CMM 23081 Series I (International) - PDFCOFFEE.COM (2025)

DC STARTER-GENERATOR 23081 SERIES I INCLUDES MODELS: 23081-001, -002, -003, 004, -007, -008, -011, -011-1, -012, -012-1, -017, -018, -022, -022A, -023, -023A, -024, -042, -043, -056, -057, -059, -063, -069, -070, -072, -073

ORIGINAL ISSUE: FEBRUARY 1, 1977 REVISION 8: OCTOBER 17, 2008

These commodities, technology or software were exported from the United States in accordance with the Export Administration Regulations. Diversion contrary to U.S. law is prohibited. ECCN: 9E991

© Copyright 2008 Goodrich Corporation - Copyright in this manual and associated documents and drawings belongs to Goodrich Corporation. All rights reserved. No reproduction of all or part of this manual shall be made without the prior written consent of Goodrich Corporation. This document contains information that may be confidential. Disclosure to others of information contained herein requires the written consent of Goodrich Corporation.

Distributed via the Goodrich Technical Publications Web Portal. Refer to https://techpubs.goodrich.com to confirm the latest revision standard.

COMPONENT MAINTENANCE MANUAL WITH ILLUSTRATED PARTS LIST

THIS DOCUMENT SUBJECT TO THE CONTROLS AND RESTRICTIONS ON THE FIRST PAGE.

Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I EXCLUSIVE DISTRIBUTOR

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Component Parts and AOG

Repair and Overhaul Services

Genuine Goodrich Corporation component parts are to be purchased from the following Exclusive Distributors:

Goodrich operates three major repair and overhaul service centers for electrical Power Systems Products. Each center can service the majority of Goodrich products.

ADDRESS

COMMUNICATIONS

ADDRESS

COMMUNICATIONS

WORLDWIDE: AOG Desk (24/7 Service)

PHONE: (44) 121 451 5904 FAX: (44) 121 451 6133

Goodrich Corporation Maintenance Repair and Overhaul 4115 Corporate Center Drive Monroe, NC 28110-1313 USA

PHONE: (1) 704 282 2500 FAX: (1) 704 282 2560

AMERICAS: Goodrich Corporation 4115 Corporate Center Drive Monroe, NC 28110-1313 USA

PHONE: (1) 704 282 2500 AOG: (1) 800 735 7899 FAX: (1) 704 282 2560

Goodrich Corporation Maintenance Repair and Overhaul Westfield Road Pitstone Green Buckinghamshire LU7 9GT UK

PHONE: (44) 1296 663000 FAX: (44) 1296 663300 EMAIL: [emailprotected]

EUROPE/MIDEAST /AFRICA: Goodrich Corporation Stratford Road Solihull B90 4LA UK

PHONE: (44) 121 451 5788 AOG: (44) 121 451 5904 FAX: (44) 121 451 6133 aog.helpdesk@goodrich. com

Goodrich Control Systems, Pty. Ltd. 84-92 Epsom Road Zetland, Sydney NSW 2017 Australia

PHONE: (61) 2 9315 3700 AOG: (61) 2 9937 2553 FAX: (61) 2 9313 7676

ASIA/PACIFIC: Goodrich Control Systems Pte. 35 & 37 Loyang Way Republic of Singapore 508733

PHONE: (65) 6545 9975 AOG: (65) 6545 6253 FAX: (65) 6543 0419

In addition, Goodrich has a worldwide network of Authorized Service Centers (ASC) that can be found as listed on the Goodrich Corporation, Power Systems Division website.

Technical Publications

Technical Support Information

Technical publications, distributions and subscriptions should be directed to the distribution administrator listed below:

Technical questions should be directed to the location listed below:

ADDRESS

COMMUNICATIONS

ADDRESS

COMMUNICATIONS

Goodrich Corporation Twinsburg Technical Publications Distribution 4115 Corporate Center Drive Monroe, NC 28110-1313 USA

PHONE: (1) 704 282 2531 FAX: (1) 704 282 2739 EMAIL: [emailprotected]

Goodrich Corporation Technical Services 8380 Darrow Road Twinsburg, OH 44087 USA

PHONE: (1) 330 487 2000 FAX: (1) 330 487 1902

Goodrich Corporation Power Systems Division Westfield Road Pitstone Green Buckinghamshire LU7 9GT UK

PHONE: (44) 1296 663000 x3149 FAX: (44) 1296 663300 EMAIL: [emailprotected]

Goodrich Corporation Power Systems Division Westfield Road Pitstone Green Buckinghamshire LU7 9GT UK

PHONE: (44) 1296 663000 FAX: (44) 1296 663300

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I

HIGHLIGHTS

REVISION 8, DATED OCTOBER 17/08 Remove the complete existing manual and replace with this full revision of the manual. Retain the Highlights page(s) in the front of the manual for future reference. This Component Maintenance Manual has been fully revised to include the latest engineering information and also to include Service Bulletin(s) and Service Information Letter(s) as listed in the Service Bulletin and Service Information List in the front of the manual. The content has been fully converted to provide customers with electronic delivery of the CMM on CD-ROM and is distributed in a “pdf” format compatible with the Adobe Acrobat Reader® that can be obtained from Adobe. The contents of this revision has technical changes individually identified with revision bars. Also, the new format of the Goodrich Corporations’ manuals was significantly changed to be more consistent with current standards set by the Air Transport Association of America Specifications ATA-100 and ATA-2100. Key items included in this revision: • Added DC Starter-Generator Models 23081-072 and -073. • New contact information and company change to Goodrich Corporation. • Added change bars for updated material, which includes enhanced detail to testing, disassembly, assembly, check, repair, fits and clearances, and special tools. • Incorporated newly released SBs/SILs/TRs. • Updated the illustrated parts list to include the latest builds. • Section 10001 was moved to the last section of the CMM to conform to ATA 2200.

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TO: Holders of Component Maintenance Manual with IPL for DC Starter-Generator Models 23081-001, -002, -003, -004, -007, -008, -011, -011-1, -012, -012-1, -017, -018, -022, -022A, -023, -023A, -024, -042, -043, -056, -057, -059, -063, -069, -070, -072 and -073. Attached to this transmittal letter is Revision 8 of the Component Maintenance Manual with IPL (basic issue dated February 1, 1977).

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I

Revision Number

Date Issued

Date Inserted into CMM

Initials

Original Issue

Feb 1/77

May 1/81

Jun 15/84

Aug 15/86

Feb 29/96

May 22/96

Jan 31/02

Sep 15/04

Oct 17/08

Retain this record in the front of the CMM. On receipt of revisions, insert affected pages into the manual. Record revision number, date issued, date inserted into the CMM, and initials on this page.

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RECORD OF REVISIONS

THIS DOCUMENT SUBJECT TO THE CONTROLS AND RESTRICTIONS ON THE FIRST PAGE.

Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I

Temporary Revision Number

Number Pages

Date Issued

Date Inserted

Initials

Date Removed

Initials

24-01

6/10/02

Sep 15/04

24-02

11/8/02

Sep 15/04

24-03

11/8/02

Sep 15/04

24-04

11/8/02

Sep 15/04

24-05

11/8/02

Sep 15/04

24-06

11/8/02

Sep 15/04

24-07

11/26/02

Sep 15/04

24-08

08/17/07

Oct 17/08

24-09

01/31/08

Oct 17/08

Retain this record in the front of the CMM. On receipt of temporary revisions, insert affected pages into the manual. Record the temporary revision number, page number, date issued, date inserted into the CMM, and initials on this page. When temporary revisions are removed from the CMM, record the date removed and initials. RECORD OF TEMPORARY REVISIONS © 2008 Goodrich Corporation

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RECORD OF TEMPORARY REVISIONS

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SERVICE BULLETIN LIST Status

Rev

Date Issued

23081-01

Incorporated

06/15/84

23081-02

Incorporated

10/05/87

23081-0XX-24-03

Superseded

07/10/91

23081-0XX-24-04

Superseded

04/22/94

23081-0XX-24-05

Incorporated

11/22/94

23081-002-24-01

Incorporated

08/03/06

23081-018-24-01

Incorporated

07/31/06

23081-023-24-04

Incorporated

10/15/89

23081-023-24-05

Incorporated

11/22/94

23081-04X-24-01

Superseded

04/22/94

23081-04X-24-02

Incorporated

09/25/06

23081-043-24-01

Incorporated

05/04/07

23081-056-24-01

Incorporated

08/11/03

23081-057-24-01

Incorporated

09/25/06

23081-063-24-01

Superseded

04/03/06

Service Bulletin Number

Status

Rev

Date Issued

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Service Bulletin Number

Retain this record in the front of the CMM. On receipt of service bulletins, record the service bulletin number, status (valid or invalid), revision number (if applicable) and the date issued.

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SERVICE INFORMATION LETTER LIST Status

Rev

Date Issued

02-5600-02

Valid

04/22/02

03-6009-XX-01

Valid

05/02/95

23072-1400-01

Valid

02/07/94

23081-0XX-01

Valid

04/10/00

23081-018-01

Limited Dist.

02/07/96

23081-023-01

Limited Dist.

02/14/95

23081-043-24-01

Valid

08/27/07

23703

Valid

01/24/97

GSIL 2004-01

Limited Dist.

06/25/04

GSIL 2006-01

Valid

09/26/06

GSIL 2006-02

Valid

09/20/06

GSIL 2007-01

Valid

07/30/07

GSIL 2008-01

Valid

02/29/08

Service Information Letter Number

Status

Rev

Date Issued

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Service Information Letter Number

Retain this record in the front of the CMM. On receipt of Service Information Letters, record the Service Information Letter number, status, revision number (if applicable) and the date issued.

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LIST OF EFFECTIVE PAGES Page

EXCLUSIVE DISTRIBUTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii RECORD OF REVISIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii iv RECORD OF TEMPORARY REVISIONS . . . . . . . . . . . . . . . . . . . . . . . v vi SERVICE BULLETIN LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii viii SERVICE INFORMATION LETTER LIST . . . . . . . . . . . . . . . . . . . . . . . ix x LIST OF EFFECTIVE PAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi xii xiii xiv xv xvi xvii xviii TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xix xx LIST OF ILLUSTRATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxi xxii xxiii xxiv LIST OF TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxv xxvi INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxvii xxviii xxix xxx xxxi xxxii DESCRIPTION AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2 3 4 5 6 7 8 9 10

Date Oct 17/08 Oct 17/08 Blank Oct 17/08 Blank Oct 17/08 Blank Oct 17/08 Blank Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Blank Oct 17/08 Blank Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Blank Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Blank Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08

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Title

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Page

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DESCRIPTION AND OPERATION (Continued) . . . . . . . . . . . . . . . . . . 11 12 13 14 15 16 17 18 19 20 TESTING AND FAULT ISOLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1001 1002 1003 1004 1005 1006 1007 1008 1009 1010 1011 1012 1013 1014 1015 1016 1017 1018 1019 1020 1021 1022 1023 1024 1025 1026 1027 1028 1029 1030 1031 1032

Date Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I LIST OF EFFECTIVE PAGES (Continued) Page

TESTING AND FAULT ISOLATION (Continued) . . . . . . . . . . . . . . . . . . 1033 1034 1035 1036 1037 1038 SCHEMATICS AND WIRING DIAGRAMS. . . . . . . . . . . . . . . . . . . . . . . 2001 2002 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3001 3002 3003 3004 3005 3006 3007 3008 3009 3010 3011 3012 3013 3014 3015 3016 3017 3018 3019 3020 3021 3022 CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4001 4002 4003 4004 4005 4006 CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5001 5002 5003 5004 5005 5006

Date Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Blank Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08

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Subject

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CHECK (Continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5007 5008 5009 5010 5011 5012 5013 5014 5015 5016 5017 5018 5019 5020 5021 5022 5023 5024 5025 5026 5027 5028 5029 5030 REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6001 6002 6003 6004 6005 6006 6007 6008 6009 6010 6011 6012 6013 6014 6015 6016 6017 6018

Date Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Blank Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08

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REPAIR (Continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6019 6020 6021 6022 6023 6024 6025 6026 6027 6028 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7001 7002 7003 7004 7005 7006 7007 7008 7009 7010 7011 7012 7013 7014 7015 7016 7017 7018 7019 7020 7021 7022 7023 7024 7025 7026 7027 7028 7029 7030 7031 7032

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FITS AND CLEARANCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8001 8002 8003 8004 8005 8006 8007 8008 SPECIAL TOOLS, FIXTURES, AND EQUIPMENT . . . . . . . . . . . . . . . . 9001 9002 9003 9004 9005 9006 9007 9008 9009 9010 9011 9012 9013 9014 9015 9016 9017 9018 SPECIAL PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11001 11002 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12001 12002 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13001 13002 SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14001 14002 STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15001 15002 15003 15004 REWORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16001 16002

Date Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Oct 17/08 Blank Oct 17/08 Blank Oct 17/08 Blank Oct 17/08 Blank Oct 17/08 Blank Oct 17/08 Oct 17/08 Oct 17/08 Blank Oct 17/08 Blank

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ILLUSTRATED PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10001 10002 10003 10004 10005 10006 10007 10008 10009 10010 10011 10012 10013 10014 10015 10016 10017 10018 10019 10020 10021 10022 10023 10024 10025 10026 10027 10028 10029 10030 10031 10032 10033 10034 10035 10036

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Subject

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I

TABLE OF CONTENTS Page

EXCLUSIVE DISTRIBUTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ii RECORD OF REVISIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii RECORD OF TEMPORARY REVISIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v SERVICE BULLETIN LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .vii SERVICE INFORMATION LETTER LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix LIST OF EFFECTIVE PAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xix LIST OF ILLUSTRATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxi LIST OF TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xxv INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxvii DESCRIPTION AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 TESTING AND FAULT ISOLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1001 SCHEMATICS AND WIRING DIAGRAMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2001 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3001 CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4001 CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5001 REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6001 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7001 FITS AND CLEARANCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8001 SPECIAL TOOLS, FIXTURES, AND EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9001 SPECIAL PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11001 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12001 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13001 SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14001 STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15001 REWORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16001 ILLUSTRATED PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10001

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Title

THIS DOCUMENT SUBJECT TO THE CONTROLS AND RESTRICTIONS ON THE FIRST PAGE.

Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I

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THIS PAGE INTENTIONALLY LEFT BLANK

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Page xx Oct 17/08

THIS DOCUMENT SUBJECT TO THE CONTROLS AND RESTRICTIONS ON THE FIRST PAGE.

Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I

LIST OF ILLUSTRATIONS Title

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1001

Typical Model 23081 Series I DC Starter-Generator Features . . . . . . . . . . . . . . 2 23081 Series I DC Starter-Generator Schematic Diagram, Shunt Start . . . . . . . 8 23081 Series I DC Starter-Generator Schematic Diagram, Series Start . . . . . . . 8 Outline Drawing 23081-001, -002, -003, -004 . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Outline Drawing 23081-007, -008 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Outline Drawing 23081-011, -011-1, -012, -012-1 . . . . . . . . . . . . . . . . . . . . . . . 11 Outline Drawing 23081-017, -018 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Outline Drawing 23081-022, -022A, -023, -023A . . . . . . . . . . . . . . . . . . . . . . . 13 Outline Drawing 23081-024 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Outline Drawing 23081-042, -043, -072 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Outline Drawing 23081-056 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Outline Drawing 23081-057, -073 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Outline Drawing 23081-059 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Outline Drawing 23081-063 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Outline Drawing 23081-069, -070 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Starter-Generator Test Connection Diagram Models 23081-001, -002, -003, -004, -017, -018, -042, -043, -057, -063, -072, -073 . . . . . . . . . . . . . . 1006 Starter-Generator Test Connection Diagram Models 23081-022, -022A, -023, -023A, -056, -059, -069, -070 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1007 Starter-Generator Test Connection Diagram Models 23081-007, -008, -011, -011-1, -012, -012-1, -024 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1008 Equalizing Voltage Acceptance Limits Models 23081-001, -002, -003, -004, -017, -018, -042, -043, -072 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1011 Equalizing Voltage Acceptance Limits Models 23081-057, -073 . . . . . . . . . 1012 Equalizing Voltage Acceptance Limits Models 23081-007, -008, -011, -011-1, -012, -012-1, -024 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1013 Equalizing Voltage Acceptance Limits Models 23081-022, -022A, -023, -023A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1014 Equalizing Voltage Acceptance Limits Models 23081-056, -059, -069, -070 . 1015 Equalizing Voltage Acceptance Limits Model 23081-063 . . . . . . . . . . . . . . . 1016 Commutation Viewing Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1017 3-Pin Connector Pin Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1018 Voltage Wave Forms for Speed Pickup Test . . . . . . . . . . . . . . . . . . . . . . . . 1019 Shunt Start Locked Armature Test Connection Diagram Models 23081-007, -008, -011, -011-1, -012, -012-1, -022, -022A, -023, -023A, -024, -056, -059, -069, -070 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1023 Series Start Locked Armature Test Connection Diagram Models 23081-001, -002, -003, -004, -017, -018, -042, -043, -057, -063, -072, -073 . 1023 Removing Terminal Block Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3004 Brush Set Locations and Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3006

1002 1003 1004 1005 1006 1007 1008 1009 1010 1011 1012 1013

1014 3001 3002

Page

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Figure

THIS DOCUMENT SUBJECT TO THE CONTROLS AND RESTRICTIONS ON THE FIRST PAGE.

Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I

LIST OF ILLUSTRATIONS (Continued)

Distributed via the Goodrich Technical Publications Web Portal. Refer to https://techpubs.goodrich.com to confirm the latest revision standard.

Figure

Title

Page

3003 3004 3005 3006 3007 3008 3009

Removing Fan From Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drive Shaft with Dampener Plate and Dampener Hub . . . . . . . . . . . . . . . . . Remove the Dampener Hub from the Drive Shaft . . . . . . . . . . . . . . . . . . . . . Removing Dampener Backplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing Bearing and Brush Support Assembly . . . . . . . . . . . . . . . . . . . . . Removing 3-Pin Connector from Stator and Housing Assembly . . . . . . . . . . Removing Drive End Bearing Support Assembly from Stator and Housing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing Speed Pickup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove the Armature from the Bearing and Brush Support Assembly . . . . Removing the Anti-Drive End Ball Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . Removing Ball Bearing from Drive End Armature Shaft .. . . . . . . . . . . . . . . . Removing Brush Holder Assemblies (Without Filter Board) . . . . . . . . . . . . . Removing Brush Holder Assemblies (With Filter Boards) . . . . . . . . . . . . . . . Remove Miscellaneous Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Terminal Block Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspecting Mounting Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement Identification Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspecting Air Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brush Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspecting Drive Shaft and Dampener Hub . . . . . . . . . . . . . . . . . . . . . . . . . . Friction Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dampener Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspecting Dampener Backplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspecting Bearing and Brush Support Assembly . . . . . . . . . . . . . . . . . . . . . Determine Spring Force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspecting Drive End Bearing Support Assembly . . . . . . . . . . . . . . . . . . . . . Inspecting Speed Pickup Screw and Leads . . . . . . . . . . . . . . . . . . . . . . . . . Armature Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bearing Retainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspecting Baffle Disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stator and Housing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Terminal Block Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3006 3007 3008 3009 3010 3011

3010 3011 3012 3013 3014 3015 3016 3017 5001 5002 5003 5004 5005 5006 5007 5008 5009 5010 5011 5012 5013 5014 5015 5016 5017 5018

3012 3013 3014 3016 3017 3018 3019 3021 3022 5006 5007 5007 5008 5009 5010 5011 5012 5013 5016 5016 5018 5019 5021 5023 5023 5026 5027

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I

Figure

Title

Page

6001 6002 6003 6004 6005 6006 6007 6008

Helicoil Insert Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Install Air Inlet Insulating Tape (P/N: 23081-1092 and -1400) . . . . . . . . . . . Inspection of Air Inlet Insulating Tape (P/N: 23081-1092 and -1400) . . . . . . Install Air Inlet Insulating Tape (P/N 23081-1571 and -1576) . . . . . . . . . . . . Inspection of Air Inlet Insulating Tape (P/N 23081-1571 and -1576) . . . . . . Air Inlet Assembly Screen Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . Measuring Bearing Liner Outside Diameter (OD) . . . . . . . . . . . . . . . . . . . . . Anti-Drive End End Bell Bearing Liner Machining Specifications (IPL 10002, P/N 23081-1050 and 23032-2165) . . . . . . . . . . . . . . . . . . . . . . Anti-Drive End End Bell Bearing Liner Machining Specifications (IPL 10002, P/N 23081-3365) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Anti-Drive End End Bell Bearing Liner Machining Specifications (IPL 10002, P/N 23032-3665) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Anti-Drive End End Bell Bearing Liner Machining Specifications (IPL 10002, P/N 23081-3320/-3322) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drive End End Bell Bearing Liner Machining Specifications (IPL 10003, P/N 23081-1130/-1131, 23032-3652, 23081-1230) . . . . . . . . . Drive End End Bell Bearing Liner Machining Specifications (IPL 10003, P/N 23081-1490) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Armature Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Terminal Block Schematic for Polarizing the Output Voltage . . . . . . . . . . . . Removal of Terminal Studs from 23081-1310 with Stud Removal Tool . . . . Installation of Terminal Studs with Stud Driver Tool . . . . . . . . . . . . . . . . . . . Terminal Block Stud Removal and Installation Using Two Nuts . . . . . . . . . Terminal Block Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Install Attaching Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Terminal Block Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembling Drive End Bearing Support Assembly . . . . . . . . . . . . . . . . . . . . Brush Spring Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Attaching Brush Holders to Anti-Drive End End Bell (Without Filter Board) . Attaching Brush Holders to Anti-Drive End End Bell (With Filter Board) . . . . Installing Baffle Disc and Ball Bearing on the Armature Shaft . . . . . . . . . . . Spacer and Retaining Ring Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Anti-Drive End Ball Bearing Installation into Bearing and Brush Support Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Attaching the Bearing Retainer and Filter Board Leads . . . . . . . . . . . . . . . . Assembling Grommet, Speed Pickup, and Guard to Drive End End Bell . . . Attaching Drive End Bearing Support Assembly (Effect Codes: A, B, C, D, E, F, J, K, L, M, N, P, Q, R, S, T, U, V, W, BA, EA) . . . . . . . . . . . . . . . . . Attaching Drive End Bearing Support Assembly (Effect Codes: X, Y, Z, CA, DA, FA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6007 6009 6009 6010 6010 6012 6013

6009 6010 6011 6012 6013 6014 6015 6016 6017 6018 7001 7002 7003 7004 7005 7006 7007 7008 7009 7010 7011 7012 7013 7014

6014 6015 6016 6017 6018 6019 6022 6024 6025 6027 6028 7005 7006 7006 7007 7008 7010 7011 7013 7014 7015 7016 7017 7019 7020

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LIST OF ILLUSTRATIONS (Continued)

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I

LIST OF ILLUSTRATIONS (Continued)

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Figure

Title

Page

7015 7016 7017 7018 7019 7020 7021 7022 7023 8001 8002 8003 8004 9001 9002 9003 9004 9005 9006 9007 9008 9009 9010 9011 9012 9013 9014 9015 9016 10001 10002 10003 10004

Attaching 3-Pin Connector to Stator and Housing Assembly . . . . . . . . . . . . 7021 Preparing Armature for Rough Seating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7022 Pressing Bearing and Brush Support onto the Armature . . . . . . . . . . . . . . . 7023 Attach Bearing and Brush Support Assembly with attached Armature . . . . . 7024 Installing Dampener or Dampener and Gear Backplate and Friction Ring . . 7025 Dampener Plate and Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7026 Installing Drive Shaft into Armature Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . 7026 Attaching the Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7027 Installing Brush Sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7028 Measuring Armature Bearing Journal Diameters . . . . . . . . . . . . . . . . . . . . . 8006 Measuring Bearing Liner Diameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8007 Terminal Blocks 23069-1236 and 23081-1310 . . . . . . . . . . . . . . . . . . . . . . 8008 Terminal Block 23032-1518 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8008 Armature Shaft Adapter, Anti-Drive End . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9002 Armature Shaft Adapter, Drive End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9003 Commutation Viewing Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9004 Inner Race Bearing Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9005 Outer Race Bearing Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9006 Dampener Hub Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9007 Dampener Plate Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9008 Speed Pickup Adjustment Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9009 Bearing and Brush Support Assembly Support . . . . . . . . . . . . . . . . . . . . . . . 9010 Armature Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9011 Anti-Drive End Bearing Hub Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9012 Drive End Bearing Hub Support (Outboard) . . . . . . . . . . . . . . . . . . . . . . . . . 9013 Horizontal Stator and Housing Assembly Support Fixture . . . . . . . . . . . . . . 9014 Vertical Stator and Housing Assembly Support Fixture . . . . . . . . . . . . . . . . 9015 Spline Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9016 Commutator Turning Fixture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9017 DC Starter-Generator Assembly, 23081 Series I . . . . . . . . . . . . . . . . . . . . 10006 Bearing and Brush Support Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10026 Drive End Bearing Support Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10030 Stator and Housing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10032

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I

LIST OF TABLES Title

Page

i 1 2 3 4 1001 1002 1003 1004 1005 3001 3002 4001 4002 5001 5002 6001 6002 6003 6004 7001 7002 8001 8002 9001 15001 10001

Material Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxix Electrical Performance and Physical Characteristics . . . . . . . . . . . . . . . . . . . . . 3 Overhung Moment, Weight and Torque for QAD Mount DC Starter-Generators 4 Mounting Flange and Drive Shaft Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 5 MOD Status Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Performance Test Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1001 Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1002 Setpoint Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1004 Fault Isolation Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1024 Component Testing Fault Isolation Table . . . . . . . . . . . . . . . . . . . . . . . . . . . 1035 Disassembly Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3001 Disassembly Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3002 Cleaning Materials and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4001 Cleaning Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4003 Inspection Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5001 Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5028 Repair Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6002 Repair Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6003 Surface Coating References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6005 Parts Required for Air Inlet Screen Replacement . . . . . . . . . . . . . . . . . . . . . 6011 Assembly Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7001 Assembly Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7002 Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8001 Acceptance Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8002 Special Tools, Fixtures, and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9001 Packaging Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15001 TSO and ETSO Information Plate Usage . . . . . . . . . . . . . . . . . . . . . . . . . . 10005

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Table

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I

INTRODUCTION 1. Purpose

• replacement of non-reusable parts such as bearings, brushes and miscellaneous hardware. • cleaning of subassemblies. • detailed inspection of parts, electrical check of all electromagnetic parts (including; insulation integrity check), Non-Destructive Test (NDT) inspections, and complete acceptance testing. NOTE: Magnetic particle inspection of the parts as specified in the CHECK section is only required when an overhaul of the generator assembly is being done. • reconditioning of surface finishes as required. • repair/rework of parts as required. • re-certification including final assembly, records, and release tags. Only an overhaul and an acceptance test authorize assignment of zero operating hours time since overhaul (TSO) to a DC Starter-Generator. Repairs performed that are partial of an overhaul do not affect TSO and equipment is released on a continue time basis. An illustrated parts list is included at the back of this CMM for component identification and ordering of approved replacement parts. The structure and content of this manual is in general accordance with requirements established by the Air Transport Association of America (ATA) for aircraft CMMs. This manual is formatted to conform to ATA Specification No. 100. Give careful attention to applicable warnings and cautions. Before starting an overhaul procedure, become thoroughly familiar with the capabilities and limitations of the equipment. Make sure all necessary safety equipment, test equipment, repair materials, special tools, and fixtures are on hand. If an error, omission, or other technical discrepancy is found in this manual, fill out a copy of the Technical Publication Comment Form found at the back of this manual and send to Supervisor of Technical Publications, Goodrich Corporation or provide information to Technical Publications e-mail at [emailprotected]. Publications can be obtained by contacting the Goodrich Corporation, Monroe, NC distribution center. Contact the distribution administrator by e-mail at [emailprotected].

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This Component Maintenance Manual (CMM) provides detailed instructions for overhaul and service repair of the 23081 Series I DC Starter-Generators. Line maintenance is supported by Maintenance Manual (MM) 23700. A DC Starter-Generator overhaul includes:

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I 2. User Qualification and Certification Requirements The information contained in this manual is intended for persons authorized to perform maintenance, preventative maintenance, rebuilding, and alterations in accordance with Federal Aviation Regulation (FAR), Part-43.3. 3. Quality Assurance Requirements Distributed via the Goodrich Technical Publications Web Portal. Refer to https://techpubs.goodrich.com to confirm the latest revision standard.

The repair stations quality assurance activity is responsible for the correct performance of all tests and inspections specified in this manual. The quality assurance activity will also be responsible for maintaining all necessary test, inspection, and maintenance records for each unit received for service. All instrumentation and inspection equipment must be calibrated and controlled in accordance with International Standards Organization (ISO) standard 10012, with all standards traceable to the National Bureau of Standards or an equivalent standards regulatory authority. The quality assurance activity will be responsible for certifying that personnel, skills, and materials meet the requirements of the work to be performed. Components of the DC Starter-Generator undergoing overhaul that are recovered as products of disassembly must be examined 100% to determine serviceability. The quality assurance activity must maintain documented evidence that specifications applicable to special processes such as soldering, nondestructive testing (NDT), plating, etc. have been complied with during repair and/or overhaul of the DC Starter-Generator. 4. Safety Advisory This manual describes physical and chemical processes that require the use of chemicals or other commercially available materials that require precautionary attention. The user of this manual should obtain Material Safety Data Sheets and Occupational Safety and Health Act (OSHA) Form 20 or equivalent from the manufacturers or suppliers of materials to be used. The user must become completely familiar with and follow all manufacturer/supplier procedures, recommendations, warnings, and cautions for the safe use, handling, storage, and disposal of these materials. Users of this manual are also advised to refer to applicable safety information contained in the “NIOSH Occupational Guideline for Chemical Hazards” published by the United States Department of Labor. Give careful attention to applicable warnings and cautions. Before starting any procedure, become thoroughly familiar with the capabilities and limitations of the equipment. Make sure all necessary safety equipment, test equipment, repair materials, special tools, and fixture are on hand. Warnings, Cautions and Notes are used throughout the text to highlight and emphasize important points, as they become necessary. Warnings give information that must be followed precisely to avoid personal injury and/or possible death. Cautions contain information that must be followed to avoid damage to equipment. Notes assist the reader and make the technician's job easier.

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I WARNING: ALERT OPERATING AND MAINTENANCE PERSONNEL TO POTENTIAL HAZARDS THAT COULD RESULT IN PERSONAL INJURY; THEY DO NOT REPLACE THE MANUFACTURER’S RECOMMENDATIONS. ALERT OPERATING AND MAINTENANCE PERSONNEL TO CONDITIONS THAT COULD RESULT IN EQUIPMENT DAMAGE.

5. Materials List The materials listed in this section are necessary for processes throughout this manual. A warning and/or caution will precede the use of materials listed in Table i. WARNING: BEFORE USING ONE OF THE FOLLOWING MATERIALS, BE AWARE OF ALL HANDLING, STORAGE, AND DISPOSAL PRECAUTIONS RECOMMENDED BY THE MANUFACTURER OR SUPPLIER. FAILURE TO COMPLY WITH MANUFACTURER OR SUPPLIER RECOMMENDATIONS CAN RESULT IN SERIOUS INJURY, PHYSICAL DISORDER, OR DEATH.

Material Acrylic Coating Anti-Seize Compound Chemical Film Solution Corrosion Preventative Detergent Grease Isopropyl Alcohol Loctite Grade E Lubricating and Assembly Paste Machine Oil Red Insulating Enamel Thread Sealing Compound Zinc Chromate Primer Zinc Phosphate Coating

Used in ASSEMBLY ASSEMBLY REPAIR CLEANING CLEANING STORAGE ASSEMBLY, CHECK, CLEANING, DISASSEMBLY, REPAIR ASSEMBLY ASSEMBLY REPAIR ASSEMBLY ASSEMBLY REPAIR REPAIR Table i - Material Table

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CAUTION:

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I 6. Non-Goodrich Corporation Authorized Components and Processes Policy Goodrich Corporation authorizes the use of genuine Goodrich Corporation spare parts which meet stringent engineering design specifications and quality standards, and have traceability to having been procured and certified to these specifications by the Goodrich Corporation Quality Assurance incoming and in-process inspection systems. The Goodrich Corporation Customer Service Centers are the only authorized distributors of genuine Goodrich Corporation replacement parts and complete units. Distributed via the Goodrich Technical Publications Web Portal. Refer to https://techpubs.goodrich.com to confirm the latest revision standard.

It is the obligation of all repair and service facilities to provide the FAA, or an other in-country air authority, with proper traceability documentation indicating approval of all spare parts, materials, and processes to make sure configuration compliance and continued air worthiness. The use of any non-Goodrich Corporation authorized parts, or any parts not having been submitted to the Goodrich Corporation Quality Assurance inspection system will invalidate any and all factory warranties. All Goodrich Corporation warranties are automatically voided on any Goodrich Corporation designed unit that has been modified by the installation of any unauthorized parts, materials or unapproved processes supplied by other outside services. The repair station’s quality assurance activity shall assume product liability for all units that have been modified in this fashion. Damage resulting from the use of non-Goodrich Corporation replacement parts, materials or processes is not covered by the Goodrich Corporation warranty or service policy for any product or for any application. 7. Abbreviations and Acronyms The following is a list of the abbreviations and acronyms used in this document. ADE

- anti-drive end

CMM

- Component Maintenance Manual

- drive end

GCU

- Generator Control Unit

IAW

- in accordance with

in.

- inch(es)

kPa

- kilopascal(s)

lbf.in

- pound force inch

µFd

- micro Farad

NDT

- Non-Destructive Test

N·m

- Newton meter

PSIG

- pounds per square inch gage

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QAD

- Quick Attach/Detach

rms

- root mean square

rpm

- Revolutions Per Minute

SPD

- Standard Practice Document

TIR

- Total Indicator Reading

TSO

- time since overhaul

UUT

- Unit Under Test

- Ohm

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I

DESCRIPTION AND OPERATION 1. Introduction

The 23081 Series I DC Starter-Generator (See Figure 1) operates as a motor to provide torque for engine starting and as a generator to provide DC electrical power after engine starting is complete. Refer to Paragraph 2. of this section for performance and equipment characteristics. The starter-generator consists of an armature that is enclosed by, and rotates within a stator and housing assembly. The armature is supported by two bearings. At the drive end (DE) of the armature, a bearing is supported by a drive end bearing support assembly. At the anti-drive end (ADE) of the starter-generator, the second bearing is supported by the bearing and brush support assembly. The starter-generator’s drive shaft is installed in the armature shaft which is hollow. The armature shaft and drive shaft have mating splines that engage at the anti-drive end of the starter-generator. At the drive end, a dampener assembly absorbs torsional vibration generated by changes in engine gearbox speed and electrical load conditions. The dampener assembly is made up of a dampener backplate, a friction ring and a dampener plate. Also, on applicable models, at the drive end of the starter-generator is a speed pickup that provides a signal to the generator control unit (GCU) for starter cutoff. A fan is attached to the anti-drive end of the drive shaft. The fan supplies forced air cooling for on-ground operation. Fins in the bearing and brush support assembly improve cooling by distributing airflow through the generator. In flight, the starter-generator is blast-cooled through the air inlet and the user’s air ducting system in addition to the fan. A QAD kit eases starter-generator installation and removal, to and from the aircraft. A QAD kit is comprised of a mounting adapter that attaches to the engine gear box accessory drive pad, and a V-band clamp which secures the starter-generator to the mounting adapter. The 23081 Series I DC Starter-Generators and associated parts are listed in the ILLUSTRATED PARTS LIST section.

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NOTE: The term “Series I” does not refer to the equipment covered in this manual. The term “Series I” distinguishes this manual from other Component Maintenance Manuals covering similar equipment.

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I

ARMATURE

STATOR AND HOUSING ASSEMBLY

TERMINAL BLOCK (TYPICAL) BRUSHES

DAMPENER ASSEMBLY

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FAN DRIVE SHAFT ANTI-DRIVE END BALL BEARING DRIVE END BALL BEARING

BEARING AND BRUSH SUPPORT ASSEMBLY

DRIVE END BEARING SUPPORT ASSEMBLY

SPEED PICKUP (ON APPLICABLE MODELS)

Figure 1 - Typical Model 23081 Series I DC Starter-Generator Features

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I 2. Equipment Specifications Details of equipment specifications are contained in this section.

Rated Power Output Rating for continuous load within speed range

Model Number(s) All models 23081-056

Specification 6 kW 200 A, 30 VDC, 7,050* to 13,000 rpm (* 27 VDC with 0.4 Ω in field circuit). 200 A, 30 VDC, 7,050* to 12,300 rpm (* 27 VDC with 0.4 Ω in field circuit). 200 A, 30 VDC, 7,500* to 12,000 rpm (* 26 VDC with 0.4 Ω in field circuit). 200 A, 30 VDC, 7,500* to 13,000 rpm (* 26 VDC with 0.4 Ω in field circuit). 200 A, 30 VDC, 7,050* to 12,000 rpm (* 26 VDC with 0.4 Ω in field circuit). 200 A, 30 VDC, 7,050* to 12,000 rpm (* 27 VDC with 0.4 Ω in field circuit). Self-limiting current load of 1000 A maximum @ 28 VDC

23081-059

23081-063

23081-069, -070

23081-072, -073

All other models

External starting power supply limitations Direction of Rotation

All models

Air Inlet Opening

23081-024

Cooling

23081-017, -018, -056, -057, -059, -063, -073 All other models All models

Counterclockwise (viewed from drive end) 2.12 in. X 3.50 in. (53,8 mm X 88,9 mm) oval opening, 3.97 in. (100,8 mm) diameter 3.00 in. (76,2 mm) diameter Self-cooled on ground. Combination cooling in flight.

Table 1 - Electrical Performance and Physical Characteristics

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Characteristic

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Characteristic

Model Number(s)

Specification

Terminal Designations

23081-007, -008, -011 -011-1, -012, -012-1, -022 -022A, -023, -023A, -024, -056, -059, -069, -070 23081-001, -002, -003, -004, -017, -018, -042, -043, -057, -063, -072, -073

Shunt Start: B+ Positive E- Negative A+ Shunt Field D Equalizer Series Start: B+ Positive E- Negative A+ Shunt Field D Equalizer C+ Starting

Table 1 - Electrical Performance and Physical Characteristics (Continued)

Characteristic Starter-Generator Maximum Total Weight Includes QAD kit

QAD Kit Maximum Weight Overhung Moment with QAD kit

Model Number(s)

Specification

23081-001, -002, -042, -043, -072

22.3 lbs. (10,1 kg)

23081-007, -008, -022, -022A, -023, -023A, -056, -069, -070 23081-003, -004, -011, -011-1, -012, -012-1, -017, -018, -024, -063 23081-057, -073 23081-059 All Models

21.5 lbs. (9,75 kg)

23081-003, -004, -024, -057, -072, -073 23081-007, -008, -022 -022A, -023, -023A, -056, -059, -069, -070 23081-001, -002, -011, -011-1, -012, -012-1, -017, -018, -042, -043, -063

22.2 lbs. (10,07 kg)

22.1 lbs. (10,02 kg) 21.5 lbs. (9,75 kg) 1.1 lbs. (0,5 kg) 78 lbf.in. (8,81 N · m) max. 75 lbf.in. (8,47 N · m) max.

80 lbf.in. (9,05 N · m) max.

Table 2 - Overhung Moment, Weight and Torque for QAD Mount DC Starter-Generators

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I

Mounting Flange & Drive Shaft Specification

Model Number(s) 23081-003, -004, -011, -012, -011-1, -012-1, -024, -057, -059, -073 23081-001, -002, -007, -008, -017, -018, -022, -022A, -023, -023A, -042, -043 23081-056

23081-063, -069, -070, -072

Drive Shaft

23081-001, -002, -007, -008, -017, -018, -022, -022A, -023, -023A, -056, -063, -069, -070 23081-059

23081-042, -043, -057, -072, -073

23081-003, -004, -011, -012, -011-1, -012-1, -024

Specification S/G’s QAD Mounting Features conform to AND10261-XI-B. Mates with AND20001. Spline conforms to AS972 (0.600 P.D.) S/G’s QAD Mounting Features conform to MS3326-2. Spline conforms to AS972A. S/G’s QAD Mounting Features conform to MS3326-2. Spline conforms to AS972B. S/G’s QAD Mounting Features conform to MS3331-1P, and Mates with MS3326-2 Drive Pad. Spline conforms to AS972B. Shear Torque: 1100 lbf.in. (124,28 N · m max.) Number of Teeth: 12 Pitch Diameter: 0.600 in. (15,24 mm) Shear Torque: 1460 to 1590 lbf.in. (164,96 to 179,65 N · m max.) Number of Teeth: 12 Pitch Diameter: 0.600 in. (15,24 mm) Shear Torque: 800 lbf.in. (62,14 N · m max.) Number of Teeth: 12 Pitch Diameter: 0.600 in. (15,24 mm) Shear Torque: 1400 lbf.in. (158,17 N · m max.) Number of Teeth: 12 Pitch Diameter: 0.600 in. (15,24 mm)

Table 3 - Mounting Flange and Drive Shaft Specifications

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Characteristic

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I 3. Equipment Improvements and Modifications

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Model 23081 Series I DC Starter-Generators (See Figure 1) can incorporate one or more modifications. A modification of a particular starter-generator is indicated by a letter in the MOD status box on the identification plate or modification status label. Information regarding modifications of 23081 Series I DC Starter-Generators is detailed in various service bulletins listed in the SERVICE BULLETIN LIST at the front of this CMM and also referenced by model number effectivity in the ILLUSTRATED PARTS LIST section of this CMM. A. MOD Status See Table for the latest MOD level of each DC Starter-Generator model: Part Number

Model(s)

MOD

23081-001, -002, -003, -004, -007, -008, -011, -011-1, -012, -012-1 23081-001, -002

03-6009-19 Bearings

03-6009-23 Bearings

23081-1834 23081-1833 23081-1092 23081-303 03-6009-19 03-6009-23

Brushes (Field use only, non-production) Brush (Field use only, non-production) Air Inlet (Field use only, non-production) Bearing and Brush Support Assembly Bearings Bearings

23081-1834 23081-1833 23081-1571 or 23081-1576 23081-307 or 23081-303 23081-1810 03-6009-23 03-6009-18 03-6009-23 23081-1834

Brushes (Field use only, non-production) Brushes (Field use only, non-production) Air Inlet (Field use only, non-production)

D 23081-017, -018, -022, -023, -024 23081-017, -018

A B C

23081-022A, -023A 23081-042, -043

B C A B C

Description

Bearing and Brush Support Assembly

Brushes Bearings Bearings Bearings Brushes (Field use only, non-production)

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I

23081-057

23081-056, -059, -063, -069, -070, -072 23081-073

MOD

Part Number

Description

23081-306 Bearing and Brush Support Assembly or 23081-309 No Mods

A B C

23081-303 Bearing and Brush Support Assembly 23081-306 Bearing and Brush Support Assembly 23081-309 Bearing and Brush Support Assembly Table 4 - MOD Status Chart

4. DC Starter-Generator Operation Electromagnetic interaction between the armature and stator produces output torque during engine starting and DC electrical power during engine operation. A. Starter Operation Dependent upon the starter-generator model, the 23081 Series I of DC StarterGenerators operate as either a shunt starter motor or a series starter motor to start the engine. (1)

Shunt Start During the engine start cycle, the aircraft power bus applies DC voltage across terminals B+ and E-, supplying current to the armature and stator windings. At the same time, a voltage is applied to shunt field terminals A+ and E- from a Generator Control Unit (GCU). Starting power can be supplied by aircraft batteries or a ground power source. See Figure 2.

(2)

Series Start During the engine start-cycle, the aircraft power bus applies DC voltage across terminals C+ and E-, supplying current to the armature and stator windings. Starting power can be supplied by aircraft batteries or a ground power source. See Figure 3.

B. Generator operation Following starter operation the GCU will “build up” the output voltage from the generator residual voltage. During generator operation, the machine provides a DC output (terminals B+ and E-) regulated by the generator shunt field current (terminal A). By quickly reacting to changes in generator operating conditions such as engine speed or electrical load, the GCU regulates the current level provided to the generator shunt field (terminal A). By regulating the shunt field current the system voltage is maintained at a nominally per Table 1. DESCRIPTION AND OPERATION © 2008 Goodrich Corporation

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Model(s)

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I

RADIO AND NOISE FILTER ARMATURE

INTERPOLE AND COMPENSATING

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SHUNT

2 µFD

2 µFD B+

A+

E-

Figure 2 - 23081 Series I DC Starter-Generator Schematic Diagram, Shunt Start

INTERPOLE AND COMPENSATING

ARMATURE

SHUNT

SERIES

2 µFD

2 µFD 0.022 µFD RADIO NOISE FILTER

C+

B+

A+

E-

Figure 3 - 23081 Series I DC Starter-Generator Schematic Diagram, Series Start

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I

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3.95 in. (100,3 mm) MAX.

24-30-09 N

2.830 in. 2.710 in. 71,88 mm 68,83 mm

Ø5.41 in. (Ø134,7 mm) MAX.

7.69 in. (195,3 mm) MAX.

Ø5.30 in. (Ø134,6 mm) MAX.

1.20 in. 1.16 in. 30,5 mm 29,5 mm

Ø5.22 in. (Ø132,6 mm) MAX.

AIR INLET

TERMINAL BLOCK

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TIO TA RO

4.56 in. (115,8 mm)

5.38 in. (136,7 mm) MAX.

3.50 in. (88,9 mm)

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I

Figure 12 - Outline Drawing 23081-057, -073

DESCRIPTION AND OPERATION

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Ø 5.19 in. MAX

Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I

2.25 in. (57,15 mm)

45°

CONNECTOR

7.82 in. MAX. (198,6 mm)

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Ø 3.185 in. (80,90 mm) 3.183 in. (80,85 mm) Ø 5.41 in. MAX. (137,4 mm)

8.96 in. MAX. (227,6 mm)

8.06 ± 0.12 in. (204,7 ± 3,0 mm)

5.82 ± 0.12 in. (147,8 ± 3,0 mm)

Ø 5.29 ± 0.01 in. (134,4 ± 0,3 mm)

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4.956 in. (125,88 mm)

AIR INLET

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I

Figure 14 - Outline Drawing 23081-063

DESCRIPTION AND OPERATION

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2.25 in. (57,2 mm)

MATING CONNECTOR MS3112E8-3S

3.185 in. (80,90 mm) Ø 3.183 in. (80,85 mm) (REF.)

1.520 in. (REF.) 1.640 in. (38,61 mm) (41,65 mm)

2.) 23081-070 without QAD kit

NOTE: 1.) 23081-069 with QAD kit

3.86 in. (98,0 mm)

10.64 in.MAX. (270,3 mm)

8.06 in. (204,7 mm)

Ø5.30 in. MAX. (134,6 mm) Ø5.43 in. (137,9 mm) MAX. 5.70 in. (144,8 mm)

4.02 in. (102,1 mm)

5.22 in. MAX. (132,6 mm)

1.125 in. (28,58 mm)

Ø3.00 +0.006/-0.015 in. (76,2 mm) (+0,15/-0,38 mm)

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I

Figure 15 - Outline Drawing 23081-069, -070

DESCRIPTION AND OPERATION

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I

TESTING AND FAULT ISOLATION

WARNING: THE DC STARTER-GENERATOR CAN PRODUCE HIGH OUTPUT CURRENT CAPABLE OF CAUSING SEVERE SHOCK OR DEATH. MAKE SURE ALL POWER IS SHUT OFF TO GENERATOR BEFORE REMOVING OR REPLACING TEST EQUIPMENT, INSTRUMENTS, OR ASSEMBLIES. TAKE EXTREME CARE WHEN PERFORMING “LIVE CIRCUIT” TESTS AND FAULT ISOLATION PROCEDURES. The procedures provided in this section are performance tests and are classified as either verification tests or acceptance tests. A verification test is conducted to assist in fault isolation or to confirm the cause for removal before the repair or overhaul of the DC StarterGenerator. An acceptance test is conducted after the repair or overhaul of the unit. Record all test results on a photocopy of the data sheet(s) provided at the end of this section. NOTE: Due to differences in test requirements between certain 23081 Series I DC startergenerator models, two data sheets are provided. The data sheets are labeled with the applicable model numbers at the top. Verification Testing: A starter-generator requiring confirmation of the cause for removal or qualification for continued service must be inspected as detailed in Paragraph 3. of the CHECK section before testing can begin. A unit that passes initial inspections can be tested in accordance with this section to determine performance or to isolate a particular fault. When a fault is identified during testing, refer to the fault isolation tables in this section to determine the probable cause. Acceptance Testing: A unit that has been overhauled or repaired and is ready to be returned to service must be tested in accordance with this section to verify minimum performance standards. Only when an acceptance test is fully completed, and in the order presented in this section, can zero operating hours time since overhaul (TSO) be assigned to an overhauled unit. 2. Test Conditions Refer to Table 1001 for a list of performance test conditions. Unless otherwise specified, all of the parameters in Table 1001 apply to a test.. Parameter

Operating Condition

Ambient Temperature Barometric Pressure Brush Seating Procedures

Forced Cooling Air

77° ± 27°F (25° ± 15°C) Ambient pressure, 30 ± 3 in. (762 ± 76 mm) of mercury, at sea level up to 1,500 ft (457,2 m). Refer to Goodrich Corporation Standard Practice Document (SPD) 1006 for brush installation, seating, and run-in procedures. None. The 23081 SI models are self-cooled

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1. Introduction

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I Parameter

Operating Condition

Physical Mounting

Drive shaft must be in horizontal position. Table 1001 - Performance Test Conditions

3. Required Test Equipment Distributed via the Goodrich Technical Publications Web Portal. Refer to https://techpubs.goodrich.com to confirm the latest revision standard.

Refer to Table 1002 for a list of special tools, fixtures, and equipment needed for testing and fault isolation. Equivalent substitutes can be used for items listed. NOTE: Airflow meters and pressure gauges used in the testing of this unit should be certified and calibrated in accordance with ISO10012-1 or should have current calibration traceable to a National Bureau of Standards (NBS) standard. If properly calibrated equipment is not available, the Unit Under Test (UUT) should be sent to an authorized Goodrich Corporation repair facility for all the procedures in this manual.

Equipment Commutation Viewing Adapter DC Ammeter DC Variable Power Supply DC Voltage Regulator DC Voltmeter (2 req’d) DC Voltmeter (Generator) DC Voltmeter (Starter) DC Voltmeter Generator Drive Stand Locked Rotor Stand

Generator Load Switch

Range and Accuracy or Equipment Rating

Ref. Des.

SPECIAL TOOLS, FIXTURES, AND EQUIPMENT section Range: 0 to 10 A Accuracy: ±1% of reading Range: 0 to 30 Vdc Range: 0 to 30 Vdc Range: 0 to 50 Vdc Accuracy: ±1% of reading Range: 0 to 50 mVdc Accuracy: ±1% of reading. Range: 0 to 100 mVdc Accuracy: ±1% of reading. Range: 0 to 10 Vdc Accuracy: ±1% of reading Range: 4,000 to 15,000 rpm, 36 Vdc rated load Rating: Capable of measuring a locked rotor torque of 13 lb.ft. and having a power supply capacity of 400 A at 12 Vdc. Rating: 30 Vdc, 300 A

See Section 9000 A1 Power Supply Voltage Regulator V2, V3 V1 V1 V4 Not Illustrated Not Illustrated

SW1

Table 1002 - Test Equipment

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I Range and Accuracy or Equipment Rating

High Potential Tester Manometer

Oscilloscope

Precision Shunt (Generator) Precision Shunt (Starter) Shunt Field Switch Terminal Block (Non-serviceable)

Rating:

Ref. Des.

300 Vac RMS, commercial frequency Range: 0 to 12 inch (0 to 305 mm) H 20 Accuracy: ± 5% of reading Digital: Band width of 100 MHz Sampling rate of 100 MS/s Analog: Bandwidth of 60 to 100 MHz Rating: 500 A; 50 mVdc

SH1

Rating:

SH1

1000 A; 100 mVdc

Resistor Thermometer (or other temperature measuring device) QAD Mounting Kit Variable Load Bank

Rating: 30 Vdc, 10 A Use a terminal block with blown capacitors during dielectric testing to avoid damaging a serviceable terminal block. Rating: 0.0 Ohm Range: 65° to 300° F (18° to 150°C) Accuracy: ±1° F (0.5°C) P/N: Refer to IPL10001 Rating: 30 Vdc, 0 to 300 A

Voltage Regulator Switch

Rating:

30 Vdc, 10 A

Not illustrated Not illustrated

Not illustrated

SW3 Terminal Block

Not Illustrated Not illustrated

Not Illustrated Variable Load Bank SW2

Table 1002 - Test Equipment 4. Generator Thermal Stabilization Stabilization is reached when either of the following conditions is met: • Temperature of shunt field winding (A-E), as determined by its resistance, rises no more than 2° F (1,1° C) in five minutes. • Frame temperature measured on side opposite terminal block, does not rise more than 2° F (1,1° C) in five minutes.

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Equipment

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I 5. Test Condition Setpoint Tolerances Test condition setpoint must be set within tolerances indicated in Table 1003, exclusive of measurement accuracy. Parameter Distributed via the Goodrich Technical Publications Web Portal. Refer to https://techpubs.goodrich.com to confirm the latest revision standard.

Speed (rpm) DC Voltage DC Current Cooling Air Pressure Torque

Test Condition Setpoint Tolerance ±20 rpm ±0.1 Vdc ±2.5 A ±0.2 inch (5,1 mm) - water ±1.0 lb-ft

Table 1003 - Setpoint Tolerances 6. Test Set Up NOTE: Unless otherwise indicated, numbers in parentheses ( ) refer to item numbers in Figure 10001 of the ILLUSTRATED PARTS LIST. A. Perform initial inspection. Examine starter-generator in a brightly lit work area. Refer to procedures in CHECK section. Inspection results determine whether disassembly and repair are required before testing. B. Check brush seating. NOTE: In a starter-generator being prepared for verification testing, installed brushes may or may not require brush seating. CAUTION:

(1)

THE STARTER-GENERATOR MUST BE SUPPORTED AT ALL TIMES DURING INSTALLATION AND REMOVAL. DO NOT ALLOW THE UNIT TO HANG UNSUPPORTED. EXCESSIVE BENDING LOADS ON THE DRIVE SHAFT CAN DAMAGE THE SHEAR SECTION.

Make sure all brushes (10001-210) are correctly seated according to procedures in SPD 1006.

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C. Install commutation viewing adapter. WARNING: DURING OPERATION, THE DC STARTER-GENERATOR CAN PRODUCE A HIGH OUTPUT CURRENT CAPABLE OF CAUSING SEVERE SHOCK OR DEATH. MAKE SURE ALL POWER IS OFF TO STARTER-GENERATOR BEFORE REMOVING OR REPLACING TEST EQUIPMENT, INSTRUMENTS, OR ASSEMBLIES. TAKE EXTREME CARE WHEN PERFORMING “LIVE CIRCUIT” TESTS AND FAULT ISOLATION PROCEDURES. CAUTION:

STARTER-GENERATOR MUST BE SUPPORTED AT ALL TIMES DURING INSTALLATION OR REMOVAL. DO NOT ALLOW UNIT TO HANG UNSUPPORTED. TOO MUCH BENDING LOAD ON DRIVE SHAFT CAN DAMAGE SHEAR SECTION.

(1)

Remove air inlet (10001-150).

(2)

Install commutation viewing adapter.

D. Attach dummy terminal block to starter generator or remove terminal block grounding lead. CAUTION: THE STARTER-GENERATOR MUST BE SUPPORTED AT ALL TIMES DURING INSTALLATION AND REMOVAL. DO NOT ALLOW THE UNIT TO HANG UNSUPPORTED. EXCESSIVE BENDING LOADS ON THE DRIVE SHAFT CAN DAMAGE THE SHEAR SECTION. CAUTION:

(1)

MAKE SURE THAT YOU USE A DUMMY TERMINAL BLOCK OR REMOVE THE TERMINAL BLOCK GROUNDING LEAD FOR ACCEPTANCE TESTING. THE TEST VOLTAGE CAN DAMAGE THE FILTER CAPACITOR IN THE TERMINAL BLOCK.

Refer to DISASSEMBLY section and ASSEMBLY section for details. NOTE: If the grounding lead is removed, make sure to cover the lead with electrical tape before doing a dielectric test. NOTE: Terminal block P/N: 23069-1236 has the lead grounded by the terminal block mounting screw (10004-60). The lead is located between terminals B and D. By removing the single mounting screw, the grounding lead will be isolated.

E. Install starter-generator on drive stand. NOTE: The starter-generator mounts to the mounting adapter (part of the QAD kit) that is attached to the drive stand. NOTE: Some 23081 Series I starter-generators included in this CMM are not supplied with a QAD kit. QAD kits must be ordered separately and used during acceptance testing. Refer to the ILLUSTRATED PARTS LIST for QAD kit part numbers.

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I CAUTION:

THE STARTER-GENERATOR MUST BE SUPPORTED AT ALL TIMES DURING INSTALLATION OR REMOVAL. DO NOT ALLOW UNIT TO HANG UNSUPPORTED. TOO MUCH BENDING LOAD ON DRIVE SHAFT CAN DAMAGE SHEAR SECTION.

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(1)

Install mounting adapter on drive stand.

(2)

While supporting anti-drive end of starter-generator, align and install drive end to mounting adapter plate.

(3)

Make sure that drive stand and starter-generator mating splines are properly engaged.

(4)

Install V-retainer coupling (10001-20) on mounting adapter and starter-generator. To secure, tighten nut to a torque of 50 lbf.in. (5,7 N · m).

F. Connect starter-generator to electrical test circuit. (1) Turn all power OFF at starter-generator drive stand. (2)

Connect starter-generator to test circuit as shown in Figure 1001, Figure 1002 or Figure 1003 depending on model number.

(3)

Assemble terminal block hardware to terminal block. Refer to ASSEMBLY section for details.

FIELD EXCITATION

SW3

SHUNT FIELD RETURN

VOLTAGE SENSE

SH 1

SW1

REGULATOR GROUND

REGULATOR POWER

SW2 VARIABLE LOAD BANK

VOLTAGE REGULATOR

SERIES START TERMINAL BLOCK

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I

Figure 1002 - Starter-Generator Test Connection Diagram Models 23081-022, -022A, -023, -023A, -056, -059, -069, -070

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I

FIELD EXCITATION

SW3

SHUNT FIELD RETURN

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VOLTAGE SENSE

SH 1

SW1

REGULATOR GROUND

REGULATOR POWER

SW2 VARIABLE LOAD BANK

VOLTAGE REGULATOR

Figure 1003 - Starter-Generator Test Connection Diagram Models 23081-007, -008, -011, -011-1, -012, -012-1, -024

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I 7. Acceptance Test Procedure

CAUTION:

IF AN ACCEPTANCE LIMIT IS EXCEEDED BY EVEN A SMALL MARGIN, DO NOT CONTINUE FURTHER TESTING OF STARTER-GENERATOR. BE AWARE THAT TESTING OF A DC STARTER-GENERATOR BY ANY LIMIT AFTER IT HAS EXCEEDED THAT LIMIT CAN DAMAGE THE STARTER-GENERATOR.

This paragraph contains the required performance tests and the sequence in which they are to be accomplished. WARNING: MAKE SURE THAT ALL POWER IS SHUT OFF TO THE STARTER-GENERATOR BEFORE REMOVING OR REPLACING COMPONENTS OR ASSEMBLIES. TAKE EXTREME CARE WHEN PERFORMING “LIVE” CIRCUIT TESTS AND TROUBLESHOOTING PROCEDURES. DURING OPERATION, THE STARTER-GENERATOR PRODUCES A VERY HIGH AMPERAGE OUTPUT THAT CAN CAUSE SEVERE SHOCK OR DEATH. A. Maximum Speed for Regulation. (For Models 23081-007, -008, -011, -011-1, -012, -012-1 and -024 only) (1) With regulator connected to the starter-generator, operate the starter-generator at 13,000 rpm, self-excited at 28.5 Vdc (V2) and no load. NOTE: Stabilization is not required. (2)

Measure and record voltage between terminals B and A (V3) and the field current at terminal A (A1).

(3)

Calculate resistance between terminals B and A by dividing the B and A voltage (V3) by the field current (A1). (a)

The calculated external field circuit resistance must not be greater than 35 Ω.

B. Continuous Operating Speed, Equalizing Voltage and Minimum Speed Test. (1) Install a thermocouple (or other temperature measuring device) to the outside of the stator and housing assembly in an area adjacent to a stator main pole. (2)

Install a second thermocouple in air inlet opening.

(3)

Operate starter-generator at 12,000 rpm and stabilize as listed below, 30 Vdc (V2), 200 A (V1/SH1). Refer to Paragraph 4. NOTE: Stabilization is reached when the temperature of the shunt field winding, as determined by the stator and housing field temperature, rises no more than 2° F (1.1° C) in five minutes.

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NOTE: Refer to IPL Figure 1001 for an illustration. Numbers in parentheses ( ) refer to item numbers on the illustration, unless otherwise specified.

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I • Operate until stabilized (For Models: 23081-007, -008, -011, -011-1, -012, -012-1, -022, -022A, -023, -023A, -024, -056, -059, -069, -070 only). • Stabilize for 15 minutes (For Models: 23081-001, -002, -003, -004, -017, -018, -042, -043, -057, -063, -072, -073 only).

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(4)

Measure and record the voltage between terminals D and E (V4).

(5)

Measure and record cooling air temperature.

(6)

Measure and record winding or frame temperature.

(7)

Immediately operate starter-generator at the minimum speed for regulation at the speed listed below, 27 Vdc (V2), and 200 A (V1/SH1). NOTE: Stabilization is not required. • 7,200 rpm (For model 23081-063). • 7,050 rpm (For all models, except 23081-063).

(8)

Measure and record field current (A1).

(9)

Calculate and record external field circuit resistance between terminals B and A by dividing the B to A voltage (V3) by the field current (A1).

(10) Acceptance Limits: (a)

Field current: 1

(b)

Not to be more than 10 A.

External field circuit resistance: 1

Must not be less than 0.4 Ω.

(11) The D to E voltage must be in the limits of Figure 1004, Figure 1005, Figure 1006, Figure 1007 and Figure 1008.

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I

120

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100 90

MA XIM U

MIN IMU M

INLET AIR TEMP. (DEGREES FAHRENHEIT)

110

70 60 50 40

1.5

1.6

1.7

1.8

1.9

2.0

EQUALIZING VOLTAGE (VOLTS) Figure 1004 - Equalizing Voltage Acceptance Limits Models 23081-001, -002, -003, -004, -017, -018, -042, -043, -072

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I

120

100

IMU M

90 80

XIM U

MIN

INLET AIR TEMP. (DEGREES FAHRENHEIT)

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113F 110

60 50 41F 40

1.4

1.5

1.6

1.7

1.8

1.9

2.0

EQUALIZING VOLTAGE (VOLTS) Figure 1005 - Equalizing Voltage Acceptance Limits Models 23081-057, -073

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I

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MAX IMU M

100

MIN IMU M

INLET AIR TEMPERATURE (DEGREES FAHRENHEIT)

113F 110

80 70 60 50

41F 40

1.3

1.4

1.5

1.6

1.7

1.8

1.9

EQUALIZING VOLTAGE (VOLTS) Figure 1006 - Equalizing Voltage Acceptance Limits Models 23081-007, -008, -011, -011-1, -012, -012-1, -024

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I

IMU M

100 90 80

MA XIM UM

MIN

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INLET AIR TEMP. (DEGREES FAHRENHEIT)

110

70 60 50 40 1.6

1.7

1.8

1.9

2.0

2.1

EQUALIZING VOLTAGE (VOLTS) Figure 1007 - Equalizing Voltage Acceptance Limits Models 23081-022, -022A, -023, -023A

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I

XIM UM

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100 MIN IMU M

INLET AIR TEMP. (DEGREES FAHRENHEIT)

110

70 60 50 40 1.5

1.6

1.7

1.8

1.9

2.0

EQUALIZING VOLTAGE (VOLTS) Figure 1008 - Equalizing Voltage Acceptance Limits Models 23081-056, -059, -069, -070

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I

100 90

MA X IM

MI NIM

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INLET AIR TEMP. (DEGREES FAHRENHEIT)

110

70 60 50 40 1.5

1.6

1.7

1.8

1.9

2.0

EQUALIZING VOLTAGE (VOLTS) Figure 1009 - Equalizing Voltage Acceptance Limits Model 23081-063 C. Overspeed Test. (1) With starter-generator hot as a result of the previous test, operate at 14,000 rpm, no load for five minutes. (a)

No indication of failure (throwing of varnish, solder, noise, vibration, loosening of parts).

D. Compounding. (For models 23081-007, -008, -011, -011-1, -012, -012-1, -024 only) (1) Operate the starter-generator at 12,000 rpm, 30 VDC. (2)

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I (3)

Measure and Record field current at Terminal A (A1). (a)

Field current must rise with increasing load.

• 12,000 rpm, 100 and 200 A (V1/SH1) (For models 23081-007, -008, -011, -011-1, -012, -012-1, -024). • 12,000 rpm, 200 A (V1/SH1) (For all other models). (2)

Record the commutation.

(3)

Visually examine the condition of commutation. NOTE: The proper angle for viewing commutation is approximately 30 to 45 degrees from the brush box as shown in Figure 1010.

(4)

Acceptance Limits: (a)

Acceptable (pin point) commutation must be interpreted to permit continuous sparking that extends 0.12 inch (3,0 mm) beyond the edge of the brush (210) and occasional (no more than 10 per minute) single sparks that extend up to 0.25 in. (6,4 mm) beyond the edge of the brush (210).

(b)

Unacceptable commutation is considered to be continuous sparking or “arcing” that extends 0.25 in. (6,4 mm) beyond the edge of the brush (210). CORRECT VIEWING ANGLE 30-45°

TRAILING EDGE OF BRUSH

ANTI-DRIVE END

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E. Commutation Test. (1) Operate the starter-generator at 30 Vdc (V2) with the speed and the loads listed below:

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I F. Speed Pickup Test. (For models 23081-007, -008, 022, -022A, -023, -023A, -024, -056, -059, -069, -070) (1) With the field switch open, adjust starter-generator speed to 6,000 rpm.

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(2)

Connect a 20 kΩ ± 10% load across pins A and B of connector (360). See Figure 1011.

(3)

Connect oscilloscope, set at 0.5 v/cm and 5 millisecond time sweep, across pins A and B of connector (360).

(4)

With field switch (SW3) open, adjust starter-generator speed to 6,000 rpm.

(5)

Adjust oscilloscope for display of 2 or 3 cycles.

(6)

Measure and record peak-to-peak voltage of speed pickup output voltage.

(7)

Observe speed pickup output voltage waveforms.

(8)

Acceptance Limits: (a)

Peak-to-peak voltage: 2.5 V Min. to 4.5 V Max.

(b)

Refer to Figure 1012 for acceptable voltage waveform. NOTE: If unacceptable results are reached, adjust air gap of speed pickup for correct voltage reading and waveform. NOTE: Reference GSIL 2008-01 to check if the correct spur gear was installed.

(9)

Disconnect and remove load from pins A and B of connector (360).

PIN A POLARIZING KEY LOCKWIRE

PIN B

PIN C Figure 1011 - 3-Pin Connector Pin Locations

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I

Unacceptable

Figure 1012 - Voltage Wave Forms for Speed Pickup Test G. Speed Pick-Up Dielectric Test. (For models 23081-007, -008, 022, -022A, -023, -023A, -024, -056, -059, -069, -070) WARNING: BEFORE YOU USE THE HIGH VOLTAGE TESTER, MAKE SURE THAT THE POWER SWITCH IS IN THE ‘OFF’ POSITION. MAKE SURE THAT NO PERSON TOUCHES THE EQUIPMENT OR THE PROBES. THIS WILL PREVENT DEATH OR INJURY FROM ELECTRIC SHOCK. CAUTION:

DO NOT DO DIELECTRIC TESTING ON A MACHINE THAT HAS NOT BEEN FULLY CLEANED.

(1)

Connect pins A and B of connector (360) together. See Figure 1011.

(2)

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

(3)

Attach negative (black) lead of high pot tester to an unfinished surface of the starter-generator frame.

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Acceptable

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I CAUTION:

INCREASE OR DECREASE THE TEST VOLTAGES SLOWLY (100 V PER SECOND, MAXIMUM) INCREASING OR DECREASING THE VOLTAGE TOO QUICKLY CAN CAUSE SERIOUS DAMAGE TO THE STARTER-GENERATOR.

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(4)

Apply dielectric test voltage of 250 V rms for one minute (commercial frequency) between combined connector pins and machine frame.

(5)

Slowly decrease voltage to zero.

(6)

Turn the power supply OFF.

(7)

Disconnect the electrical test leads from the test unit.

(8)

Acceptance Limits: (a)

Any arcing as evidenced by flashover (surface discharge), sparkover (air discharge), breakdown (puncture discharge) or leakage current more than 2 mA will be evidence of damp, dirty, weak or defective components.

H. Starter-generator dielectric test. 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 ELECTRIC SHOCK TO THE OPERATOR OR ASSISTANTS. CAUTION:

DO NOT PERFORM DIELECTRIC TESTING DURING MAINTENANCE INSPECTION OR TROUBLESHOOTING OF THE UNIT AS IT MAY CAUSE CUMULATIVE DEGRADATION OF THE ELECTRICAL CIRCUIT INSULATION. THIS TEST IS RECOMMENDED ONLY FOR ACCEPTANCE TESTING OF AN OVERHAULED UNIT THAT HAS BEEN THOROUGHLY CLEANED.

(1)

Disconnect starter-generator from test circuit.

(2)

Remove commutation viewing adapter.

(3)

While machine is still hot as a result of testing, connect all stator terminal leads (A+, B+, D and E-), or (A+, B+, C+, D and E-) for C+ terminal models, of the terminal block together.

(4)

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

(5)

Attach negative (black) lead of high pot tester to an unfinished surface of the starter-generator frame.

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I WARNING: FAILURE TO USE NECESSARY SAFETY PRECAUTIONS WHEN HANDLING HIGH VOLTAGE ELECTRICAL LEADS DURING HIGH POTENTIAL TESTING CAN CAUSE SERIOUS INJURY OR DEATH. INCREASE OR DECREASE THE TEST VOLTAGES SLOWLY (100 V PER SECOND, MAXIMUM). INCREASING OR DECREASING THE VOLTAGE TOO QUICKLY CAN CAUSE SERIOUS DAMAGE TO THE STARTER-GENERATOR.

(6)

Apply dielectric test voltage of 250 V rms for one minute or 300 V rms for one second (commercial frequency) between the circuit and machine frame.

(7)

Slowly decrease voltage to zero.

(8)

Turn the power supply OFF.

(9)

Disconnect the electrical test leads from the test unit.

(10) Acceptance Limits: (a)

Any arcing as evidenced by flashover (surface discharge), sparkover (air discharge), breakdown (puncture discharge) or leakage current more than 5 mA will be evidence of damp, dirty, weak or defective components.

Locked Rotor Test. (Shunt Start Models) (For Models 23081-007, -008, -011, -011-1, -012, -012-1, -022, -022A, -023, -023A, -024, -056, -059, -069, -070) NOTE: This test is accomplished during acceptance testing. The starter-generator must have been overhauled and have an armature with a resurfaced commutator. Reference Standards Practice Document 1001. (1)

Rigidly mount starter-generator to test stand by starter-generator mounting flange.

(2)

Connect 0.0 Ω jumper between terminals A and B as shown in Figure 1013.

(3)

With voltage output set to zero, turn power supply ON.

CAUTION:

(4)

DO NOT ENERGIZE STARTER-GENERATOR MORE THAN 4 SECONDS. TURN POWER OFF IMMEDIATELY IF POWER IS MORE THAN VOLTAGE AND AMPS OF ACCEPTANCE LIMITS.

Increase voltage between terminals B and E (V2) until output torque is 10.0 lb-ft (13,6 N · m). NOTE: If current or voltage exceeds acceptable limits before the required torque is measured, remove power. Rotate armature to a different orientation and repeat test.

(5)

Measure and record line current (V1/SH1).

(6)

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CAUTION:

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I (7)

Turn the power supply OFF.

(8)

Acceptance Limits: (a)

B to E Voltage (V2): 12.0 Vdc Maximum.

(b)

Line Current (V1/SH1): 400 A Maximum.

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J. Locked Rotor Test. (Series Start Models) (For Models 23081-001, -002, -003, -004, -017, -018, -042, -043, -057, -063, -072, -073) NOTE: This test is accomplished during acceptance testing. The starter-generator must have been overhauled and have an armature with a resurfaced commutator. Reference Standards Practice Document 1001. (1)

Rigidly mount starter-generator to test stand by starter-generator mounting flange.

(2)

Open connection between terminals A and B. See Figure 1014.

(3)

With voltage output set to zero, turn power supply ON.

CAUTION:

DO NOT ENERGIZE STARTER-GENERATOR MORE THAN 4 SECONDS. TURN POWER OFF IMMEDIATELY IF POWER IS MORE THAN VOLTAGE AND AMPS OF ACCEPTANCE LIMITS.

(4)

With an open circuit between terminals A and B, increase voltage between terminals C and E (V2) until output torque is 13.0 lb-ft (17,6 N · m).

(5)

Measure and record line current (V1/SH1).

(6)

Measure and record voltage between terminals C and E (V2). NOTE: If current or voltage is more than acceptable limits before the required torque is measured, remove power. Rotate armature to a different orientation and repeat test.

(7)

Turn the power supply OFF.

(8)

Disconnect the electrical test leads and remove the starter-generator from the test stand.

(9)

Acceptance Limits: (a)

C to E voltage is not to be more than 12 Vdc.

(b)

Line current (V1/SH1) is not to be more than 400 A.

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Figure 1013 - Shunt Start Locked Armature Test Connection Diagram Models 23081-007, -008, -011, -011-1, -012, -012-1, -022, -022A, -023, -023A, -024, -056, -059, -069, -070

Figure 1014 - Series Start Locked Armature Test Connection Diagram Models 23081-001, -002, -003, -004, -017, -018, -042, -043, -057, -063, -072, -073

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I K. Commutator runout. CAUTION: DO NOT TOUCH THE POLISHED COMMUTATOR SURFACE WITH BARE HANDS. SKIN ACIDS AND OILS CAN CONTAMINATE CONDUCTING SURFACES, CAUSING CORROSION OR POOR ELECTRICAL CONTACT.

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(1)

Rotate armature on its own bearings and measure bar-to-bar and total runout.

(2)

Acceptance Limits: (a)

Bar-to-Bar Runout: 0.0002 inch (0,005 mm) Max.

(b)

Total Indicated Runout: 0.0008 inch (0,020 mm) Max.

8. Final Assembly After Acceptance Testing After starter-generator has successfully completed and passed acceptance testing, refer to the ASSEMBLY section for final assembly instructions. 9. Fault Isolation Table The following tables list faults that can occur during acceptance testing, performance testing, or when starter-generator is in service. For each fault, probable causes are listed along with related corrective actions. When a fault is detected, perform the corrective actions necessary to return the starter-generator to a serviceable condition. A complete acceptance test is required after corrective action is accomplished.

Fault

Probable Cause

A. Maximum Speed for Regulation Test The field current limit Too much load was applied during testing. is exceeded (A1). Stator windings are shorted or grounded.

Armature is shorted or grounded.

Corrective Action Check applied load at load bank. Apply correct load. Clean stator and housing assembly, refer to procedure in CLEANING section. Dielectric test stator and housing assembly, refer to CHECK section. Replace stator and housing assembly if it fails the dielectric test. Clean armature, refer to procedure in CLEANING section Dielectric test components of the armature, refer to the CHECK section. Replace armature if it fails the dielectric test.

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I Probable Cause

Corrective Action

B. Continuous Operating Speed, Equalizing Voltage, and Minimum Speed Test Cooling air flow is low. Check air flow path for obstructions. High Equalizing Voltage (V4). Clear all obstructions. Brushes are not Perform brush run-in procedure. Refer to properly seated. SPD 1006. Loose brush lead(s). Inspect all brush leads for loose connections. If loose brush lead is found and no evidence of arcing is present, secure brush lead to complete brush holder.

Brush circuit(s) open.

Armature is shorted or grounded.

If loose brush is found and evidence of arcing is present, replace brush. Inspect all brush leads for an open circuit. If open circuit found, overhaul or repair starter-generator as necessary. Clean armature. Refer to CLEANING section. Perform dielectric test on armature according to procedure in CHECK section. If armature fails dielectric tests, check armature for a short with a growler. Refer to the CHECK section.

Stator and housing assembly is shorted or grounded.

Field current (A1) limit is exceeded.

Too much load applied during testing.

If stator and housing assembly fails dielectric tests, replace stator and housing assembly. Check and adjust applied load at load bank, as necessary.

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Fault

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I Fault Low external field resistance.

Probable Cause Cooling air flow is low.

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Brushes are not properly seated. Brushes hung up in complete brush holder. Commutator surface incorrectly filmed or irregular.

Corrective Action Check air flow path for obstructions. Clear all obstructions. Perform brush run-in procedure. Refer to SPD 1006. Inspect for proper positioning.

Check armature. Refer to CHECK section. Repair commutator surface or replace armature. Refer to REPAIR section.

Armature is shorted or grounded.

Perform brush run-in procedure. Refer to SPD 1006. Clean armature. Refer to CLEANING section. Perform dielectric test on armature according to procedure in CHECK section. If armature fails dielectric tests, check armature for a short with a growler. Refer to the CHECK section.

Stator and housing assembly is shorted or grounded.

If armature fails growler check, replace armature. Clean stator and housing assembly. Refer to CLEANING section. Perform dielectric test on stator and housing assembly according to procedure in CHECK section. If stator and housing assembly fails dielectric tests, replace stator and housing assembly.

Table 1004 - Fault Isolation Table

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I

C. Overspeed Test Noisy Operation.

Probable Cause Bearings are defective and/or installed incorrectly. Cooling fan blades rubbing or are out of balance.

Corrective Action Replace bearings.

Check fan blades and air inlet for damage. Replace cooling fan if damaged.

Drive shaft spline is worn.

Repair or replace air inlet if damaged. NOTE: There are no authorized repair procedures to balance cooling fans. Disassemble drive shaft from starter-generator. Inspect drive shaft IAW the CHECK section.

Starter-Generator vibrates.

Armature striking against the stator and housing assembly. Bearings are defective and/or installed incorrectly. Armature is out of balance.

Repair or replace drive shaft as necessary. Disassemble starter-generator. Check both parts for physical damage. Repair or replace damaged parts as necessary. Visually inspect bearings. Disassemble starter-generator and replace bearings as necessary. Disassemble starter-generator. Check armature balance. Refer to SPD 1000. Repair or replace armature as necessary in accordance with SPD 1000.

D. Compounding Shunt field current does not increase with load.

Stator compensating windings bad.

Disassemble starter-generator. Replace stator and housing assembly.

Table 1004 - Fault Isolation Table

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Fault

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I Fault

Probable Cause

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E. Commutation Test Too much sparking Brushes are not with no load. properly seated. One or more complete brush holders are loose.

Corrective Action Perform brush run-in procedure. Refer to SPD 1006. Check attaching hardware. If damage is found, REPAIR bearing and brush support assembly as necessary. Perform dielectric test on bearing and brush support assembly according to procedure in CHECK section.

Brush spring pressure below limit.

An armature winding is partially or completely open.

Perform brush run-in procedure. Refer to SPD 1006. Check brush spring pressure. Refer to SPD 1006. REPLACE brush springs that do not meet limits in FITS & CLEARANCES section. REPLACE armature.

Table 1004 - Fault Isolation Table

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I Fault Excessive sparking with no load. (Continued)

Probable Cause Commutator surface incorrectly filmed or irregular.

Corrective Action Check armature. Refer to CHECK section.

Stator and housing assembly is shorted or grounded.

Perform brush run-in procedure. Refer to SPD 1006. Clean stator and housing assembly. Refer to CLEANING section. Perform dielectric test on stator and housing assembly according to procedure in CHECK section.

Armature is out of balance.

If stator and housing assembly fails dielectric tests, REPLACE stator and housing assembly. Check armature balance. Refer to SPD 1000. REPAIR or REPLACE armature as necessary.

F. Speed Pickup Test No output voltage. Speed pickup leads are shorted to starter-generator frame.

Speed pickup coil or lead wires are open.

Check for continuity between starter-generator frame and speed pickup leads. Replace speed pickup if continuity is found. Check speed pickup for continuity between speed pickup leads. Replace speed pickup if continuity is not found.

Table 1004 - Fault Isolation Table

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REPAIR commutator surface or replace armature. Refer to REPAIR section.

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I Fault Output voltage not within limits. (Continued)

Probable Cause

Corrective Action

Incorrect air gap between speed pickup and spur gear.

CAUTION: DO NOT ADJUST THE AIR GAP WHILE THE STARTER-GENERATOR IS OPERATING. ADJUSTING THE AIR GAP DURING OPERATION CAN DAMAGE THE EQUIPMENT.

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Low output. High output. Speed pickup Incorrect air gap waveform is between speed pickup incorrect. and spur gear. Speed pickup spur gear is damaged. Speed pickup is damaged. G. Speed Pickup Dielectric Test Speed pickup Lead wires are insulation grounded to stator and breakdown. housing assembly or speed pickup has short to ground.

Adjust air gap to be within following limits: 0.004 to 0.006 inch (0,102 to 0,152 mm). Reduce air gap. See Caution. Increase air gap. See Caution. Adjust air gap to be within following limits: 0.004 to 0.006 inch (0,102 to 0,152 mm). See Caution. Replace speed pickup spur gear. Replace speed pickup.

Check for continuity between starter-generator frame and speed pickup leads. Replace speed pickup if continuity is found.

Table 1004 - Fault Isolation Table

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I Probable Cause

H. Starter-Generator Dielectric Test Starter-Generator Bearing and brush insulation support assembly is breakdown. grounded.

Corrective Action Disassemble the starter-generator. Clean bearing and brush support assembly. Refer to CLEANING section. Perform dielectric test on bearing and brush support assembly according to procedure in CHECK section.

Armature is grounded.

If bearing and brush support assembly fails dielectric test, replace insulating sleeves and washers, according to the procedures in the disassembly and assembly section. Disassemble the starter-generator. Clean armature. Refer to CLEANING section. Perform dielectric test on armature according to procedure in CHECK section. If armature fails dielectric tests, check armature for a short with a growler. Refer to the CHECK section.

Stator and housing assembly is grounded.

Table 1004 - Fault Isolation Table

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Fault

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I Fault

Probable Cause

I. Locked Rotor Test Low or no torque. Stator and housing assembly is shorted or grounded.

Corrective Action Clean stator and housing assembly. Refer to CLEANING section.

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Perform dielectric test on stator and housing assembly according to procedure in CHECK section.

Armature is shorted or grounded.

If stator and housing assembly fails dielectric tests, replace stator and housing assembly. Clean armature. Refer to CLEANING section. Perform dielectric test on armature according to procedure in CHECK section. If armature fails dielectric tests, check armature for a short with a growler. Refer to the CHECK section.

Brushes incorrectly seated or installed.

If armature fails growler check, replace armature. Remove the brush cover. Using a wire hook tool, pull brush sets away from commutator surface. CHECK commutator surface for damage. REPAIR, if limits are not exceeded in FITS & CLEARANCES. Perform brush run-in procedure. Refer to SPD 1006. Re-test starter-generator.

Table 1004 - Fault Isolation Table

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I Fault Low or no torque. (Continued)

Probable Cause Open brush circuit.

Corrective Action Remove the brush cover.

If an open circuit is found, replace brush (new brush only). Perform brush run-in procedure. Refer to SPD 1006.

Calculated efficiency is below minimum limit.

Time to reach specified rpm exceeds minimum limit.

Windings hot from testing. Field current is low. Brushes are incorrectly seated or installed. Windings hot from testing. Field current is low. Brushes are incorrectly seated or installed.

Re-test starter-generator. Allow the windings to cool. Repeat test. Check field circuit for high resistance. Refer to SPD 1006 for brush installation, seating, and run-in procedures. Allow the windings to cool. Repeat test. Check field circuit for high resistance. Refer to SPD 1006 for brush installation, seating, and run-in procedures.

Table 1004 - Fault Isolation Table

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Inspect all brush leads for an open circuit.

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I Fault

Probable Cause

Line current (V1/SH1) or voltage between terminals B and E (V2) exceeded.

Stator and housing assembly is shorted or grounded.

Corrective Action Disassemble the starter-generator. Clean stator and housing assembly. Refer to CLEANING section.

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Perform dielectric test on stator and housing assembly according to procedure in CHECK section.

Armature is shorted or grounded.

If stator and housing assembly fails dielectric tests, replace stator and housing assembly. Disassemble the starter-generator. Clean armature. Refer to CLEANING section. Perform dielectric test on armature according to procedure in CHECK section. If armature fails dielectric tests, check armature for a short with a growler. Refer to the CHECK section. If armature fails growler check, replace armature.

J. Commutator Runout Check Bar-to-bar runout or Shifted commutator total indicated runout bars. exceeded.

REPAIR commutator surface. REPLACE armature if not repairable.

Table 1004 - Fault Isolation Table

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I 10. Component Testing Fault Isolation Table Wherever possible in the component testing fault isolation procedures, repairs are made. When repair is not possible, replace components. Probable Cause

Corrective Action

A. Stator and Housing Assembly Dielectric Test Insulation breakdown Stator and housing Clean stator and housing assembly. assembly is shorted or Refer to CLEANING section. grounded. Perform dielectric test on stator and housing assembly according to procedure in CHECK section. If stator and housing assembly fails dielectric tests, replace stator and housing assembly. B. Armature Dielectric Test Insulation breakdown Armature is shorted or grounded.

Clean armature. Refer to CLEANING section. Perform dielectric test on armature according to procedure in CHECK section. If armature fails dielectric tests, clean armature. Refer to CLEANING section. Repeat dielectric test on armature according to procedure in CHECK section. If armature fails dielectric tests after a second cleaning, repeat test between commutator bars and retaining bands.

Table 1005 - Component Testing Fault Isolation Table

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Fault

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I Fault

Probable Cause

Corrective Action

C. Armature Dielectric Test, Between Commutator Bars and Retaining Bands Insulation breakdown Grounded armature. Clean armature. Refer to CLEANING section.

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Perform dielectric test on armature according to procedure in CHECK section. If armature fails dielectric tests, clean armature. Refer to CLEANING section. Repeat dielectric test on armature according to procedure in CHECK section. If armature fails dielectric tests after a second cleaning, replace armature. D. Bearing and Brush Support Assembly Dielectric Test Insulation breakdown Grounded armature. Clean bearing and brush support assembly. Refer to CLEANING section. NOTE: Note: Leads for filter capacitor should be disconnected. Perform dielectric test on bearing and brush support assembly according to procedure in CHECK section. If bearing and brush support assembly fails dielectric test, clean bearing and brush support assembly. Refer to CLEANING section. Replace insulating sleeves and washers. Repeat dielectric test on bearing and brush support assembly according to procedure in CHECK section. If bearing and brush support assembly fails dielectric tests after a second cleaning, replace bearing and brush support assembly. Table 1005 - Component Testing Fault Isolation Table (Continued)

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I VERIFICATION / FINAL ACCEPTANCE DATA SHEET 23081-

Inspection/Test Visual inspection Maximum Speed for Regulation Test (23081-007, -008, -011, -011-1, -012, -012-1 and -024) Continuous Operating Speed, Equalizing Voltage and Minimum Speed Test

Overspeed Test Compounding

Inspected by: Date:

Requirements/Limits

Measurements Accept

Check for physical damage Voltage between terminals B and A, (V3) Field current, (A1) External field resistance must not be greater than 35 Ω Measured equalizing voltage D and E (V4) Temperature Frame temperature Field current (A1) (10 A Max) Voltage between terminals B and A (V3) Calculated external field circuit resistance (0.4 Ω Min) Calculated equalizing voltage (D-E) No sign of electrical or mechanical failure Field current rises with increasing load.

(23081-007, -008, -011, -011-1, -012, -012-1, -024)

Commutation Test Commutation must not exceed pinpoint sparking. Speed Pickup Test Peak-to-peak voltage (2.5 to 4.5 VDC) (23081-007, -008, Voltage waveform

Reject

Vdc A A

Vdc °F °F A Vdc Ω Vdc

A A A A

022, -022A, -023, -023A, -024, -056, -059, -069, -070)

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Model Number: Serial Number:

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I Inspection/Test Speed Pickup Dielectric Test

Requirements/Limits

Measurements Accept

Reject

No indication of insulation breakdown

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(23081-007, -008, 022, -022A, -023, -023A, -024, -056, -059, -069, -070)

Starter-Generator Dielectric Test Locked Rotor Test (Shunt Start)

No indication of insulation breakdown. Output torque 10.0 lb-ft (13,6 N · m) Line current (V1/SH1) (23081-007, -008, (400 A Max). -011, -011-1, -012, -012-1, -022, -022A, B to E voltage (V2) -023, -023A, -024, (12 Vdc Max).

mA lb-ft (N · m) A Vdc

-056, -059, -069, -070)

Locked Rotor Test Output torque (Series Start) 13.0 lb-ft (17,6 N · m). Line current (V1/SH1) (23081-001, -002, (400 A Max). -003, -004, -017, -018, -042, -043, C to E voltage (V2) -057, -063, -072, (12 Vdc Max).

lb-ft (N · m) A Vdc

-073)

Commutator Runout

Bar-to-bar runout (0.0002 inch (0,005 mm) Max) Total indicated runout (0.0008 inch (0,020 mm) Max)

in. mm in. mm

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I

SCHEMATICS AND WIRING DIAGRAMS 1. Introduction

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This section is unassigned.

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I

DISASSEMBLY

This section provides disassembly procedures for the 23081 Series I DC Starter-Generator. Disassemble only to the extent required to replace defective parts, unless complete overhaul is required. Additional disassembly of major components is not necessary unless specifically instructed in the CHECK or TESTING AND FAULT ISOLATION sections. Before disassembly, wipe exterior surfaces with a clean cloth to remove dust, dirt, or other foreign materials. Do not remove threaded inserts. Refer to CHECK section for details. Do not disassemble riveted parts. Refer to REPAIR section to determine whether part(s) can be replaced. Do not open or desolder permanent connections unless replacement of worn, damaged, or defective parts is necessary. Tag electrical wires before removal. All soldering and desoldering procedures must be done to ANSI/IPC J-STD-001. During overhaul, all bearings, brushes, insulating parts, retaining rings, self-locking nuts and lock washers must be discarded regardless of their condition. NOTE: When a starter-generator is removed for service, the QAD kit and terminal block cover usually stay on the aircraft. 2. Disassembly Tools In addition to standard shop tools, those special tools, fixtures, and equipment listed in Table 3001 are required for disassembly. Tools Description

Source/Figure Reference

Adapter, Anti-drive end Armature Shaft Adapter, Drive end Armature Shaft Arbor Press Bearing Puller (Snap-On A78 or Equivalent) Driver, Dampener Hub Driver, Inner Race Bearing External Snap Ring Pliers Foam Cushion Pin Insertion/Extraction Tool Plastic or Leather Mallet Spline Wrench Support, Anti-drive End Hub

Figure 9001 Figure 9002 Commercially Available Commercially Available Figure 9006 Figure 9004 Commercially Available Commercially Available Commercially Available Commercially Available Figure 9015 Figure 9011

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1. Introduction

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I Tools Description

Source/Figure Reference

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Support, Bearing and Brush Support Assembly Support, Drive End Outboard Hub Support, Horizontal Stator and Housing Assembly Tweezers Wire Hook Tool

Figure 9009 Figure 9012 Figure 9013 Commercially Available Commercially Available

Table 3001 - Disassembly Tools (Continued) 3. Disassembly Materials Materials necessary for starter-generator Disassembly are listed in Table 3002. NOTE: Equivalent substitutes can be used for the materials listed in Table 3002. Disassembly materials are not available from Goodrich Corporation. All items can be purchased commercially. WARNING: BEFORE USING ONE OF THE FOLLOWING MATERIALS, BE AWARE OF ALL HANDLING, STORAGE, AND DISPOSAL PRECAUTIONS RECOMMENDED BY THE MANUFACTURER OR SUPPLIER. FAILURE TO COMPLY WITH THE RECOMMENDATIONS CAN RESULT IN SERIOUS INJURY, PHYSICAL DISORDER, OR DEATH.

Item

Description/Specification

Source (CAGE Code)

Foam Cushion Isopropyl Alcohol

N/A TT-I-735, Grade A

Commercially Available Commercially Available

See WARNING before using this material.

Flash Point: 53° F (12° C), FLAMMABLE. Refer to the Material Safety Data (MSD) Sheet for the material for additional safety information. N/A

Commercially Available

Masking Tape

Table 3002 - Disassembly Materials 4. Disassembly of the Starter-Generator NOTE: Unless otherwise specified, numbers in parentheses ( ) refer to item numbers in Figure 10001 of ILLUSTRATED PARTS LIST.

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I

NOTE: The mounting adapter coupling usually stays on the aircraft when the starter-generator is removed for service, check and inspection of the part is not required if not present. (1)

Loosen self-locking nut (30) and remove V-retainer coupling (20) from the starter-generator.

(2)

Remove QAD and mounting adapter (50) from starter-generator.

B. Remove the identification plate (60), information plate (80), caution decal (100), FAA-PMA label (-110) and modification label (-120) from stator and housing assembly (550). NOTE: Do not remove these items unless they are damaged or unreadable. NOTE: Minor scratches and superficial damage that do not affect the legibility are not reason to replace the ID plate. (1)

Use a smooth, flat tool that will not scratch the stator housing to wedge under the edge of the identification plate or information plate and pry up on the corners of the plate near the drive screws that hold it in place to dislodge the plate from the housing. NOTE: This will tear the corners of the light metal identification plate.

(2)

Remove the remaining metal from under the head of each drive screw.

(3)

Use a small pair of sidecutters with the flat face to the housing to wedge in under the head of each drive screw to hold the shank of the screw and turn out counterclockwise.

(4)

Discard the four drive screws (70) from the identification plate, and discard the two drive screws (90) from the information plate (80) from the stator and housing assembly (550).

(5)

Keep the identification plate for reference when transferring the information to a replacement identification plate (60).

WARNING: HANDLE THE TOOL CAREFULLY. WEAR EYE PROTECTION. (6)

Remove and discard the caution decal (100), FAA-PMA label (-110) and modification label (-120) from stator and housing assembly (550). (a)

Lift the corner of the caution decal, FAA-PMA label and modification label with a sharp tool.

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A. Remove QAD mounting kit from starter-generator, if present. NOTE: The V-retainer coupling usually stays on the aircraft when the starter-generator is removed for service, check and inspection of the part is not required if not present.

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I (b)

Peel off and discard the caution decal, FAA-PMA label and modification label from the starter-generator.

WARNING: ISOPROPYL ALCOHOL CAN BE DANGEROUS TO PERSONS. USE ONLY IN AN AREA WITH A GOOD FLOW OF AIR. KEEP AWAY FROM SOURCES OF IGNITION. DO NOT BREATHE THE FUMES. PREVENT SKIN CONTACT. PUT ON PROTECTIVE CLOTHING AND EYE PROTECTION. Distributed via the Goodrich Technical Publications Web Portal. Refer to https://techpubs.goodrich.com to confirm the latest revision standard.

(c)

Use isopropyl alcohol to remove adhesive residue.

(d)

Wipe dry with a soft dry cloth.

C. Remove terminal block cover (130) from starter-generator. NOTE: When a starter-generator is removed from service, the terminal block cover is usually kept with the aircraft. (1)

For models 23081-022, -022A, -023, -023A, -056, -059, -069 and -070: (a)

(2)

Pull cover off of terminal block. See Figure 3001.

For models 23081-007, -008, -011, -011-1, -012, 012-1, -024: (a)

Remove and discard the two screws (140) that attach terminal block cover to terminal block.

(b)

Remove terminal block cover by pulling it off the terminal block. See Figure 3001. TERMINAL BLOCK COVER

TERMINAL BLOCK COVER SCREW (1 OF 2)

Figure 3001 - Removing Terminal Block Cover

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I D. Remove air inlet (150) from starter-generator. (1) Remove and discard the screws (200) that attach the air inlet to bearing and brush support assembly (320). Remove air inlet.

E. If necessary, disassemble air inlet assembly (150). (1) Remove and discard the flat washers (-190) and rivets (-180) from air inlet subassembly (160) and screen (170). (2)

Remove the screen (170) from the inside of the air inlet.

F. Remove brushes (210) from bearing and brush support assembly (320). See Figure 3002. NOTE: If brushes (210) are to be reused, identify the brushes (210) and complete brush holders (10002-30) with the numbers 1 through 4. (1)

Remove and discard the screw (220) that attaches brush (210) shunt lead to complete brush holder (10002-30).

CAUTION:

RAISE AND LOWER BRUSH SPRINGS SLOWLY. DO NOT LIFT BRUSH SPRINGS MORE THAN NEEDED TO REMOVE BRUSHES FROM EACH COMPLETE BRUSH HOLDER.

(2)

Use a wire hook tool to lift two brush springs (10002-50) away from brush (210). Remove brush (210) from complete brush holder (10002-30).

(3)

Slowly return brush springs (10002-50) to a resting position on complete brush holder (10002-30).

(4)

Identify brush (210) with the number on complete brush holder (10002-30) from which it was removed.

(5)

Repeat Paragraph 4.F.(1) thru Paragraph 4.F.(4) for each remaining brush (210).

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(2)

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I WIRE HOOK TOOL BRUSH

BRUSH SPRING

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COMPLETE BRUSH HOLDER

TERMINAL BLOCK

Figure 3002 - Brush Set Locations and Numbers G. Remove fan (230) from drive shaft (260). See Figure 3003. (1) Put a spline wrench on drive spline to prevent drive shaft from turning while removing self-locking nut. (2)

Remove and discard the self-locking nut (240) and flat washer (250) from drive shaft (260).

(3)

Slide the fan (230) off of the drive shaft (260). FAN FLAT WASHER DRIVE SHAFT

SELF-LOCKING NUT

Figure 3003 - Removing Fan From Drive Shaft

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I

(1)

Lightly tap the anti-drive end of drive shaft (260) with a plastic or leather mallet to disengage it from armature (480) shaft.

(2)

Pull drive shaft (260) out of the drive end of the starter-generator.

WARNING: DO NOT CUT, RIP, OR SAND ASBESTOS-CONTAINING MATERIALS. LEAVE UNDAMAGED MATERIALS ALONE AND, TO THE EXTENT POSSIBLE, PREVENT THEM FROM BEING DAMAGED, DISTURBED, OR TOUCHED. DISCARD MATERIAL BY FIRST CHECKING WITH LOCAL HEALTH, ENVIRONMENTAL, OR OTHER APPROPRIATE OFFICIALS TO FIND OUT ABOUT PROPER HANDLING AND DISPOSAL PROCEDURES. (3)

Remove friction ring (280) from drive shaft (260). If friction ring is Part No. 02-5600-05, it must be discarded because it contains asbestos.

(4)

Remove dampener plate (290) from dampener hub (300) on drive shaft (260).

(5)

If present, remove and discard O-ring (270) from drive shaft (260).

DRIVE SHAFT WITH DAMPENER PLATE AND DAMPENER HUB FRICTION RING

Figure 3004 - Drive Shaft with Dampener Plate and Dampener Hub

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H. Remove drive shaft (260) with attached dampener hub (300), dampener plate (290), O-ring (270), and friction ring (280) from armature (480) shaft. CAUTION: DO NOT USE A HIGH AMOUNT OF FORCE WHEN YOU TAP THE DRIVE SHAFT. HIGH FORCE CAN DAMAGE THE DRIVE SHAFT THREAD.

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I I.

Remove dampener hub (300) from drive shaft (260). See Figure 3005. NOTE: Do not remove dampener hub from drive shaft unless hub or drive shaft are damaged. CAUTION:

PUT A FOAM CUSHION UNDER DRIVE SHAFT TO PREVENT IT FROM BEING DAMAGED.

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(1)

Set a foam cushion and a bearing hub support on an arbor press table.

(2)

Set a dampener hub driver on the drive shaft (260) on the flat side of dampener hub (300).

(3)

Insert drive shaft (260) through the center of the drive end hub support until dampener hub driver is seated on the drive shaft (260).

(4)

Slowly press drive shaft (260) down into the drive end hub support until dampener hub (300) disengages from drive shaft (260).

DRIVE SHAFT DAMPENER HUB DAMPENER HUB DRIVER

DRIVE END OUTBOARD HUB SUPPORT

FOAM CUSHION

ARBOR PRESS TABLE

Figure 3005 - Remove the Dampener Hub from the Drive Shaft

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I

(1)

Put drive end armature shaft adapter into the drive end of armature (480) shaft.

CAUTION:

TAPE THE JAWS OF THE BEARING PULLER TO PREVENT DAMAGE TO THE DAMPENER BACKPLATE DURING REMOVAL.

(2)

Remove dampener backplate (290) from armature (480) shaft using a suitable bearing puller.

(3)

Use external snap ring pliers to remove and discard retaining ring (540).

(4)

Remove and retain baffle disc (outboard) (530). BEARING PULLER

DAMPENER BACKPLATE RETAINING RING BAFFLE DISC

DRIVE END ARMATURE SHAFT ADAPTER MASKING TAPE

Figure 3006 - Removing Dampener Backplate

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J. Remove dampener backplate or dampener backplate and gear (310), retaining ring (540) and baffle disc (outboard) (530) from armature (480) shaft. See Figure 3006. CAUTION: FAILURE TO USE THE DRIVE END ARMATURE SHAFT ADAPTER WHEN REMOVING THE DAMPENER BACKPLATE AND SPUR GEAR CAN CAUSE PERMANENT DAMAGE TO THE ARMATURE SHAFT.

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I K. Remove bearing and brush support assembly (320) and attached armature (480) from stator and housing assembly (550). See Figure 3007. (1) Put the starter-generator on a horizontal stator support. CAUTION:

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MAKE SURE YOU USE THE DRIVE END ARMATURE SHAFT ADAPTER TO REMOVE THE BEARING AND BRUSH SUPPORT ASSEMBLY AND ATTACHED ARMATURE. THIS WILL PREVENT DAMAGE TO THE ARMATURE SHAFT.

(2)

Remove and discard eight self-locking screws (330), eight lock washers (340, and eight flat washers (350) that attach the bearing and brush support assembly (320) to stator and housing assembly (550).

(3)

Put the drive end armature shaft adapter into the armature (480) shaft.

(4)

Tap on the drive end armature shaft adapter with a rubber or plastic mallet until the bearing and brush support assembly (320) disconnects from the stator and housing assembly (550).

(5)

Carefully remove the bearing and brush support assembly (320), together with the armature (480), from the stator and housing assembly (550). NOTE: The drive end ball bearing (520) and baffle disc (530) (inboard) will stay on the armature (480) shaft when removed from the stator and housing assembly (550).

(6)

Carefully remove bearing and brush support assembly (with attached armature) from stator and housing assembly.

FLAT WASHER

SCREW

LOCK WASHER

STATOR AND HOUSING ASSEMBLY

BEARING AND BRUSH SUPPORT WITH ATTACHED ARMATURE

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I

(1)

Remove and discard the lockwire from four screws (380) that attach the 3-pin connector (360) and spacer (370) to stator and housing assembly (550).

(2)

Remove four screws (380) and pull the connector (360) from stator and housing assembly (550) to length of electrical wire.

(3)

Carefully desolder the leads from the pins. NOTE: All desoldering procedures must be done to ANSI/IPC J-STD-001.

(4)

Remove pins A, B and C from connector using pin extraction tool. Set 3-pin connector (360) and spacer (370, if applicable) aside.

POLARIZING

PIN A LOCKWIRE

KEY

PIN B

DRIVE END

SCREW (1 OF 4)

PIN C

3-PIN CONNECTOR

SPACER

LEAD CONTACTS

Figure 3008 - Removing 3-Pin Connector from Stator and Housing Assembly M. Remove drive end bearing support assembly (390) from stator and housing assembly (550). (See Figure 3009) (1) Set stator and housing assembly on a horizontal stator support. (2)

Remove and discard screws (400), lock washers (410), flat washers (420), and tooth lock washers (430, if applicable) that attach drive end bearing support assembly to stator and housing assembly.

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L. Remove 3-pin connector (360) and if applicable spacer (370), from stator and housing assembly (550). (See Figure 3008) NOTE: Only applicable to models: 23081-007, -008, -022, -022A, -023, -023A, 024, -056, -059, -069 and -070.

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I SCREW TOOTH LOCK WASHER (2 PLCS, 180° APART)

DRIVE END BEARING SUPPORT ASSEMBLY

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SCREW

SPRING LOCK WASHER FLAT WASHER

SPEED PICKUP LEADS

Figure 3009 - Removing Drive End Bearing Support Assembly from Stator and Housing Assembly CAUTION:

DO NOT USE HIGH FORCE WHEN TAPPING DRIVE END BEARING SUPPORT ASSEMBLY OR YOU CAN DAMAGE THE MATING FLANGE OF THE STATOR AND HOUSING ASSEMBLY.

(3)

Lightly tap outer diameter of drive end bearing support assembly with a plastic or leather mallet to loosen it from stator and housing assembly.

(4)

Remove drive end bearing support assembly from stator and housing assembly while carefully pulling speed pickup leads through stator windings (where applicable).

N. Remove speed pickup guard (440), speed pickup (460), and grommet (470) from drive end bearing support assembly (390). See Figure 3010 NOTE: The following applies to models 23081-007, -008, -022, -022A, -023, -023A, -024, -056, -059, -069 and -070 only. (1)

For models 23081-022, -022A, -023, -023A, -056, -059, -069 and -070:

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(a)

Remove and discard screws (450) that attach speed pickup guard (440) to drive end bearing support assembly.

(b)

Remove speed pickup guard (440).

(2)

Pull speed pickup leads through the grommet (470).

(3)

Loosen speed pickup jam nut and back it away from drive end bearing support assembly (390).

(4)

Remove speed pickup.

(5)

Remove and discard grommet (470).

NUT SPEED PICKUP GUARD (IF APPLICABLE)

SPEED PICKUP LEADS

GROMMET (IF APPLICABLE)

SCREW

DRIVE END END BELL ASSEMBLY

Figure 3010 - Removing Speed Pickup

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I O. Remove armature (480) from bearing and brush support assembly (320). See Figure 3011 CAUTION: TO PREVENT DAMAGE TO THE ARMATURE SHAFT, PUT A FOAM CUSHION AT THE BASE OF THE ANTI-DRIVE END BELL ASSEMBLY SUPPORT.

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(1)

Put a foam cushion and bearing and brush support assembly support on an arbor press table.

(2)

Put the bearing and brush support assembly (320), with the attached armature (480), onto the bearing and brush support assembly support.

CAUTION:

(3)

FAILURE TO USE THE ANTI-DRIVE END ARMATURE SHAFT ADAPTER WHEN PRESSING THE ARMATURE FROM THE BEARING AND BRUSH SUPPORT ASSEMBLY CAN CAUSE PERMANENT DAMAGE TO THE ARMATURE SHAFT.

Insert an anti-drive end armature shaft adapter into the end of the armature (480) shaft.

CAUTION:

TO PREVENT DAMAGE TO THE ARMATURE SHAFT, HOLD IT SECURELY WHEN IT IS PRESSED OUT OF THE BEARING AND BRUSH SUPPORT ASSEMBLY.

ARBOR PRESS ANTI-DRIVE END ARMATURE SHAFT ADAPTER

BEARING AND BRUSH SUPPORT ASSEMBLY ARMATURE

SUPPORT

CUSHION

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(4)

Carefully press the armature (480) shaft down and away from the bearing and brush support assembly (320).

(5)

Carefully remove armature (480) from inside the bearing and brush support assembly support.

P. Remove bearing retainer (490) and anti-drive end bearing (520) from bearing and brush support assembly (320). See Figure 3012 CAUTION: FAILURE TO USE AN ANTI-DRIVE END HUB SUPPORT WHEN BEARING IS PRESSED FROM THE ADE BEARING AND BRUSH SUPPORT ASSEMBLY CAN CAUSE PERMANENT DAMAGE TO THE BEARING AND BRUSH SUPPORT ASSEMBLY. (1)

Remove and discard screws (500) and lock washers (510) that attach bearing retainer to bearing and brush support assembly. NOTE: The leads from the filter board assemblies on bearing and brush support assembly become disconnected when the screws that attach the bearing retainer are removed. NOTE: Previous versions featured a grounding lead (10004-70) that was not built into the windings. Disconnect the lead from one of the negative brush holders.

(2)

Move filter board leads away from bearing liner.

(3)

Remove bearing retainer.

(4)

Set an anti-drive end hub support on the table of an arbor press.

(5)

Set the bearing and brush support assembly (320) on the anti-drive end hub support with the inboard side facing up.

(6)

Set an inner race bearing driver on the inner race of anti-drive end bearing (520).

(7)

Slowly press anti-drive end bearing (520) from bearing and brush support assembly (320) using an inner race bearing driver.

(8)

Remove anti-drive end bearing (520) from inside the anti-drive end hub support. Discard anti-drive end bearing. NOTE: Do not disassemble the bearing and brush support assembly (320) unless damage is found.

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I

INNER RACE BEARING DRIVER

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BEARING AND BRUSH SUPPORT ASSEMBLY

BALL BEARING

ANTI-DRIVE END HUB SUPPORT

Figure 3012 - Removing the Anti-Drive End Ball Bearing Q. Remove drive-end ball bearing (520) and baffle disc (inboard) (530) from armature (480) shaft. CAUTION: FAILURE TO USE A DRIVE END ARMATURE SHAFT ADAPTER CAN CAUSE PERMANENT DAMAGE TO ASSEMBLY. (1)

Put a drive end armature shaft adapter into drive-end of armature shaft.

(2)

Using a suitable bearing puller, remove drive-end ball bearing (520) from armature (480) shaft and discard the drive-end ball bearing (520).

(3)

Remove and retain baffle disc (inboard) from the armature shaft.

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I BEARING PULLER

DRIVE END BALL BEARING

ARMATURE SHAFT

DRIVE END ARMATURE SHAFT ADAPTER

Figure 3013 - Removing Ball Bearing from Drive End Armature Shaft 5. Disassembly of Bearing and Brush Support Assembly. Unless otherwise indicated, numbers in parentheses ( ) refer to item numbers in Figure 10002 of the ILLUSTRATED PARTS LIST. Do not disassemble further than necessary to examine, repair or replace parts. A. Remove complete brush holder (30) assemblies (without filter boards) from anti-drive end end bell (120). See Figure 3014. NOTE: Do not disassemble bearing and brush support assembly unless necessary. (1)

Remove and discard nuts (140), flat washers (90), and insulating washers (130) from bolts (100) or screws (100).

(2)

Remove brush holder assemblies from bolts.

(3)

Discard non-metallic washers (110 and 120) and insulation sleeves (80).

(4)

Repeat Paragraph 5.A.(1) thru Paragraph 5.A.(3) as required for remaining complete brush holders (30).

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BAFFLE DISC

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I SELF-LOCKING NUT FLAT WASHER INSULATING WASHER

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BRUSH HOLDER ASSEMBLY INSULATING WASHER SLEEVE

ANTI-DRIVE END END BELL

INSULATING WASHER (TYP. ALL)

SCREW

FLAT WASHER

Figure 3014 - Removing Brush Holder Assemblies (Without Filter Board) B. Remove complete brush holder (30) assemblies (with filter boards) from anti-drive end end bell (120). See Figure 3015 NOTE: Do not disassemble bearing and brush support assembly unless necessary. (1)

Remove and discard nuts (140), flat washers (90), and insulating washers (130) from bolts (100) or screws (100).

(2)

Remove filter board assemblies (60) and brush holder assemblies from the bolts.

(3)

Remove brush holder assemblies from bolts.

(4)

Discard non-metallic washers (110 and 120) and insulation sleeves (80).

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I (5)

Repeat Paragraph 5.A.(1) thru Paragraph 5.A.(3) as required for remaining complete brush holders (30).

SELF-LOCKING NUT FLAT WASHER

INSULATING WASHER

FILTER BOARD ASSEMBLY BRUSH HOLDER ASSEMBLY INSULATING WASHER SLEEVE

ANTI-DRIVE END END BELL

INSULATING WASHER (TYP. ALL)

SCREW

FLAT WASHER

Figure 3015 - Removing Brush Holder Assemblies (With Filter Boards) C. Remove brush springs (50) from brush holder (30). (1) Remove any of the eight brush springs that need to be replaced from brush holder assemblies. (2)

Discard damaged brush springs.

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SELF-LOCKING NUT FLAT WASHER

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I 6. Disassembly of Drive End Bearing Support Assembly NOTE: Unless otherwise indicated, numbers in parentheses ( ) refer to item numbers on the illustration IPL Figure 10003. NOTE: Do not disassemble drive end end bell further than required to examine, repair or replace parts determined to be unserviceable. Distributed via the Goodrich Technical Publications Web Portal. Refer to https://techpubs.goodrich.com to confirm the latest revision standard.

A. Remove screen (20) from drive end end bell (10). (1) Remove and discard attaching drive screws (30) and flat washers (40). (2)

Remove and discard screen.

B. For models 23081-007 and -008, remove the magnetic pickup bracket (50) from drive end end bell (10). (1) Remove and discard attaching screws (60). (2)

Remove magnetic pickup bracket.

7. Disassembly of Stator and Housing Assembly. NOTE: Unless otherwise indicated, numbers in parentheses ( ) refer to item numbers on the illustration IPL Figure 10004. NOTE: Use a socket wrench with a ground-down outer diameter that will not damage the terminal block while removing attaching hardware. NOTE: Do not disassemble the stator and housing assembly further than the removal of the terminal block to examine, repair, or replace parts determined to be unserviceable. A. Remove attaching hardware from the terminal block (60). See Figure 3016. (1) For stator and housing assembly effect codes A, B:

(2)

(a)

Remove three nuts (30) and flat washers (40) from the three large terminal studs. Discard flat washers (40).

(b)

Remove two nuts (10) and flat washers (20) from terminal block (60) studs A and D. Discard flat washers (20).

(c)

Remove two terminal lugs (120) from terminal block (60) studs and let rest to length of electrical wire.

For stator and housing assembly effect codes C, D and E: (a)

Remove two nuts (30) and flat washers (40) from two large terminal studs. Discard flat washers (40).

(b)

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I (c) (3)

Remove two terminal lugs (120) from terminal block (60) studs and let rest to length of electrical wire.

For stator and housing assembly effect code C, remove grommet (110) from the stator and housing assembly.

(a)

Remove the grommet from the stator and housing assembly by prying up on the edge of the grommet with a flat head screw driver until enough of the grommet is exposed.

(b)

Using needle nose pliers, remove the grommet from the stator and housing assembly.

FLAT WASHER SELF-LOCKING NUT FLAT WASHER

SELF-LOCKING NUT

FLAT WASHER

SELF-LOCKING NUT FLAT WASHER GROMMET

SELF-LOCKING NUT

SELF LOCKING NUT FLAT WASHER

FLAT WASHER

SELF-LOCKING NUT

Figure 3016 - Remove Miscellaneous Hardware

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NOTE: The grommet does not need disassembled unless damaged.

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I B. Remove the terminal block (60) from the stator and housing assembly. See Figure 3017. (1) For stator and housing assembly effect codes A, B, D, E: (a)

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(2)

For stator and housing assembly effect code C: (a)

(3)

Remove two screws (80), lock washers (90) and flat washers (100) from terminal block (60). Discard lock washers (90) and flat washers (100).

Remove three screws (80), lock washers (90) and flat washers (100) from terminal block (60). Discard lock washers (90) and flat washers (100).

Carefully remove the terminal block (60) from the stator and housing assembly by lifting slightly and rotating the terminal block (60) out from the stator and housing assembly.

SCREW LOCK WASHER FLAT WASHER

SCREW LOCK WASHER SCREW

FLAT WASHER SCREW

LOCK WASHER FLAT WASHER

Figure 3017 - Terminal Block Removal

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I

CLEANING 1. Introduction This section contains the cleaning procedures for 23081 Series I DC Starter-Generators.

Table 4001 lists equipment and materials required to perform the cleaning of assemblies, subassemblies and components. NOTE: Reference GSIL 2006-01 for the use of Brulin 815GD-NF. NOTE: Equivalent substitutes can be used for the materials listed in Table 4001. WARNING: YOU MUST OBEY THE TOOL/EQUIPMENT MANUFACTURERS WARNINGS AND CAUTIONS SHOWN ON PACKAGING, CONTAINERS AND/OR INSTRUCTION LEAFLETS. IF YOU DO NOT, YOU CAN CAUSE DEATH OR INJURY TO PERSONS AND DAMAGE TO EQUIPMENT OR PROPERTY. WARNING: ISOPROPYL ALCOHOL 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.

Material Bag, Polyethylene Brush Cleaning Pads/Wiping Cloths Corrosion Preventive

Description/Specification

Source/CAGE Code

Size that will easily enclose parts being washed. Nonmetallic, soft bristle Lint-free, soft fabric

Commercially Available

Cold application, water displacing soft film MIL-C-16173, Grade 3.

Commercially Available Commercially Available Commercially Available

Table 4001 - Cleaning Materials and Equipment

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2. Cleaning Materials

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I Material De-ionized Water

Description/Specification

Source/CAGE Code

For fresh water, Ion Exchange process to a resistivity not less than 750 kΩ/cm @ 77° F (25° C) min., when measured in accordance with ASTM D1125-95, Method A.

Commercially Available

Distributed via the Goodrich Technical Publications Web Portal. Refer to https://techpubs.goodrich.com to confirm the latest revision standard.

For rinse water that is to be reused, check that the resistivity does not fall below 500 kΩ/cm @ 77° F (25° C) min., measured in accordance with ASTM D1125-95, Method A. MIL-D-3464E Type II, Kraft bag, 4 unit bag size

Desiccant

Englehard Corporation Desiccate 25 or equivalent Formula 815 GD-NF

Detergent Refer to material technical data sheet for recommended dilution of water and detergent, and solution temperature. Equivalent detergents can be used to clean parts and assemblies. Detergents must not be destructive to the finish or material of part. Use only detergents specified in this table to clean IVD coated parts. Isopropyl Alcohol

Applications: Hot tanks - aluminum safe Steam Cleaning Pressure Sprayers Ultrasonic Cleaning Formula 1990 GD Application: Spray Wash Cleaning

Commercially Available

Brulin and Company, Inc. 2920 Dr. Andrew J Brown Ave. Indianapolis, Indiana 46205-4066 USA Phone:(1) 317/923-3211 FAX: (1) 317/925-4596 www.brulin.com (V94058)

Commercially Available

TT-I-735, Grade A See WARNING before using this material. Flash Point: 53°F (12°C), FLAMMABLE Refer to the Material Safety Data (MSD) Sheet for the material for additional safety information

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I 3. Cleaning Procedures

A. Blow out dirt particles. (1) Put the parts into a ventilated air spray booth. WARNING: COMPRESSED AIR USED FOR CLEANING MUST BE FREE OF OIL AND WATER. WHEN USING COMPRESSED AIR FOR CLEANING OR DRYING, CONTROL PRESSURE TO 30 PSIG (207 KPA) OR LESS. WEAR GOGGLES OR FACE SHIELD TO PROTECT EYES. TAKE PRECAUTIONS TO AVOID INJURY TO OTHER PERSONNEL IN AREA. CAUTION:

(2)

MAKE SURE THAT COMPRESSED AIR USED TO CLEAN/DRY THE COMPONENTS IS FREE FROM OIL AND WATER. THIS WILL PREVENT CONTAMINATION OF THE COMPONENTS.

Blow away all loose dirt with clean, dry, compressed air.

B. Clean the parts. WARNING: DETERGENT CAN BE DANGEROUS TO PERSONS. USE ONLY IN AN AREA WITH A GOOD FLOW OF AIR. DO NOT BREATHE THE FUMES. PREVENT SKIN CONTACT. PUT ON PROTECTIVE CLOTHING AND EYE PROTECTION. Wash the parts with one or more of the approved cleaning procedures given in Table 4002. Procedure Spray

Instructions Put the parts into a high pressure spray wash booth using detergent Brulin 1990 GD. CAUTION: LIMIT THE PRESSURE TO CLEAN PARTS. HIGH PRESSURE CAN REMOVE OR DAMAGE SURFACE COATINGS, CONNECTIONS AND INSULATION. Spray the parts with a solution of detergent and de-ionized water. Refer to the manufacturers specification for the recommended dilution of water and detergent and solution temperature. Table 4002 - Cleaning Procedures

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Before you do procedures given in CHECK, REPAIR, ASSEMBLY, TESTING AND FAULT ISOLATION, and final inspection, the components must be cleaned, rinsed, and dried. All signs of moisture, oil, and other contamination must be removed from the internal structure of the generator to make sure all parts and circuits function correctly. Clean the starter-generator as follows:

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I Procedure Ultrasonic

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Agitation

Soak

Instructions CAUTION:

ULTRASONIC CLEANING CAN DAMAGE PLATING, BLACK OXIDE COATINGS, AND, IN ALUMINUM PARTS, DIMENSIONAL TOLERANCES. Put the parts into the ultrasonic cleaning tank using detergent Formula 815 GD-NF and de-ionized water. Refer to the manufacturers specification for the recommended dilution of water and detergent and solution temperature. Let the parts to soak for 15 to 20 minutes maximum. Remove all evidence of dirt with a soft bristle brush or cleaning rag. Put all parts into an agitation tank and clean using detergent Brulin 1990 GD and de-ionized water. Refer to the manufacturers specification for the recommended dilution of water and detergent and solution temperature. Agitate the parts until all evidence of dirt can be removed with a soft bristle brush or cleaning rag. Put all parts into a soaking tank and clean using detergent Formula 815 GD or Brulin 1990 GD and de-ionized water. Refer to the manufacturers specification for the recommended dilution of water and detergent and solution temperature. Soak the parts until all evidence of dirt can be removed with a soft bristle brush or cleaning rag. Table 4002 - Cleaning Procedures (Continued)

C. Rinse the parts. (1) Rinse the part(s) with de-ionized water. D. Do the applicable cleaning procedure again until the parts are clean and free of dirt and carbon residue. E. Dry the parts. (1) Remove any moisture that remains on the parts with a dry lint-free cloth. WARNING: WEAR INSULATED GLOVES AND OBSERVE ALL SAFETY PRECAUTIONS WHEN HANDLING HEATED PARTS TO AVOID PERSONAL INJURY. (2)

Put the cleaned parts in an oven at a temperature of 200 to 250°F (93.3 to 121°C) for 2 to 3 hours.

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I WARNING: ISOPROPYL ALCOHOL IS TOXIC AND FLAMMABLE. DO NOT USE NEAR OPEN FLAMES, WELDING AREAS, OR ON HOT SURFACES. INHALATION OF VAPORS CAN CAUSE DROWSINESS, DIZZINESS, AND HEADACHE. CONTACT WITH SKIN CAN CAUSE IRRITATION. USE IN A WELL-VENTILATED AREA Examine each part for carbon particles by wiping with isopropyl alcohol on a clean lint-free cloth.1

4. Corrosion Preventive NOTE: If the drive shaft is not expected to be re-installed into a starter-generator immediately after cleaning, apply a corrosion preventive compound to its black oxide coating (identified by a very dark finish). WARNING: THE CORROSION PREVENTIVE COMPOUND IS FLAMMABLE AND TOXIC. EXTENDED EXPOSURE CAN CAUSE SKIN IRRITATION, DIZZINESS, AND HEADACHE. WHEN EXTENDED EXPOSURE IS NECESSARY, USE RESPIRATORY PROTECTION AND PROTECTIVE CLOTHING. (1)

Apply a layer of MIL-C-16173, grade 3, corrosion preventive compound to the drive shaft. NOTE: The drive shaft must be completely dry before you apply the corrosion preventive compound.

(2)

Let the coating air dry for four hours. The coating will remain soft after drying.

5. Cleaning After Liquid Penetrant Inspection A. Description This specifies the procedure for cleaning part(s) after liquid penetrant inspection. Cleaning is necessary to remove residual penetrant or developer that could cause interference in processing or service requirements. Rinse parts fully with water and fully dry to make sure there is no interference in processing or service requirements. B. Procedure (1)

Rinse the part(s) immediately after liquid penetrant inspection: (a)

(b)

The parts must be fully rinsed using water by manual or automated spray to remove the liquid penetrant. 1

Fully rinse the part(s) and aggressively agitate the part while it is immersed.

Pour the rinse water out from the part(s). Hold the part(s) vertical, open end down, for approximately one minute to drain.

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(3)

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I 1 (2)

Part(s) which show remaining liquid penetrant after rinsing must be fully cleaned and examined again.

Drying of part(s) after rinsing: CAUTION:

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(a)

REMAINING WATER USED FROM THE RINSING PROCEDURE MUST BE REMOVED. FAILURE TO OBEY DRYING INSTRUCTIONS CAN RESULT IN CORROSION OF THE MATERIAL.

Remove the rinse water from the part(s) with a dry lint-free cloth.

WARNING: WHEN YOU USE COMPRESSED AIR, ADJUST THE PRESSURE TO 29 PSI (200 KPA) MAXIMUM. PUT ON EYE PROTECTION TO PREVENT INJURY. CAUTION:

(b)

MAKE SURE THAT COMPRESSED AIR FOR USE TO CLEAN/DRY THE COMPONENTS IS FREE FROM OIL AND WATER. THIS WILL PREVENT CONTAMINATION OF THE COMPONENTS.

Use compressed air to remove rinse water.

WARNING: FAILURE TO USE NECESSARY SAFETY PRECAUTIONS WHEN HANDLING HOT MATERIALS CAN CAUSE SEVERE BURNS TO SKIN. WEAR THERMAL PROTECTIVE CLOTHING WHEN HANDLING HEATED PARTS. (c)

Immediately put the washed and rinsed part(s) in a vented 250° ± 10° F (121,1° ± 5,6° C) oven for a minimum of 2 hours. 1

(d)

The part(s) is to be positioned horizontally on a rack or on a block that will hold it in position.

After the part(s) is fully dried and has cooled. 1

Check for indications of possible corrosion caused by the liquid penetrant. a

Reject the part(s) if corrosion is found.

If no corrosion is found, put the part(s) in a polyethylene bag with a bag of desiccant and seal it with tape, twist tie or rubber band.

The part(s) must be kept in a bag with desiccant until just before assembled on the starter-generator.

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I

CHECK

This section provides initial and detailed component inspection procedures for starter-generators returning from service for scheduled and unscheduled maintenance. Complete an initial inspection of the starter-generator before beginning testing or disassembly. The results of this inspection will determine if a starter-generator is in satisfactory condition for a verification test or if it will need further disassembly, inspection, and/or replacement of parts. This section provides the information that is needed to perform a satisfactory inspection of the starter-generator components. During an overhaul of the starter-generator, all primary components must be examined to determine if they are serviceable. Reject a part if wear or damage is outside the acceptance limits or is not serviceable. 2. Necessary Tools and Materials WARNING: BEFORE USING ONE OF THE FOLLOWING MATERIALS, BE AWARE OF ALL HANDLING, STORAGE, AND DISPOSAL PRECAUTIONS RECOMMENDED BY THE MANUFACTURER OR SUPPLIER. FAILURE TO COMPLY WITH MANUFACTURER’S OR SUPPLIER’S RECOMMENDATIONS CAN RESULT IN SERIOUS INJURY, PHYSICAL DISORDER, OR DEATH. In addition to normal shop tools, specific tools and materials for inspection of the starter-generator are listed in Table 5001. Equivalent substitutes can be used for the tools and materials listed in Table 5001. Tool Description

Reference

Alcohol, Isopropyl Brush, non-metallic, soft bristle Cleaning pads/wiping cloths, lint-free, soft fabric Dial Indicator Dynamic Balancer Growler High Potential (Dielectric) Tester Magnifier, 7X to 10X Ohmmeter Pull Scale

Commercially Available Commercially Available Commercially Available Commercially Available Goodrich Corporation Standard Practice Document (SPD) 1001 Commercially Available Commercially Available Commercially Available Commercially Available Commercially Available

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1. Introduction

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I Tool Description

Reference

Surface Plate V-blocks

Commercially Available Commercially Available Table 5001 - Inspection Tools

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A. Use of Growler A growler is required to check for shorted armature windings. When an alternating current is passed through a growler, the current sets up a magnetic flux in the windings of the armature. As the flux passes through the windings, a potential is induced causing current to flow if the winding is short-circuited. The current flow is then detected by an iron feeler, such as a hacksaw blade. The most common way of using a growler is the ‘feeler method’ in which the growler spans a slot containing a winding. The feeler of iron is held about 0.25 inch (6,4 mm) above the slot containing the other side of the same winding. If the winding is shorted, the feeler will be pulled down to the slot and will stick and vibrate. The feeler can also be used on the same side of the winding that is spanned by the growler. 3. General Information Check Acceptance Limit Measurements for individual components are found in the FITS AND CLEARANCES section of this CMM. If part does not meet acceptance limits, discard. Use the following procedures for all inspections. A. Examine the starter-generator and its components visually for: • signs of corrosion • chipped-off enamel • nicks, cracks, dents, scratches • gouging, scoring or glazing mating surfaces • fretting corrosion on mating surfaces • loose or defective attaching parts • distortion • discoloration • crossed or stripped threads • condensation at drain holes • torn or cracked seals • galling or glazing of friction lining residue CHECK © 2008 Goodrich Corporation

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I • bent or distorted springs • rounding, stripping or uneven wear on gear teeth

• damage caused by too much heat • electrical arcing paths • corroded contacts or terminals • loose or defective electrical connector, contacts or terminals • corroded electrical pins or connector • bent connector pins • loose, broken or shorted terminations 4. Initial Inspection NOTE: If damage is found during inspection, stop the inspection immediately and begin further disassembly of the starter-generator using the instructions in the DISASSEMBLY section. A. Visually examine the starter-generator in a brightly lit work area in accordance with (IAW) Paragraph 3.A. (1) If shipping or handling damage exists, stop the inspection and notify your supervisor. (2)

If operational damage exists, write down the components that need to be replaced or repaired and continue the inspection.

B. Clean the exterior of the starter-generator. WARNING: ISOPROPYL ALCOHOL IS TOXIC AND FLAMMABLE; DO NOT USE NEAR OPEN FLAMES, WELDING AREAS, OR ON HOT SURFACES. INHALATION OF VAPORS CAN CAUSE DROWSINESS, DIZZINESS, AND HEADACHE. CONTACT WITH SKIN CAN CAUSE IRRITATION. USE IN A WELL-VENTILATED AREA. (1)

Clean the surface of the starter-generator using a lint-free cleaning cloth moistened with isopropyl alcohol.

(2)

If needed, loosen dust particles or grease with a soft bristle brush.

C. Examine the starter-generator in a brightly lit work area IAW Paragraph 3.B. D. Examine the installation between the housing and both end bells. Make sure that all attaching hardware is in place. CHECK © 2008 Goodrich Corporation

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B. Examine electrical components visually for: • loose or defective attaching parts

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I 5. Non-Destructive Test (NDT) Inspections A. Magnetic Particle: Unless otherwise specified, do magnetic particle inspections IAW ASTM-E1444. Unless otherwise specified, acceptance criteria must be IAW MIL-STD-1907 Table 1, Grade A. Distributed via the Goodrich Technical Publications Web Portal. Refer to https://techpubs.goodrich.com to confirm the latest revision standard.

B. Liquid Penetrant: Unless otherwise specified, do liquid penetrant inspections IAW ASTM-E1417 type 1 Method A or B, sensitivity 2 or higher. Unless otherwise specified, acceptance criteria must be IAW MIL-STD-1907 Table II, Grade C. 6. Replace Service Parts and Common Hardware A. Overhaul All bearings, brushes, insulating parts, retaining rings, O-rings, self-locking nuts, and lock washers shall be discarded regardless of their condition, if removed during overhaul. B. Service repair During repair, inspection or servicing, replace all exposed hardware and flat washers that are damaged, deformed, corroded, or have other apparent defects. Always replace bearings, retaining rings, lock washers, and self-locking nuts regardless of their condition if removed during disassembly. 7. Inspection Guidelines A. Repair or Service Inspection Examine only those components that have been disassembled for repair or service. Do not disassemble any component for inspections unless given instructions to do so in this section or in the TESTING AND FAULT ISOLATION section. B. The following terms are referenced in this section: • DISCARD If damage to the part is found or the part is outside of the acceptance limits in the FITS AND CLEARANCES section, the part must be removed and replaced with a new one. • REPAIR If damage to the part is found or the part is outside of the acceptance limits in the FITS AND CLEARANCES section, the part can be repaired by a procedure found in the REPAIR section.

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I • DISASSEMBLE If damage to the part is found to a part in an assembly, or part of the assembly is outside of the acceptance limits in the FITS AND CLEARANCES section, you can disassemble the part from the assembly and repair or replace the damaged part(s).

If damage occurs that causes a part to be outside of the acceptance limits in the FITS AND CLEARANCES section or there is no repair procedure for that part, replace the part. Retain the following parts to submit for remanufacture: armature and stator and housing assembly. C. Dimensions and Points Letters (i.e., A, B, C, D, etc.) used in an illustration in this section indicate dimensions or points. D. Surfaces Numbers (i.e., 1, 2, 3, 4, etc.) used in an illustration indicate surfaces. 8. Inspection of Parts and Assemblies NOTE: Unless otherwise indicated, numbers in parentheses ( ) refer to item numbers on the illustration IPL Figure 10001. NOTE: In cases where a repair is authorized but the repair does not work, discard and replace the item in question regardless of whether or not it is so spelled out in this manual. A. V-Retainer coupling (20) and T-bolt (40). (1) Examine V-retainer coupling (20) IAW the procedures found in Paragraph 3.A. (a) (2)

DISCARD the part if damage exists.

Examine the T-bolt (40) IAW the procedures found in Paragraph 3.A. (a)

REPAIR the part if two or less threads are damaged.

(b)

DISCARD the part if more than two threads are damaged.

B. Mounting Adapter (50) (1) Examine mounting adapter (50) IAW the procedures found in Paragraph 3.A. (a)

DISCARD the part if cracks or major damage exists.

(b)

REPAIR the part if minor surface damage exists.

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• REPLACE -

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I (2)

If the visual inspection finds indications which can be cracks, continue the inspection under 10X magnification. (a)

(3)

If visual indications of cracks or other structural defects are observed under 10X magnification, DISCARD the part.

If the visual inspection under 10X magnification finds indications which can be cracks perform a liquid penetrant inspection IAW Paragraph 5.B.

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NOTE: After liquid penetrant inspection, the part(s) must have the liquid penetrant removed to prevent interference with processing or with service requirements. Refer to the CLEANING section. (a)

REPLACE if damage is found. MATING SURFACE (NOT SHOWN)

MATING SURFACE

Figure 5001 - Inspecting Mounting Adapter C. Identification plate (60). See Figure 5002. NOTE: ID plates with superficial nicks, dents and scratches, that do not interfere with the legibility of the identification nameplate, can be reused providing they are sealed with acrylic coating. (1)

Examine the part IAW the procedures found in Paragraph 3.A. If damage exists or the information is faded or unreadable:

(2)

(a)

Retain the original identification plate.

(b)

Transfer the information from the original identification plate to a replacement identification plate (60).

(c)

DISCARD the original identification plate.

Make sure that the drive screws (70) are tight and in place.

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I DISCARD loose drive screws (70).

Figure 5002 - Replacement Identification Plate D. Terminal block cover (130). (1) Examine the part IAW the procedures found in Paragraph 3.A. (2)

DISCARD the part if damage exists.

E. Air Inlet/Air Inlet Assembly (150). See Figure 5003. (1) Examine the part IAW the procedures found in Paragraph 3.A.

(2)

(a)

DISCARD the part if cracks, major damage or fretting corrosion on either the inlet or mounting flange exists.

(b)

REPAIR the part if minor surface damage exists.

(c)

REPAIR the rivet (-180) if loose, missing or damaged.

Examine the insulating tape for tears or loose edges. (a)

MOUNTING FLANGE

REPAIR the insulating tape if it is loose or torn.

INLET FLANGE

INSULATING TAPE SCREEN RIVET

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(a)

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I F. Brushes (210). See Figure 5004. NOTE: For repair only. Brushes must be replaced at each overhaul. (1)

Visually examine brushes for cracks, chips, frayed leads, and loose rivets or loose connections. (a)

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(2)

DISCARD brushes if damaged.

Visually examine wear indicator for remaining allowable wear. (a)

REPLACE brushes if remaining allowable wear will be exceeded before the next overhaul. Seat new brushes in accordance with instructions in SPD 1006.

Figure 5004 - Brush Wear (Typical) G. Fan (230). See Figure 5005. (1) Examine the part IAW the procedures found in Paragraph 3.A. NOTE: Pay particular attention to the blade edges and surfaces and shaft mating surface.

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I DISCARD the part if cracks, scoring-gouging-glazing on mating surfaces, or major damage exists.

(b)

REPAIR the fan if minor surface damage is found.

If the visual inspection finds indications which can be cracks, continue the inspection under 10X magnification. (a)

(3)

If visual indications of cracks or other structural defects are observed under 10X magnification, DISCARD the part.

If the visual inspection under 10X magnification finds indications which can be cracks perform a liquid penetrant inspection IAW section Paragraph 5.B. NOTE: After liquid penetrant inspection, the part(s) must have the liquid penetrant removed to prevent interference with processing or with service requirements. Refer to the CLEANING section. (a)

REPLACE if damage is found. BLADE EDGES

BLADE SURFACE

MATING SURFACE

Figure 5005 - Fan H. Drive Shaft (260) and Dampener Hub (300). See Figure 5006. (1) Examine the part IAW the procedures found in Paragraph 3.A.

(2)

(a)

DISASSEMBLE the drive shaft (260) and dampener hub (300) if cracks or thread damage beyond two threads exist.

(b)

REPAIR the drive shaft (260) and dampener hub (300) if dents, nicks, and scratches exist.

Examine armature mating spline, drive spline, and dampener hub spline for rounding stripping, or uneven wear. (a)

DISASSEMBLE drive shaft (260) and dampener hub (300) if damaged.

(b)

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(2)

(a)

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I (3)

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(4)

Measure the drive end and anti-drive end drive spline diameters over two gage pins. (a)

DISASSEMBLE the drive shaft (260) and dampener hub (300) if the diameter is not within the limits in the FITS AND CLEARANCES section.

(b)

DISCARD the out of specification part.

If any part of the drive spline appears damaged and/or demonstrate fracture(s), perform a magnetic particle inspection IAW procedures found in Paragraph 3.A. (a)

DISCARD the drive shaft (260) and dampener hub (300) if damage is found. SCREW THREADS

MATING SPLINE FOR ARMATURE

DRIVE SPLINE

MATING SURFACE FOR DAMPENER HUB

HUB SPLINE MATING SURFACE FOR DRIVE SHAFT

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Friction ring (280). See Figure 5007. WARNING: DO NOT CUT, RIP, OR SAND ASBESTOS-CONTAINING MATERIALS. LEAVE UNDAMAGED MATERIALS ALONE AND, TO THE EXTENT POSSIBLE, PREVENT THEM FROM BEING DAMAGED, DISTURBED, OR TOUCHED. DISCARD MATERIAL BY FIRST CHECKING WITH LOCAL HEALTH, ENVIRONMENTAL, OR OTHER APPROPRIATE OFFICIALS TO FIND OUT ABOUT PROPER HANDLING AND DISPOSAL PROCEDURES. (1)

If friction ring is Part No. 02-5600-05, it must be discarded because it contains asbestos.

(2)

Examine the part IAW the procedures found in Paragraph 3.A. (a)

(3)

DISCARD the part if damage is found.

Measure the friction ring (280) thickness. (a)

DISCARD the part if thickness is not within limits in the FITS AND CLEARANCES section.

Figure 5007 - Friction Ring J. Dampener plate (290). See Figure 5008. (1) Examine the part IAW the procedures found in Paragraph 3.A.

(2)

(a)

DISCARD the part if cracks exist.

(b)

REPAIR if minor nicks, scratches, gouging, scoring, or glazing is found.

Examine the spline teeth for rounding, stripping, or uneven wear. (a)

(3)

DISCARD the part if damaged.

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I (a) (4)

Measure the distance between pins of the spline teeth. (a)

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(5)

DISCARD if thickness is below the acceptance limit in the FITS AND CLEARANCES section.

DISCARD if distance is above the acceptance limit in the FITS AND CLEARANCES section.

If any part of the dampener plate appears damaged and/or demonstrate fracture(s), perform a magnetic particle inspection IAW procedures found in Paragraph 5. (a)

DISCARD the part if it is damaged.

Figure 5008 - Dampener Plate K. Dampener Backplate or Dampener Backplate and Gear (310). See Figure 5009. (1) Examine the part IAW the procedures found in Paragraph 3.A.

(2)

(a)

DISCARD the part if cracks exist.

(b)

REPAIR if minor nicks or scratches exist.

(c)

DISCARD if gouging, scoring, or glazing exists on mating surfaces.

If any part of the dampener back plate appears damaged and/or demonstrate fracture(s), perform a magnetic particle inspection IAW procedures found in Paragraph 5. (a)

(3)

DISCARD if damage is found.

For effect codes E, F, Q, R, S, T, U, X, Z, CA, DA: NOTE: Reference GSIL 2008-01 to check if the correct spur gear was installed. (a)

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Figure 5009 - Inspecting Dampener Backplate L. Bearing and brush support assembly (320). See Figure 5010 thru Figure 5011. (1) Examine the part IAW the procedures found in Paragraph 3.A.

(2)

(a)

DISCARD the part if cracks or fretting and/or corrosion on the mating surface are found.

(b)

REPAIR if minor dents, scratches and nicks or gouging scoring or glazing on the mating surfaces (marked 1, 2, 3, and 6 on Figure 5010) are found.

If the visual inspection finds indications which can be cracks, continue the inspection under 10X magnification. (a)

(3)

If visual indications of cracks or other structural defects are observed under 10X magnification, DISCARD the part.

(4)

REPLACE if damage is found.

Measure the bearing liner diameter “A.” See Figure 5010. (a)

DISASSEMBLE the bearing and brush support assembly (320) if damage is found.

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I (b) (5)

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(6)

Examine the helicoil inserts (10002-20, -45) at location 4 and 5 (see Figure 5010) for damage. (a)

REPAIR helicoil if damage is found.

(b)

REPAIR any damaged parts.

Examine the brush holders (10002-30), the brush spring supports and the center supports for cracks, warping, and discoloration caused by electrical arcing. (a)

(7)

DISCARD the complete brush holder (10002-30) if damage is found.

If applicable, measure the capacitor capacitance value on each filter assembly (10002-60) at a frequency of 900 to 1100 Hz, 77° F (25° C). (a)

(8)

REPAIR if the bearing liner diameter is out of the limits given in the FITS AND CLEARANCES section.

DISCARD the filter assembly (10002-60) if capacitance values fall outside the required limits in the FITS AND CLEARANCES section.

Measure brush spring (10002-50) pressure using a pull scale with harness. See Figure 5011. NOTE: When measuring brush spring pressure, readings can vary widely depending on where measuring device touches spring. Measurements must be taken from curved tip of spring at point where spring touches brush.

(9)

(a)

Take six measurements.

(b)

Calculate an average from the measurements.

(c)

DISCARD any spring not within limits of FITS AND CLEARANCES.

Do a dielectric test as follows: NOTE: The bearing and brush support assembly must be clean before you do the dielectric check.

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I

CAUTION:

BEFORE YOU CONNECT OR DISCONNECT THE ELECTRICAL LEADS, TURN OFF THE POWER TO THE HIGH POTENTIAL TESTER. DAMAGE TO THE BEARING AND BRUSH SUPPORT ASSEMBLY CAN OCCUR.

(a)

With the power OFF, connect the positive test lead of the high potential tester to the metal surface of the brush holder.

(b)

Connect the negative test lead to an uncoated surface of the bearing and brush support.

(c)

With the high potential tester output voltage at 0, set the power ON.

(d)

Slowly adjust the output voltage (at a rate not more than 100 V/sec.) to 250 V rms, commercial frequency. Decrease the voltage to zero.

(e)

Set the high potential tester power OFF.

(f)

Disconnect test filter board leads from bearing and brush support assembly.

(g)

Acceptance Limits: 1

Arcing, as seen by flashover (surface discharge), spark over (air discharge), breakdown (puncture discharge), or leakage current more than 2 mA will be caused by damp, dirty, weak or defective components. If bearing and brush support assembly is unsatisfactory during the dielectric test, clean bearing and brush support assembly, and do the test again.

If bearing and brush support assembly is still unsatisfactory after cleaning; disassemble the bearing and brush support assembly, replace all insulating materials (i.e., washers, sleeves, insulators), and do the test again. If bearing and brush support assembly is still unsatisfactory, replace it.

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WARNING: BEFORE YOU USE THE HIGH VOLTAGE ELECTRICAL EQUIPMENT, MAKE SURE THAT THE POWER SWITCH IS IN THE ‘OFF’ POSITION. MAKE SURE THAT NO PERSON TOUCHES THE EQUIPMENT OR THE PROBES. THIS WILL PREVENT DEATH OR INJURY FROM ELECTRIC SHOCK.

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I

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4 BRUSH SPRING SUPPORT

6 HELICOIL

5 A

1 Figure 5010 - Inspecting Bearing and Brush Support Assembly

PE LIFT RP EN SCAL D E SP ICULA RIN RT G O

PULL SCALE

90°

POSITION "A"

HARNESS

20°

POSITION "B" 12°

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I M. 3-Pin Connector (360) and Spacer (370). (1) Examine the part IAW the procedures found in Paragraph 3.A. and Paragraph 3.B. (a)

Make sure that connector (360) pins are not bent or missing.

N. Drive End Bearing Support Assembly (390). (1) Examine part, refer to procedures found in Paragraph 3.A. See Figure 5012.

(2)

(a)

DISCARD the part if cracks or fretting and/or corrosion on the mating surface are found.

(b)

REPAIR if minor dents, scratches and nicks or gouging, scoring or glazing on the mating surfaces are found.

If the visual inspection finds indications which can be cracks, continue the inspection under 10X magnification. (a)

(3)

If visual indications of cracks or other structural defects are observed under 10X magnification, DISCARD the part.

If the visual inspection under 10X magnification finds indications which can be cracks, perform a liquid penetrant inspection IAW Paragraph 5.B. NOTE: After liquid penetrant inspection, the part(s) must have the liquid penetrant removed to prevent interference with processing or with service requirements. Refer to the CLEANING section. (a)

(4)

Measure bearing liner diameter “A”. See Figure 5012. (a)

(5)

REPAIR the bearing liner if the measurements are not within the limits of the FITS AND CLEARANCES section.

Examine the threaded holes for crossed or stripped threads. (a)

(6)

REPLACE if damage is found.

DISCARD drive end bearing support assembly (390) if threaded hole damaged.

Examine screen (10003-20) for tears. (a)

DISASSEMBLE drive end bearing support assembly (390) if damage is found.

(b)

DISCARD drive screws (10003-30) and damaged screen (10003-20).

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(2)

DISCARD the connector (360) and/or spacer (370) if damage exists.

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I

MAGNETIC PICKUP BRACKET (IF APPLICABLE)

MATING SURFACE (NOT SHOWN)

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SCREEN

MATING SURFACE

Figure 5012 - Inspecting Drive End Bearing Support Assembly O. Speed Pickup (460). See Figure 5013. (1) Examine the part IAW the procedures found in Paragraph 3.A.

(2)

(a)

REPAIR the part if two or less threads are damaged.

(b)

DISCARD the part if more than two threads are damaged or other damage exists.

Examine the insulation sleeving for damage. (a)

(3)

Measure resistance between each speed pickup lead and ground. (a)

(4)

DISCARD the part if damage exists.

REPLACE the speed pickup if it does not meet the limit in FITS AND CLEARANCES section.

Measure resistance between the two speed pickup leads. (a)

REPLACE the speed pickup if the resistance is not within the limits in FITS AND CLEARANCES section.

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Figure 5013 - Inspecting Speed Pickup Screw and Leads P. Armature (480). See Figure 5014. NOTE: Use of Glyptol on either the armature or stator and housing assembly stator windings is strictly prohibited. Units having Glyptol coating on either of these parts shall have these parts replaced prior to returning the units to service. Glyptol can be used on internal surfaces of the housing only, and only where other coatings are not required. (1)

Before the commutator is refinished, measure commutator bar-to-bar run-out in a full circumference outside the brush paths (area where the brushes do not touch). (a)

(2)

(3)

REPLACE armature (480) if bar-to-bar run-out is more than the limits of the FITS AND CLEARANCES section before refinishing the armature. NO REPAIR IS PERMITTED.

Examine the part IAW the procedures found in Paragraph 3.A. (a)

DISCARD the part if cracks or fretting and/or corrosion on the mating surface are found.

(b)

REPAIR if minor dents, scratches and nicks or gouging scoring or glazing on the mating surfaces are found.

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I

(4)

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(5)

(a)

REPAIR bearing journals if damaged.

(b)

REPLACE armature if damage is not repairable.

Measure bearing journal diameters, A and C, as shown in Figure 5014. (a)

REPAIR bearing journals if they do not meet limits in FITS AND CLEARANCES section. Refer to SPD 1000.

(b)

REPLACE armature if damage is not repairable.

Measure commutator diameter B, as shown in Figure 5014. (a)

(6)

REPLACE armature if minimum commutator diameter “B” is below limit in FITS AND CLEARANCES section.

Examine internal spline for rounding, stripping, or uneven wear. (a)

Check the drive spline for too much wear by engaging a new drive shaft into the armature internal drive spline. Reject the armature shaft if too much play is found when engaging the drive shaft. NOTE: An armature spline with too much wear will not engage tightly with a new drive shaft.

(b) (7)

Examine commutator undercut for broken, damaged or missing mica. (a)

(8)

(9)

REPLACE armature if damaged.

Examine commutator bars for burning and discoloration. (a)

REPAIR commutator if damaged.

(b)

REPLACE armature if damage is not repairable.

Measure commutator undercut. (a)

REPAIR commutator if mica undercut depth (before recut) is below limits in FITS AND CLEARANCES section.

(b)

REPLACE armature if damage is not repairable.

(10) Test armature windings for shorts using a growler and iron feeler. Refer to Paragraph 2.A. of this section for additional information about use of growler during inspection. (a)

REPLACE the armature (480) if a short exists.

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I

ARMATURE

BEFORE SURFACING

TIR & BAR TO BAR MEASUREMENTS

BEARING JOURNAL

A A

COMMUTATOR BARS RETAINING BANDS

BRUSH PATH AREAS

BAR TO BAR

SECTION A-A

BEFORE COMMUTATOR SURFACING BAR TO BAR: 0.0008 IN. (0,020 MM)

EXAMPLE OF RAISED COMMUTATOR BAR

Ø WEAR LIMIT (MEASUREMENT "B"): 1.960 IN. (49,78 MM) MIN.

ENLARGED VIEW

Figure 5014 - Armature Check

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I (11) Perform a dielectric test. WARNING: BEFORE YOU USE THE HIGH VOLTAGE ELECTRICAL EQUIPMENT, MAKE SURE THAT THE POWER SWITCH IS IN THE ‘OFF’ POSITION. MAKE SURE THAT NO PERSON TOUCHES THE EQUIPMENT OR THE PROBES. THIS WILL PREVENT DEATH OR INJURY FROM ELECTRIC SHOCK. Distributed via the Goodrich Technical Publications Web Portal. Refer to https://techpubs.goodrich.com to confirm the latest revision standard.

CAUTION:

FAILURE TO TURN OFF HIGH POTENTIAL TESTER POWER BEFORE CONNECTING OR DISCONNECTING HIGH VOLTAGE ELECTRICAL LEADS CAN CAUSE SERIOUS DAMAGE TO THE ARMATURE.

CAUTION:

ARMATURE MUST BE THOROUGHLY CLEAN BEFORE PERFORMING A DIELECTRIC TEST.

(a)

With power OFF, connect positive test lead of high potential tester to armature (480) shaft.

(b)

With power OFF, put negative test lead on commutator bar.

(c)

With the high potential tester output voltage at 0, turn power ON.

(d)

At a rate not to be more than 100 V/sec., slowly adjust output voltage to 250 V RMS, commercial frequency for one minute. Slowly decrease voltage back to 0.

(e)

Turn high potential tester power OFF.

(f)

Remove negative test lead.

(g)

Connect negative lead to retaining band.

(h)

Repeat dielectric test between retaining bands and commutator bars.

(i)

Acceptance Limits: 1

Arcing as evidenced by flashover (surface discharge), spark over (air discharge), breakdown (puncture discharge), or leakage current that is more than 2mA is evidence of damp, dirty, weak or defective components and constitutes a failure. If armature (480) fails dielectric test, clean armature and repeat dielectric test.

If armature (480) fails dielectric test after cleaning, replace armature.

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I Q. Bearing retainer (490). See Figure 5015. (1) Examine the part IAW the procedures found in Paragraph 3.A.. (a)

Carefully examine mating surfaces 1 and 2 for gouging, scoring, or glazing. (a)

DISCARD the part if damaged.

Figure 5015 - Bearing Retainer R. Baffle Disc (530). See Figure 5016. (1) Examine part, refer to procedures found in Paragraph 3.A. (a) (2)

Discard part if damaged.

Carefully examine mating surfaces 1 and 2 for gouging, scoring, or glazing. (a)

DISCARD the part if damaged. MATING SURFACE 3 (NOT SHOWN)

MATING SURFACE 1

MATING SURFACE 2

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(2)

DISCARD the part if damaged.

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I S. Stator and housing assembly (550). See Figure 5017. NOTE: Use of Glyptol on either the armature or stator and housing assembly stator windings is strictly prohibited. Units having Glyptol coating on either of these parts shall have these parts replaced prior to returning the units to service. Glyptol can be used on internal surfaces of the housing only, and only where other coatings are not required. Distributed via the Goodrich Technical Publications Web Portal. Refer to https://techpubs.goodrich.com to confirm the latest revision standard.

(1)

(2)

(3)

Examine the part IAW the procedures found in Paragraph 3.A. and Paragraph 3.B. (a)

DISCARD the part if cracks or other major damage exists.

(b)

REPAIR thread damage of two turns or less.

(c)

DISCARD the part if thread damage is more than two turns.

(d)

REPAIR the part if other damage exists.

Examine the brush leads and stator leads for damage. (a)

If brush lead damage is more than 5 percent of the brush lead, REPLACE the stator and housing assembly (550).

(b)

If stator lead damage is found, REPLACE the stator and housing assembly (550).

Perform a dielectric test. WARNING: BEFORE YOU USE THE HIGH VOLTAGE ELECTRICAL EQUIPMENT, MAKE SURE THAT THE POWER SWITCH IS IN THE ‘OFF’ POSITION. MAKE SURE THAT NO PERSON TOUCHES THE EQUIPMENT OR THE PROBES. THIS WILL PREVENT DEATH OR INJURY FROM ELECTRIC SHOCK. CAUTION:

FAILURE TO TURN OFF THE HIGH POTENTIAL TESTER POWER BEFORE CONNECTING OR DISCONNECTING HIGH VOLTAGE ELECTRICAL LEADS CAN CAUSE SERIOUS DAMAGE TO THE STATOR AND HOUSING ASSEMBLY.

CAUTION:

STATOR AND HOUSING ASSEMBLY MUST BE THOROUGHLY CLEAN BEFORE PERFORMING A DIELECTRIC CHECK.

(a)

Jumper all stator leads together.

(b)

With power OFF, connect positive test lead of high potential tester to jumpered stator leads.

(c)

With power OFF, connect negative test lead to uncoated surface of housing.

(d)

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(e)

At a rate not to be more than 100 V/sec., slowly adjust output voltage to 250 V RMS, commercial frequency for one minute. Slowly decrease voltage back to 0.

(f)

Turn high potential tester power OFF.

(g)

Disconnect test leads.

(h)

Disconnect jumper from stator leads.

(i)

Acceptance Limits: 1

Arcing as evidenced by flashover (surface discharge), spark over (air discharge), breakdown (puncture discharge), or leakage current that is more than 2 mA is evidence of damp, dirty, weak or defective components and constitutes a failure. If stator and housing assembly fails dielectric test, clean stator and housing assembly and repeat dielectric test.

2 (4)

If stator and housing assembly fails dielectric test after cleaning, replace stator and housing assembly.

Use an ohmmeter to check for continuity between terminals A and E. (a)

REPLACE the stator and housing assembly (550) if an open circuit exists.

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I . STATOR LEADS

THREADED HOLES

MATING SURFACE

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BRUSH HARNESS STRAP

MATING SURFACE AND THREADED HOLES FOR BEARING AND BRUSH SUPPORT ASSEMBLY (not shown)

*GROUND LUG FROM WINDINGS

*PREVIOUS VERSIONS FEATURED A GROUNDING LEAD THAT WAS NOT BUILT INTO THE WINDINGS

Figure 5017 - Stator and Housing Assembly T. Terminal Block (10004-60) CAUTION: THE USE OF RE-MANUFACTURED TERMINAL BLOCKS IS NOT AUTHORIZED BY GOODRICH CORPORATION. DAMAGED TERMINAL BLOCKS (OTHER THAN THOSE WITH REPAIRABLE THREAD DAMAGE) MUST BE DISCARDED. (1)

Examine part, refer to procedures found in Paragraph 3.A. (a)

(2)

DISCARD the part if damage, other than thread damage, exists.

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(3)

(a)

REPAIR if damage is two or less thread turns.

(b)

If damage is more than two turns: 1

DISCARD terminal block if P/N 23032-1518 or P/N 23069-1236 are on the terminal block.

If starter-generator has terminal block P/N 23081-1310, see REPAIR section for the proper way to replace a damaged terminal stud.

Measure the capacitance values between Terminals B and E and between B and the ground lead at a frequency of 110 to 130 Hz, 77° F (25° C). (a)

DISCARD the part if capacitance values fall outside the required limits in the FITS AND CLEARANCES section.

D E B C A

D A

B E

GROUND

B D

Figure 5018 - Terminal Block Inspection

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I 9. Terminology Table 5002 lists the definitions of terms used to describe damage conditions. Term Corrosion Distributed via the Goodrich Technical Publications Web Portal. Refer to https://techpubs.goodrich.com to confirm the latest revision standard.

Crack

Dent Fretting

Fretting corrosion

Galling

Definition The chemical or electrochemical reaction between a material, usually a metal, and its environment that produces a deterioration of the material and its properties A break in material.

A small, smoothly-rounded depression. Wear that occurs between tight-fitting surfaces subjected to cyclical relative motion of extremely small amplitude. Usually, fretting is accompanied by corrosion, especially of the very fine wear debris. Accelerated deterioration at the interface between contacting surfaces as the result of corrosion and slight oscillatory movement between the two surfaces. Transfer of metal from one surface to another.

Glazing

Smoothing and creep of a surface.

Gouging

Removal of surface material, typified by rough and deep depressions. A sharp-bottomed depression that can have rough outer edges. Removal of surface metal at corners or dulling of edges. A deep scratch following a path of part travel.

Nick Rounding Scoring

Probable cause Environmental condition that causes deterioration.

Severe stress from overload or shock; possible extension of a scratch A sharp blow or excessive pressure Vibration between mating surfaces.

Vibration between mating surfaces.

Result of localized lubrication break-down between sliding surfaces. Result of localized lubrication break-down between sliding surfaces. Protruding objects, incorrectly aligned. Dropping, banging. Result of abrasion, vibration, or poor mating surfaces. Result of localized lubrication break-down between sliding surfaces.

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I

Scratch

Short

Stripped Thread Tear Wear

Definition A very shallow furrow or irregularity, usually longer than wide. Evidenced by sparking, arcing, or high current. Electrical condition where two conductors are connected by a path of very low resistance. Thread of a nut, stud, bolt, or screw damaged by tearing away parts of the thread. Parting of material. Slow removal of material. Wear may not be visible to the naked eye.

Probable cause Movement of a sharp object across the surface. The result when two carrying conductors are connected by a path of negligible resistance.

Incorrect installation of threaded mating parts. Excessive tension, caused by external force. Result of abrasive substances contacting rolling surfaces and acting as a lapping compound.

Table 5002 - Terminology

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Term

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I

REPAIR 1. Introduction ANY USE OF PARTS, MATERIALS, OR PROCESSES NOT AUTHORIZED BY GOODRICH CORPORATION FOR MAINTENANCE OR OVERHAUL OF THE STARTER-GENERATOR CAN AFFECT CONTINUED FLIGHT WORTHINESS OR INVALIDATE CERTIFICATION.

Repairs are limited to: • repairing damaged surfaces: Paragraph 4. • restoring surface coatings of parts and assemblies: Paragraph 5. • repairing damaged threads: Paragraph 6. • replacing helicoil inserts: Paragraph 7. • replacing terminal lugs: Paragraph 8. • replacing air inlet insulating tape: Paragraph 9. • replacing air inlet assembly screen: Paragraph 10. • bearing liner and journal restoration: Paragraph 11. • commutator refinishing: Paragraph 12. • armature balancing: Paragraph 13. • repair of bearing and brush support assembly: Paragraph 14. • correcting output voltage polarity: Paragraph 15. • replacing removable terminal block studs: Paragraph 16. Repair operations not outlined or referenced in this manual are not authorized by Goodrich Corporation. In addition to specific repairs authorized by Goodrich Corporation in this manual, standard repair procedures for starter-generators are described in the following Goodrich Corporation Standard Practice Documents (SPD). • Selective (Brush Plating), Electrodeposition - Refer to SPD 1000. • Armature Balancing for DC Starter-Generators - Refer to SPD 1001. • Surface Repair and Coating - Refer to SPD 1002. • Plastic Media Blasting - Refer to SPD 1003. • Brush Holder Alignment Fixtures - Refer to SPD 1004. • Brush Installation, Seating, and Run-In - Refer to SPD 1006. REPAIR © 2008 Goodrich Corporation

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CAUTION:

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I 2. Repair Tools In addition to normal shop tools, specific tools for repair of the starter-generator are listed in Table 6001. NOTE: Equivalent substitutes can be used for the tools listed in Table 6001. Distributed via the Goodrich Technical Publications Web Portal. Refer to https://techpubs.goodrich.com to confirm the latest revision standard.

Tools

Reference

Bump Switch Commutator Turning Fixture Crimp Tool Drive End Outboard Hub Support Helicoil Insert Removal and Installation Tool India Stone 6 V Battery or Equivalent DC Power Source Stud Installer, Mustang No. 1 (P/N: M1-AQ5-08) Stud Remover, Extractor No. 2 (P/N: E23824-SQ5) NOTE: The stud removal tool is optional to SpiralockTM Nuts. NOTE: Equipped with 1/2” drive Thread Chasers

Rating: 30 VDC, 10 A Figure 9016 Commercially Available Figure 9012 Commercially Available Commercially Available Commercially Available Titan Tool Company Inc. 7410 West Ridge Road Fairview, PA 16415-1170 Ph: (814) 474-1583 Fax: (814) 474-5337 www.titantoolco.com (V60076)

Commercially Available

Table 6001 - Repair Tools 3. Repair Materials Materials necessary for starter-generator repair are listed in Table 6002. NOTE: Equivalent substitutes can be used for the materials listed in Table 6002. Repair materials are not available from Goodrich Corporation. All items can be purchased commercially.

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I

Item

Description/Material Specification

Chemical Film Solution Alodine 1200 or Pen, Touch-N-Prep

Chemical Film Solution MIL-C-5541, Class 3 or Alodine® 1132 Touch-N-Prep Pen IAW MIL-DTL-81706B

Isopropyl Alcohol

TT-I-735, Grade A

Source Henkel Surface Technologies 32100 Stephenson Hwy. Madison Heights, MI 48071 Ph: (248) 583-9300 FAX: (248) 583-2976 www.hstna.com (V1N6B3) Commercially Available

See WARNING before using this material. Flash Point: 53° F (12° C), FLAMMABLE

Oil, Machine Pads, Cleaning Primer, Zinc Chromate Abrasive paper Tape, Insulating

Refer to the Material Safety Data (MSD) Sheet for the material for additional safety information N/A Lint-free cotton TT-P-1757 Composition G, Color Yellow. 400/600 grit (non-aluminum oxide only) P/N SG13-06R 8 mil, PTFE coated fiberglass, acrylic adhesive

Commercially Available Commercially available Commercially Available Commercially Available Saint Gobain New Haven, CT www.saint-gobain.com/us (V1DS07)

Table 6002 - Repair Materials

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WARNING: BEFORE USING ANY OF THE FOLLOWING MATERIALS, BE AWARE OF ALL HANDLING, STORAGE AND DISPOSAL PRECAUTIONS RECOMMENDED BY THE MANUFACTURER OR SUPPLIER. FAILURE TO COMPLY WITH THE RECOMMENDATIONS MAY RESULT IN SERIOUS INJURY, PHYSICAL DISORDER, OR DEATH.

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I 4. Surface Repair Repair corroded or damaged surfaces of parts that have qualified for repair according to the CHECK section inspection guidelines.

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A. Repair Procedure (1) Remove corrosion, sharp edges, burrs, nicks, or scratches from cast surfaces, machined mating surfaces, and sealing surfaces with india stone or abrasive paper. Remove only sharp edges or burrs that are above surface of part. (2)

Remove minor raised edges, burrs, nicks, or scratches on polished or load-bearing surface. Remove only material that extends above polished surface. Make sure that dimensional tolerances are within limits

5. Restoring the Surface Coatings of Parts and Assemblies A. Removal of surface coatings. Remove the surface coatings of parts and assemblies that have been damaged using plastic blasting equipment and procedures in accordance with (IAW) SPD 1003. NOTE: Follow the quality assurance guidelines listed in SPD 1003 for the use of plastic media blasting equipment. B. Restoration of surface coatings. Repair the surface coatings of parts and assemblies that have been damaged or removed as given in the procedures in Goodrich Corporation SPD 1002. Clean all parts per CLEANING section of this CMM. 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.

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I

10001-50

Nomenclature Mounting Adapter

Process Refinish/Paint

10001-150

Coating Repair Chemical Film touch-up or Wash Primer and paint Prime and paint

Air Inlet Refinish/Paint P/Ns: 23081-1090, -1091, -1092, -1430, -1570, -1571, -1575, -1576, -1670 Air Inlet Refinish/Paint Chemical Film touch-up or Wash P/Ns: 23081-1470, Primer and paint -1400 10001-310 Dampener Back Plate Refinish Re-phosphate IAW TT-C-490 or or Dampener Back phosphate Phosphate touch-up Plate and Gear 10001-550 Stator and Housing Refinish/Paint Chemical Film touch-up or Wash Assembly. Housing can Primer and paint be refinished. 10002-10 Anti-drive end end bell Refinish/Paint Prime and paint P/Ns: 23032-2165 (black), 23032-3665 (white), 23081-1050 (black) Anti-drive end end bell Refinish/Paint Chemical Film touch-up IAW P/Ns: MIL-C-5541, Class 3 23081-3320, -3322 -3365 10003-10 Drive end bearing Refinish/Paint Chemical Film touch-up IAW support MIL-C-5541, Class 3 P/Ns: 23081-1130, -1131, 1490 Drive end bearing Refinish/Paint Prime and paint support P/Ns: 23032-3652 (white), 23081-1230 (white) NOTE: Use this table with Goodrich Corporation SPD 1002 to determine the proper surface coating repair procedures. NOTE: Before adding primer/paint to any surface of any part, first record any part numbers or Goodrich CAGE codes to where primer/paint is applied. These will be reapplied after primer/painting is completed. Table 6003 - Surface Coating References

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Item Number

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I 6. Thread Repair A. Repair damaged threads as follows: CAUTION: DO NOT USE A THREAD-CUTTING DIE. UNREPAIRABLE DAMAGE CAN RESULT FROM USING A THREAD-CUTTING DIE.

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(1)

Repair damaged threads with a thread-chaser.

(2)

Remove any remaining sharp edges or burrs with an india stone.

(3)

Apply a light coating of machine oil to repaired threads to prevent corrosion.

7. Helical Coil Insert Replacement NOTE: Unless otherwise indicated, numbers in parentheses ( ) refer to item numbers on the illustration IPL Figure 10002. A. Remove and replace damaged helical coil inserts (20) as needed. (1) Remove damaged helical coil insert with helical coil insertion/removal tool. (2)

Clean hole for helical coil insert. Refer to the CLEANING section.

WARNING: PRIMER CAN BE DANGEROUS TO PERSONS. USE ONLY IN AN AREA WITH A GOOD FLOW OF AIR. KEEP AWAY FROM SOURCES OF IGNITION. DO NOT BREATHE THE FUMES. PREVENT SKIN CONTACT. PUT ON PROTECTIVE CLOTHING AND EYE PROTECTION. IF NECESSARY, PUT ON A RESPIRATOR. (3)

Apply a small quantity of zinc chromate primer to the outer surface of the replacement helicoil insert.

(4)

Install helicoil coil insert to the depth shown in Figure 6001 below part surface while primer is still wet.

(5)

Break off helicoil coil insert installation tang.

WARNING: KEEP CHEMICAL FILM AWAY FROM SOURCES OF HEAT, SPARKS AND FLAME. CHEMICAL FILM IS FLAMMABLE. WARNING: DO NOT GET CHEMICAL FILM ON YOUR SKIN AND DO NOT BREATHE THE FUMES. CHEMICAL FILM IS A POISONOUS MATERIAL. (6)

Apply chemical film solution MIL-C-5541 to bare metal.

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I

FOR ADE END BELL P/N: 23032-2165 HELI-COIL INSERT IAW MS33537 INSTALL 0.032 TO 0.047 IN. (0,81 TO 1,20 MM) BELOW SURFACE. (QTY: 4)

HELI-COIL INSERT IAW MS33537 INSTALL 0.02 TO 0.04 IN. (0,5 TO 1,0 MM) BELOW SURFACE. (QTY: 4)

EFFECT CODES: E, G

EFFECT CODES: A, B, C, D, F

Figure 6001 - Helicoil Insert Replacement 8. Terminal Lug Replacement A. Remove and replace damaged terminal lugs as follows: (1) Cut the wire at the base of the terminal(s). Discard the terminal(s). (2)

Remove 0.25 inch (6.4 mm) of insulation sleeving from the end of the electrical wire(s).

(3)

Use a crimping tool to install the new terminal(s).

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HELI-COIL INSERT IAW MS33537 INSTALL 0.02 TO 0.04 IN. (0,5 TO 1,0 MM) BELOW SURFACE. (QTY: 4)

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I 9. Air Inlet Insulating Tape Repair (Air Inlet models 23081-1092, -1400, -1571 and -1576 only) NOTE: Unless otherwise indicated, numbers in parentheses ( ) refer to item numbers on the illustration IPL Figure 10001.

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A. Replace the insulating tape. (1) Remove all signs of the insulating tape and clean the inside surface of the brush access cover (150). Refer to the CLEANING section. (2)

If the plating on the inner surface of the brush access cover (150) is damaged, repair the surface.

(3)

For air inlet 23081-1092 and -1400:

(4)

(5)

(a)

Install 4 pieces of insulating tape, 1.50 ± 0.06 in. square (38,1 ± 1,5 mm sq.), equally spaced. See Figure 6002.

(b)

Install 1 piece of insulating tape, 1.50 ± 0.06 in. (38,1 ± 1,5 mm) with a length of 15.75 in. (400 mm). See Figure 6003.

For air inlet 23081-1571 and -1576: (a)

Install 4 pieces of insulating tape, 1.56 ± 0.06 in. square (39,6 ± 1,5 mm sq.), equally spaced. See Figure 6004.

(b)

Install 1 piece of insulating tape, 1.56 ± 0.06 in. (39,6 ± 1,5 mm) with a length of 15.75 in. (400 mm). See Figure 6005.

Beginning at one of the four screw holes, attach strip of insulating tape inside the air inlet. NOTE: A gap centered on one of the four screw holes, no more than 0.25 in. (6,4 mm) between the beginning and end of the insulating tape strip is permitted.

(6)

Remove insulating tape from screw holes.

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I TRIM AT HOLES 3 PLACES

25° ±5° TYP

1.50 ± 0.06 in. (38,1 ± 1,5 mm) INSULATING TAPE

1.50 ± 0.06 in. (38,1 ± 1,5 mm) SQUARE INSULATING TAPE INSTALLED PRIOR TO INSTALLATION OF 1.50 STRIP, 4 PLACES EQUALLY SPACED AS SHOWN.

Figure 6002 - Install Air Inlet Insulating Tape (P/N: 23081-1092 and -1400)

REMOVE INSULATING TAPE FROM 3 SCREW HOLES

INSULATING TAPE

0.25 in. (6,4 mm) MAX. GAP CENTERED ON HOLE PART MARK

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0.06 ±0.06 in. (1,5 ±1,5 mm)

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I

0.69 in. (17,5 mm) MAX.

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1.25 in. (31,8 mm) MAX.

25° ±5° TYP

0.06 ± 0.06 in. (1,5 ± 1,5 mm)

0.81 ± 0.25 in. (20,6 ± 6,4 mm)

1.56 ± 0.06 in. (39,62 ± 1,5 mm)

1.56 ± 0.06 in. (39,6 ± 1,5 mm) SQUARE INSULATING TAPE INSTALLED PRIOR TO INSTALLATION OF 1.56 STRIP, 4 PLACES EQUALLY SPACED AS SHOWN.

Figure 6004 - Install Air Inlet Insulating Tape (P/N 23081-1571 and -1576)

REMOVE INSULATING TAPE FROM 3 SCREW HOLES

INSULATING TAPE

0.25 in. (6,4 mm) MAX. GAP CENTERED ON HOLE PART MARK

Figure 6005 - Inspection of Air Inlet Insulating Tape (P/N 23081-1571 and -1576)

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I

Part Number

Description

Quantity

10001-170 10001-180 10001-190

Screen, Air Inlet Rivet, Aluminum Alloy Washer, Flat

1 6 12

Table 6004 - Parts Required for Air Inlet Screen Replacement A. Repair Procedure. See Figure 6006. (1) Drill out six rivets (10001-180). NOTE: Do not deform rivet mounting hole. (2)

Discard damaged screen (10001-170).

(3)

Install screen inboard of inlet.

(4)

Put one washer (10001-190) on each rivet.

(5)

Install rivet with washer through inlet and screen. NOTE: The rivet can be installed with formed head facing inboard or outboard.

(6)

Put one washer on installed rivet.

CAUTION:

A SPLIT IN THE ROLLED OVER SURFACE OF RIVET MUST NOT EXTEND INTO THE RIVET BODY. NO MORE THAN (2) SPLITS WILL BE ALLOWED IN A 90-DEGREE AREA. A TOTAL OF NO MORE THAN 3 SPLITS WILL BE ALLOWED. VISUALLY INSPECT THE ASSEMBLY PER THE INSTRUCTIONS IN THE CHECK SECTION.

(7)

Roll over drilled end of rivet.

(8)

Repeat Paragraph 10.A.(4) thru Paragraph 10.A.(7) for remaining five rivet locations.

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10. Replacing Air Inlet Screen for Air Inlet & Screen Assembly (10001-150)

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I

RIVET FLAT WASHER

AIR INLET

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SCREEN

FLAT WASHER

Figure 6006 - Air Inlet Assembly Screen Replacement 11. Bearing Journal and Liner Restoration A. Bearing Journals (1) If the armature shaft bearing journals are worn beyond limits in the FITS AND CLEARANCES section, restoration may be possible by electrodeposition plating in accordance with Goodrich Corporation Standard Practice Document (SPD) 1000. NOTE: If armature shaft is out of concentricity, machine shaft within concentricity before plating. (2)

Maximum allowable thickness of plating shall be 0.01 in. (0.254 mm), or 0.02 in. (0.508 mm) measured across a diameter.

(3)

Armature shaft bearing journals may be plated to final dimensions, or overplated then ground to final dimensions listed in the FITS AND CLEARANCES section.

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I

(2)

Stainless steel bearing liners cannot be repaired. Use a magnet to check if the bearing liner is stainless steel. If the bearing liner is stainless steel, the magnet does not attract to the bearing liner.

(3)

Sintered metal bearing liners were used for a short time during the 1980’s and cannot be repaired per SPD 1000. Determine if the bearing liner is sintered by measuring the outside diameter (OD) of the bearing liner. See Figure 6007. (a)

For anti-drive end end bell bearing liners: • Sintered bearing liner will have an exposed OD of approximately 1.67 in. (42,4 mm). • Steel bearing liners will have an exposed OD of approximately 1.746 in. (44,35 mm).

(b)

For drive end end bell bearing liners: • Sintered bearing liners will have an OD of approximately 1.78 in. (45,2 mm) where it projects from the drive end end bell. • Steel bearing liners will have an exposed OD of approximately 1.725 in. (43,82 mm).

FOR SINTERED ANTI-DRIVE END BEARING LINERS: Ø 1.67 in. (42,4 mm) OD FOR STEEL ANTI-DRIVE END BEARING LINERS: Ø 1.746 in. (44,35 mm) OD

FOR SINTERED DRIVE END BEARING LINERS: Ø 1.78 in. (45,2 mm) OD FOR STEEL DRIVE END BEARING LINERS: Ø 1.725 in. (43,8 mm) OD

ANTI-DRIVE END END BELL BEARING LINER O.D.

DRIVE END END BELL BEARING LINER O.D.

DRIVE END END BELL

ANTI-DRIVE END END BELL

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B. Bearing Liner Restoration (1) If bearing liners are worn beyond acceptance limits, restoration can be possible. Refer to SPD 1000 for repair limitations and procedures for selective electrodeposition nickel plating. Components not in compliance with the dimensions as applicable, must be reworked or replaced.

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I (4)

Anti-Drive End (ADE) End Bell Restoration Refer to SPD 1000 for detailed instructions. Components not in compliance with the dimensions in Figure 6008, Figure 6009, Figure 6010 and Figure 6011 must be reworked, or replaced.

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2.413 in. (61,29 mm) 2.407 in. (61,14 mm)

5.142 in. (130,61 mm) Ø 5.140 in. (130,56 mm)

0.445 in. 0.440 in. (11,30 mm) 1.5747 in. (39,997 mm) Ø (11,18 mm) 1.5750 in. (40,005 mm)

0.06 in. WIDE X Ø 1.594 in. 1,5 mm WIDE X Ø 40,49 mm UNDER CUT (0.01 in. MAX. FILLET RADII) (0,3 mm MAX. FILLET RADII)

Figure 6008 - Anti-Drive End End Bell Bearing Liner Machining Specifications (IPL 10002, P/N 23081-1050 and 23032-2165)

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I

2.413 in. (61,29 mm) 2.407 in. (61,14 mm)

BEARING SEAT

125 125

0.06 in. (1,5 mm)

Ø 1.594 in. (40,49 mm)

BEARING SEAT

30°

±30°

-BMAX. 2X R 0.02 in. (0,5 mm)

5.142 in. (130,61 mm) Ø 5.140 in. (130,56 mm)

125

0.440 in. 0.445 in. 1.5747 in. (39,997 mm) (11,18 mm) Ø1.5750 in. (40,005 mm) (11,30 mm)

DETAIL

4X SIZE

SEE DETAIL

Figure 6009 - Anti-Drive End End Bell Bearing Liner Machining Specifications (IPL 10002, P/N 23081-3365)

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.002 C .002 B

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I

2.113 in. (53,67 mm) 2.107 in. (53,52 mm)

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MACHINE IF NECESSARY 0.05 in. MAX. X 45° (1,3 mm)

5.142 in. (130,61 mm) Ø 5.140 in. (130,56 mm)

0.493 in. (12,52 mm) 1.5747 in. (39,997 mm) Ø MAX. 1.5750 in. (40,005 mm)

SEE DETAIL UNDERCUT

Ø 1.594 in. (40,49 mm)

0.06 in. (1,5 mm)

0.01 in. MAX. (0,3 mm) FILLET RADIUS

Figure 6010 - Anti-Drive End End Bell Bearing Liner Machining Specifications (IPL 10002, P/N 23032-3665)

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I 2.413 in. (61,29 mm) 2.407 in. (61,14 mm)

125 125

0.06 in. (1,5 mm)

Ø 1.594 in. (40,49 mm)

BEARING SEAT

30°

±30°

MAX. 2X R 0.02 in. (0,5 mm)

5.142 in. (130,61 mm) Ø 5.140 in. (130,56 mm)

125

0.440 in. 0.445 in. 1.5747 in. (39,997 mm) (11,18 mm) Ø1.5750 in. (40,005 mm) (11,30 mm)

DETAIL

4X SIZE

SEE DETAIL

Figure 6011 - Anti-Drive End End Bell Bearing Liner Machining Specifications (IPL 10002, P/N 23081-3320/-3322)

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BEARING SEAT

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I (5)

Drive End (DE) End Bell Restoration Refer to SPD 1000 for detailed instructions. Components not in compliance with the dimensions in Figure 6012 and Figure 6013 must be reworked, or replaced.

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-A4.959 in. (125,96 mm) 4.957 in. (125,91 mm)

1.5745 in. (39,992 mm) 1.5748 in. (40,000 mm)

5.250 in. (133,35 mm) 5.252 in. (133,40 mm)

125

-B-

Figure 6012 - Drive End End Bell Bearing Liner Machining Specifications (IPL 10003, P/N 23081-1130/-1131, 23032-3652, 23081-1230)

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-A4.959 in. (125,96 mm) 4.957 in. (125,91 mm)

1.5745 in. (39,992 mm) 1.5748 in. (40,000 mm)

5.250 in. (133,35 mm) 5.252 in. (133,40 mm)

125

-B-

Figure 6013 - Drive End End Bell Bearing Liner Machining Specifications (IPL 10003, P/N 23081-1490)

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I 12. Commutator Refinishing NOTE: Unless otherwise indicated, numbers in parentheses ( ) refer to item numbers on the illustration IPL Figure 10001. If inspection reveals that the commutator is rough, pitted, scored, or burned, refinish the commutator on a lathe that is accurately set up and adjusted. Distributed via the Goodrich Technical Publications Web Portal. Refer to https://techpubs.goodrich.com to confirm the latest revision standard.

A. Setup WARNING: MAKE SURE THE POWER TO THE LATHE IS SHUT OFF OR “LOCKED OUT” WHILE PREPARING THE MACHINE FOR COMMUTATOR RE-FINISHING. USE ALL SAFETY PRECAUTIONS WHILE WORKING WITH OR AROUND POWER MACHINE TOOLS. WEAR EYE PROTECTION. (1)

Install a bearing into the commutator turning fixture.

(2)

Position the drive end of the armature (480) shaft at the lathe chuck head and the commutator turning fixture in the tail stock.

B. Repair procedure CAUTION: DO NOT REMOVE TOO MUCH MATERIAL FROM THE COMMUTATOR. IF YOU DO, THE LIFE OF THE COMMUTATOR WILL BE DECREASED. CAUTION:

(1)

DO NOT TOUCH THE COMMUTATOR WITH YOUR BARE HANDS. CONTAMINATION FROM YOUR SKIN CAN CAUSE CORROSION AND UNSATISFACTORY ELECTRICAL CONTACT.

Cut the commutator to a surface finish of 64 to 100 microinches (1,6 to 2,5 microns) RMS. The finish surface must go from the end of the full undercut to within 0 to 0.060 in. (0 to 1,5 mm) of the outboard end of the commutator. NOTE: We recommend the feed rate is 0.006 to 0.007 in./rev (0,13 mm) at a surface speed of 1000 to 1500 surface feed/min. (305 to 457 surface m/min.).

WARNING: WHEN USING COMPRESSED AIR FOR CLEANING OR DRYING, CONTROL PRESSURE TO 29 PSIG (200 KPA) OR LESS. WEAR GOGGLES OR FACE SHIELD TO PROTECT EYES. TAKE PRECAUTIONS TO AVOID INJURY TO OTHER PERSONNEL IN AREA. CAUTION:

(2)

MAKE SURE THAT COMPRESSED AIR USED TO CLEAN OR DRY COMPONENTS IS FREE FROM OIL AND WATER. THIS WILL PREVENT CONTAMINATION OF THE COMPONENTS.

Clean the armature (480) surfaces with compressed air, 29 PSIG (200 kPa) maximum.

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(3)

Measure the depth of the mica undercut between the commutator bars. Refer to the FITS AND CLEARANCES section for the limits.

(4)

If the undercut is out of limits, use a 0.31 to 0.50 inch (7,9 to 12,7 mm) max. diameter cutter wheel to undercut the mica to a depth of 0.050 inch (1,27 mm) min. to 0.070 inch (1,78 mm) max. and a width of 0.035 to 0.045 inch (0,89 to 1,14 mm). (a)

The beginning of mica undercut must be 0.01 to 0.03 inch (0,25 to 0,76 mm) max. from the finished face of the risers.

(b)

All cuts must be equally spaced and parallel with the centerline of the armature shaft within 0.005 inch (0,13 mm) of true position.

(c)

All mica must be removed from the edges of the undercut.

(5)

Use a triangular scraping tool to remove sharp edges and burrs.

(6)

Remove the undercut residue from between the commutator bars with a soft bristle brush.

MAKE SURE THAT COMPRESSED AIR USED TO CLEAN OR DRY COMPONENTS IS FREE FROM OIL AND WATER. THIS WILL PREVENT CONTAMINATION OF THE COMPONENTS.

(7)

Clean the armature (480) surfaces with compressed air, 29 PSIG (200 kPa) maximum.

(8)

After the commutator is refinished, measure the commutator bar-to-bar and total indicator reading (TIR) run-out in full circumference of the commutator. Support the armature (480) on two “V” blocks. (a)

REPLACE the armature if the limits cannot be met in the FITS AND CLEARANCES section.

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I 13. Balancing the Armature NOTE: Unless otherwise indicated, numbers in parentheses ( ) refer to item numbers on the illustration IPL Figure 10001.

14. Repair of Bearing and Brush Support Assembly Refer to the DISASSEMBLY Paragraph 5. for disassembly instructions. Refer to the ASSEMBLY Paragraph 6. for assembly instructions. 15. Polarizing the Output Voltage NOTE: If the polarity of the output voltage of a DC starter-generator has been reversed, this can be corrected by polarizing the field. A. Setup CAUTION:

NO OTHER POWER SUPPLY IS TO BE CONNECTED TO THE STARTER-GENERATOR.

(1)

Connect a 6 VDC, wet cell battery (or 6 VDC power supply) and bump switch in series with the starter-generator field, as shown in Figure 6015.

(2)

Connect the negative lead to terminal stud E.

(3)

Connect the positive lead and bump switch to terminal stud A.

B. Procedure CAUTION: (1)

DO NOT POLARIZE THE FIELD WHILE THE STARTER-GENERATOR IS IN OPERATION.

Turn the power ON and turn bump switch ON for a maximum of five seconds to polarize the field. NOTE: If the polarity of the field has not been corrected, check for incorrect connections or a defective field circuit.

(2)

Turn the power OFF and disconnect the leads.

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Balance the armature (480) to the limits given in FITS AND CLEARANCES and using the procedure in Goodrich Corporation Standard Practice Document (SPD) 1001.

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I

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Figure 6015 - Terminal Block Schematic for Polarizing the Output Voltage 16. Replacement of B or E Terminal Block Studs, All Models but 23081-056 NOTE: Unless otherwise specified, numbers in parentheses ( ) refer to item numbers in Figure 10004 of ILLUSTRATED PARTS LIST. A. Removal. For terminal block P/N: 23081-1310, there are two options available for removal of terminal studs: • Using a stud removal tool. • Using two nuts. (1)

Stud removal using a stud removal tool. (a)

Screw the stud removal tool (refer to Table 6001) onto the stud (50). See Figure 6016.

(b)

Apply force in a counterclockwise direction to the drive head of the stud removal tool.

(c)

Continue to rotate the stud removal tool until the stud (50) is removed from the terminal block (60).

(d)

Move the clutch ring of the stud removal tool away from the collet holder.

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(e)

While gripping the collet holder with a wrench, rotate the drive head of the stud removal tool in a clockwise direction until the tension is released between the stud removal tool and the stud.

(f)

Screw the stud out of the stud removal tool.

Figure 6016 - Removal of Terminal Studs from 23081-1310 with Stud Removal Tool (2)

Stud removal using two nuts. (a)

Put one nut (30) upside down on the stud (50).

(b)

Put another nut (30), correct way up, on the same stud (50). See Figure 6018. Use two open ended wrenches to tighten the two nuts (30) together.

(c)

Turn the bottom nut (30) in a counter-clockwise direction with an open ended wrench, to remove the stud (50).

(d)

Remove the two nuts (30) from the stud (50).

(e)

Repeat this process on the other terminal stud.

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I B. Installation For models 23081-022, 23081-022A, 23081-023, 23081-023A, 23081-056, 23081-059, 23081-069 and 23081-070: • Using a stud driver. • Using two nuts. Distributed via the Goodrich Technical Publications Web Portal. Refer to https://techpubs.goodrich.com to confirm the latest revision standard.

(1)

Stud insertion using a stud driver. See Figure 6017. (a)

Screw the new stud (50) into the stud driver. NOTE: To make adjustment to the stud engagement length, lift the clutch ring and turn the drive head. NOTE: Stud driver can be powered by hand or can be attached to a non-impacting power tool.

(b)

Drive the stud (50) into the terminal block (60). Torque the stud 70 to 110 lbf.in (7,9 to 12,4 N · m). NOTE: If the torque limit is reached before the stud shoulder touches the terminal block, remove the stud. Remove a small amount of the Nylock material from the stud threads by lightly brushing with a wire brush, and then install the stud again. NOTE: If a torque of 70 lbf.in (7,9 N · m) is not reached when the stud shoulder touches the terminal block, replace the stud.

(c)

After the stud shoulder is fully seated on the terminal block, proceed to tighten the stud to a torque of 300 to 325 lbf.in (33,9 to 36,7 N · m).

(d)

Remove the stud driver by turning it counterclockwise until it releases from the stud.

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Figure 6017 - Installation of Terminal Studs with Stud Driver Tool (2)

Stud insertion using two nuts. (a)

Place one nut (30) upside down on the new stud (50).

(b)

Put another nut (30) correct way up, on the same stud (50). See Figure 6018.

(c)

Use two open ended wrenches to tighten the two nuts (30) together.

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I (d)

Attach the stud (50) to the terminal block (60) by turning the top nut (30) in a clockwise direction. Torque the stud 70 to 110 lbf.in (7,9 to 12,4 N · m). NOTE: If the torque limit is reached before the stud shoulder touches the terminal block, remove the stud. Remove a small amount of the Nylock material from the stud threads by lightly brushing with a wire brush, and then install the stud again.

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NOTE: If a torque of 70 lbf.in (7,9 N · m) is not reached when the stud shoulder touches the terminal block, replace the stud. (e)

After the stud shoulder is fully seated on the terminal block, proceed to tighten the stud to a torque of 300 to 325 lbf.in (33,9 to 36,7 N · m).

(f)

Remove the two nuts (30) from the stud (50).

Figure 6018 - Terminal Block Stud Removal and Installation Using Two Nuts

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I

ASSEMBLY 1. Introduction

In addition to specific procedures authorized by Goodrich Corporation in this manual, standard assembly procedures for starter-generators are described in the following Goodrich Corporation Standard Practice Documents (SPDs). • Surface Repair and Coating - Refer to SPD 1002. • Brush Holder Alignment Fixtures - Refer to SPD 1004. • Brush Installation, Seating, and Run-In - Refer to SPD 1006. 2. Assembly Tools In addition to normal shop tools, specific tools for assembly of the starter-generator are listed in Table 7001. NOTE: Equivalent substitutes can be used for the tools listed in Table 7001. Tool Description Arbor Press Brush Holder Alignment Fixture Driver, Dampener Plate Driver, Inner Race Bearing Driver, Outer Race Bearing Heat Gun Leather or Plastic Mallet Pin Insertion/Extraction Tool Pliers, Snap Ring Speed Pickup Adjustment Plug Spline Wrench Support, Armature Support, Bearing and Brush Support Assembly Support, Drive End Outboard Hub Support, Horizontal Stator and Housing Assembly

Reference Commercially Available SPD 1004 Figure 9007 Figure 9004 Figure 9005 Commercially Available Commercially Available Commercially Available Commercially Available Figure 9008 Figure 9015 Figure 9010 Figure 9009 Figure 9012 Figure 9013

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This section gives assembly instructions for DC Starter-Generators 23081 Series I. Assemble the unit in a clean work area away from machining or other metal removing operations. Clean all parts in accordance with (IAW) instructions in the CLEANING section before final assembly.

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I Tool Description Support, Vertical Stator and Housing Assembly Terminal Block - Unserviceable (Optional) Torque wrench Wire Hook Tool

Reference Figure 9014 None Commercially Available Commercially Available

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Table 7001 - Assembly Tools (Continued) 3. Assembly materials Materials necessary for starter-generator assembly are listed in Table 7002. NOTE: Equivalent substitutes can be used for the materials listed in Table 7002. Assembly materials are not available from Goodrich Corporation. All items can be purchased commercially. WARNING: BEFORE USING ANY OF THE FOLLOWING MATERIALS, BE AWARE OF ALL HANDLING, STORAGE, AND DISPOSAL PRECAUTIONS RECOMMENDED BY THE MANUFACTURER OR SUPPLIER. FAILURE TO COMPLY WITH THE RECOMMENDATIONS CAN RESULT IN SERIOUS INJURY, PHYSICAL DISORDER, OR DEATH.

Item

Description/Specification

Source (CAGE Code)

Acrylic coating

HumiSeal Type 1B31, Type AR MIL-I-46058

Cloth Enamel, Red Insulating, Baking

Lint-free Synthite ER-41

Grease Insulation Sleeving

Lubricating/MIL-PRF-81322 Heat-shrinkable, MIL-I-23053/5, 1/8 inch

Chase Corporation Woodside, NY 11377 Ph: (718) 932-0800 Fax: (718) 932-4345 www.humiseal.com (V0SR97) Commercially Available John C. Dolph Company 320 New Road, PO Box 267 Monmouth, NJ 08852 Ph: (732) 329-2333 Fax: (732) 329-1143 www.dolphs.com (V72688) Commercially Available Commercially Available

Table 7002 - Assembly Materials

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I Description/Specification

Isopropyl Alcohol

TT-I-735, Grade A

See WARNING before using this material.

Flash Point: 53° F (12° C), FLAMMABLE

Lockwire Lubricating and Assembly Paste

Masking Tape Sandpaper Solder Thread Locking Adhesive

Source (CAGE Code) Commercially available

Refer to the Material Safety Data (MSD) Sheet for the material for additional safety information NASM20995C20 Altemp QNB 50

Not Applicable 180 grit, Non-aluminum Oxide Resin Core, ANSI J STD-006, Type Sn 95 Loctite Grade E MIL-C-22473, Class E

Thread Sealing Compound

Lead Free/Soft Set Gasoila

Zinc Chromate Primer

Composition G, color Y, TT-P-1757

Commercially Available Klueber Lubrication Londonderry, NH Ph: (603) 647-4104 www.klueber.com (V3EZL6) Commercially available Commercially Available Commercially available Loctite Corporation Aurora, IL Ph: (860) 571-5100 www.loctite.com (V7V827) GSA Supply on-line www.gsasupplyco.com or Federal Process Co. 4620 Richmond Rd. Beachwood, OH 44128 Commercially Available

Table 7002 - Assembly Materials 4. Assembly of Stator and Housing Assembly NOTE: Unless otherwise specified, numbers in parentheses ( ) refer to item numbers in Figure 10004 of ILLUSTRATED PARTS LIST. A. Attach terminal block (60) to the stator and housing assembly. See Figure 7001 and Figure 10004. NOTE: Before acceptance testing, attach an unserviceable terminal block to the stator housing. Acceptance testing can damage internal capacitors of a new or serviceable terminal block. (1)

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Item

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I (a)

Set the stator and housing assembly onto a horizontal stator support.

(b)

Set the terminal block (60) onto stator and housing assembly and slide the terminal block studs into the three large stator leads.

(c)

Attach the terminal block (60) to stator and housing assembly with two lock washers (90), two flat washers (100) and screws (80).

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For stator and housing assembly effect codes A, B: a

For stator and housing assembly effect codes D and E: a

(2)

Tighten two screws (80) to a torque of 28.0 to 37.8 lbf.in. (3,2 to 4,3 N · m).

Tighten two screws (80) to a torque of 13.5 to 18.0 lbf.in. (1,5 to 2,0 N · m).

For stator and housing assembly effect code C: CAUTION:

DO NOT BEND THE LARGE STATOR LEADS MORE THAN NECESSARY TO INSTALL THE TERMINAL BLOCK.

CAUTION:

MAKE SURE SMALL TERMINAL LEADS A AND D ARE NOT UNDERNEATH TERMINAL BLOCK AS IT IS PUSHED INTO POSITION.

(a)

Set terminal block (60) onto the stator and housing assembly and slide it into position in the large stator leads, B and E.

(b)

Put stator terminal leads through grommet (110) onto terminal studs A and D.

(c)

Put the small stator lead terminal lugs (120) on studs A and D.

(d)

Place leads to terminal studs A and D in grooves in the terminal block (60).

(e)

Put a lock washer (90) and flat washer (100) onto each of the three screws (80).

(f)

Put the remaining screw (80) into the center hole on the terminal block (60).

(g)

Tighten the three screws (80) to a torque of 28.0 to 37.8 lbf.in. (3,2 to 4,3 N · m).

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I

SCREW (1 OF 2) LOCK WASHER (1 OF 2)

SOCKET HEAD SCREW (1 OF 2) LOCK WASHER (1 OF 2)

SCREW (1 OF 3) LOCK WASHER (1 OF 3)

FLAT WASHER (1 OF 2)

FLAT WASHER (1 OF 3)

Figure 7001 - Terminal Block Attachment B. Install attaching hardware on terminal block (60). See Figure 7002. (1) Set the stator and housing assembly onto a horizontal stator support. (2)

Position one terminal lug (120) on each of terminal block (60) terminals A and D. Secure each terminal lug (120) with one flat washer (20) and nut (10). NOTE: Do not tighten the nuts (10) on terminal block (60) terminals A and D. They will be tightened at the time of installation into the aircraft. It is necessary to install the wires from the GCU at that time.

(3)

For stator and housing assembly effect code A, B: (a)

Install one flat washer (40) and nut (30) on each of three terminals C, B and E. NOTE: Do not tighten the nuts (30) on terminals C, B and E. They will be tightened at the time of installation into the aircraft.

(4)

For stator and housing assembly effect codes C, D and E: (a)

Install one flat washer (40) and nut (30) on each of two terminals B and E. NOTE: Do not tighten the nuts (30) on terminals B and E. They will be tightened at the time of installation into the aircraft. ASSEMBLY © 2008 Goodrich Corporation

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FLAT WASHER (1 OF 2)

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I FLAT WASHER (1 OF 3) SELF-LOCKING NUT (1 OF 3)

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FLAT WASHER (1 OF 3) SELF-LOCKING NUT (1 OF 3)

FLAT WASHER (1 OF 2) SELF-LOCKING NUT (1 OF 2)

SELF-LOCKING NUT (1 OF 2) FLAT WASHER (1 OF 2)

SELF-LOCKING NUT (1 OF 2)

FLAT WASHER (1 OF 2)

SELF-LOCKING NUT (1 OF 2)

Figure 7002 - Install Attaching Hardware C. Attach terminal block cover (10001-130) (if present). See Figure 7003. NOTE: When a starter-generator is removed from aircraft for service, the terminal block cover usually stays on aircraft. (1)

Attach terminal block cover (10001-130) to the terminal block, with two screws (10001-140), if applicable.

(2)

Tighten screws (10001-140) to a torque of 7.7 to 10.3 lbf.in. (0,87 to 1,16 N · m).

TERMINAL BLOCK COVER SCREW (1 OF 2)

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I 5. Assembly of the Drive End Bearing Support Assembly

A. If necessary, attach the screen (20) to the drive end bearing support assembly. See Figure 7004. (1) Put the screen (20) on the drive end bearing support and secure with four flat washers (40) and four drive screws (30). (2)

Installation of drive screws (30) will require a plastic mallet to pound the drive screws in place.

(3)

For drive end bearing support assembly effect code E: (a)

Apply thread locking adhesive, grade E, to screws (60).

(b)

Attach magnetic pickup bracket (50) to drive end end bell with two screws (60).

(c)

Tighten screws (60) to a torque of 7.7 to 10.3 lbf.in. (0,87 to 1,16 N · m).

SCREEN

MAGNETIC PICKUP BRACKET (IF APPLICABLE)

DRIVE END END BELL (TYP.)

MACHINE SCREW

FLAT WASHER

DRIVE SCREW

Figure 7004 - Assembling Drive End Bearing Support Assembly

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NOTE: Unless otherwise specified, numbers in parentheses ( ) refer to item numbers in Figure 10003 of the ILLUSTRATED PARTS LIST.

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I 6. Assembly of the Bearing and Brush Support Assembly NOTE: Unless otherwise specified, numbers in parentheses ( ) refer to item numbers in Figure 10002 of the ILLUSTRATED PARTS LIST.

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A. Install the brush springs (50) on the complete brush holder (30). See Figure 7005. CAUTION: DO NOT WIND THE BRUSH SPRINGS TOO TIGHTLY OR THIS CAN RESULT IN REDUCED BRUSH SPRING RELIABILITY. (1)

Wind the brush spring (50) about 3/4 turn and put brush spring (50) onto brush holder (30). Repeat for remaining brush springs (50). INSTALL BRUSH SPRING WITH CLOSED END OF LOOP IN LOCATION SHOWN

BRUSH SPRING BEARING AND BRUSH SUPPORT ASSEMBLY

Figure 7005 - Brush Spring Installation B. Attach each complete brush holder (30) to the anti-drive end end bell (10). See Figure 7006, Figure 7007 and Figure 10002. CAUTION: CORRECT INSTALLATION OF THE INSULATION SLEEVES IS CRITICAL. USE GREAT CARE WHEN INSERTING THE INSULATION SLEEVES INTO THE ANTI-DRIVE END END BELL. IF AN INSULATION SLEEVE IS PINCHED BETWEEN THE ANTI-DRIVE END END BELL AND A COMPLETE BRUSH HOLDER, CARBON DUST WILL COLLECT IN THE AREA WHERE THE INSULATION SLEEVE IS DAMAGED, CAUSING A PATH TO GROUND AND EQUIPMENT FAILURE. THE DAMAGE IS NOT DETECTABLE DURING THE DIELECTRIC TEST AFTER ASSEMBLY. (1)

Insert two insulation sleeves (80) at a brush holder location into two adjacent through holes in the anti-drive end end bell (10). NOTE: Make sure the insulation sleeves (80) extend out of the through holes on both sides of the anti-drive end end bell (10).

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I (2)

Put a non-metallic washer (110) onto the ends of the exposed insulation sleeves (80) on the inboard side of the anti-drive end end bell (10).

(3)

Put a non-metallic washer (120) onto the ends of each exposed insulation sleeves (80) on the outboard side of the anti-drive end end bell (10).

(4)

Put one flat washer (90) on each of two screws or bolts (100).

(5)

Insert one screw or bolt (100) into each of two insulation sleeves (80) on the outboard side of the anti-drive end end bell (10). NOTE: Make sure that the insulation sleeves (80) do not slide and that the non-metallic washers (110) do not fall off.

(6)

Put a complete brush holder (30) against the two screws or bolts (100) on the inboard side of the anti-drive end end bell (10).

(7)

Attach the complete brush holder (30) to the anti-drive end end bell (10) with the two screws or bolts (100).

(8)

For bearing and brush support assemblies that have a filter board (60), effect codes B, C, E, F and G: (a)

Install a filter board assembly (60) onto screws or bolts. NOTE: The filter board installs at the 3 O’clock and the 9 O’clock position when the notch in the ring is at 12 O’clock. See Figure 7007.

(b) (9)

Install an insulating washer (130) on each of the four screws or bolts that do not attach the filter board assemblies.

For bearing and brush support assemblies that do not have a filter board (60), effect codes A and D: (a)

Install an insulating washer (130) on top of each screw or bolt.

(10) Put a flat washer (90) onto each screw or bolt. (11) Loosely thread a self-locking nut (140) on the end of each screw or bolt. NOTE: ATTACH LOOSELY. DO NOT TIGHTEN THE SCREWS OR BOLTS (100) AT THIS TIME. (12) Repeat Paragraph 6.B.(1) through Paragraph 6.B.(11) for remaining brush holder locations. (13) Lower the bearing and brush support assembly onto the brush holder alignment fixture as referenced in SPD 1004.

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NOTE: Make sure the insulation sleeves (80) do not slide and that the non-metallic washers (120) do not fall off.

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I

FLAT WASHER

SELF-LOCKING NUT

INSULATING WASHER

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BRUSH HOLDER ASSEMBLY NON-METALLIC WASHER SLEEVE

ANTI-DRIVE END END BELL

BRUSH HOLDER COMPLETE

NUT SCREW

INSULATING WASHER (TYP. ALL)

FLAT WASHER

SCREW FLAT WASHER

FLAT WASHER

INSULATING SLEEVE INSULATING WASHER WASHER NON-METALLIC WASHER

Figure 7006 - Attaching Brush Holders to Anti-Drive End End Bell (Without Filter Board)

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I

INSULATING WASHER

SELFLOCKING NUT FLAT WASHER INSULATING WASHER

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FILTER BOARD ASSEMBLY

SELFLOCKING NUT FLAT WASHER

FILTER BOARD ASSEMBLY

SIDE

BRUSH HOLDER ASSEMBLY

NON-METALLIC WASHER SLEEVE

ANTI-DRIVE END END BELL BRUSH HOLDER COMPLETE

INSULATING WASHER (TYP. ALL)

FLAT WASHER

SCREW OR BOLT

NUT

SCREW OR BOLT

FLAT WASHER

INSULATING SLEEVE INSULATING WASHER WASHER NON-METALLIC WASHER

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I CAUTION:

MAKE SURE THE COMPLETE BRUSH HOLDERS ARE PROPERLY ALIGNED IN THE BRUSH HOLDER ALIGNMENT FIXTURE. IMPROPER ALIGNMENT CAN CAUSE ELECTRICAL FAILURE.

(14) Adjust all complete brush holders (30) until they are properly aligned. Refer to SPD 1004. (15) Tighten screws or bolts (100) to a torque of 27.0 to 36.0 lbf.in. (3,1 to 4,1 N · m). Distributed via the Goodrich Technical Publications Web Portal. Refer to https://techpubs.goodrich.com to confirm the latest revision standard.

(16) Remove the bearing and brush support assembly from the brush holder alignment fixture. WARNING: INSULATING ENAMEL IS TOXIC AND FLAMMABLE. DO NOT BREATHE VAPORS. USE IN A WELL VENTILATED AREA FREE FROM SPARKS, FLAME AND/OR HOT SURFACES. WEAR SPLASH GOGGLES, SOLVENT-RESISTANT GLOVES, AND OTHER PROTECTIVE GEAR. IN CASE OF EYE CONTACT, FLUSH WITH WATER AND SEEK MEDICAL ATTENTION. IN CASE OF SKIN CONTACT, WASH WITH SOAP AND WATER. (17) Apply insulating enamel to bearing and brush support assembly according to the procedure in SPD 1002. C. Perform a dielectric test. Perform a dielectric test of the bearing and brush support assembly. Refer to the CHECK section. 7. Final assembly of the DC Starter-Generator NOTE: Unless otherwise indicated, numbers in parentheses ( ) refer to item numbers on the illustration IPL Figure 10001. A. Install drive end baffle disc (inboard) (530) and drive end ball bearing (520) on drive end of armature (480) shaft. See Figure 7008. CAUTION: DO NOT TOUCH MACHINED SURFACE OF COMMUTATOR WITH BARE HANDS. SKIN ACIDS AND OILS CAN CONTAMINATE CONDUCTING SURFACES CAUSING CORROSION AND/OR POOR ELECTRICAL CONTACT. (1)

Set armature support on arbor press table.

(2)

Set armature (480), commutator down, on armature support.

(3)

Put drive end baffle disc (inboard) (530) on drive end of armature (480) shaft.

(4)

Set drive end ball bearing (520) onto armature shaft (480).

(5)

Set inner race bearing driver on drive end ball bearing (520).

(6)

Press drive end ball bearing (520) onto armature shaft (480).

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I (7)

Make sure that drive end ball bearing (520) is fully seated against inboard drive end baffle disc.

BALL BEARING BAFFLE DISC

ARMATURE

ARMATURE SUPPORT

Figure 7008 - Installing Baffle Disc and Ball Bearing on the Armature Shaft B. Installing drive end baffle disc (outboard) (530) and retaining ring (540) onto drive end of armature (480) shaft. See Figure 7009. (1) Install a drive end baffle disc (outboard) (530) onto drive end of armature (480) shaft. (2)

Using external snap ring pliers, put retaining ring (540) in groove (on drive end of armature shaft) making sure the retaining ring (540) is fully engaged in the groove.

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INNER RACE BEARING DRIVER

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I RETAINING RING

BAFFLE DISC

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ARMATURE

Figure 7009 - Spacer and Retaining Ring Installation C. Press anti-drive end ball bearing (520) into bearing and brush support assembly (320). See Figure 7010. NOTE: Unless otherwise indicated, numbers in parentheses ( ) refer to item numbers on the illustration IPL Figure 10001. CAUTION:

FAILURE TO USE ANTI-DRIVE END HUB SUPPORT DURING ASSEMBLY OPERATIONS CAN CAUSE PERMANENT DAMAGE TO BEARING AND BRUSH SUPPORT ASSEMBLY.

(1)

Set the anti-drive end hub support on the arbor press table.

(2)

Put the bearing and brush support assembly (320), brush holders down, on the anti-drive end hub support.

(3)

Put the anti-drive end bearing on bearing liner of bearing and brush support assembly.

(4)

Set outer race bearing driver onto anti-drive end ball bearing (520).

(5)

Press anti-drive end ball bearing (520) into bearing and brush support assembly bearing liner.

(6)

Make sure that anti-drive end ball bearing (520) is fully seated against inner lip of bearing liner.

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I OUTER RACE BEARING DRIVER

BEARING AND BRUSH SUPPORT ASSEMBLY

ANTI-DRIVE END HUB SUPPORT

Figure 7010 - Anti-Drive End Ball Bearing Installation into Bearing and Brush Support Assembly D. Attach bearing retainer (490) and filter board leads (if applicable) to bearing and brush support assembly (320). (1) Feed leads from filter board assembly through bearing and brush support assembly (where applicable). CAUTION:

DO NOT ATTACH FILTER BOARD TERMINALS TO ANTI-DRIVE END END BELL BEFORE ACCEPTANCE TESTING TO AVOID DAMAGE TO THE FILTER CAPACITORS.

(2)

If applicable, secure filter board terminals away from cast surfaces of anti-drive end end bell.

(3)

Install a lock washer (510) on each of the screws (500).

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BALL BEARING

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I 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. CAUTION: Distributed via the Goodrich Technical Publications Web Portal. Refer to https://techpubs.goodrich.com to confirm the latest revision standard.

IF BEARING AND BRUSH SUPPORT ASSEMBLY HAS FILTER BOARD ASSEMBLIES, DO NOT APPLY ANTI-SEIZE COMPOUND TO SCREWS AT THIS TIME. THE FILTER BOARD LEADS WILL BE RE-ATTACHED AFTER ACCEPTANCE TESTING.

(4)

Apply thread sealing compound to threads of four screws (500).

(5)

Attach bearing retainer to bearing and brush support assembly using attaching screws (500) and lock washers (510). ANTI-DRIVE END VIEW

FILTER BOARD LEAD

SCREW

LOCK WASHER SCREW

FILTER BOARD LEAD BEARING RETAINER

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I E. Attach grommet (470), speed pickup (460), and speed pickup guard (440) to drive end bearing support assembly (390). See Figure 7012. (1) Press grommet into an opening in the screen of the drive end bearing support assembly.

(2)

Screw speed pickup through threaded hole in drive end bearing support assembly.

(3)

Insert speed pickup adjustment plug into bearing liner of drive end bearing support assembly.

(4)

Adjust speed pickup until tip of speed pickup touches the adjustment plug, and tighten the jam nut to 15 to 25 lbf.in. (1,7 to 2,9 N · m).

(5)

If the heat shrink sleeving was removed during disassembly, put a piece of 1/8 inch (3,2 mm) diameter heat shrinkable sleeving over the speed pickup leads.

(6)

Shrink the sleeving into place on the leads with a heat gun.

(7)

Thread speed pickup leads through the grommet.

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. (8)

Apply thread sealing compound to the threads in the drive end bearing support assembly for the screws (450).

(9)

Attach speed pickup guard to drive end bearing support assembly with two screws (450), and tighten the screws from 4.2 to 5.5 lbf.in. (0,5 to 0,6 N · m).

SPEED PICKUP

SPEED PICKUP ADJUSTMENT PLUG DRIVE END BEARING SUPPORT ASSEM.

GROMMET

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NOTE: If a speed pickup adjustment plug is not available, do not adjust the speed pickup until after the dampener and sensor back plate is installed.

THIS DOCUMENT SUBJECT TO THE CONTROLS AND RESTRICTIONS ON THE FIRST PAGE.

Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I F. Assemble the drive end bearing support assembly (390) to the stator and housing assembly (550). See Figure 7013 and Figure 7014. (1) Place the stator and housing assembly vertically on the work bench with the drive end up.

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Apply thread sealing compound to the threads in the stator and housing assembly for the screws (400).

(3)

For effect codes A, B, C, D, E, F, J, K, L, M, N, P, Q, R, S, T, U, V, W, BA, EA: See Figure 7013. (a)

Install eight spring lock washers (410) on all eight screws (400).

(b)

On six of the screws (400), install six flat washers (420).

(c)

On the remaining two screws (400), install two tooth lock washers (430).

WARNING: ZINC CHROMATE PRIMER IS FLAMMABLE. DO NOT USE NEAR OPEN FLAMES, OPEN WELDING AREAS, OR ON HOT SURFACES. CONTACT WITH SKIN CAN CAUSE IRRITATION. VAPORS CAN CAUSE EYE IRRITATION, DIZZINESS AND HEADACHE. USE IN A WELL-VENTILATED AREA. (d) (4)

For effect codes X, Y, Z, CA, DA, FA: See Figure 7014. (a)

(5)

Apply zinc chromate paste to the tooth lock washers (430) before installation.

Install eight spring lock washers (410), and eight flat washers (420) on all eight screws (400).

While holding drive end bearing support assembly (390), thread the speed pickup (460) leads through the stator and housing assembly and out the hole. NOTE: Sometimes it is easier to slide a separate 12 inch (305 mm) length of wire through the hole and pass between the stator poles out to the drive end. Attach this extra wire to the speed pickup leads. Pull out the extra wire as the speed pickup leads are pulled in on the same path. Disconnect the extra wire.

(6)

Place the drive end bearing support assembly (390) on the stator and housing assembly. Align the speed pickup unit towards the terminal block (10004-60) on the stator and housing assembly.

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I

(8)

For effect codes A, B, C, D, E, F, J, K, L, M, N, P, Q, R, S, T, U, V, W, BA, EA: See Figure 7013. (a)

Attach two of the screws (400) that contain the tooth lock washers (430) 180° apart on the drive end bearing support assembly.

(b)

Attach the remaining six screws on the drive end bearing support assembly.

For effect codes X, Y, Z, CA, DA, FA: See Figure 7014. (a)

(9)

Attach all eight screws on the drive end bearing support assembly.

Tighten the eight screws (400) to a torque of 18.0 to 24.0 lbf.in. (2,03 to 2,07 N · m). NOTE: Make sure that the head of the screws are flush or below face of the drive end bearing support assembly when installed. NOTE: The speed pickup leads can dangle outside the stator and housing assembly until connected in later paragraphs. SCREW (1 OF 8)

TOOTH LOCK WASHER (2 PLCS, 180° APART) (1 OF 2)

DRIVE END BEARING SUPPORT ASSEMBLY FOR MODELS: 23081-001, -002, -003, -004, -007, -008, -011, -011-1, -012, -012-1, -017, -018, -022, 022A, -023, -023A, -024, -042, -043, -063, -072

SPRING LOCK WASHER (1 OF 8) FLAT WASHER (1 OF 6) SPEED PICKUP LEADS

Figure 7013 - Attaching Drive End Bearing Support Assembly (Effect Codes: A, B, C, D, E, F, J, K, L, M, N, P, Q, R, S, T, U, V, W, BA, EA)

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(7)

THIS DOCUMENT SUBJECT TO THE CONTROLS AND RESTRICTIONS ON THE FIRST PAGE.

Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I DRIVE END BEARING SUPPORT ASSEMBLY FOR MODELS: 23081-056, -057, -059, -069, -070, -073

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SCREW (1 OF 8)

SPRING LOCK WASHER (1 OF 8) FLAT WASHER (1 OF 8)

SPEED PICKUP LEADS

Figure 7014 - Attaching Drive End Bearing Support Assembly (Effect Codes: X, Y, Z, CA, DA, FA) G. Attach the spacer (370) and connector (360) to the stator and housing assembly (550). See Figure 7015. NOTE: Allow enough lead length to reach through spacer. (1)

Solder black lead to pin A and white lead to pin B of connector. NOTE: All soldering procedures must be done to ANSI/IPC J-STD-001.

(2)

If needed, assemble wire adapter sleeve on each of three leads.

(3)

Shrink sleeving in place with a heat gun.

(4)

Thread magnetic speed pickup leads through slot in spacer.

(5)

Use a pin insertion/extraction tool to insert pins into connector (360). NOTE: When properly installed, the slot in the spacer (370) will be against the stator and housing assembly. The speed pickup leads route through the slot in the spacer.

(6)

Position the 3-pin connector (360) on spacer (370). NOTE: Position polarizing key of 3-pin connector as shown.

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I

(7)

Apply thread sealing compound to threads of four screws (380).

(8)

Attach spacer (370) and connector (360) to the stator and housing assembly using four screws (380).

(9)

Tighten the screws (380) to a torque of 4.2 to 5.5 lbf.in. (0,47 to 0,62 N · m).

(10) Check for continuity between speed pickup connector pins. (11) Lockwire the four screws (380) with lockwire (MS20995C20) IAW MS33540.

LOCKWIRE PIN B

PIN C KEYWAY FACING ANTI-DRIVE END PIN A

CONNECTOR

SPACER

DRIVE END VIEW

Figure 7015 - Attaching 3-Pin Connector to Stator and Housing Assembly

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THIS DOCUMENT SUBJECT TO THE CONTROLS AND RESTRICTIONS ON THE FIRST PAGE.

Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I H. Prepare armature (480) for coarse brush seating. (1) Prepare the armature for coarse brush seating. Refer to SPD 1006. NOTE: Make sure taped end of sandpaper is in the normal direction of rotation and abrasive side of sandpaper faces away from the commutator. See Figure 7016. Distributed via the Goodrich Technical Publications Web Portal. Refer to https://techpubs.goodrich.com to confirm the latest revision standard.

COMMUTATOR BARS TAPE SANDPAPER

Figure 7016 - Preparing Armature for Rough Seating I.

Press bearing and brush support assembly (320) onto armature (480) shaft. See Figure 7017. CAUTION: DO NOT TOUCH MACHINED SURFACE OF COMMUTATOR WITH BARE HANDS. SKIN ACIDS AND OILS CAN CONTAMINATE CONDUCTING SURFACES CAUSING CORROSION AND/OR POOR ELECTRICAL CONTACT. (1)

Put the armature (480) on a stand. Put the stand on an arbor press table so that the commutator points up.

(2)

Set bearing and brush support assembly (320), brush holders down, on commutator end of armature (480) shaft.

(3)

Use an inner race bearing driver to push the bearing and brush support assembly (320) onto the anti-drive end of the armature (480).

(4)

Make sure that anti-drive end ball bearing (520) is fully seated against shoulder of armature (480) shaft.

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I INNER RACE BEARING DRIVER

ARMATURE

ARMATURE SUPPORT

Figure 7017 - Pressing Bearing and Brush Support onto the Armature J. Attach bearing and brush support assembly (320), with attached armature (480) to stator and housing assembly (550). See Figure 7018. (1) Set the drive end hub support on the arbor press table. (2)

Set the stator and housing assembly with attached drive end bearing support assembly (390) (drive end down) onto drive end outboard 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. (3)

Apply lubricating and assembly paste to the inside of the bearing liner of the drive end bearing support (390).

(4)

Insert armature (480) with attached bearing and brush support assembly (320) into the stator and housing assembly making sure the drive end ball bearing (520) on armature shaft is aligned with bearing liner of drive end bearing support assembly (390).

(5)

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ANTI-DRIVE END END BELL ASSEMBLY

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I (6)

Press drive end ball bearing (520) into bearing liner of drive end bearing support assembly (390) making sure screw holes (of bearing and brush support assembly) are aligned with holes in stator and housing assembly and that the machined faces are fully flush.

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Install a lock washer (340) and a flat washer (350) on each of the eight screws (330).

(8)

Apply thread sealing compound to threads of the eight attaching screws (330).

(9)

Attach bearing and brush support assembly (320) to stator and housing assembly with eight screws (330).

(10) Torque the eight screws (330) from 18.0 to 24.0 lbf.in. (2,03 to 2,07 N · m).

LOCK WASHER (1 OF 8)

SCREW (1 OF 8)

FLAT WASHER (1 OF 8)

BEARING AND BRUSH SUPPORT WITH ATTACHED ARMATURE

STATOR AND HOUSING ASSEMBLY

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I

(2)

Twist dampener or dampener and gear backplate (310) onto drive end of armature shaft until fully seated.

(3)

Put friction ring (280) onto the recess of the dampener and sensor back plate. NOTE: Friction ring cannot stay in place until drive shaft with dampener plate is installed.

DAMPENER AND SENSOR BACKPLATE

FRICTION RING

Figure 7019 - Installing Dampener or Dampener and Gear Backplate and Friction Ring L. Assemble dampener hub (300) and dampener plate (290) on drive shaft (260). See Figure 7020. CAUTION: DO NOT FORCE DAMPENER HUB ON DRIVE SHAFT MATING TAPER. TOO MUCH FORCE CAN CAUSE THE DAMPENER HUB TO FRACTURE. (1)

Using hand pressure, press dampener hub (300) on drive shaft (260) if it was removed.

(2)

Put drive shaft (260) and dampener hub (300) through dampener plate (290) and driver. Align splines.

(3)

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K. Install dampener or dampener and gear backplate (310) and friction ring (280) onto armature shaft. See Figure 7019. (1) Set stator and housing assembly on a horizontal stator support.

THIS DOCUMENT SUBJECT TO THE CONTROLS AND RESTRICTIONS ON THE FIRST PAGE.

Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I

DAMPENER HUB DRIVE SHAFT DAMPENER PLATE

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DAMPENER PLATE DRIVER

Figure 7020 - Dampener Plate and Driver M. Insert drive shaft (260) into armature shaft (150). See Figure 7021. CAUTION: DO NOT USE TOO MUCH FORCE TO ENGAGE THE DRIVE SHAFT AND ARMATURE SHAFT MATING SPLINES. FAILURE TO CORRECTLY ENGAGE THE SPLINES CAN CAUSE DAMAGE TO THE DRIVE SHAFT AND ARMATURE SHAFT. (1)

Lubricate internal mating spline on anti-drive end of drive shaft with grease. Do not apply grease to the screw thread at end of drive shaft.

DRIVE SHAFT

DAMPENER PLATE

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(2)

Insert anti-drive end of drive shaft into drive end of armature shaft.

(3)

Push drive shaft through armature shaft until dampener plate is fully engaged against friction ring.

(4)

Turn drive shaft in the direction of rotation to make sure that armature shaft and drive shaft splines are correctly engaged.

N. Attach fan (230) to drive shaft. See Figure 7022. (1) Put fan onto drive shaft and engage internal spline on fan with mating spline on drive shaft. (2)

Attach fan (230) to drive shaft with a flat washer (250) and a self-locking nut (240).

(3)

Use a spline wrench to hold the drive shaft (260) in place.

(4)

Tighten self-locking nut (240) to a torque of 100 to 120 lbf.in. (11,3 to 13,6 N · m). FAN FLAT WASHER DRIVE SHAFT

SELF-LOCKING NUT

Figure 7022 - Attaching the Fan O. Insert brushes (210) into starter-generator. See Figure 7023. NOTE: If new brushes (210) are to be used, identify the brushes (210) with the numbers 1 through 4. CAUTION:

(1)

RAISE AND LOWER BRUSH SPRINGS SLOWLY. DO NOT LIFT BRUSH SPRINGS MORE THAN NEEDED TO INSERT BRUSH SETS INTO BRUSH HOLDER ASSEMBLY.

Install four brushes (210) into the corresponding complete brush holders (10002-30). (a)

Set starter-generator, anti-drive end up, onto a vertical stator support.

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I

(2)

(b)

At each brush holder location, lift one brush spring at a time with a wire hook tool and insert brush set into a brush holder assembly.

(c)

Slowly lower springs on top of brushes. Make sure that brush leads are not caught under brush springs.

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Secure the four brush (210) leads and four braided stator leads to complete brush holders (10002-30) with four screws (210) to a torque of 22.7 to 35.0 in-lbs (2,6 to 4,0 N · m).

CAUTION: (3)

FAILURE TO PROPERLY FORM THE BRUSH LEAD CAN RESULT IN BRUSH HANG UP.

Form the brush leads IAW SPD 1006. NOTE: Also reference GSIL 2007-01 for brush lead installation instructions for applicable models. WIRE HOOK TOOL

BRUSH SPRING

Figure 7023 - Installing Brush Sets P. Coarse seat the new brushes (210). (1) Coarse seat the brushes (210) IAW SPD 1006. NOTE: The sandpaper should first touch the leading edge (short side) of the brush (210) when the armature (480) is rotated in its normal direction. (2)

Remove any remaining sandpaper IAW SPD 1006 when done with brush run-in.

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I

CAUTION:

(1)

DO NOT LET THE STARTER-GENERATOR HANG UNSUPPORTED DURING INSTALLATION ONTO AND REMOVAL FROM THE DRIVE STAND. TOO MUCH LOAD ON THE DRIVE SHAFT SHEAR SECTION CAN DAMAGE THE UNIT.

Run-in the brushes as given in Goodrich Corporation SPD 1006. NOTE: A correctly seated brush (210) has a smooth and semi-gloss contact surface.

R. If applicable, assemble the air inlet assembly (150). (1) Place the hexagonal screen (170) inside the air inlet (160) and line up the holes with the screen. (2)

Put a flat washer (-190) on each rivet (-180).

(3)

Insert the rivet in each hole through an opening in the screen.

(4)

Put another flat washer on the rivet and flatten the head.

S. Attach air inlet or air inlet assembly (150). CAUTION: USE AN INSULATED AIR INLET ASSEMBLY WITH MODELS FEATURING NON-INSULATED BRUSH LEADS. SEE THE ILLUSTRATED PARTS LIST SECTION FOR MODELS THAT REQUIRE INSULATED AIR INLETS WITH MATCHING BRUSHES. (1)

Using a vertical stator support, put the starter-generator, fan end up, on a work bench.

(2)

Install four screws (200) onto the air inlet and tighten the four screws (200) to a torque of 7.7 to 10.3 in-lbs (0,87 to 1,2 N · m).

8. Identification and Other Plates A. Attach replacement identification plate (60), information plate (80), hi-pot decal (100), FAA-PMA label (-110) and modification status label (-120) to starter-generator. NOTE: See ILLUSTRATED PARTS LIST for applicable model and modification status when re-identifying a starter-generator. CAUTION: (1)

DO NOT STAMP INFORMATION DIRECTLY ONTO ANY PART OF STATOR AND HOUSING ASSEMBLY.

Identification plate replacement (60), if necessary.

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Q. Perform brush (210) run-in. CAUTION: FAILURE TO FULLY SEAT THE BRUSHES CAN DECREASE BRUSH LIFE, LOWER STARTER- GENERATOR PERFORMANCE, OR CAUSE STARTER-GENERATOR FAILURE.

THIS DOCUMENT SUBJECT TO THE CONTROLS AND RESTRICTIONS ON THE FIRST PAGE.

Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I (a)

Copy the information from old identification plate to the replacement identification plate (60). (b) Assemble the replacement identification plate (60) on the stator and housing assembly and attach with four drive screws (70). WARNING: KEEP ACRYLIC COATING AWAY FROM SOURCES OF HEAT, SPARKS AND FLAME. ACRYLIC COATING IS FLAMMABLE.

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WARNING: DO NOT GET ACRYLIC COATING ON YOUR SKIN AND DO NOT BREATHE THE FUMES. ACRYLIC COATING IS A POISONOUS MATERIAL.

(2)

(c) Apply acrylic coating to the replacement identification plate (60). If information plate was damaged, attach a replacement information plate (80) to stator and housing assembly with two drive screws (90).

(3)

Install hi-pot instruction decal (100), if required. WARNING: ISOPROPYL ALCOHOL CAN BE DANGEROUS TO PERSONS. USE ONLY IN AN AREA WITH A GOOD FLOW OF AIR. KEEP AWAY FROM SOURCES OF IGNITION. DO NOT BREATHE THE FUMES. PREVENT SKIN CONTACT. PUT ON PROTECTIVE CLOTHING AND EYE PROTECTION. (a)

(4)

Clean stator and housing assembly surface where decal is to be applied using isopropyl alcohol and a clean, lint-free cloth. (b) Allow the alcohol to dry. (c) Remove the protective backing on the hi-pot instruction decal (100) and install hi-pot instruction decal (100) on stator and housing assembly. Install FAA-PMA label (-110), if required. WARNING: ISOPROPYL ALCOHOL CAN BE DANGEROUS TO PERSONS. USE ONLY IN AN AREA WITH A GOOD FLOW OF AIR. KEEP AWAY FROM SOURCES OF IGNITION. DO NOT BREATHE THE FUMES. PREVENT SKIN CONTACT. PUT ON PROTECTIVE CLOTHING AND EYE PROTECTION. (a) (b) (c)

Clean stator and housing assembly surface where decal is to be applied using isopropyl alcohol and a clean, lint-free cloth. Allow the alcohol to dry. Remove the protective backing on the FAA-PMA label (-110) and install FAA-PMA label (-110) on stator and housing assembly.

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I (5)

Install modification status label (-120), if required.

(a)

Clean stator and housing assembly surface where decal is to be applied using isopropyl alcohol and a clean, lint-free cloth. (b) Allow the alcohol to dry. (c) Remove the protective backing on the modification status label (-120) and install modification status label (-120) on stator and housing assembly. 9. Perform acceptance test on starter-generator CAUTION:

BEFORE ACCEPTANCE TESTING, ATTACH AN UNSERVICEABLE TERMINAL BLOCK TO THE STATOR AND HOUSING ASSEMBLY.

Perform acceptance test procedure on the assembled generator as detailed in the TESTING AND FAULT ISOLATION section. 10. Final Assembly after Acceptance Testing NOTE: Numbers in parentheses ( ) refer to item numbers given in Figure 10001 through Figure 10004 of the ILLUSTRATED PARTS LIST. A. Attach a serviceable terminal block (10004-60) to starter-generator or reconnect the grounding lead. NOTE: A dummy terminal block is used during acceptance testing, or the grounding lead was isolated. (1)

If the grounding lead was disconnected and taped, remove the tape and reconnect the grounding lead.

(2)

Remove dummy terminal block according to instructions in Paragraph 7.B. of the DISASSEMBLY section.

(3)

Attach a terminal block according to instructions in Paragraph 4.A. of this section.

B. Put the attaching hardware onto the terminal block (10004-60). (1) Attach terminal block attaching hardware according to instructions in Paragraph 4.B. of this section. C. Attach terminal block cover (10001-130) to starter-generator if present. (1) Attach terminal block cover according to instructions in Paragraph 4.C. of this section.

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I D. If present, attach QAD mounting kit (10001-10) to starter-generator. NOTE: When a starter-generator has been removed from service, the QAD mounting kit usually remains attached to the engine.

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(1)

Be sure that pilot diameters of mounting adapter and drive end bearing support assembly are fully engaged.

(2)

While holding mounting adapter (10001-50) firmly in place, put rim-clenching clamp (10001-20) over flanges of mounting adapter and drive end bearing support assembly.

(3)

Tighten self-locking nut (10001-30) onto T-bolt (10001-40).

(4)

Torque to 50 lbf.in. (5,7 N · m) to lock the QAD mounting kit to starter-generator.

11. Preparation for shipment/storage Refer to STORAGE section for shipment/storage instructions. 12. Package the generator for shipment or storage. Coat drive spline with grease MIL-G-81322 and wrap the drive spline with protective paper according to MIL-B-121A, Grade A, Type II, Class 1. Put a new o-ring (10001-270) into a suitable container and label container with instructions to user to lubricate and install o-ring on drive shaft prior to installation of the generator into the aircraft. For shipment or storage, seal starter-generator unit in suitable plastic container to protect against corrosion and airborne contaminants. Refer to STORAGE section in this manual for packing materials.

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I

FITS AND CLEARANCES

A. The following paragraphs provide information for determining the acceptability of fits and clearances of the starter-generator. B. Examine the parts for damage. Refer to CHECK section, for details. C. Repair the parts before assembly. Refer to REPAIR section, for details. D. The required torque values to be used during repair and assembly of starter-generator components and attaching parts are listed in Paragraph 2. E. The acceptance limits for starter-generator components and subassemblies are listed in Paragraph 3. 2. Torque Values NOTE: Unless otherwise specified, numbers in parentheses ( ) refer to item numbers on the figure of ILLUSTRATED PARTS LIST. Table 8001 gives information necessary to tighten fasteners to specified torque. Values shown do not include frictional torque caused by self-locking devices or rundown resistance. Frictional torque values must be added to the specified torque. Nuts, bolts, and screws not listed in Table 8001 are to be tightened in accordance with Goodrich Corporation methods and techniques or practices acceptable to your administration as specified in FAR PART 43. Hardware Description

Torque Acceptance Limits

V-Retainer Nut (10001-30) Flat Head Screw (10001-140) Nut (10001-240) Screw (10001-330) Fillister Head Screw (10001-380) Socket Head Screw (10001-400) Screw (10001-460) Speed Pickup Jam Nut (10001-460) Screw or Bolt (10002-100) Screw (10003-60) Stud (10004-50) Stator Effect Codes: C Fillister Head Screw (10004-80) Stator Effect Codes: A,B

50 lbf.in. (5,7 N · m) 7.7 to 10.3 lbf.in. (0,87 to 1,16 N · m) 100 to 120 lbf.in. (11,3 to 13,6 N · m) 18.0 to 24.0 lbf.in. (2,03 to 2,07 N · m) 4.2 to 5.5 lbf.in. (0,47 to 0,62 N · m) 18.0 to 24.0 lbf.in. (2,03 to 2,07 N · m) 4.2 to 5.5 lbf.in. (0,5 to 0,6 N · m) 15 to 25 lbf.in. (1,7 to 2,9 N · m) 27.0 to 36.0 lbf.in. (3,1 to 4,1 N · m) 7.7 to 10.3 lbf.in. (0,87 to 1,16 N · m) 300 to 325 lbf.in (33,9 to 36,75 N · m) 28.0 to 37.8 lbf.in. (3,2 to 4,3 N · m)

Table 8001 - Torque Values

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1. Introduction

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I Hardware Description Socket Head Screw (10004-80) Stator Effect Codes: D,E Fillister Head Screw (10004-80) Stator Effect Codes: C

Torque Acceptance Limits 13.5 to 18.0 lbf.in. (1,5 to 2,0 N · m) 28.0 to 37.8 lbf.in. (3,2 to 4,3 N · m)

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Table 8001 - Torque Values 3. Acceptance Limits Refer to Table 8002 for starter-generator component and subassembly acceptance limits. Paragraph designations in the CHECK column refer to the applicable inspection procedure found in the CHECK section. NOTE: Refer to the IPL for illustrations. Numbers in parentheses ( ) refer to item numbers on the illustration, unless otherwise specified. CHECK Para. Ref.

Nomenclature and IPL Number

Inspect for...

Acceptance Limits

8.B.

Mounting Adapter (50)

Pilot Flange and/or Pilot Bore

8.H.

Drive Shaft (260)

12-tooth drive spline diameter

Model 23032-2452 3.183 to 3.185 in. (80,85 to 80,90 mm) Model 23032-2453 3.247 to 3.249 in. (82,47 to 82,52 mm) 0.757 in. (19,23 mm) min. with gage pin dia. of 0.1094 in (2,779 mm) 0.4813 in. (12,225 mm) min. with gage pin dia. of 0.060 in. (1.52 mm) 0.060 in. (1,52 mm) min.

8.I. 8.J.

Friction Ring (280) Dampener Plate (290)

13-tooth armature mating spline diameter Thickness Thickness Distance between pins of spline teeth

0.038 in. (0,97 mm) min. 0.6547 in. (16,629 mm) max. with gage pin dia. of 0.090 in. (2,29 mm)

Table 8002 - Acceptance Limits

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CHECK Para. Ref.

Nomenclature and IPL Number

8.L.

Bearing and Brush Support Assembly (320) Brush Spring (10002-50)

8.N.

8.O.

Filter Assembly (10002-60) Drive End Bearing Support Assembly (390) Speed Pickup (460)

Inspect for...

Acceptance Limits

Bearing Liner Diameter

1.5747 to 1.5750 in. (39,997 to 40,005 mm) See Figure 8002

Force

Position “A” 2.50 lb (1,13 kg) max. Position “B” 1.75 lb (0,79 kg) min. 0.3 to 0.36 μFd

Capacitance value Bearing Liner Diameter Resistance, lead to ground P/N 23072-1400 Resistance between leads P/N 23072-1280 Resistance between leads

1.5745 to 1.5748 in. (39,992 to 40,000 mm) See Figure 8002 More than 1 MΩ 20 to 45 Ω 95 to 137 Ω

Table 8002 - Acceptance Limits

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I

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Component Maintenance Manual with Illustrated Parts List DC Starter-Generator, 23081 Series I CHECK Para. Ref.

Nomenclature and IPL Number

8.P.

Armature (480)

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Inspect for...

Acceptance Limits

Bearing Journals (A, C) Commutator Diameter (B) Commutator Bar to Bar (Before Refinishing)

0.6691 to 0.6694 in. (16,995 to 17,003 mm) 1.960 in. (49,784 mm) min.

Commutator Bar to Bar and concentricity (After Refinishing) Mica Undercut (before recut)

Mica Undercut (after recut)

Armature Balance Surface Finish Internal Spline Diameter

Bar to Bar: 0.0008 in. (0,020 mm) max. If max is exceeded, do not repair, replace armature Bar to Bar: 0.0001 inch (0,0025 mm) max. T.I.R: 0.0005 inch (0,0127 mm) max. Depth: 0.045 inch (1,143 mm) min. to 0.070 inch (1,780 mm) max. Width: 0.035 inch (0,889 mm) to 0.045 inch (1,142 mm). Depth: 0.050 inch (1,270 mm) min. to 0.070 inch (1,780 mm) max. Width: 0.035 inch (0,889 mm) to 0.045 inch (1,142 mm). See SPD 1001 64 to 100 μin. RMS (1,6 to 2,5 μ RMS) 0.3677 in. (9,345 mm) max. with gage pin dia. of 0.045 in. (1,14 mm)

Table 8002 - Acceptance Limits

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CHECK Para. Ref.

Nomenclature and IPL Number

Inspect for...

Acceptance Limits

8.T.

Terminal Block (10004-60)

P/N: 23032-1518 Capacitance Values B and E

2.0 µFd +50%/-20% 100 VDC/