Kohler COMMAND CH18, Service Manual

Page: 152 / 232

8.28
Section 8
Electrical System and Components
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 8-40.
Figure 8-40. 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.
Starter Reassembly
1. Place the thrust washer (if so equipped) over the
drive shaft of the armature.
Figure 8-39. Style ‘‘A’’ Commutator End Cap with
Brushes.
Self-
Tapping
Screw
Negative
(-) Brush
Stud Terminal with
Positive (+) Brushes
Brush Springs
Brush
Holder
Negative
(-) Brush
Self-Tapping
Screw
Sheet Metal Brush
Holder Tool
Brush Holder Tool Installed
Over Brushes and End Cap
1/2"
1"
1 3/4"
2 1/2"
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 8-41.
Figure 8-41. 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 the starter frame. Hold the drive end and
the commutator end caps firmly to the starter
frame. Remove the brush holder tool.
For Style ‘‘B’’ Commutator End Caps:
4. 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
8-42.
5. 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 installed. Position the end cap over the brush
assembly, so the holes for the thru bolts are
aligned with those in the brush carrier.