TM 5-4240-501-14&PSTARTERSGear Drive 12V & 120VFig. 107 - Assembling Armature to End CapSlide motor housing over armature with the notch towardcommutator end cap. Match alignment marks. Fig. 94.Care should be used to prevent damage to magnets inmotor housing during assembly. Assemble spacers anddrive head end bracket, again aligning match marks.Armature end play is .006 to .038" (.15 to .97 mm) afterassembly.Assemble thru bolts and washers. Torque thru bolts, 45to 55 inch pounds (5.1 to 6.2 Nm) for 1/4- 20 thru boltsand 40 to 45 inch pounds (4.5 to 5.1 Nm) for 10-24 thrubolts.HIGH POTENTIAL (HI-POT) TEST -120 VAC (ONLY)Before anc after repairing the 120 volt AC starter motor,a Hi-Pot test must be made to prevent injury. If theproper test equipment is not available, take the startermotor to a qualified electric motor repair shop for testing.After assembly of the starter motor drive and Hi-Pot testis passed, the starter motor is now ready for installationto the engine.GEAR DRIVE STARTERS120 VOLT AC; 12 VOLT DCSTARTER MOTOR - USED ON SERIES140000, 170000 and 190000These starter motors use a gear type engagementmethod, similar to an automobile starter. When thestarter motor is activated, the helix on the starter motorshaft drives a pinion gear into engagement with a ringgear attached to the engine flywheel and cranks theengine.Electrical shock is always a hazard with any electricalequipment. To minimize the hazard of electrical shock,the 120 volt starter motor is provided with a three wirepower source connection. To maintain the safetyprovided against electrical shock, the extension cordused between the starter motor and the power sourcemust be a three wire cord, which connects to a properlygrounded receptacle. DO NOT USE power cords longerthan 25 feet.Fig. 108 - 120 Volt Gear Drive Starter MotorCAUTION: DO NOT run starter motor for more than oneminute without cooling 15 minutes.It is recommended a battery of 32 ampere hour capacitybe used with the 12 volt starter. The battery cable sizeshould be #4 or #6. Note: A battery of higher amperagemay be required for extremely cold weather startingconditions.Replacing a Ring GearTo replace a worn or damaged flywheel ring gear, seepage 23, Fig. 82.30
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