8.12. Control devices

On the car the following control devices are installed: speedometer and guard of devices.
For the drive of a speedometer the flexible shaft representing the four-layer cable concluded in a flexible metal cover is used.
Do not allow shift by places of the sensor of the index of temperature of cooling liquid in the block of cylinders of the engine and the sensor of an alarm lamp of an emergency overheat of cooling liquid in a radiator as devices at the same time will not work.
After 25 000–30 000 km of a run of the car, but at least once a year check operation of control devices.
At removal of sensors of indexes of temperature of cooling liquid and sensors of pressure of oil, and also the fuel level sensor index, switch-off the rechargeable battery the weights switch.
If the sensor of the index of level of fuel was removed for any reason (washing of a tank, repair etc.), then at its return installation take measures to preservation of tightness between a tank and the sensor.
Do not allow considerable lowering of the level of cooling liquid in the engine cooling system (exposures of tubes in the top tank of a radiator) as from an overheat the sensor of the index of temperature of cooling liquid in a radiator can fail.
 Speedometer and flexible shaft. Periodically check reliability of an inhaling of nuts of fastening of a flexible shaft to a speedometer and the transfer case. The shaft nut from a speedometer has to be wrapped so that the nipple of a cover was densely pressed to a shaft of a speedometer and did not move from rocking by his hand.
At survey of the car from below check correctness of installation of a shaft. The shaft has to be reliably fixed by brackets and not have abrupt bends, especially near its ends. Radiuses of bends of a shaft should not be less than 150 mm, otherwise fluctuations of an arrow of a speedometer and knocks of a cable appear. When replacing the shaft has to be established on the former place.
Check correctness of indications of instrumentations by means of the special device. In the absence of such device check control devices as follows:

Fig. 7.38. The scheme of check of the generator at the stand: 1 – tachometer; 2 – electric motor; 3 – gene-rator; 4, 8 – voltmeters; 5 – ampermeter; 6, 10 – switches; 7 – a rheostat on 40 A; 9 – a rheostat on 5 A;
11 – accumulator battery


 Check the voltmeter comparing its indications to indications of the control voltmeter with an accuracy not lower than ±0,1 V. For determination of accuracy of indications turn on the voltmeter consistently with control according to the scheme of check of the generator (see fig. 7.38). The rejection of indications should not exceed ±0,8 Century.
 Check the index of level of fuel, filling the fuel tank with fuel from measured ware. If the index and the sensor are serviceable and correctly adjusted, then at a voltage of 12,5 V and temperature of 20±5 °C the accuracy of indications in points of a scale of the index 0 and 1/4 makes about 5%, in a point of the index 1/2 – about 7%, and in a point of the index P – about 9%. Determine an error of indications by an index arrow deviation from the axial line of a stroke of a scale. Arrow width at the same time is accepted equal 7% of scale length. Thus, the deviation of an axis of an arrow from a scale stroke axis to the left or to the right on width of an arrow corresponds to an error of the index, equal 7%.
At change of ambient temperature or change of tension in a device chain the device error increases a little.
If instrument readings in all points of a scale are evenly overestimated or underestimated, then this defect can be eliminated a rheostat float lever podgibaniye. If the error of instrument readings exceeds admissible limits, replace the sensor and if it does not yield positive results, then replace also the index.
At the switched-off ignition of the shooter of the device has to be to the left of a zero stroke.
 Check the index of temperature of cooling liquid comparing its indications to indications of the mercury thermometer. For this purpose turn out the sensor of temperature of cooling liquid in the block of cylinders, extend a wire, connect the sensor a separate wire to "mass" of the car and place together with the mercury thermometer in a vessel with boiled water (in the middle of a vessel). The head of the mercury thermometer has to be near the sensor. The plug of the sensor should not be immersed in boiled water. Then write down indications of the index of temperature and the thermometer. You bring water temperature to the required size, adding cold water in a vessel.
The error of indications of the index should not exceed ±8 °C. If instrument readings exceed the specified value, replace the sensor and if it does not yield positive results, then replace also the index of temperature.
 Check the index of pressure of oil by means of the control manometer with the price of division of 0,5 kgfs/cm2 which joins lubricant system of the engine by means of an additional hose through an opening of the sensor of emergency pressure of oil.
At a voltage of 12-16 V, the ambient temperature of (20±5) °C and with an oil pressure in system of 196 kPa (2 kgfs/cm2) the error of indications should not exceed ±41 kPa (0,42 kgfs/cm2), with a pressure in system of 588 kPa (6 kgfs/cm2) – ±59 kPa (0,6 kgfs/cm2). If the error of instrument readings exceeds the specified limits, replace the sensor and if it does not yield positive results, then replace also the index of pressure of oil.

Repair
 Rechargeable battery
For elimination of such malfunctions as short circuit, sulphation of plates or destruction of separators disassemble the rechargeable battery.
Before dismantling discharge the battery as the loaded negative plates on air become useless. You make a discharge the current which is not exceeding 5 A up to the voltage of 1,7 V in each element. Discharge only the loaded elements as in the presence in the battery of the discharged elements of their plate there will be perepolyusovana current from the next charging elements.
At emergency the battery can be disassembled also without preliminary discharge, but then immediately rinse the taken-out semi-blocks of negative plates with the distilled water and keep them shipped in the distilled water.
If it is known that some one element of the battery is faulty, take out from the case only it, previously having cut a hacksaw (approximately in the middle) interelement crossing points. If all elements (sulphation or short circuit of plates) are faulty, take out from the case all elements one block together with covers.
You make dismantling of the battery in the following order:
1. Merge electrolyte.
2. Remove from covers filling mastic with a heated metal shovel.
3. Take out blocks of plates of all elements from the case.
4. Remove with tweezers separators.
5. Wash out plates flowing water within 15–20 min.
After drying examine details and define the nature of repair. At the same time replace the damaged separators new or old, suitable for further work.
The plate is considered suitable for further use if the lattice is whole, and active weight dropped out no more than of seven cells in its different places. Under an ear of a plate loss of active weight no more than from two cells is allowed. Active weight has to keep strongly in a lattice, not have cracks, bubbles and a raid of coarse-grained sulfate of lead. The active mass of positive plates has to be brown color and velvety to the touch. The active mass of negative plates has to be light gray color and firm to the touch. Remove a small raid of sulfate on plates with a knife, and replace strongly zasulfatirovanny plates.
If some plates are unsuitable, replace all block of plates of an element, having taken it also from the disassembled earlier similar battery with serviceable plates and separators.
When replacing one or several plates instead of them establish not the new, and being in the use plates on the state coming to remained.
At assembly of the repaired accumulators put separators the smooth party to a negative plate, ridge – to positive. Before assembly of the battery carefully clear the case and covers of mastic and acid. After installation of the block of elements or a separate element of edge of covers fill in with the mastic heated to temperature of 175-180 °C. For receiving a plain glossy surface slightly warm up the hardened mastic a blowtorch flame.
Weld the cut interelement connections by means of a coal electrode with a diameter of 6-7 mm. When welding connect a positive pole of the battery to the welded detail, and negative – to a coal electrode. Smooth out surfaces of the welded crossing points to gloss. As additive material apply lead in bars, as gumboil – stearin.
After assembly fill in in the rechargeable battery electrolyte with a density of 1,125 (for batteries with the discharged plates) or 1,32 (with loaded). Then carry out a control and training cycle for definition of the validity of the battery.
 G250P2 generator
You carry out dismantling of the generator in the following order:
1. Remove the brush holder with brushes.
2. Uncover the bearing and turn off a nut of fastening of the back end of a shaft of a rotor.
3. Unscrew coupling screws of the generator and remove a back cover with the stator.
4. Disconnect the phase ends of a winding of the stator from the vypryamitelny block and remove the stator.
5. Remove a pulley, the fan, a spline and the expansion plug from a rotor shaft.

Fig. 7.29. Device for removal of a pe-redny cover of the generator


6. Remove from a rotor shaft a forward cover together with the bearing, using carving openings in a cover and special adaptation (fig. 7.29).
Examine and check details and knots of the generator.

Fig. 7.30. Check of short circuit of windings of the stator on the case


Stator. By means of the special device or the control lamp included in the alternating current main check whether there is no short circuit of coils of the stator on the case (fig. 7.30). When checking by a control lamp connect it to any conclusion of a winding of the stator and the case. At the same time tips should not concern the case. The lamp should not burn. If the lamp burns, then it indicates short circuit of a winding of the coil of the stator on the case. In this case eliminate malfunction or replace the stator.

Fig. 7.31. Check of mezhvitkovy short circuit of windings of the stator


Then by means of a control lamp check whether there is no short circuit in stator windings between rounds. For this purpose serially connect a control lamp to two tips of conclusions of each winding (fig. 7.31); at a serviceable winding the lamp has to burn. If between any two conclusions the lamp does not burn, then it indicates break of a winding or violation of connection in an average point of phases.
On poles of the stator rotor zadevaniye traces should not be observed. In the presence of a zadevaniye check covers and bearings, if necessary replace.
 Covers. At survey pay attention to absence of damage of covers, especially in the locations of paws of fastening. The bearing has to enter a back cover (from contact rings) freely, but without noticeable weak point.
Diameter of an opening under the bearing has to be 35+0,03 mm. If diameter of an opening under the bearing stated above, then a cover is subject to replacement.
Make sure that the bearing in a forward cover (from a pulley) is installed densely (press landing).
Diameter of an opening under the bearing has to be 47+0,03 mm.

Fig. 7.32. Check of mezhvitkovy short circuit of a winding of a rotor


Fig. 7.33. Check of short circuit of a winding of a rotor on the case


 Rotor. Whether check by means of an ohmmeter there is no short circuit between rounds in a winding of a rotor (fig. 7.32) and short circuit of a winding on the case (fig. 7.33). In the presence of damages replace a rotor.

Fig. 7.34. Cleaning of contact rings skin


If contact rings of a rotor are polluted, have traces of a podgar and uneven wear on width, smooth out them a small glass skin granularity 80 or 100. For cleaning of contact rings fix the generator for a forward cover in a vice and, smoothly turning a rotor, smooth out rings a skin, as shown in fig. 7.34.
If rings have strong wear and a beating of a surface, pierce also to their proshlifuyta (for the G250P2 generator minimum admissible diameter of a pro-point of contact rings of 29,2 mm). The roughness of a surface of rings has to be on the 7th class.

Fig. 7.35. Check of a beating of contact rings


After a pro-point check the indicator a beating of contact rings (fig. 7.35). The beating of rings leads more than 0,08 mm to their bystry podgoraniye and wear of brushes, especially with a big frequency of rotation.
 Brush knot. Check whether there is no jamming of brushes in brush holders, and also a state and size of wear of brushes and force of a tension of brush springs. By weak pressing of brushes sparking amplifies and rings burn. Excessive pressing of brushes causes their increased wear. The effort of pressing of brushes has to be within 180–260 gs. You watch that brushes in brush holders moved freely, without jammings and an excess gap. Even insignificant jamming of brushes which is sometimes difficult for defining increases sparking under them. Replace the brushes which are worn out up to the height of 8 mm or damaged new the M1 type. Do not apply a brush of other type.

Fig. 7.36. Vypryamitelny block: 1 – positive tire; 2 – insulating plugs;
3 – negative tire; 4, 5 – diodes of various polarity


Fig. 7.37. Scheme of check of diodes: 1 – switch; 2 – diode; 3 – the lamp is control;
4 – accumulator battery


 (Fig. 7.36) carefully clear the Vypryamitelny VBG-1 block (or PBV-4-45) of dirt. Check diodes by means of a control lamp of 3 (fig. 7.37). Because in each section of the block diodes of various polarity are mounted, check them at various polarity (fig. 7.37, and, b) turning on of the rechargeable battery. At the serviceable diode in position of switches I the lamp has to burn, and in situation II should not burn. If in situation I the lamp does not burn, then it indicates break of transition of the diode. If the control lamp in position II of switches burns, then it indicates short circuit in the diode.
Replace Vypryamitelny section with the faulty diode. Raspaivayte conclusions of vypryamitelny section two soldering irons at the same time at the turned-off nut of the plug of accession of a phase winding. At installation of new section keep in mind that it is possible to heat the place of the soldering no more than on 150 °C within five seconds.
Do more careful check of diodes by means of the special device for check of semiconductor devices.
You make assembly of the generator upside-down.

Control check of the generator
Determine serviceability of the generator and correctness of its assembly by check of frequency of rotation of a rotor at which tension 12,5 B is reached during the operation of the generator without loading and at full loading.
You make check at the test bench consisting of the electric motor allowing to change smoothly the frequency of dyeing of the generator up to 3000 min.-1, the rheostat allowing to create loading to 40 A in a chain of the generator, rechargeable battery 6ST-60-EM, a rheostat in an excitement winding chain on 3-5 A and devices. It is possible to use the control test bench of the GARO model 533.
The scheme of check of the generator at the elementary stand is shown in fig. 7.38.
For check of the generator turn on the switch 10 and a rheostat 9 adjust tension of 12,5 Century on the voltmeter 8. Without loading (the switch is switched off) when the generator cold, the voltmeter 4 has to show 12,5 B with a frequency of rotation of a rotor no more than 900 min.-1. Then turn on the switch 6 and, increasing the frequency of rotation of a rotor of the generator, increase loading. At loading 28 A and tension 12,5 B (on the voltmeter 4) the frequency of rotation of a rotor has to be no more than 2100 min.-1. During these tests support by a rheostat tension on the plug "Sh" within 12,5 B (on the voltmeter 8).

Generators 665.3701-01 and 161.3771
You carry out dismantling of the generator 665.3701-01 in the following order:
1. Turn off nuts of fastening of a plus conclusion of the generator and disconnect a condenser conclusion.
2. Unscrew two screws of fastening of a casing to a cover.
3. Separate a casing from a cover for what disconnect from the wire generator with plugs.
4. Unscrew the screw of fastening of the brush holder and remove it.
5. Turn off four nuts of coupling screws and uncover the party of contact rings together with the stator.
6. Turn off three nuts of fastening of different conclusions from the vypryamitelny block and separate the stator from a cover.
7. Turn off a nut of fastening of a pulley.
8. Remove a pulley, beat out a spline.
9. Uncover from the drive together with the bearing a rotor shaft.
In need of replacement of the regulator of tension unscrew two screws fixing tension regulator to a casing and then two screws fixing tension regulator to the insulating basis.
In need of separation of the vypryamitelny block from a cover turn off a contact bolt, a nut of a plus conclusion, three screws of fastening of the block to a cover and separate a block conclusion with the block plug.
Examine and check details and knots of the generator. You make assembly of the generator upside-down. Dismantling and assembly of the generator 161.3771 are similar.
The main difference consists in lack of a back protective cover. The regulator of tension is located in the brush holder case.

Brush knot
Make sure that brushes are whole, do not jam in brush holders and reliably adjoin to contact rings. If brushes wore out, replace them.
Before installation of the brush holder into place blow a nest in the generator.

Tension regulator
 Check on the car
For check it is necessary to have the voltmeter of a direct current with a scale to 15–30 V, an accuracy class not lower than 1,0.
After 15 min. operation of the engine at an average frequency of rotation at the included headlights measure tension between the + plug and mass of the generator. Tension has to be in the limits specified in specifications this type of the generator. In case adjustable tension goes beyond admissible limits and is observed systematic недозаряд or the recharge of the rechargeable battery, the regulator of tension need to be replaced with new (same).
 Check of the removed regulator

Fig. 7.39. Scheme of check of the regulator of tension: 1 – switch; 2 – lamp; 3 – tension regulator; 4 – rechargeable battery


The regulator removed from the generator is checked as follows (fig. 7.39):
– between conclusions "In" and "Ш" the regulator include the 1-3 W, 12 Century lamp.
– "In" and to "mass" of the regulator connect the power supply to the second conclusion at first of 12 V, and then of 15-16 V, it is possible to use two rechargeable batteries, connecting the regulator to six elements of the battery (12 V) in the beginning, and then to eight (16 V). At the serviceable regulator of tension in the first case the lamp has to burn, in the second – should not burn. If the lamp burns or does not burn in both cases, the regulator is faulty.

Stator
The stator is checked after dismantling of the generator. Conclusions of its winding have to be disconnected from rectifier gates.
By means of an ohmmeter or a control lamp and the rechargeable battery check whether there are no breaks in a winding of the stator and whether its rounds on "weight" become isolated. Mezhvitkovy short circuit in coils of a winding of the stator is determined by an ohmmeter or by the defectoscope.
Isolation of wires of a winding has to be without traces of an overheat which occurs at short circuit in rectifier gates.
Replace the stator with the damaged winding.
Rotor zadevaniye traces for stator poles should not be observed.
In the presence of a zadevaniye check covers and bearings, if necessary replace.

Vypryamitelny block
Operations and receptions on check of the vypryamitelny block are similar to the Vypryamitelny VBG-1 block described above. 

Condenser
The condenser serves for are sewn up the electronic equipment of the car from tension impulses in system of ignition, and also decrease in hindrances to radio reception.
In the presence in the car of the radio receiver of damage of the condenser or weakening of its fastening on the generator (deterioration in contact with "weight") it is found on increase in hindrances to radio reception at the working engine.
Approximately serviceability of the condenser can be checked the megohm meter or a tester (on a scale of 1-10 megohms). If in the condenser there is no break, then at the time of connection of probes of the device to conclusions of the condenser of the shooter has to deviate towards reduction of resistance, and then return gradually back.
The condenser capacity measured by the special device has to be 2,2 мкФ±20%.

Covers
At survey pay attention to absence of damage of covers, especially in the locations of paws of fastening, seats for bearings. Replace the damaged covers.

Control check of the generator

Fig. 7.40. The scheme for check of the generator at the stand: 1 – generator; 2 – voltmeter; 3 – ampermeter; 4 – switches; 5 – rheostat; 6 – rechargeable battery. (* For the generator 161.3771)


For definition of working capacity and compliance to technical characteristics the generator is checked at the stand according to the scheme provided on fig. 7.40.
Turn on the stand electric motor. Check is made directly after the generator works 1,5 hours with a frequency of rotation of a rotor of the mines-1 generator 3000, current of loading 40 A and voltage of 13 V at the switched-on switches.
At test gradually increase the frequency of rotation of a rotor until tension on the voltmeter reaches 13 V. U of the serviceable generator the current of return has to be not less than 55 (57 *) And with a frequency of rotation of a rotor of 5000 min.-1.

(* For the generator 161.3771)

If the measured size of the given current is less, then it speaks about malfunctions in windings of the stator and a rotor, about damage of gates or wear of contact rings and brushes. In this case careful check of windings and diodes is necessary to define the place of malfunction.
Tension at the exit of the generator is checked with a frequency of rotation of a rotor (3500±125) min.-1. Current of the generator is supported by means of a rheostat equal (18±0,9) A.
Measure tension at the generator exit which has to be in the limits specified in specifications this type of the generator.
If tension does not keep within the specified limits, then replace tension regulator control, obviously serviceable, and repeat check. If tension still does not keep within the specified limits, then it is necessary to check windings and diodes of the generator.

Regulator of tension 2702.3702

Fig. 7.41. Scheme of check of the regulator of a nap-ryazheniye: 1 – generator; 2 – tension regulator; 3 – rheostat; 4 – accumulator battery;
5, 6 – switches; 7 – ampermeter; 8 – voltmeter


Repair of the regulator of tension has to be made in a workshop by the qualified specialist. It is necessary to have the test bench, for example, of the E-211 GARO model or to manufacture the stand equipped with the electric motor for rotation of a rotor of the generator with smooth change of frequency of its rotation to 3000 min.-1, the rechargeable battery, a rheostat for creation of loading to 40 A and the device for check of semiconductor devices. The scheme of the elementary stand for check of the regulator of tension is shown in fig. 7.41.
For check turn on the switch 5 and smoothly increase the frequency of rotation of a rotor of the generator up to 3000 min.-1. Then turn on the switch 6 and a rheostat 3 create loading from 5 to 25 And on the ampermeter 7. Tension changed by the regulator will show the voltmeter 8. If when checking at the stand it turned out that the regulator of tension gives the increased or lowered tension, then selection of resistance achieve adjustable tension according to "Specifications of the regulator of tension" for three ranges of control. If the regulator does not provide normal excitement of the generator (current does not come to an excitement winding chain), then check power failure size in tension regulator at current 3 A. Power failure should not exceed 2 Century.

Fig. 7.42. The scheme of check of falling of tension in tension regulator: 1 – accumulator battery; 2, 3 – switches; 4 – voltmeter; 5 – rheostat; 6 – ampermeter; 7 – the checked tension regulator


The scheme of check of power failure is provided on fig. 7.42. Before turning on of the switch 2 the rheostat 5 has to have resistance of 4 Ohms. After installation of current 3 A on the ampermeter 6 turn on the switch 3. At the same time the voltmeter 4 has to show no more than 2 Century.

Fig. 7.43. Check of a stabilitron


Fig. 7.44. Check of the transistor


If the regulator does not change generator tension, then first of all check stabilitrons, and then other semiconductors (fig. 7.43 and 7.44). Replace faulty semiconductors.

Starter
You make dismantling of a starter in the following order:

Fig. 7.18. Starter 42.3708: 1 – a cover from the drive; 2 – flood ring; 3 – persistent ring; 4 – castle ring; 5 – drive; 6 – anchor; 7 – case; 8 – brush; 9 – traverse; 10 – persistent washer; 11 – adjusting washer; 12 – lock washer; 13 – a cover from a collector;
14 – contact bolt; 15 – contact plate; 16 – relay cover; 17 – returnable spring; 18 – rod; 19 – relay anchor; 20 – the compensating spring; 21 – buffer spring; 22 – gear wheel; 23 – M5x14 screw; 24 – nut of a coupling hairpin; 25 – M6x16 screw; 26 – M8 nut; 27 – input of coils of the relay;
28 – M6x30 screw; 29 – lever; 30 – M8 nut; 31 – lever axis


1. Turn off a nut 26 (see fig. 7.18) and disconnect a conclusion from a contact bolt 14.
2. Unscrew screws 28 of fastening of the traction relay to a cover from the drive and remove the relay.
3. Turn off nuts 24 on coupling hairpins.
4. Unscrew two screws 25 and take off a cap.
5. Remove lock 12 and adjusting the 11th washers.
6. Uncover 13 from a collector.
7. Take out brushes 8 of brush holders and remove to a traverse 9.
8. Remove the case 7.
9. Turn off a nut, the fixing lever axis, turn out an axis of the lever 31 and take out the lever 29.
10. Take out an anchor 6 with the drive assembled from a cover from the drive.
11. Remove a persistent ring 3 to the left, remove a castle ring 4, and then the drive 5 from a shaft.
12. For survey of contacts of the traction relay unscrew two screws 23, unsolder two inputs 27 and uncover the relay 16.
Carefully clear details of dirt. Examine and check details and knots of a starter. Replace the damaged details.
 Case. By means of the special device or the control lamp included in the alternating current main check whether there is no short circuit of coils of a winding of excitement on the case.

Fig. 7.45. Check of short circuit of coils of a winding of excitement on the case


When checking by a control lamp connect it to the case and a conclusion located on the case (fig. 7.45). If the lamp burns, then it indicates damage of isolation of coils of a winding of excitement. In this case number poles of coils, unscrew screws of fastening of poles and remove excitement winding coils. Wind the damaged places of isolation with an insulating tape. After this pole and the coil establish into place. You zakernit screws of poles.

Fig. 7.46. Check of short circuit of the isolated brush holders on the case


 Cover from a collector. By means of the special device or a control lamp check whether there is no short circuit of the isolated brush holders on the case (fig. 7.46). In case of short circuit replace insulating laying and the plug of rivets of the brush holder. Brushes in brush holders have to move freely, without jamming. Check a condition of the plug of the bearing in a cover and in case of wear replace. Diameter of an opening of the new plug after a press fitting and development has to be 12,5+0,035 mm with a surface roughness on the 8th class. With a height of brushes less than 6-7 mm replace them.
 Cover from the drive. Check a condition of the plug (bearing) in a cover and in case of wear replace the plug. Diameter of an opening of the new plug after a press fitting and development has to be 12,5 +0,035 mm with a surface roughness on the 8th class.

Fig. 7.47. Check of short circuit of a winding of a rotor on a rotor iron package


 Rotor. Whether check by means of the special device or a control lamp there is no short circuit of a winding of a rotor on a rotor iron package. For this purpose connect one end to any of rotor lamels, and another – to a rotor iron package. At the same time the lamp should not burn (fig. 7.47).
Attentively examine a rotor. A forward part of a winding of a rotor has to be on diameter less package of iron. The increased diameter of a forward part of a winding indicates winding "rating". Replace such rotor. The ends of wires of windings have to be reliably soldered to collector plugs.
Check whether there are no short circuits between rotor rounds. In case of detection of short circuit replace a rotor.
The collector of a rotor has to be pure. In case of a considerable roughness of a collector or a vystupaniye of mica pierce it on the turning or special machine. After a pro-point of the collector grind a glass skin granularity 100 to a surface roughness on the 7th class.
The collector beating concerning pins of a shaft should not exceed 0,05 mm. The rotor iron package beating concerning pins of a shaft should not exceed 0,25 mm. At the same time check whether there is no shaft deflection as the deflection can be the reason of jamming of the drive on a shlitsevy part of a shaft. If on a rotor shaft in that place where the starter gear wheel rotates, there is a yellow raid from the bearing, then it should be removed with a small skin. Existence of a yellow raid often leads to jamming of a gear wheel on a shaft after launch of the engine and to rotor winding shift.
 Drive. Examine the starter drive outside and check whether there is no pro-slipping. The drive has to freely, move without jammings by a shlitsevy part of a shaft. At strong wear of plugs (bearings) of the drive replace them.
At deduction of a rotor the gear wheel has to rotate freely clockwise. Counterclockwise the gear wheel has to rotate only together with a rotor. You make check of the coupling of a free wheeling on pro-slipping at the stand at test of a starter for full braking.
 Traction relay. Check serviceability of the involving and holding windings by means of an ohmmeter or measuring resistance by means of the voltmeter and the ampermeter. In case of malfunction of windings replace the traction relay. Smooth out contacts on klemmovy bolts, and at their strong burning out turn bolts on 180 ° around an axis. At strong wear of a contact disk turn it not worn-out party to contacts.
The anchor of the traction relay has to move freely in the case.
You make assembly of a starter as it should be, the return to dismantling, taking into account the following:
1. Grease before assembly bearings, pins and a shlitsevy part of a shaft engine oil.
2. Collect starter rotor knot for what put on a shaft of a rotor the intermediate bearing, the drive 5 (see fig. 7.18) and the persistent knot consisting from persistent 3 and castle 4 rings. Apply a mandrel to convenience of installation of a castle ring.
3. Establish on a rotor from a collector a persistent washer 10.
4. At a final inhaling of coupling screws of the case combine pins and grooves on covers and the case.
5. Check the size of an axial gap of a rotor which has to be about 0,8 mm.
After assembly check and adjust a starter.

Adjustment of a starter

Fig. 7.48. Provision of a gear wheel of the drive of a starter: 1 – a conclusion to the relay; 2 – a conclusion to the rechargeable battery; 3 – axis eccentric drive lever


Installation of a gear wheel in the switched-off situation has to be no more than 34 mm from the privalochny plane of a flange of a starter (fig. 7.48). Check a full speed of a gear wheel at the switched-on traction relay. The distance between an end face of a gear wheel and an emphasis has to be (4±1) mm. This gap adjust turn of an eccentric axis 3 levers of turning on of the drive.
After adjustment tighten an axis nut.

Control check of a starter
Are necessary for check of a starter the low-voltage unit (or completely charged battery), the voltmeter of a direct current with a scale from 0 to 30 V, the ampermeter of a direct current with the shunt to 1000 A, a tachometer with a scale to 10 000 min.-1 and a dynamometer.

Fig. 7.49. The scheme of inclusion of a starter for check: 1 – lever; 2 – dynamometer; 3 – starter; 4 – traction relay of a starter; 5 – switch;
6 – voltmeter; 7 – ampermeter; 8 – shunt of an ampermet-r; 9 – accumulator battery


The scheme of inclusion of a starter for check is shown in fig. 7.49. You make check at the special stand. In the absence of the special stand strengthen a starter in a vice and connect it to the rechargeable battery (a clip of a starter connect via the ampermeter with positive, and the starter case – to the negative plug of the battery). Apply wires with a section not less than 25-35 mm2 to connection of a starter with the battery. Idling measure the current and frequency of rotation of a rotor at test through 30 from later inclusion of a starter.
The starter is considered passed test if at a voltage of 12 V it consumes current no more than 75 And yes not less than 5000 min.-1 develop rotation frequency.
At hard rotation of a rotor which usually is caused by distortions as a result of the wrong assembly of a starter or a rotor zadevaniye for poles and also at short circuit of a winding of a rotor on "weight" or at mezhvitkovy short circuit of a winding of a rotor the starter consumes current of bigger force, and the frequency of rotation of a rotor is less than specified. The small size of the consumed current and the lowered rotation frequency at a normal tension on clips of a starter demonstrate bad contact in connections of wires or weak pressing of springs brushes.
For check of a starter at full braking fix on a drive gear wheel the lever 1 (see fig. 7.49) connected to a dynamometer 2. Use a hydraulic dynamometer better. The brake moment is determined by a formula:
M=PL,
where M – the brake moment, N · m (kgf · l);
Р – indication of a dynamometer, N (kgf);
L – length of the lever, m.
In order to avoid a starter overheat you make test within a short period of time. If at the slowed-down gear wheel the rotor rotates, then replace the drive.

Note
When conducting this check be careful as at the time of inclusion of a starter there will be a strong breakthrough of the lever strengthened on a gear wheel.

The serviceable starter when using of completely charged battery consumes current no more than 520 And at a voltage no more than 7 V and develops the moment equal to about 15,7 N · m (1,6 kgfs · м). If the consumed current more than 520 And, and the brake moment less than 15,7 N · m (1,6 kgfs · l), it indicates malfunction of a winding of a rotor or winding of excitement. If the size of the brake moment and force of the consumed current of less normal, then it (at a normal tension on starter clips) indicates bad contacts in a starter or weak pressing of springs brushes. Tension on starter clips indicates less than 7 V bad contacts in wires or on malfunction of the battery.
The additional relay of a starter in operation of special service does not demand.

Fig. 7.50. The scheme of turning on of the additional relay of a starter for check and adjustment: 1 – accumulator battery; 2 – rheostat;
3 – control lamp; 4 – additional relay of a starter; 5 – switch; 6 – voltmeter; "To", "B", "With" – relay conclusions


You make check of the relay according to the scheme specified fig. 7.50. Smooth movement of a cursor of a rheostat 2 increase tension until turning on of the relay 4 (at the same time the control lamp 3 lights up).
Moving of a cursor to the opposite side reduce tension until switching off of the relay (the lamp dies away). The relay is considered serviceable if its inclusion happens at a voltage of 5,5-8,5 V, and switching off at a voltage of 2-4,5 V.
The gap between an anchor and the core at the closed contacts has to be not less than 0,15 mm, and a gap between contacts in the opened state – not less than 1,0 mm.

Devices of lighting and alarm systems
You make replacement of the fused lamp in a headlight through the opening closed by a plastic cover. Before installation of a new lamp remove dust from a reflector surface.
The burst or damaged lens replace. You make repair of the switch of indexes of turn, the switch of ignition, the central switch of light, a sound signal replacement of the failed details and knots with new. Switches and switches of light are not subject to repair, and are replaced with new.
The lamps applied on cars are presented in tab. 7.4.