ARMY TM 9-6115-464-12
AIR FORCE TO 35C2-3-445-1
NAVY NAVFAC P-8-624-12
Inspect electrical leads and visible starter assembly wiring for burned insulation, bare wires and
rub marks. Replace starter assembly if damage is present.
Check all attaching hardware for stripped, crossed or otherwise damaged threads. Replace any
damaged or defective parts.
(m) Install brushholders (19 and 20) and spring (18) and secure with pin (17).
(n) Install brushes (11 and 15) and electrical leads (10 and 14) and secure with lockwashers (9 and
13) and screws (8 and 12).
Use care when installing end frame to avoid damaging the bronze armature
shaft bushing. Equipment damage could result if caution is not observed.
(o) Install commutator end frame (7) and O-ring (4) and secure with lockwashers (2) and screws (1).
(p) Install oil wick (6), saturate with oil and secure with pipe plug (5).
(2) Solenoid replacement.
It is not necessary to remove the starter assembly from the generator set to re-
place the solenoid assembly.
Remove nut (1, Figure 4-6) and lockwasher (2) to disconnect electrical lead (3).
Remove nut (4), lockwasher (5), nut (6), lockwasher (7) and terminal lead (8).
Loosen damp (9) and remove screws (10) to remove solenoid frame assembly (11). Remove
Remove drive housing plug (13).
Remove retaining ring (14) and lever pin (15) to remove plunger assembly (16) from starter
Remove retaining ring (18) to separate spring retainer (19), spring (20), seal (21), seal retainer (22),
and spring retainer (23) from plunger (24).
Clean solenoid frame assembly with filtered compressed air and a soft bristle brush.
Using an ohmmeter, check for continuity between solenoid frame assembly terminals. Replace entire
solenoid assembly if discontinuity is noted.
Clean all other parts in an approved solvent and dry thoroughly.
Inspect plunger for cracks, corrosion. and other damage.
Inspect seal for damage and deterioration.
Inspect spring for cracks, breaks, and distortion.
Replace any defective parts.
Install spring retainer, seal retainer, seal (21), spring (20), and spring retainer (19) onto
plunger (24) and secure with retaining ring (18).
Install plunger assembly (16) into drive end housing.
Install lever pin (15) and secure with retaining ring (14).
Install plug (13).
Install sleeve (12) and clamp (9) onto drive end housing.