Lamar 02

MAINTENANCE & OVERHAUL MANUAL
© Copyright 2013 all rights reserved

Hartzell Engine Technologies (HET) Starter (formerly LAMAR)
2900 Selma Highway, Montgomery AL 36108 USA
3343865400, FAX 3343865410
Lycoming Engines, Inc. (LYC) Engine Applications
Effective: March 8, 2013
This manual includes disassembly and assembly, of the starter, starter motor, cleaning, visual
inspection, tools, torques, service inspection limits, test specifications and an illustrated parts list.
It contains overhaul instructions for both 12 and 24 volt HET starters (formerly Lamar
Technologies) as used on Lycoming Engines, Inc. (LYC) engines.
Models covered in this manual are PM1201, PM1203, PM1204, PM2401, PM2403, and PM2404.
LAOH-CD REV B Page 1 of 48 Revised: March 8, 2013

Hartzell Engine Technologies LLC
TABLE OF CONTENTS
DESCRIPTION PAGE
Table of contents ............................................................................................................................... 2
Record of Revisions .......................................................................................................................... 4
Record of Temporary Revisions ........................................................................................................ 6
Introduction ........................................................................................................................................ 8
Revising the Manual .................……………................................................................................. 8
Airworthiness Limitations ............................................ .................................................................... 10
Troubleshooting Procedure LYC Starter .......................................................................................... 11
Support …..…………...............................................…………………………….……….…….…..….... 13
Disassembly Procedure ................................................................................................................... 16
Cleaning and Visual Inspection ........................................................................................................ 17
Storage & Shelf Life …...............................................………………….……………..………..…….... 20
Assembly Procedure ...............................…..................................................................................... 21
Nose End Assembly ..................……………............................................................................... 21
Intermediate Carrier Assembly ....................…........................................................................... 22
Comm. End Assembly ....................…........................................................................................ 23
Output Shaft Assembly ......…..................................................................................................... 23
Starter Drive ....................…........................................................................................................ 24
Drive End ....................…............................................................................................................ 25
Planetary Gears ..........…............................................................................................................ 26
Anchor Ring ..........….................................................................................................................. 27
Positive Brush Installation ...........…............………………………………………..…………......... 27
Negative Brush Installation ......................................................................................................... 28
Flux Ring Installation .................................................................................................................. 29
Armature ....................…............................................................................................................. 30
Motor Case ..........…................................................................................................................... 32
Comm. End Assembly ..........….................................................................................................. 33
Final Inspection ..........…............................................................................................................ 33
Service Inspection Limits & Torques ........................................................................................…… 34
Special Tools ............................................................................................................................…… 35
Test Specifications, No Load Test …..………….........................................................................….. 35
Test Specifications, Torque Test …..…………...........................................................................….. 36
Duty Cycle …..………….............................................................................................................….. 36
Periodic Inspection & Service .......................................................................................................... 37
Starter Drive Maintenance ......................…..................................................................................... 38

TABLE OF CONTENTS (Cont’d)
Starter Parts List & Overhaul Kits ..........................…..................................................................... 39
Overhaul Kit, PM1201-OHK ..................…………….............................................................. 39
LIST OF ILLUSTRATIONS
DESCRIPTION PAGE
Figure 1 Troubleshooting Diagram .......................................................................................... 13

Figure 2 Exploded View ........................................................................................................... 14
Figure 3 Drive End Exploded View .......................................................................................... 15
Figure 4 Nose Bushing Replacement ...................................................................................... 21
Figure 5 Intermediate Bushing Replacement .......................................................................... 22
Figure 6 Ball Burnishing the Bushing ...................................................................................... 22
Figure 7 Bearing Replacement ................................................................................................ 23
Figure 8 Shaft Assembly .......................................................................................................... 23
Figure 9 Starter Drive Installation ............................................................................................ 24
Figure 10 Shaft Assembly Installation …...................................................................,,,,,,,,,,....... 25
Figure 11 Planetary Gear Installation …..................................................................,,,,,,,,,,......... 26
Figure 12 Anchor Ring Installation ........................................................................,,,,,,,,,,........... 27
Figure 13 Positive Brush Replacement ….................................................................................. 27
Figure 14 Negative Brush Replacement …................................................................................ 28
Figure 15 Comm. Ass’y Complete with Brush Retainers ........................................................... 28
Figure 16 Flux Ring Installation ................................................................................................. 29
Figure 16a Flux Ring Orientation (R/H rotation) .......................................................................... 29
Figure 17 Flux Ring Orientation L/H rotation) ............................................................................ 30
Figure 18 Armature Installation ................................................................................................. 31
Figure 19 Motor Case Installation .............................................................................................. 32
Figure 20 Comm. End Installation ............................................................................................. 33
Figure 21 Tool, Starter Drive Plate ............................................................................................ 35
Figure 22 Starter Test Rig .......................................................................................................... 35

RECORD OF REVISIONS
Revision Issue Page Inserted
Status Date Revised Description Date By
New 11/15/98 All Pages Original Issue under Lamar Technologies
A 8/16/01 All Pages Revised Issue under Lamar Technologies
B 2/15/13 All Pages Revised under Hartzell Engine Technologies

RECORD OF REVISIONS (CONT’D)
Revision Issue Page Inserted
Status Date Revised Description Date By

RECORD OF TEMPORARY REVISIONS
Temporary Page Issue Date
Rev Letter Revised Date by Removed by

RECORD OF TEMPORARY REVISIONS (CONT’D)
Temporary Page Issue Date
Rev Letter Revised Date by Removed by

INTRODUCTION
WARNING:
DO NOT USE OBSOLETE OR OUTDATED INFORMATION. PERFORM ALL
INSPECTIONS OR WORK IN ACCORDANCE WITH THE MOST RECENT
REVISION OF THIS MANUAL. INFORMATION CONTAINED IN THIS
MANUAL MAY BE SIGNIFICANTLY CHANGED FROM EARLIER REVISIONS.
IMPROPER OR UNAUTHORIZED APPLICATIONS OF THE INFORMATION
CONTAINED IN THE MANUAL MAY RENDER THE AIRCRAFT OR THE
COMPONENT UNAIRWORTHY AND RESULT IN LOSSES, DAMAGES, OR
INJURY TO THE USER.
The service procedures herein apply to PM1201, PM1203, PM1204, (12 volt) PM2401, PM2403,
and PM2404 (24 volt) starters.
The starters in this manual are designed as limited field serviceable accessories. Replacement of
the starter in most cases may be the most economic means of repair. However, overhaul may be
accomplished by use of specific overhaul kits using the instructions and test procedures found
herein. In addition individual service components are available for service repair.
DESCRIPTION
The starter consists of six main subassemblies:
1. Drive end pinion housing containing replaceable bushing.
2. Starter Drive
3. Rotor shaft assembly (Armature).
4. Brush holder assembly containing two replaceable brushes.
5. Commutator end cover assembly containing replaceable bearing.
6. Starter housing assembly containing a field coil, with two replaceable brush sets.
The drive-end pinion housing provides the mounting flange for attachment of the starter to the
engine and supports the bearing through which the armature shaft protrudes and attaches the
starter drive.
The starter drive is designed to engage its pinion in the flywheel ring gear on the engine as the
starter motor turns and extends and then disengage the pinion as soon as the engine reaches a
predetermined speed at start.
The rotor shaft assembly (armature) carries the rotating field coil enclosed within the rotor with
connecting wires terminated at the commutator. The commutator in conjunction with the brushes,
located in the commutator end of the starter housing, provides a rotating connection through
which the rotor assembly may be energized.
The spring-loaded brushes are a positive and negative set located in precise positions within the
motor case.
The commutator end cover assembly contains a bearing in which the aft end of the armature shaft
is supported.
REVISING THE MANUAL

From time to time, HET will make changes in this manual. This may be due to the print or
technical errors, addition of information or products, and change of parts or nomenclature, to
name a few. Due to the small size of the manual all pages will be revised.
REVISING THE MANUAL (CONT’D)
Upon receipt of a new revision, remove all pages and replace with revised pages. Do Not retain
the old pages. The footer at the bottom of the page will indicate the new revision level.
Significant or whole page changes are indicated by short black bar beside the revision level in the
footer. Minor changes will be indicated by black bars on the edge of the page adjacent to the
revised material.
WARNING:
WHEN SERVICING, REPAIRING, OR OVERHAULING THE STARTER,
GREAT CARE AND CAUTION MUST BE TAKEN TO AVOID HAZARDOUS
SITUATIONS. WHEN MOUNTED AND USED ON AN AIRCRAFT, THE
STARTER WILL PRESENT A PHYSICAL HAZARD FROM PROPELLERS
AND OTHER ROTATING DEVICES. WHEN TESTED OFF THE AIRCRAFT,
THE STARTER PRODUCES A HIGH TORQUE AND USES HIGH
ELECTRICAL CURRENT, WHICH PRESENTS BOTH PHYSICAL AND
ELECTRICAL SHOCK HAZARD THAT CAN RESULT IN SERIOUS INJURY
IF PROCEDURES IN THIS MANUAL OR IN THE AIRCRAFT/ENGINE
SERVICE MANUALS ARE NOT FOLLOWED.
PRECAUTIONS
CAUTION:
DISCONNECT THE AIRCRAFT BATTERY BEFORE REMOVING OR
SERVICING THE STARTER SYSTEM TO AVOID “HOT TERMINAL”
SPARKING WITH POSSIBLE BATTERY AREA EXPLOSION FROM GAS,
REMOVE THE GROUNDING LEAD FIRST AND THEN THE POSITIVE
LEAD. INSTALLATION OF THE BATTERY, CONNECT THE POSITIVE
LEAD FIRST AND THE GROUNDING LEAD LAST. THIS WILL MINIMIZE
THE RISK OF SHORTING OR SPARKING THE “HOT TERMINAL” DURING
INSTALLATION.
It is imperative that regular maintenance must be accomplished per this manual and per the
applicable aircraft or rotorcraft service manuals and publications. In addition, observe the
following precautions:
1. DISCONNECT THE BATTERY before connecting or disconnecting test instruments (except
voltmeter), or before removing or replacing any unit. Accidental grounding or shorting of
power from the battery may cause severe damage to the unit, airframe, and/or wiring.
2. If the starter is tested on an aircraft to observe starter performance, make sure that the area
in and around the aircraft is secure and all staff and personnel are warned that testing is
progress. Contact with propeller may cause injury or death. DO NOT exceed the duty cycle
durations found in this manual.
3. If the starter is being tested on the bench without a starter test machine, be sure that the
starter is retained and secure before power is applied. High torque can cause the starter to
move with force. Starter testing uses high current while testing the motor, make sure that
the power connection is secure and insulated and do not touch during operation. Keep
fingers away from the drive end.

AIRWORTHINESS LIMITATIONS
General Information
CAUTION:
THE AIRWORTHINESS LIMITATIONS HEREIN ARE THOSE
MANDATED BY HARTZELL ENGINE TECHNOLOGIES LLC. THESE
LIMITATIONS ARE THE MINIMUM REQUIRED TO MEET CONTINUED
AIRWORTHINESS BUT MAY BE SUPERCEDED BY MORE
STRINGENT REQUIREMENTS AS PUBLISHED BY THE ENGINE,
AIRCRAFT OR OTHER MANUFACTURER USING THIS COMPONENT
IN THEIR APPLICATION. FAILURE TO OBSERVE THESE
LIMITATIONS MAY COMPROMISE THE COMPONENT OR THE
APPLICATION IT IS USED IN.
Airworthiness Limitation Statement

1. The Airworthiness Limitations section is FAA approved and specifies maintenance
required under Secs. 43.16 and 91.403 of the Federal Aviation Regulations unless
an alternative program has been FAA approved.
2. Not Applicable

TROUBLESHOOTING PROCEDURE
The following procedure will help troubleshoot the starter drive and aircraft wiring system in the
event the starter will not turn the engine adequately. (Lycoming Engines)
PROBLEM CAUSE SOLUTION

• Starter Drive • Engine idle speed is below 450 • To check, lightly advance throttle
remains engaged RPM and see if pinion gear disengages.
too long. • Faulty drive. • Clean Starter Drive as described
• Dirty or gummy drive. below.
• Replace Starter Drive.
• Starter Drive fails • Excessive amount of dirt, a • Clean Starter Drive as described
to engage engine gummy or dry Starter Drive. below
ring gear. • Voltage too low • Verify voltage at the starter is above
10 volts for a 12 volt system and
• Starter Drive • Dirty, cold temperature, and/or above 18 volts on a 24 volt system
spins but fails to lack of lubrication. • Refer to latest revision of LSI-011
engage. Rev. A for special re-lube
procedures.
• Starter Drive is • Improper drive action or lack of • Clean as described below. If
noisy. lubrication. symptoms persist drive should be
replaced.
• Starter Drive • This is noted by a highly • Replace Starter Drive
does not objectionable noise at any • Clean as described below. If
disengage. normal engine speeds. symptoms persist drive should be
• Faulty drive. replaced.
• Dirty or gummy drive.
The average voltage drop of a good condition system is a 0.5 (one half) volt between the battery
and the starter. Example: If the battery is reading 24 volts and the starter is receiving 23.75 volts
at the input terminal (7), there is a 0.25 volt drop in the system. This condition would be
acceptable.
Example: If the battery is reading 13 volts and the starter is receiving 12.25 volts at the input
terminal, there is a 0.75 volt drop in the system that needs to be investigated.
Causes for Low Voltage:

1. Weak/Dead Battery.
2. Excessive Resistance in Relay Contacts.
3. High Resistance Between Terminals.
4. Corroded Terminals.
5. Undersized Wiring.
6. Inadequate Grounding of the Engine.

Troubleshoot Electrical - Ref: Fig. 1
Perform the following resistance/voltage checks using a VOM to determine where in the system
the problem is originating. (# Items listed are from Fig. 1 chart, not from IPL.)
NOTE: Original ground point must be maintained at NEGATIVE TERMINAL of battery.

1. Connect the VOM between the negative (1) and positive post (2) of the battery and record the
voltage reading. Voltage reading should be a minimum of 9 volts on a 12/14 volt battery and
18 volts on a 24/28 volt battery. If the battery voltage is low, recharge or replace the battery.
2. Connect the VOM probes between the airframe (10) and negative post of the battery (1) not to
the cable terminals. Record the resistance reading. Maximum resistance allowed is 0.2
ohms. If >.2 ohms, investigate the battery ground.
3. Connect the VOM probes between the airframe (10) and the case of the starter (8). Record the
resistance reading. Maximum resistance allowed is 0.2 ohms. If >.2 ohms, investigate the
engine to airframe ground.
4. Energize the master switch and connect the VOM probes between the input post of the master
relay (3) and airframe ground (10). Record the reading. Compare to voltage is step 3. If there
is more than a 0.5 volt difference, investigate the master relay input wire and connections.
5. Energize the master switch and connect the VOM probes between the output post of the
master relay (4) and airframe ground (10). Record the reading. Compare to voltage is step 3. If
there is more than a 0.5 volt difference, investigate the master relay.
6. Energize the master switch and connect the VOM probes between the input side of the starter
relay (5) and airframe ground (10). Record the reading. Compare to voltage is step 3. If there
is more than a 0.5 volt difference, investigate the starter relay input wire and connections.
WARNING: THE FOLLOWING STEPS ENERGIZE THE MASTER AND STARTER RELAYS
WHICH WILL CAUSE THE PROPELLER TO ROTATE & MAY RESULT IN INJURY OR DEATH.
7. Energize the master switch and starter switch and connect the VOM probes between the
output side of the starter relay (6) and airframe ground (10). Record the reading. Compare to
voltage is step 3. If there is more than a 0.5 volt difference, investigate the starter relay.
8. Energize the master switch and starter switch and connect the VOM probes between the
starter input terminal (7) and airframe ground (10). Record the reading. Compare to the
voltage reading in step 3. If there is more than 0.5 volt difference, investigate input wiring and
connections.

Figure 1 - Troubleshooting Diagram
SUPPORT
For technical support contact:
Hartzell Engine Technologies LLC
2900 Selma Highway
Montgomery, AL 36108, USA
334-386-5400 (888-461-6077) FAX 334-386-5410
http://www.hartzellenginetech.com

Figure 2: Exploded View

Fig 3: Drive End, Exploded View

DISASSEMBLY PROCEDURE
Starter Assembly Complete - Ref: Fig. 2 & 3 unless noted.
NOTE: Item numbers (#) referenced also correspond to those found in the IPL.
1. Separate comm assembly by removing the four thru-bolts (#4) releasing the drive end.
2. Remove comm end cap assembly (complete).
3. Remove bearing (#17) from comm. end cap (#13) and discard bearing. (See Figure 7.)
4. Remove comm assembly (complete). In most cases the comm. assembly will separate
from the nose case with the flux ring assembly (#38) and armature assembly (#6).
Remove armature (#6) from comm assembly by pushing commutator end of the shaft with
thumbs until it is free.
5. Remove flux ring assembly (#38) from comm assembly (complete) by pushing from the
comm end of the starter. It may be necessary to gently tap the flux ring from the brush
end of the comm assembly with a non-metallic punch or a soft faced hammer to get it
started. Pay attention not to damage or break the flux ring pins (#19). These pins are
included in a kit, if replacement is necessary.
6. From the comm assembly (complete), remove circular voltage label (#39) from motor case
at power stud and remove brushes (#24 & #25), brush bracket (#21), brush spring (#22),
and related hardware items (#2, #29 & #35) and discard. (See Figures 13 & 14.)
7. Remove and discard four screws (#1) from the anchor ring (#36). Remove the anchor ring
(#36), wave washer (#30), grease shield (#14) and planetary gears (#8). Discard planetary
gears.
8. Remove and discard the three screws (#2) and washers (#33) from drive end.
9. To dislodge the shaft assembly from housing, tap open end of casting on a solid wood
surface with enough force to dislodge shaft assembly.
10. Remove and discard drive end housing bushing (#16) and remove and discard the starter
maintenance label (#20). Note location of the label for later installation of a new label.
11. Remove starter drive pin and discard (#18). To remove, compress starter drive to gain
access to pin for removal. Remove and discard starter drive (#5).
12. Remove and discard snap ring (#37) and thrust washer (#28) from the shaft.
13. Remove Intermediate shaft support (#11) then remove and discard bushing (#15).
14. Name label (data tag) must remain on the starter for repair or should remain on the starter
for overhaul. If it is damaged or not legible, the name label (#40) may be replaced if:
A. All data on the existing tag is transferred to the new tag.
B. The overhauler’s repair station or other I.D. numbers are marked on the label.

CLEANING AND VISUAL INSPECTION
WARNING:
PROLONGED EXPOSURE TO VOLATILE CLEANING AGENTS IS
HAZARDOUS TO YOUR HEALTH. USE DEGREASERS AND
SOLVENTS IN WELL VENTILATED AREAS. USE APPROPRIATE
EYE PROTECTION, GLOVES, AND COTTON APRONS. REVIEW ALL
SAFETY INFORMATION FOR THE CHEMICAL BEING USED PRIOR
TO USING IT!
Cleaning chemicals:
Use of the following cleaning chemicals or their equivalents are recommended.
Aviation Quality degreaser
Aviation Quality carbon solvent
Isopropyl alcohol
Stoddard® solvent
Cleaning materials:
Use of the following cleaning materials or their equivalents are recommended.
Lint free shop cloth
Non-metallic bristle brush and pick
Crocus cloth or Scotch-Brite®
Low pressure oil free filtered dry air source (30 to 60 psi)
Inspection Tools:
10X magnifying glass
Mirror
White light source 1,700 lumens output (100W incandescent or equivalent)
Inspection*:
NOTE: 1 Serviceability of starter components can be determined by visual inspection under
bright light of at least 1,700 lumens and if required by using 10x magnifying glass.
Abnormal wear, cracks, warping or damage and wear beyond the limits shown in
Service Inspection Limits are all cause for rejection and discard.
NOTE: 2 Clean all parts to ensure all grease, oil and foreign materials are removed. Use of
Stoddard® solvent or equivalent cleaner is recommended. Do not soak armature or
Flux Ring. DO NOT use Carbon Tetrachloride when cleaning the motor section.
When cleaning is complete, blow dry with low pressure compressed air.

Inspection*: (Cont’d)
NOTE 3 If starter has #8 thru bolts (Fig. 2, #4, #31, #32), kit OHK-0003 can be ordered to
upgrade to current standard #10 thru bolts. This includes hardware and anchor ring.
1. Flux Ring & Magnets:
Inspect flux ring magnets for chipping and/or separation. Inspect the flux ring for delamination
of plates. Replace the flux ring assembly if this occurs.
A. Check for corrosion and remove if desired, corrosion is not important on the flux ring.
Use Scotch-Brite® or similar and treat with machine oil by wiping on a light coating.
2. Armature Assembly:
A. Complete Armature:
1. To test the armature (#6) for grounds, use a set of test probes connected in series
with a 120 volt AC powered 75W light. Touch one probe to a commutator segment
and the other to the armature core. If the test lamp lights, armature is grounded and
MUST be replaced.
2. To test for shorted armature coils, use a common armature growler. Place the
armature in the growler cradle and slowly rotate by hand while a holding steel strip
over the core so that it passes over each armature core slot. If a coil is shorted, the
steel strip will vibrate (growl). Check for opens by inspecting the trailing edge (in
direction of rotation) of the commutator segments for excessive discoloration.
Discoloration can indicate that an open circuit exists.
B. Shaft: Inspect the armature shaft for signs of scoring, galling, over heating or damage.
1. Inspect the drive end of shaft for excessive wear on gear teeth.
2. Inspect drive end of shaft for wear on diameter at bushing end.
3. Inspect comm end of shaft for wear on diameter.
(Refer to Service Inspection Limits and replace armature as necessary.)
C. Coil: Inspect the armature coil for signs of over heating, arcing, flaking or cracking of
the insulating varnish, or other damage. Any of these conditions require replacement
of the armature. Touchup of the varnish (clear coating on coil) is not allowed.
D. Commutator: Satisfactory condition is indicated by an even, burnished copper color.
1. Place the armature in two “V” blocks and set up a dial indicator to check run out.
Rotate armature through several revolutions. The indicator will easily locate high
commutator bars indicating a delaminated segment, if found replace armature
assembly. This check will also determine depth of any groove and overall wear dia.
of the commutator. Grooves must be within the minimum dia. after resurfacing per
the Service Inspection Limits.
2. Inspect the contact surface of the commutator. If the contact surface is rough,
pitted, scored, or darkened by a hard film of carbon or oil which cleaning failed to
remove, the commutator must be resurfaced. Use Scotch-Brite® to clean armature
and commutator then clean again to remove any carbon or copper particles.
Imbedded particles in the insulation between the commutator bars must be
removed by undercutting. (Refer to Service Inspection Limits).

Inspection*: (Cont’d)
3. Output Shaft:
A. Inspect output shaft pins, which support planetary gears (#8) for excessive wear.
B. Inspect output shaft bushing for uneven or excessive wear, inspect bushing bore for
maximum I.D. per the Service Inspection Limits.
C. If either pins or bushing are out of tolerance, the output shaft (#7) must be replaced.
Refer to Service Inspection limits, as required. (See Fig. 10 & Fig. 11.)
4. Starter Nose Assembly:
A. Inspect ring gear for broken teeth and/or damaged or scared teeth.
B. Inspect engine pad pins for signs of being loose or missing.
C. Replace starter nose assembly should either condition exist. Inspect nose casting (#10)
for cracks, unapproved modifications, or perforating corrosion. Replace if any of these
conditions are found. (See Fig. 3, Fig. 9, & Fig. 10)
D. If removed for overhaul, inspect bushing bore dia. per the Service Inspection Limits.
E. Clean area where the name label (#40) if required, and starter maintenance label (#20)
was installed.
5. Intermediate Shaft Support:
A. Clean and inspect intermediate shaft support (#11) for stripped threads and general
condition. Replace as necessary. (See Fig. 8.)
B. If removed for overhaul, inspect bushing bore for wear per the Service Inspection Limits.
6. Threaded Anchor Ring:
A. Clean and inspect anchor ring (#36) for stripped threads, warping, and general condition.
Replace as necessary. Refer to “Note 3” for bolt size. (See Fig. 12.)
7. Comm End Housing:
A. Clean and inspect for general condition or any obvious signs of unusual wear. Clean
the area where the self adhesive circular voltage label (#39) was attached.
B. If removed for overhaul, inspect bushing bore dia. for wear per the Service Inspection
Limits.
C. Brushes must be replaced at overhaul, however if performing a repair, brushes may be
examined per the Service Inspection Limits.
* Reference to Advisory Circular AC 43-204 is advised for guidance in inspection.

STORAGE & SHELF LIFE
RECOMMENDED STORAGE: When storing a new or overhauled starter there are two categories
to consider, short term storage or a long term storage on or off the aircraft. Short term storage will
be considered as storage up to but not exceeding thirty-six (36) calendar months. Long term
storage picks up at thirty-six (36) calendar months but does not exceed twelve (12) calendar
years. There is no special environment required except the storage space should be clean and
covered.
Short term, if on the shelf, requires only that the unit be kept in it original packaging. If unit is
being stored on the aircraft, clean pinion area of debris and examine ring gear then start engine
using starter at an interval of sixty (60) days. (Engine must start to allow the pinion gear to retract
on the starter drive.)
Long term, if on the shelf, requires that the starter be removed from the packaging and examined
on an annual basis. Remove from the plastic bag as originally packaged and discard the bag as
long term use may allow condensation in bag. (If bag contains a desiccant and color does not
indicate moisture, unit may be kept in original bag.) If removed from bag, wipe or lightly spray
outside with preservative oil and wrap tightly with a waxed type paper. Place back into original
shipping container. Overhauled starters must be packaged if they are to be stored.
If it is anticipated or determined that the aircraft will be in a long term storage situation, as soon as
practicable, wipe and spray the outside of the starter with preservative oil, start engine using
starter at an interval of sixty (60) days (Engine must start to allow the pinion gear to retract on the
starter drive.)
SHELF LIFE: All starters have a shelf life of up to, but not to exceed twelve (12) calendar years at
which time the unit must be overhauled. (Does not express a warranty.)

ASSEMBLY PROCEDURE
NOTE: Application of Loctite® must be used sparingly and any excess wiped away quickly.
1. Nose Assembly - Ref: Fig. 4

Bushing Replacement: Apply RC680 Loctite® to outer surface of new bushing (#16) and
press flush with outer surface of casting (#10). Make sure to inspect bushing bore dia. per
the Service Inspection Limits before installing a new bushing.
Figure 4: Nose Bushing Replacement

2. Intermediate Carrier Assembly - Ref: Fig. 5 & 6
Bushing Installation: Apply Loctite® RC680 to outer surface of Bushing (#15), press flush
into intermediate carrier from the cup side of the assembly. Burnish to size using supplied
tooling ball (#41) supported with a 15/16th socket, press ball thru bushing as shown. Make
sure to inspect bushing bore dia. per the Service Inspection Limits before installing a new
bushing.
Figure 5: Intermediate Bushing Replacement
Figure 6: Ball Burnishing the Bushing

3. Comm. End Assembly - Ref: Fig. 7:
Bearing Installation: Apply Loctite® RC680 to outer surface of bearing (#17) and press in
from inside flush to the inside surface of comm. end (#13). Make sure to inspect bearing
bore per the Service Inspection Limits before installing a new bearing. and should be
pressed from inside
Figure 7: Bearing Replacement
4. Output Shaft - Ref: Fig. 8: Install intermediate carrier assembly (complete), new thrust
washer (#28), and new snap ring (#37) on shaft (#7).
Figure 8: Output Shaft Assembly

5. Starter Drive - Ref: Fig. 9:
A. Coat the shaft (#7) with silicone lube, prior to installing starter drive.
B. Install new starter drive assembly (#5) and new starter drive pin (#18). To install drive
pin depress the drive to gain access to the pinhole. This will require the use of two
compression plates made locally (see special tools Fig. 21).
C. Place starter drive in the “U” groves of the compression plates. One on pinion end and
the other on drive base. Make sure pin hole is pointing at the open end of the groove
to expose pin hole. Install the two bolts through the plates at the provided holes and
install the washer and nut. Tighten snugly. Tighten each nut one turn each until the
pin hole is fully exposed. (A vise may be used on the base of the compression plates if
desired.)
D. Install new pin flush with output shaft (starter drive end must fully seat past the pin).
Release the starter drive and remove the compression plates.
E. Use LPS® Heavy Duty Silicon Lubricant LPS P/N 01516 or equivalent. Also
permissible, LPS® Magnum Premium Lubricant LPS P/N: 00616.
Figure 9: Starter Drive Installation
NOTE: If the starter drive pinion is rolled out it will lock in place in the extended position. If this
happens it will stay in that position until the starter is mounted on the aircraft and started.

6. Drive End: - Ref: Fig. 10:
Insert complete shaft assembly into nose housing, ensuring the alignment notches are
aligned. Install three new split lock washers (#33) and three new screws (#33). Apply
Loctite® 242 to screws prior to installation. Refer to Service Inspection Limits for torque.
Figure 10: Shaft Assembly Installation

7. Planetary Gears - Ref: Fig. 11:
Apply a coat of grease P/N X99-0073 (supplied with kit) to the output shaft pins, the face of
the shaft, and the ring gear. Install the planetary gears (#8) onto shaft pins. Apply
remaining grease around both the sun gear (in nose housing) and planetary gears, with a
thin coat on top of the planetary gears.
Figure 11: Planetary Gear Installation

8. Anchor Ring - Ref: Fig. 12: Install grease shield (#14) with raised center ridge facing
away from planetary gears, wave washer (#30) and threaded anchor ring (#14). Attach
anchor ring to nose housing with four new screws (#14) using Loctite® 242. Refer to
Service Inspection Limits for torque as required.
Figure 12: Anchor Ring Installation
9. Positive Brush Installation - Ref: Fig. 13: Install new brushes (#23). Ensure that the
oval steel washer goes on the stud first then nylon shoulder washer next. Insert the brush
assembly (#23) from the inside of the motor case with the nylon shoulder washer inserted
into the stud hole with the long brush lead to the right looking down on the assembly. Next
install the black insulating washer followed by the flat washer (#26) then lock washer (#25)
then nut (#34) torque to spec and then temporarily install second lock washer (#25) and
nut (#34) on the outside of the motor case. Brush springs are leaf type and tension is not
important as long as brush meets minimum length for service (replaced at overhaul).
Refer to Service Inspection Limits for torque as required.
Figure 13: Positive Brush Replacement

10. Negative Brush Installation - Ref: Fig. 14 & 15: Install new brushes (#24) by first
inserting the brush mounting bracket in the brush bracket slot with the tab cutout facing
down (#21). Then insert the brush spring (#22) with mounting screw (#2) followed by the
brush (#24). Ensure the brush wire on mounting tab is on top with the exposed copper
wire against the spring. Minor dings, scratches and anodize wear of the motor case are
not cause for rejection. Note: ensure the brush bracket is parallel to the rim of the comm
can and the brush springs compress completely without binding on the brush guides.
Brush springs are leaf type and tension is not important as long as brush meets minimum
length for service (replaced at overhaul). Refer to Service Inspection Limits for torque as
required.
Figure 14: Negative Brush Replacement
IMPORTANT: Brushes must be oriented 90° as shown in (Fig. 15) for proper starter
performance. Install the brush retaining clips by sliding the brush on the brush
holder and compressing as shown, for ease of assembly.
Figure 15: Comm Ass’y Complete with Brush Retainers

11. Flux Ring Installation - Ref: Fig. 16 & 17:
A) For proper flux ring installation and orientation on starter part numbers PM1201,
PM1203, PM2401, and PM2403, refer to Fig. 16 & 16a.
B) For proper flux ring installation and orientation on starter part numbers PM1204,
PM2404, refer to Fig. 17.
Figure 16: Flux Ring Installation
Figure 16a: Flux Ring Orientation

(right hand rotation)

Figure 17: Flux Ring Orientation (left hand rotation)
IMPORTANT: Installing the flux ring backwards or upside down will result in incorrect rotation.

12. Armature - Ref: Fig. 18: Insert thrust ball (#9) ensuring that it is fully seated in the end of
the shaft assembly. If ball gets into gear assembly, extreme damage and starter failure will
occur. Slide armature (#6) into flux ring. (Use care, as magnets will want to pull it in very
fast).
Figure 18: Armature Installation

13. Motor Case - Ref: Fig. 19: With brush retainers in place, ensure the locating pin (#38)
and hole inside the motor case align. Slide comm. assembly over the flux ring making sure
the pin slides into locating hole. The power terminal should be opposite the bracket mount.
Remove brush retainers to release Brush tension on to the commutator end of armature.
Figure 19: Motor Case Installation

14. Comm. End Assembly - Ref: Fig. 20: Attach to motor case with four thru bolts (#4), four
split lock washers (#31) and four flat washers (#32), Refer to Service Inspection Limits for
torque as required. Make sure that the brush leads are on the inside of the thru bolts and
the thru bolts are next to the comm can, so there is no pinching or rubbing during
operation.
Figure 20: Comm. End installation
15. Starter and motor housings are treated using an Alodine® process on the surfaces. If
desired, exterior surface blemishes may be touched up using a MIL-C-81706 treatment or
equivalent. Sample touchup device is a Henkel Alodine® 1132 Touch-N-Prep pen.
Complete instructions are included and the pen is available at common aviation or
industrial supply dealers.
16. Final inspection:
A. Verify all hardware is installed per these instructions.
B. Install the self adhesive circular voltage label (#39) on motor case at power stud.
(Make sure 12v label goes with 12v starter & 24v label goes with 24v starter.)
C. Install the self adhesive starter maintenance label (#20) at location previously noted.
D. Attach Duty Cycle tag, HET P/N F0366 upon completion of overhaul or repair of the
starter prior to delivery to the customer.

SERVICE INSPECTION LIMITS & AND TORQUES
DESCRIPTION LIMITS TORQUES
Armature Shaft Drive end shaft dia. at pinion shall not be smaller
than 0.393 in. at any point with 32 RMS finish.
Comm end shaft dia. shall not be smaller than
0. 6692 in. at any point with 32 RMS finish.
Brushes: Brushes must not be shorter than 0.390 in. for service
& to maintain proper spring tension (if repairing starter)
Visually inspect for cracks & breaks in brushes.
Brush replacement required at overhaul.
Visually inspect for cracks & breaks in brushes.

Brush & spring replacement required at overhaul.
Commutator Commutator shall not be smaller than 1.600 in.
after re-surfacing.
Segment under cut no more than 0.003 in.
T.I.R. no more than 0.002 in.
Bushing I.D. no greater than 0.750 in. (replace)
(if repairing starter)
Comm End Housing Comm end bearing bore shall not be greater
Assembly than 0.9385 in. at any point.
No flat spots or damage to needle rollers.
(for repair)
Intermed. Support Bushing Ball Burnish bushing to size, 0.748 to 0.750 in.
(Support #11) Use P/N LT102 tooling ball.
Intermed. Bushing I.D. (#15) Bushing I.D. no greater than 0.750 in. (replace if)
Intermed. Bushing Bore Bushing bore shall not be greater than 0.8760 in.
Nose End Housing Bushing bore of nose end shall not be greater
Assembly than 0.5925 in. at any point.
Bushing I.D. no greater than 0.4735 in. before install
Output Shaft Shaft dia. at drive shall not be smaller than
0. 4691 in. at any point with 25 RMS finish.
Interm. shaft dia. at interm. support shall not be
smaller than 0.7458 in. at any point with 32 RMS finish.
Output Shaft Pins (Fig. 10) Gear pins no smaller than 0.236 in.
Output Shaft Bushing (Fig. 10) I.D. no greater than 0.397 in.
Screw, 8-32 x 5/8 (#2) Fig. 14 10-15 in.-lb.

Nut, lock (#35) Fig. 14 10-15 in.-lb.
Support Screws, Interm. (#3) Fig. 10 10-15 in.-lb.
Screws, Anchor Ring (#1) Fig. 12 10-15 in.-lb.
Thru bolts (#4) Fig. 20 10-15 in.-lb.
Power Terminal Nut (#34) Fig. 13 55-60 in.-lb.

SPECIAL TOOLS
Tooling BALL P/N LT-102
Brush Retaining Tool P/N LT-103
Starter Drive Compression Plate (2) Make Locally
Locally produce two (2) plates 4 ½ X 4 ½ inch made from ¼

inch steel plate. Cut a “U” groove as shown. Size of groove
should allow starter drive pinion and starter drive base end to
in fit groove with clearance. Drill two ¼ inch holes in plate as
shown. Use two ¼ inch steel bolts at least two 4 inch long
with washer and nut to match.
Fig. 21 – Starter Drive Plate
TEST SPECIFICATIONS
NO LOAD TEST
Part Numbers: PM1201, PM1203, PM1204
Apply 12 volts D.C. Verify Starter Motor turns while power is applied (3 sec. Max.).
Part Numbers: PM2401, PM2403, PM2404

Apply 24 volts D.C. Verify Starter Motor turns while power is applied (3 sec. Max.)
Secure starter so it cannot move. Using the starter test rig per Fig. 13. Use a rheostat 0.05
to 0.2 ohms range, 95 amp, a DC ammeter 0 to 100 amp range, a DC voltmeter 0 to 30 volt
range, and momentary switch 100 amp rating. With rheostat at zero, press the momentary
switch to apply the applicable voltage to the starter. Turn up rheostat to the voltage required
and observe that the pinion is turning. DO NOT place hands or fingers near the pinion.

Figure 22 – Starter Test Rig
TEST SPECIFICATIONS (CONT’D)
TORQUE TEST
P/N VOLT (constant) AMP (max.) TORQUE (constant) R.P.M. (min)

______________________________________________________________________________________________________
PM1201 12.0 ± 0.5 V 200 ± 5 amps 75 ft.- lb. (min) 85

PM1203 12.0 ± 0.5 V 200 ± 5 amps 75 ft.- lb. (min) 85
PM1204 12.0 ± 0.5 V 200 ± 5 amps 75 ft.- lb. (min) 85
PM2401 24.0 ± 0.5 V 100 ± 5 amps 75 ft.- lb. (min) 85
PM2403 24.0 ± 0.5 V 100 ± 5 amps 75 ft.- lb. (min) 85
PM2404 24.0 ± 0.5 V 100 ± 5 amps 75 ft.- lb. (min) 85
The starter torque test is more complicated than the no load test and thus not suitable for a simple
test rig. To determine the proper test specifications above, use of a starter tester (or alternator/
starter tester) must be employed. Tester must be able to measure voltage, amperage, rpm, and
torque. The tester must have the capability of applying a dynamic load to the starter at the output
shaft. One example of a tester can be found on website www.crumbliss.com. Crumbliss testers
come in several models and prices. Equivalent machines of the same capability may be used.
Crumbliss Test Equipment

P.O. Box 3201
Collegedale, TN 37315-3201
Tel. (239) 693-8588
Fax: (239) 236-1999
E-mail: crumbliss@aol.com
DUTY CYCLE
The Duty Cycle for PM12/24 series starters is the amount of time the starter is engaged in start
and the rest time to cool down. With the starter properly mounted with a good ground, apply the
start cycle as follows: fifteen (15) seconds on, thirty (30) seconds rest for up to six (6) starts after
which a thirty (30) minute cool down period is required. DO NOT apply power unless the starter is
mounted to the engine. Uncontrolled free run may cause internal damage to starter.
The Duty Cycle is noted on a tag, HET P/N F0366. This tag indicates the data above and upon
completion of any starter overhaul or repair, it MUST be attached to the starter.

PERIODIC INSPECTION
General:
This section calls out the various checks and inspections needed to assure reliable and safe
operation of the starter while in service. The checks are listed in hours time in service (TIS) or
calendar time whichever is applicable. Some checks are one time initial and others are recurring.
Inspection Checks: (Use engine or aircraft manufacturers manuals as required.)
10 Hours (TIS). (one time)

Perform an initial check of the starter assembly. Check starter assembly mounted on the
engine for security. Check the attach bolts per the per the engine service manual. Check
for signs of overheating or electrical arcing, if noted, determine cause and correct. Make
sure the starter assembly is clear of interference with any airframe structure. Check power
terminal hardware for tightness and insulators for condition.
50 Hours (TIS) & each 50 hours thereafter. (or each annual insp, the first to occur)
Clean and lubricate the drive pinion and surrounding area when dirty or sluggish in
operation. After cleaning the starter drive, rotate the pinion to the engaged position.* Clean
the spiral threads as clean as possible and lubricate properly using the Starter Drive
Maintenance instructions found on page 38 of the HET Maintenance and Overhaul manual.
100 Hours (TIS) & each 100 hours thereafter. (or each annual insp, the first to occur)
Check for corrosion at power terminal. If present, clean and coat terminal with Dow Corning
DC-4 or equivalent. Check for signs of overheating or electrical arcing, if noted, determine
cause and correct. Check power terminal hardware for tightness and insulators for
condition.
500 Hours (TIS) & each 500 hours thereafter.

Perform a re-lubrication of the starter drive in accordance with the starter maintenance
section of this manual**. (This TIS is a minimum requirement. Should severe operating
environment exist, this requirement may be necessary on a more frequent basis.)
2000 Hours (TIS) max* (any engine overhaul or 12 calendar years, the first to occur.)
Overhaul Starter
*Engine overhaul is defined by Lycoming Engines, Inc. (the OEM) in the Service Instruction
SI1009AS or most recent version. If different, the OEM data shall supersede the HET
recommendation.
** Starter drive will not retract until it is placed on the engine and the engine is started.

STARTER DRIVE MAINTANENCE
Starter Drive Maintenance:

Clean and lubricate starter drive (also known as starter Bendix) when dirty or sluggish (every 50
hrs.) per these HET maintenance instructions.
DO NOT dip or immerse the entire drive in any cleaning solution, as this will remove grease from
the starter drive assembly that cannot be replaced.
DO NOT attempt to disassemble the starter drive in any manner.
After cleaning the starter drive, rotate the pinion to the engaged position*. Wipe the spiral threads
as clean as possible. If the threads are exceptionally gummy, or covered with foreign matter,
apply a reliable cleaning solution such as Stoddard® solvent with a small brush and tilt the drive so
that a little of it will run between spiral splines. Wipe clean, lubricate with very light molybdenum
grease.
The Starter Drive must be lubricated with dry film spray silicon after any cleaning to assure
satisfactory operation.
DO NOT use grease, oil, or graphite lubricants**. Use dry film spray silicon to provide satisfactory
operation especially in cold weather. Use LPS® Heavy Duty Silicon Lubricant LPS P/N 01516 or
equivalent. Also permissible, LPS® Magnum Premium Lubricant LPS P/N: 00616.
REMEMBER, the starter drive must be replaced at overhaul and cleaned and lubricated at any
repair.
* NOTE: Starter drive will not retract until it is placed on the engine and the engine is started.
** Refer to Lycoming Service Instruction SI1278 of latest revision.

STARTER PARTS LIST & OVERHAUL KITS
PM1201-OHK Overhaul Kit, PM1201
ITEM# KIT # PART # DESCRIPTION QTY REQ
F0366 Tag, Duty Cycle
LT-EBB-131A Kit, Starter Drive PMXX01 Starters 1 ea.

5 2005001 Starter Drive, Lycoming 149T 1 ea.
18 6201003 Pin, Starter Drive 1 ea
OHK-0001 Kit, Overhaul Tools, Lycoming 1 ea.

41 LT-102 Tooling Ball 1 ea.
42 LT-104 Brush Retaining Tool 4 ea.
43 X99-0071 Loctite®, 680, Single Use Tab 1 ea.
45 X99-0073 Grease, OHK 1 ea.
OHK-0002 Kit, Planetary Gears, Lycoming 1 ea.

8 2505002 Planetary Gear Assembly 3 ea.
OHK-0004 Kit, Brush Assembly, 12V pos. 1 ea.

23 7505001 Assembly, Brush, 12V pos 2 ea
25 7801001 Washer, Lock, 5/16 Cad, Split 1 ea.
26 7801002 Washer, Flat, 5/16, Cad 1 ea
27 7801003 Washer, Insulating, 5/16, Fiber 2 ea.
34 8101001 Nut, 5/16-24, Bronze 1 ea.
39 L51-0009 Label, 12V, Round, Green 1 ea.
OHK-0005 Kit, Brush Assembly, 12V neg. 1 ea.

24 7505002 Assembly, Brush, 12V neg. 2 ea.
OHK-0008 Kit, Brush Bracket & Spring 1 ea.

2 1501005 Screw, PFH, #8-32 x 5/8", Cad 2 ea.
21 7301001 Bracket, Brush Holder 2 ea.
22 7401001 Spring, Brush 2 ea.
29 7801006 Washer, Lock, #8, Split 2 ea.
35 8101003 Nut, Lock, #8-32, zinc 2 ea.
OHK-0009 Kit, Hardware, Lycoming Starter 1 ea.

9 3701001 Ball, Thrust, .250 1 ea.
15 6001003 Bushing, Intermediate Support 1 ea.
16 6001007 Bushing, Starter, Drive End 1 ea.
17 6101001 Bearing, Comm. End 1 ea.
19 6201005 Pin, Flux Ring 2 ea.
28 7801005 Washer, Thrust 1 ea.
37 8501001 Ring, Snap, External, 3/4" 1 ea.
OHK-0010 Kit, Fasteners, Lycoming Starter 1 ea.

1 1501003 Screw, PFH, #8-32 x 1/2", Cad. 4 ea.
3 1501010 Screw, PPH, #6-32 x 11/16", Cad. 3 ea.
33 7801013 Washer, Lock, #6, Split, Cad. 3 ea.

Available Components, not included in PM1201-OHK Overhaul Kit
OHK-0003 Kit, Thru Bolt and Anchor Ring #10 1 ea.

4 1501019 Bolt, Thru, #10 x 4-3/8" 4 ea.
32 7801012 Washer, Flat, #10, Cad 4 ea.
36 8101008 Ring, Threaded Anchor, #10 1 ea.
The following are not included in any kits and, if needed, must be purchased individually.
6 2305002 Armature, 12V, Lycoming 1 ea.

7 2305017 Ass’y, Shaft, Output 1 ea.
10 5005001 Ass’y, Starter Nose 1 ea.
11 5101002 Support, Intermediate, Shaft 1 ea.
12 5201001 Case, Motor, Lycoming 1 ea.
13 5301001 Comm. end 1 ea.
14 5401001 Shield, Grease 1 ea.
20 6301003 Label, Starter Drive Maintenance 1 ea.
30 7801008 Washer, Wave 1 ea.
38 9005001 Ass’y, Flux Ring, LYC, Complete 1 ea.
40 L52-0044 Label, Name 1 ea.
ITEM# KIT # PART # DESCRIPTION QTY REQ

18 6201003 Pin, Starter Drive 1 ea.


OHK-0006 Kit, Brush Assembly, 24V pos. 1 ea

26 7801002 Washer, Flat, 5/16, Cad 1 ea.
34 8101001 Nut, 5/16-24, Bronze 2 ea.
39 L51-0010 Label, 24V, Round, Yellow 1ea.
23 7505003 Assembly, Brush, 24V pos 1 ea.

2 1501005 Screw, PFH, #8-32 x 5/8", Cad 2 ea.
35 8101003 Nut, Lock, #8-32, zinc 2 ea.

9 3701001 Ball, Thrust, .250 1 ea.

1 1501003 Screw, PFH, #8-32 x 1/2", Cad 4 ea.
3 1501010 Screw, PPH, #6-32 x 11/16", Cad 3 ea.
33 7801013 Washer, Lock, #6, Split, Cad 3 ea.

4 1501019 Bolt, Thru, #10 x 4-3/8" 4 ea.

13 5301001 Comm. End 1 ea.

ITEM # KIT # PART # DESCRIPTION QTY REQ




34 8101001 Nut, 5/16-24, Bronze 2 ea.


2 1501005 Screw, PFH, #8-32 x 5/8", Cad 2 ea.
35 8101003 Nut, Lock, #8-32, zinc 2 ea.

9 3701001 Ball, Thrust, .250 1 ea.

1 1501003 Screw, PFH, #8-32 x 1/2", Cad 4 ea.
3 1501010 Screw, PPH, #6-32 x 11/16", Cad 3 ea.


4 1501019 Bolt, Thru, #10 x 4-3/8" 4 ea.

13 5301001 Comm. End 1 ea.




34 8101001 Nut, 5/16-24, Bronze 2 ea.
39 L51-0010 Label, 24V, Round, Yellow 1 ea.


2 1501005 Screw, PFH, #8-32 x 5/8", Cad 2 ea.
35 8101003 Nut, Lock, #8-32, zinc 2 ea.

9 3701001 Ball, Thrust, .250 1 ea.

1 1501003 Screw, PFH, #8-32 x 1/2", Cad 4 ea.
3 1501010 Screw, PPH, #6-32 x 11/16", Cad 3 ea.

4 1501019 Bolt, Thru, #10 x 4-3/8" 4 ea.

13 5301001 Comm. End 1 ea.


5 2005004 Starter Drive, LYC 149T, Rev Rotation 1 ea.



34 8101001 Nut, 5/16-24, Bronze 2 ea.


2 1501005 Screw, PFH, #8-32 x 5/8", Cad 2 ea.
35 8101003 Nut, Lock, #8-32, zinc 2 ea.

9 3701001 Ball, Thrust, .250 1 ea.

1 1501003 Screw, PFH, #8-32 x 1/2", Cad 4 ea.
3 1501010 Screw, PPH, #6-32 x 11/16", Cad 3 ea.


4 1501019 Bolt, Thru, #10 x 4-3/8" 4 ea.

13 5301001 Comm. End 1 ea.

5 2005004 Starter Drive, LYC 149T, Rev Rotation 1 ea.

X99-
43 0071 Loctite®, 680, Single Use Tab 1 ea.
X99-
44 0072 Loctite®, 242, Single Use Tab 1 ea.
X99-
45 0073 Grease, OHK 1 ea.


34 8101001 Nut, 5/16-24, Bronze 2 ea.
39 L51-0010 Label, 24V, Round, Yellow 1 ea.

OHK-0007 Kit, Brush Assembly, 24V neg 1 ea.
24 7505004 Assembly, Brush, 24V neg 2 ea.

2 1501005 Screw, PFH, #8-32 x 5/8", Cad 2 ea.
35 8101003 Nut, Lock, #8-32, zinc 2 ea.

9 3701001 Ball, Thrust, .250 1 ea.

1 1501003 Screw, PFH, #8-32 x 1/2", Cad 4 ea.
3 1501010 Screw, PPH, #6-32 x 11/16", Cad 3 ea.
OHK-0003 Kit, #10 Bolt & Anchor Ring, Lyc Starter 1 ea.
4 1501019 Bolt, Thru, #10 x 4-3/8" 4 ea.

13 5301001 Comm. End 1 ea.
40 L52‐0044 Label, Name 1 ea.

INTENTIONALLY LEFT BLANK

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MAINTENANCE & OVERHAUL MANUAL

© Copyright 2013 all rights reserved

Lycoming Engines, Inc. (LYC) Engine Applications

Effective: March 8, 2013

LAOH-CD REV B Page 1 of 48 Revised: March 8, 2013

LAOH-CD REV B Page 2 of 48 Revised: March 8, 2013

Figure 1 Troubleshooting Diagram .......................................................................................... 13

LAOH-CD REV B Page 3 of 48 Revised: March 8, 2013

New 11/15/98 All Pages Original Issue under Lamar Technologies

A 8/16/01 All Pages Revised Issue under Lamar Technologies

B 2/15/13 All Pages Revised under Hartzell Engine Technologies

LAOH-CD REV B Page 4 of 48 Revised: March 8, 2013

LAOH-CD REV B Page 5 of 48 Revised: March 8, 2013

LAOH-CD REV B Page 6 of 48 Revised: March 8, 2013

LAOH-CD REV B Page 7 of 48 Revised: March 8, 2013

REVISING THE MANUAL

LAOH-CD REV B Page 9 of 48 Revised: March 8, 2013

Airworthiness Limitation Statement

LAOH-CD REV B Page 10 of 48 Revised: March 8, 2013

PROBLEM CAUSE SOLUTION

Causes for Low Voltage:

LAOH-CD REV B Page 11 of 48 Revised: March 8, 2013

NOTE: Original ground point must be maintained at NEGATIVE TERMINAL of battery.

LAOH-CD REV B Page 12 of 48 Revised: March 8, 2013

LAOH-CD REV B Page 13 of 48 Revised: March 8, 2013

LAOH-CD REV B Page 14 of 48 Revised: March 8, 2013

LAOH-CD REV B Page 15 of 48 Revised: March 8, 2013

LAOH-CD REV B Page 16 of 48 Revised: March 8, 2013

Aviation Quality degreaser

Aviation Quality carbon solvent

Lint free shop cloth

Non-metallic bristle brush and pick

Crocus cloth or Scotch-Brite®

White light source 1,700 lumens output (100W incandescent or equivalent)

LAOH-CD REV B Page 17 of 48 Revised: March 8, 2013

LAOH-CD REV B Page 18 of 48 Revised: March 8, 2013

* Reference to Advisory Circular AC 43-204 is advised for guidance in inspection.

LAOH-CD REV B Page 19 of 48 Revised: March 8, 2013

LAOH-CD REV B Page 20 of 48 Revised: March 8, 2013

1. Nose Assembly - Ref: Fig. 4

Figure 4: Nose Bushing Replacement

LAOH-CD REV B Page 21 of 48 Revised: March 8, 2013

Figure 5: Intermediate Bushing Replacement

Figure 6: Ball Burnishing the Bushing

LAOH-CD REV B Page 22 of 48 Revised: March 8, 2013

Figure 7: Bearing Replacement

Figure 8: Output Shaft Assembly

LAOH-CD REV B Page 23 of 48 Revised: March 8, 2013

Figure 9: Starter Drive Installation

LAOH-CD REV B Page 24 of 48 Revised: March 8, 2013

Figure 10: Shaft Assembly Installation

LAOH-CD REV B Page 25 of 48 Revised: March 8, 2013

Figure 11: Planetary Gear Installation

LAOH-CD REV B Page 26 of 48 Revised: March 8, 2013

Figure 12: Anchor Ring Installation

Figure 13: Positive Brush Replacement

LAOH-CD REV B Page 27 of 48 Revised: March 8, 2013

Figure 14: Negative Brush Replacement

Figure 15: Comm Ass’y Complete with Brush Retainers

LAOH-CD REV B Page 28 of 48 Revised: March 8, 2013

Figure 16: Flux Ring Installation

Figure 16a: Flux Ring Orientation

LAOH-CD REV B Page 29 of 48 Revised: March 8, 2013