Unit Assembly

Electrical Group:

Aligning Timing Marks:

Support the gear reduction and drive group with the pinion gear end down and proceed as follows:

IMPORTANT If the armature bearings are being replaced, install them on the armature, refer to "Armature Bearing Replacement".

Electrical Group:

Gear Reduction And Drive Group:

Aligning Timing Marks:

Install or Connect
1. Solenoid assembly.
A. Pivot the plunger of the solenoid assembly into engagement with the shift lever in the gear reduction and drive group.
B. Position the solenoid assembly mounting flange and install the solenoid mounting screws.
Tighten
- Solenoid screws to 2.8 N.m (25 lb in).
2. Frame seal.
3. Armature assembly with bearings into the gear reduction and drive group.
- Make sure the gear teeth are aligned, then seat the bearing on the armature shaft fully into the housing recess.
4. Frame, field, and brush holder group.
A. Place the dowel pin in the hole in the armature support bracket of the gear reduction and drive group.
B. Position the frame, field, and brush holder group over the armature assembly, align the hole for the dowel pin and marks made prior to disassembly, and seat in the gear reduction and drive group.

Electrical Group:

C. Twist the brush springs away from the brushes, slide the brushes in to contact the commutator on the armature, and release the brush springs to contact the ends of the brushes.
- Brush spring tension should be 44.5 to 49 N (10 to 11 lbs). If not, replace the springs before proceeding.
5. O-ring seal.
IMPORTANT The O-ring seal can easily be damaged during installation of the commutator end frame. To prevent such damage, install the O-ring seal as described in the following steps.
A. Install the O-ring seal on the frame, field, and brush holder group so that it is against the shoulder on the field frame. The O-ring seal will abut the commutator end frame when installed. This is the normal-installed position of the O-ring seal.
B. Carefully roll the O-ring seal out of its normal-installed position up onto the major outer diameter of the field frame. Allow the seal to remain in this position until the commutator end frame is partially installed.
6. Commutator end frame.

Aligning Timing Marks:

A. Align the marks on the commutator end frame and frame and field assembly made prior to disassembly.
B. Start the commutator end frame onto the frame and field assembly, leaving a gap just slightly larger than the thickness of the O-ring seal.
7. Brush plate screws.

Electrical Group:

- Use a scribe or similar tool to align the tapped holes in the brush holder assembly with the screw holes in the commutator end frame.
Tighten
- Brush plate screws to 2.8 N.m (25 lb in).
8. Through-bolts.
A. Install the through-bolts and tighten by hand, but do not close the gap between the commutator end frame and frame and field assembly where the O-ring seal goes.
B. Roll the O-ring seal back down into its installed position between the commutator end frame and the frame and field assembly.

Aligning Timing Marks:

C. Align the timing ribs on the edge of the commutator end frame with the timing spots on the frame and field assembly to ensure proper brush alignment. Marks are located in two places on the motor, but will only match one way.
Tighten
- Through-bolts to 8.5 N.m (75 lb in).

Electrical Group:

9. Motor lead onto the frame and field assembly.
- Remove the nut from the terminal on the solenoid, install the motor lead terminal, and reinstall the nut.
Tighten
- Solenoid motor terminal nut to 11 N.m (100 lb in).