Unit Assembly Procedure

1. Support the gear reduction and drive group with the pinion gear end down.

NOTE: Refer to Fastener Notice in Cautions and Notices.

IMPORTANT: If the armature bearings are being replaced, install the armature bearings on the armature. Refer to Starter Motor Inspection (SD Series) or Starter Motor Inspection (28-MT Series). Testing and Inspection

2. Install the solenoid assembly.
2.1. Pivot the plunger of the solenoid assembly into the engagement with the shift lever in the gear reduction and drive group.
2.2. Position the solenoid assembly mounting flange and install the solenoid mounting screws.

Tighten
Tighten the solenoid mounting screws to 2.8 N.m (25 lb in).

3. Install the frame seal.
4. Install the armature assembly with the bearings into the gear reduction and drive group.
4.1. Make sure the gear teeth of the armature are aligned.
4.2. Fully seat the bearing on the armature into the housing recess.

Frame, Field, And Brush Holder Group:

5. Install the frame, field, and brush holder group.
5.1. Place the dowel pin in the hole of the armature support bracket of the gear reduction and drive group.
5.2. Position the frame, field, and brush holder group over the armature assembly. Align the hole for the dowel pin and the alignment marks.
5.3. Seat the frame, field, and brush holder group in the gear reduction and drive group.

IMPORTANT: Brush spring tension should be 44.5 -49.0 N (10-11 lbs). If not, replace the springs before proceeding.

5.4. Twist the brush springs away from the brushes. Slide the brushes into contact with the commutator on the armature.
5.5. Release the brush springs in order to contact the ends of the brushes.





IMPORTANT: The O-ring seal can easily be damaged during installation of the commutator end frame. Carefully follow the installation procedure.

6. Install the O-ring seal on the frame, field, and brush holder group.
6.1. Install the O-ring seal so that the seal is against the shoulder of the field frame that will abut the commutator end frame when installed.
6.2. Carefully roll the O-ring seal out of the installed position and up onto the major outer diameter of the field frame.
6.3. Allow the seal to remain in this position until the commutator end frame is painfully installed.

Aligning Timing Marks:

7. Install the commutator end frame.
7.1. Align the marks made prior to disassembly on the commutator end frame and the frame and field assembly.
7.2. Start the commutator end frame onto the frame and field assembly, but leave a gap just slightly larger than the thickness of the O-ring seal.
7.3. Use a scribe or similar tool to align the tapped holes in the brush holder assembly with the screw holes in the commutator end frame.
7.4. Install the brush plate screws.

Tighten
Tighten the brush plate screws to 2.8 N.m (25 lb in).

8. Install the through-bolts.
8.1. Tighten the through-bolts by hand, but do not close the gap left for the seal between the end frame and the frame and field assembly.
8.2. Roll the 0-ring seal into the installed position between the commutator end frame and the frame and field assembly.

IMPORTANT: Marks are located in two places on the motor, but will only match one way in order to ensure proper alignment.

8.3. Align the timing ribs on the edge of the commutator end frame with the timing spots on the frame and field assembly.

Tighten
Tighten the through-bolts to 8.5 N.m (75 lb in).




9. Connect the motor lead onto the frame and field assembly.
9.1. Remove the nut from the terminal on the solenoid.
9.2. Install the motor lead terminal. Reinstall the nut.

Tighten
Tighten the solenoid motor terminal nut to 11 N.m (100 lb in).

10. After completion of the overhaul of the starter motor, do a starter no load test. Refer to Starter No Load Test. Testing and Inspection