File: TM101

Original Issue March. 15, 1979

Revision 14 December 09, 2009

OVERHAUL INSTRUCTIONS with

ILLUSTRATED PARTS BREAKDOWN

STARTER-GENERATOR

MODELS

150SG111Q 150SG121Q
150SG114Q 150SG122Q
150SG115Q 150SG123Q
150SG116Q 150SG124Q
150SG117Q 150SG125Q
150SG117Q-3 150SG125Q-2
150SG117Q-4 150SG144Q
150SG118Q
150SG119Q
150SG120Q

PROPRIETARY INFORMATION NOTICE

The information contained in this document is Skurka Aerospace Inc. (SAI) proprietary information and is disclosed in
confidence. It is the property of Skurka Aerospace Inc. and shall not be used, disclosed to others or reproduced without
the express written consent of Skurka Aerospace Inc. If consent is given for reproduction in whole or in part, this notice
and the notice set forth on each page of this document shall appear in any such reproduction in whole or in part.

This technical data is considered ITAR and/or EAR controlled pursuant to 22 CFR Part 120-130 and 15 CFR Parts
730-774 respectively. Transfer of this data by any means to a Non-US Person, whether in the United States or abroad,
without the proper U.S. Government authorization (e.g., License, exemption, NLR, etc.), is strictly prohibited.

Skurka Aerospace Inc.

4600 Calle Bolero
P. O. Box 2869
Camarillo, CA 93011
THIS PAGE INTENTIONALLY BLANK
 Skurka Aerospace Inc.
4600 Calle Bolero, P. O. Box 2869
Camarillo, CA 93011

PARTS DISTRIBUTION and PRODUCT SUPPORT

Skurka Aerospace Inc. (SAI) in house Product Support and Sales Organizations are
augmented by an extensive network of SAI Approved Distribution Organizations. The
approved Distributor Network is located at most regions worldwide, including the
Americas, U.K., France, Canada, Hong Kong, Singapore, Australia, Holland, New
Zealand, Denmark, Germany, and Sweden.

For current list of Approved SAI Distributors, and Overhaul Service Centers, you may
contact our main office

Skurka Aerospace Inc.

4600 Calle Bolero
P. O. Box 2869
Camarillo, CA 93011

TM101—150SG Series
SKURKA AEROSPACE INC.-- PROPRIETARY INFORMATION Page I
Subject to the restrictions on the first page Rev. 14
December 09, 2009
 Skurka Aerospace Inc.
4600 Calle Bolero, P. O. Box 2869
Camarillo, CA 93011

RECORD OF REVISIONS

Revision Number Date Issued Date Manual Initials

Replaced
Original Issue Mar. 15, 1979 Factory
Revision 1 Dec. 9, 1980 Factory
Revision 2 Jul. 1, 1981 Factory
Revision 3 Dec. 1, 1983 Factory
Revision 4 Aug. 16, 1984 Factory
Revision 5 Apr 1, 1987 Factory
Revision 6 May 12, 1992 Factory
Revision 7 Jul. 3, 1992 Factory
Revision 8 Oct. 14, 1993 Factory
Revision 9 Feb. 1, 1994 Factory
Revision 10 Nov. 7, 1994 Factory
Revision 11 Nov. 15, 2002 Factory
Revision 12 Feb. 28, 2007 Factory
Revision 13 Nov. 24, 2009 Factory
Revision 14 Dec. 9, 2009

Retain this record in front of Manual. Only the latest revision level of this manual is considered
valid for current work being performed on SAI starter generators. Operators/maintainers shall
dispose of superseded material in accordance with their own technical documentation
procedures.

TM 101—150SG Series SKURKA AEROSPACE INC.-- PROPRIETARY INFORMATION

Page II Subject to the restrictions on the first page
Rev. 14
December 09, 2009
 Skurka Aerospace Inc.
4600 Calle Bolero, P. O. Box 2869
Camarillo, CA 93011

SERVICE BULLETIN CONTROL

Service Bulletin Number Status Latest Rev.

Date
SB150SG101 Incorporated Jan. 6, 1981
SB150SG102 Incorporated Mar. 29, 1995
SB150SG103 Incorporated Jan. 1982
SB150SG104 Incorporated Dec. 21, 1983
SB150SG105 Valid Dec. 9, 2009
SB150SG106 Incorporated July. 28, 1982
SB150SG107 Incorporated Jan. 4, 1986
SB150SG114 Valid Dec. 9, 2009
19-SB150SG122 Incorporated Jan. 29, 2001
19-SB150SG124 Vaild Dec. 9, 2009
19-SB150SG127 Incorporated Jan. 22, 2002
SB150SG127-1 Valid Dec. 9, 2009
SB150SG139 Valid Dec. 9, 2009
SB150SG150 Valid Dec. 9, 2009
SB150SG151 Valid Dec. 9, 2009
SB150SG155 Valid Dec. 9, 2009

Retain this record in front of Manual. On receipt of service bulletins, record service
bulletin number, status (valid or invalid), revision date issued. Unless invalidated, all
service bulletins affecting the 150SG Series of DC Starter-Generators should be kept
with this Manual.

TM101—150SG Series
SKURKA AEROSPACE INC.-- PROPRIETARY INFORMATION Page III
Subject to the restrictions on the first page Rev. 14
December 09, 2009
 Skurka Aerospace Inc.
4600 Calle Bolero, P. O. Box 2869
Camarillo, CA 93011

SERVICE LETTER CONTROL

Service Letter Number Status Latest Rev.

Date
103 Incorporated Oct. 7, 1993
107 Incorporated Jan. 29, 2001
112 Incorporated Jan. 29, 2001
113 Incorporated Oct. 21, 2002
114 Incorporated Nov. 1, 1996
115 Valid Dec. 9, 2009
117 Incorporated Jan. 29, 2001
120 Incorporated Aug. 24, 1998
121 Incorporated Jan. 29, 2001
134 Valid Dec. 9, 2009
135 Incorporated Feb. 28, 2000
136 Incorporated May 12, 1999
168 Incorporated Sept. 29, 2003
170 Valid Dec. 9, 2009
209 Valid Dec. 9, 2009

Retain this record in front of Manual. On receipt of Service Letters, record the Service
Letter number, status (valid or invalid), revision date issued. Unless invalidated, all
Service Letters affecting the 150SG Series of DC Starter-Generators should be kept
with this Manual.

TM 101—150SG Series SKURKA AEROSPACE INC.-- PROPRIETARY INFORMATION

Page IV Subject to the restrictions on the first page
Rev. 14
December 09, 2009
 Skurka Aerospace Inc.
4600 Calle Bolero, P. O. Box 2869
Camarillo, CA 93011

TABLE OF CONTENTS
SECTION PAGE
AL AIRWORTHINESS LIMITATIONS AL-1
I INTRODUCTION 1-1
II MAINTENANCE INSTRUCTIONS
2-1 Special Tools 2-1
2-3 Disassembly 2-1
2-6 Cleaning 2-4
2-9 Inspection 2-7
2-15 Testing 2-11
2-20 Repair or Replacement 2-15
2-26 Reassembly 2-21

III TEST PROCEDURE

3-1 General 3-1
3-3 Test Equipment 3-1
3-11 Tests 3-7

IV ILLUSTRATED PARTS CATALOG 4-1

V DIFFERENCE DATA SHEETS 5-1

VI ADDENDUM: 150SG “XL” SERIES STARTER- 6-1

GENERATOR MAINTENANCE INSTRUCTIONS
AND PARTS LIST

VII APPENDIX I: SERVICE BULLETINS--Valid 7-1

APPENDIX II: SERVICE LETTERS--Valid 8-1

VIII
TECHNICAL DOCUMENTATION SUGGESTION FORM

TM101—150SG Series
SKURKA AEROSPACE INC.-- PROPRIETARY INFORMATION Page V
Subject to the restrictions on the first page Rev. 14
December 09, 2009
 Skurka Aerospace Inc.
4600 Calle Bolero, P. O. Box 2869
Camarillo, CA 93011

LIST OF ILLUSTRATIONS
FIGURE SECTION II PAGE
2-1 CLEANING OF ARMATURE 2-6
2-2 CLEANING OF STATOR 2-6
2-3 TERMINAL BLOCK AND GENERATOR 2-14
WIRING DIAGRAM
2-4 DIAMOND CUTTING TOOL 2-17
2-5 CARBOLOY TIPPED CUTTING TOOL 2-18
2-6 MOUNTING OF COMMUTATOR CUTTING TOOL 2-19
2-7 DRIVE END BELL MODIFICATION 2-20
2-8 T150SG1073 DAMPER PLATE INSTALLATION TOOL 2-25
2-9 BEARING PUSHER (INNER AND OUTER RACE) 2-26
2-10 GENERATOR SCHEMATIC WIRING DIAGRAM 2-29
2-11 BELLEVILLE SPRING INSTALLATION INSTRUCTIONS 2-30
2-12 POSITIONING OF BRUSH LEADS 2-31

SECTION III
3-1 TEST SCHEMATIC FOR TESTING SHUNT START 3-2
GENERATORS
3-2 TYPICAL BRUSH SEATING 3-6
3-3 EQUALIZING VOLTAGE 3-9

SECTION IV PAGE
4-1 ILLUSTRATED PARTS BREAKDOWN 4-14
4-2 ILLUSTRATED PARTS BREAKDOWN – 4-15
END BELL ASSY, COMMUTATOR END

SECTION V PAGE
5-1 POSITIONING OF BRUSH LEADS 5-10
5-2 POSITIONING OF BRUSH LEADS 5-14

TM 101—150SG Series SKURKA AEROSPACE INC.-- PROPRIETARY INFORMATION

Page VI Subject to the restrictions on the first page
Rev. 14
December 09, 2009
 Skurka Aerospace Inc.
4600 Calle Bolero, P. O. Box 2869
Camarillo, CA 93011

LIST OF TABLES

TABLE DESCRIPTION PAGE

NUMBER

TABLE I LEADING PARTICULARS--DIFFERENCES 1-2

BETWEEN MODELS
TABLE IA LEADING PARTICULARS—COMMON ITEMS 1-3
BETWEEN MODELS
TABLE II SPECIAL TOOLS AND TEST EQUIPMENT 2-3
TABLE III WEAR INSPECTION MEASUREMENTS 2-9
TABLE IV SERIES 150 ACCEPTANCE TEST DATA SHEET 3-14

TM101—150SG Series
SKURKA AEROSPACE INC.-- PROPRIETARY INFORMATION Page VII
Subject to the restrictions on the first page Rev. 14
December 09, 2009
 Skurka Aerospace Inc.
4600 Calle Bolero, P. O. Box 2869
Camarillo, CA 93011

REVISIONS

Revision
Page No. Description Date Approved
II List of illustrations Section IV 12/09/80 Factory
2-1 Maintenance Instructions 2-5 a.
2-8 Wear Inspection Measurements
2-12 Capacitor, Terminal Block 2-19
2-19 Commutator Head Bearing Liner 2-25 a.
2-21 Main Assembly 2-29 a,b,c
3-7 Equalizing Voltage 3-14 b.
4-1 Section IV A

2-22 Main Assembly 2-29 d. e. 12/11/80 Factory

3-8 Minimum Speed 07/01/81 Factory

All Re-typed 12/01/83 Factory

Cover Added Generators:
150SG121Q
150SG124Q
150SG125Q
2-1 Revised paragraphs 2-5 c,e and Removed
paragraph 2-5 f.
2-2 Removed P/N APT1002
2-4 Removed Paragraph 2-7 c.
2-9 Revised Paragraph 2-12 a.
2-14 Revised Paragraph 2-21 d
2-19 Revised Paragraph 2-25 A
3-4 Added “NOTE”
3-11 Added Paragraph 3-20
4-1 Retyped to incorporate new generator part numbers
Thru In all IPL’s and Difference Data Sheets
5-13
5-9 Added Model 150SG121Q
5-12 Added Model 150SG124Q
5-13 Added Model 150SG125Q

II Added Figure 2-6A 08/16/84 Factory

2-9 Revised Paragraph 2-12 a.
2-18A Added Page 2-18A including Figure 2-6A

TM 101—150SG Series SKURKA AEROSPACE INC.-- PROPRIETARY INFORMATION

Page VIII Subject to the restrictions on the first page
Rev. 14
December 09, 2009
 Skurka Aerospace Inc.
4600 Calle Bolero, P. O. Box 2869
Camarillo, CA 93011

REVISIONS

Revision
Page No. Description Date Approved
2-15 “Surface” was misspelled 04/01/87 Factory
2-20 Revised Paragraph 2-28 a.
2-22 Paragraph 2-22 g. was 2-29 f.
4-2A Figure 4-2-8A was 4-2-8
4-5C Figure 4-2-8A was 4-2-8

4-2B Added P/N 200SGL1301-1 05/12/92 Factory

4-5 Added P/N 200SGL1301-1

4-2A Added P/N 150SG1106-1 07/03/92 Factory

Added P/N 150SG1106-1

All Retyped Manual 10/14/93 Factory

2-4 Changed Paragraph “G” to “F” and Paragraph
“H” to “G”. Paragraph “F” was originally mislabeled
2-13 Under Paragraph “c” changed 50-68 ounces to read
32-48 ounces.
4-3 Added P/N 150SG1004
Added P/N 150SG1005S
4-9 Added P/N 150SG1004
4-12 Added P/N 150SG1005S
4-13 Changed P/N 150SG1112 to P/N 150SG1112-1

Change Notice #100 02/01/94 Factory

4-11 Changed P/N 150SGL1064 to P/N 150SG1064

Retyped Manual 11/07/94 Factory

Put Index in Numerical Order
Revised List of illustrations to reflect New Page
Numbers
1-2 Rotation Specification Corrected to CCW
(Counterclockwise)
2-2 Sec. 2-5, Para. “g” Added Washer Reference
2-26 Sec. 2-28, Para. “c”, Changed Non-Metallic Washer
Reference
2-29 Changed Sec. 2-29, Para. “j”
2-34 Changed Figure 2-9 to correct illustration
3-4 Revised Note under Sec. 3-9 to Add SB150SG105
Revised Section IV to include 150SG144Q Starter
Generator- See usage Codes

TM101—150SG Series
SKURKA AEROSPACE INC.-- PROPRIETARY INFORMATION Page IX
Subject to the restrictions on the first page Rev. 14
December 09, 2009
 Skurka Aerospace Inc.
4600 Calle Bolero, P. O. Box 2869
Camarillo, CA 93011

REVISIONS

Revision
Page No. Description Date Approved
4-3 Changed P/N AN960B10 to AN960C10 11/07/94 Factory
Changed P/N AN960B616 to AN960C616
Changed P/N MS20364B-1032C to MS20364-1032C
Changed P/N MS20364B-624C to MS20364-624C
Added Superseded by MS21318-13 to P/N AN535-2-2
Changed P/N MS21318-15 to MS21318-14
Added P/N 150SG144Q to Numerical Index
Removed P/N 150SG1004
Removed P/N 150SG1005S
4-4 Added P/N 150SG1011-7
Moved P/N 200SGL1040-1 & 200SGL1040-2 to
Page 4-6
Changed P/N 200SG1009 to P/N 150SG1009-1 &
Changed Index No. to 11A
Changed P/N 150SG1009-5 Fig. & Index to 4-2-11
Added P/N 150SG1083, -1,-2,-3,-5
Added P/N 150SG1040
Added P/N 150SG1092-20
4-5 Removed P/N 150SG1193
Changed P/N 150SG1154-1 Index No. to 1A
4-8 Changed P/N 150SG114Q Usage Code to B
Changed P/N 150SG115Q Usage Code to C
Added P/N 150SG116Q
Added P/N 150SG144Q
Corrected P/N 150SGL1103 to P/N 150SG1103
Corrected P/N 150SGL1103-1 to P/N 150SG1103-1
Corrected P/N 150SGL1103-2 to P/N 150SG1103-2
Removed P/N 150SGL1103-3
Corrected P/N 150SGL1103-4 to P/N 150SG1103-4
Corrected P/N 150SGL1103-5 to P/N 150SG1103-5
4-9 Corrected P/N 150SGL1103-7 to P/N 150SG1103-7
Corrected P/N 150SGL1103-9 to P/N 150SG1103-9
Corrected P/N 150SGL1103-10 to P/N 150SG1103-10
Added P/N 150SG1103-11
P/N 150SG1070, added Usage Code “All”
P/N MS9013-17, added Usage Code “All”
P/N 150SG1108, added Usage Code “All”
4-10 P/N 150SG1017, added Usage Code “All”

TM 101—150SG Series SKURKA AEROSPACE INC.-- PROPRIETARY INFORMATION

Page X Subject to the restrictions on the first page
Rev. 14
December 09, 2009
 Skurka Aerospace Inc.
4600 Calle Bolero, P. O. Box 2869
Camarillo, CA 93011

REVISIONS

Revision
Page No. Description Date Approved
4-10 Added “-B” to P/N 150SG1052 and usage Code “All” 11/07/94 Factory
Change Description of P/N 200SGL1301-1 from Bell,
Drive End to Housing & Screen Assy.
P/N AN935-8L, added Usage Code “All”
P/N 150SG1113, added usage Code “All”
Removed P/N 150SG1004
Added P/N MS21318-14
4-11 P/N 150SG1139, added Usage Code “All”
P/N AN535-2-2, added Usage Code “All”
P/N 150SG1061, added Usage Code “All”
Added Superseded by P/N MS21318-13 to P/N
AN535-2-2
Added P/N 150SG1092-20
4-12 P/N AN500A10-12, added usage Code “All”
P/N AN960-10L, added usage Code “All”
Corrected Index No. -1,-17 was P/N AN960-10L to
P/N AN935-10L, added Usage Code “All”
Changed P/N AN960B10 to P/N AN60C10, added
Usage Code “All”
Changed P/N AN960B616 to P/N AN60C616, added
Usage Code “All”
Changed P/N MS20364B-1032C to MS20364-1032C.
added Usage Code “All”
Changed P/N MS20364B-624C to MS20364-624C.
added Usage Code “All”
P/N 150SG1006, added Usage code “All”
P/N 150SG1113, added Usage code “All”
4-13 P/N AN935-8L, added Usage code “All”
P/N AN500A8-8, added Usage code “All”
Added P/N 150SG1011-7
P/N 150SG1071, added Usage code “All”
P/N 150SG1093, added Usage code “All”
P/N 150SG1104, added Usage code “All”
P/N 150SG1116, added Usage code “All”
4-14 P/N AN960-10L, added Usage code “All”
Removed P/N 150SG1005S
P/N 150SG1045, added Usage code “All”
P/N 150SG1046, added Usage code “All”
P/N 150SG1057, added Usage code “All”
P/N 150SG1112-1, added Usage code “All”
P/N 150SG1114, added Usage code “All”
TM101—150SG Series
SKURKA AEROSPACE INC.-- PROPRIETARY INFORMATION Page XI
Subject to the restrictions on the first page Rev. 14
December 09, 2009
 Skurka Aerospace Inc.
4600 Calle Bolero, P. O. Box 2869
Camarillo, CA 93011

REVISIONS

Revision
Page No. Description Date Approved
4-14 P/N MS20364-1032C, added Usage Code “All” 11/07/94 Factory
P/N 200SG1020, added Usage Code “All”
4-15 Fig. 4-2, Revised to correct Brush (Index No. 11) and
Brush (Index No. 11A) and to add brush holder,
(Index No. 1A)
5-15 Added Difference Data Sheet for 150SG114Q
Added Service Bulletin SB150SG105

4-3 Changed P/N AN960C10 to P/N AN960C10L 04/13/95 Factory

4-7 Fig. 4-1 Revised to Correct Index No. for Terminal
Block screw from 19 to 16
4-12 Changed P/N AN960C10 to P/N AN960C10L
Changed Fig. & Index No. for P/N 150SG1009-1 from
2-11 to 2-11A

Entire Manual Retyped (Electronically) 11/15/02 Factory

Cover Added Starter Generator 150SG125Q-2

I Added:
Thru Parts Distribution and Product Support Information
IV Record of Revisions Table
Service Bulletin List Table
Service Letter List Table

V Added:
Thru Sec VI Addendum to Starter Generator
VI Additional Service Information List.
Fig. 2-9 Bearing Pusher
Fig. 5-1, 5-2, Positioning of Brush Leads

Corrected Typing Errors:

1-2 Minimum rated speed 8100 was 7700
Overspeed 14000 was 4000

2-3 Added to Test Equipment:

Growler
Dynamic Balancer

2-9 Added Note relating to Plating or Rework of Drive End

or Commutator housing bearing liners
2-10 Added ASTM-E1444 to Magnaflux testing

TM 101—150SG Series SKURKA AEROSPACE INC.-- PROPRIETARY INFORMATION

Page XII Subject to the restrictions on the first page
Rev. 14
December 09, 2009
 Skurka Aerospace Inc.
4600 Calle Bolero, P. O. Box 2869
Camarillo, CA 93011

REVISIONS

Revision
Page No. Description Date Approved
2-11 Paragraph 2-13c Updated spring tension values to 11/15/02
reflect different springs.

2-23 Paragraph d,e,f. Update anti-seize Compound,

2-24 From: JAN-A-669, TO: 150SG1309
2-25 Updated Fig 2-8 to add .020 U-cut
2-26 Added Fig. 2-9 Bearing Pusher (Inner Race and Outer
Race)

2-31 Fig. 2-12 Updated Pictorial to show correct and

incorrect orientation of Brush Leads
4-3 Part Number AN500A10-12 superseded by MS35265-
Thru 65
4-5 Part Number AN935-8L superseded by 150SG1379-8
Part Number AN935-10L superseded by MS35338-43
Part Number MS9013-17 superseded by MS16624-
4066
Part Number MS20364-1032 superseded by
SPS27FT-1032
Part Number MS20364-624C superseded by
SPS27FT-624
Part Number 150SG1005 superseded by
150SG1005S-3
Part Number 150SG1116 superseded by 250SG1116
Removed: 200SGL1040, 200SGL1040-2
Added: 150SG1168, 200SGL1360
4-15 Usage Code “K”, Part Number 150SG1009-5
replaced by 150SG1009-20
4-16 Updated Fig. 4-1
5-5 Updated to reflect Service Bulletin 19-SB150SG122
5-7 Updated to reflect Service Bulletin SB150SG104
5-9 Updated to reflect Service Bulletin SB150SG102
5-11 Updated to reflect Service Bulletin SB150SG101
5-17 Added: (See Fig. 5-1)
5-23 Added: (See Fig. 5-2)
- Added “Additional Service Information List”
- Added Technical Documentation Form
- Added Service Letter #115,134
- Added Service Bulletins
- 19-SB150SG105
- 19-SB150SG114
- 19-SB150SG124
TM101—150SG Series
SKURKA AEROSPACE INC.-- PROPRIETARY INFORMATION Page XIII
Subject to the restrictions on the first page Rev. 14
December 09, 2009
 Skurka Aerospace Inc.
4600 Calle Bolero, P. O. Box 2869
Camarillo, CA 93011

REVISIONS

Revision
Page No. Description Date Approved
Cover Added starter generators: 02/28/07
150SG117Q-3
150SG117Q-4
APC address and phone number changes (throughout
manual)

3-5 Added ‘Record readings on test data sheet, Table IV.”

to paragraph 3-10f.
3-7 Added new paragraph 3-13e - ‘Record readings on
test data sheet, Table IV.”
3-8 Added ‘Record readings on test data sheet, Table IV.”
to paragraph 3-14a,b,c,d. Added reference to new
figure 3-3 in paragraph 3-14c.
3-9 Added new figure 3-3. Added ‘Record readings on
test data sheet, Table IV.” To paragraph 3-15.
3-10 Added ‘Record readings on test data sheet, Table IV.”
to paragraph 3-16e.
3-11 Added new paragraph 3-17f - ‘Record readings on
test data sheet, Table IV.”
3-12 Added ‘Record readings on test data sheet, Table IV.”
to paragraph 3-18b. Added ‘Record readings on test
data sheet, Table IV.” To paragraphs 3-20 and
3-21.
3-13 Added Table IV, 150 Series Acceptance Test Data
Sheet

4-3 Added to Numerical Index:

150SG1011-4
150SG1052-1
4-4 Added to Numerical Index:
150SG1092-23
150SG1092-25
4-7 thru Added Usage Code callouts (P,Q) for new starter
4-15 generators.

5-31 Added 150SG117Q-3 Difference Data Sheet

5-33 Added 150SG117Q-4 Difference Data Sheet

Entire Company name changed from Aircraft Parts Corp. to

11/24/09
Manual Skurka Aerospace Inc.

TM 101—150SG Series SKURKA AEROSPACE INC.-- PROPRIETARY INFORMATION

Page XIV Subject to the restrictions on the first page
Rev. 14
December 09, 2009
 Skurka Aerospace Inc.
4600 Calle Bolero, P. O. Box 2869
Camarillo, CA 93011

REVISIONS

Revision
Page No. Description Date Approved
III Added SB150SG127-1 11/24/09
Added SB150SG139
Added SB 150SG150
Added SB 150SG151
Added SB 150SB155

IV Added SL168
Added SL 170
Added SL 209

Additional Eliminated page from rear of manual due to

Service redundancy of information with respect to SB and
Information SL lists in this section.
Page

Technical Updated contact information to reflect company

Documentation name change.
Suggestion
Form
II Revised statement at bottom to better reflect actual 12/09/09
practices and document control requirements.
III Changed title to “Service Bulletin Control”
IV Changed title to “Service Letter Control”
V Added Section AL, “Airworthiness Limitations”
Added Section VII for valid Service Bulletins
Added Section VIII for valid Service Letters
VII Slight formatting change to List of Tables
Changed description of Table I
Added Table IA
XV Included NOTE at bottom to emphasize revision
currency considerations.
Corrected Page No. to III and IV in revision section
of 11/24/09. Information was incorrectly shown.
XIV Included NOTE at bottom to emphasize revision
currency considerations.
AL-1 Added “Airworthiness Limitations” section AL to
manual

NOTE: Due to possible addition/deletion of pages during revision process, only the most recent
dated page numbers and information in these descriptions of revisions is considered current. All
earlier entries are for historical reference only.

TM101—150SG Series
SKURKA AEROSPACE INC.-- PROPRIETARY INFORMATION Page XV
Subject to the restrictions on the first page Rev. 14
December 09, 2009
 Skurka Aerospace Inc.
4600 Calle Bolero, P. O. Box 2869
Camarillo, CA 93011

REVISIONS

Revision
Page No. Description Date Approved
1-1 Added 1-2a, “Changes to Starter-Generator” 12/09/09
Added 1-2b, description of changes to starter-
generator
1-2 Revised text of section 1-7
Replaced information of Table I with differences
information for all models covered by this manual.
1-3 Added Table IA to reflect items common to all
models covered by this manual.
2-3 Updates to Table II:
Revised Damper Plate Tool information.
Added Bearing Pusher
Added APT 1006 Plain Reamer
2-9 Removed statement “Sophisticated measuring
equipment and dimensioning is required”.
2-10 2-12 b. Removed “Magnaflux” and inserted
“Magnetic particle test”.
2-13 b. Removed mention of air gage and
reference ring and added “Check bearing
liner for wear and damage”.
2-11 2-13 c. Replaced term “brush spring scale” with
“standard spring scale”.
2-14A Removed “…with gage as per paragraph 2-
13(b)” from first sentence.
2-13 2-19a. Replaced “capacitance bridge” with
“capacitance tester”.
2-19b. Replaced “capacitance bridge” with
“capacitance tester”.
2-16 2-23c. In last sentence removed “Exacto knife” and
inserted “thin blade”.
2-20 Replaced “Special Tools Required” to “Tools
Required:”.
2-28 2-29n. In NOTE: Removed statement “This
armature and stator contain a sophisticated
insulation system which is proprietary to
Aircraft Parts Corp.”
6-4 In first paragraph, replaced “APC” with “SAI”.
7-1 Added Section VII to manual for SB’s
8-1 Added Section VIII to manual for SL’s
NOTE: Due to possible addition/deletion of pages during revision process, only the most recent
dated page numbers and information in these descriptions of revisions is considered current. All
earlier entries are for historical reference only.

TM 101—150SG Series SKURKA AEROSPACE INC.-- PROPRIETARY INFORMATION

Page XVI Subject to the restrictions on the first page
Rev. 14
December 09, 2009
 Skurka Aerospace Inc.
4600 Calle Bolero, P. O. Box 2869
Camarillo, CA 93011

AL-1 AIRWORTHINESS LIMITATIONS

The Airworthiness Limitations section is FAA approved and specifies

maintenance required under 14 CFR §§ 43.16 and 91.403, unless an
alternative program has been FAA approved.

AL-2 RECOMMENDED OVERHAUL PERIOD

Unless established otherwise in the aircraft operator’s own Airworthiness

Limitations or Operating Specifications, the recommended overhaul period for
150SG series starter-generators is 1,000 hours with a minimum of 1 brush change
prior.

NOTE

See Service Letter 115 for related information

concerning calculation of brush inspection intervals.

AL-3 FIELD SERVICING LIMITS

Field service on starter-generator units is limited to brush inspection

and replacement only. All other repair and/or overhaul activity shall
be carried out by an authorized repair station.

Except for brush inspection and replacement, aircraft airworthiness is

accomplished through removal and replacement of the starter-
generator.

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TM101—150SG Series
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Camarillo, CA 93011

SECTION I
INTRODUCTION

1-1 GENERAL

1-2 This manual contains maintenance instructions, test procedure and illustrated
parts breakdown for type 150SG SERIES DC starter-generators. This unit is
manufactured by:
Skurka Aerospace Inc.
4600 Calle Bolero, P. O. Box 2869
Camarillo, CA 93011

NOTE
If an error, omission, or other discrepancy is found in this manual, please fill out a
copy of the Technical Documentation Suggestion Form found at the back of this
manual and send to Technical Department at Skurka Aerospace Inc.

1-2a CHANGES TO STARTER-GENERATOR

1-2b Changes to the starter-generator are communicated and distributed by revision
to the Component Maintenance Manual, and by SB’s or SL’s. SB’s and SL’s
may be incorporated at the next revision change when applicable. Active or valid
service information pertinent to this manual is located in the appropriate
appendix of the manual.

1-3 PURPOSE OF EQUIPMENT

1-4 The Starter-Generator is used as an engine-driven source of DC power in a

28 volt aircraft electrical system and as a source of starting power for light-weight
turbine engines. An efficient integral fan draws air in at anti-drive end of
generator to permit self-cooled operation.

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1-5 LEADING PARTICULARS

1-6 The leading particulars of the Starter-Generator are given in Table I.

1-7 Section II of this manual contains maintenance instructions for 150SG type
starter-generators identified in this CMM. Test procedure is covered in Section
III. Section IV contains an Illustrated Parts Breakdown. Section V lists
Difference Data Sheets.

TABLE I LEADING PARTICULARS*

DIFFERENCES BETWEEN STARTER-GENERATOR MODELS IN THIS CMM

Number of Spline Overall Length
Model Number Mounting Flange
Teeth (max)
150SG111Q 12 AND10261-XIB 8.1
150SG114Q 12 AND10261-XIB 8.46
150SG115Q 12 MS3331-1 8.1
150SG116Q 12 MS3331-1 8.1
150SG117Q 12 AND10261-XIB 8.1
150SG117Q-3 12 AND10261-XIB 8.1
150SG117Q-4 12 AND10261-XIB 9.15
150SG118Q 12 AND10261-XIB 8.1
150SG119Q 16 AND10262-XIIA 9.24
150SG120Q 12 MS3331-1 8.1
150SG121Q 12 AND10261-XIB 7.48
150SG122Q 12 NFL34161 9.32
150SG123Q 12 AND10261-XIB 8.1
150SG124Q 12 AND10261-XIB 7.48
150SG125Q 12 AND10261-XIB 8.1
150SG125Q-2 12 AND10261-XIB 8.1
150SG144Q 12 AND10261-XIB 9.15

*Leading Particulars continued with Table IA, next page.

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TABLE IA LEADING PARTICULARS

(Continued from previous page)

ITEMS COMMON TO ALL STARTER-GENERATOR MODELS IN THIS CMM

Volts 30 V
DC OUTPUT
Amperes 150 A
Continuous 12,000 rpm
Overspeed
Minimum Speed 7,200 rpm
Minimum Rated 8,100 rpm
SPEED RANGE Speed
Overspeed 14,000 rpm
Cooling Self-Cooling
Rotation CCW
(view from drive end)
Teeth 12
SPLINE DATA Pitch 20/40
Pressure Angle 30°
DC Volts 30 V
EXTERNAL STARTING
Amperes 500 A
Dimension 6.63
(max over terminal
OVERALL DIMENSIONS block)
Diameter 5.38
(maximum)

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SECTION II

MAINTENANCE INSTRUCTIONS

2-1 SPECIAL TOOLS

2-2 Special tools and test equipment are listed in Table II.

2-3 DISASSEMBLY

2-4 GENERAL

a. Disassemble the starter-generator as shown in parts list

(Figure 4-1 & 4-2).

2-5 MAIN ASSEMBLY (Refer to IPL Figure 4-1 ).

a. Remove fan cover. (35) Lift up brush springs (2) (Figure 4-2) and
remove and discard brushes (11)

b. Hold the drive end of drive shaft assembly (1) using a spline wrench.
Remove lock nut (34), springs (33) and fan (31). Remove the drive
shaft assembly.

c. Remove back damper plate (3) using gear puller, taking care to
prevent damage to end of armature shaft by gear puller.

d. Remove eight screws (8) and washers (9), (10). Remove drive
end bell (7).

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e. Remove eight screws (27), lock washers (26) and washers (25).
Remove commutator end bell assembly (24) with assembled
armature. Press out armature (23) using a suitable pusher to protect
armature shaft end.

f. Using a bearing puller, remove ball bearing (6) from generator

armature. Remove four screws (30) and lock washers (29). Remove
bearing retainer (28). Press ball bearing out of commutator head (24).
Do not disassemble commutator head unless necessary.

g. Do not disassemble stator assy. To remove terminal block (15),

remove nuts (22) (20) and washers (21) (19) from terminal block,
remove screws (16) and washers (17) (18). Then remove terminal
block.

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TABLE II

SPECIAL TOOLS

Part Number Nomenclature Application

T150SG1073 Damper Plate Tool Position armature

(fig. 2-8) damper plate on
armature shaft.

Bearing Pusher Positioning bearings

(fig. 2-9)

APT 1006 0.0935 Plain Reamer Drive end bell mod.

TEST EQUIPMENT

Part Number Nomenclature Application

Growler To test intercoil shorts

in armatures

Hi- Pot Tester To test for shorts in

electrical wiring.

GE9069199G Double Bridge For measuring resistance

of various coils.

Sprague TelOhmike Capacitance Tester Testing of capacitors

Model TO-GA or equal

Dynamic Balancer For checking armature

balance.

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2-6 CLEANING

2-7 GENERAL

a. For oily parts, use Stoddard Solvent or Mineral Spirits. For non-oily
parts, use isopropyl alcohol and 50 percent water. Dip a stiff non-wire
brush in the solvent and scrub the parts thoroughly. Do not soak parts
in the solvent for extended length of time.

Steam cleaning using a detergent that does not conduct electricity is

also recommended. After cleaning with detergent, rinse parts with
clean steam (no detergent). Bake the armature and stator at 250° F,
for six hours.

WARNING

When using cleaning solvents, take

precaution to avoid burning skin or
Inhaling fumes. Use solvent in a well-
Ventilated room only.

CAUTION

Solvents or cleaning methods

other than those described above,
are not recommended since their
use may damage the insulating
varnish used in this equipment.

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b. Ultrasonic cleaning equipment may be used. However, consult the

manufacturer of this equipment for the proper cleaning solutions and
methods to be used.

2-8 ARMATURE AND STATOR (Refer to IPL Figure 4-1)

a. Using a stiff non-wire brush, clean the armature (23) and stator (11).
Be sure that all carbon and copper particles are removed from the
area between the commutator bars of the armature. Wash the
windings of the stator to remove carbon particles. When using air to
blow cleaning fluids and dirt from armature, blow air in direction as
shown in Figure 2-1. When using air to blow cleaning fluids from
stator, blow air from drive end side toward commutator end of stator
as shown in Figure 2-2.

b. After cleaning, bake armature and stator in an oven for three hours at
93 degrees C (200 degrees F).

c. Apply a light film of oil or anti-corrosion compound to all bare steel

metal surfaces such as bearing liners, armature drive shafts, and
damper faces to prevent rusting, if storing for a length of time.

CAUTION

Do not apply oil to the commutator

or electrical wires or coils.

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FIGURE 2-1 CLEANING OF ARMATURE

Figure 2-2 Cleaning of Stator

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2-9 INSPECTION

2-10 GENERAL

a. Inspect all parts and wiring for wear and damage. Refer to Table III
for wear inspection measurements.

b. Replace all worn or damaged parts except where a repair procedure is

given.

2-11 ARMATURE (Refer to IPL Figure 4-1)

a. Examine the armature (23) for wear and damage. Replace the
armature if the bearing journals are worn beyond the minimum
dimensions specified in Table III.

b. Check the bands of the armature for firmness and tightness. Check

the commutator for loose or misaligned bars. Measure the depth of

undercut between commutator bars. The depth should not be less

than .032 inch. If so, cut the slot to a depth of .045. Inspect the brush

contact surfaces of commutator, which should be even, highly

burnished and copper in color. If brush contact surfaces are rough,

pitted, scored, burned, or have a film of carbon or oil that cleaning will

not remove, turn down the commutator and undercut as instructed in

paragraph 2-23. (It is recommended the commutator be refinished

each time brushes are changed.)

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NOTE

Badly burned commutator bars are

usually the result of:

• open or shorted armature coils

• undersize brushes
• brushes too tight in brush boxes
• loose brush terminal screws
• operating generator in starter mode
for too long a time.
• hung brush

All of the above will cause brush and commutator overheating.

c. Inspect the armature windings for burned, cracked, or frayed

insulation. Check to see all conductors are firmly brazed to
commutator risers.

d. Closely examine the splines inside the armature shaft for wear. The
degree of spline wear may be determined by visual comparison with a
new spline. Replace the armature if a new drive shaft shows
excessive radial play when inserted in the armature.

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TABLE III

WEAR INSPECTION MEASUREMENTS

See Figure 4-1 Checkpoint Dimensions/Inches

Min Max

Armature (23) Armature Bearing 0.6692 0.6695

Journals OD

Drive End Bell (7) Bearing Liner ID 1.5747 1.5750

Commutator Housing Bore ID 1.5747 1.5750

Housing (24)

Armature (23) Commutator OD 2.030 --------

NOTE

Plating or rework of Drive End or Commutator End

housing bearing liners is not recommended.

This procedure can lead to premature

bearing failures.

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2-12 DRIVE SHAFT ASSEMBLY (Refer to IPL Figure 4-1)

a. Check the drive shaft assembly splines (1) for wear. Large 12 tooth
splines should measure .696 inches minimum over two .0864 inch
diameter pins. The small 11 tooth spline is checked for wear by
installing it in the armature and a new drive shaft into the same
armature, and then comparing both for radial play. Discard the used
shaft for excess radial play.

b. Magnetic particle test the drive shaft per ASTM–E1444 for cracks, in
particular the shear point. Discard the shaft if a crack is noted.

c. When inspecting for evidence of overheating, bear in mind that

although discoloration may indicate a weakened shaft, the condition
can also be present in a sound shaft. Uniform discoloration along the
pencil section of a new shaft may be disregarded. However, if
localized or blotchy discoloration is noted, overheating in service is
indicated. This shaft should be replaced. If slight bluing has occurred,
the shaft may still be serviceable provided a magnetic particular
inspection reveals no surface cracks. If black discoloration is present,
discard the drive shaft assembly. Steps should be taken also to
eliminate the cause of the condition, such as, overload or excessive
vibration.

2-13 COMMUTATOR, END BELL ASSEMBLY (Refer to IPL Figure 4-2.)

a. Inspect the parts of the commutator end bell assembly for wear and
damage. Be sure that brush holder assemblies (1) are not bent,
distorted, or loose.
b. Check bearing liner for wear and damage. If bearing liner inside
diameter is worn beyond permissible dimensions specified in Table III,
replace the commutator head.
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c. Using a standard spring scale with a small loop of wire, measure the
tension of all brush springs, lifting the spring a maximum of 1/16 of an
inch, off a new brush which is flush with the bottom of brush box.
Tension should be as shown below:

Part Number Spring Type Size Tension

150SG1005 Carbon Steel .017 Thk. x .250 Wide 32-48 ounces
150SG1005S Stainless Dyed Yellow .020 Thk. x .265 Wide 36-48 ounces
150SG1005S-3 Stainless Dyed Orange .016 Thk. x .265 Wide 18-27 ounces

If new springs are required, P/N 150SG1005S-3 supersedes all others

No mixing of different type springs in the same Starter-Generator

2-14 STATOR (Refer to IPL Figure 4-1)

a. Inspect the stator (11) for wear and damage. Check for damaged
insulation and loose or broken terminals. Check for tightness of coils
visible brazed joints, and tightness of welded screens. Screens should
not rest on stator coils.

2-14A DRIVE END BELL (Refer to IPL Figure 4-1)

a. Measure the bearing liner in Drive End Bell (7). Replace end bell if
liner is worn beyond those dimensions shown in Table III.

2-15 TESTING
2-16 ARMATURE (Refer to IPL Figure 4-1)

a. After cleaning and baking armature (23) per paragraph 2-8 and using
a Hi-Pot insulation tester, ground test armature. Apply 300 volts AC,
60 Hz for 1 second between a commutator bar and the shaft (ground)
and between the two stainless steel bands and the commutator.
Replace the armature if it is grounded, unless steam cleaning and

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baking for five hours at 250° F will reduce the short to within the limits
stated above.

NOTE

See Section VI, page 6-1, for instructions on

“XL” Series Starter-Generators.

WARNING

When making electrical checks,

take precaution to avoid touching conductors
carrying high voltages. Make sure the
test probes are well insulated.

CAUTION

Keep the test probe outside the

Commutator brush path to avoid
damaging the contact surface.

b. Test for a short or open circuit by placing the armature in a growler.

Holding a thin strip of steel (such as a hacksaw blade) over the
armature core, slowly rotate the armature by hand. If the steel strip
vibrates, replace the armature.

2-17 STATOR (Refer to IPL Figure 4-1)

a. After removing terminal block (15), using a Hi-Pot insulation tester,

ground test the stator (11). Apply 300 volts AC at commercial
frequency (60 Hz) for one second between any winding and the stator
housing (ground). Replace the stator if the insulation breaks down.

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b. Using a double bridge GE Model 9069199G, or equivalent device,

measure shunt field (terminals A to D). The resistance of the shunt
field should be between 1.75 and 2.00 ohms at a temperature of 25
degrees C (77 degrees F). If the resistances are outside the
permissible range, replace the stator.

2-18 COMMUTATOR HEAD (Refer to IPL 4-1)

a. Test the commutator head (24) for grounds and shorts, using Hi-Pot

tester described in Table II. Check for shorts between the end bell

casting and brush holders. Apply 300 volts AC at commercial

frequency (60 Hz) for one second. If ground is indicated, disassemble

the end bell to repair the short. (See paragraph 2-25)

CAUTION

Do not test across adjacent brush

holders as capacitors wired across
the holders will be damaged

2-19 CAPACITORS AND TERMINAL BLOCK (Refer to IPL 4-1)

a. Using a capacitance tester, measure the capacitance of the capacitors

in the terminal block (15). The capacitance must
measure as indicated in TERMINAL BLOCK AND GENERATOR
WIRING DIAGRAM Figure 2-3.

b. Using a capacitance tester, measure the capacitance of the capacitors

in the commutator head P.C boards. Capacitance should measure
.022 MFD ± 20%

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NOTE:
CAPACITOR TOLERANCES
2 MFD CAPACITORS +/- 10%
0.02 MFD CAPACITORS +/-20%

Figure 2-3 Terminal Block & Generator Wiring Diagram

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2-20 REPAIR OR REPLACEMENT

2-21 GENERAL

a. Replace all worn or damaged parts except where a repair procedure is

given.

b. Replace all brushes (11) (Figure 4-2) at each overhaul. New brushes
must be run-in for proper seating. (Refer to paragraph 3-10.)

c. Replace ball bearings (6) (Figure 4-1) at each overhaul.

d. Replace damper springs (Figure 4-1) (33) and nut (34) at each
overhaul. Also replace friction ring (2) at each overhaul. This is
important for proper operation of drive shaft damper assembly.

2-22 ARMATURE

a. Replace the armature (23) (IPL Figure 4-1) if any of the following
conditions exist:

1. If the bearing journals diameter are not within .6692-.6695

inches (See Table III).

2. If the commutator bars are badly burned and cannot be

repaired by cutting on a lathe. (See paragraph 2-11)

3. If the commutator bars are loose or out of alignment.

4. If turning down the commutator would reduce the outside

diameter below the allowable minimum of 2.030 inches.

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2-23 RESURFACING THE COMMUTATOR

a. At each overhaul, cut the commutator to remove wear marks, oil or carbon
film. Take a single light cut at a speed of approximately 600 surface feet per
minute. If the surface is scored or pitted, take a series of light cuts at a speed
of approximately 200 surface feet per minute. A diamond tipped cutting tool
is recommended. (See Figure 2-4.) The point of the cutting tool must be held
on the centerline of the armature shaft. (See Figure 2-6). If a carboloy-tipped
commutator cutting tool (See Figure 2-5) is used, the point of the cutting tool
must be held 1/32 inch below the center line of the armature shaft. The
minimum diameter to which the commutator may be turned down is 2.030
inches.

b. After the commutator is turned down, measure the depth of the under-cutting
between commutator bars. If the depth is less than .032 inches, undercut the
mica to .045 inches deep maximum and to a width of .030-.035.

c. After the commutator is undercut, take a final cut of not more than 0.001
inches across the face of the commutator to remove burrs. If a diamond-
tipped commutator cutting tool is not available, make the final cut with a
freshly honed carboloy-tipped commutator cutting tool. The cutting speed
should be 600 surface feet per minute with either type cutting tool. Do not
use polishing abrasives. After the final cut, remove burrs between
commutator bars with a strip of fiber or a thin blade.

d. The commutator should be concentric with bearing surfaces of the armature

shaft within a 0.0005 inch full indicator reading. Bar to bar concentricity
should be within .0002.

NOTE
See Section VI, Page 6-1, for instructions on
“XL” Series Starter-Generators.
TM101—150SG Series
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Figure 2-4 Typical Diamond-Tipped Commutator Cutting Tool

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Figure 2-5 Typical Carboloy-Tipped Commutator Cutting Tool

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Figure 2-6 Mounting of Commutator Cutting Tool

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Figure 2-7 Drive End Bell Modification

TOOLS REQUIRED:
No. 43 High Speed Drill (4 inches long)
APT1006 .0935 Plain Reamer (4 inches long)

Modification Procedure:

1. Mount the liner securely in a drill vise, making sure you are not damaging the
aluminum housing.

2. Using a No. 43 drill bit, drill a hole .340 from end of bearing liner as shown in
Figure 2-7, taking care not to drill an oversize hole.

3. After drilling the hole, ream the hole using tool APT1006 (.0935 Reamer ) to
finish the hole to size. The hole size is important to assure tightness of the dowel
pin.

4. Mount a round steel shaft, 1 ½ inches in Diameter in a vise. Support the drive end
mounting flange on the round steel shaft.

5. Using a hammer and pin punch slightly larger than the dowel pin. Drive the pin
into the housing, chamfered end first.

6. Drive the pin into the housing until the pin is almost flush with the inside of the
steel bearing liner. Make sure the pin is less than flush with the inside bore of the
bearing liner.

7. A properly installed pin will be .005 to .008 away from the inside diameter of the
bearing liner. Pin should not touch the bearing when it is installed in the drive end
bell.

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2-24 REBALANCE OF ARMATURE

a. Using a dynamic balance machine, check the armature for static and
dynamic balance. The armature should not be out of balance by more
than 5 grain inches. If balance is required, mill the stainless steel
bands at either end of armature to a maximum of 0.031 inch deep
max. and 0.250 wide cuts, until proper balance is obtained. Only two
0.25 inch wide cuts are permitted in each band to maintain band
strength.

2-25 COMMUTATOR END BELL, BEARING LINER AND

DRIVE END BELL BEARING LINER (Refer to Figure 4-1)

a. If the commutator end bell bearing liner (24) or the drive

end mounting flange bearing liner (7) are worn beyond 1.5747 to
1.5750 inches, replace the commutator end bell or drive end bell.
Replating of the bearing liner is not recommended.

b. If the drive end bell liner (7) does not have a dowel pin installed
as per Figure 2-7, then modify the drive end bell as per the
instructions show in Figure 2-7

2-26 REASSEMBLY

2-27 GENERAL

a. Reassembly is basically the reverse of disassembly.

b. Follow the exploded views (Figures 4-1 & 4-2), disassembly paragraph
2-3 through 2-5 and the schematic wiring diagram (Figure 2-10) for
reassembly information.
c. Special procedures and tool applications are covered in paragraph 2-29.

2-28 COMMUTATOR END BELL ASSEMBLY (Refer to Figure 4-2)

a. Place end bell (24) (Figure 4-1) in a suitable holding fixture.

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NOTE:
Coat insulating tubes, non-metallic washers
and metallic washers prior to installation with red
insulator No. ER-41 and thinner T-200X
(John C. Dolph Co., Monmouth Junction, NJ)
Allow to dry for 30 minutes.

b. Install two brush springs (2) on brush holder (1). Each spring must be
wound approximately 3/4 turn before installation on brush holder
spring support bar.

CAUTION

Do not over wind spring. Overwinding

spring will cause spring to take a permanent
set and produce insufficient pressure.

c. Install insulating tubes (7), non-metallic washers (8a), metal washers

(6), and lock nut (1) on the brush box mounting screw (5) in proper
order. Position printed circuit board assembly (3) across to adjacent
brush holders (1).

d. Using a wrench, tighten nut (9) until snug. Torque Nut to 25-30 in. Lbs.

e. Coat area between nut (9) and screw 5) with ER/41 or insulating paint
to prevent entry of carbon dust under washers and brush box
mounting ears. This will prevent shorting to ground of brush boxes.
Bake end bell at maximum 150 degrees F (66 degrees C) for one
hour.

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2-29 MAIN ASSEMBLY (Refer to IPL Figure 4-1)

a. Mount disc baffle (5) with protruding surface facing bearing (6) on the
drive end of generator armature (23). Mount bearing on same end of
armature shaft using an aluminum block or suitable fixture to support
armature shaft on opposite end. Press on bearing by pushing the
inner race with a suitable bearing pusher. See Fig. 2-9.

b. Install remaining disc baffle (5) on shaft with protruding surface facing
bearing. Install retaining ring (4) on armature shaft making sure that
ring is fully seated in the groove.

c. Press bearing (6) into bell assy, commutator end (24), using a suitable
bearing pusher against the outer race.

d. Support armature in arbor press on an aluminum block or suitable

fixture. Position commutator end bell with bearing previously installed
over the armature shaft. Press commutator end bell assy and bearing
(24) on to armature shaft by pushing inner race of bearing with
suitable pusher. Apply anti-seize compound part number 150SG1309
to four screws (30). Secure bearing in end bell with bearing retainer
(28) using four screws (30), and lock washers(29).

e. Position armature with assembled commutator end bell on stator assy

(11). Stator should be mounted on a suitable fixture to allow armature
shaft to project through opposite end of generator. Apply anti-seize
compound part number 150SG1309 to threads of eight screws (27).
Install eight lock washers (26) and eight plain washers (25) on screws.
Insert screws and tighten.

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f. Apply a continuous film of Never-Seize Anti-Seize compound to the

bearing liner of the drive end bell assembly (7), then position the drive
end bell assembly over drive end bearing. Insure that the bell is fully
seated against stator housing. Apply anti-seize compound part
number 150SG1309 to threads of screws (8). Place lock washers (9)
and plain washers (10) on screws. Install eight screws (8).

g. Install terminal block (15) as follows:

Position terminal block (15) on stator (11) with stator leads positioned
on terminal block studs and install two screws (16), lock washer (17)
and flat washers (18). Tighten screws. Install washers (19) (21) and
nuts (20) (22) on terminal block).

h. Place damper plate (3) on armature shaft by hand. Make sure damper
plate is squarely seated on taper.

CAUTION

Do not hammer damper plate on shaft or use arbor

press to force on the damper plate.

TM101—150SG Series
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FIGURE 2-8 DAMPER PLATE INSTALLATION TOOL (T150SG1073)

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FIGURE 2-9 BEARING PUSHER (INNER RACE AND OUTER RACE)

TM101—150SG Series
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i. Press armature damper plate (3) into position on the armature shaft
using a hand arbor press and installation tool T150SG1073. (See
Figure 2-8) Place the generator drive end up on an aluminum block
under the ram of the arbor press. Place tool T150SG1073 over the
armature drive shaft resting on the damper plate (3). Using the arbor
press, gently press tool T150SG1073 until the tool bottoms against the
end of the armature shaft and positions the armature damper plate.
The damper plate should be square and tight on the armature. If not
tight, replace the armature shaft damper plate (3).

j. Coat the small spline of the drive shaft assembly (1) with
Lubriplate 630-AA or equal.

k. Place a new friction ring (2) on drive shaft (1). Push shaft into
armature (23) making contact with plate on armature shaft (1).

l. Position the fan (31) and Spring Retainer(32) on back end of the drive
shaft. Install two each new Belleville tension springs (33) per (Figure
2-11). With a suitable holding tool, hold drive shaft and install nut
(34), and gently tighten until the nut and springs bottom gently against
the fan.
Then, back off the nut, 3/4 of a turn. Drive shaft should be tight
against damper plate (3).

CAUTION

When bottoming the nut, do not

overtighten or damper springs will be
damaged.

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m. Install four brushes (11) (IPL Figure 4-2) securing brush leads with
screws (10). See Figure 2-12 for correct positioning of brush leads to
prevent brush hang-up on the brush box.

n. Install fan cover (35) (Figure 4-1) and install four screws (36).

NOTE

The rewinding of the armature or stator

in this generator is not recommended.

The varnishes used cannot be removed without

destroying the magnetic qualities of the
armature which in turn will degrade engine
starting and brush life.

MAINTENANCE NOTE

Due to mishandling during overhaul, the screen

That is welded to the starter may be pushed
against the field coils.
Before final assembly, gently push the screen
Away from the field coils if necessary

ANY REPAIRS OR ALTERATIONS

TO THIS GENERATOR,
NOT COVERED BY THIS MANUAL,
ARE NOT RECOMMENDED.

TM101—150SG Series
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Figure 2-10- Generator Schematic Wiring Diagram

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Figure 2-11 Belleville Spring Installation Instructions

TM101—150SG Series
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Incorrect Installation Correct Installation

Incorrect installation will result in reduction of brush life, reduction of Starter-

Generator life and may result in unrepairable damage

Figure 2-12 Positioning of Brush Leads

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THIS PAGE LEFT INTENTIONALLY BLANK

TM101—150SG Series
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SECTION III

TEST PROCEDURE

3-1 GENERAL

3-2 If the unit under test fails to meet any of the following requirements and visual
inspection does not disclose the cause of the trouble, disassemble and repeat
inspection and testing as instructed in Section II. After reassembling, repeat
procedure from the beginning.

3-3 TEST EQUIPMENT AND PREPARATION FOR TEST

3-4 The standard test equipment required is a generator test stand capable of speed
of 6,500 to 14,000 rpm and a cabinet containing the necessary wiring, switches
and meters as shown in Figure 3-1. The load bank should provide graduated
load steps and a minimum load rating of 150 amperes.

3-5 VOLTAGE REGULATION

For voltage regulation, connect a carbon pile regulator, Generator Control Unit or
rheostat capable of controlling the field current from 0 to 10 amperes as shown
in Figure 3-1.

3-6 AMBIENT TEMPERATURE

Conduct all tests with an air inlet temperature of 50 degrees F (10 degrees C) to
104 degrees F (40 degrees C).

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Figure 3-1- TEST SCHEMATIC FOR SERIES STARTER GENERATORS

TM101—150SG Series
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3-7 FLASHING THE FIELD

If required, flash the field as follows:

a. Connect the positive terminal of a 12-volt battery through a single-pole,

single-throw knife switch to generator terminal A on the terminal board
(Figure 2-10).

b. Connect the negative terminal of the battery to terminal E on the

generator terminal board.

c. Apply battery current to the field for 5 seconds by closing the knife switch.

d. Repeat the operation several times to be sure that the field is properly
flashed.

WARNING

Use a knife switch when flashing the field.

Opening or closing the circuit at the generator or
battery terminals can result in severe
damage to the generator or battery terminals
or explosion of the battery.

CAUTION

Do not flash field while generator is in

operation.

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3-8 TEST CONNECTION

a. Connect the starter-generator to the test circuit, as shown in Figure 3-1.

b. Move all load switches to the OFF position.

c. Attach a thermocouple directly over a pole shoe screw to measure yoke

temperature.

3-9 ROTATION

Operate the starter-generator in a counter-clockwise direction, as viewed from

the drive-end, during the tests.

NOTE

Brush run-in by motorizing the

starter-generator can be utilized in
lieu of Paragraph 3-10. See the
enclosed copy of APC Service Bulletin
19-SB150SG105.

3-10 BRUSH SEATING

a. Start the drive motor and increase the starter-generator speed to

approximately 8100 rpm as indicated on a tachometer.

b. Close suitable switches on the DC load bank to apply 50 amperes load as

indicated on the DC load ammeter.

c. Operate the starter-generator for a minimum of two hours. Shut off the
starter-generator at the end of this period.

d. Examine the brush seating one brush at a time. The face of each brush
should contact the commutator surfaces 100 percent in the direction of
rotation, and at least 85 percent of the surface parallel to the armature
shaft. (See Figure 3-2).

TM101—150SG Series
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e. If the brush seating is close to the required values, increase the DC load
between 75 and 125 amperes for short periods while inspecting to see if
the brushes are properly seated. See Figure 3-2 for typical brush
seating.

NOTE

Using a brush spring lifter

when removing the brushes from
the brush holders, be sure to
return each brush to the brush holder
from which it was removed.

f. When the brush seating is completed, open all load switches and shut
down the starter-generator. Allow the unit to cool before proceeding with
tests. Record readings on test data sheet, Table IV.

CAUTION

Do not use abrasives or abrasive

stones to seat the brushes.

NOTE

See Section VI, Page 6-1, for instructions

on “XL” Series Starter-Generators.

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Figure 3-2 Typical Brush Seating

TM101—150SG Series
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3-11 TEST

3-12 CONTINUOUS OPERATING CONDITION

Continuous operating condition is defined as follows:

While the starter-generator is cold, the resistance and temperature of the shunt
field shall be determined for use in calculating the average field temperature rise
during continuous operation at full load. The starter-generator is considered to
have reached its continuous operating condition when the rate of rise of the
shunt field temperature does not increase by more than two (2) degrees F during
a five minute period.

3-13 MAXIMUM SPEED FOR REGULATION

The starter-generator should not be given an operational warm-up prior to this

test. Perform the test as follows:

a. Connect starter-generator to the generator test stand.

b. Place all load switches to the OFF position.

c. Increase the speed of the drive motor until a reading of 12,100 rpm is
obtained on the tachometer. Adjust the field rheostat or carbon pile
regulator until generator voltmeter reads 30 volts. Shunt field voltage
current should not be less than 0.81 amperes minimum.

d. Reduce the drive motor to zero rpm.

e. Record readings on test data sheet, Table IV.

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3-14 HEATING, COMMUTATION, MINIMUM SPEED AND EQUALIZING VOLTAGE

a. MINIMUM SPEED FOR REGULATION

(Stabilization Not Required)

Decrease the starter-generator speed to 8500 rpm. The starter-

generator must deliver 150 amperes at 28.5 volts. Operate the starter-
generator (stabilization not required) and record field current, which
should not exceed 10.0 amperes. Record readings on test data sheet,
Table IV.

b. CONTINUOUS OPERATING SPEED

Start the drive motor. Increase the speed of the starter-generator to

12,100 rpm. Close suitable switches of the DC load bank to apply a load
of 150 amperes. When the starter-generator reaches its continuous
operating conditions as described in Paragraph 3-12 , (no more than 2
degrees F rise in five minutes) check the readings of the temperature
instruments. Frame temperature should not exceed air inlet temperature
by 175 degrees F. Record readings on test data sheet, Table IV.

c. EQUALIZING VOLTAGE

Measure the paralleling voltage across terminals D and E (Figure 2-10).

The voltage must be within the limits shown on figure 3-3. Record
readings on test data sheet, Table IV.

d. MINIMUM SPEED

Decrease the starter-generator speed to 7200 rpm. Reduce the terminal

voltage to 26 volts DC. The starter-generator must deliver 120 amperes
at 26 volts. Record readings on test data sheet, Table IV.

TM101—150SG Series
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130

120

110
AIR INLET TEMPERATURE (°F)

100

90

80

70

60

50

40
1.60 1.70 1.80 1.90 2.00 2.10 2.20 2.30 2.40 2.50 2.60

EQUALIZING VOLTAGE (VOLTS)

Figure 3-3 Equalizing Voltage

3-15 COMMUTATION AND COMPOUNDING

Immediately following the previous heat runs with the starter-generator hot,
observe the commutation of the starter-generator over the speed range of 8700
to 12,100 rpm at no-load, half-load, full-load. Sparking must be limited to pin
point sparking at the brushes. Commutator should be black for best generator
performance. Modify a fan cover to have a plastic window. Rotate the cover to
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observe each brush when performing this test. If sparking is excessive, check
brush seating surfaces and brush tension. The field current must increase with
any increase in generator load. Record readings on test data sheet, Table IV.

CAUTION

Do not use abrasives or abrasive

stones to seat the brushes.

CAUTION

If the plastic window is not available,

and the test is to be performed with the cover removed.
The test must be completed in 3 to 4 minutes since
proper cooling cannot be maintained and the starter-
generator may overheat.

3-16 OVERSPEED

a. Perform this test with the starter-generator hot as a result of testing.

b. Open all load switches and the field switch

c. Increase the speed of the starter-generator to 14,000 rpm. The starter-

generator must operate at this speed for 5 minutes without mechanical
failure, throwing of varnish or impairment of electrical performance.

d. At the end of 5 minutes overspeed run, reduce the speed to 12,100 rpm.
Close suitable load switches to obtain rated load of 150 amperes.

TM101—150SG Series
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e. Operate the starter-generator for 1 minute and check the electrical

performance which should compare with that observed in paragraph 3-15.
Record readings on test data sheet, Table IV.

3-17 DIELECTRIC STRENGTH TEST (IPL FIG. 4-1)

Perform this test while the starter-generator is hot as a result of testing.

a. Remove all external connections from the terminals. Disconnect the

terminal block (15) by removing the block.

b. Using a Hi-Pot, apply 250 volts AC, 60 Hz between E and the stator
housing (ground).

c. Apply the same voltage between series field and interpole and
compensating field terminals (D, E, B and C) and the stator housing
(ground).

d. The insulation should not breakdown.

CAUTION
Do not apply voltage across shunt,
Series interpole and compensating fields
As damage may occur.

e. After the dielectric strength test, install and reconnect the terminal block
(15).

f. Record readings on test data sheet, Table IV.

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3-18 ACCELERATION RUN

a. Remove the starter-generator from the generator test stand and allow the
unit to cool. Then connect to an acceleration test stand with a steel
flywheel 12 inches in diameter and .836 inches thick. The flywheel
should rotate on ball bearings sized to the weight and RPM of the wheel.

CAUTION

The flywheel should be protected

by a metal protective shield to avoid
injury.

b. With 28 volts DC starting power applied, close starting switch. The

starter-generator must accelerate the flywheel to a speed of 6,500 rpm
within 30 seconds. Record readings on test data sheet, Table IV.

3-19 COMMUTATOR FILM

It is important for brush life and good generator operating characteristics that the
commutator have a black film. Inspect the commutator after the final test for a
black film. If the film is not evident, run the generator at 10,000 rpm and 150
amperes for 30 minutes.

3-20 COMMUTATOR RUN-OUT

Using a dial indicator firmly mounted to the generator and with the probe located
on the commutator, the total commutator run-out shall be .0005 inch maximum.
Bar to bar run-out shall be .0002 inch maximum. Record readings on test data
sheet, Table IV.

TM101—150SG Series
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3-21 VIBRATION

Radial Vibration. After completion of the preceding tests, place generator in a

rubber padded cradle, accelerate to 4000-4500 rpm no load speed. Vibration
shall not exceed 0.001 inch total deflection as a starter and supported in a
resilient cradle. It shall be permissible to employ a drive shaft support during the
test to keep the drive shaft in axial alignment. Record readings on test data
sheet, Table IV.

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TABLE IV
150 SERIES ACCEPTANCE TEST DATA SHEET

REPAIR STATION NAME

ADDRESS
TESTED PER TM101
REV
REPAIR STATION CERTIFICATE NO. REV DATE

S/G MODEL NO. SERIAL NO. SALES/WORK ORDER NO. TESTED BY DATE:
150SG TEST STAND
NO.
MOD / REV
TEST
PARA. INSPECTION / TEST REQUISITES MEASUREMENT ACC REJ

3-10 Brush Seating 100% Seating all Brushes (See Fig. 3-2) X X

Maximum Speed for Regulation

3-13 12,100 +0/-100 RPM No Load, Ammeter readout (A+) 0.81 amps min. amps
30.0 ± 0.1 VDC

Minimum Speed for Regulation

3-14a 8,500 +100/-0 RPM 28.5 ± 0.1 Field Current (A+ within 10.0 amps) amps
VDC, 150 ± 5 Amp
D - E Voltage (see Fig. 3-3) vdc
Continuous Operating Speed
and Equalizing Voltage Stabilized Temp. (gen. yoke) °F
3-14b,c
12,100 ± 100 RPM,
150 ± 5 Amp, 30 ± 0.1 VDC Air In Temp. °F
Paralleling Voltage Temp. rise (Yoke-air in) 175°F max °F
(Equalizing)
Voltmeter Readout (A+ to B+) vdc
Minimum Speed
3-14d 7200 + 100/-0 RPM, Ammeter Readout (A+) amps
125 ± 5 Amp, 26 ± 0.1 VDC
Ext. Field Resistance (0.5 ohms min) ohms
8700 +100/-0 RPM, Not to exceed pinpoints
0, 75, 150 (± 5) Amp
X X

3-15 10,000 ± 100 RPM, Not to exceed pinpoints X X

0, 75, 150 (± 5) Amp
12,100 ± 100 RPM, Not to exceed pinpoints, Field Current rises with X X
0, 75, 150 (± 5) Amp Load
Overspeed 5 min 14,000 No Sign of Failure X X
± 100 RPM
3-16 Post Overspeed 12,100 ± 100
RPM, 30 ± 0.1 VDC, 150 ± 5 No Sign of Failure X X
Amps
Dielectric Strength
3-17 No Sign of Failure X X
250 ± 10 VAC, RMS, 1.0 sec

Peak Current (725 amps max) amps

0 - 6500 ± 100 RPM within 70 seconds for

Cranking Torque and Speed at series starter generators (within 60 seconds for sec
3-18
28.5 ± 0.1 VDC Supply Voltage high speed winding generators)
(1783 lb in2 Flywheel)
0 - 6500 ± 100 RPM within 30 seconds for .836 sec
Thick Flywheel, 12 inch diameter
Bar-to-Bar (not to exceed 0.0002 inch) inch
3-20 Commutator Runout
inch
TIR (not to exceed 0.0005 inch)

3-21 Radial Vibration, Within Limits (0.001 inch total max) inch
4000 - 4500 RPM

TM101—150SG Series
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SECTION IV

ILLUSTRATED PARTS CATALOG

A. General

This section contains listings of assemblies and detail parts.

B. Figure and Index Numbers

The figure and index numbers indicate the figure on which the part is illustrated and its
identification on the illustration.

C. Part Numbers

This column contains numbers for identification of parts.

D. Description
Description of each item is indented by columns to indicate relationship to the next higher
assembly.

E. Units Per Assembly

The numbers listed in the “Units per Assembly” column indicates the quantity of parts used per
assembly at the location shown, and are not necessarily the total quantity used per unit.

F. Numerical Index
This index contains an alphabetical and numerical listing of part numbers and is crossed
referenced to figure and index number. The part number is listed once with its corresponding
figure and index number or numbers in the appropriate column. The quantity shown is the total
quantity used per unit.

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NUMERICAL INDEX

Fig &
Part Index Qty per
Number Number Article
AN500A8-8 4-1-30 4
AN503-8-16 4-1-27 8
AN960-10L 4-1-18 2
AN960-10L 4-2-6 16
AN960C10 4-1-19 2
AN960C616 4-1-21 3
MS16624-4066 4-1-4 1
MS21318-13 4-1-14 4
MS21318-14 4-1-7D 4
MS35265-65 4-1-16 2
MS35338-43 4-1-17 2
M83248/1-113 4-1-1A 1
SPS27FT-624 4-1-22 3
SPS27FT-1032 4-2-9 8
4-1-20 2
150SG1004-1 4-1-7B 1
150SG1005S-3 4-2-2 8
150SG1005-1 4-2-2 4
150SG1006 4-1-28 1
150SG1008 4-2-4 1
150SG1008-1 4-2-4 1
150SG1009-1 4-2-11A 4
150SG1009-5 4-2-11 4
150SG1011-4 4-1-35B 1
150SG1011-7 4-1-35A 1
150SG1014 4-1-35 1
150SG1014-1 4-1-35 8
150SG1017 4-1-5 2
150SG1028 4-1-7 1
150SG1028-2 4-1-7 1
150SG1040 4-1-4B 1
150SG1040-2 4-1-4B 1
150SG1040-3 4-1-4B 1
150SG1040-4 4-1-4C 1
150SG1040-5 4-1-4C 1
150SG1040-6 4-1-4C 1
150SG1045 4-2-7 8
150SG1046 4-2-8A 8
150SG1052-B 4-1-6 2
150SG1052-1 4-1-6A 2
TM101—150SG Series
Page 4-2 SKURKA AEROSPACE INC. -- PROPRIETARY INFORMATION
Rev. 14 Subject to the restrictions on the first page
December 09, 2009
 Skurka Aerospace Inc.
4600 Calle Bolero, P. O. Box 2869
Camarillo, CA 93011

NUMERICAL INDEX

Fig &
Part Index Qty per
Number Number Article
150SG1057 4-2-3 2
150SG1061 4-1-15 1
150SG1064 4-1-23 1
150SG1064-1 4-1-23 1
150SG1070 4-1-2 1
150SG1071 4-1-34 1
150SG1073 4-1-3 1
150SG1083 4-1- 1
150SG1083-1 4-1- 1
150SG1083-2 4-1- 1
150SG1083-3 4-1- 1
150SG1083-5 4-1- 1
150SG1092 4-1-13 1
150SG1092-1 4-1-13 1
150SG1092-2 4-1-13 1
150SG1092-3 4-1-13 1
150SG1092-4 4-1-13 1
150SG1092-5 4-1-13 1
150SG1092-6 4-1-13 1
150SG1092-7 4-1-13 1
150SG1092-8 4-1-13 1
150SG1092-9 4-1-13 1
150SG1092-10 4-1-13 1
150SG1092-13 4-1-13 1
150SG1092-14 4-1-13 1
150SG1092-20 4-1-13 1
150SG1092-21 4-1-13 1
150SG1092-23 4-1-13 1
150SG1092-25 4-1-13 1
150SG1093 4-1-33 2
150SG1103 4-1-1 1
150SG1103-1 4-1-1 1
150SG1103-2 4-1-1 1
150SG1103-4 4-1-1 1
150SG1103-5 4-1-1 1
150SG1103-7 4-1-1 1
150SG1103-9 4-1-1 1
150SG1103-10 4-1-1 1
150SG1103-11 4-1-1 1

TM101—150SG Series
SKURKA AEROSPACE INC. -- PROPRIETARY INFORMATION Page 4-3
Subject to the restrictions on the first page Rev. 14
December 09, 2009
 Skurka Aerospace Inc.
4600 Calle Bolero; P. O. Box 2869
Camarillo, CA 93011

NUMERICAL INDEX

Fig &
Part Index Qty per
Number Number Article
150SG1104 4-1-32 1
150SG1105 4-1-27 8
150SG1106 4-1-8 8
150SG1106-1 4-1-8 8
150SG1107 4-1-31 1
150SG1107-1 4-1-31 1
150SG1108 4-1-4A 1
150SG1112-1 4-2-5 8
150SG1113 4-1-10 8
150SG1113 4-1-25 8
150SG1114 4-2-8 4
150SG1138 4-2- 4
150SG1138-1 4-2- 4
150SG1139 4-1-12 1
150SG1153 4-1-24 1
150SG1153-1 4-1-24 1
150SG1154 4-2-1 4
150SG1154-1 4-2-1A 4
150SG1156 4-1-11 1
150SG1156-1 4-1-11 1
150SG1156-2 4-1-11 1
150SG1156-3 4-1-11 1
150SG1168 4-1-12A 1
150SG1379-8 4-1-9 8
150SG1379-8 4-1-26 8
150SG1379-8 4-1-29 4
150SG1381 4-1-12C 1
200SGL1028-1 4-1-7A 1
200SGL1301-1 4-1- 1
200SGL1360 4-1-12B 1
200SG1020 4-2-10 4
250SG1116 4-1-36 4
250SG1302 4-1-7C 4

TM101—150SG Series
Page 4-4 SKURKA AEROSPACE INC. -- PROPRIETARY INFORMATION
Rev. 14 Subject to the restrictions on the first page
December 09, 2009
 Skurka Aerospace Inc.
4600 Calle Bolero, P. O. Box 2869
Camarillo, CA 93011

FIG & UNITS

INDEX PART DESCRIPTION PER USAGE
NO. NUMBER 1234567 ASSY CODE

4-1- 150SG111Q STARTER-GENERATOR ASSY 1 A

4-1- 150SG114Q STARTER-GENERATOR ASSY 1 B

4-1- 150SG115Q STARTER-GENERATOR ASSY 1 C

4-1- 150SG116Q STARTER-GENERATOR ASSY 1 D

4-1- 150SG117Q STARTER-GENERATOR ASSY 1 E

4-1- 150SG118Q STARTER-GENERATOR ASSY 1 F

4-1- 150SG119Q STARTER-GENERATOR ASSY 1 G

4-1- 150SG120Q STARTER-GENERATOR ASSY 1 H

4-1- 150SG121Q STARTER-GENERATOR ASSY 1 I

4-1- 150SG122Q STARTER-GENERATOR ASSY 1 J

4-1- 150SG123Q STARTER-GENERATOR ASSY 1 K

4-1- 150SG124Q STARTER-GENERATOR ASSY 1 L

4-1- 150SG125Q STARTER-GENERATOR ASSY 1 M

4-1- 150SG144Q STARTER-GENERATOR ASSY 1 N

4-1- 150SG125Q-2 STARTER-GENERATOR ASSY 1 O

4-1- 150SG117Q-3 STARTER-GENERATOR ASSY 1 P

4-1- 150SG117Q-4 STARTER-GENERATOR ASSY 1 Q

TM101—150SG Series
SKURKA AEROSPACE INC. -- PROPRIETARY INFORMATION Page 4-5
Subject to the restrictions on the first page Rev. 14
December 09, 2009
 Skurka Aerospace Inc.
4600 Calle Bolero; P. O. Box 2869
Camarillo, CA 93011

FIG & UNITS

INDEX PART DESCRIPTION PER USAGE
NO. NUMBER 1234567 ASSY CODE

4-1-1 150SG1103 . SHAFT, DRIVE ASSY 1 A,F,M

4-1-1 150SG1103-1 . SHAFT, DRIVE ASSY 1 B

4-1-1 150SG1103-2 . SHAFT, DRIVE ASSY 1 C,E,K,N,O,P,Q

4-1-1 150SG1103-4 . SHAFT, DRIVE ASSY 1 D

4-1-1 150SG1103-5 . SHAFT, DRIVE ASSY 1 H

4-1-1 150SG1103-9 . SHAFT, DRIVE ASSY 1 I

4-1-1 150SG1103-7 . SHAFT, DRIVE ASSY 1 J

4-1-1 150SG1103-10 . SHAFT, DRIVE ASSY 1 L

4-1-1 150SG1103-11 . SHAFT, DRIVE ASSY 1 G

4-1-1A M83248/1-113 . “O” RING 1 C,D,E,H,K,L,N,O,

P,Q

4-1-2 150SG1070 . FRICTION RING 1 ALL

4-1-3 150SG1073 . PLATE DAMPENER 1 ALL

4-1-4 MS16624-4066 . RING, RETAINING. 1 ALL

4-1- 150SG1083 . QAD KIT 1 A,E,F,K,M,N,O,P,Q

4-1- 150SG1083-2 . QAD KIT 1 B

TM101—150SG Series
Page 4-6 SKURKA AEROSPACE INC. -- PROPRIETARY INFORMATION
Rev. 14 Subject to the restrictions on the first page
December 09, 2009
 Skurka Aerospace Inc.
4600 Calle Bolero, P. O. Box 2869
Camarillo, CA 93011

FIG & UNITS

INDEX PART DESCRIPTION PER USAGE
NO. NUMBER 1234567 ASSY CODE

4-1- 150SG1083-1 . QAD KIT 1 C,D,H

4-1- 150SG1083-3 . QAD KIT 1 G

4-1- 150SG1083-5 . QAD KIT 1 I,L

4-1-4A 150SG1108 . . CLAMP, RING 1 ALL except J

4-1-4B 150SG1040 . . MOUNTING FLANGE 1 A,E,F,K,M,N,O,P,Q

4-1-4C 150SG1040-6 . . MOUNTING FLANGE 1 I,L

4-1-4B 150SG1040-3 . . MOUNTING FLANGE 1 B

4-1-4B 150SG1040-2 . . MOUNTING FLANGE 1 C,D,H

4-1-4C 150SG1040-4 . . MOUNTING FLANGE 1 G

4-1-4C 150SG1040-5 . . MOUNTING FLANGE 1 J

4-1-5 150SG1017 . DISC, BAFFLE 2 ALL

4-1-6 150SG1052-B . BEARING, BALL 2 A,B,C,D,E,F,G,H,I,

J,K,L,M,N,O

4-1-6A 150SG1052-1 . BEARING, BALL 2 P,Q

4-1-7 150SG1028 . BELL, END DRIVE 1 A,B,C,D,E,F,G,H,K,

MNOPQ
4-1 150SG1028-2 . BELL, END DRIVE 1 J

TM101—150SG Series
SKURKA AEROSPACE INC. -- PROPRIETARY INFORMATION Page 4-7
Subject to the restrictions on the first page Rev. 14
December 09, 2009
 Skurka Aerospace Inc.
4600 Calle Bolero; P. O. Box 2869
Camarillo, CA 93011

FIG & UNITS

INDEX PART DESCRIPTION PER USAGE
NO. NUMBER 1234567 ASSY CODE

4-1- 200SGL1301-1 . HSG & SCREEN ASSY 1 I,L

4-1-7A 200SGL1028-1 . . BELL, END DRIVE 1 I,L

4-1-7B 150SG1004-1 . . SCREEN 1 I,L

4-1-7C 250SG1302 . . WASHER, SCREEN 4 I,L

4-1-7D MS21318-14 . . DRIVE SCREW 4 I,L

4-1-8 150SG1106 . SCREW, MTG. HEAD 8 ALL except J

4-1-8 150SG1106-1 . SCREW, MTG. HEAD 8 J

4-1-9 150SG1379-8 . WASHER, LOCK 8 ALL

4-1-10 150SG1113 . WASHER, FLAT 8 ALL

4-1-11 150SG1156 . STATOR ASSY 1 A,B,C,E,G,H,J,P,Q

4-1-11 150SG1156-1 . STATOR ASSY 1 D,F,K,N,

4-1-11 150SG1156-2 . STATOR ASSY 1 I,L

4-1-11 150SG1156-3 . STATOR ASSY 1 M,O

4-1-12 150SG1139 . . DECAL, HI-POT WARNING 1 ALL

4-1-12A 150SG1168 . . DECAL, QAD WARNING 1 ALL

4-1-12B 200SGL1360 . . APC-XL LABEL 1 XL MODELS ONLY

TM101—150SG Series
Page 4-8 SKURKA AEROSPACE INC. -- PROPRIETARY INFORMATION
Rev. 14 Subject to the restrictions on the first page
December 09, 2009
 Skurka Aerospace Inc.
4600 Calle Bolero, P. O. Box 2869
Camarillo, CA 93011

FIG & UNITS

INDEX PART DESCRIPTION PER USAGE
NO. NUMBER 1234567 ASSY CODE
4-1-12C 150SG1381 . . DECAL, WET SPLINE 1 O

4-1-13 150SG1092 . . NAMEPLATE 1 A

4-1-13 150SG1092-4 . . NAMEPLATE 1 B

4-1-13 150SG1092-1 . . NAMEPLATE 1 C

4-1-13 150SG1092-2 . . NAMEPLATE 1 D

4-1-13 150SG1092-7 . . NAMEPLATE 1 E

4-1-13 150SG1092-3 . . NAMEPLATE 1 F

4-1-13 150SG1092-5 . . NAMEPLATE 1 G

4-1-13 150SG1092-6 . . NAMEPLATE 1 H

4-1-13 150SG1092-9 . . NAMEPLATE 1 I

4-1-13 150SG1092-8 . . NAMEPLATE 1 J

4-1-13 150SG1092-10 . . NAMEPLATE 1 K

4-1-13 150SG1092-13 . . NAMEPLATE 1 L

4-1-13 150SG1092-14 . . NAMEPLATE 1 M

4-1-13 150SG1092-20 . . NAMEPLATE 1 N

4-1-13 150SG1092-21 . . NAMEPLATE 1 O

4-1-13 150SG1092-23 . . NAMEPLATE 1 P

4-1-13 150SG1092-25 . . NAMEPLATE 1 Q

4-1-14 MS21318-13 . . SCREW, NAMEPLATE 4 ALL

4-1-15 150SG1061 . . TERMINAL BLOCK, AXIAL 1 ALL

4-1-16 MS35265-65 . . SCREW, TERM. BLOCK MTG, 2 ALL

4-1-17 MS35338-43 . . WASHER, LOCK TERM. BLOCK 2 ALL

TM101—150SG Series
SKURKA AEROSPACE INC. -- PROPRIETARY INFORMATION Page 4-9
Subject to the restrictions on the first page Rev. 14
December 09, 2009
 Skurka Aerospace Inc.
4600 Calle Bolero; P. O. Box 2869
Camarillo, CA 93011

FIG & UNITS

INDEX PART DESCRIPTION PER USAGE
NO. NUMBER 1234567 ASSY CODE

4-1-18 AN960-10L . . WASHER, FLAT, TERM. BLOCK 2 ALL

4-1-19 AN960C10 . . WASHER, TERM BLOCK 2 ALL

4-1-20 *SPS27FT-1032 . . NUT, TERMINAL BLOCK 2 ALL

4-1-21 AN960C616 . . WASHER, TERM. BLOCK 3 ALL

4-1-22 *SPS27FT-624 . . NUT, TERMINAL BLOCK 3 ALL

4-1-23 150SG1064 . ARMATURE ASSY 1 A,B,C,D,E,F,G,H,J,

K,M,N,O,P,Q

4-1-23 150SG1064-1 . ARMATURE ASSY 1 I,L

4-1-24 150SG1153 . COMM. END BELL ASSY 1 A,B,C,D,E,F,G,H,J,

K,M,N,O,P,Q

4-1-24 150SG1153-1 . COMM. END BELL ASSY 1 I,L

4-1-25 150SG1113 . WASHER, FLAT, COMM HEAD MTG 8 ALL

4-1-26 150SG1379-8 . WASHER, LOCK, COMM HEAD MTG 8 ALL

4-1-27 150SG1105 . SCREW, COMM. HEAD MTG. 8 A,B,C,D,E,F,G,H,J,

K,M,N,O,P,Q

4-1-27 AN503-8-16 . SCREW, COMM. HEAD MTG. 8 I,L

* SPS Technologies P/N or equiv.

TM101—150SG Series
Page 4-10 SKURKA AEROSPACE INC. -- PROPRIETARY INFORMATION
Rev. 14 Subject to the restrictions on the first page
December 09, 2009
 Skurka Aerospace Inc.
4600 Calle Bolero, P. O. Box 2869
Camarillo, CA 93011

FIG & UNITS

INDEX PART DESCRIPTION PER USAGE
NO. NUMBER 1234567 ASSY CODE
4-1-28 150SG1006 . RETAINER, BEARING 1 ALL

4-1-29 150SG1379-8 . WASHER, LOCK 4 ALL

4-1-30 AN500A8-8 . SCREW, BEARING RETAINER 4 ALL

A,B,C,D,E,F,G,H,J,
4-1-31 150SG1107 . FAN ASSY 1
K,M,N,O,P,Q

4-1-31 150SG1107-1 . FAN ASSY 1 I,L

4-1-32 150SG1104 . SPRING RETAINER 1 ALL

4-1-33 150SG1093 . SPRING, BELLEVILLE 2 ALL

4-1-34 150SG1071 . NUT, SELF LOCKING 1 ALL

A,B,C,D,E,F,G,H,J,
4-1-35 150SG1014 . COVER ASSY, FAN 1
K,M,O,P

4-1-35 150SG1014-1 . COVER ASSY, FAN 1 I,L

4-1-35A 150SG1011-7 . COVER ASSY, FAN 1 N

4-1-35B 150SG1011-4 . COVER ASSY, FAN 1 Q

4-1-36 250SG1116 . SCREW, FAN COVER 4 ALL

TM101—150SG Series
SKURKA AEROSPACE INC. -- PROPRIETARY INFORMATION Page 4-11
Subject to the restrictions on the first page Rev. 14
December 09, 2009
 Skurka Aerospace Inc.
4600 Calle Bolero; P. O. Box 2869
Camarillo, CA 93011

FIG & UNITS

INDEX PART DESCRIPTION PER USAGE
NO. NUMBER 1234567 ASSY CODE

4-2- 150SG1138 . . HOLDER ASSY, BRUSH & SPRING 4 A,B,C,D,E,F,G,H,J,

K,M,N,O,P,Q

4-2- 150SG1138-1 . . HOLDER ASSY, BRUSH & SPRING 4 I,L

4-2-1 150SG1154 . . . HOLDER, BRUSH 4 A,B,C,D,E,F,G,H,J,

K,M,N,O,P,Q

4-2-1A 150SG1154-1 . . . HOLDER, BRUSH 4 I,L

4-2-2 *150SG1005S-3 . . . SPRING 8 A,B,C,D,E,F,G,H,J,

Supersedes 150SG1005 K,M,N,O,P,Q
150SG1005S

4-2-2 150SG1005-1 . . . SPRING 4 I,L

4-2-3 150SG1057 . . P.C. BOARD ASSY. 2 ALL

4-2-4 150SG1008 . . HEAD, COMMUTATOR 1 A,B,C,D,E,F,G,H,J,

K,M,N,O,P,Q

4-2-4 150SG1008-1 . . HEAD, COMMUTATOR 1 I,L

4-2-5 150SG1112-1 . . SCREW BRUSH HOLDER 8 ALL

4-2-6 AN960-10L . . WASHER, PLAIN 16 ALL

4-2-7 150SG1045 . . TUBE, INSULATOR 8 ALL

4-2-8 150SG1114 . . WASHER, INSULATOR 4 ALL

* Do not mix with 150SG1005 & 150SG1005S Springs (Install Full set of 8)

TM101—150SG Series
Page 4-12 SKURKA AEROSPACE INC. -- PROPRIETARY INFORMATION
Rev. 14 Subject to the restrictions on the first page
December 09, 2009
 Skurka Aerospace Inc.
4600 Calle Bolero, P. O. Box 2869
Camarillo, CA 93011

FIG & UNITS

INDEX PART DESCRIPTION PER USAGE
NO. NUMBER 1234567 ASSY CODE

4-2-8A 150SG1046 . . WASHER, INSULATOR BR. BOX 8 ALL

4-2-9 SPS27FT-1032 . . NUT, SELF LOCKING 8 ALL

4-2-10 200SG1020 . . SCREW, BRUSH MOUNTING 4 ALL

4-2-11 *150SG1009-5 . . BRUSH 4 A,B,C,D,E,F,G,H,J,

M,N,O,P,Q

4-2-11A 150SG1009-1 . . BRUSH 4 I,L

4-2-11 150SG1009-20 . . BRUSH 4 K

* ‘XL’ Series Starter Generators are shown in Section VI

TM101—150SG Series
SKURKA AEROSPACE INC. -- PROPRIETARY INFORMATION Page 4-13
Subject to the restrictions on the first page Rev. 14
December 09, 2009
 Skurka Aerospace Inc.
4600 Calle Bolero; P. O. Box 2869
Camarillo, CA 93011

FIGURE 4-1 ILLUSTRATED PARTS BREAKDOWN- STARTER GENERATOR

TM101—150SG Series
Page 4-14 SKURKA AEROSPACE INC. -- PROPRIETARY INFORMATION
Rev. 14 Subject to the restrictions on the first page
December 09, 2009
 Skurka Aerospace Inc.
4600 Calle Bolero, P. O. Box 2869
Camarillo, CA 93011

FIGURE 4-2 ILLUSTRATED PARTS BREAKDOWN- BELL ASSY, COMMUTATOR END

TM101—150SG Series
SKURKA AEROSPACE INC. -- PROPRIETARY INFORMATION Page 4-15
Subject to the restrictions on the first page Rev. 14
December 09, 2009
 Skurka Aerospace Inc.
4600 Calle Bolero; P. O. Box 2869
Camarillo, CA 93011

THIS PAGE INTENTIONALLY BLANK

TM101—150SG Series
Page 4-16 SKURKA AEROSPACE INC. -- PROPRIETARY INFORMATION
Rev. 14 Subject to the restrictions on the first page
December 09, 2009
 Skurka Aerospace Inc.
4600 Calle Bolero, P. O. Box 2869
Camarillo, CA 93011

SECTION V

MODEL DIFFERENCE DATA SHEET INDEX

The instructions contained in the preceding sections of this manual apply to the following
additional models.

150SG114Q ................................................................... 5-2

150SG115Q ................................................................... 5-3

150SG116Q ................................................................... 5-4

150SG117Q ................................................................... 5-5

150SG118Q ................................................................... 5-6

150SG119Q ................................................................... 5-7

150SG120Q ................................................................... 5-8

150SG121Q ................................................................... 5-9

150SG122Q ................................................................. 5-11

150SG123Q ................................................................. 5-12

150SG124Q ................................................................. 5-13

150SG125Q ................................................................. 5-15

150SG144Q ................................................................. 5-16

150SG125Q-2.............................................................. 5-17

150SG117Q-3.............................................................. 5-18

150SG117Q-4.............................................................. 5-19

TM101—150SG Series
SKURKA AEROSPACE INC. -- PROPRIETARY INFORMATION Page 5-1
Subject to the restrictions on the first page Rev. 14
December 09, 2009
 Skurka Aerospace Inc.
4600 Calle Bolero; P. O. Box 2869
Camarillo, CA 93011

DIFFERENCE DATA SHEETS

STARTER-GENERATOR 150SG114Q

The basic parts differences between Models 150SG111Q and 150SG114Q is the QAD
Mounting Flange and Drive Shaft.

DESCRIPTION AND OPERATION Same as for Model 150SG111Q

DISASSEMBLY AND ASSEMBLY Same as for Model 150SG111Q

REPAIR & REPLACEMENT Same as for Model 150SG111Q

TESTING Same as for Model 150SG111Q

ILLUSTRATED PARTS LIST Same as for Model 150SG111Q

except variations as noted by
Usage Code Symbols

TM101—150SG Series
Page 5-2 SKURKA AEROSPACE INC. -- PROPRIETARY INFORMATION
Rev. 14 Subject to the restrictions on the first page
December 09, 2009
 Skurka Aerospace Inc.
4600 Calle Bolero, P. O. Box 2869
Camarillo, CA 93011

DIFFERENCE DATA SHEETS

STARTER-GENERATOR 150SG115Q

The basic parts differences between Models 150SG111Q and 150SG115Q is the QAD
Mounting Flange and Drive Shaft. The drive drive shaft and QAD housing are designed
for mounting on an engine with a MS333-1 mounting flange.

To convert a 150SG115Q Starter Generator (Only when required by Schweizer Aircraft

Corp.) into a Model 150SG117Q, request Service Bulletin 19-SB150SG122

DESCRIPTION AND OPERATION Same as for Model 150SG111Q

DISASSEMBLY AND ASSEMBLY Same as for Model 150SG111Q

REPAIR & REPLACEMENT Same as for Model 150SG111Q

TESTING Same as for Model 150SG111Q

ILLUSTRATED PARTS LIST Same as for Model 150SG111Q

except variations as noted by
Usage Code Symbols

TM101—150SG Series
SKURKA AEROSPACE INC. -- PROPRIETARY INFORMATION Page 5-3
Subject to the restrictions on the first page Rev. 14
December 09, 2009
 Skurka Aerospace Inc.
4600 Calle Bolero; P. O. Box 2869
Camarillo, CA 93011

DIFFERENCE DATA SHEETS

STARTER-GENERATOR 150SG116Q

The basic parts differences between Models 150SG111Q and 150SG116Q is the Stator,
Drive Shaft and QAD Mounting Flange. The stator gives the generator different starting
speed characteristics. The drive shaft and QAD housing are designed for mounting on an
engine with a MS3331-1 mounting flange.

To convert a 150SG116Q Starter Generator into a Model 150SG123Q Wet Spline

Generator or a 150SG118Q Dry Spline Generator (Used on Bell 206B or 206L
Helicopters), request Service Bulletin SB150SG104

DESCRIPTION AND OPERATION Same as for Model 150SG111Q

DISASSEMBLY AND ASSEMBLY Same as for Model 150SG111Q

REPAIR & REPLACEMENT Same as for Model 150SG111Q

TESTING Same as for Model 150SG111Q

ILLUSTRATED PARTS LIST Same as for Model 150SG111Q

except variations as noted by
Usage Code Symbols

TM101—150SG Series
Page 5-4 SKURKA AEROSPACE INC. -- PROPRIETARY INFORMATION
Rev. 14 Subject to the restrictions on the first page
December 09, 2009
 Skurka Aerospace Inc.
4600 Calle Bolero, P. O. Box 2869
Camarillo, CA 93011

DIFFERENCE DATA SHEETS

STARTER-GENERATOR 150SG117Q

The basic parts differences between Models 150SG111Q and 150SG117Q is the Drive
Shaft which is suited for use with an engine with a wet spline.

To convert a 150SG111Q Starter Generator into a Model 150SG117Q Wet Spline

Generator, request Service Bulletin SB150SG102

DESCRIPTION AND OPERATION Same as for Model 150SG111Q

DISASSEMBLY AND ASSEMBLY Same as for Model 150SG111Q

REPAIR & REPLACEMENT Same as for Model 150SG111Q

TESTING Same as for Model 150SG111Q

ILLUSTRATED PARTS LIST Same as for Model 150SG111Q

except variations as noted by
Usage Code Symbols

TM101—150SG Series
SKURKA AEROSPACE INC. -- PROPRIETARY INFORMATION Page 5-5
Subject to the restrictions on the first page Rev. 14
December 09, 2009
 Skurka Aerospace Inc.
4600 Calle Bolero; P. O. Box 2869
Camarillo, CA 93011

DIFFERENCE DATA SHEETS

STARTER-GENERATOR 150SG118Q

The basic parts differences between Models 150SG111Q and 150SG118Q is the Stator.
The stator gives the generator different starting speed characteristics.

To convert a 150SG118Q Starter Generator into a Model 150SG123Q Wet Spline

Generator, request Service Bulletin SB150SG101

DESCRIPTION AND OPERATION Same as for Model 150SG111Q

DISASSEMBLY AND ASSEMBLY Same as for Model 150SG111Q

REPAIR & REPLACEMENT Same as for Model 150SG111Q

TESTING Same as for Model 150SG111Q

ILLUSTRATED PARTS LIST Same as for Model 150SG111Q

except variations as noted by
Usage Code Symbols

TM101—150SG Series
Page 5-6 SKURKA AEROSPACE INC. -- PROPRIETARY INFORMATION
Rev. 14 Subject to the restrictions on the first page
December 09, 2009
 Skurka Aerospace Inc.
4600 Calle Bolero, P. O. Box 2869
Camarillo, CA 93011

DIFFERENCE DATA SHEETS

STARTER-GENERATOR 150SG119Q

The basic parts differences between Models 150SG111Q and 150SG119Q is the QAD
Mounting Flange and Drive Shaft.

DESCRIPTION AND OPERATION Same as for Model 150SG111Q

DISASSEMBLY AND ASSEMBLY Same as for Model 150SG111Q

REPAIR & REPLACEMENT Same as for Model 150SG111Q

TESTING Same as for Model 150SG111Q

ILLUSTRATED PARTS LIST Same as for Model 150SG111Q

except variations as noted by
Usage Code Symbols

TM101—150SG Series
SKURKA AEROSPACE INC. -- PROPRIETARY INFORMATION Page 5-7
Subject to the restrictions on the first page Rev. 14
December 09, 2009
 Skurka Aerospace Inc.
4600 Calle Bolero; P. O. Box 2869
Camarillo, CA 93011

DIFFERENCE DATA SHEETS

STARTER-GENERATOR 150SG120Q

The basic parts differences between Models 150SG111Q and 150SG120Q is the QAD
Mounting Flange and Drive Shaft.

DESCRIPTION AND OPERATION Same as for Model 150SG111Q

DISASSEMBLY AND ASSEMBLY Same as for Model 150SG111Q

REPAIR & REPLACEMENT Same as for Model 150SG111Q

TESTING Same as for Model 150SG111Q

ILLUSTRATED PARTS LIST Same as for Model 150SG111Q

except variations as noted by
Usage Code Symbols

TM101—150SG Series
Page 5-8 SKURKA AEROSPACE INC. -- PROPRIETARY INFORMATION
Rev. 14 Subject to the restrictions on the first page
December 09, 2009
 Skurka Aerospace Inc.
4600 Calle Bolero, P. O. Box 2869
Camarillo, CA 93011

DIFFERENCE DATA SHEETS

STARTER-GENERATOR 150SG121Q

The basic parts differences between Models 150SG111Q and 150SG121Q is the QAD
Mounting Flange, Drive Shaft, Drive End Bell, Stator, Commutator End Bell, Armature,
Fan, Fan Cover, Brushes and Brush Springs.

DESCRIPTION AND OPERATION Same as for Model 150SG111Q

DISASSEMBLY AND ASSEMBLY Same as for Model 150SG111Q

REPAIR & REPLACEMENT Same as for Model 150SG111Q

Except positioning of Brush Leads
(See Fig. 5-1)

TESTING Same as for Model 150SG111Q

ILLUSTRATED PARTS LIST Same as for Model 150SG111Q

except variations as noted by
Usage Code Symbols

TM101—150SG Series
SKURKA AEROSPACE INC. -- PROPRIETARY INFORMATION Page 5-9
Subject to the restrictions on the first page Rev. 14
December 09, 2009
 Skurka Aerospace Inc.
4600 Calle Bolero; P. O. Box 2869
Camarillo, CA 93011

FIGURE 5-1 Positioning of Brush Leads

(Model 150SG121Q)

TM101—150SG Series
Page 5-10 SKURKA AEROSPACE INC. -- PROPRIETARY INFORMATION
Rev. 14 Subject to the restrictions on the first page
December 09, 2009
 Skurka Aerospace Inc.
4600 Calle Bolero, P. O. Box 2869
Camarillo, CA 93011

DIFFERENCE DATA SHEETS

STARTER-GENERATOR 150SG122Q

The basic parts differences between Models 150SG111Q and 150SG122Q is the QAD
Mounting Flange, Drive End Bell, Drive Shaft,

DESCRIPTION AND OPERATION Same as for Model 150SG111Q

DISASSEMBLY AND ASSEMBLY Same as for Model 150SG111Q

REPAIR & REPLACEMENT Same as for Model 150SG111Q

TESTING Same as for Model 150SG111Q

ILLUSTRATED PARTS LIST Same as for Model 150SG111Q

except variations as noted by
Usage Code Symbols

TM101—150SG Series
SKURKA AEROSPACE INC. -- PROPRIETARY INFORMATION Page 5-11
Subject to the restrictions on the first page Rev. 14
December 09, 2009
 Skurka Aerospace Inc.
4600 Calle Bolero; P. O. Box 2869
Camarillo, CA 93011

DIFFERENCE DATA SHEETS

STARTER-GENERATOR 150SG123Q

The basic parts differences between Models 150SG111Q and 150SG123Q is the Stator
and Drive Shaft. The Stator gives the generator different starting speed characteristics.
The drive shaft is designed for mounting on an engine with a wet (lubricated) spline.

DESCRIPTION AND OPERATION Same as for Model 150SG111Q

DISASSEMBLY AND ASSEMBLY Same as for Model 150SG111Q

REPAIR & REPLACEMENT Same as for Model 150SG111Q

TESTING Same as for Model 150SG111Q

ILLUSTRATED PARTS LIST Same as for Model 150SG111Q

except variations as noted by
Usage Code Symbols

TM101—150SG Series
Page 5-12 SKURKA AEROSPACE INC. -- PROPRIETARY INFORMATION
Rev. 14 Subject to the restrictions on the first page
December 09, 2009
 Skurka Aerospace Inc.
4600 Calle Bolero, P. O. Box 2869
Camarillo, CA 93011

DIFFERENCE DATA SHEETS

STARTER-GENERATOR 150SG124Q

The basic parts differences between Models 150SG111Q and 150SG124Q is the QAD
Mounting Flange, Drive Shaft, Drive End Bell, Stator, Commutator End Bell, Armature,
Fan, Fan Cover, Brushes and Brush Springs.

DESCRIPTION AND OPERATION Same as for Model 150SG111Q

DISASSEMBLY AND ASSEMBLY Same as for Model 150SG111Q

REPAIR & REPLACEMENT Same as for Model 150SG111Q

Except positioning of Brush Leads
(See Fig. 5-2)

TESTING Same as for Model 150SG111Q

ILLUSTRATED PARTS LIST Same as for Model 150SG111Q

except variations as noted by
Usage Code Symbols

TM101—150SG Series
SKURKA AEROSPACE INC. -- PROPRIETARY INFORMATION Page 5-13
Subject to the restrictions on the first page Rev. 14
December 09, 2009
 Skurka Aerospace Inc.
4600 Calle Bolero; P. O. Box 2869
Camarillo, CA 93011

FIGURE 5-2 Positioning of Brush Leads

(Model 150SG124Q)

TM101—150SG Series
Page 5-14 SKURKA AEROSPACE INC. -- PROPRIETARY INFORMATION
Rev. 14 Subject to the restrictions on the first page
December 09, 2009
 Skurka Aerospace Inc.
4600 Calle Bolero, P. O. Box 2869
Camarillo, CA 93011

DIFFERENCE DATA SHEETS

STARTER-GENERATOR 150SG125Q

The basic parts differences between Models 150SG111Q and 150SG125Q is the Stator.
The stator gives the generator different starting speed characteristics.

DESCRIPTION AND OPERATION Same as for Model 150SG111Q

DISASSEMBLY AND ASSEMBLY Same as for Model 150SG111Q

REPAIR & REPLACEMENT Same as for Model 150SG111Q

TESTING Same as for Model 150SG111Q

ILLUSTRATED PARTS LIST Same as for Model 150SG111Q

except variations as noted by
Usage Code Symbols

TM101—150SG Series
SKURKA AEROSPACE INC. -- PROPRIETARY INFORMATION Page 5-15
Subject to the restrictions on the first page Rev. 14
December 09, 2009
 Skurka Aerospace Inc.
4600 Calle Bolero; P. O. Box 2869
Camarillo, CA 93011

DIFFERENCE DATA SHEETS

STARTER-GENERATOR 150SG144Q

The basic parts differences between Models 150SG111Q and 150SG144Q is the Stator,
Drive Shaft and Fan Cover

DESCRIPTION AND OPERATION Same as for Model 150SG111Q

DISASSEMBLY AND ASSEMBLY Same as for Model 150SG111Q

REPAIR & REPLACEMENT Same as for Model 150SG111Q

TESTING Same as for Model 150SG111Q

ILLUSTRATED PARTS LIST Same as for Model 150SG111Q

except variations as noted by
Usage Code Symbols

TM101—150SG Series
Page 5-16 SKURKA AEROSPACE INC. -- PROPRIETARY INFORMATION
Rev. 14 Subject to the restrictions on the first page
December 09, 2009
 Skurka Aerospace Inc.
4600 Calle Bolero, P. O. Box 2869
Camarillo, CA 93011

DIFFERENCE DATA SHEETS

STARTER-GENERATOR 150SG125Q-2

The basic parts differences between Models 150SG125Q and 150SG125Q-2 is the Drive
Shaft. The 150SG125Q-2 is a Wet Spline configuration.

DESCRIPTION AND OPERATION Same as for Model 150SG111Q

DISASSEMBLY AND ASSEMBLY Same as for Model 150SG111Q

REPAIR & REPLACEMENT Same as for Model 150SG111Q

TESTING Same as for Model 150SG111Q

ILLUSTRATED PARTS LIST Same as for Model 150SG111Q

except variations as noted by
Usage Code Symbols

TM101—150SG Series
SKURKA AEROSPACE INC. -- PROPRIETARY INFORMATION Page 5-17
Subject to the restrictions on the first page Rev. 14
December 09, 2009
 Skurka Aerospace Inc.
4600 Calle Bolero; P. O. Box 2869
Camarillo, CA 93011

DIFFERENCE DATA SHEETS

STARTER-GENERATOR MODEL: 150SGL117Q-3

The basic parts differences between Models 150SG111Q and 150SG117Q-3 is the Drive Shaft
Assy and O-Ring , which is suited for use with an engine with a wet spline.

To convert a 150SG111Q Starter Generator into a Model 150SG117Q-3 Wet Spline Generator,
request Service Bulletin SB150SG102.

DESCRIPTION AND OPERATION: Same as for Model 150SG111Q

DISASSEMBLY & ASSEMBLY: Same as for Model 150SG111Q

CLEANING: Same as for Model 150SG111Q

INSPECTION: Same as for Model 150SG111Q

REPAIR: Same as for Model 150SG111Q

FITS AND CLEARANCES: Same as for Model 150SG111Q

TESTING: Same as for Model 150SG111Q

TROUBLESHOOTING: Same as for Model 150SG111Q

SPECIAL TOOLS, FIXTURES & EQUIPMENT: Same as for Model 150SG111Q

ILLUSTRATED PARTS LIST: Same as for Model 150SG111Q

Except the 150SG117Q-3 uses the
following parts:

Drive Shaft Assy: 150SG1103-2

O-ring M83248/1-113
Bearings: 150SG1052-1

TM101—150SG Series
Page 5-18 SKURKA AEROSPACE INC. -- PROPRIETARY INFORMATION
Rev. 14 Subject to the restrictions on the first page
December 09, 2009
 Skurka Aerospace Inc.
4600 Calle Bolero, P. O. Box 2869
Camarillo, CA 93011

DIFFERENCE DATA SHEETS

STARTER-GENERATOR MODEL: 150SGL117Q-4

The basic parts differences between Models 150SG111Q and 150SG117Q-4 is the Drive Shaft
Assy, O-Ring, which is suited for use with an engine with a wet spline, Bearings and Fan Cover.

To convert a 150SG111Q Starter Generator into a Model 150SG117Q-4 Wet Spline Generator,
request Service Bulletin SB150SG102.

DESCRIPTION AND OPERATION: Same as for Model 150SG111Q

DISASSEMBLY & ASSEMBLY: Same as for Model 150SG111Q

CLEANING: Same as for Model 150SG111Q

INSPECTION: Same as for Model 150SG111Q

REPAIR: Same as for Model 150SG111Q

FITS AND CLEARANCES: Same as for Model 150SG111Q

TESTING: Same as for Model 150SG111Q

TROUBLESHOOTING: Same as for Model 150SG111Q

SPECIAL TOOLS, FIXTURES & EQUIPMENT: Same as for Model 150SG111Q

ILLUSTRATED PARTS LIST: Same as for Model 150SG111Q

Except the 150SG117Q-4 uses the
following parts:

Drive Shaft Assy: 150SG1103-2

O-ring M83248/1-113
Bearings: 150SG1052-1
Fan Cover: 150SG1011-4

TM101—150SG Series
SKURKA AEROSPACE INC. -- PROPRIETARY INFORMATION Page 5-19
Subject to the restrictions on the first page Rev. 14
December 09, 2009
 Skurka Aerospace Inc.
4600 Calle Bolero; P. O. Box 2869
Camarillo, CA 93011

THIS PAGE INTENTIONALLY BLANK

TM101—150SG Series
Page 5-20 SKURKA AEROSPACE INC. -- PROPRIETARY INFORMATION
Rev. 14 Subject to the restrictions on the first page
December 09, 2009
 Skurka Aerospace Inc.
4600 Calle Bolero, P. O. Box 2869
Camarillo, CA 93011

MAINTENANCE INSTRUCTIONS

ADDENDUM TO STARTER-GENERATOR

150SG SERIES -- TM101

FOR

150SG “XL” SERIES STARTER-GENERATORS

TM101—150SG Series
SKURKA AEROSPACE INC. -- PROPRIETARY INFORMATION Page 6-1
Subject to the restrictions on the first page Rev. 14
December 09, 2009
 Skurka Aerospace Inc.
4600 Calle Bolero; P. O. Box 2869
Camarillo, CA 93011

PREFACE

SKURKA AEROSPACE INC. (SAI) “XL” SERIES STARTER-GENERATORS REQUIRE THE

LISTED MAINTENANCE CHANGES FROM THE STANDARD OVERHAUL MANUAL.
THESE CHANGES ARE OUTLINED ON THE FOLLOWING PAGES.

SAI “XL” SERIES STARTER-GENERATORS ARE CAPABLE OF VERY

LONG ARMATURE AND COMMUTATOR LIFE, THE MAINTENANCE RULES OUTLINED IN
THE FOLLOWING PAGES SHOULD BE ADHERED TO.

SAI “XL” SERIES STARTER-GENERATORS ARE IDENTIFIED BY (-XL) IMMEDIATELY

FOLLOWING THE LAST DIGIT OF THE SERIAL NUMBER.

TM101—150SG Series
Page 6-2 SKURKA AEROSPACE INC. -- PROPRIETARY INFORMATION
Rev. 14 Subject to the restrictions on the first page
December 09, 2009
 Skurka Aerospace Inc.
4600 Calle Bolero, P. O. Box 2869
Camarillo, CA 93011

150SG “XL” SERIES STARTER-GENERATORS ARE TO BE MAINTAINED

ONLY BY SAI AUTHORIZED REPAIR STATIONS.

REFERENCE: OVERHAUL MANUAL TM-101,

150SG SERIES STARTER-GENERATORS

Page 2-1, Paragraph 2-5a

XL Series Generator

a. Based on the established brush life for the operator whose generator is being
serviced, and his Time Between Overhauls (TBO), the operator can amend this
paragraph to utilize the brushes for another operating period. If this is the case, the
brushes and brush holders should be marked so as to return the same brush to the
brush box it was removed from. This will reduce time to re-seat the brushes. Brush
life remaining can be calculated as per “Brush Life Calculation Procedure”. (See
additional service information list in back of manual)

Page 2-11, Paragraph 2-16

Armature Testing - XL Series Generator

a. If the XL Series armature shows a ground short at 300 volts AC after steam
cleaning or has a band short, that armature can be returned to Skurka Aerospace
Inc. for evaluation and possible repair at the customers’ cost.

Page 2-16 - 2-19, Paragraph 2-23

Resurfacing the Commutator

The commutator of an XL Series Starter-Generator must be resurfaced with specialized

commutator cutting equipment. Correct cutting will remove .002-.004” while holding .0002”
concentricity between the commutator and bearing journals. Minimum commutator diameter
is as stated on page 2-16, paragraph 2-23.

If approved commutator turning equipment is not available, the armature can be returned to
Skurka Aerospace Inc. for immediate turning at the customers expense.
TM101—150SG Series
SKURKA AEROSPACE INC. -- PROPRIETARY INFORMATION Page 6-3
Subject to the restrictions on the first page Rev. 14
December 09, 2009
 Skurka Aerospace Inc.
4600 Calle Bolero; P. O. Box 2869
Camarillo, CA 93011

Page 3-4 - 3-6, Paragraph 3-10

Brush Seating

Brush seating for XL Series can be accomplished under load as stated in Paragraph 3-10. Brush
seating by motorizing is also acceptable. When new brushes are installed, brush seating of “XL” Series
brushes may take longer as they are extremely slow to wear. See enclosed copy of SAI Service Bulletin
SB150SG105

FIG & UNITS

INDEX PART DESCRIPTION PER USAGE
NO NUMBER 1234567 ASSY CODE

4-2-11 150SG1009-20 . . BRUSH ‘XL’ SERIES 4 * See Below

CARBON GRADE AP128
MARKED ON BRUSH FACE

TO RECEIVE “XL” GENERATOR ARMATURE LIFE, THE SAI ARMATURE IS THE

ONLY ARMATURE THAT CAN BE USED IN AN “XL” SERIES GENERATOR

TO MODIFY A STANDARD UNIT INTO AN “XL” CONFIGURATION, PLEASE

REQUEST SERVICE BULLETIN 19-SB150SG127

* SAI -”XL” SERIES BRUSHES CAN ONLY BE INSTALLED IN AN “XL” SERIES

STARTER-GENERATOR. THEY ARE APPROVED FOR NO OTHER STARTER-
GENERATORS – SAI OR COMPETITIVE UNITS.
CHECK NAMEPLATE PRIOR TO INSTALLING “XL” SERIES BRUSHES. NAME
PLATE MUST BE IDENTIFIED WITH AN “XL” DESIGNATION AFTER SERIAL
NUMBER.

TM101—150SG Series
Page 6-4 SKURKA AEROSPACE INC. -- PROPRIETARY INFORMATION
Rev. 14 Subject to the restrictions on the first page
December 09, 2009
 Skurka Aerospace Inc.
4600 Calle Bolero, P. O. Box 2869
Camarillo, CA 93011

SECTION VII

APPENDIX I: SERVICE BULLETINS--Valid

Service Bulletin Number Description Latest Revision

Date
Brush Seating in High Speed
SB150SG105 Dec. 9, 2009
Starter-Generators…

Starter-Generator Removal
SB150SG114 Dec. 9, 2009
and Installation Procedures

Brush Seating in High Speed

Starter-Generators and Mid-
SB150SG124 Dec. 9, 2009
Life Brush Change
Information

Modification of 150SG and

SB150SG127-1 Dec. 9, 2009
160SG to “XL2” Configuration

Modification of 150SG117Q-
SB150SG139 Dec. 9, 2009
3-1 to 150SG117Q-4-1

Modification no Longer
Required on 150SG Series
SB150SG150 Dec. 9, 2009
Armatures when Using “XL”
Series Brushes

Omitted Information from

SB150SG151 Dec. 9, 2009
Nameplates

Assembly Checks of
SB150SG155 Dec. 9, 2009
150SG122Q

TM101—150SG Series
SKURKA AEROSPACE INC. -- PROPRIETARY INFORMATION Page 7-1
Subject to the restrictions on the first page Rev. 14
December 09, 2009
 Skurka Aerospace Inc.
4600 Calle Bolero, P.O. Box 2869
Camarillo, CA 93011

SERVICE BULLETIN NO.: SB150SG105

SUBJECT: Brush Seating SAI Brushes in High Speed (Approx. 12,000 RPM)
Starter-Generators and Application of SAI Brushes to SAI Generators

PURPOSE:

To describe a procedure to be utilized in replacing and seating new brushes in a serviceable

starter-generator. Brush seating is of extreme importance. If brushes are not seated prior to use,
severe arcing will occur during the starting mode of operation causing damage to the commutator
surface and accelerated brush wear.

PROCEDURE:

Brushes installed in newly overhauled starter-generators should have a commutator resurfaced by

turning the armature in a lathe to a very fine mirror finish using a diamond or newly honed carbide
turning tool. Refer to Overhaul Manual for details.

When installing new Skurka Aerospace Inc. designed brushes in a generator for the first time, it is
mandatory that the commutator be resurfaced as mentioned in the paragraph above. The best
brush life will always be obtained when resurfacing the commutator prior to installing brushes.
Imperfections in the commutator surface and movement of the commutator bars as a result of
generator usage over extended periods of time, accelerate brush wear. Do not use any abrasive
paper to sand the commutator as the sand particles may become embedded between the
commutator bars and cause accelerated brush wear.

Mount the generator securely on a bench in a horizontal position. Motorize the starter-generator by
connecting the positive lead of a DC supply to starter-generator terminal C+ for a series start or B+
and A for a shunt start. Connect the negative lead of the DC supply to starter-generator terminal
E-. Adjust the DC supply voltage to 15 volts. This will enable the machine to run at approximately
7000-9000 rpm for a series start, and 3000-6000 for a shunt start. The DC input amperes will be
approximately 20-40 amperes for 150-250 ampere generators and approximately 30-60 amperes
for 300-400 ampere generators.

To remove carbon accumulations, fan cover should be removed, exposing the brush area. A
portable blower or fan should be set to blow air across the brush area when the starter-generator is
running. This procedure will remove the carbon dust from the starter-generator as the brushes are
being seated.

An acceptable brush seat should indicate 85-100% brush contact in the direction of rotation and at
least 85% parallel to the armature shaft. Continue running the generator to achieve this seating, if
brush seating is unacceptable. Refer to Page 2 for typical brush seating. (This film does not
indicate brush run-in. See above paragraph).

Most SAI grades of brushes are instant filming types and during the procedure of brush seating, a
dark film will appear on the commutator surface. This film lowers brush friction and increases
brush life.

PAGE 1 of 2
SB150SG105 Revision C.
DEC 9, 2009
 Skurka Aerospace Inc.
4600 Calle Bolero, P.O. Box 2869
Camarillo, CA 93011

PAGE 2 of 2
SB150SG105 Revision C.
DEC 9, 2009
 Skurka Aerospace Inc.
4600 Calle Bolero, P.O. Box 2869
Camarillo, CA 93011

SERVICE BULLETIN NO.: SB150SG114

S UBJ ECT: S TARTER-GENERATOR REMOVAL a n d INS TALLATION

TO: All Airlin e s , Fixe d Ba s e Op e ra to rs a n d Airc ra ft Own e rs

MODELS AFFECTED: All S ta rte r-Ge n e ra to rs u s in g QAD Ho u s in g s

DIS CUS S ION:

Expanded procedures have been developed to remove or install the Starter-Generator in

conjunction with the procedures provided in current applicable maintenance manuals. These
procedures should be utilized each time the Starter-Generator is removed or installed to
assist in improving the service life of the Starter-Generator bearings, brushes and drive
shaft friction disc.

NOTE: Two mechanics are required to properly remove or install the Starter-Generator.

CAUTION

S lig h t m is a lig n m e n t a n d /o r b in d in g
o f th e S ta rte r-Ge n e ra to r d rive c a n
re d u c e th e u n it’s s e rvic e life .

1. Removal of Starter-Generator

a .One mechanic is to maintain the alignment of the Starter Generator by holding the
Starter-Generator in position by keeping the mounting surfaces flush with the Quick
Attach /Detach adapter (QAD pad), while the other mechanic loosens and removes the
‘V’ -band clamp.

b . Carefully remove the Starter-Generator from the QAD pad by maintaining the
spline’s alignment to prevent binding of the Starter-Generator drive.

PAge 1 of 2
SB150SG114 Revision C.
DEC 9/2009
 Skurka Aerospace Inc.
4600 Calle Bolero, P.O. Box 2869
Camarillo, CA 93011

2 .Prior to installing the Starter-Generator, verify the following:

a . There are no burrs or foreign objects on the Starter-Generator Shaft.

b . The Starter-Generator guide pins are clean and not bent or damaged.

c . The mounting surfaces of the Starter-Generator and the QAD pad are clean and
free of burrs.

d . Verify that the QAD pad is properly secured to the engine.

e . The QAD pad guide pin holes are free of burrs, foreign objects and in good
condition .

3 . Installation of the Starter-Generator

a . One mechanic is to gently align the Starter-Generator to the

QAD pad, being careful not to put the Starter-Generator drive spline
in a bind.

b . After the Starter-generator has been properly aligned, one mechanic should hold
the Starter-Generator in position by keeping the mounting surfaces flush with the
QAD pad while the other mechanic installs and secures the ‘V ’ -band clamp.

NOTE: Refer to the applicable aircraft

maintenance manual for proper torque,
safetying and other detailed removal and
installation instructions.

PAge 2 of 2
SB150SG114 Revision C.
DEC 9/2009
 Skurka Aerospace Inc.
4600 Calle Bolero, P.O. Box 2869
Camarillo, CA 93011

SERVICE BULLETIN NO.: SB150SG124

SUBJECT: BRUSH SEATING Skurka Aerospace Inc. (SAI)

BRUSHES IN HIGH SPEED (APPROX. 12,000 RPM)
STARTER-GENERATORS AND APPLICATION OF SAI
BRUSHES TO SAI GENERATORS DURING MID-LIFE
BRUSH CHANGE BETWEEN OVERHAULS

PURPOSE:

To describe a procedure to be utilized in replacing and seating new brushes in a serviceable

starter-generator. Brush seating is of extreme importance. If brushes are not seated prior to
use, severe arcing will occur during the starting mode of operation causing damage to the
commutator surface and accelerated wear. Replacement of brushes between starter-generator
overhauls may be accomplished if required.

PROCEDURE:

Install new SAI designed brushes in the generator. Do not use any abrasive paper to sand the
commutator as the sand particles may become embedded between the commutator bars and
cause accelerated brush wear.

Mount the generator securely on a bench in a horizontal position. Motorize the starter-generator
by connecting the positive lead of a DC supply to starter-generator terminal C+ for a series start
or B+ and A for a shunt start. Connect the negative lead of the DC supply to starter-generator
terminal E-. Adjust the DC supply voltage to 15 volts. This will enable the machine to run at
approximately 7000-9000 rpm for a series start, and 3000-6000 for a shunt start. The DC input
amperes will be approximately 20-40 amperes for 150-250 ampere generators and
approximately 30-60 amperes for 300-400 ampere generators.

To remove carbon accumulations, fan cover should be removed exposing the brush area. A
portable blower or fan should be set to blow air across the brush area when the starter-
generator is running. This procedure will remove the carbon dust from the starter-generator as
the brushes are being seated.

An acceptable brush seat should indicate 85-100% brush contact in the direction of rotation and
at least 85% parallel to the armature shaft. Continue running the generator to achieve seating,
if brush seating is unacceptable. Refer to Page 2 for typical brush seating.

Most SAI grades of brushes are instant filming types and, during the procedure of brush seating,
a dark film will appear on the commutator surface. This film lowers brush friction and increases
brush life.
(This film does not indicate brush run-in. See above paragraph.)

PAGE 1 of 2
SB150SG124 Revision C.
DEC 9, 2009
 Skurka Aerospace Inc.
4600 Calle Bolero, P.O. Box 2869
Camarillo, CA 93011

PAGE 2 of 2
SB150SG124 Revision C.
DEC 9, 2009
 Skurka Aerospace Inc.
4600 Calle Bolero, P.O. Box 2869
Camarillo, CA 93011

SERVICE BULLETIN NO.: SB150SG127-1

SUBJECT: MODIFICATION OF APC MODEL 150SG AND 160SG SERIES

STARTER-GENERATORS TO LONG LIFE “XL2”
CONFIGURATION

PURPOSE:

This modification is offered to operators of Skurka Aerospace Inc. (SAI) 150SG/160SG series
starter-generators who may require increased brush life and lower operating costs. The
modification consists of one time only internal inspection of the starter-generator and a change
of brushes and, if required, brush springs to SAI new Long Life “XL2” P/N
150SG1009-20XL2 and 150SG1005S respectively. This modification is performed a SAI
authorized facilities.

Approval to perform this modification by an SAI Authorized Repair Station, may be granted by
SAI, on a case by case basis.

REASON:

Some operators of SAI 150SG/160SG starter-generators may experience reduced brush life on
some aircraft installations. Brush life can be adversely affected by many variables, including
operating environment, duty cycle, starting requirements, chemical contamination, maintenance
procedures, etc. For those operators, SAI is offering this new “XL2” upgrade which may provide
substantial increase in brush life. In addition, armature commutator wear will be reduced when
installing the new brushes, P/N 150SG1009-20XL2 and brush springs P/N 150SG1005S.
Springs are optimized to operate in conjunction with the “XL2” brushes.

Provided the starter-generator is overhauled at and SAI Authorized Repair Station, SAI
guarantees minimum of 600 hours brush life for “XL2” series starter-generators. Many
operators may experience much higher brush life.

APPROVAL:

This Service Bulletin has the approval of Skurka Aerospace Inc.

AVAILABILITY:

The modification to “XL2” Long Life configuration is performed at SAI. For subsequent brush
maintenance and starter-generator overhauls, the operators may utilize their currently used
facilities, and pertinent Starter-Generator Maintenance Manual. SAI recommends maintaining
the “XL2” series starter-generators at one of SAI’s authorized Repair Stations.

PAGE 1 of 2
SB150SG127-1 Revision D.
DEC 9, 2009
 Skurka Aerospace Inc.
4600 Calle Bolero, P.O. Box 2869
Camarillo, CA 93011

Brush life will be guaranteed for starter-generator’s overhauled at an SAI approved Repair
Station.

Spring tension should be checked during overhauls according to procedures outlined in the
Maintenance Manual. Allowable spring tension range is 32-48 ounces.

IDENTIFICATION:

SAI “XL2” series starter-generators are identified by (-XL2) immediately following the last digit of
the serial number.

NOTE: 1. The rewinding of the armature, replacement of the

commutator, or rewinding of the stator in the “XL” series starter-
generator is not recommended and will void any warranty.

2. SAI 150SG1009-20XL2 brushes can only be installed in an “XL”

series starter-generator.
SAI 150SG1009-20XL2 brushes are not approved for any other
starter-generators – SAI or competitive units.

Incorrect installation will result in reduction of brush life, reduction of Starter-Generator

life and may result in unrepairable damage

Incorrect Installation Correct Installation

PAGE 2 of 2
SB150SG127-1 Revision D.
DEC 9, 2009
 Skurka Aerospace Inc.
4600 Calle Bolero; P.O Box 2869
Camarillo, CA 93011

Modification of Skurka Aerospace Inc. (SAI) Starter-Generator P/N 150SG117Q-3-1 to 150SG117Q-4-1.

1. SUMMARY

Current configuration fan cover provides insufficient cooling in one new aircraft application. This
new application will require a higher amperage limit and higher ambient temperature, thus the fan
cover change is needed. This bulletin provides authorization to upgrade starter generator.

2. PLANNING INFORMATION.

A. Effectivity.

This Service Bulletin applies to SAI Starter-Generator P/N 150SG117Q-3-1 serial numbers
10287XL2 and 10362XL2.

B. Reason.

(1) Problem:

Insufficient cooling of starter generator for the new environment definition.

(2) Cause:

Current configuration fan cover does not provide sufficient cooling in one new
aircraft application.

(3) Solution:

Upgrade starter generator to use enhanced fan cover.

C. Description.

This Service Bulletin provides instructions to upgrade Starter Generator P/N

150SG117Q-3-1 to 150SG117Q-4-1.

D. Compliance.

It is recommended that this Service Bulletin be performed when approved or required by

Enstrom Helicopters.

E. Approval.

This Service Bulletin has been shown to comply with the applicable Federal Aviation
Regulations and is FAA approved for the Starter Generator.

F. Man-hours Required.

No additional time required when doing overhaul.

PAge 1 of 2
SB150SG139 Revision A.
DEC 9/2009
 Skurka Aerospace Inc.
4600 Calle Bolero; P.O Box 2869
Camarillo, CA 93011

G. Weight and Balance.

Not affected.

H. Electrical Load Data.

Not Changed.

I. References.

TM101 150SG Series Starter-Generator Overhaul Manual

J. Other Publications Affected.

None.

K. Interchangeability.

Not Applicable.

3. ACCOMPLISHMENT INSTRUCTIONS

A. Disassembly Procedure.

(1) Remove four fan cover retainer screws.

CAUTION: DO NOT DISTURB BRUSH LEAD WHEN REMOVING FAN COVER.

(2) Carefully remove the fan cover.

B. Assembly Procedure.

CAUTION: DO NOT DISTURB BRUSH LEAD WHEN INSTALLING FAN COVER.

(1) Install fan cover part number 150SG1011-7 and secure with four retainer screws.

C. Re-identify Starter Generator.

(1) Metal stamp a line through ‘-3’ on the identification label.

(2) Metal stamp ‘-4’ on the label to indicate upgrade of starter generator 150SG117Q3-1 to
150SG117Q-4-1.

D. Test starter generator in accordance with TM101.

4. MATERIAL INFORMATION.

New P/N Qty Nomenclature Old P/N Disposition

150SG1011-7 1 Fan Cover 150SG1011-4 Replace

PAge 2 of 2
SB150SG139 Revision A.
DEC 9/2009
 Skurka Aerospace Inc.
4600 Calle Bolero, P.O. Box 2869
Camarillo, CA 93011

Modification no longer required for Skurka Aerospace Inc. (SAI) Starter-Generator

150SG Series Armatures when using SAI -”XL” Series Brushes.

1. SUMMARY
Due to product experience, it is no longer required that an “XL” Armature be
installed in 150SG Series Starter-generators that are approved for SAI -”XL”
Series Brushes. Armature part numbers designated for use in specific Starter-
generator part numbers may either be modified or not modified to the “XL”
Series.

2. PLANNING INFORMATION.

A. Applicability
This Service Bulletin applies to SAI 150SG Starter-Generator Series.

B. Reason
Product Usage Experience: Changes in 150SG Series Armature life have not
been experienced with or without Armature modification.

C. Description.
This Service Bulletin provides authorization to use applicable Armatures
that either have been or have not been Modified to “XL” Series.

D. Compliance.
It is recommended that this Service Bulletin be performed at overhaul.

E. Approval.
This Service Bulletin has been shown to comply with the applicable Federal
Aviation Regulations and is FAA approved for the Starter Generator.

F. Man-hours Required.
No additional time required when doing overhaul.

G. Weight and Balance.

Not affected.

PAGE 1 of 2
SB150SG150 Revision A.
DEC 9, 2009
 Skurka Aerospace Inc.
4600 Calle Bolero, P.O. Box 2869
Camarillo, CA 93011

H. Electrical Load Data.

Not Changed.

I. References.

TM101 150SG Series Starter-Generator Overhaul Manual

J. Other Publications Affected.

None.

K. Interchangeability.

150SG series starter generator series “non-XL” Armature is Form, Fit,

and Function interchangeable with the “XL” Armature.

150SG1064 = 150SG1064-XL
150SG1064-1 = 150SG1064-1-XL

3. ACCOMPLISHMENT INSTRUCTIONS

A. Disassembly Procedure.

Disassemble per TM101 150SG Series Starter-Generator Overhaul Manual.

B. Assembly Procedure.

Assemble per TM101 150SG Series Starter-Generator Overhaul Manual. Assembly includes
Armatures that either have been or have not been Modified to “XL” Series.

4. MATERIAL INFORMATION.

Not Applicable.

PAGE 2 of 2
SB150SG150 Revision A.
DEC 9, 2009
 Skurka Aerospace Inc.
4600 Calle Bolero, P.O. Box 2869
Camarillo, CA 93011

SERVICE BULLETIN NO.: SB150SG151

JP01230

Information omitted from nameplates on 150, 160, 250, 300, 400 SG and 200, 300 SGL Series Starter Generators.

1. SUMMARY

A number of starter generators were shipped with incomplete nameplate marking regarding RTCA
DO-160A environmental categories, mounting and/or power ratings. Supplemental nameplates which
specify the omitted information can be ordered from Skurka Aerospace Inc. (SAI).

2. PLANNING INFORMATION.

A. Applicability

This Service Bulletin applies to the following Skurka Aerospace Inc. Starter-Generators:

150SG Mo d els
150SG117Q-3 150SG130Q 150SG135Q 150SG144Q
150SG117Q-4 150SG133Q 150SG142Q

160SG Mo d els
160SG136Q 160SG139Q 160SG140Q 160SG142Q
160SG137Q 160SG139Q-2 160SG141Q

200SGL Mo d els
200SGL111Q-2 200SGL129Q(3) 200SGL132Q-3 200SGL147Q-2
200SGL111Q-3 200SGL129Q(4) 200SGL138Q 200SGL148Q
200SGL115Q-2 200SGL129Q(5) 200SGL140Q 200SGL149Q
200SGL119Q-2 200SGL130Q 200SGL141Q 200SGL149Q-2
200SGL121Q 200SGL130Q-2 200SGL142Q 200SGL150Q
200SGL124Q 200SGL131Q 200SGL143Q 200SGL151Q
200SGL126Q 200SGL131Q-2 200SGL144Q
200SGL129Q 200SGL132Q 200SGL145Q
200SGL129Q(1) 200SGL132Q-2 200SGL147Q

250SG Mo d els
250SG111Q-2 250SG122Q 250SG123Q-2 250SG127Q
250SG120Q 250SG123Q 250SG125Q

300SG Mo d els
300SG121Q 300SG125Q 300SG129Q 300SG141Q
300SG121Q-2 300SG127Q 300SG130Q-4

PAGE 1 of 4
SB150SG151 Revision A.
DEC 9, 2009
 Skurka Aerospace Inc.
4600 Calle Bolero, P.O. Box 2869
Camarillo, CA 93011

300SGL Mo d els
300SGL111Q-2 300SGL127Q-3 300SGL138Q-5 300SGL146Q
300SGL114Q 300SGL129Q 300SGL138Q-6 300SGL146Q-2
300SGL115Q 300SGL129Q-2 300SGL139Q 300SGL146Q-3
300SGL116Q 300SGL133Q 300SGL140Q 300SGL150Q
300SGL118Q 300SGL137Q 300SGL141Q 300SGL152Q
300SGL126Q 300SGL138Q 300SGL142Q 300SGL153Q
300SGL126Q-2 300SGL138Q-2 300SGL144Q 300SGL157Q
300SGL127Q-1 300SGL138Q-4 300SGL145Q 300SGL158Q

400SG Mo d els
400SG111Q-1 400SG129Q 400SG146Q 400SG165Q
400SG111Q-4 400SG134Q 400SG147Q 400SG166Q
400SG115Q 400SG135Q 400SG148Q 400SG168Q
400SG119Q 400SG137Q 400SG155Q 400SG173Q
400SG121Q 400SG139Q 400SG157Q 400SG176Q
400SG126Q 400SG142Q 400SG160Q
400SG127Q 400SG143Q-1 400SG162Q
400SG128Q 400SG143Q-4 400SG163Q-2

B. Reason

To bring starter generators into compliance with marking requirements per TSO-C56a/RTCA
DO-160A.

C. Description.

This Service Bulletin provides instructions on ordering supplemental nameplates and their
installation.

D. Compliance.

This Service Bulletin shall be accomplished at the next overhaul or service of the starter
generator, but may also be performed at any time the unit is accessible. It has no effect on product
performance or flight safety.

E. Approval.

This Service Bulletin has been shown to comply with the applicable Federal Aviation Regulations
and is FAA approved for the Starter Generator.

F. Man-hours Required.

Approximately 2 - 5 minutes.

G. Weight and Balance.

Not affected.

H. Electrical Load Data.

Not Changed.

PAGE 2 of 4
SB150SG151 Revision A.
DEC 9, 2009
 Skurka Aerospace Inc.
4600 Calle Bolero, P.O. Box 2869
Camarillo, CA 93011

I. References.

TM101 150SG Series Starter-Generator Overhaul Manual

TM102 160SG Series Starter-Generator Overhaul Manual
TM105A 200SGL Series Starter-Generator Overhaul Manual
TM107 250SG Series Starter-Generator Overhaul Manual
TM108 300SG Series Starter-Generator Overhaul Manual
TM109 300SGL Series Starter-Generator Overhaul Manual
TM110 400SG Series Starter-Generator Overhaul Manual
TM112 200SGL149Q Series Starter-Generator Overhaul Manual

J. Other Publications Affected.

None.

K. Interchangeability.

None.

3. ACCOMPLISHMENT INSTRUCTIONS

A. To order the appropriate supplemental nameplate for your starter generator, contact Skurka
Aerospace Inc, Customer Service Representative, at: (805) 484-8884.

Skurka Aerospace Inc.

4600 Calle Bolero
Camarillo, CA 93012
U.S.A.

B. Use isopropyl alcohol to clean the area on the starter generator adjacent to the original
nameplate where the supplemental nameplate will be placed. Affix supplemental nameplate to
the starter generator.

4. MATERIAL INFORMATION.

See Table 1 for a list of starter generator model numbers and corresponding nameplate part numbers.

Example: To order the correct label for the 150SG117Q-3 starter generator, order 150SG1092-29001.

PAGE 3 of 4
SB150SG151 Revision A.
DEC 9, 2009
 Skurka Aerospace Inc.
4600 Calle Bolero, P.O. Box 2869
Camarillo, CA 93011

PAGE 4 of 4
SB150SG151 Revision A.
DEC 9, 2009
 Skurka Aerospace Inc.
4600 Calle Bolero, P.O. Box 2869
Camarillo, CA 93011

SERVICE BULLETIN NO.: SB150SG155

JP01249

Assembly checks of Skurka Aerospace Inc. Starter-Generator P/N 150SG122Q.

1. SUMMARY

This Service Bulletin provides direction to properly assemble and tension the damping system on SAI
starter-generator 150SG122Q.

2. PLANNING INFORMATION.

A. Effectivity.

This Service Bulletin applies to Skurka Aerospace Inc. Starter-Generator P/N 150SG122Q.
This Service Bulletin is valid until requirements are incorporated in SAI CMM TM101.

B. Reason.

(1) Problem:

Improperly assembled and tensioned damping systems have been noted during field
inspection.

(2) Cause:

More clarity and detail to the damping assembly and tensioning is required to clarify
procedure and adjustment check.

(3) Solution:

A new adjustment procedure has been defined to provide consistency to SAI starter-
generator damping assembly.

C. Description.

This Service Bulletin provides direction to disassemble and assemble the damping system, replace
the Belleville springs and self-locking drive shaft nut, and properly adjust and check the damping
system.

D. Compliance.

S AI RENDERS COMP LIANCE WITH THIS S ERVICE BULLETIN, MANDATORY. WORK

SHALL BE ACCOMPLISHED BY 05-06-09 ON UNITS NOT IDENTIFIED “004” PER FIGURE
4 AND ANY S UBS EQUENT MAINTENANCE ACTIVITY INVOLVING DAMP ING
S YS TEM DIS AS S EMBLY.

PAGE 1 of 6
SB150SG155 Revision A.
DEC 9, 2009
 Skurka Aerospace Inc.
4600 Calle Bolero, P.O. Box 2869
Camarillo, CA 93011

E. Approval.

This Service Bulletin has been shown to comply with the applicable Federal Aviation
Regulations and is FAA approved for the 150SG122Q starter generator.

F. Man-hours Required.

(1) No additional time required when done at overhaul.

(2) 1 Mechanic / 0.5 hours at inspection.

G. Weight and Balance.

Not affected.

H. Electrical Load Data.

Not Changed.

I. References.

TM101 150SG Series Starter-Generator Overhaul Manual

J. Other Publications Affected.

None.

K. Interchangeability.

None.

3. ACCOMPLISHMENT INSTRUCTIONS

A. Disassembly Procedure.

(1) Remove fan cover.

(2) Lay down starter-generator in the horizontal position on a stable workbench.

Remove and discard drive shaft nut 150SG1071 and Belleville springs150SG1093.
Check fan assembly 150SG1107 for retainer spring 150SG1104. Replace if
missing.

B. Assembly Procedure.

(1) Install fan assembly 150SG1107 with new Belleville springs 150SG1093, retainer
spring 150SG1104 (if needed), and drive shaft nut 150SG1071. See Figure 1 for
correct orientation of Belleville springs.

(2) Make sure the shaft damping system is correctly aligned. See Figure 2.

PAGE 2 of 6
SB150SG155 Revision A.
DEC 9, 2009
 Skurka Aerospace Inc.
4600 Calle Bolero, P.O. Box 2869
Camarillo, CA 93011

PAGE 3 of 6
SB150SG155 Revision A.
DEC 9, 2009
 Skurka Aerospace Inc.
4600 Calle Bolero, P.O. Box 2869
Camarillo, CA 93011

PAGE 4 of 6
SB150SG155 Revision A.
DEC 9, 2009
 Skurka Aerospace Inc.
4600 Calle Bolero, P.O. Box 2869
Camarillo, CA 93011

(3) Use a fixed-type ratchet to tighten drive shaft nut so that it just contacts Belleville
springs.

(4) Using a support to avoid any stress on the shaft, put the starter-generator in the
vertical
position with the fan at the top.

(5) Hold the external part of the fan assembly and use a calibrated torque wrench to
tighten the drive shaft nut to 30 lb.in. (3.4 N.m.) maximum.

(6) Loosen drive shaft nut by one-half turn (180°).

(7) Tighten drive shaft nut by one-eighth turn (45°).

(8) Fit the fan cover and reinstall screws. Secure the fan cover.

(9) Check for radial movement of the splined shaft to verify the damping system is not in
a locked position. See Figure 3. If needed, realign the assembly as shown in
Figure 2.

NOTE: A locked damping system is indicated when disk “A” in Figure 2 cannot be
moved with respect to disk “B” when checking for radial movement

PAGE 5 of 6
SB150SG155 Revision A.
DEC 9, 2009
 Skurka Aerospace Inc.
4600 Calle Bolero, P.O. Box 2869
Camarillo, CA 93011

(10) Punch-mark “004” on the I.D. Plate in location shown in Figure 4, if not already
stamped.

4. MATERIAL INFORMATION

SAI P/N Qty Nomenclature

150SG1071 1 Drive Shaft Nut

150SG1093 2 Belleville Spring

150SG1104 1 Retainer Spring (if needed)

PAGE 6 of 6
SB150SG155 Revision A.
DEC 9, 2009
THIS PAGE INTENTIONALLY BLANK
 Skurka Aerospace Inc.
4600 Calle Bolero, P. O. Box 2869
Camarillo, CA 93011

SECTION VIII

APPENDIX I: SERVICE LETTERS--Valid

Service Letter Number Description Latest Revision

Date
Brush Life Calculation
Procedures for 150SG and
115 Dec. 9, 2009
160SG Series Starter-
Generators

134 Drive Shaft Alignment Dec. 9, 2009

170 P/N 150SG1005S-3 Spring Dec. 9, 2009

Difference Data Sheet for

209 Dec. 9, 2009
Model 150SG123Q-3

TM101—150SG Series
SKURKA AEROSPACE INC. -- PROPRIETARY INFORMATION Page 7-1
Subject to the restrictions on the first page Rev. 14
December 09, 2009
 Skurka Aerospace Inc.
4600 Calle Bolero; P.O Box 2869
Camarillo, CA 93011

SERVICE LETTER NO.: SL115

TO: ALL HOLDERS OF SKURKA AEROSPACE INC. (SAI) 150SG and 160SG
SERIES STARTER-GENERATORS

FROM: S. SHERMAN

SUBJECT: DATA WHICH WILL ALLOW YOU TO CALCULATE YOUR BRUSH LIFE
FOR YOUR SAI STARTER-GENERATORS

We have found that repeated brush inspections of Starter-Generators can result in rapid brush
wear and even hang-ups. When inspecting brushes, many operators will slide the brush cover
off the back of the generator causing the brush leads to be misplaced.

Sliding the cover forward again, further misplaces the brush leads. If the generator is mounted
on the engine while the inspection is being made, some brush boxes cannot be seen, making
brush lead positioning impossible.

Removing brushes from brush boxes can cause the brush position in the box and the
relationship to the commutator of the brush to be disturbed. The disturbed brush may wear
faster than normal.

One brush inspection between overhauls of the SAI generator is all that may be required of the
SAI brushes.

In essence, this procedure allows the operator to determine his time between brush changes
and may help fix the overhaul periods to be at the same time brushes must be replaced.

At 300 hours, remove the generator for brush inspection. Remove the shortest brush only to
measure the remaining brush life. Do not remove more than one brush, as brush seating will be
affected. Your brush inspection time will be obtained by measuring three different generators
and using the shortest brush length, as the basis for determining your fleet wide brush life.
Filling in the attached form, will show you how to determine remaining brush life. Using this
procedure will aid you in determining your Mean Time Between Overhauls (MTBO). The
generator must be overhauled at 1,000 hours, at which time the bearing must be replaced.

The SAI 150SG and 160SG ampere Starter-Generators can usually operate for a minimum of
500-800 hours without brush change. At 1,000 hours time, the generator must be removed for
overhaul and bearings changed, unless the SAI overhaul manual or aircraft manufacturer states
the bearings can be operated in excess of 1,000 hours.

Please note, this procedure can only be accomplished with a new generator or a generator that
has been overhauled in accordance with SAI Overhaul Procedures and the commutator has
been turned (resurfaced) in a lathe.

PAge 1 of 3
SL115 Revision B.
DEC 9, 2009
 Skurka Aerospace Inc.
4600 Calle Bolero; P.O Box 2869
Camarillo, CA 93011

GENERATOR SERIES 150SG/160SG SAMPLE CALCULATION PROCEDURE

At 300 hours, remove the generator for brush inspection. Remove the shortest brush only. Do
not remove more than one brush as brush seating will be affected.

SAMPLE CALCULATION
Date: 01/09/97

Generator P/N: 150SG111Q Serial No.: 1200

Calculate brush life left as per example below:

Maximum wear length of a new 150SG1009-5 Brush (1) .520

Brush wear left (as measured from shortest brush) (2) .300

TOTAL BRUSH WEAR (3) .220

Hours brush has operated: (4) 300

(3) .220 ÷ (4) 300 = (5) .0007 Rate of brush wear per hour
Total Brush Hours Brush
Wear (from #3 Operated (from
above) #4 above)
Hours of brush left before brushes must be
(2) .300 ÷ (5) .0007 = (6) 429 replaced
Brush Wear Left Rate of Brush
(from Item #2 Wear per Hour
above) (from Item #5
above)

Generator Operating Hours: 429 + 300 = 729

Hours Left Total Hours on Total Hours Generator
(from Item #6) Generator Thus Far Can Operate Before
(from Item #4) Brush Change

If 150 hours or more of brush life is left, reinstall the brush and operate the generator for the
remaining hours of brush wear left, as calculated above or for a maximum of 1,000 hours. At
that time, return the unit to an Authorized SAI Repair Station for overhaul.

New Brush Shortest Brush from Generator

Remove the generator the second time after the additional operating hours established by your
calculations has been reached. Inspect the brushes. If all are below the maximum brush wear
mark, the generator MTBO has been established. If you desire, two or three more generators
can be tested to establish an average brush life.

PAge 2 of 3
SL115 Revision B.
DEC 9, 2009
 Skurka Aerospace Inc.
4600 Calle Bolero; P.O Box 2869
Camarillo, CA 93011

GENERATOR SERIES 150SG/160SG SAMPLE CALCULATION PROCEDURE

At 300 hours, remove the generator for brush inspection. Remove the shortest brush only. Do
not remove more than one brush as brush seating will be affected.

Date:

Generator P/N: Serial No.:

Calculate brush life left as per example below:

Maximum wear length of a new 150SG1009-5 Brush (1) .520

Brush wear left (as measured from shortest brush) (2)

TOTAL BRUSH WEAR (3)

Hours brush has operated: (4)

(3) ÷ (4) = (5) Rate of brush wear per hour

Total Brush Hours Brush
Wear (from #3 Operated (from
above) #4 above)
Hours of brush left before brushes must be
(2) ÷ (5) = (6) replaced
Brush Wear Left Rate of Brush
(from Item #2 Wear per Hour
above) (from Item #5
above)

Generator Operating Hours: + =

Hours Left Total Hours on Total Hours Generator
(from Item #6) Generator Thus Far Can Operate Before
(from Item #4) Brush Change

If 150 hours or more of brush life is left, reinstall the brush and operate the generator for the
remaining hours of brush wear left, as calculated above or for a maximum of 1,000 hours. At
that time, return the unit to an Authorized APC Repair Station for overhaul.

New Brush Shortest Brush from Generator

Remove the generator the second time after the additional operating hours established by your
calculations has been reached. Inspect the brushes. If all are below the maximum brush wear
mark, the generator MTBO has been established. If you desire, two or three more generators
can be tested to establish an average brush life.

PAge 3 of 3
SL115 Revision B.
DEC 9, 2009
 Skurka Aerospace Inc.
4600 Calle Bolero; P.O Box 2869
Camarillo, CA 93011

SERVICE LETTER #134

ATTENTION: OPERATORS OF SKURKA AEROSPACE INC. (SAI)

STARTER-GENERATORS

SUBJECT: DRIVE SHAFT ALIGNMENT

The drive shaft must stay aligned with and concentric to the armature.

The drive shaft may be pushed off center and out of position due to mishandling during shipping
or installation. If the starter-generator is allowed to be installed with the drive shaft out of
position, excessive vibration and damage may develop during operation.

Therefore, before installation of the starter-generator on an engine, carefully inspect the drive
shaft and dampner plate assembly. See enclosed sketch. If the drive shaft appears to be out of
position, lightly tap on the drive shaft spline, using a plastic mallet to move it back into full
concentric position.

The starter-generator should be installed or removed in accordance with procedures as outlined

in Service Bulletin SB150SG114.

PAge 1 of 2
SL134 Revision B.
DEC 9, 2009
 Skurka Aerospace Inc.
4600 Calle Bolero; P.O Box 2869
Camarillo, CA 93011

PAge 2 of 2
SL134 Revision B.
DEC 9, 2009
 Skurka Aerospace Inc.
4600 Calle Bolero; P.O Box 2869
Camarillo, CA 93011

SERVICE LETTER #170

ATTENTION: ALL HOLDERS OF SKURKA AEROSPACE INC. OVERHAUL

MANUALS TM101 150SG SERIES STARTER-GENERATORS
AND TM102 160SG SERIES STARTER-GENERATORS

SUBJECT: PART NUMBER: 150SG1005S SPRING

REFERENCE: SECTION IV ILLUSTRATED PARTS BREAKDOWN

FIGURE 4-2, INDEX NUMBER 2

Part number *150SG1005S SPRING, Supersedes 150SG1005, 150SG1005S-3 as

indicated in Section IV, Illustrated Parts Breakdown Figure 4-2, Index No. 2, should be
part number *150SG1005S SPRING Supersedes 150SG1005 , 150SG1005S-3).

On bottom of the page revised the following note:

From: *Do not mix with 150SG1005 & 150SG1005S Springs (Install Full set of 8)
TO: *Do not mix with 150SG1005 & 150SG1005S-3 Springs (Install Full set of 8)

Please update your current copy of TM101 and TM102 Overhaul Manuals with this
Service Letter.

This correction will be included in the next revision issued of the TM101 Overhaul
Manual for 150SG Starter-Generators and TM102 Overhaul Manual for 160SG Starter-
Generators.

PAge 1 of 1
SL170 Revision A.
DEC 9, 2009
 Skurka Aerospace Inc.
4600 Calle Bolero; P.O Box 2869
Camarillo, CA 93011

ATTENTION: ALL HOLDERS OF OVERHAUL MANUAL TM101

SUBJECT: SERVICE LETTER # 209

STARTER-GENERATOR MODEL 150SG123Q-3

DIFFERENCE DATA SHEET

REFERENCE: SECTION V DIFFERENCE DATA SHEETS

Please update Section V Difference Data Sheet with the enclosed Difference Data
Sheet for starter-generator Model 150SG123Q-3.

This Service Letter includes an Acceptance Test Data Sheet for this model.

This update and starter-generator Model 150SG123Q-3 will be included in the next
revision issued of TM101 Overhaul Manual.

PAge 1 of 4
SL209 Revision A.
DEC 9, 2009
 Skurka Aerospace Inc.
4600 Calle Bolero; P.O Box 2869
Camarillo, CA 93011

SERVICE LETTER # 209

DIFFERENCE DATA SHEET

STARTER-GENERATOR MODEL: 150SG123Q-3

The basic parts differences between Models 150SG123Q and 150SG123Q-3 are the
Brush Holder Assembly, Fan Cover, Drive Shaft Assembly, Brush & Spring Holder
Assembly, Comm Head Assembly, Bearing, Mount Head, Brushes and Nameplate.

DESCRIPTION AND OPERATION: Same as for Model 150SG123Q.

DISASSEMBLY AND ASSEMBLY: Same as for Model 150SG123Q

CLEANING: Same as for Model 150SG123Q.

INSPECTION: Same as for Model 150SG123Q.

REPAIR: Same as for Model 150SG123Q.

FITS AND CLEARANCES: Same as for Model 150SG123Q.

TESTING: Use Acceptance Test Data Sheet

as provided in this Service Letter.

TROUBLESHOOTING: Same as for Model 150SG123Q.

SPECIAL TOOLS, FIXTURES Same as for Model 150SG123Q.

ILLUSTRATED PARTS LIST: Same as for Model 150SG123Q

Except 150SG123Q-3 uses the following
parts:
(1) Mounting Head – 150SG1028-7
(2) Bearing - 150SG1052-1
(3) Comm Head Assy – 150SG1153-5
(4) Holder Assy, Brush and Spring – 150SG1138-2
(5) Brush holder Assy – 150SG1154-6
(6) Brush – 150SG1009-20XL2
(7) Fan Cover – 200SGL1011-17
(8) Drive Shaft Assy, Wet– 150SG1103-23
(9) Nameplate – 150SG1092-27

PAge 2 of 4
SL209 Revision A.
DEC 9, 2009
 Skurka Aerospace Inc.
4600 Calle Bolero; P.O Box 2869
Camarillo, CA 93011

MODEL 150SG123Q-3 ACCEPTANCE TEST DATA SHEET

Repair Station Name____________________
Repair Station Number________________

Address____________________ Tested per TM101

____________________ Rev___________
Rev Date_______
TEST OUTPUTS
INSPECTION / TEST ACC REJ
PARAGRAPH REQUISITES MEASUREMENT

3.10 100% Seating all Brushes (See Fig. 3-2) X X

BRUSH SEATING
MAX. SPEED FOR REGULATION 12,500 + 0 / -100 RPM Shunt Field Current (A+) .81 amps
3.13 Amps
No Load, 28.5 ± 0.1 VDC minimum

MIN. SPEED FOR REGULATION 8,100 +100 / -0 RPM, Field Current (A+ within 10.0 amps) Amps
3.14A 28.5 ± 0.1 VDC 140 ± 5 Amp
External field res 35.00 Ω Max Ohms

D – E Voltage (See Fig. 3-3) VDC

Stabilized Temp. (gen. yoke) (See Fig.

Continuous Operating Speed and Equalizing Voltage °F
3-3)
12,100 +/- 100 RPM, 150 +/- 5 Amp 28.5 +/- 0.1 VDC
3-14B,C
Air in Temp. °F
Paralleling Voltage (Equalizing)
Temp. rise (Yoke-air in) 175°F
°F
Maximum
External field res 35.00 Ω Max Ohms

Voltmeter readout (A+ to B+) VDC

Minimum Speed
3.14D 7,200 +100 /-0 RPM, Ammeter Readout (A+) Amps
125 +/- 5 Amp, 26 +/- 0.1 VDC

Exterior Field Resistance--0.5 Ω Min. Ohms

8700 + 100/-0 RPM Not to exceed pinpoints, Field Current

X X
Compounding
Commutation

0,37, 75,112,150 (+/- 5) Amps rises with load

28.5 +/- 0.1

10000 + 100/-0 RPM Not to exceed pinpoints, Field Current

VDC
and

3.15 X X
0,37, 75,112,150 (+/- 5) Amps rises with load
12,100 + 100/-0 RPM Not to exceed pinpoints, Field Current
X X
0,37, 75,112,150 (+/- 5) Amps rises with load
Overspeed 5 minutes
No sign of Failure X X
14,000 +/- 100 RPM
3-16
Post Overspeed for 1 minute
No sign of Failure X X
12,100 +/- 100 RPM, 30 +/- 0.1 VDC, 150 +/- 5 Amps
Dielectric Strength
3.17 250 +/- 10 VAC, RMS, 1.0 sec No sign of Failure X X
Perform while unit is hot

PAge 3 of 4
SL209 Revision A.
DEC 9, 2009
 Skurka Aerospace Inc.
4600 Calle Bolero; P.O Box 2869
Camarillo, CA 93011

MODEL 150SG123Q-3 ACCEPTANCE TEST DATA SHEET

Continued
Repair Station Name____________________
Repair Station Number________________

Address____________________ Tested per TM101

____________________ Rev___________
Rev Date_______

OUTPUTS
TEST PARAGRAPH INSPECTION / TESTS ACC. REJ.
REQUISITES MEASUREMENT

Peak Current (725 amps max.) Amps

Cranking Torque and Speed

3.18 at 28.5 +/- 0.1 VDC Supply
Voltage
0 to 6500 +/- 100 RPM 60 seconds. Sec.

3-19 Commutator Film Black Film Visually Evident X X

Bar-To-Bar (0.0002 in. max.) Inch

3-20 COMMUTATOR RUNOUT
TIR (0.0005 in. max.) Inch

RADIAL VIBRATION
3-21 Velocity 0.2 IPS Peak (max) at just below terminal block.
9200 ±100 RPM IPS

TESTED & INSPECTED BY ATP TECHNICIAN:

NAME: SIGNATURE: DATE:

PAge 4 of 4
SL209 Revision A.
DEC 9, 2009
 Skurka Aerospace Inc.
4600 Calle Bolero, P. O. Box 2869
Camarillo, CA 93011

TECHNICAL DOCUMENTATION SUGGESTION FORM

Suggested Additions(s), deletions(s), or corrections(s):

Pleases attach a copy of each affected page Submittal Date:____________

Company/Organization Name/Title

Full Address: Telephone:

Fax:

Please send completed Form to the attention of “Sales— Skurka Aerospace Inc.
Product Line Manager”, at: 4600 Calle Bolero
P. O. Box 2869
Camarillo, CA 93011