TM 5-3805-254-20-1
ORGANIZATIONAL TROUBLESHOOTING - CONTINUED
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
3. ENGINE FAILS TO CRANK.
WARNING
Although KEY SWITCH must be on and battery ground cable connected to test electrical circuit
voltage, turn off KEY SWITCH and disconnect battery ground cable before doing resistance tests
or replacing parts. This will keep you from getting shocked and prevent damage to parts and
equipment.
Step 1
Have assistant rotate KEY SWITCH (1) clockwise to on position and press ENGINE START
button (2) for 5 seconds. Listen to starter motor (3) and solenoid (4) for clicking, thumping,
grinding, or spinning noise. Have assistant rotate KEY SWITCH (1) counterclockwise to off
position.
a
If solenoid (4) made clicking noise or no noise was heard, go to step 4.
b
If solenoid (4) thumped but starter motor (3) did not crank engine, notify Direct
Support Maintenance.
c
If starter motor (3) made grinding noise, go to step 2.
d
If starter motor (3) spun without cranking engine, replace starter motor (3) (page 2-
896).
Step 2
Remove starter motor (3) (page 2-896). Look for broken teeth on starter motor drive gear (5).
Check that starter motor drive gear (5) turns in one direction only. Look for cracks or breaks on
starter motor end housing (6).
a
If teeth on starter motor drive gear (5) are broken, go to step 3.
b
If starter motor drive gear (5) turns in both directions, replace starter motor (3) (page
2-896).
c
If starter motor end housing (6) is cracked or broken, go to step 3.
Step 3
Crank over engine (TM 5-3805-254-10) while inspecting flywheel ring gear (7) for broken or
missing teeth.
a
If flywheel ring gear (7) has broken or missing teeth, notify Direct Support
Maintenance.
b
If flywheel ring gear (7) has no broken or missing teeth, replace starter motor (3)
(page 2-896) and go to step 4.
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