PILATUS AIRCRAFT LTD.

CH-6371 STANS, SWITZERLAND

SERVICE LETTER
SUBJECT: GOODRICH POWER SYSTEMS DC STARTER/GENERATOR SERVICE BULLETINS 23085-
025-24-1 AND 23085-024-24-01

To all Customers, Operators and Service Centers: Date: Sep 08/08

Electrical Power - DC Starter/Generator Drive Shaft Isolation Model 23085-025 - SB 23085-025-24-01

Electrical Power - DC Starter/Generator Drive Shaft Isolation Model 23085-024 - SB 23085-024-24-01

This Service Letter is issued to draw attention to the Goodrich Power Systems Service Bulletins above.

The Vendor Service Bulletins give instructions for the modification of Starter/Generator Model Numbers
23085-024 (Pilatus P/N 978.91.23.422) and 23085-025 (Pilatus P/N 978.91.23.433) to give an isolated drive
shaft, which eliminates Electrical Discharge Damage (EDD). In addition, new bearings are installed as part of
the modification to enhance bearing performance. Embodiment of Goodrich Service Bulletins 23085-025-24-
01 and 23085-024-24-01 is available from the following Goodrich approved facilities:

• Goodrich Monroe, NC 28110-1313

• Ametek B&S Aircraft Parts and Accessories Ltd.
• API Technologies
• Canadian Aero Accessories Ltd.
• Consolidated Aircraft Supply Co.
• Embraer Aircraft Maintenance Service
• Future Aviation Inc.
• NIACC-AVITECH Technology Inc.
• Muirhead Avionics and Accessories

After embodiment of these Service Bulletins, the Starter/Generator Model numbers change as follows:

• Model -024 becomes -030 (Pilatus P/N 978.91.23.436), as installed on MSN 849 and 864 on
delivery.
• Model -025 becomes -029 (Pilatus P/N 978.91.23.435), installed as standard on MSN 791 thru
888.

This Service Letter does not affect Starter/Generator Model 23085-031 (PIL P/N 978.91.23.437) installed on
PC-12NG aircraft (MSN 545 and 1001 up). This model Starter/Generator has an isolated drive shaft to
eliminate EDD to the engine.

Pilatus recommends the incorporation of these Service Bulletins at the next removal/overhaul of the Starter/
Generator as the modification eliminates the potential of Electrical Discharge Damage to the engine. After an
aircraft has EDD modified Starter/Generators installed, Pilatus recommends that unmodified Starter/
Generators are not used as a replacement.

SERVICE LETTER 123

PAGE 1 of 2
 SERVICE LETTER

Operators requiring further information on this subject, please contact one of the addresses
given below:

PILATUS AIRCRAFT LTD., PILATUS BUSINESS AIRCRAFT LTD., PILATUS AUSTRALIA (Pty.) LTD.,
CUSTOMER SUPPORT MANAGER, PRODUCT SUPPORT DEPARTMENT, 17 James Schofield Drive,
CH-6371 STANS, 11755 AIRPORT WAY, Adelaide Airport SA 5950,
SWITZERLAND. BROOMFIELD, CO 80021. AUSTRALIA
USA
General Aviation Tel : +61 (08) 8234 4433
Tel : + 41 41 619 6208 Tel : 303 465 9099 Fax: +61 (08) 8234 4499
Fax: + 41 41 619 7311 Fax: 303 465 6040 Free Call: 1800 445 007
eMail: SupportPC12@pilatus-aircraft.com eMail: Productsupport@PilBal.com eMail: info@pilatus.com.au

Attachments: Goodrich Power Systems Service Bulletins 23085-025-24-01 and 23085-024-24-01

SERVICE LETTER 123

PAGE 2 of 2
 SERVICE BULLETIN
Number 23085-024-24-01
ELECTRICAL POWER - DC STARTER-GENERATOR
DRIVE SHAFT ISOLATION - CONVERSION OF MODEL 23085-024
TO MODEL 23085-030
"THESE COMMODITIES, SOFTWARE, OR TECHNOLOGY WERE EXPORTED FROM THE UNITED STATES
IN ACCORDANCE WITH THE EXPORT ADMINISTRATION REGULATION. DIVERSION CONTRARY TO U.S.
LAW IS PROHIBITED."
THIS DOCUMENT CONTAINS INFORMATION PROPRIETARY TO GOODRICH CORPORATION AND IS
FURNISHED UPON THE EXPRESS CONDITION THAT THE INFORMATION CONTAINED HEREIN WILL NOT
BE USED DIRECTLY OR INDIRECTLY IN ANY WAY DETRIMENTAL TO THE INTEREST OF GOODRICH
CORPORATION.
1. PLANNING INFORMATION

A. Effectivity
This Service Bulletin (SB) applies to all Goodrich Corporation Model 23085-024 DC
Starter-Generators.

NOTE: Model 23085-014 Starter-Generators can be converted to model 23085-030,

but they must first be converted to model 23085-024 by following SB
23085-0XX-24-05.

B. Concurrent Requirements
None.

C. Reason
This conversion is required to electrically insulate the starter-generator drive shaft
from the armature and stator housing. Bearing shields and ceramic hybrid ball
bearings have also been added for enhanced bearing performance.

D. Description
This SB provides instructions for the conversion of starter-generator model 23085-024
to starter-generator model 23085-030. The conversion consists of updating the ADE
end bell (if required), new bearings, bearing shields, new isolated drive shaft,
armature, fan, dampener back plate, fan cap plug, dampener hub, washer assembly,
isolator and identification plate. See Table 3 for all parts used. The starter-generator
model 23085-024 is to be re-identified as a model 23085-030.

NOTE: Use this SB and the referenced Component Maintenance Manual (CMM) for
repair and overhaul of model 23085-030 until a CMM with Illustrated Parts
List (IPL) is issued.

23085-024-24-01
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The anti-drive end (ADE) end bell (P/N 23085-1810) must have four holes drilled,
spot faced and tapped with heli-coils put in to relocate ground leads for the filter board
assembly. Also, the four bearing retainer holes must have heli-coils installed. If
heli-coils are not installed in the ribs of the anti-drive end (ADE) end bell (P/N
23085-1810) and in the bearing retainer holes, disassemble the bearing and brush
support assembly following the instructions in the DISASSEMBLY section of the
referenced CMM. Refer to Figure 1 for the location of required heli-coils. The following
options are available for the modification of the ADE end bell:

(1) For ADE end bells (P/N 23085-1810) that already include heli-coils in the holes
on the ribs and bearing retainer screw holes, no modification is necessary.

(2) If the ADE end bell (P/N 23085-1810) does not include heli-coils in the ribs,
proceed with modification steps in paragraph 3.F.(2).

(3) If the ADE end bell (P/N 23085-1810) does not include heli-coils in the bearing
retainer holes, proceed with modification steps in paragraph 3.F.(3).

E. Compliance
RECOMMENDED

Goodrich Corporation recommends that this conversion be considered during the next
removal or repair.

F. Approval
This SB has the approval of Goodrich Corporation and Pilatus Aircraft Ltd. Repairs
and conversions specified in this SB are in compliance with the approved data and
applicable Federal Aviation Regulations and EASA regulations.

This document provides approval for conversion of model 23085-024 to the model
23085-030 configuration by Authorized Repair Centers that have been approved and
audited by Goodrich Corporation. The use of any parts, materials, or processes not
authorized by Goodrich Corporation invalidates the conversion of the units.

G. Manpower
An estimated 1.0 man-hour is required to complete the modification in this SB when
done at overhaul or repair.

If modification to the ADE end bell (P/N 23085-1810) is required in paragraph 3.F.,
an estimated additional 1.0 man-hour is required to complete the modification in this
SB when done at overhaul or repair.

H. Weight and Balance

Effect on weight: None.

Effect on overhung moment: None.

I. Electrical Load Data

Not Changed.

23085-024-24-01
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 SERVICE BULLETIN
J. References
Refer to the 23085 Series Component Maintenance Manual (CMM) with Illustrated
Parts List (IPL), ATA 24-30-19.

Refer to SB 23085-0XX-24-05 for model 23085-014 conversion to model 23085-024.

K. Other Publications Affected

A Component Maintenance Manual (CMM) with Illustrated Parts List (IPL) will be
created to include the model 23085-030 introduced in this SB.

2. MATERIAL INFORMATION

A. Material - Price and Availability

Required parts and pricing information are available from the following Goodrich
Corporation Exclusive Distributors:

REGION ADDRESS COMMUNICATIONS

AMERICAS: Goodrich Corporation PHONE: (1) 704 282 2500
Customer Service Desk AOG: (1) 800 735 7899
4115 Corporate Center Drive FAX: (1) 704 282 2560
Monroe, NC 28110-1313
USA
EUROPE/ Goodrich Corporation PHONE: (44) 121 451 5755
MIDEAST/ Customer Service Desk AOG: (44) 121 451 5904
AFRICA: Stratford Road FAX: (44) 121 451 5949
Solihull B90 4LA UK AOG: aog.helpdesk@goodrich.com
ASIA Goodrich Control Systems Pte. Ltd. PHONE: (65) 6545 9975
PACIFIC: Customer Service Desk AOG: (1) 800 735 7899
35 & 37 Loyang Way FAX: (65) 6545 9965
Republic of Singapore 508733

B. Technical Support Information

Technical questions should be directed to the location listed below:

ADDRESS COMMUNICATIONS
Goodrich Corporation PHONE (1) 330 487 2000
Technical Services FAX (1) 330 487 1902
8380 Darrow Road
Twinsburg, OH 44087 USA

Goodrich Corporation PHONE (44) 1296 663000

Power Systems Division FAX (44) 1296 663300
Westfield Road
Pitstone Green
Buckinghamshire LU7 9GT
UK

23085-024-24-01
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 SERVICE BULLETIN
C. Material Requirements
The following materials and tools are required for modification:

Item Description/Specification Source (CAGE Code)

Acrylic Coating HumiSeal Type 1B31 Chase Corporation
MIL-I-46058 Woodside, NY 11377
Ph: (718) 932-0800
Fax: (718) 932-4345
www.humiseal.com
(V0SR97)
Chemical Film Solution Chemical Film Solution Henkel Surface Technologies
MIL-C-5541, Class 3 32100 Stephenson Hwy
Madison, Heights, MI 48071 USA
Alodine 1200 Ph: 800-521-6895
Ph: 248-583-9300
Fax: 248-583-2976
www.hstna.com
(V1N6B3)
Lockwire NASM20995C32 Aircraft Tool Supply Company
P.O. Box 370
Oscoda, MI 48750
Ph: 1-800-248-0638
Ph: 1-989-739-1447
www.aircraft-tool.com
(V11138)
Lubricating and Altemp QNB 50 Klueber Lubrication
Assembly Paste Londonderry, NH
Ph: (603) 434-7704
Ph: (800) 447-2238
Fax: (603) 434-8046
www.klueber.com
(V3EZL6)
Tape Electrical Commercially Available
Threaded Inserts (4) for NAS1130-06-15 Emhart Teknologies
Ribs or equivalent Industrial Division
50 Shelton Technology Center
P.O. Box 859
Threaded Inserts (4) for NAS1130-08L15D Shelton, CT 06484 USA
Ph: 203-924-9341
Bearing Retainer Alt: MS21209C0815 Fax: 203-925-3109
or equivalent (V1D1Q0)
Thread Sealing Gasoila, Soft Set, Lead Free GSA Supply on-line
Compound Ph: 1-800-846-7325
www.gsasupplyco.com
Zinc Chromate Primer TT-P-1757, Composition G, Commercially Available
Color Y
Table 1 - Assembly Materials

23085-024-24-01
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 SERVICE BULLETIN
D. Tooling Requirements

Tools Vendor
Spanner Socket Torque Adapter Goodrich Corporation
TG-1277-1011
Table 2 - Special Tools

E. Parts Requirements
Use the parts listed for the starter-generator model 23085-024 in the ILLUSTRATED
PARTS LIST section of the CMM, but replace with the following new P/N listed in
Table 3 and Table 4 for conversion to starter-generator model 23085-030:

New P/N Qty. Nomenclature Old P/N Instruction

52-230094 1 KIT, Starter-Generator N/A Install
Conversion See Table 4
23085-1743 1 INLET, Air 23085-1743 Alternate can be
Alt:23085-1740 used
MS35338-42 8 WASHER, Lock MS35338-42 Updated Quantity
Spring Used. Deleted four
lock washer’s used
with bearing retainer
23085-1810 1 End Bell, Anti-Drive 23085-1810 If required, modify
End (ADE) with machined holes
as specified in
paragraph 3.F.
See Figure 1
NOTE: Quantities listed are for one (1) starter-generator.
Table 3 - Model Conversion/Required Parts

New P/N Qty. Nomenclature Old P/N Instruction

06-209285 1 PLATE, Identification ----- Remove/Install new
(Replacement)
23078-1844 1 SHAFT, Drive 23085-1358 Remove/Install new
23078-1802 1 ISOLATOR N/A Install new
02-5600-17 1 RING, Friction 02-5600-13 Remove/Install new
23032-1916 1 HUB, Dampener 23032-1901 Remove/Install new
23032-2716 1 BACK PLATE, 23032-2711 Remove/Install new
Dampener
Table 4 - Isolated Drive Shaft Conversion Kit 52-230094 Contents

23085-024-24-01
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 SERVICE BULLETIN
New P/N Qty. Nomenclature Old P/N Instruction
23088-1340 1 SHIELD, Drive End, 23032-1143 Remove/Install new
Bearing
23085-1507 1 ARMATURE 23085-1503 Remove/Install new
03-6009-25 2 BEARING, Ball, 03-6009-23 Remove/Install new
Ceramic Hybrid
MS35265-45 4 SCREW, Slotted MS35206-246 Install new
Fillister Head
23078-1860 1 PLUG, Fan Cap N/A Install new
23078-1873 1 ASSEMBLY, Washer AN960-416 Remove/Install new
MS172239 1 NUT, Spanner N/A Install new
MS172204 1 WASHER, Key, N/A Install new
Bearing Retainer
23078-1851 1 FAN, Axial 23065-1873 Remove/Install new
23088-1342 1 SHIELD, Anti-Drive N/A Install new
End, Bearing
MS16555-301 1 PIN, Straight, N/A Install new
Headless
MS35206-227 4 SCREW, Pan Head N/A Install new
MS35338-41 4 WASHER, Lock N/A Install new
02-4022-02 4 SCREW MS35265-45 Remove/Install new
NOTE: Quantities listed are for one (1) starter-generator.
Table 4 - Isolated Drive Shaft Conversion Kit 52-230094 Contents

3. ACCOMPLISHMENT INSTRUCTIONS
This SB provides instructions for the conversion of starter-generator model 23085-024 to
starter-generator model 23085-030. The conversion consists of updating the ADE end
bell (if required), new bearings, bearing shields, new isolated drive shaft, armature, fan,
dampener back plate, fan cap plug, dampener hub, washer assembly, isolator and
identification plate. See Table 3 for all parts used. The starter-generator model 23085-024
is to be re-identified as a model 23085-030.

NOTE: Use this SB and the referenced Component Maintenance Manual (CMM) for
repair of model 23085-030 until a CMM with Illustrated Parts List (IPL) is issued.

23085-024-24-01
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 SERVICE BULLETIN
The anti-drive end (ADE) end bell (P/N 23085-1810) must have four holes drilled, spot
faced and tapped with heli-coils put in to relocate ground leads for the filter board assembly.
Also, the four bearing retainer holes must have heli-coils installed. If heli-coils are not
installed in the ribs of the anti-drive end (ADE) end bell (P/N 23085-1810) and in the
bearing retainer holes, disassemble the bearing and brush support assembly following
the instructions in the DISASSEMBLY section of the referenced CMM. Refer to Figure 1
for the location of required heli-coils. The following options are available for the
modification of the ADE end bell:

(1) For ADE end bells (P/N 23085-1810) that already include heli-coils in the holes
on the ribs and bearing retainer screw holes, no modification is necessary.

(2) If the ADE end bell (P/N 23085-1810) does not include heli-coils in the ribs,
proceed with modification steps in paragraph 3.F.(2).

(3) If the ADE end bell (P/N 23085-1810) does not include heli-coils in the bearing
retainer holes, proceed with modification steps in paragraph 3.F.(3).

A. Preparation
All work performed on the DC starter-generator must be performed in a clean, dry
area free of oil, dirt, moisture and other contamination. The DC starter-generator must
be kept clean to ensure the operating effectiveness of the unit.

B. Disassembly
Disassemble the DC starter-generator as required, according to the DISASSEMBLY
section of the referenced CMM, to the extent necessary to remove the armature.

(1) Disassemble the bearing and brush support assembly to the extent necessary
to permit machining of the ADE end bell (P/N 23085-1810) as detailed in
paragraph 3.F.
(2) Remove the identification plate from the starter-generator as follows:
NOTE: Record the information from the identification plate before it is removed
to make sure the information is not lost by damage during removal.

(a) Use a smooth, flat tool that will not scratch the stator housing to wedge
under the edge of the identification plate and pry up on the corners of the
plate near the four drive screws that hold it in place to dislodge the plate
from the stator housing.
NOTE: This will tear the corners of the light metal identification plate.
(b) Remove the remaining metal from under the head of each drive screw.
(c) Use a small pair of side cutters with the flat face to the stator housing to
wedge in under the head of each drive screw to hold the shank of the screw
and turn out counterclockwise.
NOTE: Use a dull pair of small side cutters so that you do not cut the head
of the drive screw off.

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 SERVICE BULLETIN
C. Cleaning
Clean unit and disassembled parts according to the CLEANING section instructions
of the referenced CMM.

D. Check
Inspect the unit according to the CHECK section instructions of the referenced CMM.

E. Repair
Repair parts as specified in the REPAIR section of the referenced CMM. Replace
parts as specified in the CHECK section that cannot be repaired.

F. Modification of the Anti-Drive End (ADE) End Bell

(1) Refer to the REPAIR section of the referenced CMM and SPD (Standard Practice
Document) 1003 for removal of surface coatings.

(2) If required, install threaded inserts (heli-coils), (P/N NAS1130-06-15) into ribs,
as shown in Figure 1 and as follows:

(a) Elongated spotface, if not already included, a 0.31 inch (7,8 mm) diameter
located 38° counter-clockwise from the rivnuts to a depth of 3.15 inch (80,0
mm) from the opposite end of the ADE end bell located on a 2.87 inch
(72,9 mm) diameter.

NOTE: 100% cleanup of the ADE end bell is not required.

(b) Drill through on a bolt circle diameter of 2.87 inch (72,9 mm) with #26 0.147
inch (0,37 mm) drill bit.

(c) Tap through for 0.138-32 UNC-3B using 06CPB heli-coil tap, four places
equally spaced on a bolt circle diameter of 2.87 inch (72,9 mm).

(d) Clean each hole for threaded inserts by removing burrs or raised metal.

WARNING: KEEP ZINC CHROMATE PRIMER AWAY FROM SOURCES OF

HEAT, SPARKS AND FLAME. ZINC CHROMATE PRIMER IS
FLAMMABLE.

WARNING: DO NOT GET ZINC CHROMATE PRIMER ON YOUR SKIN AND

DO NOT BREATHE THE FUMES. ZINC CHROMATE PRIMER
IS A POISONOUS MATERIAL.

(e) Coat four new (P/N NAS1130-06-15) heli-coil inserts with zinc chromate
primer and install them while wet into the rib screw holes.

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 SERVICE BULLETIN

Figure 1 - Location of Heli-Coils in the Anti-Drive End (ADE) End Bell

23085-024-24-01
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 SERVICE BULLETIN
(3) If required, install threaded inserts (heli-coils), (P/N NAS1130-08L15D, Alt:
MS21209C0815) into bearing retainer screw holes, as shown in Figure 1 and
as follows:

(a) Drill through with a 0.1708 to 0.1781 inch (4,338 to 4,524 mm) drill bit. The
four holes are located on a 2.000 inch (50,8 mm) basic diameter. See
Figure 1.

(b) Countersink the bearing retainer screw holes 115° to 125° to a 0.20 to 0.23
inch (5,1 to 5,8 mm) diameter.

(c) Tap 0.164-32 UNC-3B using a 2CPB heli-coil tap.

(d) Clean each hole for threaded inserts by removing burrs or raised metal.

WARNING: KEEP ZINC CHROMATE PRIMER AWAY FROM SOURCES OF

HEAT, SPARKS AND FLAME. ZINC CHROMATE PRIMER IS
FLAMMABLE.

WARNING: DO NOT GET ZINC CHROMATE PRIMER ON YOUR SKIN AND

DO NOT BREATHE THE FUMES. ZINC CHROMATE PRIMER
IS A POISONOUS MATERIAL.

(e) Coat four new P/N NAS1130-08L15D (Alt. MS21209C0815) heli-coil

inserts with zinc chromate and install them into the bearing retainer screw
holes to a depth of 0.05 to 0.07 inch (1,3 to 1,8 mm) below the counterbore
surface. This measurement is to the start of the heli-coil wire. Break off the
tang if required.

WARNING: CHEMICAL CONVERSION MATERIALS ARE POISONOUS AND

CAN CAUSE EXPLOSIONS WHEN MIXED WITH ACIDS, REDUCING
AGENTS COMBUSTIBLE AND OXIDIZING MATERIALS. ISOLATED
STORAGE OF THESE MATERIALS IS MANDATORY.

WARNING: BEFORE YOU USE CHEMICAL CONVERSION MATERIALS, PUT

ON A RESPIRATOR, RUBBER APRON, RUBBER GLOVES AND
EYE PROTECTION. THIS WILL PREVENT INJURY FROM SPILLS
AND FROM THE FUMES.

WARNING: KEEP CHEMICAL CONVERSION MATERIALS AWAY FROM

SOURCES OF HEAT, SPARKS AND FLAME. CHEMICAL
CONVERSION MATERIALS ARE FLAMMABLE.

(4) If required, touch up with chemfilm in the area that was reworked.

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 SERVICE BULLETIN
WARNING: KEEP THE PAINT AWAY FROM SOURCES OF HEAT, SPARKS AND
FLAME. THE PAINT IS FLAMMABLE.

(5) If required, REPAIR the surface coating of the ADE end bell using red insulating
enamel. Refer to the REPAIR section of the referenced CMM and SPD (Standard
Practice Document) 1002.

NOTE: There is to be no red insulating enamel on the 0.31 inch (7,9 mm) spot
face surfaces on the ribs.

G. Assembly
Assemble the DC Starter-Generator as specified in the ASSEMBLY section of the
referenced CMM and as follows:

NOTE: Assembly must be done using a modified or original ADE end bell (P/N
23085-1810) that has heli-coils installed into the ribs and bearing retainer
holes of the ADE end bell as shown in Figure 1.

NOTE: If necessary, attach brush holders to ADE end bell as specified in the
ASSEMBLY section of the referenced CMM. Reference SPD 1004 for brush
alignment tooling.

(1) Press ball bearing (P/N 03-6009-25) into bearing and brush support assembly.
See Figure 2.

(a) Put ADE hub support on arbor press table.

(b) Set bearing and brush support assembly (brush holder side down) on
anti-drive end hub support.

WARNING: DO NOT LET PASTE TOUCH THE EYES OR SKIN. OBEY THE
MANUFACTURER’S INSTRUCTIONS. REFER TO MSDS
SHEET BEFORE PASTE IS USED.

(c) Apply a light coating of lubricating and assembly paste to the inside
diameter of the bearing liner of bearing and brush support assembly.

(d) Set a ball bearing (P/N 03-6009-25) onto bearing liner of ADE end bell
assembly.

NOTE: The Goodrich Corporation part marking on the bearing (P/N

03-6009-25) must be facing towards the inside of the
Starter-Generator.

(e) Set an outer race bearing driver onto ball bearing (P/N 03-6009-25).

(f) Press ball bearing (P/N 03-6009-25) into bearing liner of ADE end bell
assembly until bearing is fully seated against inner lip of bearing liner.

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 SERVICE BULLETIN

Figure 2 - Ball Bearing Installation

(2) Attach bearing retainer to the bearing and brush support assembly as follows:
NOTE: The ADE end bell must have heli-coil inserts for attachment of the slotted
leads of filter assemblies as specified in modification procedures in
Paragraph 3.F.
WARNING: THREAD SEALING COMPOUND IS DANGEROUS TO
PERSONS. USE ONLY IN AN AREA WITH A GOOD FLOW OF
AIR. KEEP AWAY FROM SOURCES OF HEAT, SPARKS AND
FLAME. DO NOT BREATHE THE FUMES. PREVENT SKIN
CONTACT. PUT ON PROTECTIVE CLOTHING AND EYE
PROTECTION.

(a) Apply thread sealing compound to the threads of four attaching screws
(P/N 02-4022-02).

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 SERVICE BULLETIN
CAUTION: DO NOT PUT SPRING LOCK WASHERS ON SCREWS FOR
BEARING RETAINER. SPRING LOCK WASHERS ARE NOT
USED ON THE SCREWS THAT ATTACH THE BEARING
RETAINER. THIS CAN CAUSE INTERFERENCE WITH THE
BEARING SHIELD.

(b) Attach bearing retainer to bearing and brush support assembly with
attaching screws (P/N 02-4022-02).
(3) Insulate slotted lead terminals of filter board assemblies with electrical insulating
tape or equivalent.
NOTE: Filter board lead wires are not to be attached until after acceptance
testing.

(4) Install the DE bearing shield (P/N 23088-1340) and ball bearing (P/N
03-6009-25) onto drive end of armature (P/N 23085-1507) as follows:
See Figure 3.

CAUTION: DO NOT TOUCH POLISHED SURFACE OF COMMUTATOR

WITH BARE HANDS. SKIN ACIDS AND OILS CAN
CONTAMINATE CONDUCTING SURFACES CAUSING
CORROSION AND/OR POOR ELECTRICAL CONTACT.

(a) Put armature support on arbor press table.

Figure 3 - Bearing Shield and Ball Bearing Installation

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 SERVICE BULLETIN
(b) Set armature (P/N 23085-1507) (commutator end down) onto armature
support.

CAUTION: ORIENT THE DRIVE END BEARING SHIELD WITH THE PART
IDENTIFICATION STAMPING FACING INBOARD.

(c) Install the DE bearing shield (P/N 23088-1340) to drive end of armature
shaft with the part marking facing toward the armature.

(d) Set ball bearing (P/N 03-6009-25) onto armature shaft.

NOTE: The Goodrich Corporation part marking on the bearing (P/N

03-6009-25) must be facing towards the inside of the
starter-generator.

(e) Set inner race bearing driver on ball bearing (P/N 03-6009-25).

(f) Press ball bearing (P/N 03-6009-25) down onto armature shaft making
sure bearing is fully seated against bearing shield (P/N 23088-1340).

(g) Install spacer and retaining ring as specified in the ASSEMBLY section of
the referenced CMM.

NOTE: Sharp edges of the retaining ring should be facing away from the
DC starter-generator.

(5) Prepare armature (P/N 23085-1507) for coarse brush seating according to the
referenced CMM and IAW SPD (Special Practice Document 1006).

CAUTION: DO NOT TOUCH POLISHED SURFACE OF COMMUTATOR WITH

BARE HANDS. SKIN ACIDS AND OILS CAN CONTAMINATE
CONDUCTING SURFACES CAUSING CORROSION AND/OR POOR
ELECTRICAL CONTACT.

(6) Attach bearing and brush support assembly to armature (P/N 23085-1507)
according to the ASSEMBLY section of the CMM.

(7) Calculate and install the shim pack and spring wave washer into the drive end
bearing support assembly, and install the bearing and brush support assembly
with attached armature into the stator and housing assembly as specified in the
ASSEMBLY section of the referenced CMM. Reference Figure 4.
(8) Install dampener back plate (P/N 23032-2716) on the armature shaft with the
recessed side facing away from the starter-generator.

(9) Install dampener hub (P/N 23032-1916) on drive shaft (P/N 23078-1844).

NOTE: Make sure that the dampener hub is fully seated on the taper of the
drive shaft.

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Figure 4 - Drive End Bearing Support Assembly with Preload Stack and Bearing Shield

(10) Install dampener plate on splined dampener hub (P/N 23032-1916). Make sure
that dampener plate is installed flush to shoulder of dampener hub (P/N
23032-1916).

(11) Install friction ring (P/N 02-5600-17) to turned recess of dampener back plate.

Figure 5 - Installation of Isolator on the Drive Shaft

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(12) Install drive shaft (P/N 23078-1844) with isolator (P/N 23078-1802), ADE bearing
shield (P/N 23088-1342) and axial fan (P/N 23078-1851) as follows.
See Figure 5 and Figure 6.

(a) Slide isolator (P/N 23078-1802) onto the drive shaft square spline until the
isolator (P/N 23078-1802) is flush against the drive shaft square spline
shoulder. See Figure 5.

(b) Insert drive shaft (P/N 23078-1844) through the armature shaft. Make sure
that drive shaft square spline engages armature shaft spline and that
friction ring (P/N 02-5600-17) is correctly positioned on dampener back
plate.

Figure 6 - Assembly of ADE Drive Shaft Isolation

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(c) Slide anti-drive end bearing shield (P/N 23088-1342) followed by the axial
fan (P/N 23078-1851) on the armature shaft and locate by installing the
straight headless pin (P/N MS16555-301) onto the armature shaft keyway.

NOTE: Make sure the part marking of the ADE bearing shield (P/N
23088-1342) is facing towards the outside of the unit.

(d) Attach key washer (P/N MS172204) on armature shaft as shown in Figure
6, locate key washer (P/N MS172204) on armature shaft by aligning the
key washer inner tab with the armature keyway.

NOTE: The key washer (P/N MS172204) should have the rounded
surface seated against the axial fan (P/N 23078-1851).

(e) Secure the fan (P/N 23078-1851) and key washer (P/N MS172204) with
spanner nut (P/N MS172239).

NOTE: The spanner nut (P/N MS172239) should have the rounded
surface seated against the key washer (P/N MS172204).

(f) Put the spline wrench on drive end of drive shaft spline and torque the
spanner nut (P/N MS172239) to 150 to 200 in.-lb (16,9 to 22,6 N · m) with
a spanner wrench (Table 2).

(g) Loosen the spanner nut to zero in.-lb and tighten to a final torque of 80 to
100 in.-lb (9,0 to 11,3 N · m).

(h) Lock one tab of the key washer (P/N MS172204) into a slot of the spanner
nut (P/N MS172239).

(i) Put washer assembly (P/N 23078-1873) onto the drive shaft (P/N
23078-1844) with the largest washer facing the spanner nut and secure
with self-locking nut.

(j) Use the spline wrench on drive end of drive shaft spline and torque nut to
80 to 100 in.-lb (9,0 to 11,3 N · m).

(k) Press the fan cap plug (P/N 23078-1860) onto the fan. See Figure 6 for
proper orientation.

NOTE: Verify that key washer (P/N MS172204) tab is locked into a slot of
the spanner nut (P/N MS172239) before installing the fan cap plug
(P/N 23078-1860).

(13) Install brushes as specified in the ASSEMBLY section of the referenced CMM
and IAW SPD (Special Practice Document 1006).

(14) Attach air inlet (P/N 23085-1743, Alt: P/N 23085-1740). See Figure 7.

(a) Put air inlet (P/N 23085-1743, Alt: P/N 23085-1740) on the bearing and
brush support assembly. Align the four screw holes on the air inlet with the
screw holes on the bearing and brush support assembly.

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Figure 7 - Attaching Air Inlet

WARNING: THREAD SEALING COMPOUND IS DANGEROUS TO

PERSONS. USE ONLY IN AN AREA WITH A GOOD FLOW OF
AIR. KEEP AWAY FROM SOURCES OF HEAT, SPARKS AND
FLAME. DO NOT BREATHE THE FUMES. PREVENT SKIN
CONTACT. PUT ON PROTECTIVE CLOTHING AND EYE
PROTECTION.

(b) Apply thread sealing compound to threads of four screws (P/N

MS35265-45).

(c) Install air inlet (P/N 23085-1743, Alt: P/N 23085-1740) with four attaching
screws (P/N MS35265-45) to a torque of 13.5 to 18.0 in.-lb (1,5 to 2,0 N · m)
as shown.

NOTE: Do not attach lockwire to screws until after acceptance testing.

(d) After acceptance testing, lockwire (MS20995C32) four attaching screws
(P/N MS35265-45) IAW MS33540.

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H. Testing
Test the DC Starter-Generator according to Goodrich Corporation TEST AND FAULT
ISOLATION section as given for starter-generator model 23085-024 and as follows:

NOTE: The filter board assembly leads must remain electrically isolated from both
the stator housing, and bearing and brush support assembly until acceptance
testing is complete. Wrap terminal ends with electrical tape or equivalent to
prevent contact with stator housing.

Acceptance procedures are to be performed in the following sequence:

(1) Continuous Operating Speed, Equalizing Voltage, and Minimum Speed:

(a) Operate starter-generator at 12,000 RPM, 30 VDC, 300 Amps for 15

minutes. Use a thermocouple or suitable equivalent to record frame
temperature.

(b) Measure and record voltage between terminals D and E: Voltage must be
within limits in Figure 8.

(c) Measure and record inlet air temperature.

(d) Measure and record winding or frame temperature.

(e) Immediately operate generator at minimum speed for regulation at 7,200

RPM, 30 VDC, 300 Amps (stabilization not required).

(f) Record field current and voltage between terminals B and A.

(g) Acceptance Limits:

1 Field Current: Not to be more than 10 Amps.

2 External Field Circuit Resistance (terminals B to A):

a Calculate resistance between terminals B and A by dividing B-A

voltage by field current.

b External field circuit resistance must be 0.5 Ω minimum.

3 Open the field circuit and record the residual voltage (B to E):

a Residual voltage must not be less than 0.8 V.

(2) Minimum Speed:

(a) Reduce the starter-generator speed to 6,950 RPM, 28.5 VDC, 300 Amps
and operate for 15 minutes.

(b) Measure and record field current and B to A voltage.

(c) Calculate (B to A) resistance by dividing B-A voltage by field current.

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(d) Acceptance Limits:

1 Field current: Not to be more than 10 Amps.

2 External field circuit resistance must be 0.5 Ω minimum.

Figure 8 - Equalizing Voltage Diagram

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(3) Residual Voltage Test:

(a) Immediately after minimum speed test, operate the starter-generator at

12,000 RPM with an open field circuit. Record the residual voltage between
terminals B and E.

(b) Acceptance Limits:

1 Residual voltage must not be more than 3.6 V at 12,000 RPM.

(4) Overspeed:

(a) With the starter-generator hot from the previous test, increase speed to
14,000 RPM with an open field circuit for 5 minutes.

(b) Acceptance Limits:

1 There must be no indication of failure (noise, vibration, loosening of

parts, etc.).

(5) Commutation:

(a) Operate the starter-generator at 12,000 RPM, 300 Amps. See Figure 9.

Figure 9 - Correct Viewing Angle

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(b) Acceptance Limits:

1 Continuous pinpoint sparking is not to be more than approximately

0.12 inch (3,0 mm) beyond the trailing edge of each brush with no
more than 10 single sparks extending up to 0.25 inch (6,0 mm) in any
one minute period. Sparks beyond 0.25 inch (6,0 mm) must be
considered arcing.

2 Arrow “A” shows the correct viewing angle for finding any sparking.
Arrow “B” shows the correct viewing angle, when viewed from the
anti-drive end for seeing if commutation is black or pin point.

(6) Dielectric Test:

NOTE: With the starter-generator still hot from testing.

WARNING: BEFORE USING HIGH VOLTAGE TESTER, MAKE CERTAIN

TESTER HAS BEEN TURNED “OFF” AND THAT NO ONE IS
TOUCHING ANY PORTION OF CONNECTION POINTS OR
PROBE LEAD WIRES. FAILURE TO COMPLY WITH THIS
WARNING CAN RESULT IN SEVERE ELECTRICAL SHOCK.

CAUTION: THIS TEST IS ACCOMPLISHED ONLY DURING ACCEPTANCE

TESTING AND ONLY FOR STARTER-GENERATORS THAT
HAVE BEEN CLEANED AND OVERHAULED. USE A DUMMY
TERMINAL BLOCK OR DISCONNECT STATOR TERMINAL
LEADS FROM TERMINAL BLOCK.

(a) Operating Instructions:

1 Turn all power off at generator drive stand.

2 Disconnect starter-generator from test circuit.

3 Disconnect stator leads from terminal block.

4 Remove terminal block from stator.

5 Remove 4 filter leads from bearing retainer holding screws making

certain filter lead terminals do not contact frame and insulate lead ends
by applying tape or plastic caps.

6 Remove commutator viewing adapter.

7 Connect all stator terminal leads (A+, B+, C+ where applicable, D and
E-) of dummy terminal block together.

8 Attach positive (red) lead of high pot tester to connected terminal leads.

9 Attach negative (black) lead of high pot tester to an unfinished surface

of the starter-generator frame.

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CAUTION: APPLY AND REMOVE TEST VOLTAGE AT A UNIFORM
RATE NOT TO BE MORE THAN 100 VOLTS PER SECOND.

10 Apply dielectric test voltage of 250 V rms, commercial frequency, for

one minute or 300 V rms, commercial frequency, for one second.

(b) Acceptance Limits:

Any arcing as evidenced by flashover (surface discharge), spark-over (air

discharge) breakdown (puncture discharge) or leakage current no more
than 5 mA will be evidence of damp, dirty, weak or defective components.

(7) Insulation Resistance Test of Isolated Drive Shaft:

CAUTION: MAKE SURE THE DRIVE SHAFT IS NOT TOUCHING THE

INSIDE OF THE ARMATURE SHAFT. THIS CAN BE FIXED BY
CENTERING THE DRIVE SHAFT IN THE ARMATURE SHAFT.

(a) Apply 30 VDC with a commercial megohm meter as follows:

1 Between the drive spline and the starter-generator stator housing.

2 Between the drive spline and the fan.

3 Measure and record the insulation resistance values.

(b) Acceptance Limits:

1 Insulation resistance must be greater than 1 MΩ.

(8) Locked Rotor Test for Series Start DC Starter-Generators:

(a) Mount the starter-generator to the test mounting flange.

(b) With the voltage output of the DC power supply set to zero turn the power
supply to the ON position.

CAUTION: DO NOT ENERGIZE UNIT FOR MORE THAN 5 SECONDS.

(c) With 0.2 Ω connected between terminals A and C, quickly increase voltage
between terminals C and E until the output torque of 20 ft-lbs (27,1 N · m)
is reached. Measure and record current.

(d) Acceptance Limits:

1 Current is not to be more than 630 Amps and voltage must not be more
than 9.5 V.

NOTE: If current is too high, rotate armature to a different position and

repeat test.

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(9) Residual Voltage Test:

(a) Operate the starter-generator at 7,200 RPM with an open field circuit.
Record the residual voltage between terminals B and E.

(b) Acceptance Limits:

1 Residual voltage must not be less than 0.5 V.

(10) Commutator Runout

NOTE: This test is to be accomplished only during acceptance testing after

completion of overhaul and the armature’s commutator has been
resurfaced.

(a) Operating Instructions:

CAUTION: DO NOT TOUCH SURFACE OF COMMUTATOR WITH

BARE HANDS. ACIDS AND OILS ON SKIN CAN
CONTAMINATE CONDUCTING SURFACES CAUSING
CORROSION AND POOR ELECTRICAL CONTACT.

CAUTION: ONLY ROTATE COMMUTATOR IN CLOCKWISE

DIRECTION AS VIEWED FROM THE ADE.

1 Rotate armature and measure the commutator total runout and

bar-to-bar runout between adjacent commutator bars with a dial
indicator or suitable equivalent.

2 Measure and record commutator total indicated run-out. Maximum

total indicated run-out not to be more than 0.0008 inch (0,02 mm).

3 Measure and record adjacent bar-to-bar run-out. Maximum bar-to-bar

run-out not to be more than 0.0002 inch (0,005 mm).

(11) After successful completion of acceptance testing, install the filter board
assembly leads to the bearing and brush support assembly as follows:
(a) Put a lockwasher (P/N MS35338-41) on each of the four screws (P/N
MS35206-227).
WARNING: THREAD SEALING COMPOUND IS DANGEROUS TO
PERSONS. USE ONLY IN AN AREA WITH A GOOD FLOW OF
AIR. KEEP AWAY FROM SOURCES OF HEAT, SPARKS AND
FLAME. DO NOT BREATHE THE FUMES. PREVENT SKIN
CONTACT. PUT ON PROTECTIVE CLOTHING AND EYE
PROTECTION.

(b) Apply sealing compound to threads of four screws (P/N MS35206-227).

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Figure 10 - Fastening Ground Wires to the ADE end bell

(c) Put the slotted terminal end of the lead from the filter board assembly on
the screw and install the screw (P/N MS35206-227) into the holes in finned
bearing support as shown in Figure to ground the filter board assembly
lead. Torque screws (P/N MS35206-227) from 7.7 to 10.3 in.-lb (0,9 to 1,2
N · m).
I. Re-identification
(1) Re-identify the DC Starter-Generator as follows:

(a) Remove the old identification plate as given in paragraph 3.B.(2).

(b) Put the replacement identification plate (P/N 06-209285) on a wood

backing surface and metal stamp or vibra etch the MODEL NO., WT. LB.,
ROTATION, VOLTS MAX, AMPS MAX, SPEED RPM, VOLTS and AMPS
as shown in Figure 11.

NOTE: Identify this unit as a 23085-030.

(c) Metal stamp or vibra etch the data from the old identification plate to the
blocks identified with the asterisk ( ) of the replacement identification plate
(P/N 06-209285). *
NOTE: Do not transfer modification status stamping from the 23085-024
identification plate.

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Figure 11 - Replacement Identification Plate

(d) After the serial number has been transferred, for serial numbers that start
with “P1” metal stamp or vibra etch the suffix “/CA” after the serial number.

NOTE: This only applies to units with “P1###” serial numbers.

(e) Install the replacement identification plate with four drive screws (P/N
MS21318-13) as described in the referenced CMM.

NOTE: If the drive screw holes have become elongated, or if the drive
screw head breaks off or damages the screw hole, the stator
housing cannot be field repaired.

WARNING: KEEP ACRYLIC COATING AWAY FROM SOURCES OF HEAT,

SPARKS AND FLAME. CONFORMAL COATING IS
FLAMMABLE.

WARNING: DO NOT GET ACRYLIC COATING ON YOUR SKIN AND DO

NOT BREATHE THE FUMES. ACRYLIC COATING IS A
POISONOUS MATERIAL.

(f) Coat the replacement identification plate with acrylic coating (or equivalent)
and let the coating air dry.

23085-024-24-01
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Number 23085-025-24-01
ELECTRICAL POWER - DC STARTER-GENERATOR
DRIVE SHAFT ISOLATION - CONVERSION OF MODEL 23085-025
TO MODEL 23085-029
"THESE COMMODITIES, SOFTWARE, OR TECHNOLOGY WERE EXPORTED FROM THE UNITED STATES
IN ACCORDANCE WITH THE EXPORT ADMINISTRATION REGULATION. DIVERSION CONTRARY TO U.S.
LAW IS PROHIBITED."
THIS DOCUMENT CONTAINS INFORMATION PROPRIETARY TO GOODRICH CORPORATION AND IS
FURNISHED UPON THE EXPRESS CONDITION THAT THE INFORMATION CONTAINED HEREIN WILL NOT
BE USED DIRECTLY OR INDIRECTLY IN ANY WAY DETRIMENTAL TO THE INTEREST OF GOODRICH
CORPORATION.
1. PLANNING INFORMATION

A. Effectivity
This Service Bulletin (SB) applies to all Goodrich Corporation Model 23085-025 DC
Starter-Generators.

NOTE: Model 23085-015 Starter-Generators can be converted to model 23085-029,

but they must first be converted to model 23085-025 by following SB
23085-0XX-24-05.

B. Concurrent Requirements
None.

C. Reason
This conversion is required to electrically insulate the starter-generator drive shaft
from the armature and stator housing. Bearing shields and ceramic hybrid ball
bearings have also been added for enhanced bearing performance.

D. Description
This SB provides instructions for the conversion of starter-generator model 23085-025
to starter-generator model 23085-029. The conversion consists of updating the ADE
end bell (if required), new bearings, bearing shields, new isolated drive shaft,
armature, fan, dampener back plate, fan cap plug, dampener hub, washer assembly,
isolator and identification plate. See Table 3 for all parts used. The starter-generator
model 23085-025 is to be re-identified as a model 23085-029.

NOTE: Use this SB and the referenced Component Maintenance Manual (CMM) for
repair and overhaul of model 23085-029 until a CMM with Illustrated Parts
List (IPL) is issued.

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The anti-drive end (ADE) end bell (P/N 23085-1810) must have four holes drilled,
spot faced and tapped with heli-coils put in to relocate ground leads for the filter board
assembly. Also, the four bearing retainer holes must have heli-coils installed. If
heli-coils are not installed in the ribs of the anti-drive end (ADE) end bell (P/N
23085-1810) and in the bearing retainer holes, disassemble the bearing and brush
support assembly following the instructions in the DISASSEMBLY section of the
referenced CMM. Refer to Figure 1 for the location of required heli-coils. The following
options are available for the modification of the ADE end bell:

(1) For ADE end bells (P/N 23085-1810) that already include heli-coils in the holes
on the ribs and bearing retainer screw holes, no modification is necessary.

(2) If the ADE end bell (P/N 23085-1810) does not include heli-coils in the ribs,
proceed with modification steps in paragraph 3.F.(2).

(3) If the ADE end bell (P/N 23085-1810) does not include heli-coils in the bearing
retainer holes, proceed with modification steps in paragraph 3.F.(3).

E. Compliance
RECOMMENDED

Goodrich Corporation recommends that this conversion be considered during the next
removal or repair.

F. Approval
This SB has the approval of Goodrich Corporation and Pilatus Aircraft Ltd. Repairs
and conversions specified in this SB are in compliance with the approved data and
applicable Federal Aviation Regulations.

This document provides approval for conversion of model 23085-025 to the model
23085-029 configuration by Authorized Repair Centers that have been approved and
audited by Goodrich Corporation. The use of any parts, materials, or processes not
authorized by Goodrich Corporation invalidates the conversion of the units.

G. Manpower
An estimated 1.0 man-hour is required to complete the modification in this SB when
done at overhaul or repair.

If modification to the ADE end bell (P/N 23085-1810) is required in paragraph 3.F.,
an estimated additional 1.0 man-hour is required to complete the modification in this
SB when done at overhaul or repair.

H. Weight and Balance

Effect on weight: None.

Effect on overhung moment: None.

I. Electrical Load Data

Not Changed.

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J. References
Refer to the 23085 Series Component Maintenance Manual (CMM) with Illustrated
Parts List (IPL), ATA 24-30-19.

Refer to SB 23085-0XX-24-05 for model 23085-015 conversion to model 23085-025.

K. Other Publications Affected

A Component Maintenance Manual (CMM) with Illustrated Parts List (IPL) will be
created to include the model 23085-029 introduced in this SB.

2. MATERIAL INFORMATION

A. Material - Price and Availability

Required parts and pricing information are available from the following Goodrich
Corporation Exclusive Distributors:

REGION ADDRESS COMMUNICATIONS

AMERICAS: Goodrich Corporation PHONE: (1) 704 282 2500
Customer Service Desk AOG: (1) 800 735 7899
4115 Corporate Center Drive FAX: (1) 704 282 2560
Monroe, NC 28110-1313
USA
EUROPE/ Goodrich Corporation PHONE: (44) 121 451 5755
MIDEAST/ Customer Service Desk AOG: (44) 121 451 5904
AFRICA: Stratford Road FAX: (44) 121 451 5949
Solihull B90 4LA UK AOG: aog.helpdesk@goodrich.com
ASIA Goodrich Control Systems Pte. Ltd. PHONE: (65) 6545 9975
PACIFIC: Customer Service Desk AOG: (1) 800 735 7899
35 & 37 Loyang Way FAX: (65) 6545 9965
Republic of Singapore 508733

B. Technical Support Information

Technical questions should be directed to the location listed below:

ADDRESS COMMUNICATIONS
Goodrich Corporation PHONE (1) 330 487 2000
Technical Services FAX (1) 330 487 1902
8380 Darrow Road
Twinsburg, OH 44087 USA

Goodrich Corporation PHONE (44) 1296 663000

Power Systems Division FAX (44) 1296 663300
Westfield Road
Pitstone Green
Buckinghamshire LU7 9GT
UK

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C. Material Requirements
The following materials and tools are required for modification:

Item Description/Specification Source (CAGE Code)

Acrylic Coating HumiSeal Type 1B31 Chase Corporation
MIL-I-46058 Woodside, NY 11377
Ph: (718) 932-0800
Fax: (718) 932-4345
www.humiseal.com
(V0SR97)
Chemical Film Solution Chemical Film Solution Henkel Surface Technologies
MIL-C-5541, Class 3 32100 Stephenson Hwy
Madison, Heights, MI 48071 USA
Alodine 1200 Ph: 800-521-6895
Ph: 248-583-9300
Fax: 248-583-2976
www.hstna.com
(V1N6B3)
Lockwire NASM20995C32 Aircraft Tool Supply Company
P.O. Box 370
Oscoda, MI 48750
Ph: 1-800-248-0638
Ph: 1-989-739-1447
www.aircraft-tool.com
(V11138)
Lubricating and Altemp QNB 50 Klueber Lubrication
Assembly Paste Londonderry, NH
Ph: (603) 434-7704
Ph: (800) 447-2238
Fax: (603) 434-8046
www.klueber.com
(V3EZL6)
Tape Electrical Commercially Available
Threaded Inserts (4) for NAS1130-06-15 Emhart Teknologies
Ribs or equivalent Industrial Division
50 Shelton Technology Center
Threaded Inserts (4) for NAS1130-08L15D P.O. Box 859
Bearing Retainer Alt: MS21209C0815 Shelton, CT 06484 USA
Ph: 203-924-9341
or equivalent Fax: 203-925-3109
(V1D1Q0)
Thread Sealing Gasoila, Soft Set, Lead Free GSA Supply on-line
Compound Ph: 1-800-846-7325
www.gsasupplyco.com
Zinc Chromate Primer TT-P-1757, Composition G, Commercially Available
Color Y
Table 1 - Assembly Materials

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D. Tooling Requirements

Tools Vendor
Spanner Socket Torque Adapter Goodrich Corporation
TG-1277-1011
Table 2 - Special Tools

E. Parts Requirements
Use the parts listed for the starter-generator model 23085-025 in the ILLUSTRATED
PARTS LIST section of the CMM, but replace with the following new P/N listed in
Table 3 and Table 4 for conversion to starter-generator model 23085-029:

New P/N Qty. Nomenclature Old P/N Instruction

52-230080 1 KIT, N/A Install
Starter-Generator See Table 4
Conversion
23085-1743 1 INLET, Air 23085-1743 Alternate can be
ALT:23085-1740 used
MS35338-42 8 WASHER, Lock MS35338-42 Updated Quantity
Spring Used. Deleted four
lock washer’s used
with bearing retainer
23085-1810 1 End Bell, 23085-1810 If required, modify
Anti-Drive End with machined holes
(ADE) as specified in
paragraph 3.F.
See Figure 1
NOTE: Quantities listed are for one (1) starter-generator.
Table 3 - Model Conversion/Required Parts

New P/N Qty. Nomenclature Old P/N Instruction

06-209285 1 PLATE, Identification, ----- Remove/Install new
Replacement
23078-1840 1 SHAFT, Drive 23085-1355 Remove/Install new
23078-1802 1 ISOLATOR N/A Install new
02-5600-17 1 RING, Friction 02-5600-13 Remove/Install new
23032-1916 1 HUB, Dampener 23032-1901 Remove/Install new
23032-2716 1 BACK PLATE, 23032-2711 Remove/Install new
Dampener
Table 4 - Isolated Drive Shaft Conversion Kit 52-230080 Contents

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New P/N Qty. Nomenclature Old P/N Instruction
23088-1340 1 SHIELD, Drive End, 23032-1143 Remove/Install new
Bearing
23085-1507 1 ARMATURE 23085-1503 Remove/Install new
03-6009-25 2 BEARING, Ball, 03-6009-23 Remove/Install new
Ceramic Hybrid
MS35265-45 4 SCREW, Slotted MS35206-246 Install new
Fillister Head
23078-1860 1 PLUG, Fan Cap N/A Install new
23078-1873 1 ASSEMBLY, Washer AN960-416 Remove/Install new
MS172239 1 NUT, Spanner N/A Install new
MS172204 1 WASHER, Key, N/A Install new
Bearing Retainer
23078-1851 1 FAN, Axial 23065-1873 Remove/Install new
23088-1342 1 SHIELD, Anti-Drive N/A Install new
End, Bearing
MS16555-301 1 PIN, Straight, N/A Install new
Headless
MS35206-227 4 SCREW, Pan Head N/A Install new
MS35338-41 4 WASHER, Lock N/A Install new
02-4022-02 4 SCREW MS35265-45 Remove/Install new
NOTE: Quantities listed are for one (1) starter-generator.
Table 4 - Isolated Drive Shaft Conversion Kit 52-230080 Contents

3. ACCOMPLISHMENT INSTRUCTIONS
This SB provides instructions for the conversion of starter-generator model 23085-025 to
starter-generator model 23085-029. The conversion consists of updating the ADE end
bell (if required), new bearings, bearing shields, new isolated drive shaft, armature, fan,
dampener back plate, fan cap plug, dampener hub, washer assembly, isolator and
identification plate. See Table 3 for all parts used. The starter-generator model 23085-025
is to be re-identified as a model 23085-029.

NOTE: Use this SB and the referenced Component Maintenance Manual (CMM) for
repair of model 23085-029 until a CMM with Illustrated Parts List (IPL) is issued.

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The anti-drive end (ADE) end bell (P/N 23085-1810) must have four holes drilled, spot
faced and tapped with heli-coils put in to relocate ground leads for the filter board assembly.
Also, the four bearing retainer holes must have heli-coils installed. If heli-coils are not
installed in the ribs of the anti-drive end (ADE) end bell (P/N 23085-1810) and in the
bearing retainer holes, disassemble the bearing and brush support assembly following
the instructions in the DISASSEMBLY section of the referenced CMM. Refer to Figure 1
for the location of required heli-coils. The following options are available for the
modification of the ADE end bell:

(1) For ADE end bells (P/N 23085-1810) that already include heli-coils in the holes
on the ribs and bearing retainer screw holes, no modification is necessary.

(2) If the ADE end bell (P/N 23085-1810) does not include heli-coils in the ribs,
proceed with modification steps in paragraph 3.F.(2).

(3) If the ADE end bell (P/N 23085-1810) does not include heli-coils in the bearing
retainer holes, proceed with modification steps in paragraph 3.F.(3).

A. Preparation
All work performed on the DC starter-generator must be performed in a clean, dry
area free of oil, dirt, moisture and other contamination. The DC starter-generator must
be kept clean to ensure the operating effectiveness of the unit.

B. Disassembly
Disassemble the DC starter-generator as required, according to the DISASSEMBLY
section of the referenced CMM, to the extent necessary to remove the armature.

(1) Disassemble the bearing and brush support assembly to the extent necessary
to permit machining of the ADE end bell (P/N 23085-1810) as detailed in
paragraph 3.F.
(2) Remove the identification plate from the starter-generator as follows:
NOTE: Record the information from the identification plate before it is removed
to make sure the information is not lost by damage during removal.

(a) Use a smooth, flat tool that will not scratch the stator housing to wedge
under the edge of the identification plate and pry up on the corners of the
plate near the four drive screws that hold it in place to dislodge the plate
from the stator housing.
NOTE: This will tear the corners of the light metal identification plate.
(b) Remove the remaining metal from under the head of each drive screw.
(c) Use a small pair of sidecutters with the flat face to the stator housing to
wedge in under the head of each drive screw to hold the shank of the screw
and turn out counterclockwise.
NOTE: Use a dull pair of small sidecutters so that you do not cut the head
of the drive screw off.

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C. Cleaning
Clean unit and disassembled parts according to the CLEANING section instructions
of the referenced CMM.

D. Check
Inspect the unit according to the CHECK section instructions of the referenced CMM.

E. Repair
Repair parts as specified in the REPAIR section of the referenced CMM. Replace
parts as specified in the CHECK section that cannot be repaired.

F. Modification of the Anti-Drive End (ADE) End Bell

(1) Refer to the REPAIR section of the referenced CMM and SPD (Standard Practice
Document) 1003 for removal of surface coatings.

(2) If required, install threaded inserts (heli-coils), (P/N NAS1130-06-15) into ribs,
as shown in Figure 1 and as follows:

(a) Elongated spotface, if not already included, a 0.31 inch (7,8 mm) diameter
located 38° counter-clockwise from the rivnuts to a depth of 3.15 inch
(80,0 mm) from the opposite end of the ADE end bell located on a 2.87 inch
(72,9 mm) diameter.

NOTE: 100% cleanup of the ADE end bell is not required.

(b) Drill through on a bolt circle diameter of 2.87 inch (72,9 mm)
with #26 0.147 inch (0,37 mm) drill bit.

(c) Tap through for 0.138-32 UNC-3B using 06CPB heli-coil tap, four places
equally spaced on a bolt circle diameter of 2.87 inch (72,9 mm).

(d) Clean each hole for threaded inserts by removing burrs or raised metal.

WARNING: KEEP ZINC CHROMATE PRIMER AWAY FROM SOURCES OF

HEAT, SPARKS AND FLAME. ZINC CHROMATE PRIMER IS
FLAMMABLE.

WARNING: DO NOT GET ZINC CHROMATE PRIMER ON YOUR SKIN AND

DO NOT BREATHE THE FUMES. ZINC CHROMATE PRIMER
IS A POISONOUS MATERIAL.

(e) Coat four new (P/N NAS1130-06-15) heli-coil inserts with zinc chromate
primer and install them while wet into the rib screw holes.

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Figure 1 - Location of Heli-Coils in the Anti-Drive End (ADE) End Bell

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(3) If required, install threaded inserts (heli-coils), (P/N NAS1130-08L15D, Alt:
MS21209C0815) into bearing retainer screw holes, as shown in Figure 1 and
as follows:

(a) Drill through with a 0.1708 to 0.1781 inch (4,338 to 4,524 mm) drill bit. The
four holes are located on a 2.000 inch (50,8 mm) basic diameter. See
Figure 1.

(b) Countersink the bearing retainer screw holes 115° to 125° to a 0.20 to
0.23 inch (5,1 to 5,8 mm) diameter.

(c) Tap 0.164-32 UNC-3B using a 2CPB heli-coil tap.

(d) Clean each hole for threaded inserts by removing burrs or raised metal.

WARNING: KEEP ZINC CHROMATE PRIMER AWAY FROM SOURCES OF

HEAT, SPARKS AND FLAME. ZINC CHROMATE PRIMER IS
FLAMMABLE.

WARNING: DO NOT GET ZINC CHROMATE PRIMER ON YOUR SKIN AND

DO NOT BREATHE THE FUMES. ZINC CHROMATE PRIMER
IS A POISONOUS MATERIAL.

(e) Coat four new P/N NAS1130-08L15D (Alt. MS21209C0815) heli-coil

inserts with zinc chromate and install them into the bearing retainer screw
holes to a depth of 0.05 to 0.07 inch (1,3 to 1,8 mm) below the counterbore
surface. This measurement is to the start of the heli-coil wire. Break off the
tang if required.

WARNING: CHEMICAL CONVERSION MATERIALS ARE POISONOUS AND

CAN CAUSE EXPLOSIONS WHEN MIXED WITH ACIDS, REDUCING
AGENTS COMBUSTIBLE AND OXIDIZING MATERIALS. ISOLATED
STORAGE OF THESE MATERIALS IS MANDATORY.

WARNING: BEFORE YOU USE CHEMICAL CONVERSION MATERIALS, PUT

ON A RESPIRATOR, RUBBER APRON, RUBBER GLOVES AND
EYE PROTECTION. THIS WILL PREVENT INJURY FROM SPILLS
AND FROM THE FUMES.

WARNING: KEEP CHEMICAL CONVERSION MATERIALS AWAY FROM

SOURCES OF HEAT, SPARKS AND FLAME. CHEMICAL
CONVERSION MATERIALS ARE FLAMMABLE.

(4) If required, touch up with chemfilm in the area that was reworked.

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WARNING: KEEP THE PAINT AWAY FROM SOURCES OF HEAT, SPARKS AND
FLAME. THE PAINT IS FLAMMABLE.

(5) If required, REPAIR the surface coating of the ADE end bell using red insulating
enamel. Refer to the REPAIR section of the referenced CMM and SPD (Standard
Practice Document) 1002.

NOTE: There is to be no red insulating enamel on the 0.31 inch (7,9 mm) spot
face surfaces on the ribs.

G. Assembly
Assemble the DC Starter-Generator as specified in the ASSEMBLY section of the
referenced CMM and as follows:

NOTE: Assembly must be done using a modified or original ADE end bell (P/N
23085-1810) that has heli-coils installed into the ribs and bearing retainer
holes of the ADE end bell as shown in Figure 1.

NOTE: If necessary, attach brush holders to ADE end bell as specified in the
ASSEMBLY section of the referenced CMM. Reference SPD 1004 for brush
alignment tooling.

(1) Press ball bearing (P/N 03-6009-25) into bearing and brush support assembly.
See Figure 2.

(a) Put ADE hub support on arbor press table.

(b) Set bearing and brush support assembly (brush holder side down) on
anti-drive end hub support.

WARNING: DO NOT LET PASTE TOUCH THE EYES OR SKIN. OBEY THE
MANUFACTURER’S INSTRUCTIONS. REFER TO MSDS
SHEET BEFORE PASTE IS USED.

(c) Apply a light coating of lubricating and assembly paste to the inside
diameter of the bearing liner of bearing and brush support assembly.

(d) Set a ball bearing (P/N 03-6009-25) onto bearing liner of ADE end bell
assembly.

NOTE: The Goodrich Corporation part marking on the bearing (P/N

03-6009-25) must be facing towards the inside of the
Starter-Generator.

(e) Set an outer race bearing driver onto ball bearing (P/N 03-6009-25).

(f) Press ball bearing (P/N 03-6009-25) into bearing liner of ADE end bell
assembly until bearing is fully seated against inner lip of bearing liner.

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Figure 2 - Ball Bearing Installation

(2) Attach bearing retainer to the bearing and brush support assembly as follows:
NOTE: The ADE end bell must have heli-coil inserts for attachment of the slotted
leads of filter assemblies as specified in modification procedures in
paragraph 3.F.

WARNING: THREAD SEALING COMPOUND IS DANGEROUS TO

PERSONS. USE ONLY IN AN AREA WITH A GOOD FLOW OF
AIR. KEEP AWAY FROM SOURCES OF HEAT, SPARKS AND
FLAME. DO NOT BREATHE THE FUMES. PREVENT SKIN
CONTACT. PUT ON PROTECTIVE CLOTHING AND EYE
PROTECTION.

(a) Apply thread sealing compound to the threads of four attaching screws
(P/N 02-4022-02).

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CAUTION: DO NOT PUT SPRING LOCK WASHERS ON SCREWS FOR
BEARING RETAINER. SPRING LOCK WASHERS ARE NOT
USED ON THE SCREWS THAT ATTACH THE BEARING
RETAINER. THIS CAN CAUSE INTERFERENCE WITH THE
BEARING SHIELD.

(b) Attach bearing retainer to bearing and brush support assembly with
attaching screws (P/N 02-4022-02).
(3) Insulate slotted lead terminals of filter board assemblies with electrical insulating
tape or equivalent.
NOTE: Filter board lead wires are not to be attached until after acceptance
testing.

(4) Install the DE bearing shield (P/N 23088-1340) and ball bearing
(P/N 03-6009-25) onto drive end of armature (P/N 23085-1507) as follows:
See Figure 3.

CAUTION: DO NOT TOUCH POLISHED SURFACE OF COMMUTATOR

WITH BARE HANDS. SKIN ACIDS AND OILS CAN
CONTAMINATE CONDUCTING SURFACES CAUSING
CORROSION AND/OR POOR ELECTRICAL CONTACT.

(a) Put armature support on arbor press table.

Figure 3 - Bearing Shield and Ball Bearing Installation

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(b) Set armature (P/N 23085-1507) (commutator end down) onto armature
support.

CAUTION: ORIENT THE DRIVE END BEARING SHIELD WITH THE PART
IDENTIFICATION STAMPING FACING INBOARD.

(c) Install the DE bearing shield (P/N 23088-1340) to drive end of armature
shaft with the part marking facing toward the armature.

(d) Set ball bearing (P/N 03-6009-25) onto armature shaft.

NOTE: The Goodrich Corporation part marking on the bearing (P/N

03-6009-25) must be facing towards the inside of the
starter-generator.

(e) Set inner race bearing driver on ball bearing (P/N 03-6009-25).

(f) Press ball bearing (P/N 03-6009-25) down onto armature shaft making
sure bearing is fully seated against bearing shield (P/N 23088-1340).

(g) Install spacer and retaining ring as specified in the ASSEMBLY section of
the referenced CMM.

NOTE: Sharp edges of the retaining ring should be facing away from the
DC starter-generator.

(5) Prepare armature (P/N 23085-1507) for coarse brush seating according to the
referenced CMM and IAW SPD (Special Practice Document 1006).

CAUTION: DO NOT TOUCH POLISHED SURFACE OF COMMUTATOR WITH

BARE HANDS. SKIN ACIDS AND OILS CAN CONTAMINATE
CONDUCTING SURFACES CAUSING CORROSION AND/OR POOR
ELECTRICAL CONTACT.

(6) Attach bearing and brush support assembly to armature (P/N 23085-1507)
according to the ASSEMBLY section of the CMM.

(7) Calculate and install the shim pack and spring wave washer into the drive end
bearing support assembly, and install the bearing and brush support assembly
with attached armature into the stator and housing assembly as specified in the
ASSEMBLY section of the referenced CMM. Reference Figure 4.
(8) Install dampener back plate (P/N 23032-2716) on the armature shaft with the
recessed side facing away from the starter-generator.

(9) Install dampener hub (P/N 23032-1916) on drive shaft (P/N 23078-1840).

NOTE: Make sure that the dampener hub is fully seated on the taper of the
drive shaft.

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Figure 4 - Drive End Bearing Support Assembly with Preload Stack and Bearing Shield

(10) Install dampener plate on splined dampener hub (P/N 23032-1916). Make sure
that dampener plate is installed flush to shoulder of dampener hub
(P/N 23032-1916).

(11) Install friction ring (P/N 02-5600-17) to turned recess of dampener back plate.

Figure 5 - Installation of Isolator on the Drive Shaft

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(12) Install drive shaft (P/N 23078-1840) with isolator (P/N 23078-1802), ADE bearing
shield (P/N 23088-1342) and axial fan (P/N 23078-1851) as follows.
See Figure 5 and Figure 6.

(a) Slide isolator (P/N 23078-1802) onto the drive shaft square spline until the
isolator (P/N 23078-1802) is flush against the drive shaft square spline
shoulder. See Figure 5.

(b) Insert drive shaft (P/N 23078-1840) through the armature shaft. Make sure
that drive shaft square spline engages armature shaft spline and that
friction ring (P/N 02-5600-17) is correctly positioned on dampener back
plate.

Figure 6 - Assembly of ADE Drive Shaft Isolation

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(c) Press the fan cap plug (P/N 23078-1860) onto the fan. See Figure 6 for
proper orientation.

NOTE: Verify that key washer (P/N MS172204) tab is locked into a slot of
the spanner nut (P/N MS172239) before installing the fan cap plug
(P/N 23078-1860).

(d) Slide anti-drive end bearing shield (P/N 23088-1342) followed by the axial
fan (P/N 23078-1851) on the armature shaft and locate by installing the
straight headless pin (P/N MS16555-301) onto the armature shaft keyway.

NOTE: Make sure the part marking of the ADE bearing shield (P/N
23088-1342) is facing towards the outside of the unit.

(e) Attach key washer (P/N MS172204) on armature shaft as shown in

Figure 6, locate key washer (P/N MS172204) on armature shaft by aligning
the key washer inner tab with the armature keyway.

NOTE: The key washer (P/N MS172204) should have the rounded
surface seated against the axial fan (P/N 23078-1851).

(f) Secure the fan (P/N 23078-1851) and key washer (P/N MS172204) with
spanner nut (P/N MS172239).

NOTE: The spanner nut (P/N MS172239) should have the rounded
surface seated against the key washer (P/N MS172204).

(g) Put the spline wrench on drive end of drive shaft spline and torque the
spanner nut (P/N MS172239) to 150 to 200 in.-lb (16,9 to 22,6 N · m) with
a spanner wrench (Table 2).

(h) Loosen the spanner nut to zero in.-lb and finally tighten to a final torque of
80 to 100 in.-lb (9,0 to 11,3 N · m).

(i) Lock one tab of the key washer (P/N MS172204) into a slot of the spanner
nut (P/N MS172239).

(j) Put washer assembly (P/N 23078-1873) onto the drive shaft (P/N
23078-1840) with the largest washer facing the spanner nut and secure
with self-locking nut.

(k) Use the spline wrench on drive end of drive shaft spline and torque nut to
80 to 100 in.-lb (9,0 to 11,3 N · m).

(13) Install brushes as specified in the ASSEMBLY section of the referenced CMM
and IAW SPD (Special Practice Document 1006).

(14) Attach air inlet (P/N 23085-1743, Alt: P/N 23085-1740). See Figure 7.

(a) Put air inlet (P/N 23085-1743, Alt: P/N 23085-1740) on the bearing and
brush support assembly. Align the four screw holes on the air inlet with the
screw holes on the bearing and brush support assembly.

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Figure 7 - Attaching Air Inlet

WARNING: THREAD SEALING COMPOUND IS DANGEROUS TO

PERSONS. USE ONLY IN AN AREA WITH A GOOD FLOW OF
AIR. KEEP AWAY FROM SOURCES OF HEAT, SPARKS AND
FLAME. DO NOT BREATHE THE FUMES. PREVENT SKIN
CONTACT. PUT ON PROTECTIVE CLOTHING AND EYE
PROTECTION.

(b) Apply thread sealing compound to threads of four screws (P/N

MS35265-45).

(c) Install air inlet (P/N 23085-1743, Alt: P/N 23085-1740) with four attaching
screws (P/N MS35265-45) to a torque of 13.5 to 18.0 in.-lb (1,5 to 2,0 N · m)
as shown.

NOTE: Do not attach lockwire to screws until after acceptance testing.

(d) After acceptance testing, lockwire (MS20995C32) four attaching screws
(P/N MS35265-45) IAW MS33540.

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H. Testing
Test the DC Starter-Generator according to Goodrich Corporation TEST AND FAULT
ISOLATION section as given for starter-generator model 23085-025 and as follows:

NOTE: The filter board assembly leads must remain electrically isolated from both
the stator housing, and bearing and brush support assembly until acceptance
testing is complete. Wrap terminal ends with electrical tape or equivalent to
prevent contact with stator housing.

Acceptance procedures are to be performed in the following sequence:

(1) Continuous Operating Speed, Equalizing Voltage, and Minimum Speed:

(a) Operate starter-generator at 12,000 RPM, 30 VDC, 300 A for 15 minutes.

Use a thermocouple or suitable equivalent to record frame temperature.

(b) Measure and record voltage between terminals D and E: Voltage must be
within limits in Figure 8.

(c) Measure and record inlet air temperature.

(d) Measure and record winding or frame temperature.

(e) Immediately operate generator at minimum speed for regulation at

7,200 RPM, 30 VDC, 300 A (stabilization not required).

(f) Record field current and voltage between terminals B and A.

(g) Acceptance Limits:

1 Field Current: Not to be more than 10 A.

2 External Field Circuit Resistance (terminals B to A):

a Calculate resistance between terminals B and A by dividing B-A

voltage by field current.

b External field circuit resistance must be 0.5 Ω minimum.

3 Open the field circuit and record the residual voltage (B to E):

a Residual voltage must not be less than 0.8 V.

(2) Minimum Speed:

(a) Reduce the starter-generator speed to 6,950 RPM, 28.5 VDC, 300 A and
operate for 15 minutes.

(b) Measure and record field current and B to A voltage.

(c) Calculate (B to A) resistance by dividing B-A voltage by field current.

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(d) Acceptance Limits:

1 Field current: Not to be more than 10 A.

2 External field circuit resistance must be 0.5 Ω minimum.

Figure 8 - Equalizing Voltage Diagram

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(3) Residual Voltage Test:

(a) Immediately after minimum speed test, operate the starter-generator at

12,000 RPM with an open field circuit. Record the residual voltage between
terminals B and E.

(b) Acceptance Limits:

1 Residual voltage must not be more than 3.6 V at 12,000 RPM.

(4) Overspeed:

(a) With the starter-generator hot from the previous test, increase speed to
14,000 RPM with an open field circuit for 5 minutes.

(b) Acceptance Limits:

1 There must be no indication of failure (noise, vibration, loosening of

parts, etc.).

(5) Commutation:

(a) Operate the starter-generator at 12,000 RPM, 300 A. See Figure 9.

Figure 9 - Correct Viewing Angle

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(b) Acceptance Limits:

1 Continuous pinpoint sparking is not to be more than approximately

0.12 inch (3,0 mm) beyond the trailing edge of each brush with no
more than 10 single sparks extending up to 0.25 inch (6,0 mm) in any
one minute period. Sparks beyond 0.25 inch (6,0 mm) must be
considered arcing.

2 Arrow “A” shows the correct viewing angle for finding any sparking.
Arrow “B” shows the correct viewing angle, when viewed from the
anti-drive end for seeing if commutation is black or pin point.

(6) Dielectric Test:

NOTE: With the starter-generator still hot from testing.

WARNING: BEFORE USING HIGH VOLTAGE TESTER, MAKE CERTAIN

TESTER HAS BEEN TURNED “OFF” AND THAT NO ONE IS
TOUCHING ANY PORTION OF CONNECTION POINTS OR
PROBE LEAD WIRES. FAILURE TO COMPLY WITH THIS
WARNING CAN RESULT IN SEVERE ELECTRICAL SHOCK.

CAUTION: THIS TEST IS ACCOMPLISHED ONLY DURING ACCEPTANCE

TESTING AND ONLY FOR STARTER-GENERATORS THAT
HAVE BEEN CLEANED AND OVERHAULED. USE A DUMMY
TERMINAL BLOCK OR DISCONNECT STATOR TERMINAL
LEADS FROM TERMINAL BLOCK.

(a) Operating Instructions:

1 Turn all power off at generator drive stand.

2 Disconnect starter-generator from test circuit.

3 Disconnect stator leads from terminal block.

4 Remove terminal block from stator.

5 Remove 4 filter leads from bearing retainer holding screws making

certain filter lead terminals do not contact frame and insulate lead ends
by applying tape or plastic caps.

6 Remove commutator viewing adapter.

7 Connect all stator terminal leads (A+, B+, C+ where applicable, D and
E-) of dummy terminal block together.

8 Attach positive (red) lead of high pot tester to connected terminal leads.

9 Attach negative (black) lead of high pot tester to an unfinished surface

of the starter-generator frame.

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CAUTION: APPLY AND REMOVE TEST VOLTAGE AT A UNIFORM
RATE NOT TO BE MORE THAN 100 V PER SECOND.

10 Apply dielectric test voltage of 250 V rms, commercial frequency, for

one minute or 300 V rms, commercial frequency, for one second.

(b) Acceptance Limits:

Any arcing as evidenced by flashover (surface discharge), spark-over (air

discharge) breakdown (puncture discharge) or leakage current no more
than 5 mA will be evidence of damp, dirty, weak or defective components.

(7) Insulation Resistance Test of Isolated Drive Shaft:

CAUTION: MAKE SURE THE DRIVE SHAFT IS NOT TOUCHING THE

INSIDE OF THE ARMATURE SHAFT. THIS CAN BE FIXED BY
CENTERING THE DRIVE SHAFT IN THE ARMATURE SHAFT.

(a) Apply 30 VDC with a commercial meg ohm meter as follows:

1 Between the drive spline and the starter-generator stator housing.

2 Between the drive spline and the fan.

3 Measure and record the insulation resistance values.

(b) Acceptance Limits:

1 Insulation resistance must be greater than 1 MΩ.

(8) Locked Rotor Test for Series Start DC Starter-Generators:

(a) Mount the starter-generator to the test mounting flange.

(b) With the voltage output of the DC power supply set to zero turn the power
supply to the ON position.

CAUTION: DO NOT ENERGIZE UNIT FOR MORE THAN 5 SECONDS.

(c) With 0.2 Ω connected between terminals A and C, quickly increase voltage
between terminals C and E until the output torque of 20 ft-lbs (27,1 N · m)
is reached. Measure and record current.

(d) Acceptance Limits:

1 Current is not to be more than 630 A and voltage must not be more
than 9.5 V.

NOTE: If current is too high, rotate armature to a different position and

repeat test.

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(9) Residual Voltage Test:

(a) Operate the starter-generator at 7,200 RPM with an open field circuit.
Record the residual voltage between terminals B and E.

(b) Acceptance Limits:

1 Residual voltage must not be less than 0.5 V.

(10) Commutator Runout

NOTE: This test is to be accomplished only during acceptance testing after

completion of overhaul and the armature’s commutator has been
resurfaced.

(a) Operating Instructions:

CAUTION: DO NOT TOUCH SURFACE OF COMMUTATOR WITH

BARE HANDS. ACIDS AND OILS ON SKIN CAN
CONTAMINATE CONDUCTING SURFACES CAUSING
CORROSION AND POOR ELECTRICAL CONTACT.

CAUTION: ONLY ROTATE COMMUTATOR IN CLOCKWISE

DIRECTION AS VIEWED FROM THE ADE.

1 Rotate armature and measure the commutator total runout and

bar-to-bar runout between adjacent commutator bars with a dial
indicator or suitable equivalent.

2 Measure and record commutator total indicated run-out. Maximum

total indicated run-out not to be more than 0.0008 inch (0,02 mm).

3 Measure and record adjacent bar-to-bar run-out. Maximum bar-to-bar

run-out not to be more than 0.0002 inch (0,005 mm).

(11) After successful completion of acceptance testing, install the filter board
assembly leads to the bearing and brush support assembly as follows:
(a) Put a lockwasher (P/N MS35338-41) on each of the four screws
(P/N MS35206-227).
WARNING: THREAD SEALING COMPOUND IS DANGEROUS TO
PERSONS. USE ONLY IN AN AREA WITH A GOOD FLOW OF
AIR. KEEP AWAY FROM SOURCES OF HEAT, SPARKS AND
FLAME. DO NOT BREATHE THE FUMES. PREVENT SKIN
CONTACT. PUT ON PROTECTIVE CLOTHING AND EYE
PROTECTION.

(b) Apply sealing compound to threads of four screws (P/N MS35206-227).

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Figure 10 - Fastening Ground Wires to the ADE end bell

(c) Put the slotted terminal end of the lead from the filter board assembly on
the screw and install the screw (P/N MS35206-227) into the holes in finned
bearing support as shown in Figure 10 to ground the filter board assembly
lead. Torque screws (P/N MS35206-227) from 7.7 to 10.3 in.-lb (0,9 to
1,2 N · m).
I. Re-identification
(1) Re-identify the DC Starter-Generator as follows:

(a) Remove the old identification plate as given in paragraph 3.B.(2).

(b) Put the replacement identification plate (P/N 06-209285) on a wood

backing surface and metal stamp or vibra etch the MODEL NO., WT. LB.,
ROTATION, VOLTS MAX, AMPS MAX, SPEED RPM, VOLTS and AMPS
as shown in Figure 11.

NOTE: Identify this unit as a 23085-029.

(c) Metal stamp or vibra etch the data from the old identification plate to the
blocks identified with the asterisk ( ) of the replacement identification plate
(P/N 06-209285). *
NOTE: Do not transfer modification status stamping from the 23085-025
identification plate.

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SERVICE BULLETIN

Figure 11 - Replacement Identification Plate

(d) After the serial number has been transferred, for serial numbers that start
with “P1” metal stamp or vibra etch the suffix “/CA” after the serial number.

NOTE: This only applies to units with “P1###” serial numbers.

(e) Install the replacement identification plate with four drive screws
(P/N MS21318-13) as described in the referenced CMM.

NOTE: If the drive screw holes have become elongated, or if the drive
screw head breaks off or damages the screw hole, the stator
housing cannot be field repaired.

WARNING: KEEP ACRYLIC COATING AWAY FROM SOURCES OF HEAT,

SPARKS AND FLAME. CONFORMAL COATING IS
FLAMMABLE.

WARNING: DO NOT GET ACRYLIC COATING ON YOUR SKIN AND DO

NOT BREATHE THE FUMES. ACRYLIC COATING IS A
POISONOUS MATERIAL.

(f) Coat the replacement identification plate with acrylic coating (or equivalent)
and let the coating air dry.

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