TCM STARTER

SERVICE
INSTRUCTIONS
SERVICE INSTRUCTIONS
FOR
AIRCRAFT STARTER
ENERGIZER®

MODEL TCM 646238 &

646238-1 12 VOLT

MODEL TCM 646275

24 VOLT

Wi TELEDYNE
CONTINENTAL MOTORS
An Allegheny Teledyne Company

FORM X30592 FAA APPROVED

© 1987 TELEDYNE INDUSTRIES, INC. FEBRUARY 1987
 TABLE OF CONTENTS

INTRODUCTION . . . . . . . . . . . . . . . . . . . .. I

DES RITON.. . .. .. . .. ..T.. .. . .. . ... . . 1

TESTING ....................... 2

Test Specifications ................................... 2

DISASSEMBLY . . . . . . . . . . . . . . I . . . . . . . . . . . . . . I . . . I. . . . .. 2

End Housings ....................................... 3

Rotor Shaft Assermbly (Armature) .............................. 3

Brush Holder Assembly .................................. 3

MNSECTION AND REPAIR .................................... 3

Brushes. ........................................ 3

Ol Sea . ........................................ 4

Rotor Shaft Assemnbly (Affnature). ............................. 4

Fleld Colts....................................... 4

Bearings.......................................... 5

REASSMBLY...............I.......................... 6

Brush Holder Assembly.................................. 6

Rotor Shaft Assembly (Armature). ............................ 6

End Housings ........................................ 6

PARTS UST ENERGIZER 12 VOLTM(64238) .8.............. .

PARTS UST ENERGIZER 12 VOLT (646238-1)........................... 9

PARTS UST ENERGIZER 24 VOLT (648275) ............................ 10

- I -
 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 procedares 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, connecd positive to positive
arnd negative to negative.
3. Disconnect the aircraft battery before removing or servicing the starter system.
4. kms"r starter teriniaj is niot grounded prior to connecting lead to starter terminal.

DESCRIPTION
The starter consists of five main subassemblies:
1. Drive end flange containng replaceable bearing and oil seal.
2. Rotor shaft assembly (Armature).
3. Brush holder assembly containing two replaceble brushes.
4. Commnutator-end cover assembly containing replaceable bearing.
5. Starter housing assemkbly containing a fil col, with two replaceable brushes.
The dvriveed flang assembly provides the mnounting flange for afttchmentd 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 (armnature) carries the rotating field coil enclosed within the rotor with
connecting wires teffnnated at the comrnutalor. The commutator In conjunction with the brushes, located
In thre 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-plece device which provides placement and spring loaclng of the
brushe&
The commutator-end cover assembly contains a bearing in which the rear end of the rotor shaft is
suppotd~

I
 The starter housing assembly supports the non-replaceable field winding pole shoes and brush holder
assembly.

TEST SPECIFICATIONS (7S°F)

l 2 No load test 5.7 volts*, 53-91 AMPS 3650 RPM minimum.
~ n e r g i z e r ~volt:

~ 2 4 No load test 20 volts*, 30.50 AMPS 4300 RPM minimum.

~ n e r ~ i z e r volt:

FIGURE 1. TEST CONNECTION DIAGRAM.

1. Rheostat (0.05 to 0.2 ohma rang., 96 amp capablllty) 3. Swltch (100 amp ntlng)
2 D.C. Ammeter (0 to 100 amps) 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-lbs. of torque, the starter should function satisfactorily on the engine.
I

DISASSEMBLY
m
Only limited replacement items are available for servicing the starter. If items other than brushes, w
bearings or oil seal require replacement, a new starter will be required.
A. End Houslngs

1. Remove the four (4) through bolts.

2. Remove the two end housings.

B. Rotor Shaft Assembly (Armature)

1. 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.

C. 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.

FIGURE 2.
 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 termrinral post for silver soldering of new brushes.
S. Place insulation on new brush lead, holding brush lead to field terrminal, 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)..
B. Oil Seatl
1. If oil seal shows signs of leakage or wear it should be replaced, TCM recommends 100%
replacement of oil seal.
C. 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:
Mhirnium Diameter 1.50"
Un'dercut .003" Max.
Total Runout from
Bearing Surfaces .002' Max.
Surface FinIsh 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 shorl circulits, opens, and grounds.
5. SHORT CIRCUfTS. 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 tihe 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, lead originally soldered to the riser bars can be resoldered.
7. GROUNDS. Grounds in the armature can be detected by the use of a test lamnp and probes. If
the lamp lights when one test piebe Is placed on the commutator and the other probe on the
armature core or shaft, the armature Isgrounded. Armiature will require replacement.
D. FIELD COILS. Check field coils for grounds and opens using atest lamp.
1. GROUNDS. Disconnect field colt ground connections. Connect one test probe to the field
framne and th other to the field connector. if the taMp 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 niot
light, the field coils are open.
3. If the stationary field assembly Is found to be unservlceable, a new starter will be required.

4
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. 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.
(See 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 and flange assembly.
b. Commrutator 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.

FIGURE 3. DRIVE END FLANGE ASSEMBLY FIGURE 4. DRIVE END FLANGE

BEARING REMOVAL & INSTALLATION. ASSEMBLY OIL SEAL REMOVAL.

5
 I MM
PRESS NEV
BEARING IP
TO .700

END COVER
I COVER -- ,- I
FIGURES5. COMMUTATOR END FIGURE 6. COMMUTATOR END
COVER BEARING REMOVAL COVER BEARING INSTALLATION.

F. Reassembly
After all parls have been inspected, repaired or found to be in a serviceable condition, starter may
be re-assembled.
a. Brush Holder Assembly

1. Assemble the two field coil brushes into the brush holder assembly.
2. Place brush holder assembly into starter housing, mie up holes and secure with three
retaining screws.
b. 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.
c. 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 3600 to insure free movement and square up end housings.
4. Torque through bolts to 95-105 inch pounds. Check starter shaft torque. Torque must
not exceed 5 inch pounds.
d. Test starter per test specifications given prior to installation.

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FIGURE 7.
 PARTS LIST ENERGIZER'12 VOLT 646238

FIG. & PART USABLE

INDEX NUMBER 12 3 4 5 DESCRIPTION OTY. ON CODE

2- 1 64623 Starter, 12 Volt ....... 1

646328 * Flange Assy. - Drive End 1
- 2 * . Flange Drive End Starter NS
- 3 646327 * . Bushing - .750 I.D. 1
- 4 846328 ,..Seali-OU0.75 Shaft Dia. 1
- 5 MS16562-21 * . RollIPin . . . . . . . . . 1
646502 * Cover Assy. - Commutator End I
-6 * . Cover - Commutator End . NS
-7 64633 * . Bushing - Commutalor End.- 1
-8a Armature - 12 Volt
-9 *Plate - Identification .. .. . NS
-10 24784 *Screw - No. 0-.19 DRi
-11 Housing Assy. - 12 V4 I. ...... NS
-12 848349 Screw - Self Threac Bring. ..... 3
-13 646357 Stud - TefrrTnal
-14 .846349 *.Screw - Self Threec
-15 640359 Washer - Insulator .~~~2
-18 646360 Insulator - Square
-17 8463w Washer - Insulator
-18 846362 .Washier -Flat .
-19 646363 Washer - Lock .1 .... A
-20 646364 Nut - Hex .312-18
-21 64638 Washer ......
-22 64636 Washer- Fiber
-23 646365 .Bolt-Hex Flange.
-24 646340 *Brush Holder Assamil .~~~~4
-25 84634 Brush .......
-26 MS35=344 *Washer, Lock . .. .~~~~6

AR - As Required
NS - Not Sold

a
 PARTS LIST ENERGIZER"12 VOLT 646238-1

FIG. & PART USABLE

INDEX NUMBER 12 3 4 5 DESCRIPTION OTY. ON CODE
2- 1 646238 Starter, 12 Volt ....... 1
646326 *Flange Assy. - Drive End 1
-2 *.Flange Drive End Starter NS
-3 646327 *.Bushing - .750 I.D. I
-4 646328 e".SI-oil .7 SWfDia. I
-5 MS16562-21 .Roll
* Pin . . . . . . . . . 1
646502 *Cover Assy. - Commutator End 1
-6 *.Cover - Commnutator End . NS
-7 646332 *.Bushing - Commutator End . I
-8a 646333 .Armature-l12 Volt I
-9 *Plate - identification ... NS
-10 24764 *Screw -No. 0-.19 DRV. 4
-11 *Housing Assy. - 12 Volt NS
-12 648349 *.Screw -Self Threading 3
-13 646357 Stud - Terminal . . I1
-44 646349 *.Screw - Self Threading 1
-15 646359 Washer - Insulator .... 2
-16 646360 Insulator - Square .... 1
-17 646361 *.Washer - Insulator .. 1
-18 646362 Washer- Flat ....... I
-19 648363 .Washer- Lock . 2
-20 848364 Nut - Hex .312-18 2
-21 6463S7 .Washer ........... 1
-22 64636 Washer -Fiber. AR
-23 646365 SBoft -Hex Flange ...... 4
-24 646340 Brush Holder Assembly. ., I
-25 646348 *Brush ............ 4
-26 MS35336.44 Washer, Lock ........ 6
-27 640107 Solenoid, 12 Volt ....... 1
-28 649063-25-5 Screw ............ 2
-29 6401083 Coonrector .......... 1

AR - As Required
NS - Not Sold

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 PARTS LIST ENERGIZER*24 VOLT 646275

FIG. & PART USABLE

.INDEX NUMBER 12 3 4 5 DESCRIPTION OTY. ON CODE

11-1 646275 Starter, 24 Volt .......... 1

84032 *Flange Assy. - Drive End.
-2 *.Flange Drive End Starter .... NS
-3 646327 *.Bushing - .750 I.0 . .......
-4 646328 Seal -Oil .75 ShaftDia. ....
I
.5 MS16562-21
1
846502
*.RolliPin

*Cover Assy. - Commutator E nd. 1

-6 *.Cover - Commutator End ..... NS
-7 64633 *.Bushing -Commutator End .
-8a 646374 .Armature-24 Volt ........ 1
-9 *Plate - Identiffication ...... NS
-10 24764 Screw - No. 0-.19 DRV ....... 4
411 *Housing Assy. - 24 Volt ...... NS
-12 646349 .Screw - Self Threading 3
-13 646357 Stud - Tefrminal......... 1
-14 64034 *Screw - Self Threading 1
-15 648359 *Washer.- Insulator .... 2
-16 64636D *.Insulator - Square ....... I
-17 646361 Washer - Insulator ....... 1
-18 646362 Washer -RFat .......... 1
-19 646363 Washer - Lock . . ........ 2
-20 646364 Nut - Hex .312-18 ........ 2
-21 646367 .Washer .............. 1
-22 646368 Washer -Fiber .......... AR
-23 646365 .Bolt-Hex Flange ......... 4
-24 646340 Brush Holder Assembly ....... 1
-25 646348 Brush ............... 4
-26 MS35338.44 Washer, Lock ........... 8

AR - As Required
NS - Not Sold

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