Gear starter: description of differences and design, possible breakdowns and repair methods

The gear starter design is distinguished by a gear transmission between the armature and the overrunning clutch. The safety margin is ensured by increasing the torque in the gearbox supplied to the flywheel of the internal combustion engine.

By analogy with a conventional starter, the gear version uses permanent magnets instead of windings, simplifying the design, reducing its weight and size. Maintainability is practically not reduced; the main causes of breakdowns and repair methods are discussed below.

Gear starter

This is a device for autostarting the internal combustion engine of a car with a built-in gearbox. Any gearbox serves to change the rotation speed and facilitate the operation of the drive shaft. In the case of such a starter, the gearbox greatly facilitates the rotation of the starter shaft. Therefore, the component parts and overall dimensions themselves are much smaller than those of a starter without a gearbox.

The gearbox is installed between the armature and the bendix. The anchor rotates the gearbox mechanisms, and they rotate the bendix, which engages with the flywheel of the internal combustion engine crankshaft and transmits rotational motion to it.

General information

The planetary gear and planetary mechanism are named so by analogy with our Solar system, which can be conventionally represented as follows: in (the central wheel in the mechanism). "Planets" (small wheels or satellites) move around you. All of these planetary gear parts have external teeth. The conventional solar system has a limit on its diameter. Its role in the planetary mechanism is played by a large wheel or epicycle. He also has teeth, only internal ones. Most of the work in this design is performed by the carrier, which is a lever mechanism. The movement can be carried out in different ways: either the sun or the epicycle will rotate, but always together with the satellites.

Gear starter device

The main parts of the mechanism are the same as in a regular car starter, only there is also a gearbox.

The starter structure consists of:

• anchor;
• bendix;
• mask;
• solenoid relay;
• gearbox;
• stator;
• sleeve;
• fork.

Although the main parts are the same, they are located differently. The Bendix in the gear starter sits on its shaft. This design and the presence of a gearbox make it easier to start when the car battery is low.

The efficiency of a gear starter is 1.5 times greater than the efficiency without a gear starter.

Operating principle of a gear starter:

1. The current is supplied by the relay.
2. The anchor is retracted.
3. Bendix is ​​thrown out.
4. The pin contacts are closed and voltage is applied directly to them.
5. The armature rotates and transmits the rotational force to the gears of the gearbox, which rotates the bendix.
6. Bendix is ​​directly engaged with the flywheels of the car engine and rotates it.
7. The engine starts.

What is a starter with gearbox

A gear starter is one of the most common types of devices that provide engine starting in a car. The gearbox is able to change the speed and torque of the starting shaft, improving its performance. Depending on the given conditions, the gearbox can increase or decrease the amount of torque. Quick and easy engine starting is guaranteed thanks to the effective interaction of the bendix and the armature, between which the gearbox is located.

The geared starter mechanism makes it easy to start the engine even at low temperatures. Therefore, in regions with cold climates, such devices are recommended to be installed in cars.

Differences from a conventional starter

As already noted, the main difference is the presence of a gearbox and the location of the bendix.

There are modernized gear starters. They do not have an interacting section with splines. Many parts in the new modernized starter with gearbox are plastic. Due to this, the weight is not large and the price is lower. These starters are not repairable, that is, they cannot be repaired. A gear starter requires much less current to activate and operate. This helps when the car battery discharges quickly, for example, in severe frosts.

A little about agricultural machinery

Let's make a small rating of MTZ gear starters . I will briefly describe their advantages and disadvantages. There will be no clear divisions: “best in price”, “best in performance”. Of all, we will choose the most optimal option for an ordinary tractor driver.

1st place – Starter with electric motor D 240 12 Volt Slovak

This device has an optimal price-quality ratio. It has an increased power of 4.2 kW and has a rotating mask. The first advantage is that the engine turns easier, the second is that it is easier to install on the tractor.

Among analogues, Magneton is the best gear starter . Among the design features, one can note the presence of a shock-absorbing bendix. It transmits torque “softer” from the electric motor to the motor. This softens the impact of its gear on the flywheel, which prolongs its life.

Price – 6500 – 6900 rubles.

2nd place – MTZ 80 (82) 12 Volt 4.9 KW Slovak

It contains an additional power relay. It helps the main relay work correctly. This will come in handy when the battery is very low. In addition, it protects the unit from overheating when it is turned for a long time.

The only disadvantage of the MTZ 80 gear starter is its high price . It costs about 7500-7800 rubles. But an additional relay increases the life of the device. In addition, greater power smoothes out its high price.

3rd place – Magneton MTZ, ZIL (9142780)

Operating voltage 12 V and power 2.7 kW. This is the most famous manufacturer on the market of starters for special equipment. It is famous for its quality of products and their reliability. Because of this, the price is the highest in comparison with analogues.

From owner reviews, it is known that its service life exceeds that of competitors' products. Due to the price and great fame, there are many fakes on the market . Therefore, be very careful when purchasing a new gear starter of this brand.

4th place - TTB 12V 2.7 kW analogue of Magneton

With the lowest price, this gear starter has increased starting ability. Having low power, in comparison with Magneton, it has the lowest price. But this does not mitigate its merits.

Increased starting torque coupled with a long service life makes it a “favorite” of tractor drivers. It requires the least maintenance.

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Advantages and disadvantages

Like any other device, a starter with a gearbox has not only advantages, but also disadvantages.

Pros:

1. Long service life.
2. Low energy consumption.
3. Small dimensions and less weight.
4. Low price.

Minuses:

1. Repair is more difficult, if possible.
2. Weakness of the design. It has a certain power limit, so it is better not to install gear starters on trucks.

Such starters with gearboxes are especially effective in areas with cold climates.

Advantages and disadvantages of the design

A gear starter is considered a more advanced and reliable version of the device. However, if the mechanism had no shortcomings, the use of this type of starter would be much more widespread.

Important advantages include:

• fastest engine start even at low temperatures;
• low energy consumption;
• compact dimensions and light weight.

Along with the advantages, the gear starter has its disadvantages:

• difficulty of repair (often the mechanism only needs to be replaced);
• weakness of the design (to reduce weight, plastic parts are used that can withstand the load only to certain limits).

Gear starter repair

A gearbox failure will cost approximately the same as a new gearbox. Other starter parts can be changed one by one.

And in this photo you can see how the gears of the gearbox wear out, and how many chips accumulate and how the lubricant becomes coked over time.

Reducer gears.

Frequent breakdowns of a starter with gearbox:

• When turning the ignition key, the starter does not operate. The reason for the starter itself not responding is in the pin contacts of the solenoid relay. Also, it often happens that the battery terminals are loose and fire every other time.
• Sometimes there are problems starting the internal combustion engine when the starter is working properly. In this case, the starter works, but there may be a breakdown in the bendix or gearbox.
• Sometimes there are problems with starting a car engine when the solenoid relay is working properly. The reason is most likely in the starter and armature windings.

If you don’t have experience at least monitoring the repair of the starter, you can only disassemble and check the parts for integrity. Let an auto electrician check the winding.

How to choose a starter manufacturer

The variety of models in specialized stores poses the question to the car owner: which starter to choose for your car? It is better to install components recommended by the car manufacturer. If this is not possible, then it is necessary to take into account the power of the electric starter, its design features and the compliance of the model with the battery parameters. When choosing, you should pay attention to the reputation of the manufacturer and confirm the originality of the product. This will help you avoid purchasing counterfeit parts and purchase a reliable and durable electric starter.

Geared or gearless

A conventional gearless starter has a simple design, which makes the device reliable and easy to maintain. Models of this type are heavy, making installation difficult. The device consumes a large amount of current, which complicates battery requirements. The disadvantage of the equipment is the high price.

Installing a gearbox allowed manufacturers to increase power and increase torque. This made it easier to start the engine at low temperatures. The weight of the devices is 45-48% less than that of similar gearless models. This made installation easier. The advantages of the design are durability and reliable protection against short circuits. Such models ensure that the engine starts when the battery charge level is insufficient.

Power

This characteristic demonstrates the amount of force with which the electric starter moves the engine crankshaft. The power of the electric starter depends on the size of the engine being started. For 1 volume of 1 liter, 0.15-0.16 kW is required. This ratio allows you to calculate which starter can be installed on a car with a 3-liter engine. Simple calculations give a figure of 0.45-0.48 kW.

The calculation formula is relevant for countries with a pleasant climate and for operating the car in the summer. In severe frost, more power is required to turn the crankshaft. Recommended margin: 15-20%. It should be noted that the higher the parameter, the more power is required for the starter.

Battery Compliance

The higher the battery's starting amps, the more it receives from the electric starter during starting. The data specified by the battery manufacturer is based on a temperature of -18 degrees. When the frost increases to -25, the starting current will decrease by 20%. The battery capacity also plays a role; it determines how many attempts the driver can make when starting the engine.

The amount of energy consumed by the starter depends on the engine size and engine type. To start a 2-liter gasoline engine you will need 230-240A; cranking the crankshaft of a diesel engine of the same volume is possible only with a starting current of 400A. The larger the engine, the more difficult it is to start. If the battery is new, you must select a starting device based on the characteristics of the battery. If the car has an old battery, then it is better to buy an electric starter that is more powerful for the engine parameters, and then buy a new battery.

Manufacturer

Good startups operate in Germany, Japan, Denmark, the Netherlands, France and Russia. Leading companies offer components for 80-90% of vehicles produced and produced by automakers in Europe, Asia and America. In our review we will analyze all the advantages and disadvantages of popular brands. The presented companies have an impeccable reputation and service centers in dozens of countries around the world. When purchasing products with manufacturing defects, representative offices offer prompt replacement of parts.

When choosing a manufacturer, it should be taken into account that companies have chosen a certain price range for themselves. Most of the companies presented operate in the mid-price segment. Some brands offer new and remanufactured parts. This is taken into account when choosing a provider.

Video

How to replace a gear starter with your own hands.

How to start a car at -30 degrees with a gear starter.

Tips: which gear starter is better to choose for the OKA, OKA 2 machine.

How to check the performance of the starter using the battery.

This video shows the process of repairing the starter.

For those who want to tinker, there is an opportunity to improve the gear starter.

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Starter with planetary gear

Starter: A device in a vehicle's starting system that rotates the engine's crankshaft at the speed required to start it. Work in the field of improving electric motors has made it possible to create a fairly light and simple starting design with excitation from permanent magnets and a gearbox.

The figure shows the armature and gearbox of a Bosch DW starter. The gearbox is a set of planetary gears, the sun (central) gear of which is fixed to the armature shaft, and the output power is removed from the carrier, on the shafts of which freely rotating satellites are installed. Planetary gears with external teeth are made of steel, and epicyclic gears (with internal teeth) are made of a polyamide compound with mineral additives or powder metallurgy to increase wear resistance.

The satellites, pressed from powder, rotate on shafts in plain bearings or needle bearings. The latter are preferable, as they provide greater gearbox efficiency. The satellite axis is also the inner race of the needle roller bearing. This places high demands on the material and precision of the shafts. The sun gear is integral with the armature shaft or can be removable. To obtain minimal mechanical losses and ensure a long service life, increased demands are placed on the manufacturing accuracy of gears and other gearbox parts. High-quality lubricants are used for the same purpose. The gear ratio is usually 3…5.

The geared starter anchor has design features. The armature winding is impregnated with a compound that reduces the likelihood of it coming off. Due to the increased rotation speed, the armature is necessarily dynamically balanced. To reduce losses due to hysteresis and eddy currents, the armature package is assembled from thin-film (0.5 mm thick) sheets of electrical steel.

Due to lower metal consumption and increased power density, starters with gearboxes have a higher thermal load compared to starters without gearboxes.

The biggest problem with geared starters is the brush/commutator assembly. The current density under the brushes in full power mode is 1.5...2.5 times higher than the current density of conventional starters. In such conditions, the use of special brushes with a high graphite content on the working edge is required. This increases the resistance of the switched circuit and improves switching. In addition, the brushes move against the direction of rotation by 0.3...0.5 commutator divisions. As a result, the wear rate of brushes and commutators is reduced to the level of starters without gearboxes.

The magnets used are permanent magnets made of strontium ferrite, which have a higher coercive force compared to magnets made of barium ferrite. An increase in coercive force increases the resistance of the magnets to demagnetization by the armature reaction at the moment the starter is turned on in the presence of a short circuit current. To increase resistance to demagnetization, special treatment of the magnet runaway area is used, which leads to a further local increase in the coercive force and also increases the number of poles.

This starter is 40% lighter than a conventional starter and is designed for engines up to 5 liters.

Start with the gearbox

The parameter that determines the rational coordination of the power characteristics of the electric starter with the starting characteristics of the internal combustion engine is the gear ratio /ds of the drive from the starter to the engine. This parameter affects the angle of inclination of the mechanical characteristic of the starter, reduced to the crankshaft of the internal combustion engine. For each engine and taking into account starting conditions, there are optimal gear ratios that allow better use of the power characteristics of the starting device. However, with gearless

the gear ratio /ds cannot exceed 16, which is limited by the mechanical strength of the starter drive gear.

On the other hand, increasing the gear ratio makes it possible to reduce the dimensions and, consequently, the weight of the starter, since these parameters change in inverse proportion to the shaft rotation speed. In recent years, one of the main directions for improving launch systems is reducing the mass of active materials, the cost of which is about 50% of the original cost. At the same time, in addition to the use of well-known methods, such as replacing copper winding wires with lighter aluminum ones and reducing dimensions through the use of insulation of a higher heat resistance class, steel is being used more and more widely.

In Fig. Figure 2.20 shows, as an example, the dependence of the mass of active materials m on the calculated nominal rotor speed of a 1.4 kW starting electric motor. The total mass of the starter c depends on its rated power Rs (Fig. 2.21). In this case, the advantages of gear starters appear already from a power of about 1 kW. For low-power starters installed on small-volume carburetor internal combustion engines, the use of a gearbox does not reduce the overall weight of the vehicle. For them it is advisable to use direct drive.

What kind of starter is installed on MTZ 80 and 82 from the factory?

Which starter MTZ comes with from the factory depends on the modification and year of manufacture of the tractor. Modern tractors of the 80 and 82 families are equipped with an ST-212A 12V 3708.10 starter, the power of which is up to 3 kW. It is powered by two 12/88 3703.16 batteries.

All starters that can be installed at MTZ must have 10 teeth on the gear.

On older modifications of MTZ 80 and 82 tractors you can find different versions of the same starter from different manufacturers. Power varies in the range of 3-3.5 kW. The most common are ST-212A starters produced by Iskra, BATE, Katek, KZATE and others.

Before it, a starter ST 142M produced by BATE with a power of 3.5 kW was installed.

In the catalogs you can find different variations of ST-212-3703 starters, but not all of them are suitable for MTZ tractors. For these tractors, a starter with the index “A” is suitable - ST-212A. Similar models with other indexes have an excellent configuration and will not fit on the Belarusian 80 and 82 series engine.

Final advice

It is preferable to install a geared power unit starting device on a vehicle in those regions where a cold climate prevails for a long time, which makes starting the power unit much more difficult. As you can see, the model with a gearbox is better than the classic version, since it has a long service life, is less demanding on the starting current and battery capacity, and its low price allows you to simply replace the faulty element.

Technical progress does not stand still and is constantly evolving. Every year new technologies emerge, allowing engineers to improve or create completely new parts. This also applies to mechanical engineering. Hundreds of thousands of modern cars are sold in Russia every year. Each of them contains the latest technologies. We will talk about such a small unit as a starter, and we will figure out which starter is better: a gearbox or a regular one.

Let's sum it up

If you decide to replace this unit, then you first need to decide where the starter is located. This is usually the driver's side under or to the side of the engine. To remove it, you need to make room. Depending on the location, it may be necessary to remove the engine protection or the air filter with the box. Next, disconnect the wires and unscrew the bolts. Determining where the starter is located is not difficult. It has a cylindrical shape, and several wires come from it, secured with a nut. Everything is done quite simply and quickly.

So we answered the question about which starter is better: gear or conventional. Classic starters are good in their own way, but are gradually being phased out. But they also have their strengths, just as gearboxes have their weaknesses. For example, in the outback it will be difficult to find spare parts for a starter with a gearbox, but for a regular one - no problem. The same can be said about repairs - not everyone has encountered gearboxes on the starter and not everyone will undertake it. How much does a starter with gearbox cost? It all depends on the brand of the car; a normal one will cost 5-7 thousand rubles.

Starter and its functions

A car starter is a small 4-band electric motor that provides primary rotation of the crankshaft. This is necessary in order to ensure the necessary rotation speed to start the internal combustion engine. As a rule, to start a medium-sized gasoline engine, it is necessary to have a starter that has an average of 3 kW of energy. The starter is a DC motor and supplies energy from the battery. Taking voltage from the battery, the electric motor increases its power with the help of 4 brushes, which are an integral part of any car starter.

Background

Fans of old newsreels will immediately be able to remember the video with the first motorists picking up such a healthy, crooked thing and pushing it somewhere in front under the engine, and then starting to rotate it with force. This is the very first automobile starter (correctly called a “crank/starter” or, in everyday life, a “crooked starter”) with a power of approximately “one human force” - and using it in practice is quite dangerous.

The fact is that after a successful start and in the presence of a direct mechanical connection, the internal combustion engine begins to turn this handle - and if the unlucky car enthusiast does not have time to pull it back in time, then it is quite capable of damaging not only his hands.

With the advent of an electric battery on a car, it became possible to delegate the troublesome work of first starting the internal combustion engine to a special small electric motor, simultaneously adding another mechanical element to the design: the so-called overrunning clutch. This device allows rotation to be transmitted only from the driving rotating shaft to the driven shaft - that is, an already running engine will not be able to spin the starter motor.

It is curious that the popular name “Bendix” for such a clutch is a literal copy of Bendix - the name of one of the first automobile parts manufacturers that invented and produced this useful device.

Which starter is suitable for MTZ (regular)

The options for which starter is suitable for Belarus tractors are presented in the table.

Which starter should be installed at MTZ, choosing among direct-acting electric motors? First of all, pay attention to the reliability of a particular model (for example, many owners call Iskra starters unsuccessful). All other things being equal, it is better to install a starter with the highest starting power on the tractor.

Malfunctions and repairs

In order to properly repair the starting mechanism of the power unit, it is necessary to determine the cause of the breakdown.

The main reasons for the failure of this mechanism include:

• slipping of the freewheel;
• failure of the mechanism shutdown lever;
• premature wear of the handles;
• malfunction of the buffer spring mechanism;
• drive ring wear;
• damage to teeth;
• weak tension of the fastening bolts of the gear mechanism;
• damage to the bearing bushings and journals on the armature;
• weak anchor fastening;
• damage to the traction relay;
• drive jamming on the shaft or drive frame.

Before you begin to repair the electric starter, you must install the vehicle on a special platform or inspection hole and turn off the power unit.

Do-it-yourself UAZ starter faults and repairs:

1. Battery low. In this case, it is recommended to recharge the battery.
2. Oxidation of wires. It is necessary to clean the tips with a toothbrush.
3. Poor tip tension. To ensure quality contact, you need to tighten the tips.
4. Damage to the electrical circuit. It is necessary to carry out an external inspection and eliminate the defect.
5. The anchor device jams and does not turn the solenoid relay. In this case, the worn mechanism should be replaced.
6. If there is an interturn short circuit, it is necessary to conduct an external inspection of the coil of the solenoid relay. If there are breaks or other defects, it is recommended to rewind the wire.
7. If the contacts in the ignition switch are broken, they should be replaced with new ones, because they cannot be repaired.
8. If the collector device burns out during operation of the power unit, then the entire collector must be replaced.
9. If the brush mechanism hangs or it wears out quickly, then you need to replace the brushes, having first disassembled the entire starter mechanism.
10. If the starter turns on, but the crankshaft does not rotate, the starter drive and buffer spring must be replaced, and sticking of the drives must also be eliminated.
11. If the gears do not mesh with the flywheel, it is necessary to check the serviceability of the buffer spring, remove nicks, and adjust the travel of the gears.

Starter relay wiring diagram

The starter relay is located on the safety device mounting block. A complete color connection diagram is available in the vehicle's instruction manual.

In order to connect the electric starter relay, you need to connect the vehicle wire to the starter terminal. After this, the plus is transmitted through the generator set to the ignition switch. After the contacts are closed, the coil of the intermediate type relay closes.

Replacing bushings and assembling starter

In order to replace the starter bushings, it is necessary to remove the battery terminal and then disconnect the two wires from the solenoid relay. After this, unscrew all the fasteners with which the starting device is attached to the coupling mechanism block.

Then disconnect the solenoid relay housing by removing the two bolts. After this, remove the rotor from the bendix plate and use a wrench to remove the starter rear cover. The retaining ring is removed using a flat-head screwdriver. You need to unscrew the two nuts that are on the studs, remove the worn bushing from the seat and install a new one.

To assemble the starter, you must perform the following steps:

1. Press the front bearing into the starter cover on the drive side.
2. Install the clutch onto the trigger armature.
3. Install the retaining ring.
4. Install the thrust washer.
5. Engage the lever clutch with the starter drive and install the clutch together with the armature.
6. Install the rubber plug.
7. Insert the lever axle into the front cover.
8. Install the cotter pin on the front cover.
9. Press the rear bearing onto the rear cover.
10. Install brushes, brush holders and springs.
11. Install the insulating tube.
12. Install the protective cover.
13. Insert the pusher into which the spring must first be installed.
14. Install the winding output.

Starter replacement

Replacing the starter on a UAZ is carried out only in the inspection pit.

First, you need to remove the terminals from the batteries, remove the battery from the vehicle body, remove the air filter element and unscrew the bracket on which the engine cooling system pipe is located.

After this, you can begin to disconnect all the wires that come from the battery. To do this, use a wrench to unscrew the fastening nut that secures the positive terminal, and then remove the wire that leads to the control contacts of the pull-in type relay.

Then you need to unscrew the lower nut using a 13mm wrench and remove the upper bolts. The device should be moved behind the body towards the passenger seat, this will help the bendix come out of its seat near the flywheel.

It is necessary to pull out the old mechanism through the top. After this, you can install a new mechanism. Reassembling the system is carried out in reverse order.

If the UAZ is equipped with a power unit equipped with 16 valves, then it is recommended to first dismantle the right front wheel and the exhaust system manifold reinforcement device, as well as the rear engine mount.