Figure 5-13 Checking Pinion Clearance STYLE I Starter

(8) Slide spring (35), pinion gear(34) and Stopper (33) onto shaft. Position retaininq ring (32) in groove on shaft and pull stopper over ring to secure it. A bearing puller tool may be required. (9) Place bearings (16) and (18) on the armature shaft, and insert armature into the center bracket. Slide Stator (15) over armature and into center bracket. Align stator to bracket by fitting tab on stator into notch on center bracket. (10) Place brush holder (14) with brush springs (12) in place, over the communtator of the armature. Lift each brush spring (12) and insert brush (13) into the guide on the brush holder (14). (11) Place rear cover (11) over brush holder and against stator (15). Rotate slighly and align threaded holes in brush holder with holes in cover. Secure brush holder to cover with screws (10). (12) Pass thru studs (9) through rear cover (11) into tappd holes in front bracket assembly (37) and secure. (13) Place washers (7) on thru studs, place terminal bracket assembly (8) on studs and add nuts (6). (14) Place spacers (4) on solenoid switch (5) and align solenoid plunger slot over lever (30). Secure solenoid and spacers to front bracket assembly (37) with screws (3). (15) Install field coil lead from stator (15) onto lower threaded terminal of the solenoid (5). Secure with nut (1) and washer (2). J. Test after Repair/Overhaul. Style I Starter (1) After the starter is assembled, check the armature end play by inserting thickness gauge between thrust washer (27) and pinion housing (28). See figure 5-1. It should be bet- wen 0.005 and 0.035 inch. Adjust end play by adding or removing thrust washers (27) on the commutator end of the Armature. (2) Check pinion gear clearance. See figure 5-13. Proper clearance is important to insure starter engagement. To check, press on solenoid plunger to shift pinion gear into full mesh posi- tion. While holding plunger in, measure clearance with feeler gauge (4) between pinion gear and step. The proper clearance is 0.096 +0.030/-0.020 inch. Adjust clearance by turning solenoid plunger link (1) in to decrease gap, or out to increase the gap. See figure 5-13 cutaway view. Reinstall the pin (2) and cotter pin (3) securing plunger link (1) to yoke. TM5-6115-585-34 NAVFAC P-8-623-34 TO-35C2-455-2 TM-05684C/05685B-34 Figure 5-13 Checking Pinion Clearance STYLE I Starter K. Test after Repair/Overhaul. Style II Starter. (1) After starter is assembled, check the pinion gear travel to ensure proper starter enga- gement. See figure 5-14. (a) To measure, provide as 24 volt DC power source, such as battery. Connect the positive“+” battery to the solenoid terminal (S) with a electrical lead that includes a momentary switch. (b) Connect the negative “-” battery ter- minal to the ground terminal (G), with electrical lead. (c) Remove nut and lockwasher from terminal (M), than remove and secure lead (L) away from the solenoid. (d) Close and hold the momentary switch to apply power to terminal (S) forcing the solenoid plunger to pull the lever and move the pinion gear forward. Measure the distance between mounting surface of starter front bracket and outer edge of pinion gear to determine the maximum travel(X). Release the power source and the internal springs will move lever to original position, returning the pinion gear to its at rest position. Measure this distance (Y). The difference between measur- ement (X) and (Y) should fall within the nominal travel distance (Z) of 17mm + or - lmm. Change 8 5-11