, starter of 5MT of smaller capacity
|1. BRUSH HOLDER
2. CASE OF WINDINGS OF STATOR
3. BRUSH HOLDER
Installation of the plug, persistent washer and spring ring
Check of an axial gap of a gear wheel
After dismantle from the engine of a starter it is necessary to check freedom of moving of a gear wheel on screw cutting of a shaft and freedom of rotation of a shaft of the electric motor (by means of a screw-driver).
If the shaft jams, it is necessary to disassemble a starter at once. In case of normal rotation of a shaft it is necessary to check at first a starter idling, and then if necessary to disassemble.
To collect an electric circuit for the starter check, shown in the drawing Dismantling, check and starter assembly. To include a starter and to measure a consumed current, tension and frequency of rotation of a shaft of the electric motor. To compare the received values to the nominal.
If nominal rates are given without a current consumed by the traction relay, it is necessary to correct results of measurements, having subtracted from the received value the rated current consumed by the holding winding of the relay.
To switch off a food and to disassemble an electric circuit.
1. If the consumed current and frequency of rotation of a shaft of the electric motor correspond to nominal rates, the starter is serviceable.
2. Low speed of rotation of a shaft and a big consumed current are signs of the following malfunctions:
– the increased resistance to shaft rotation because of a big tightness, wear or pollution of bearings, a bend of an anchor of the engine etc.;
– short circuit of windings of an anchor;
– short circuit of windings of an anchor or excitement windings.
3. If the shaft does not rotate at a big consumed current, the possible reasons are:
– short circuit on weight in a winding of excitement or on plugs;
– jamming of bearings. (It is necessary to check, rotating an anchor by hand). To disassemble a starter.
4. If the shaft does not rotate in the absence of a current in a chain, the possible reasons are:
– a gap in an excitement winding. To disassemble a starter and to check internal switching and integrity of windings by means of a control lamp;
– a gap in an anchor winding. To disassemble a starter and to examine an anchor;
– breakage of a spring of a brush, wear of brushes, pollution of plates of a collector and other reasons worsening contact of brushes with plates of a collector. To disassemble a starter.
5. Low speed of rotation of a shaft at a small consumed current:
– the increased internal resistance because of bad contact, malfunction of wires, pollution of plates of a collector and other reasons. To disassemble a starter.
6. High speed of rotation of idling at a big consumed current testifies usually to short circuit in an excitement winding. To disassemble a starter and to check windings of excitement of a stator.
| PERFORMANCE ORDER
| 1. To unscrew screws of fastening of plugs and the traction relay. To turn the relay case on 90 degrees and to remove together with an anchor and a spring. To check and repair the relay.
| 2. To turn out two coupling bolts, to remove a back cover and a washer. (On a starter for the car with the diesel engine to remove in addition insulating laying).
| 3. To disconnect the stator case from a forward cover. (On a starter for the diesel car the anchor of the electric motor remains in a forward cover). Operation is carried out only on the starters intended for diesel cars.
|4. To take out an axis of the bifurcate lever. Operation is carried out only on the starters intended for diesel cars.
|5. To take out an electric motor anchor from the plug of a forward cover. After that the lever and a relay anchor freely act in film (see fig. Lever of a drive and anchor of the traction relay).
|6. If necessary to dismantle MCX anchors from a shaft to execute the following operations (see fig. Gear wheels and coupling of a free wheeling):
|6а. To remove a persistent washer.
|6б. To put on a shaft and to rest against the plug 4 a long tip in diameter about 16 mm or a piece of a suitable tube. In easy blow on a tube to remove the plug from a spring ring.
|6в. To take out from a flute on a shaft a spring ring. If the ring was deformed, it is necessary to replace it new (at the subsequent assembly).
| 6г. To remove from an anchor shaft the plug and MCX. (On a stator for the diesel car in addition to dismantle from a shaft a fiber washer and the average bearing).
|7. To take out a finger and to remove the lever of a drive and a relay anchor.
|8. If necessary to dismantle a shchetkoderzhatel on a standard starter to execute the following operations (see fig. Replacement of a shchetkoderzhatel, standard starter):
|8а. To take out an axis of a shchetkoderzhatel.
|8б. To remove a spring of a shchetkoderzhatel.
|8в. To replace in need of a brush.
|9. If necessary to dismantle a shchetkoderzhatel on a starter of 5MT to execute the following operations (see fig. Replacement of a shchetkoderzhatel, starter of 5MT of smaller capacity):
|9а. To remove a shchetkoderzhatel from an arm
|9б. To turn out the screw from a shchetkoderzhatel and to remove a brush
|9в. To check serviceability of a shchetkoderzhatel, lack of defects or wear.
9г. If necessary to replace brushes and/or shchetkoderzhatel.
| PERFORMANCE ORDER
| 1. To establish on an anchor of MCX with a gear wheel:
|1а. To grease the end of a shaft of an anchor with greasing 1960954 or similar.
|1б. To establish on a shaft the average bearing (starters for diesel cars). The bearing should be turned to an anchor winding. Then to establish on a shaft a fiber washer.
|1в. To put on a shaft of MCX with a gear wheel. The gear wheel should settle down closer to the end of a shaft.
|1г. To establish on an anchor shaft the plug. The pro-point of the plug should be turned by the shaft end.
|1д. To establish in a flute of a shaft of an anchor a spring ring.
|1е. To establish a persistent washer on a shaft.
|1ж. To arrange the plug and a persistent washer on the different parties from a spring ring. By means of two flat-nose pliers to compress the plug and a spring ring and to press a spring ring in the plug. The plug should be reliably fixed in the axial direction on an anchor shaft.
| 2. To grease the plug of a forward cover of a starter with greasing 1960954 or similar.
| 3. To insert the end of the lever of a drive into a ring pro-point of the plug MCX and to establish MCX in a forward cover of a starter. On starters for cars with petrol engines the lever of a drive can be established previously.
|4. To insert an axis of the lever of a drive and to fix it.
|5. To establish the traction relay in collecting and a lever finger.
|6. To put a layer of N 1050026 hermetic or similar structure on the interfaced plane of the relay contacting to the case of a stator.
|7. To attach the stator case to a forward cover, having established it on directing pin. To show care, not to damage a brush.
|8. To grease the plug of a back cover of a starter with greasing 1960954 or similar.
|9. To establish for the back end of a shaft of an anchor a washer, to put on a back cover, to establish and tighten coupling bolts in through openings. On starters for diesel cars before installation of a back cover it is necessary to establish isolating laying. At installation of coupling bolts to track that they passed through openings in laying.
| 10. To attach wires of a winding of a stator to conclusions of the traction relay. At assembly of a starter or after replacement of the traction relay it is necessary to check an axial gap of a gear wheel. The correct gap of a gear wheel is necessary for an exception of a friction of a fork of the lever about the plug MCX at operation of the electric motor of a starter.
|11. To disconnect a wire of a winding of a stator from the plug of the traction relay and properly to isolate a wire.
|12. To connect one wire from аккумуля the even battery to the plug of a winding of the traction relay, and another — to a stator.
|13. To connect for short time by means of a lengthening wire the plug of the traction relay to a stator. Thus the gear wheel should be pushed forward into position and remain in this situation before battery shutdown.
|14. To move a gear wheel back, having completely chosen an axial gap. To measure an axial gap of a gear wheel by means of flat щупа. The axial gap of a gear wheel should be in limits of 0,25-3,5 mm. In a design of a starter it is not provided means of adjustment of an axial gap of a gear wheel. If the gap falls outside the limits an admissible range, to check correctness of assembly of a starter and to replace worn-out details.