MODELS 646238
646275
CONTINENTAL® ENGINE ACCESSORIES
STARTER
SERVICE
SUPPORT
MANUAL
Publication X30592-1
©
2011 CONTINENTAL MOTORS, INC.
AUG 2011
Supersedure Notice
This manual revision replaces the front cover and list of effective pages for Publication Part No. X30592, dated
February 1987. Previous editions are obsolete upon release of this manual.
Effective Changes for this Manual
0 ..............February 1987
1 ............ 31 August 2011
List of Effective Pages
Document Title: Starter Service Support Manual
Publication Number: X30592-1
Page
Change
Page
Change
Initial Publication Date: February 1987
Page
Change
Page
Change
Cover............................ 1
A................................... 1
i .................................... 0
ii - blank added............. 1
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Published and printed in the U.S.A. by Continental Motors, Inc.
Available exclusively from the publisher: P.O. Box 90, Mobile, AL 36601
Copyright © 2011 Continental Motors, Inc. All rights reserved. This material may not be reprinted, republished, broadcast, or otherwise
altered without the publisher's written permission. This manual is provided without express, statutory, or implied warranties. The publisher will
not be held liable for any damages caused by or alleged to be caused by use, misuse, abuse, or misinterpretation of the contents. Content is
subject to change without notice. Other products and companies mentioned herein may be trademarks of the respective owners.
A
Starter Service Support Manual
31 August 2011
TABLE OF CONTENTS
INTRODUCTION.
DESCRIPTION.
2
TESTING . . .
2
Test Specifications
DISASSEMBLY. . . .
2
End Housings.
3
Rotor Shaft Assembly (Armature) .
3
Brush Holder Assembly
3
3
INSPECTION AND REPAIR
Brushes
3
Oil Seal
4
Rotor Shaft Assembly (Armature) .
4
"
Field Coils
4
Bearings
5
REASSEMBLY.
6
Brush Holder Assembly
6
Rotor Shaft Assembly (Armature)
6
End Housings. . . . . . . . . .
6
PARTS LIST ENERGIZER ® 12 VOLT (646238).
8
PARTS LIST ENERGIZER®12 VOLT (646238-1).
9
PARTS LIST ENERGIZER ® 24 VOLT (646275). . . . . . . . . . . . . . . . . . . . . . . . . . . .
-1-
10
Intentionally Left Blank
SERVICE INSTRUCTIONS
INTRODUCTION
The ·following service procedures covered herein apply to the 646238 -- 12 volt, 646238-1 12 volt and
646275 -- 24 volt gear driven starters.
The Energizer ® starter is designed as a field non-serviceable accessory. Therefore, TCM recommends
replacement with a new exchange starter which should result in the most economic means of repair.
However, TCM offers the following test procedures and service components for service repair.
CAUTION . .. The following precautions must be observed when servicing the starter system or serious
damage may be incurred by the starter or the Aircraft Electrical System.
1. Make absolutely certain that the aircraft battery is installed with the negative terminal grounded.
2. When connecting a charger or booster battery to the aircraft battery, connect positive to positive
and negative to negative.
3. Disconnect the aircraft battery before removing or servicing the starter system.
4. Insure starter terminal is not grounded prior to connecting lead to starter terminal.
DESCRIPTION
The starter consists of five main subassemblies:
1. Drive end flange containing replaceable bearing and oil seal.
2. Rotor shaft assembly (Armature).
3. Brush holder assembly containing two replaceable brushes.
4. Commutator-end cover assembly containing replaceable bearing.
5. Starter housing assembly containing a field coil, with two replaceable brushes.
The drive-end flange assembly provides the mounting flange for attachment of the starter to the engine
and supports the bearing through which the rotor shaft protrudes to support the starter drive.
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 brush holder assembly is a one-piece device which provides placement and spring loading of the
brushes.
The commutator-end cover assembly contains a bearing in which the rear end of the rotor shaft is
supported.
1
The starter housing assembly supports the non-replaceable field winding pole shoes and brush holder
assembly.
TEST SPECIFICATIONS (75°F)
Energizer®12 volt: No load test 5.7 volts*, 53-91 AMPS 3650 RPM minimum.
Energ;zer®24 volt: No load test 20 volts*, 30-50 AMPS 4300 RPM minimum.
4
2
3
1
STARTER
+
==o.c.
SUPPLY
FIGURE 1. TEST CONNECTION DIAGRAM_
1. Rheostat (0.05 to 0.2 ohms range. 95 amp capability)
2. D.C. Ammeter (0 to 100 amps)
3. Switch (100 amp rating)
4. D.C. Voltmeter (0 to 30 volts)
TESTING
1.
Install starter on test fixture. 2. Adjust rheostat to obtain the specified voltage. 3. Read current
and shaft speed. 4. If starter meets test requirements, operates without excessive noise and shaft
turns with less than 5 in-Ibs. of torque, the starter should function satisfactorily on the engine.
DISASSEMBLY
Only limited replacement items are available for servicing the starter. If items other than brushes,
bearings or oil seal require replacement, a new starter will be required.
2
A.
B.
End Housings
1.
Remove the four (4) through bolts.
2.
Remove the two end housings.
Rotor Shaft Assembly (Armature)
1.
c.
Making note as to the number of spacers mounted on each end of the rotor shaft, remove the
rotor shaft assembly from the starter housing.
Brush Holder Assembly
1.
Remove the three (3) brush holder retaining screws.
2.
Disassemble the two (2) field coil brushes from brush holder and remove the brush. holder
assembly.
INSPECTION AND REPAIR
A.
Brushes
1.
If brushes are less than .39 or 25/64 of an inch long they should be replaced.
2.
On. the brush holder assembly, heat the brush lead connector and pry crimp from the wire.
CUT OLD BRUSH
OFF HERE
CLEAN TERMINAL
AND SILVER
SOLDER NEW
BRUSH HERE
STARTER
HOUSING
FIGURE 2.
3
B.
3.
Place insulation on new brush lead, install lead and crimp into place. Silver solder brush lead
at the open end of crimp.
4.
On the field coil assembly, cut the brushes as close as possible to the field terminal. Clean
the side of the terminal post for silver soldering of new brushes.
5.
Place insulation on new brush lead, holding brush lead to field terminal, silver solder. Do not
allow solder to wick up the flexible brush lead during the soldering process. If silver solder
makes the lead rigid it must be replaced with a new lead (see Figure 2).
011 Seal
1.
c.
If oil seal shows signs of leakage or wear it should be replaced, TCM recommends 100%
replacement of oil seal.
Rotor Shaft Assembly (Armature)
1.
Inspect the commutator for cleanliness, excessive wear or pitting. If required, the commutator
can be reworked to the following specifications:
Minimum Diameter
Undercut
Total Runout from
Bearing Surfaces
Surface Finish
D.
4
1.50"
.003" Max.
.002" Max.
50 Microinch Max.
2.
Inspect bearing surfaces for galling or excessive wear. No replacement parts are available and
a new starter will be required.
3.
Inspect rotor for wear, broken wires or cracked insulation.
4.
Check armature for short circuits, opens, and grounds.
5.
SHORT CIRCUITS. Short circuits are located by rotating the armature in a growler with a
steel strip such as a hacksaw blade held on the armature. The steel strip will vibrate on the
area of the short circuit. Shorts between bars are sometimes produced by brush dust or copper
between the bars. Undercutting the insulation will eliminate these shorts.
6.
OPENS. Inspect the points where the conductors are joined to the commutator for loose
connections. Poor connections cause arCing and burning of the commutator. If the bars are not
badly burned, leads originally soldered to the riser bars can be resoldered.
7.
GROUNDS. Grounds in the armature can be detected by the use of a test lamp and probes. If
the lamp lights when one test probe is placed on the commutator and the other probe on the
armature core or shaft, the armature is grounded. Armature will require replacement.
FIELD COILS. Check field coils for grounds and opens using a test lamp.
1.
GROUNDS. Disconnect field coil ground connections. Connect one test probe to the field
frame and the other to the field connector. If the lamp lights the field coils are grounded and
must be repaired or replaced.
2.
OPENS. Connect test lamp probes to the ends of the field coil leads. If the lamp does not
light, the field coils are open.
3.
If the stationary field assembly is found to be unserviceable, a new starter will be required.
E.
Bearings
1.
Inspect bearings for excessive wear (see dimensions given in Figures 3 thru 6) and galling. If
replacement is required refer to Figures 3 thru 6, and proceed as follows:
a.
b.
Drive End Flange Bearing
1)
Make a suitable fixture to hold the drive end flange on the press bench. Press the
bearing through the drive end flange and oil seal.
2)
Carefully bend approximately one-half (1/2) the diameter of the steel oil seal
retainer down using a small, sharp chisel and mallet. Do not score drive end flange.
(~ee Figure 4).
3)
USing a pair of common pliers, grasp bent portion of oil seal retainer and remove
oil seal from drive end flange.'
4)
Press new bearing into drive end flange using dimensions given in Figure 3.
5)
Press a new oil seal into drive end flange assembly.
Commutator End Cover
1)
USing a blind hole bearing puller remove bearing from commutator end cover (See
Figure 5).
2)
Press new bearing into commutator end cover to dimension given in Figure 6.
PRESS RAM
14---1-- .8437 DIA.
BALLPEEN~
BARSTOCK
HAMMER
.750 1.0. -;t::::t.,~
.748
,
~
DRIVE END
FLANGE ASSY.
CHISEL
OIL SEAL
STEEL
RETAINER
DRIVE END
FLANGE
ASSEMBLY
FIXTURE
FIGURE 3. DRIVE END FLANGE ASSEMBLY
BEARING REMOVAL & INSTALLATION.
FIGURE 4. DRIVE END FLANGE
ASSEMBLY OIL SEAL REMOVAL
5
I
BLIND HOLE
BEARING PULLER
PRESS NEW
BEARING IN
TO .700
8-
.593 DIA.
BAR STOCK
.5625 I.D.-~.-jl
.5610
BEARING
BEARING
COMMUTATOR END
COVER
FIGURE 5. COMMUTATOR END
COVER BEARING REMOVAL
F.
FIGURE 6. COMMUTATOR END
COVER BEARING INSTALLATION.
Reassembly
After all parts have been inspected, repaired or found to be in a serviceable condition, starter may
be re-assembled.
a.
b.
c.
, I
Brush Holder Assembly
1.
Assemble the two field coil brushes into the brush holder assembly.
2.
Place brush holder assembly into starter housing, line up holes and secure with three
retaining screws.
Rotor Shaft Assembly (Armature)
1.
Insure that spacers are installed in the same manner (place) and sequence from which
they were removed. TMC recommends that any time the starter is dissembled the fiber
spacers be replaced 100%.
2.
Install rotor shaft assembly (armature) into starter housing.
End Housings
1.
Install the two end housings lining up the bolt holes.
2.
Install the four starter through bolts (bolts positioned in holes located on the raised
portion of the commutator end cover require one lockwasher, two lockwashers are used
on the remaining two through bolts) and screw in finger tight.
3.
Rotate starter shaft 360° to insure free movement and square up end housings.
4.
Torque through boits to 95·105 inch pounds. Check starter shaft torque.
not exceed 5 inch pounds.
I
I
I
d.
6
Test starter per test specifications given prior to installation.
Torque must
1
20
FIGURE 7.
7
PARTS LIST ENERGIZER@12 VOLT 646238
FIG. &
INDEX
2- 1
PART
NUMBER
646238
646326
- 2
- 3
- 4
- 5
- 6
- 7
- 8
- 9
-10
-11
-12
-13
-14
-15
-16
-17
-18
-19
-20
-21
-22
-23
-24
-25
-26
AR - As Required
NS - Not Sold
8
646327
646328
MS16562-21
646502
646332
646333
24764
646349
646357
.646349
646359
646360
646361
646362
646363
646364
646367
646368
646365
646340
646348
MS35338.44
12 3 4 5
DESCRIPTION
Starter, 12 Volt
· Flange Assy. - Drive End
· . Flange Drive End Starter
· . Bushing - .750 1.0.
· . Seal - Oil .75 Shaft Dia.
· . Roll Pin
· Cover Assy. - Commutator End .
· . Cover - Commutator End .
· . Bushing - Commutator End .
· Armature - 12 Volt
· Plate - Identification
· Screw - No. 0-.19 DRV
· Housing Assy. - 12 Volt
· . Screw - Self Threading
· . Stud - Terminal
· . Screw - Self Threading
· . Washer - Insulator
· . Insulator ~ Square
· . Washer - Insulator
· . Washer - Flat
· . Washer - Lock .
· . Nut - Hex .312-18
· Washer.
· Washer - Fiber
· Bolt - Hex Flange
· Brush Holder Assembly.
· Brush.
· Washer, Lock
QTY.
1
1
NS
1
1
NS
1
1
NS
4
NS
3
1
1
2
1
1
2
2
1
AR
4
1
4
6
USABLE
ON CODE
PARTS LIST ENERGIZER®12 VOLT 646238-1
FIG. &
INDEX
2- 1
•
2
3
4
5
- 6
- 7
- 8
- 9
-10
-11
-12
-13
-14
-15
-16
-17
-18
-19
-20
-21
-22
-23
-24
-25
-26
-27
-28
-29
PART
NUMBER
646238
646326
94
6327
646328
MS16562-21
646502
646332
646333
24764
646349
646357
646349
646359
646360
646361
646362
646363
646364
646367
646368
646365
646340
646348
MS35338.44
649107
649083-25-5
649108
DESCRIPTION
1 2 345
Starter, 12 Volt
· Flange Assy. - Drive End
· . Flange Drive End Starter
· . Bushing - .750 I.D.
· . Seal - Oil .75 Shaft Dia.
· . Roll Pin
· Cover Assy. - Commutator End.
· . Cover - Commutator End . .
· . Bushing - Commutator End .
· Armature - 12 Volt
· Plate - Identification
· Screw - No. 0-.19 DRV .
• Housing Assy. - 12 Volt .
· . Screw - Self Threading
· . Stud - Terminal .
· . Screw - Self Threading
· . Washer - Insulator
· . Insulator - Square
· . Washer - Insulator
· . Washer - Rat
.
· . Washer - Lock .
· . Nut - Hex .312-18
· Washer . .
· Washer - Fiber
· Bolt - Hex Flange
· Brush Holder Assembly.
· Brush ..
· Washer, Lock .
Solenoid, 12 Volt
· Screw.
· Connector.
·
·.
·.
..
QTY.
USABLE
ON CODE
1
1
NS
1
1
1
1
NS
1
1
NS
4
NS
3
1
1
2
1
1
1
2
2
1
AR
4
1
4
6
1
2
AR - As Required
NS - Not Sold
9
PARTS LIST ENERGIZER®24 VOLT 646275
FIG. &
INDEX
1- 1
-
2
3
4
5
- 6
- 7
- 8
- 9
-10
-11
-12
-13
-14
-15
-16
-17
-18
-19
-20
-21
-22
-23
-24
-25
-26
AR - As Required
NS - Not Sold
10
PART
NUMBER
646275
646326
646327
646328
MS16562-21
646502
646332
646374
24764
646349
646357
646349
646359
646360
646361
646362
646363
646364
646367
646368
646365
646340
646348
MS35338.44
12345
DESCRIPTION
Starter, 24 Volt
· Flange Assy. - Drive End
· . Flange Drive End Starter
· . Bushing - .750 I.D.
· . Seal - Oil .75 Shaft Dia.
· . Roll Pin
· Cover Assy. - Commutator End .
· . Cover - Commutator End .
· . Bushing - Commutator End .
· Armature - 24 Volt
· Plate - Identification
· Screw - No. 0-.19 DRV
· Housing Assy. - 24 Volt
· . Screw - Self Threading
· Stud - Terminal .
· . Screw - Self Threading
· . Washer - Insulator
· . Insulator - Square
· . Washer - Insulator
· . Washer - Flat ..
· . Washer - Lock . ..
· . Nut - Hex .312-18
· Washer.
· Washer - Fiber ..
· Bolt - Hex Flange
· Brush Holder Assembly.
· Brush.
· Washer, Lock . . . . .
.
QTY.
1
1
NS
1
1
1
NS
1
1
NS
4
NS
3
1
1
2
1
1
1
2
2
1
AR
4
1
4
6
USABLE
ON CODE
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