What was found
INSTALLED 3 DIFFERENT HARTZELL 149-12HT-H2 STARTERS (S/NS H-X112418, H-Z112422 & H-Z050870) BETWEEN 03/28/2025 AND 07/24/2025 ON A ROBINSON R44. EACH FAILED IN THE SAME MANNER AT 105.19, 82.66 & 9.91 HOURS TIME IN SERVICE RESPECTIVELY. IN EACH CASE THE ST2405 CONTACT BRACKET CAME LOOSE CAUSING THE STARTER TO SHORT OR OVERHEAT. IN THE THIRD CASE THERE WAS THERMAL DAMAGE AND CHARRING TO THE STARTER AND SMOKE/SOOT STAINS ON THE ENGINE. THE MANUFACTURER ATTRIBUTED THE FAILURE TO "SUSPECT LOOSE COMPONENT DUE TO EXCESSIVE TENSION AND/OR VIBRATION FROM CUSTOMER INSTALLED CABLE.” BUT THE 22 GAUGE 'STARTER ENGAGED INDICATOR LAMP' WIRE CONNECTED TO THE TERMINAL WAS PROPERLY SUPPORTED, STRAIN RELIEVED, AND APPEARS TOO SMALL TO HAVE CAUSED THE DAMAGE TO THE STARTER.