TM5-6115–585–34 NAVFAC  P-8-623-34 TO-35C2-455-2 TM-05684C/05685B-34 CHAPTER  5 MAINTENANCE  OF  STARTING Section I.    DESCRIPTION  AND 5-1. GENERAL SYSTEM FUNCTION The  engine  is  cranked  by  a  24  volt  electric  starter. when the starter motor solenoid is energized, the solenoid  core  pulls  in,  shifting  the  pinion  gear into  engagement  with  the  engine  flywheel  ring  gear. The starting motor is protected from overspeeding by  an  overrunning clutch. At the same time, con- tacts in the solenoid close to provide a circuit for  the  starter.  Two  12  volt  batteries  in  series are used. The starting switch for this starting circuit  is  located  in  the  control  cubicle. Refer to the Operator and Organizational Mainten- ance  Manual.  for  starting  and  operating  the  set.  A blower wheel alternator is utilized to recharge the  batteries. a.  A  new(Style  II)  gear-reduction  electric starter will be installed on engines manufactured during  1990;  and  will  be  available  as  a  replacement when the original starter, (Style I) is no longer available. The Style II starter are interchange- able  with  the  Style  I  starter. Section  II.  MAINTENANCE 5-2. a. STARTER  ASSEMBLY Test on Equipment. Refer to the Operator and organizational   Maintenance   Manual. b. Renuval. Refer to the Operator and Organiz- ational   Maintenance   Manual. c. Disassembly; Style I (see figure 5-1) (1)  Remove  nut  (1)  and  lockwasher  (2)  from solenoid (13). Remove nut (3) and lockwasher (4) from brush assembly (21) terminal. Tag and remove lead (5).Remove nut (6) and lockwasher (7) from lower solenoid terminal, and loosen field coil connector   (8). (2) Remove cutter pin (9) and pin (10) from yoke  (32).  Remove  screws  (ll),lockwasher  (12) and remove solenoid switch (13). (3)  Remove  through  bolts  (14),  lockwasher (15) and remove back plate assembly (16) and thrust washer (27). Remove nut (17) and lockwasher (18)  from  brush  assembly  (21)  terminal.  Lift  brush springs  (20)  and  remove  brush  assembly  (21). the insulating washer set (19) from brush assembly (21). With brush spring raised, remove other brushes (26) from brush holder (24). Remove screws (22), lockwashers (23) and remove brush holder  (24). (4)  Remove  retainer  (29),  boot  (30),  pin  (31) and separate pinion housing (28) and frame assem- bly (25). Do not lose thrust washer (27). (5) Remove yoke (32) ad  remove armature  (33) and drive assemblv (35). Remove lock ring and stop (34) by forcing stop toward armature until lock ring becomes accessable. See figure 5-3. Remove lock  ring  and  stop(34),  and  drive  assembly  (35) from armature (33). Do not disassemble drive assembly. (6) Remove bearing (36) by pressing from pinion  housing  (28). d.Disassembly; Style II (see figure 5-2) (1) Remove nut (1) and lockwasher (2) from Solenoid (5). Move lead terminal off solenoid and swing it aside. Install nut and lockwasher on solenoid threaded terminal for safe-keeping. (2)  Remove  screws  (3),  spacer(s)  (4)  and remove  solenoid  (5)  from  front  bracket. NOTE Solenoid mounting screw removal may requ- ire  the  use  of  a  impact  type  driver. (3)  Remove  nuts  (6),  flat  washers  (7)  and remove  ground  terminal  bracket  assembly  (8). NOTE Disassembly of ground terminal bracket assembly not required unless the terminal threads have been damaged. Refer to the repair  parts  manual  for  terminal  components. C h a n g e    8   5-1