TM 5-6115-465-12
NAVFAC P-8-625-12
T.O. 35C2-3-446-1
TM 06858B/06859D-12
CAUTION
Repair
c.
Use care when installing end frame to
(1)
Brush replacement.
avoid damaging the bronze armature
shaft bushing.
NOTE
(n) Install commutator end frame (3) and o-ring
It is not necessary to remove the starter
(4) and secure with lockwashers (2) and screws (1).
assembly from the engine to replace the
brushes.
(2) Solenoid replacement.
(a) Remove screws (1, figure 3-12B) and lock-
NOTE
washers (2).
It is not necessary to remove the starter
(b) Carefully remove commutator end frame (3)
assembly from the generator set to re-
and o-ring (4).
place the solenoid assembly.
(c) Remove screws (5 and 8) to remove electri-
(a) Remove nut (1, figure 3-12A) and lockwasher
cal leads (6 and 9) and brushes (7 and 10).
(2) to disconnect electrical lead (3).
(d) Remove brushholder pin (12) to remove
(b) Remove nut (4), lockwasher (5), nut (6),
brushholder spring (13) and brushholders (14 and 15) from
lockwasher (7) and connector (8).
brush support.
(c) Loosen clamp (9) and remove screws (10) to
(e) Clean commutator end frame, brush support,
remove solenoid assembly (11). Remove boot (12).
brushholders, and brushholder springs in an approved sol-
vent and dry thoroughly.
(d) Remove inspection plug (13) and gasket (14).
(f) Measure brush length. Replace brushes if
(c) Remove adjusting nut (15) and remove plun-
length is 3/8 inch or less.
ger assembly (16) from starter assembly (17).
CAUTION
(f) Remove snap ring (18), o-ring (19), spring re-
tainer (20), spring (21), o-ring (22), spring retainer (23), and
Use extreme care to avoid enlarging
washer (24) from plunger (25).
commutator slots.
(g) Clean solenoid frame assembly with filtered
(g) Inspect starter armature commutator slots
compressed air and a soft bristle brush.
for thrown solder. Remove any found with a narrow blunt
instrument.
(h) Using an ohmmeter, check for continuity be-
tween solenoid frame assembly terminals. Replace entire
(h) Check bronze bushing in commutator end
solenoid assembly if discontinuity is noted.
frame and armature shaft for deep wear patterns, scoring,
or other damage. Replace starter assembly if damage exists.
(i) Clean all other parts in an approved solvent
and dry thoroughly.
(i) Check brushholders and brush support for
corrosion, cracks, breaks, and other damage. Replace any
Inspect plunger for cracks, corrosion, and
(j)
defective parts.
other damage.
(j) Inspect electrical leads and visible starter
(k)
Inspect seal for damage and deterioration.
assembly wiring for burned insulation, bare wires and rub
marks. Replace starter assembly if damage is present.
Inspect spring for cracks, breaks, & distortion.
(l)
(k) Check all attaching hardware for stripped,
Replace any defective parts.
(m)
crossed or otherwise damaged threads. Replace any dam-
aged or defective parts.
(n) Install washer (24), spring retainer (23), o-
ring (22), spring (21), spring retainer (20), and o-ring (19)
(l) Install brushholders (14 and 15) and spring
onto plunger (25) and secure with snap ring (18).
(13) and secure with pin (12).
(o) Install plunger assembly (16) into lever hous-
(m) Install brushes (7 and 10) and electrical
ing.
leads (6 and 9) and secure with screws (5 and 8).
Change 7
