Onan T260G Service Manual page 36

Brush Replacement: Cut old positive brush from pigtail
at the brush. Be careful not to damage field coil. Clean
1 / 4 to 3/8 inch (6.5 to 9.5 mm) of brush end of pigtail
with sandpaper or emery cloth (Figure 11).
PIGTAIL
STILL ATTACHED
TO FIELD COIL (approx. CLEAN 1/4 to 3/8 inch)
MUST NOT
EXTEND BEYOND
BRUSH SURFACE
SMALL CHAMFER
LARGE CHAMFER
REPLACEMENT
BRUSH
FIGURE
11.
BRUSH REPLACEMENT
Push prepared end of pigtail lead into hole in replace-
ment brush from the small chamfered side. Solder pigtail
lead to replacement brush on the large chamfered side,
using 50/50 tin/lead, rosin core solder and a standard
240/325 Watt soldering iron. Use a file to remove any
excess solder that may extend beyond brush surface.
CAUTION
Pigtail lead must not protrude from
surface on the soldered side of brush.
Toprevent stiffening of pigtaillead to not use excessive
amount of solder and heat.
Starter Mounting
Before installing starter motor, make sure the starter
mounting surface on the engine base is clean and free
of oil.
To install starter on T-260G (Spec A) engines use the
following procedure. On these engines starter pinion
gear lash requires adjustment and must be checked
when starter is installed.
Install starter motor and tighten mounting capscrews
just enough to hold starter in place.
Remove spark plugs from the engine. This allows
free movement of the flywheel.
Manually pull the starter pinion gear outward on its
shaft until pinion gear teeth mesh completely with
flywheel ring gear teeth. Energize solenoid on
solenoid shift starter.
Measure the amount of free travel (lash) between
the pinion gear teeth and the ring gear teeth. See
Figure 12. If lash is too tight, causing binding and
slow starter operation, or if lash is greater than 0.035
inch (0.889 mm), lash must be adjusted.
9-6
FLYWHEEL RING GEAR
STARTER GEAR FREE TRAVEL WHEN
0.020 0.015 inch (0.51 0.38 mm)
ENGAGED WITH FLYWHEEL GEAR
STARTER MOTOR
PINION GEAR
ES-1003
5.
6.
7.
8.
9.
FIGURE 12. CHECKING STARTER GEAR LASH
To adjust lash on starters without slotted mounting
holes, remove starter. Use a 21/64 inch (8.334 mm)
drill to enlarge one mounting hole in starter mounting
bracket.
Install starter motor and adjust lash to 0.020 in.
0 . 0 1 5
in: (0.51 mm 0.38 mm).
Remove flywheel and torque starter mounting
capscrews to 24 to 26 ft-lbs (33 to 35 Nm). Use Onan
flangehead capscrews or SAE grade 8 capscrews
with a hardened flatwasher. Do not use lockwashers.
CAUTION
properly may cause starter failure
Failure to torque starter bolts
and ring gear damage.
Install flywheel spark plugs, blower housing, and
cylinder air housings. For correct cylinder air
housing installation (required on some models),
refer to Cylinder Air Housing Clearance.
Connect battery cable and wires to starter. Connect
battery cables to battery. Connect ground cable last.
To install starter on T-260G (Beginning Spec B) engines
use the following procedure. On these engines starter
pinion gear lash does not require adjustment.
1.
2.
3.
Install starter motor and torque mounting capscrews
to 24 to 26 ft-lbs (33 to 35 Nm).
Install flywheel, blower housing, and cylinder air
housing. For correct cylinder air housing instal-
lations (required on some models), refer to Cylinder
Air Housing Clearance.
Connect battery cable and wires to starter. Connect
battery cables to battery. Connect ground cable last.