ARMY TM 9-6115-464-34
AIR FORCE TO 35C2-3-445-2
NAVY NAVFAC P-8-624-34
f. Installation. Refer to the Operator and Unit Maintenance Manual for starter assembly installation
procedures.
3-5. STARTER ASSEMBLY. (Effective with serial numbers RZ60001 and up and KZ00001 thru KZ01226).
a. Removal. Refer to the Operator and Unit Maintenance Manual for starter removal procedures.
b.Disassembly.
(1) Remove nut (1, figure 3-4), lockwasher (2), nut (3) and Iockwasher (4).
(2) Loosen clamp (5) and remove screws (6) to remove solenoid assembly (7) from starter assembly.
(3) Remove boot (8) and clamp (5).
c. SoIenoid disassemble.
(1) Remove nuts (9), Iockwashers (10), nuts (11), flat washers (12), insulating washers (13) and
connector (14).
(2) Remove screws (15) and flat washers (16) to remove cover (17) and gasket (18) from solenoid frame
assembly (19).
(3) Remove terminal studs (20 and 21) and terminal clip (22) from cover (17). Remove spring (23) and
contact (24).
d. Starter Disassembly.
(1) Remove inspection plug (25) and gasket (26). Remove adjusting nut (27) to remove plunger.
(2) Remove snap ring (29), o-ring (30), spring retainer, spring (32), o-ring (33), spring retainer
and washer (35) from plunger (28).
(3) Remove screws (36) and Iockwashers (37) to remove commutator end frame (38), o-ring (39) and
space washer (40).
(4) Do not remove bushing (41) unless inspection reveals damaged parts.
(5) Remove pins (42) to remove brush springs (43) and brushholders (44).
(6) Remove screws (45), electrical leads (46) and brushes (47) from brushholders (44).
(7) Remove screws (48), Iockwashers (49), and nuts (50) to remove brush supports (51).
(8) Remove screws (52) to remove drive housing (53) and o-ring (54).
(4) Conduct starter assembly stalled torque test as follows:
CAUTION
(a)
(b)
(c)
(d)
(e)
(f)
Rheostat must have a minimum capacity of 1000 amperes. Failure to observe this
caution could result in equipment damage
Install starter assembly in test setup shown in figure 3-3.
Adjust rheostat until voltmeter indicates 14 Vdc.
Ammeter should indicate 540 amperes maximum at a minimum torque of 26 ft-lb indicated on
scale.
If both current and torque are low, disassemble the starter and check for poor internal connections
or improper brush contact. Both of these conditions would result in high internal resistance.
High current and low torque may be caused by defective armature or field coil assembly.
Remove starter assembly from test setup and install terminal lead (3, figure 3-1).
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