Direct Drive Starting Motor

Maintenance and Overhaul

…………………………………………………………
Covers Starter Series: All Except ES646 & MagnaFlite Lightweight Starter ES2001
NOTE:
Circled items in this chapter
represent replacement parts
required at each overhaul.

GENERAL:
The starting circuit is designed to carry high current
with a minimum loss of voltage. The starting circuit
includes the battery, solenoid switch, manual
starting switch, starter motor, wiring and frame.
The starter motor cranks the engine for starting
while the battery supplies the power and the
manual key-switch and solenoid starting switch
control the operation.

Figure 1 - Direct Drive Starters,

The starter motor must develop a high cranking

Except Lycoming Style MagnaFlite.

torque during the period of time when the starting
switch is closed. The starter motor is designed to
engage its pinion in the flywheel ring gear on the
engine at the beginning of the starting cycle, and then disengage the pinion as soon as the
engine starts. This is accomplished through the use of a starter drive clutch assembly,
commonly referred to as a “Starter” drive. See (Figure 1).

DESCRIPTION AND PRINCIPLES OF OPERATION:

Figure 2:
Principle
Components
of Typical
Direct Drive
Starting Motor,
3

Except
1

MagnaFlite 1
Lightweight
Starter.
2

4
6
5

Overhaul Manual - Aircraft Alternators & Starters

Part Number OE-A2 - Rev. 06 8-30-01
 The starter motor consists of six main components: (1) The Frame and Field Assembly, (2)
The Armature, (3) The Commutator End Head, (4) The Intermediate Bearing Assembly
(where applicable), (5) The Pinion Housing, and (6) The Starter Drive Assembly (where
applicable). See (Figure 2).

When the starting circuit is energized, battery current is applied to the starting motor terminal.
Current flows through the starter field coils creating a strong magnetic field. At the same
time, current flows through the brushes to the commutator, through the armature windings to
ground. The magnetic forces created in the armature and in the field windings, combine and
begin to turn the armature.

When the armature turns, the Bendix drive pinion meshes with the flywheel ring gear by
inertia and action of the screw threads within the Bendix sleeve. A detent pin engages in a
notch in the screw threads which prevents disengaging if the engine fails to start when the
starting circuit is de-energized.

When the engine reaches a predetermined speed, centrifugal action forces the detent pin out
of the notch in the screw shaft and allows the pinion gear to de-mesh from the flywheel ring
gear.

1. The Frame and Field Assembly includes the frame - which physically supports the other
components of the motor, the field coils, the brush holders (on certain models) and
brushes, and the pole shoes. The field coils supply the strong magnetic field required for
producing torque while the pole shoes and frame provide the path for the magnetic field.

2. The Armature consists of a laminated soft iron core assembled on the armature shaft, a
commutator and the windings, which are wound in slots in the core and connected to the
commutator. The commutator is made up of a number of copper segments insulated from
each other and from the armature shaft. The armature shaft extends through the pinion
housing and supports the starter drive (on certain models).

3. The Commutator End Head contains a bearing and in certain models the brush holder and
brushes in which the armature shaft rotates.

4. The Intermediate Bearing Assembly supports the armature shaft at a point between the
frame and field assembly, and the pinion housing.

5. The Pinion Housing partially encloses the drive mechanism and contains the other bearing
in which the armature shaft rotates.

6. The Starter Drive operates using a combination of screw action and inertia. The pinion is
mounted on a threaded sleeve, which is driven by the armature.

Overhaul Manual - Aircraft Alternators & Starters

8-40-01 Part Number OE-A2
STARTER OVERHAUL INSTRUCTIONS:

!
CAUTION: WHEN SERVICING THE STARTER, ALL REPLACEMENT PARTS
MUST BE ORIGINAL EQUIPMENT PARTS MANUFACTURED BY HET OR AN
APPROVED HET SOURCE. FAILURE TO USE GENUINE HET REPLACEMENT
PARTS MAY RESULT IN SERIOUS DAMAGE TO THE STARTER OR OTHER
ELECTRICAL SYSTEM COMPONENT AND MAY RESULT IN INJURY.

NOTE 1: During overhaul the following components must be replaced with new:
1. Drive End Bearing
2. Starter (Bendix) Drive
3. Thrust Washer Package
4. Needle Bearing
5. Brush Set
6. Commutator End Bearing
7. Field Coil
8. Terminal Stud Package
9. Hardware

NOTE 2:
Before removing the starting motor from the engine, disconnect the ground cable
from the battery post to prevent short circuiting. Disconnect the lead from the
starter motor terminal, then remove the mounting bolts and nuts. The starter
motor can then be removed and taken to the bench for overhaul.

STARTER DISASSEMBLY:
Direct Drive Starter Motor With Starter (Bendix) Drive:

NOTE:
As the motor is disassembled, each part should be cleaned and inspected for
excessive wear or damage. Bushings must be replaced during overhaul. Oil and
dirt should be removed from insulation and the condition of insulation should be
checked. The armature should be checked for shorts, grounds or open circuits.

1. Remove the cover band from the field case (where applicable).

2. Remove the battery terminal stud nuts, lockwashers, and insulators from the battery
terminal stud. Discard nuts, washers and insulator.

3. Using a flat blade screwdriver or other suitable tool,

unload the brush spring tension from the four brushes
as shown in (Figure 3). Remove the screws that hold
the commutator end head assembly to the field case,
and separate the commutator end head assembly
from the field case.

4. Carefully bend the negative brush shunt clamps out Figure 3 - Unload Brush
and remove the brush shunts. Discard the brushes. Spring Tension.

Overhaul Manual - Aircraft Alternators & Starters

Part Number OE-A2 - Rev. 05 8-50-01
 5. Remove the four screws that secure the drive end head assembly
to the field case, and remove the drive end head assembly,
intermediate bearing assembly, and armature.

6. Remove the two screws that secure the intermediate bearing

assembly to the drive end head assembly.

7. Remove the armature and the bendix drive from the drive end
head assembly and push the drive end bearing from the drive end
Figure 4 - Drive End
head assembly (Figure 4).

Bearing Removal.

8. Remove the four screws that hold the field pole shoes to the field case.

NOTE:
Strike the pole shoe screws once or twice firmly with hammer and drift pin
punch to loosen the screws for ease of removal. De-solder Battery terminal
from field coil assembly.

9. Remove the field coils and discard them.

10. Remove the battery terminal stud from the field case and discard.

11. Place the bendix assembly in a vise or other holding fixture, and press together until roll
pin is visible.

12. Use a drift pin punch to carefully drive out the

retaining roll pin as demonstrated in (Figure 5).
Remove the armature shaft and intermediate
bearing assembly from the bendix drive.
Discard the bendix drive.

Figure 5 - Roll Pin Removal.

13. Remove the intermediate bearing assembly from the armature shaft and remove the
bushing. Discard the bushing.

14. Using an internal bearing removal tool, remove the commutator end bearing from the
commutator end head assembly, and discard it.

Upon completion of disassembly, all parts should be cleaned and visually inspected for
cracks, wear, distortion and any signs of overheating or mechanical interference. Any
cracked, worn, or distorted parts must be discarded and replaced with new HET parts. Refer
to the Specifications and Limitation Table for tolerances on the parts removed and inspected
for wear.

Overhaul Manual - Aircraft Alternators & Starters

8-60-01 Part Number OE-A2 - Rev. 05
Direct Drive Starter Motor Without Starter (Bendix) Drive:

NOTE:
As the motor is disassembled, each part should be cleaned and inspected for
excessive wear or damage. Bushings and bearings must be replaced during
overhaul. Oil and dirt should be removed from insulation and the condition of
insulation should be checked. The armature should be checked for shorts,
grounds or open circuits. For ES646 series, refer to page 8-410-01.

1. Remove safety wire from commutator end head assembly (where used).

2. Remove the battery terminal stud nuts, lockwashers, and insulators from the battery
terminal stud. Discard nuts, washers and insulator.

3. Remove the two screws that secure the drive end head assembly to the field case (MHJ
Series, MCL Series).

4. Remove the thru-bolts from the field case.

5. Remove the commutator end head assembly from the field case.

6. Remove the three screws that secure the brush plate assembly to the field case, and
remove the brush plate assembly. On 28-volt direct drive starting motors there is a field
shunt screw that must be removed before the brush plate assembly can be removed from
the field case.

7. Unload the brush spring tension from the positive field brushes, and remove the brushes
from the brush plate assembly.

8. Carefully bend the negative brush shunt clamps out, and remove the brushes.

9. Remove the armature from the field case.

10. Press out the drive end bushing and the oil seal from the drive end head.

11. Remove the four screws that hold the field pole shoes to the field case. Remove the field
coils and discard them.

NOTE:
Strike the pole shoe screws once or twice firmly with hammer and drift pin punch
to loosen the screws for ease of removal. De-solder Battery terminal from field
coil assembly.

12. Remove the battery terminal stud from the field case, and discard it.

Upon completion of disassembly, all parts should be cleaned and visually inspected for
cracks, wear, distortion and any signs of overheating or mechanical interference. Any
cracked, worn, or distorted parts must be discarded and replaced with new HET parts. Refer
to the Specifications and Limitation Table for tolerances on the parts removed and inspected
for wear.

Overhaul Manual - Aircraft Alternators & Starters

Part Number OE-A2 - Rev. 06 8-70-01
COMPONENT INSPECTION AND TESTING:
NOTE:
Before removing the starting motor from the engine, disconnect the ground
cable from the battery post to prevent short-circuiting. Disconnect the lead
from the starter motor terminal, then remove the mounting bolts and nuts.
The starter motor can then be removed for overhaul or testing. Exercise
extreme caution when using 110 volt test light or any other high voltage test
equipment.

1. Armature - To test the armature for grounds, use a set

of test probes connected in series with a 110 volt light.
Touch one probe to a commutator segment and the
other to the armature core. If the test lamp lights, then
the armature is grounded and MUST be replaced. To
test for shorted armature coils, use a growler (Figure
6). Place the armature in the growler and slowly rotate Figure 6 - Armature
by hand while a holding steel strip over the core so on Growler.
that it passes over each armature core slot. If a coil is
shorted, the steel strip will vibrate. A quick check for opens can be made by inspecting
the trailing edge (in direction of rotation) of the commutator segments for excessive
discoloration. This condition indicates an open circuit.

An alternate method for testing the armature for grounded or shorted windings is to use
an appropriate surge/hipot tester, such as the Baker Instrument, Model ST106A. Refer
to the manufacturer for suitable instructions and settings.

Check the commutator for uneven wear, excessive

glazing or evidence of excessive arcing. If it is only
slightly dirty, glazed or discolored, then the
commutator can be cleaned with 00 or 000 sandpaper.
If the commutator is rough or worn, then it should be
turned on a lathe (refer to Tolerances and
Figure 7 - Commutator
Specifications). (Figure 7) The armature shaft should
in Lathe.
be inspected for rough bearing surfaces and rough or
damaged splines.

2. Brush Holders - To test brush holders use a set of test probes connected in series with a
110 volt light. Touch one test probe to the frame or brush plate and the other to each
brush holder. The test lamp should light when the grounded brush holders are touched
and should not light when the insulated brush holders are touched.

3. Pinion Housing - Inspect housings for cracks. Replace the bushing and ream to proper
dimension found in Section 9. Remove corrosion, paint or grease from mounting
surfaces.

4. Drive Mechanism - The bendix drive must be replaced during overhaul.

Overhaul Manual - Aircraft Alternators & Starters

8-80-01 Part Number OE-A2
STARTER ASSEMBLY:
NOTE:
When installing the absorbent bronze bushings, always use the proper bearing
arbor to obtain the proper fit.

Direct Drive Starter Motor With Starter (Bendix) Drive:

1. Install a new battery terminal stud package into the field
case, as shown in (Figure 8), being sure to assemble
washers, spacers, and nuts in their proper order.

Figure 8 - Battery Terminal

2. Install new field coils

Stud Installation.
into the pole shoes, and
assemble to the field
case, using the screws

Figure 9 - Tighten Pole

previously removed at disassembly. Tighten the four pole
shoe screws evenly using a pneumatic air hammer and finish
torque dry to 25 to 40 ft.-lbs. (Figure 9). Shoe Screws.

3. Install a new commutator end bearing into the

commutator end head and new intermediate bushings
into the intermediate housing (Figure 10). Ream
commutator end and
intermediate housing
bushings to the
dimension specified

Figure 10 - New
in the Tolerances and

Commutator End Bearing

Specifications section

Installation.
(Figure 11). Insert
felt and apply several
drops of SAE 30
weight oil for Figure 11 - Ream Bushings.
lubrication.

4. Install new negative brush shunts into the clamps of the

commutator end head assembly, and bend the clamps
back around the brush shunt (Figure 12). While holding
the brush shunt close to the clamp with pliers, carefully
solder the negative brush shunts to the clamps (Figure
13). Make certain that the solder does not wick up the
Figure 12 - Bend Clamps
brush shunt. Use 60/40 rosin core solder.

Around Brush Shunts.

Overhaul Manual - Aircraft Alternators & Starters

Part Number OE-A2 8-90-01
 5. Install the negative brushes into the brush rack.

6. Lubricate the armature shaft in the area where the

intermediate bushing
will be located with
Lubriplate® #777
grease. Install the
Figure 13 - Solder Brush
intermediate bushing

Shunts to Clamps.
assembly onto the
drive end of the

Figure 14 - Bushing
armature shaft

Assembly Installation.
(Figure 14).

7. Install the armature shaft into the bendix drive, and

align the retaining pin holes. (Slide the starter drive
onto the armature shaft.) Compress as necessary to
expose the retaining pin hole. Insert the retaining pin
into the bendix drive and armature shaft. Using an
appropriate punch, tap spiral pin in place making sure
the spiral pin does not project beyond the outside
Figure 15 - Spiral Pin
diameter of the pinion sleeve (Figure 15).

Installation.
8. Press the drive end bearing into the drive end head
assembly until the bearing is flush with the outside of the drive end head assembly.
Ream to the dimension specified in the Tolerances and Specifications section. Apply a
thin coat of Lubriplate #777 (or equivalent) to the armature shaft at the end located in the
drive end assembly.

9. Install the armature-and-bendix-drive assembly into the

drive end head assembly. Install intermediate bearing
assembly screws to the drive end head assembly (Figure
16). Torque screws to 25-35 in.-lbs.

10. Install the commutator end head assembly to the field

case, carefully positioning the positive brushes through
Figure 16 - Bearing Assembly
the brush windows in the field case. Secure the

Screws Installation.
commutator end head assembly with four new screws.
Torque screws to 25-35 in.-lbs.

11. Install the thrust washer onto the armature shaft at the commutator end. Apply a slight
amount of Lubriplate #777 to armature shaft at commutator end.

12. Install the armature-and-drive-end-head assembly into the field case assembly, and
secure with four new screws. Torque screws to 25-35 in.-lbs. Add thrust washer as

Overhaul Manual - Aircraft Alternators & Starters

8-100-01 Part Number OE-A2
 necessary to obtain the proper armature end-play, while maintaining proper armature
spacing.

To check for proper bearing alignment rotate the armature shaft in either direction. The
shaft should rotate freely with no binding and/or interference using 5 in.-lbs. of torque
or less.

13. Load the springs onto the four brushes and install the cover band.

Direct Drive Starter Motor Without Starter (Bendix) Drive:

1. Install a new battery terminal stud package into the
field case, being sure to assemble washers, spacers,
and nuts in the proper order (Figure 17).

2. Install new field

coils into the pole
shoes (Figure 18).

Figure 17 - Battery Terminal

Install the pole

Stud Package Installation.

shoes into the field
case, using the
screws removed

Figure 18 - Field Coil

previously. Tighten

Installation.
the four pole shoe screws evenly using a pneumatic air
hammer and finish torque dry to 25-40 ft.-lbs. Note:
The pole shoes must be installed so that the longer tip is
pointed in the same direction as armature rotation.

3. Install new negative

brush shunts into the
clamps, and bend the
clamps back around the
brush shunt (Figure 19).
While holding the brush
shunt close to the clamp

Figure 19 - Negative Brush Figure 20 - Negative Brush

with pliers, carefully

Shunt Installation. Shunt Solder.

solder the negative
brush shunts to the
clamps (Figure 20).
Make sure that the solder does not wick up the brush shunt. Use 60/40 rosin core solder.

4. Install the negative brushes into the brush plate assembly.

5. Install the brush plate assembly into the field case, and secure with the three screws.

6. 28-volt direct drive starting motors, secure the field shunt to the field case with the
screw.

Overhaul Manual - Aircraft Alternators & Starters

Part Number OE-A2 8-110-01
 7. Press a new bearing into the commutator end head assembly. Apply a thin coat of
“Lubriplate” #777 grease, or equivalent to the inside of the bearing.

8. Install a new bearing and seal into the drive end head assembly. Apply a thin coat of thin
coat of “lubriplate” #777 grease, or equivalent to the inside of the bearing.

9. Install a thrust washer onto the drive end of the armature shaft.

10. Place the drive end head assembly on a stable support, and install the armature into the
drive end bearing.

11. Assemble the field case onto the drive end head assembly, and secure with the 2 screws.
(MHJ Series only). Torque screws to 25-35 in.-lbs.

12. Install the positive brushes into the brush plate assembly. Load the springs onto the 4
brushes.

13. Install the thrust washer onto the armature shaft. Install the thru-bolts through the
commutator end head assembly. Install insulation tubes onto thru-bolts (provided in kits
for certain models only).

14. Assemble the commutator end head assembly to the field case, and secure with the thru-
bolts. Torque bolts to 35-45 in.-lbs.

15. Add thrust washer as necessary to obtain the proper armature end play, while
maintaining proper armature spacing. To check for proper end play pull the armature
forward. Take a dimension from the top of the armature shaft slot to the bottom side of
the drive end housing. Now push the armature shaft backward. Take the dimension using
the same criteria as above. Refer to the models part number service information section
for proper dimensions. Adjust as needed with thrust washers for proper position and end
play.

16. Torque the thru-bolts and safety-wire (where applicable). Test the starter for proper
operation.

BENCH TESTING OF STARTER:

After the starter motor is reassembled, it should be checked to see that the no-load current at
a certain voltage is within specifications. To make this test, connect the assembled unit as
shown in (Figure 21). If current is too high, check the bearing alignment and end-play as
described in the assembly process to make sure there is no binding or interference. If no
difficulty is indicated in the above test, a stall torque test may be made to see if the starter
motor is producing its rated cranking power. Make test connections as shown in (Figure 22).

Overhaul Manual - Aircraft Alternators & Starters

8-120-01 Part Number OE-A2
If the torque and current are not
within specifications, check the
Knife
seating of the brushes and Switch
Carbon
Pile Ammeter Voltmeter
internal connections for high
resistance. If these checks are
made and found to be in good
order, replace the armature
assembly and retest the starter.

Operation - The starting motor

Ground
Tachometer
Battery

should be operated for a few Ground

seconds (not to exceed 10 Starting Motor

seconds) with the ignition

Figure 21 - No Load Current Test Connection.

disconnected to make sure that
the pinion engages properly and
that it turns freely without
binding or excessive noise. To
do this, connect a jumper lead to Knife Carbon
the “P” (primary) lead of both Switch Pile Ammeter Voltmeter
magnetos while connecting the
other end to a convenient clean
Spring Scale
engine grounding point. The
engine will now be inoperative
until the jumper lead is removed.
After making the above test,
remove the jumper lead. Engines Battery
incorporating the Starter Drive Ground

clutch assembly should be started

two or three times to see that the Starting Motor
Ground

Figure 22 - Stall Torque Test Connection.

pinion disengages properly when
the engine is turned off.

Overhaul Manual - Aircraft Alternators & Starters

Part Number OE-A2 8-130-01
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Overhaul Manual - Aircraft Alternators & Starters

8-140-01 Part Number OE-A2