Kohler COMMAND CV11-16 Service Manual page 81

NOTE: Use a brush holder tool to keep the
brushes in the pockets. A brush holder
tool can easily be made from thin sheet
metal See Figure 8-22.
Stud Terminal with Positive (+) Brushes
Self-Tapping
Screw
Negative
(-) Brush
Figure 8-21. Style "A" Commutator End Cap with
Brushes.
Brush Holder Tool Installed
Over Brushes and End Cap
2 1/2"
1"
1 3/4"
Sheet Metal Brush
Holder Tool
Figure 8-22. Brush Holder Tool (Style "A" End
Cap).
Style "B" End Cap Brush Replacement
Starters with Style "B" end caps have the brushes in
a plastic carrier housing, separate from the end cap.
Replacement brushes come preassembled in the
carrier housing, retained with two carton staples.
Commutator Service
Clean the commutator with a coarse, lint free cloth. Do
not use emery cloth.
If the commutator is badly worn or grooved, turn it
down on a lathe or replace the armature.
Negative (-) Brush
Brush Holder
Self-Tapping
Screw
Brush Springs
(Under Brushes)
1/2"
Electrical System and Components
Starter Reassembly
1. Place the thrust washer (if so equipped) over the
drive shaft of armature.
2. Insert the armature into the starter frame. Make
sure the magnets are closer to the drive shaft end
of armature. The magnets will hold the armature
inside the frame.
3. Install the drive end cap over the drive shaft.
Make sure the match marks on the end cap and
starter frame are aligned. See Figure 8-23.
Match Marks
Figure 8-23. Starter Assembly Match Marks.
For Style "A" Commutator End Caps:
4. Install the brush holder tool to keep the brushes
in the pockets of the commutator end cap.
5. Align the match marks on the commutator end
cap and starter frame. Hold the drive end and
commutator end caps fi rmly to the starter frame.
Remove the brush holder tool.
For Style "B" Commutator End Caps:
4a. If the brush assembly is not being replaced,
position the brushes in their pockets in the carrier,
move them to the retracted position, and install
carton staples to retain them. See Figure 8-24.
5a. Align the terminal stud block with the notch in the
starter frame and slide the brush/carrier assembly
into the frame. The commutator will push the
carton staples out as the brush assembly is
inserted. Position the end cap over the brush
assembly, so the holes for the thru bolts are
aligned with those in the brush carrier.
Section 8
8
8.21