Document No.

: 80-09-01-1
Original Issue 02 April, 2014
Revision : N/R

O-LEVEL INSTRUCTIONS:

150SG122Q and 150SG122Q-4

STARTER-GENERATORS

PROPRIETARY INFORMATION NOTICE

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

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

ECCN: 9E991
Skurka Aerospace Inc.
4600 Calle Bolero
P. O. Box 2869
Camarillo, CA 93011

Internet: www.skurka-aero.com

The document reference is online, please check the correspondence between the online documentation and the printed version.
 Skurka Aerospace Inc.
4600 Calle Bolero, P. O. Box 2869
Camarillo, CA 93011

LIST OF EFFECTIVE PAGES

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9 N/R
10 N/R
11 N/R
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STARTER GENERATOR 80-09-01-1

150SG122Q Page 2 of 17
O-Level Instructions Rev. N/R
02 April, 2014
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 Skurka Aerospace Inc.
4600 Calle Bolero, P. O. Box 2869
Camarillo, CA 93011

TABLE OF CONTENTS
SECTION PAGE
1 Introduction 4
2 Description and Operation 4
3 Testing and Fault Isolation 5
4 Schematics and Wiring Diagram 5
5 Disassembly 5
6 Cleaning 5
7 Check 5
8 Repair 5
9 Assembly 5
10 Fits and Clearances 5
11 Special Tools, Fixtures, and Equipment 5
12 Illustrated Parts List 5
13 Special Procedures 6

A. Brush Inspection Procedures 6

B. Brush Replacement Procedures 11
C. Dampener Check for 150SG122Q Type Units 13
D. Dampener Check for 150SG122Q-4 15
E. Drive Shaft Spline Inspection 150SG122Q and
16
150SG122Q-4
14 Removal 16
15 Installation 16
16 Servicing 16
17 Storage 17
18 Rework 17

80-09-01-1 STARTER GENERATOR

Page 3 of 17 150SG122Q
Rev. N/R O-Level Instructions
02 April, 2014
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 Skurka Aerospace Inc.
4600 Calle Bolero, P. O. Box 2869
Camarillo, CA 93011

1. INTRODUCTION

This O-Level manual is for the Skurka Aerospace Inc. (SAI) 150SG122Q and
150SG122Q-4 Starter Generator models. The 150SG122Q-4 is the same as the
150SG122Q except for the items listed in the following table:

150SG1009-16 Brush, Infinity, GR-1

150SG1093-2 Wave Spring
150SG1391 Spring Holder
150SG1107-9 Hi-Flow Fan Assy
150SG1092-31S Name Plate

150SG122Q & 150SG122Q-4 LEADING PARTICULARS

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

2. DESCRIPTION AND OPERATION

The Starter-Generator is used as an engine-driven source of DC power in 28 volt

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

Except for brush inspection, brush replacement, and dampener adjustments, aircraft
airworthiness is maintained by replacement of the starter generator. Starter
generators requiring maintenance beyond brush inspections and dampener
adjustments should be sent to a qualified repair/overhaul facility for proper
disposition. Starting duty cycle limitations are addressed in the aircraft flight manual.
STARTER GENERATOR 80-09-01-1
150SG122Q Page 4 of 17
O-Level Instructions Rev. N/R
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 Skurka Aerospace Inc.
4600 Calle Bolero, P. O. Box 2869
Camarillo, CA 93011

3. TESTING AND FAULT ISOLATION (N/A)

4. SCHEMATICS AND WIRING DIAGRAM (N/A)

5. DISASSEMBLY (N/A)

6. CLEANING (N/A)

7. CHECK (N/A)

8. REPAIR (N/A)

9. ASSEMBLY (N/A)

10. FITS AND CLEARANCES (N/A)

11. SPECIAL TOOLS, FIXTURES, AND EQUIPMENT (N/A)

12. ILLUSTRATED PARTS LIST (N/A)

80-09-01-1 STARTER GENERATOR

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Rev. N/R O-Level Instructions
02 April, 2014
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 Skurka Aerospace Inc.
4600 Calle Bolero, P. O. Box 2869
Camarillo, CA 93011

13. SPECIAL PROCEDURES

A. BRUSH INSPECTION PROCEDURES

GENERAL INFORMATION

Repeated brush inspections of Starter-Generators can result in rapid brush wear

and even hang-ups. When inspecting brushes, many operators will slide the
brush cover off the back of the generator causing the brush leads to be
misplaced.

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

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

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

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

At the manufacturer recommended check, remove the generator for brush

inspection. Remove only the shortest brush to measure the remaining
brush life. Do not remove more than one brush, as brush seating will be affected.
Your brush inspection time will be obtained by measuring three different
generators and using the shortest brush length, as the basis for determining
your fleet wide brush life. Filling in the attached form, will show you how to
determine remaining brush life.

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

Brush Recommended Hours

For First Check
150SG1009-5 300
150SG1009-16 600

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O-Level Instructions Rev. N/R
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 Skurka Aerospace Inc.
4600 Calle Bolero, P. O. Box 2869
Camarillo, CA 93011

A. BRUSH INSPECTION PROCEDURES (cont’d)

Perform brush inspection as follows:

a. Remove fan cover.

b. Remove brush screw and its two washers (flat and locking) from the
shortest brush set.

CAUTION
DO NOT DROP WASHERS INSIDE
STARTER GENERATOR.

c. Use a brush spring lifter or other suitable tool to gently release the brush
springs and remove the single brush set.

d. Visually inspect the condition of the commutator surface. If severe

damage (i.e., arcing, pitting etc.) is noted, then replace starter generator on
the aircraft.
e. Measure from the wear indicator line on the side of the brush to the end of
the brush following the figures for Brush Length on the Brush Life
Calculation Worksheet at the end of this section.

f. Use the steps in the Brush Life Calculation Worksheet in this section to
calculate remaining brush life.

CAUTION
DO NOT SNAP THE BRUSH SPRINGS
INTO PLACE DURING REASSEMBLY.
THIS CAN CAUSE DAMAGE TO THE
BRUSH SET AND DECREASE BRUSH
LIFE.

g. If sufficient hours remain on brushes, reinstall brush set in reverse order of

items a – c. Refer to Figure 1 for proper brush leads position. If there are
not sufficient hours remaining, then replace all four brush sets on starter
generator in accordance with section 13-B.

h. Reinstall fan cover and tighten screws.

80-09-01-1 STARTER GENERATOR

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Rev. N/R O-Level Instructions
02 April, 2014
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 Skurka Aerospace Inc.
4600 Calle Bolero, P. O. Box 2869
Camarillo, CA 93011

Spread brush leads

over brush springs
pushing them down
against top of brush

Top of slot in
brush is maximum
wear point

Figure 1
Positioning of Brush Leads

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

STARTER-GENERATOR SAMPLE BRUSH LIFE CALCULATION PROCEDURE

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

SAMPLE CALCULATION
Date: 01/09/12

Generator P/N: 150SG122Q Serial No.:

Maximum wear length of a new 150SG1009-5 Brush (0.520)

Maximum wear length of a new 150SG1009-16 Brush (0.620)

Calculate brush life left as per example below for 150SG1009-5 brush:

Maximum wear length of a new 150SG1009-5 Brush (0.520) (1) .520

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

TOTAL BRUSH WEAR (3) .220

Hours brush has operated: (4) 300

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

Generator Operating 429 + 300 = 729

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

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

New Brush 150SG1009-5 Shortest Brush from Generator

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

80-09-01-1 STARTER GENERATOR

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Rev. N/R O-Level Instructions
02 April, 2014
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 Skurka Aerospace Inc.
4600 Calle Bolero, P. O. Box 2869
Camarillo, CA 93011

STARTER-GENERATOR BRUSH LIFE CALCULATION WORKSHEET

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

Date:

Generator P/N: Serial No.:

Maximum wear length of a new 150SG1009-5 Brush (0.520)

Maximum wear length of a new 150SG1009-16 Brush (0.620)

Calculate brush life left as per example below:

Maximum wear length of a new Brush (0.520 or 0.620) (1)

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

TOTAL BRUSH WEAR (3)

Hours brush has operated: (4)

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

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

Generator Operating Hours: + =

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

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

New Brush 150SG1009-5 Shortest Brush from Generator

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

STARTER GENERATOR 80-09-01-1

150SG122Q Page 10 of 17
O-Level Instructions Rev. N/R
02 April, 2014
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 Skurka Aerospace Inc.
4600 Calle Bolero, P. O. Box 2869
Camarillo, CA 93011

B. BRUSH REPLACEMENT PROCEDURES

1. Remove starter generator from aircraft.

2. Remove all four brush sets in accordance with steps 13A, items a – c.

3. Visually inspect commutator surface. If severe damage (i.e., arcing, pitting etc.) is noted,
then replace starter generator on the aircraft.

4. Install new brushes in reverse order of steps 13A, items a – c.

CAUTION
DO NOT SNAP THE BRUSH SPRINGS
INTO PLACE DURING REASSEMBLY.
THIS CAN CAUSE DAMAGE TO THE
BRUSH SET AND DECREASE BRUSH
LIFE.

5. Perform brush seating of starter generator as follows:

a. Mount the generator securely on a bench in a horizontal position. Motorize

the starter generator by connecting the positive lead of a DC supply to
starter-generator terminals B+ and A. Connect the negative lead of the DC
supply to starter-generator terminal E-. Adjust the DC supply voltage to 15
volts. This will enable the machine to run at approximately 3000-6000
rpm’s. The DC input amperes should be approximately 20-40 amperes.

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

c. An acceptably seated brush should indicate 85-100% brush contact in the

direction of rotation and at least 85% parallel to the armature shaft. Continue
running the generator to achieve this seating criteria, if brush seating is
unacceptable. Refer to Figure 2 for brush seating visual guideline.

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

NOTE: The presence of a film on commutator does not indicate the degree
of brush seating. Only a visual inspection of the brush contact areas
indicates proper brush seating.

80-09-01-1 STARTER GENERATOR

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Rev. N/R O-Level Instructions
02 April, 2014
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 Skurka Aerospace Inc.
4600 Calle Bolero, P. O. Box 2869
Camarillo, CA 93011

e. Once the brushes have achieved the correct seating criteria, reinstall fan
cover and tighten screws.

Figure 2

STARTER GENERATOR 80-09-01-1

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O-Level Instructions Rev. N/R
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 Skurka Aerospace Inc.
4600 Calle Bolero, P. O. Box 2869
Camarillo, CA 93011

C. DAMPENER CHECK FOR 150SG122Q TYPE UNITS

If the starter-generator is without the -004 marking applied as shown in Figure 5

and Figure 6 please refer the starter generator to an authorized repair center for
accomplishment of SB 150SG155 .

If a -004 is applied to the nameplate go directly to Section 1 to check adjustment.

Section 1 - Check Radial Movement

a. Check for radial movement of the splined shaft to determine if the damping system
is not in a locked position. See Figure 3. If needed, realign the assembly as
shown in Figure 4.

b. If the assembly does not move, is “locked” or moves very easily please refer the
starter generator to an authorized repair facility to install and adjust properly per
SB 150SG155.

NOTE: A locked damping system is indicated when disk “A” in Figure 4 cannot be
moved with respect to disk “B” when checking for radial movement

Figure 3
Radial Movement Check

80-09-01-1 STARTER GENERATOR

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

Compliant Alignment of
Shaft/Dampener Assembly

Non-Compliant Alignment of
Shaft/Dampener Assembly

Figure 4
Alignment of Starter-Generator Dampener Plate

STARTER GENERATOR 80-09-01-1

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

Figure 5

(Aircraft Parts Corp.)

Figure 6
I.D. Plate
(Skurka Aerospace Inc.)

D. DAMPENER CHECK FOR 150SG122Q-4

a. Check for radial movement of the splined shaft to determine if the damping system is
not in a locked position. See Figure 3. If needed, realign the assembly as shown in
Figure 4.

NOTE: A locked damping system is indicated when disk “A” in Figure 4 cannot be
moved with respect to disk “B” when checking for radial movement

80-09-01-1 STARTER GENERATOR

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Rev. N/R O-Level Instructions
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 Skurka Aerospace Inc.
4600 Calle Bolero, P. O. Box 2869
Camarillo, CA 93011

E. DRIVE SHAFT SPLINE INSPECTION 150SG122Q AND 150SG122Q-4

a. Check drive shaft splines for general condition and wear. Wear limit is 0.696 inches
minimum over two 0.0864 inch diameter pins. Replace starter generator if condition
or wear are unsatisfactory.

Figure 7 Spline Measurement Diagram

14. REMOVAL

For removal information, see aircraft maintenance manual.

15. INSTALLATION

For installation information, see aircraft maintenance manual.

16. SERVICING

a. For overhaul interval limitations, consult the aircraft maintenance manual.

b. Recommended field service on starter-generator units is limited to brush

inspection/replacement, spline dimensional check and dampener system inspection
only. All other repair and/or overhaul activity should be carried out by an authorized
repair station.

c. Except for brush inspection/replacement, spline dimensional check and dampener

system inspection aircraft airworthiness is accomplished through removal and
replacement of the starter-generator.

STARTER GENERATOR 80-09-01-1

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O-Level Instructions Rev. N/R
02 April, 2014
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 Skurka Aerospace Inc.
4600 Calle Bolero, P. O. Box 2869
Camarillo, CA 93011

17. STORAGE

If the starter generator has been in storage for longer than 36 months, it should not
be installed on an aircraft. It must be returned to a repair/overhaul facility for bearing
change, testing and if necessary repair.

18. REWORK (N/A)

80-09-01-1 STARTER GENERATOR

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