Direct Drive Starting Motor Maintenance and Overhaul
Direct Drive Starting Motor Maintenance and Overhaul
Direct Drive Starting Motor Maintenance and 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.
Except
1
MagnaFlite 1
Lightweight
Starter.
2
4
6
5
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.
!
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.
4. Carefully bend the negative brush shunt clamps out Figure 3 - Unload Brush
and remove the brush shunts. Discard the brushes. Spring Tension.
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.
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.
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.
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).
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.
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.
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.
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.
Stud Installation.
into the pole shoes, and
assemble to the field
case, using the screws
Figure 10 - New
in the Tolerances and
Installation.
(Figure 11). Insert
felt and apply several
drops of SAE 30
weight oil for Figure 11 - Ream Bushings.
lubrication.
Shunts to Clamps.
assembly onto the
drive end of the
Figure 14 - Bushing
armature shaft
Assembly Installation.
(Figure 14).
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.
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
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.
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.
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.
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.