ARMY A-A-59294-1998 STARTERS ENGINE ELECTRICAL 24-VOLT DIRECT-CURRENT [Superseded ARMY MIL-S-3785 E CANC NOTICE 1 ARMY MIL-S-3785 E ARMY MIL-S-3785 D (1) ARMY MIL-S-3785 D ARMY MIL.pdf

1、INCH-POUNDA-A-59294September 24, 1998SUPERSEDINGMIL-S-3785E(AT)24 March 1998MS53011E6 February 1976COMMERCIAL ITEM DESCRIPTIONSTARTERS, ENGINE, ELECTRICAL:24-VOLT DIRECT-CURRENTThe General Services Administration has authorized the use of this commercial itemdescription (CID) for all federal agencie

2、s.1. SCOPE. This specification covers 24-volt (V) direct-current (dc) starters for crankingnonaircraft internal-combustion engines.2. ClASSIFICATION. Starters will be of the following type, grade, class, and duty specifiedbelow.Type II - For peri pheral (ring gear) engagement.Grade A - Waterproof.Cl

3、ass 1 - Positive drive - solenoid.Duty - Heavy.Beneficial comments recommendations, additions, deletions and any pertinent data which may beof use in improving this document should be addressed to: U.S. Army Tank-automotive andArmaments Command, ATTN: AMSTA-TR-E/BLUE, Warren, MI 48397-5000.AMSC N/A

4、FSC 2920DISTRIBUTION STATEMENT A . Approved for public release; distribution is unlimited.Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-A-A-5929423. SALIENT CHARACTERISTICS3.1 Design, materials, and manufacturing processes . The design, materials,

5、and manufacturingprocess selection shall be the prerogative of the contractor as long as all articles submitted to theGovernment fully meet the physical and performance characteristics of this CID. The use ofrecovered material made in compliance with regulatory requirements is acceptable providing a

6、llrequirements of this CID are met.3.2 Operating characteristics .3.2.1 Cranking torque and speed . Starter shall evidence no damage and shall conform tofigure 1 when mounted on a test stand to simulate actual mounting in use. RecommendedSAE practice for ring gears or starter-driven gears dimensions

7、 and pitch circle clearances shall beused.3.2.1.1 Stalling torque . The starter shall meet the following stalling torque requirements:a. Volts: 3.5 (approximately)b. Current amperes (A) (max.): 500c. Torque (pound-foot (lb-ft) (minimum.): 163.2.1.2 Solenoid current consumption . Solenoid current con

8、sumption (pull-in plus hold -in) shallnot exceed 81 A.3.2.2 Position . The starter shall operate within specified performance requirements (see 3.2.1)and without evidence of damage when the longitudinal axis is in any angular position within45 degrees of the intended operating position.3.2.3 Overspe

9、ed capability . When subjected to 24 V properly applied at the motor terminals, thestarter shall evidence no damage after operation of 1 minute at no load.3.2.4 Dielectric strength . When subjected to an applied voltage of 500 V at a frequency of60 hertz (Hz), the insulation shall evidence no burnin

10、g, charring, loosening or cracking (arcing),smoking, rupture or other damage.3.2.5 Loaded static torque . When energized into a stationary ring gear, pinion and clutch dentilsshall have consistent engagement without hesitation and shall provide 350 lb-ft of torque at thedrive.3.2.6 Tooth abutment lo

11、ad . With a maximum axial force of 38 pounds (lb), applied to a singlepinion tooth at its pitch diameter, the pinion shall move to its full indexing position.Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-A-A-5929433.2.7 Overrunning torque . When te

12、sted to the following procedures, pinion and clutch dentilsshall be separated between 10 000 and 14 000 revolutio ns per minute (rpm). When pinion andclutch dentils are separated, the overrunning torque shall be less than 8 pound-inch (lb-in.) at15 000 rpm.a. Rotate positork drive pinion to overrunn

13、ing direction by mechanical means(see figure 1).b. Measure speed of the drive pinion at which pinion and clutch dentils separate.Separation of the dentils can be determined by change in sound.c. Increase speed of the drive pinion to 15 000 rpm, and measure overrunning torque ofthe drive.3.3 Design i

14、nterface .3.3.1 Drive . The drive shall consist of a pinion for meshing with the flywheel ring gear and ameans of effecting such meshing. The pinion shall employ a positive drive for meshing with theflywheel ring gear. The pinion shall be actuated into mesh by a solenoid.3.3.2 Mounting flange . The

15、mounting flange shall conform to figure 2 and figure 3, and shall beadjustable to all positions (A thru L) shown in figure 3.3.3.3 Pinion . The starter shall include one of three different pinion configurations, as applicable.The starter/pinion combinations, identified by Part or Identifying Numbers

16、 (PINs), shall conformto figure 4 and the following (see 7.1):a. PINs AA59294-1 and : - 11 teeth (12 tooth blank); 6/8 pitch; 2.000 inch (in.) PD;AA59294-3 2.250 in. OD; 20 pressure angle; 0.015 to 0.025 in.PL clearance.b. PIN AA59294-2 - 12 teeth (13 tooth blank); 8/10 pitch; 1.625 in. PD;1.825 in.

17、 OD; 20 pressure angle; 0.015 to 0.025 in.PL clearance.c. PIN AA59294-4 - 13 teeth (14 tooth blank); 8/10 pitch; 1.750 in. PD;1.950 in. OD; 20 pressure angle; 0.015 to 0.025 in.PL clearance.3.3.4 Terminals . Terminal location, thread size, and length shall conform to figure 4 and thefollowing:a. Bat

18、tery - 1/2-13 UNC 2A; 0.50 in. minimum, 1.00 in. maximumlength beyond outside nut when jam nut, washer andoutside nut are assembled on to the stud.Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-A-A-592944b. M otor - Ground, 1/2-13 UNC 2A, 0.50 maxim

19、um length beyondoutside nut when starter is assembled.c. Switch - No. 10-32 UNF 2A (PINs AA59294-1, 2, and 4)- 1/4-20 UNF 2A (PIN AA59294-3)3.3.5 Rotation . Unless otherwise specified (see 7.3), the direction of the rotation of the drive, asviewed from the driving end of the starter, shall be clockw

20、ise.3.4 Ownership and support .3.4.1 Life test (live engine test) . The starter drive shall have a minimum life of 45 000 cycles.3.4.2 Endurance . The starter shall be sufficiently durable to complete 1000 cycles of endurancecycles on a test stand without servicing or replacement of parts. Each cycl

21、e shall consist of30 seconds of operation under load followed by 5.5 minutes off time. The load shall be soadjusted that the starter produces 95% of the maximum horsepower shown in figure 5. The loadshall be applied at the starter pinion through ring gear engagement means as in intendedoperation. An

22、 air velocity of approximately 1500 linear feet per minute to force air over andaround the starter is allowable. During the last 200 cycles, the longitudinal axis of the starter shallbe positioned at an angle with the starter pinion 45 degrees above and below the horizontal for100 cycles each. Follo

23、wing the endurance test, the starter shall operate within 10 percent (%) ofthe performance requirements specified in 3.2.3.4.2.1 Positive drive solenoid . The solenoid, its components, and engaging linkages shall besufficiently durable to complete 1000 hours of endurance cycles without malfunction.

24、The drivepinion shall not mill the flywheel or mating gear used.3.4.2.2 Brush wear . Brushes shall be sufficiently durable to complete 1000 cycles of endurancecycling without loss of more than 50% of the original effective brush length on any one brush.3.4.2.3 Extreme temperature . The starter and i

25、ts drive and clutch assembly shall operatesatisfactorily at ambient temperatures from -65 to +160 degrees Fahrenheit ( F) (-54 to 71degrees Celsius ( C).3.4.3 Painting . Unless otherwise specified (see 7.3), exterior surfaces of the starter shall bepainted with black gloss enamel.3.4.4 Identificatio

26、n and marking . Identification and marking of the starter shall be permanent andlegible and shall include the following minimum information.Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-A-A-592945a. Starter, 24 Vdc.b. Rotation (indicated by arrow).

27、c. CID A-A-59294 and Part Number (see 7.1).d. National Stock Number (NSN).e. Manufact urers serial number.f. Manufacturers name, identification (CAGE), or Logo.3.5 Environmental .3.5.1 Waterproofness . The starter shall be capable of operating submerged with no accumulationof water in its interior.

28、To determine conformance to the characteristics, the starter with itselectrical connections and drive end sealed shall be submerged in a 5% saline solution with theuppermost surface a minimum of 1 in. below the surface of the solution and installed in thechamber. The motor shall be subjected to 6 ps

29、i internal vacuum for 30 minutes. Whilesubmerged, the motor shall be operated three times for 30 seconds each at 5 minutes intervals andreduced voltage of 18 to 20 V. There shall be no air leakage from the interior of the motor orwater accumulation inside the motor. Air bubbles which are the results

30、 of air trapped in pocketson the exterior of the motor shall not be considered a leak.3.5.2 Corrosion . The starter shall evidence no corrosion affecting operation when subjected to a5% sodium chloride salt spray duration for 96 hours, after which the exposure shall be continuedwith the drive end ex

31、posed for 96 hours. Subsequently, the starter with its components shall meetthe operating and waterproofness requirements of 3.2 and 3.5.1.3.5.3 Fungus . The starter shall evidence no microbial growth when subjected to the fungus testspecified in ASTM G21, except the test duration shall be a continu

32、ous 90 days.3.5.4 Vibration . The starter shall function as intended with no loosened or damaged parts whensubjected to a simple harmonic motion having an amplitude of 0.03 in. (0.06 in. maximum totalexcursion), at a frequency ranging between 10 and 55 Hz. The entire frequency range, from 10 to55 Hz

33、 and return to 10 Hz shall be traversed in approximately 1 minute. The motion shall beapplied for a period of 1 hour in each of 3 mutually perpendicular directions (total of 3 hours).3.5.5 Shock . The starter shall function as intended with no loosened or damaged parts whenexposed to severe shock co

34、nditions in accordance with figure 6.4. REGULATORY REQUIREMENTS4.1 Recovered material . The offeror/contractor is encouraged to use recovered materials to themaximum extent practicable, in accordance with paragraph 23.403 of the Federal AcquisitionRegulation (FAR).Provided by IHSNot for ResaleNo rep

35、roduction or networking permitted without license from IHS-,-,-A-A-5929465. QUALITY ASSURANCE PROVISIONS5.1 Responsibility for inspection . The contractor is responsible for the performance of allinspections (examinations and tests).5.2 Product conformance . The products provided shall meet the sali

36、ent characteristics of thiscommercial item description, conforms to the producers own drawings, specifications, standards,and quality assurance practices, and be the same product offered for sale in the commercialmarket. The Government reserves the right to require proof of such conformance.6. PACKA

37、GING. Preservation, packing, and marking shall be as specified in the contract ororder (see 7.3).7. NOTES(This section contains information of a general or explanatory nature that may be helpful, but isnot mandatory.)7.1 Part or identification number (PIN) . The following part identification numberi

38、ng procedureis for government purposes and does not constitute a requirement for the contractor. The PINs tobe used for starters acquired to this CID are created as follows:AA 59294 -XPinion/switch terminal size1 = 11 teeth/ 10-32 UNF-2A2 = 12 teeth/ 10-32 UNF-2A3 = 11 teeth/ 1/4-20 UNF-2A4 = 13 tee

39、th/ 10-32 UNF-2ACID numberCID designator7.2 Addresses for obtaining copies of referenced documents .7.2.1 Non-Government publication . Copies of ASTM G21 “Standard Practice for DeterminingResistance of Synthetic Polymeric Materials to Fungi” is available from the American Society forTesting and Mate

40、rials (ASTM), 100 Barr Harbor Drive, West Conshohocken, PA 19428 -2959.Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-A-A-5929477.3 Ordering data . Acquisition documents should specify the following:a. Title, number, and date of this specification.b

41、. Direction for rotation, if other than specified (see 3.3.4).c. Painting, if other than specified (see 3.4.3).d. Packaging requirements (see 5.1).7.4 Cross-reference . The starter conforming to this CID is interchangeable/substitutable withtype II, grade A, class 1, heavy-duty starter conforming to

42、 MIL-S-3785E(AT), dated24 March 1989 and MS53011, dated 6 February 1976.VARIABLESPEEDMOTORSPLINEBEARINGTORQUEARMSCALEBEARINGPINIONPOSITORKDRIVEFIGURE 1. Mechanical means for conducting the overrunning torque test .Provided by IHSNot for ResaleNo reproduction or networking permitted without license f

43、rom IHS-,-,-A-A-592948FIGURE 2. Mounting flange mean unit .Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-A-A-592949FIGURE 3. Mounting flange positions .Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-

44、,-A-A-5929410Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-A-A-5929411FIGURE 5. Performance curve .Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-A-A-59294121.15P0.07D0.07D0.2P-0.2PD0.3DRef. lineze

45、ro (g)-0.15P0.05P-0.05PIdeal sawtooth pulse0.15PPTolerance limitsVi = PD/2V = Vi + 10%NOTES:1. The oscillogram should include a time about 3D long with the pulse approximately inthe center. The integration to determine the velocity change should extend from 0.4Dbefore the pulse to 0.1D beyond the pu

46、lse. The peak acceleration magnitude of thesawtooth pulse is P and its duration is D. Any measured acceleration pulse which canbe contained between the broken line boundaries is a nominal terminal-peak sawtoothpulse of nominal peak value, P, and nominal duration, D. The velocity-changeassociated wit

47、h the measured acceleration pulse is V i .2. P = 30(gs), D = 11 (ms), and V i = 5.3 ft/sec.FIGURE 6. Tolerances for terminal-peak sawtooth shock pulse .MILITARY INTERESTS: CIVIL AGENCY COORDINATING ACTIVITY:GSA-FSSCustodian: Preparing Activity:Army - AT Army - ATReview Activities: (Project 2920-0497)Army - CR4DLA - CCProvided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-