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ARMY TM 9-2815-253-24 AIR FORCE TO 38G1-93-2 MARINE CORPS TM 2815-24/3 g. Install cover (10) and secure with two screws (9). h. Install armature (8) in center bracket (15). i. Install brushes in brush holder assembly (5). j. Position  frame  assembly  (7)  on  center  bracket  (15).    Tab  on  frame  assembly  (7)  must  fit  in  notch  in  center bracket. k. Pull brushes upward and install brush holder assembly (15) on frame assembly (7).  Ensure brushes in brush holders seat against commutator bars. l. Position rear bracket (6) and secure brush holder assembly (5) to rear bracket (6) with two screws (4). m. Install two through bolts (3). NOTE Be sure that rectangular hole in solenoid (1) plunger shaft engages lever (21) in housing. NOTE Apply sealing compound (MIL-R-46082) to screws (2) before assembly. n. Install solenoid (1) and secure with screws (2). o. Reconnect wire to solenoid.  Remove tag. p. Check pinion gap as follows: (1) Connect  a  24  VDC  power  source  positive  lead  to  terminal  'S'  on  solenoid  and  negative  lead  to  starter frame. (2) Apply power to solenoid and pinion gear will shift. (3) Disconnect terminal 'M' wire to stop pinion from rotating. (4) Gently push pinion shaft towards solenoid and measure amount of travel.  Refer to FIGURE 3-26.  Pinion gap should be 0.0118 to 0.787 in.  (0.3 to 2.0 mm). (5) Adjust  gap  by  increasing  or  decreasing  number  of  fiber  washers  between  solenoid  and  front  bracket. Increasing number of washers decreases gap and decreasing number of washers increase gap. 3-24.6.  Installation. a. Remove cover in flywheel housing. b. Position starter in flywheel housing and secure with two capscrews (5, FIGURE 3-21) and washers (6).  Tighten capscrews to 30 ft-lbs (40.7 Nm). c. Connect wires to starter as tagged during removal using capscrew (3), new lockwasher (4), nuts (1), and new lockwashers (2).  Remove tags. FIGURE 3-26.  Checking Pinion Gap 3-46


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