(15) Using a 110 V ac test lamp or multimeter set

Figure 4-6. Testing Starter Armature for Grounds and Opens

TM-9-6115-604-34 Generator Set Diesel Engine Driven Tactical Skid Mtd 5 Kw. 1 Phase-2 Wire 1 Phase -3 Wire 3 Phase -4 Wire 120. 120/240 and 120/208 Volts Manual
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TM 9-6115-604-34 NAVFAC P-8-633-34 (15) Using a 110 V ac test lamp or multimeter set to RX1 scale, test for field coil ground. Touch one probe to the field coil terminal and the other probe to the field frame (64). If lamp lights, the coil or terminal is grounded. Remove attaching parts (37 through 54) and position the terminal and insulators (56) so that they are not in contact with the field frame (64). Repeat the test. I the lamp lights, the coil(s) are grounded. If the lamp does not light, the terminal was grounded. Replace the field terminal washers (54) and terminal bushing (55) and field coil insulator (56) to correct the defect. (16) Test the field coils for continuity by connecting the 110 V ac test lamp, or multimeter set to RX1 scale, between the two field coil leads. If the lamp does not light, the field coils are open and must be replaced. (17) Visually check the brush holders, electrical holder assembly (51) and flat washer (52) for physical damage. (18) Using a 110 V ac test lamp, or multimeter set to RX1 scale, test the insulated brush holders for grounding to the electrical holder assembly (51). N the test lamp lights, replace the electrical holder assembly. (19) Test the electrical holder assembly (51) for isolation from the starter housing (43) by placing one probe of the 110 V ac test lamp, or multimeter set to RX1 scale, to the terminal on the electrical holder assembly, and the other probe to the starter housing. If the test lamp lights, replace the insulators (41, 42, and 46) as necessary. (20) Temporarily install the electrical holder assembly (51) and electrical brushes (48) over the commutator. Inspect the helical springs (50) for heat discoloration and check the spring tension using a spring scale and suitable bent rod. The tension required to lift a brush just dear of the commutator shall not be less than 2 pounds (0.9 kg). (21) Test the electrical solenoids B1 L3 or 82L4 (13) in accordance with the Operator and Organizational Maintenance Manual. (22) Check the fit of the plunger (1 2) in the bore of the electrical solenoids B1L3 or B2L4 (13), the plunger must move freely in the bore. (23) Check the free length of the plunger spring (8). The minimum free length shall be 2.296 inches (58.32 mm). (24) Check the shift lever shaft (17) for wear. (25) Check the shaft lever (15) for wear or elongation of the shaft holes, and excessive wear at the drive contact pads. (26) Check the pinion teeth of the drive assembly (25) for burrs, nicks, cracks, and uneven wear. Replace a defective drive assembly. (27) Check the overrunning clutch in the drive assembly (25) for proper action. The pinion should turn freely in a clockwise direction, and lock when turned counterclockwise. No detectable backlash should be felt when going from the overrunning to the locked position. CAUTION To avoid damage to the armature In the following test, do not damp the commutator or the bushing surfaces of the armature In the vise. Pad the vise laws with thick leather, wood, or several layers of shop cloths. (28) Temporarily install the drive assembly (25) on the armature (63) and clamp the armature in a padded vise. Using a 12-point deep socket and torque wrench, apply 50 pound-feet (68 newton-meters) of torque in a counterclockwise direction of the pinion. Replace the drive assembly if slippage occurs. (29) Check the prevailing torque of the plunger rod nut (5) in accordance with Table 1-3. Replace the plunger rod nut if it does not meet the minimum requirements of Table 1-3. (30) Replace the starter housing (43, Figure 4-3) and stator and lever housings (21 and 28) if cracks or other damage are found that would impair proper functioning. (31) Repair threaded holes in accordance with paragraph 2-12. (32) The drive housing and housing lever bushings (24 and 32) and sleeve bearing (45) are bronze and must be lubricated and installed properly to achieve long service life. Replace worn bushings and bearings as follows: (a) Remove drive housing and housing lever bushings (24 and 32) using bushing drivers. Remove sleeve bearing (45) using a blind-hole bushing puller, or a bushing cutter, being careful not to cut into the starter housing (43). 4-12

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