TM 55-2925-236-40

DEPARTMENT

OF

THE

ARMY

TECHNICAL

MANUAL

GS MAINTENANCE MANUAL

STARTER
PART

GENERATOR

NO.

30E20-61-A

(BENDIX)

HEADQUARTERS,

DEPARTMENT
MAY 1969

OF

THE

ARMY

WARNING
PRECAUTIONARY DATA
Personnel performing instructions involving operations, procedures, and
practices which are included in this technical manual shall observe the
following instructions. Disregard of these warnings and precautionary
information can cause serious injury, death, or an aborted mission.
PRECAUTIONARY DATA DEFINITION

PRECAUTIONARY DATA PRESENTATION.

CLEANING SOLVENT

Use solvent in a well-ventilated area. Avoid inhaling solvent fumes. Do not allow solvent to contact
skin as burns may occur.

TM 55-2925-236-4
C5
HEADQUARTERS
DEPARTMENT OF THE ARMY
WASHINGTON, D. C., 19 December 1988

CHANGE
No.

GS Maintenance Manual
Including Repair Parts and Special Tools Lists
STARTER GENERATOR
PART NO. 30E20-61-A
NSN 2925-00-927-9483
(BENDIX)
TM 55-2925 -236-40,2 May 1969, is changed as follows:

Cover and page i. Title is changed as shown above.

Page 1-1, para. b. 7th and 8th lines. ATTN: AMSAV-R-M, P. O. Box 209, St. Louis, Missouri 63166 i
changed to read ATTN: AMSAV-MMD, 4300 Goodfellow Blvd., St. Louis, Mo. 63120-1798.
Page 1-1, para. 1-3, 2nd and 4th lines. TM 38-750 is changed to read DA PAM 738-751.
Page 1-2, para. 1-7. Add after the first sentence: For general technical information on preparation]
for storage and shipment refer to TM 55-1500-204-25/1 and TM 743-200-1.
Page 2, Change 2, Figure 3-2, Index Nos 11, 18, and 25. Add alternate part number MS2503-150
(96906).

Page 2-2, Change 3. The following item is added to Table 2-3:

Item No.

20

Nomenclature
Epoxy Lead Putty

Number Specification
Devon L. (FMC 16059)

Page 3-1c. (1) Delete the last sentence - Do not attempt to remove terminals (4, 11, 18, or 25) unless
damaged.

Page 3-1. Add note following paragraph 3-16. (8): NOTE. Replace capacitor lead terminals with alter
nate part number for indexes 11, 18, 25 (Figure 3-2). These leads will be reconnected to brush holders (28)
Figure 3-2 with screws (5), Figure 3-1.
Page 3-3, Figure 3-1, Index No. 19. Part Number 59NTE2834-054 is changed to read F52NTE2834054.

Page 3-11, para. 3-12a. (1) The note is superseded as follows: NOTE. Terminals of capacitors 6, 13
20, and 27 will be secured to electrical contact holders (28) when the brushes are installed, para. b. (18).
Page 3-12, para. 3- 12b. (14) is rescinded.

TM 55-2925-236-40
Page 3-12, para. 3-12b. (14) is added after para. 3-12b. (13). (14) Use setting gage (1106353-1) to
measure and check the compressed length of compression spring (21). This assembled length should be
1.100 inches. Insert the gage size plug into the fan housing end of the fan (18) and install washer (20) and
self-locking nut (19). Insure washer (20) and self-locking nut (19) are seated flat on the shoulder of the gage
size plug. Seat the setting gage on the washer and adjust gage indicator to read zero. Remove the setting
gage, self-locking nut, washer, and gage size plug. Install front plate (23) on drive shaft assembly (22) and
insert the shaft through armature assembly (39). Install fan (18) on drive shaft assembly (22). Install compression spring (21), washer (20), self-locking nut (19) and the setting gage. Using spline wrench (QB80059-3)
to keep the shaft from turning, retighten self-locking nut (19) with the 7/16 inch (12 point thin wall) socket
wrench until the setting gage again indicates zero, plus or minus 0.005 inch. Remove the setting gage.
NOTE: Insure indicator makes at least one full revolution prior to zeroing to insure contact is made between plunger and washer.
Page 3-12 para. 3-12b. (18) is rescinded.
Page 3-12 para. 2-12b. (18) is added after para 3-12b. (17). (18) Align the terminals of capacitors (6, 13,
20, and 27, Figure 3-2) over the threaded holes for brush cap screws (5, Figure 3-1). Install split-type
brushes ((4, Figure 3-1) in brush holders, and secure, along with capacitor terminals, using eight screws (5),
eight lockwashers (6), and eight plainwashers (7). Tighten the screws to a torque of 35 to 50 pound-inches.
Page 4-3, para. 4-5b. Is rescinded.
Page 4-3, para. 4-5b. Is added after para. 4-5a. b. Disconnect all capacitor terminals using insulation
breakdown test set 13700-lC, apply 250 present volts, 60 CPS for one minute between each terminal post
and the frame (ground).
Page 4-3, para. 4-5c, 1st line. Is changed to read 1.5.
Page 6, change 1.

NSN 5310-804-0075 is rescinded.

Page 6, change 1. Part Number EB054 is changed to read F52NTE2834-054.

Page A-1. TM 38-750 is rescinded.
Page A-1. Add before MS 33540 (ASG) DA PAM 738-751 Functional Users Manual for the Army
Maintenance Management Systems Aviation (TAMMS-A).
Page A-1. TM 55-405-10 is rescinded.
Page A-1. Add after QQ-S-571, TM 743-200-1 Storage and Materials Handling.
Page A-1. Add after TM 743-200-1, TM 55-1500-204-25/ 1, General Aircraft Maintenance Manual.

TM 55-2925-236-4

By Order of the Secretary of the Army:

CARL E. VUONO
General, United States Army
Chief of Staff

Official:
R. L. DILWORTH
Brigadier General, United States Army
The Adjutant General

DISTRIBUTION :
To be distributed in accordance with DA Form 12-31, AVUM and AVIM Maintenance
requirements for AH-1G Helicopter, Attack and UH-1C, UH-1H and UH-1M Helicopter,
Utility.

*U.S.Goverment Printing Office;1989-654-030/00124

TM 55-2925-236-40
HEADQUARTERS
DEPARTMENT OF THE ARMY
W ASHINGTON , D. C., 2 May 1969

TECHNICAL MANUAL

No. 55-2925-236-40
GS Maintenance Manual
STARTER GENERATOR
PART NO.30E20-61-A
(BENDIX)

TABLE OF CONTENTS
Page

LIST OF ILLUSTRATIONS ----------------------------------------------------------------------------- ii

SECTION I. INTRODUCTION ____________________________________________________________________________ 11
1-1. General Information --------------------------------------------------------------------------------------------------------------- 1-1
12. Purpose of Equipment ___________________________________ 1-1
1-3. Equipment Records _____________________________________________ 1-1
1-4. Description ____________________________________________________________________________ 12
1-5.
Leading
Particulars-------------------------------------------------------------------------------------------------1-2
1-6. Painting Requirements _________________________________________________________________ 12
17. Preservation, Packaging, Packing, and Marking Requirements _____________________________ 1-2
I I . TEST EQUIPMENT, SPECIAL TOOLS, AND MATERIALS ___________________________________ 2-1
2-1. Test Equipment ________________________________________________________________________ 2-1
2-2. Special Tools __________________________________________________________________________ 2-1
2-3. Consumable Materials ___________________________________________________________________ 2-1
I I I . GENERAL SUPPORT MAINTENANCE ____________________________________ 3-1
3-1. Disassembly-------------------------------------------------------------------------3-1
3-2. Inspection Requirements ________________________________________________________________ 3-6
3-3. Cleaning _______________________________________________________________________________ 37
3-4. Repair
or
Replacement---------------------------------------------------------------------------------------3-8
3-5. A r m a t u r e A s s e m b l y _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ 3 - 8
3-6. Resurfacing the Commutator----------------------------------------------------------------------------------------------------------- 3-8
3-7. Metalilizing Bearing Bores-------------------------------------------------------------------------------------------------------------- 3-9
3-8. S o l d e r i n g
___________________________________________
3-9
Replacement _______________________________ 3-10
3-9. S l e e v i n g
3-10. Capacitor Mounting----------------------------------------------------------------------------------------------------------------- 3-10
311. L u b r i c a t i o n
_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _________________________________________________ 311
3-11
3-12. Reassembly___________________________________________________________________
IV. FINAL TEST PROCEDURES _______________________________________________________________ 4-1
4-1
4-1. General---------------------------------------------------------------------------------------------------------------------------------------4-2. Flashing the Field---------------------------------------------------------------------------------------------------------- 4-2
4-3. Brush Seating --------------------------------------------------------------------------------------------------------------- 4-2
4-4. Stall Torque Test----------------------------------------------------------------------------------------------------------- 4-2
4-5. Dielectric Strength --------------------------------------------------------------------------------------------------------- 4-3
4-6. Final Tests----------------------------------------------------------------------------------------------------------------------------- 4-3
APPENDIX A. REFERENCES--------------------------------------------------------------------------------------------------------------------------------------- A-1

TM 55-2925-236-40

LIST OF ILLUSTRATIONS
Number

1-1.
1-2.
3-1.
3-2.
3-3.
3-4.
3-5.
3-6.
3-7.
4-1.
4-2.

ii

Title

Page

Three-quainter View, Starter Generator, Type 30E20-61-A --------------------------------------------- 1-1

Preservation, Packaging, Packing and Marking Requirements _________________________________________ 1-3
Starter Generator, Exploded View -------------------------------------------------------------------- 3-3
End Bell Assembly, Exploded View ------------------------------------------------------------------------------------------- 3-5
Fabrication of Diamond-tipped Cutting Tool _________________________________________________________ 3-9
Mounting of Commutator Cutting Ted _______________________________________________________________ 3-9
Fabrication of Carboloy-tipped Cutting Tool __________________________________________________________ 3-10
Capacitor Mounting Position __________________________________________________________________________ 3-11
Starter Generator, Schematic Diagram-------------------------------------------------------------------------------------------------------3-11
Typical Brush Sealing ----------------------------------------------------------------------------------------------------------------------------4-2
Stall Torque Curve _________________________________________________________________________________ 4-4

TM 55-2925-236-40

SECTION I
INTRODUCTION
1-1. General information

a. This technical manual comprises overhaul

instructions for starter generator, part no.
30E2061A (figure 11 ). This equipment is
manufactured by The Bendix Corporation, Electric Power Division (83298), Eatontown, New
Jersey 07724. Sections I through IV of this technical manual contain instructions only for the
basic type.
b. Report of errors, omissions, and recommendations for improving this publication by the individual user is encouraged. Reports should be
submitted on DA Form 2028 (Recommended
Changes to DA Publications) and forwarded direct to Commanding General, US. Army Avia-

tion Systems Command, ATTN: AMSAV-RM,

P. O. Box 209, St. Louis, Missouri 63166.
12. Purpose of Equipment
The starter generator is used to start the engine, and generate the electrical power required
for 28-volt aircraft electrical systems.
1-3. Equipment Records

The Army equipment record system and procedures established in TM 38750 apply to this
equipment. The applicable forms as required by
TM 38750 shall be used.

Figure 1-1. Three-quarter View, Starter Generator Part No, 30E20-61-A.

1-1

TM 55-2925-236-40
Table 1-1. Leading Particulars

1-4. Description

The starter generator is a brush-type rotating

machine capable of delivering 30 volts dc at a
rated current of 300 amperes, when driven at a
speed within its rated speed range. The unit is
self-cooled by means of an integral fan rotating
with the output shaft. A terminal board is
mounted on the housing to facilitate external
connections. Slotted mounting holes are provided
for ease of installation on the engine.

Item

Characteristic

Rated Voltage
Rated current
Rated speed
Minimum Speed for Regulation
Maximum Speed for Regulation
Cooling Air
Weight
Diameter (Housing)
Length (Housing)
Outside Spline
Mounting Bolt Circle Diameter
No. of Mounting Slots
Rotation (Viewing Drive. End)

30 v
300 amp
4000-8600 rpm
4400 rpm
10,000 rpm
40C (max)
47 lb (approx)
6-1/2 in.
10-7/8 in.
16 teeth
5.000 in.
6
Counterclockwise

1-5. Leading Particulars

1-6. Painting Requirements

Refer to table 1-1 for leading particulars of

the starter generator.

Repainting or touching up surfaces if required

shall be done in accordance with table 1-2.

Table 1-2. Painting Requirement

Item Name

Fan Housing

End Bell

Fig. No.

3-1

.3-2

Index No.

16

84

Paint Type and

Specification

MIL-P-8585, Primer
MIL-E-5557, Type I,
Color Black, Enamel
MIL-P-8585, Primer
MIL-E-5557, Type I,
Color Black, Enamel

Method of
Application

No.of
Coats

Notes

Brush
Brush

1
2

Paint Flange and Rear

Face Only

Brush
Brush

1
2

No Paint or Prime in
Area Covered by Brush
Access Cover or in
Bearing Mounting Surface

1-7. Preservation, Packaging, Packing and Marking Requirements

Preservation, packaging, packing and marking shall be in accordance with figure 1-2.

1-2

TM 55-2925-236-40

Figure 12. Preservation, Packaging, Packing and Marking Requirements.

1-3

TM 55-2925-236-40

SECTION II
TEST EQUIPMENT, SPECIAL TOOLS, AND MATERIALS
2-1. Test Equipment

Refer to table 21 for a list of test equipment required to perform the procedures described in
this manual.
Table 2-1. Test Equipment Required
Part, Model
or Mil Des

Nomenclature

FML

Technical Description

Model 40B
1650A
13700-1C

06365
24655
19315

Balancing Machine
Capacitance Bridge
Insulation Breakdown Test Set

70855

99664

Electrical Test Stand

7199-1

99664

Aircraft Generator Test Stand

Type B-1

99664

Starter Torque Tester

Used to Balance Armature Assembly.

Used to Check Capacitor Values.
Used to Perform Insulation Breakdown
Tests.
Used to Provide Load Conditions for
Performance Testing.
Used for Performance Testing of
Starter Generator.
Used to Test Starter Generator Torque.

Note. Equivalent teat equipment may be used.

Table 2-2. Special Tools Required - Continued

22. Special Tools

Refer to table 22 for a list of special tools required to perform the procedures described in
this manual.
Table 2-2. Special Tools Required
Nomenclature

QB80059-3
QB80277-1
1106005-1
1106006-1
1106023-1
1106140-3
1106149
1106187

Spline Wrench
Brush Spring Hook
Brush Box Aligner Pilot
Brush Box Aligner
Bearing Puller
Spring Scale
Rotor Stand
Generator Overhaul Stand

Part, Model
or Mil Des

1106269
1106353-1
1106354-1

Nomenclature

Bearing Retainer Puller

Setting Gage
Interface

Note. All tools listed above are manufactured by The

Bendix Corporation, Electric Power Division, Eatontown,
New Jersey. Equivalent tools may be used.

2-3. Consumable Materials

Refer to table 2-3 for a list of all consumable
materials required to perform the procedures described in this manual.

Table 2-3. Consumable Materials

Item No.

1
2
3
4
5
6
7
8
9

Nomenclature

Trichlorethylene
Solvent
Lint-free Cloth
Lubricating Oil
Corrosion Preventive
Shellac
Dentured Alcohol
Soft Solder
Epoxy Resin (red)

Specification
Number

MIL-T-7003
P-D-680
CCC-C-440
MIL-L-7870
MIL-C-4339
TTS-271
MIL-A-6091
MIL-S-6872
Type CR-1056B
(FMC 72688)

Title

Trichlorethylene, Stabilized Degreasing

Dry Cleaning Solvent
Cloth, Cotton, Cheesecloth, Bleached and Unbleached
Lubricating Oil, General Purpose, Low Temperature
Corrosion Preventive, Soluble Oil
Shellac, Dry
Alcohol, Ethyl, Specially Denatured, Aircraft
Soldering Process, General Specification for

2-1

TM 55-2925-236-40
Table 2-3. Consumable Materia1s-Continued
Item No.

Nomenclature

Number
Specification

10

Epoxy Reactor (tan)

11

Spline Lubricant.

12
13

High Temperature Lubricating

Grease (Alternate for item 11)
Red Glyptal Lacquer

14

Sealant, Grade C

Part No. 1201

(FMC 04314)
MIL-S-22473

15

Sealant, Grade A

MIL-S-22473

16

LockWire

MS20995C32-6

2-2

Type CC1056A
(FMC 72688)
Pioneer No. 31
(FMC 83298)
MIL-G-3545

Title

Lubricating Grease, High Temperature

Sealing, Lock and Retaining Compounds, Single

Component
Sealing, Locking and Retaining Compounds, Single
Component

TM 55-2925-236-40

SECTION Ill
GENERAL SUPPORT MAINTENANCE
3-1. Disassembly

a. General.
(1) Disassemble the starter generator to the
extent necessary for repair by following the illustrated parts breakdowns and the exploded
views (figures 3-1 and 3-2), as described in
paragraphs b and c.
(2) The index numbers are assigned in the
order of disassembly, except that attaching parts
are listed immediately following the parts they
attach.

b. Starter Generator.
(1) Secure the starter generator to interface
(1106354-1) and mount both on generator overhaul stand (1106187).
(2) Loosen screw (2, figure 3-1) enough so
that brush access cover assembly (1) can be
slipped off from the fan end of the housing and
stator (53).
Note. The last two threads of screws (2) have
been distorted to captivate nut (3).
(3) Remove eight screws (5), eight lock
washers (6), and eight washers (7). Using brush
spring hook ( QB802771, lift up the brush
springs, and remove eight split-type brushes (4).
Discard the brushes.
(4) Remove three self-locking nuts (8) and
three washers (9), and disconnect capacitor terminals from the B + and E- studs.
(5) Remove two self-locking nuts (10) and
two washers (11), and disconnect the stator terminals from the A+ and D terminal studs.
(6) If visual inspection indicates damage,
remove capacitors (15) with terminals (12
through 14).
(7) Remove six screws (17) and fan housing (16). Hold the spline of drive shaft assembly
(22) with spline wrench (QB80059-3), and using
a 7/16-inch (12-point thin wall) socket wrench,
remove self-locking nut (19), washer (20), fan
(18), and compression spring (21), Remove drive
shaft assembly (22), and front plate (23).

(8) Remove three screws (24), three lock

washers (25), and three washers (26) to free
capacitor leads,
(9) Using retaining ring pliers, remove lock
rings (27 and 38). Remove outer dirt slingers
(35 and 43). Remove four screws (28) and four
lock washers (29) to free bearing retainer (37).
(10) Remove four screws (41) to free bearing retainer (45), Remove outer race bearing
retainer (40).
(11) Remove six screws (31), six lock washers (32), and six special washers (33), Press
armature assembly (39), with attached end bell
assembly (30), out of housing and stator (53).
Note. Use bearing retainer puller (1106269)
only if there is bearing or other internal failure.

(12) Using bearing retainer puller (1106269),

press armature assembly (39), with ball bearings (36 and 44) attached, out of end bell assembly (30). Refer to paragraph c below for disassembly instructions of the end bell assembly.
(13) Using bearing puller (1106023-1), pull
ball bearings (36 and 44) off the shaft of armature assembly (39). Discard the ball bearings at
each overhaul.
(14) Remove inner dirt slingers (35 and 43)
and bearing retainers (37 and 45). Remove four
bushings (42) from housing and stator (53).
(15) Remove four screws (47) and identification plate (46).
(16) Remove two screws (50), two washers
(51), terminal board (49), and terminal board
insulators (52 ) if they are damaged.
c. End Bell Assembly.
(1) Remove capacitors (6, 13, 20, and 27,
figure 32) if physical damage is indicated, by
removing two screws (1), two lock washers (2),
and two washers (3), self -locking nuts (7, 14,
and 21), washens (8, 15, and 22), washers (9,
16, and 23), and screws (10, 17, and 24). Do not
attempt to remove terminals (4, 11, 18, or 25)
unless damaged.

3-1

TM 55-2925-236-40

Figure 32. End Bell Assembly, Exploded View.

LEGEND FOR FIGURE 3-2
I\d~

Part Number

3-2-

1543956
1545592-1

-1
-2
-3

819106-110
MS35833-41
890487

-4
5
-6

1329221
15328274
1102113-2
154559%3

-7
-8
-9

MS21044NO6
33338
AN960-6L

Description

END BELL ASSEMBLY (See item 30, fig. 3-1 for nha)
. CAPACITOR ASSEMBLY
(ATTACHING PARTS)
. SCREW, fil h, cad. PI st.1, No. 6-32 x 5/16 in. lg
. WASHER, Lock
. WASHER, Flat, sst, for No. 6 screw
_-_*___
. . TERMINAL
. . CLAMP, hp
. . CAPACITOR, Fixed, 40 uf +20 pet -15 pet, 75 V de
. CAPACITOR ASSEMBLY
(ATTACHING PARTS)
. NUT, Self-locking
. WASHER, Flat, cad. pl stl, for No. 6 screw
. WASHER

QtY Per Assy

Ref
2
2
2
2
1
1
1
1
1
1
1
3-5

TM 55-2925-236-40
hdnd
Pert

Numker

Q& Per Amy

Desmbt.ion

3-2-10

MS35265-31

-11
12
-13

34110
1532827-19
1545592-3
121 P104O1R5S2

-14
-15
16
-17

MS21044NO6
333188
AN960-CL
MS35265-31

-18
-19
20

34110
1532327-20
69F196G3

. SCREW
*
-----. . TERMINAL, Solderless (00779) (33298, part No. 11022323-4)
. . CLAMP, Loop
. . CAPACITOR, Fixed, 0.10 uf, 150 V dc (56289) (83298, part No. 1111769+
. CAPACITOR ASSEMBLY
(ATTACHING PARTS)
. NUT, Self-locking
. WASHER, Flat, cad. PI S@ for No. 6 screw
. WASHER
. SCREW
_--*--. . TERMINAL, solderless (00779) (83298, part No. 1102238-tj
. . CLAMP, LOOp
. . CAPACITOR, Fixed, 4.7 uf A 10 pet, 100 V dc (06001) (33298, part No.
1545591-1)
. CAPACITOR ASSEMBLY
(ATTACHING PARTS)
. NUT, Self-locking
. WASHER, Flat, cad. pl stl, for No. 6 screw
. WASHER
. SCREW
*
-----. . TERMINAL, Solderless (00779) (83298, part No. 1102238-4)
. . CLAMP, hop
. . CAPACITOR, Fixed, 0.47 uf &20 pet, 50 V dc (56289) ($33298, part No.
1545590)
. HOLDER, Electrical contact
(ATTACHING PARTS)
SCREW, Cap, hex hd, 5/16-18 x 1-1/8 in. lg
: WASHER, Lock
. WASHER, Flat, cad, pl sM, for 5/16 in. screw
. WASHER, Insulating
. TUBE, Insulating
___*--
. BELL, End

154559%t
-21
22
-23
-24

MS21044NO6
33338
AN960-6L
MS35265-31

-25
-26
-27

34110
1532627-19
121 P4740R5S1

-28

1542776

-29
-3$0
-31
-32
-33

1543503
MS35338-45
867491
1543622
1328928

-34

1543976

(2) Remove four screws (29), four lock.

washers (30), four washers (31), sixteen insulating washers (32), and four insulating tubes
(33), from end bell (34). Do not remove four
electrical contact holders (28 ) unless damage is
visible.

1
1

1
1
1
1

1
1
1
1
1
1
1
1
1
1
1
1
1
1
4
4
4
4
16
4

Caution: Do not attempt to remove the

cast-in bearing liner from end bell (34).
3-2. Inspection Requirements
a. Refer to table 31 for detail inspection requirements for components of the starter generator.

Table 3-1. Detail Inspection Requirements

Fig.
No.

Index No.

3-1

15

3-2
3-1

6,13,20,27
21

Compression Spring

3-1

22

Drive Shaft Assembly

3-1

39

Armature Assembly

3-6

Nomenclature

Capacitor

Inspection Category

Cracks, Leaks, Damaged

Insulation
Electrical Rating
Cracks, Distortion
Load at Compressed
Length of 1.100 in. to be
180 to 200 lb
Cracks
Commutator Undercut to
0.030 in. Wide by 1/32
in. Deep

Method of Inspection

Remarks

Visual
*1650A
Visual

Refer to Parts List

for Ratings

Magnetic Particle Para 32b

(Specification
MIL-I-6868)

TM 55-2925-236-40
Table 3-1. Dental Inspection Requirements - Continued
Fig
No.

Nomenclature

Index No.

3-1

Inspection Category

Housing and Stator

53

3-2

28

Electrical Contact Holder

3-2
3-2

33
34

Insulating Tube
End Bell

Commutator Contact
Surface
Cracks, Damaged Insulation, Damaged Conductors
Insulation Breakdown 300
volts, 60 cps for 1 sec
Between Commutator
Bars and Shaft
(Ground)
Static and Dynamic
Balance within 0.020
oz in.
Bearing Surfaces
Cracks, Damaged Insulation
Bearing Bore Worn
Insulation Breakdown 300 volts, 60 cps for 1
sec Between Terminals
and Housing (Ground)
Cracks, Distorted Springs
Spring Pressure to be 46
to 52 oz when Spring is
Just Lifted Beyond
Brush Position
Cracks
Cracks, Damaged Threads
Bearing Bore Worn

Method of Inspection

Remarks

Para 3-2c

Visual
Visual

*13700-1C

Para 3-5e

*Model 40B

Table 3-2
Visual
Para 3-2d
*13700-1C

Visual
*1106140-3

Visual
Visual
Para 3-2d

See tables 21 and 2-2.

Check the drive shaft assembly (22, figure

31) splines for wear. The top land dimension
of new spline teeth are 0.029 inch minimum for
the 16-tooth spline, and 0.039 inch minimum for
the 12-tooth spline. Replace the drive shaft when
the top land dimension of a spline reaches zero.
b.

Note. The spline is safe down to a top land

dimension of zero, but if service records indicate top
land dimension may reach zero during the next service
period, the drive shaft should be replaced.
Caution: Spline wear rate will increase
rapidly after reaching the zero top land dimension condition.

c. Inspect the commutator of armature assembly (39). The brush contact surface should be
even, high burnished, and dark brown or almost
black in color. If the contact surface is rough,
pitted, burned, or covered by a hardened film of
carbon or oil which cleaning does not remove,
resurface the commutator as described in paragraph 36.
d. Refer to table 32 for fits and clearances
of component parts. If the inside diameter of
housing and stator (53) or end bell (34, figure
3-2) bearing bore is worn beyond 2.0475 inches,
as measured with an air gage, air probe, and
2.0475-inch setting ring, metallize the worn surface as described in paragraph 3-7.

Table 3-2 Fits and Clearances

1543957-1
1543976
1543960

Nomenclature

Armature
Assembly
End Bell
Generator
Stator

Mating

Service
Tolerance
(Inches)

Nomenclature

Service
Dimensions
(Inches)

0.9843 OD

890659-5

Ball Bearing

0.9843 ID

0.0000 L/L

2.0475 ID
2.4075 ID

890659-5
8906595

Ball Bearing
Ball Bearing

2.0470 OD
2.0470 OD

0.0005 L
0.0005 L

Service

Part No.

Dimensionss
(Inches)

Part No.

3-3. Cleaning
a. General. Clean all parts of the starter generator with trichlorethylene (item 1, table 2-3)

or dry cleaning solvent (item 2, table 23). Do not

dip parts into the solvent. Use a stiff, non-wire
brush to scrub the parts thoroughly.
3-7

TM 55-2925-236-40
Warning: Use solvent only in a well-ventilated area. Avoid inhaling solvent fumes. Do not
allow solvent to contact the skin as burns may
occur.
Note. Refer to paragraph b for specific cleaning procedures for armature assembly (39, figure 3-1)
and housing and stator (53).

(1) Ultrasonic cleaning equipment may be

used, if available. Consult the manufacturer of
this equipment for proper cleaning solutions and
methods to be used.
(2) Dry parts with a clean, lint-free cloth
(item 3, table 2-3).
b. Armature Assembly and Housing Stator.

Using a cleaning solvent specified in paragraph

3-3 with a stiff, non-wire brush, scrub armature
assembly (39, figure 31 ) and housing and stator
(53) thoroughly to remove any carbon and copper particles imbedded between commutator bars
and stator bars.
(1) After cleaning, bake the armature assembly and the housing and stator in an oven
at 250 F (121 C) for two hours or at 200 F
(93 C) for three hours.
(2) After baking, apply a light film of lubricating oil (item 4, table 23 ) or corrosion preventive (item 5, table 2-3) to all ferrous metal
surfaces to prevent rusting.
Caution: Do not apply oil to the commutator.

3-4. Repair or Replacement

Note. Paragraphs 3-5 through 3-7 list and
describe procedures for reparable parts only.

a. General.
(1) Replace all parts that are worn and

damaged,
(2) Replace split-type brushes (4, figure 31) and ball bearings (36 and 44) at each overhaul.
(3) Replace all wiring having burned or
cracked insulation, or broken or corroded terminals.
3-5. Armature Assembly
Replace armature assembly (39, figure 3-1) If
any of the following conditions exist:
a. If the shaft diameter is less than 0.9843 in.
b. If the commutator has badly burned bars,
because such a condition is usually the result of
open-circuited armature coils.
c. If commutator bars are loose or out of alignment.
3-8

d. If resurfacing the commutator (paragraph

36) would reduce the outside diameter below
the allowable minimum of 2.800 inches. This diameter is indicated by a step cut into the edge
of the commutator.
e. If the insulation breakdown test (table 31)
between commutator bars and ground shows indication of insulation breakdown.

Caution: When performing this test, keep

test probes outside brush path to avoid damaging contact surface.
3-6. Resurfacing the Commutator
a. To remove oil or carbon film, mount armature assembly (39, figure 31) in a lathe and
take a single light cut across the face of the commutator at a speed of approximately 600 surface
feet per minute. If the contact surface is scored
or pitted, take a series of light cuts at approximately 200 surface feet per minute. A diamondtipped cutting tool (figure 3-3) is recommended,
The point of the cutting tool must be held on the
centerline of the armature shaft (see figure 34). If a Carboloy-tipped cutting tool (figure 3-5)
is used, the point of the cutting tool must be held
0.031 in, below the centerline of the armature
shaft. The minimum diameter to which the commutator may be turned down is 2.800 inches. This
limit is indicated by a step cut into the commutator. If necessary to remove metal beyond this
point, replace the armature assembly.
b. After the commutator has been turned
down, measure the depth of undercutting between
commutator bars. If the depth is less than 1/32
in., undercut to this depth and to a width of .030
in,
c. After undercutting, take a final light cut
of not more than 0.001 in. across the face of the
commutator to remove burrs, If a diamond-tipped
cutting tool is not available, make the final cut
with a freshly honed Carboloy-tipped tool. Cutting speed should be approximately 600 surface
feet per minute with dither type tool. Do not use
polishing abrasives. After the final cut, remove
burrs between commutator bars with a strip of
fiber.
d. Check that the commutator is concentric
with the bearing surfaces of the armature shaft
within 0.005 in.. full indicator reading.
e. After resurfacing, clean the commutator to
remove all traces of oil, grease, and metal chips,
as specified in paragraph 3-36.
f. Check the armature assembly for static and
dynamic balance, using balancing machine, model

TM

55-2925-236-40

37. Metalizing Bearing Bores

If the bearing bore of end bell (34, figure 3-2)

or housing and stator (53, figure 31 ) is worn
beyond 2.0475 in., metallize the bore as described
in steps a through i.
a. Degrease the face of the bore and adjacent
areas from which contaminants might be introduced, using a solvent specified in paragraph 332.
b. Mask the area adjacent to the face of the
bearing bore with shellac (item 6, table 2-3) to
prevent adherence of the sprayed metal to these
surfaces. Any shellac on the face of the bore will
be removed by boring (step c).
c. Using a feed which will provide a suitable
base for metallizing, roughbore the bearing surface to correct any taper or out-of-round condition. Remove at least 0.006 in., but do not exceed
the original dimension by more than 0.015 in. on
the radius.
d. Insert the housing in a lathe, and rotate it
at a speed of approximately 60 rpm.
Caution: The area to be metallized must be
absolutely clean.
Figure 3-3. Fabrication of Diamond-tipped Cutting
TOOl

Figure 34. Mounting of Commutator Cutting Tool.

40B. If out of balance by more than 0.020 oz in.,

rebalance by inserting leaded epoxy material inside and under winding openings as required.

e. To prevent condensation of moisture, make

several rapid passes over the work with the
flame only, immediately before applying the
molybdenum (spraybond or molybond) coating.
Should the bore be so impregnated with grease
as to prevent metallizing, replace the end bell or
housing and stator.
f. Make several passes over the bearing bore,
to deposit a thin coat of molybdenum.
g. Complete the metallizing with molybdenum
or 0.80 percent carbon steel wire to a thickness
of 0.006 in. on top of the finished diameter (finished diameter minus 0.012 in. )
h. Rough-bore the surface to 0.010 in. under
the finished diameter. Finish the surface by
grinding to an inside diameter of 2.0472, plus
0.0003, minus 0.0000 in. The concentricity between the inside diameter of the bearing bore
and both the outermost (4.122 in.) diameter of
the housing and stator, and the largest inside diameter (6.125 in. ) of the end bell must be within
0.002 in., full indicator reading.
i. Remove masking shellac and grinding residue with denatured alcohol (item 7, table 2-3).
3-8. Soldering

a. In all soldering operations (capacitor leads

to terminals), use a resin core solder composed of
63 percent tin and 37 percent lead (item 8, table
3-9

TM

55-2925-236-40

Figure 3-5. Fabrication of Carboloy-tipped Cutting Tool.

2-3). This solder has a melting temperature of

357 F (181 C).
Caution: Do not use an acid core solder or
an acid flux. Do not burn insulation when soldering.
b. All soldering must be done in accordance
with Federal Specification QQS571.
c. After soldering, clean all joints with denatured alcohol (item 7, table 2-3) to remove all
traces of resin and other foreign matter.
3-9. Sleeving Replacement
All sleeting used on the starter generator is
teflon natural color sleeving, and with the exception of the one length specified in step a, all
sleeving has an inside diameter between 0.032
and 0.039 in. The wall thickness on all sleeving
is 0.030 in. Lengths are given in steps a through

f.
a. The length of sleeving joining capacitors
(15, figure 3-1) to terminal post E- has an inside diameter between 0.051 and 0.061 in. and is
11/2 in. long.
b. The sleeving on the lead of capacitor (15)
to terminal post B + is 2-1/16 in. long.
3-10

c. The two lengths of sleeving on capacitor (6,

figure 32) are 2 in. long.
d. The sleeving on capacitor (13) is 1-5/32
in. long.
e. The sleeving on capacitor (20) is 1-15/32
in. long.
f. The sleeving on capacitor (27) is 1-1/4 in.
long.
Note. All capacitors are firm components.
There is no alternate or equivalent part number for
capacitors.

3-10. Capacitor Mounting

If any capacitors have been removed or replaced, they must be cemented in their mounting
positions. The material to be used consists of two
parts of red epoxy resin (item 9, table 2-3) to
one part of tan epoxy reactor (item 10, table
23) by weight. Follow the procedure of steps a
through f.

a. Make sure areas to be cemented are free

from grease, oil, or any contaminant that might
prevent adhesion.
b. Stir the epoxy mixture until uniform in
color.
Note. The pot life of the mixture is 3 hours.

TM 55-2925-236-40
c. Secure the end bell capacitors in place with
mounting hardware (see figure 3-2).
d. Position the terminal board capacitors as
shown in figure 36.
e. Apply the epoxy mixture with a paddle or
spatula to form a fillet. On the end bell capacitors, cement the capacitors and loop clamps to
the housing. Wipe away all excess material before curing.
f. Allow the mixture to cure for 24 hours at
room temperature or for 3 hours at 150 F (66

c).

3-11. Lubrication

The only lubrication required for the starter

generator is after assembly, coat the drive shaft
spline with a light film of spline lubricant (item
11, table 2-3). If this lubricant is not available,
use high-temperature lubricating grease (item
12, table 2-3).
Note. Use of sealing compounds is specified
throughout the reassembly paragraphs.

312. Reassembly

Reassembly is basically the reverse of disassembly. Follow the exploded views (figures 3-1
and 3-2 ), the schematic diagram (figure 37)
and the detailed instructions (paragraphs a and
b) for reassembly information.
a. End Bell Assembly.
(1) If capacitors (6, 13, 20, and 27, figure
32) were removed or replaced, secure them to
end bell (34) and cement as described in paragraph 3-10.
Note. Terminals of capacitors (6) will be
secured to electrical contact holders (28) when split-type
brushes are installed (paragraph b). Terminals of capacitors (13, 20, and 27) will be secured to threaded holes in
heads of screws (29) at final assembly (paragraph b).

(2) Using brush box aligner (1106006-1)

and brush box aligner pilor ( 11060051 ), secure
electrical contact holders (28) to end bell (34)
with four screws (29), four lock washers (30),

Figure 3-6. Capacitor Mounting Position.

Figure 37. Starter Generator, Schematic Diagram.

four washers (31), sixteen insulating washers

(32), and four insulating tubes (33).
(3) Coat the area between the insulating
washers and the electrical contact holder bosses
with red glyptal lacquer (item 13, table 2-3), and
tighten screws (29) to a torque of 75 to 80 poundinches.
b. Starter Generator.
(1) Mount three terminal board insulators
(52, figure 31 ) in position on housing and stator
(53). Apply sealing compound (item 14, table 23) to threads of two screws (50). Secure terminal board (49) to the housing and stator with
two screws (50) and two washers (51), making
sure to install the terminal of capacitor (15) under one screw as shown in figure 36.
(2) If capacitors (15, figure 3-1) were removed or replaced, secure them to terminal board
(49) as described in paragraph 3-10.
(3) Install identification plate (46) on
housing and secure with four screws (47).
(4) Mount bearing retainer (45) and one
dirt slinger (43) on the drive end of armature
assembly (39).
(5) Mount bearing retainer (37) and one
dirt slinger (35) on the commutator end of armature assembly (39).
(6) Stand armature assembly (39) on rotor
stand (1106149). Heat ball bearings (36 and 44)
to 250 F ( 121 C) and install on armature assembly (39), making sure that the dirt slingers
are properly positioned.
3-11

TM 55-2925-236-40

(7) Insert armature assembly (39) into

housing and stator (53), seating ball bearing
(44) in the bore of the housing.
(8) Mount end bell assembly (30) on ball
bearing (36), and secure to housing and stator
(53) with six screws (31), six lock washers (31),
and six special washers (33 ). Tighten screws to
a torque of 35 to 40 pound-inches.
(9) Secure the housing to interface
(1106354-1) and mount on generator overhaul
stand (1106187).
(10) Install the remaining dirt slingers (35
and 43) and lock rings (17 and 38).
(11) Align bearing retainer (45) with the
holes in housing and stator (53). Apply sealing
compound (item 15, table 2-3 ) to the threads of
four screws (41). Install bushings (42) and outer
race bearing retainer (40), and secure with four
screws (41 ).
(12) Align bearing retainer (37) with the
four holes in end bell assembly (30). Apply sealing compound (item 15, table 2-3) to the threads
of four screws (28), and install the screws with
four lock washers (29).
(13) Align the terminals of end bell capacitors (13, 20, and 27, figure 32) over the threaded holes in four screws (29), and secure with
three screws (24, figure 31), three lock washers (25), and three washers (26).
(14) Use setting gage (1106353-1) to measure and check the compressed length of compression spring (21 ). This assembled length should
be 1.100 inches. Insert the gage size plug into
the fan end of armature assembly (39), and install washer (20) and self-locking nut (19). Seat
the setting gage on the washer, and tighten the
self-locking nut, using a 7/16-inch (12-point thin
wall) socket wrench until the gage indicator is
at zero, plus or minus 0.005 inch. Remove the
setting gage, self-locking nut, washer, and gage
size plug. Install front plate (23) on drive shaft
assembly (22) and insert the shaft through ar-

3-12

mature assembly (39). Install fan (18) through

the armature assembly. Install compression
spring (21), washer (20), self-locking nut (19)
and the setting gage. Using spline wrench
(QB800593) to keep the shaft from turning, retighten selflocking nut (19) with the 7/16-inch
(12-point thin wall) socket wrench until the setting gage again indicates zero, plus or minus
0.005 inch. Remove the setting gage.
(15) Apply sealing compound (item 14, table
23) to the threads of six screws (17). Secure
fan housing (16) to end bell assembly (30) with
six screws (17).
(16) Fasten generator stator terminals to
terminal posts D and A+ with two self-locking
nuts (10) and two washers (11).
(17) Fasten generator stator terminals and
capacitor terminals to terminal posts E, B+,
and C+ with three self-locking nuts (8) and
three washers (9) (see figure 3-6 and 3-7).
(18) Install split-type brushes (4, figure 31) in brush holders, and secure, along with two
end bell capacitor terminals, with eight screws
(5), eight lock washers (6), and eight washers
(7). Tighten the screws to a torque of 35 to 40
pound-inches.
(19), Slide brush access cover assembly (1)
over fan housing (16), and tighten screw (2) and
square nut (3).
(20) After the starter generator has been
tested satisfactorily, safety wire the drilled head
screw (2) to brush access cover assembly (1)
with lock wire (item 16, table 2-3 ) in accordance
with Military Standard MS33540 (ASG).
(21) After the final test procedure has established optimum position of brushes, lock the
end bell assembly in position. Using the notch in
the end bell for location, drill a 0.062, plus 0.003,
minus 0.000 in. diameter hole through the housing, and press in roll pin (34) flush to the housing.

TM 55-2925-236-40

SECTION IV
FINAL TEST PROCEDURES
4-1. General
If the starter generator fails to meet any of
the test requirements and visual inspection does
not disclose the cause of the trouble, refer to the

troubleshooting table 4-1, disassemble, and repeat inspection procedures as outlined in Section
III. After reassembling, repeat the test procedure
from the beginning.

Table 4-1. Troubleshooting

Item

Trouble

Short Brush Life or Excessive

Sparking

Generator Noisy

Output Voltage Low or no

Reading

Output Voltage Indicates

High

10

Output Voltage Erratic or

Fluctuates

Output Phase Sequence

Incorrect With Generator
Rotation Correct
System Meters Indicates
Zero, Low, or Fluctuating
Reading (Output Voltage
satisfactory)
System Meters Read Off
Scale in Wrong Direction,
with Generator Connected
to Load
Equipment Operating Unsatisfactorily Although No
Load Voltage is at Proper
Value
Generator Overheats

Probable Cause

Worn, Improperly Seated, or Loose

Fitting Brushes
Low Brush Spring Tension
Dirty Commutator
Scored, Pitted, or out-of-round
Commutator
Short, Ground, or Open Armature
Ball Bearings Worn
Shorted Compensating Winding
Faulty Condensers
Discharged Battery
Excessive Sparking at Generator
Brushes
Shorted or Open Rotor or Exciter
and/or Shorted or Open Diodes
control Panel Faulty
Shorted and/or Open Output
Windings
Drive Inoperative
Control Panel Faulty
Wrong or Faulty Connection Between
Generator and Control Panel
Faulty Control Panel
High Resistance, Internal or External
Connection in the dc Connection
of Generator
Intermittently Shorted, Grounded,
or Open ac Rotor and/or Stator
External Wiring Not Properly
Connected
External Wiring Not Properly
Connected
Improper Adjustment of Voltage
Regulator
Generator Field Magnetized in
Wrong Direction
External Wiring Not Properly
Connected

Remedy

Replace, Service, and/or Readjust

Brushes as Necessary.
Readjust and/or Replace Spring.
Service Commutator.
Resurface Commutator.
Replace Armature,
Replace Ball Bearings.
Replace Yoke Assembly.
Replace Condensers.
Replace Battery.
See Item 1.
Test; if Faulty, Replace Rotor and/or
Diodes.
Replace Control Panel.
Test; Replace Housing if Necessary.
Check Drive.
Replace Control Panel.
Make Proper Connections and/or
Tighten Connections.
Replace Control Panel.
Clean and/or Tighten Connections.
Test; Replace Rotor and/or Housing
if Necessary.
Check External Wiring. Make Proper
Connections. (Refer to External
Wiring Diagram.)
Check External Wiring. Make Proper
Connections and Tighten.
Check Adjustments. Make Proper
Adjustments.
Flash Field in Proper Direction.

Faulty Control Panel

Improper Frequency

Refer to Wiring Diagram. Check All

Wiring Connections. All Connections
Should be Clean and Tight.
Replace Control Panel.
Check Drive.

Excessive Load

Check and Reduce Load, if Necessary.

4-1

TM 55-2925-236-40
a. Test Conditions.

(1) Temperature. Since the starter generator is self-cooled, no cooling air is required. Check
that the ambient temperature is 77 27 F (25
15C).
(2) Direction of rotation. Drive the starter
generator in a counterclockwise direction, as
viewed from the drive end, during all tests.
(3) Plastic windows. It is recommended that
a transparent plastic window strap be used during the brush seating procedure, so that the commutator end brushes will be visible. A spare
brush access cover can be modified in the shop
by cutting out squares, and riveting transparent
non-flammable plastic window panes in place on
the cover.
Caution: Do not operate the starter generator without the brush access cover in place,
as overheating may occur.
(4) Mounting. The starter generator should
be mounted on aircraft generator test stand
(7199-1), or an equivalent test stand, capable of
driving the generator continuously over the rated
speed. The longitudinal axis of the generator
should be horizontal.
(5) Excitation. The starter generator should
be self-excited and controlled by a suitable variable resistance with the shunt field.
Note. The shunt field current should not be
considered as part of the starter generator load current.

(6) Load location. The load for the starter

generator should be located so that it will not affect the ambient temperature.
(7) Warm-up. The starter generator should
be operated at a continuous operating speed delivering the rated load at the rated voltage, to
obtain a constant temperature.
(8) Voltage measurements. The voltages
should be measured between terminals E and B.
(9) Shunt field voltage. The voltage drop
across the shunt field should be measured between terminals A and E. (See figure 3-7.)
b. Test Equipment. When performing stall
torque test, use starter torque tester, type B-1.
4-2. Flashing fhe Field
To be sure that the d-c magnetic circuit retains
enough residual magnetism to allow the starter
generator voltage to build up properly, flash the
field as described in steps a through d.
a. Connect the positive terminal of a 12-volt
battery through a singlepole, single throw knife
switch to terminal A+ on terminal board (49,
figure 3-1).
4-2

b. Connect the negative terminal of the battery to terminal E- on the terminal board.
c. Apply battery current to the field for 5 seconds by closing the knife switch.
d. Repeat the operation several times to be
sure that the field is properly flashed.
Caution: Use a knife switch when flashing
the field. Opening the circuit at the starter generator or battery terminals can result in severe
damage to the terminals or explosion of the battery.
4-3 Brush Seating

a. Remove the brush access cover and replace

it with the plastic window strap. (Refer to paragraph 4-1a(3). ) The brush run-in can now be
observed.
b. Operate the starter generator at the rated
speed until the face of each brush contacts the
commutator 100 percent in the direction of rotation and for at least 75 percent of brush dimension parallel to the shaft. (See figure 4-1.) There
must be no evidence of excessive grooving or
other surface damage to the face of the brush.
c. There must be no sparking except for fine
pinpoint sparking at the generator brushes.
Brushes should be removed from their brush
holders for periodic inspection.
Note. If the brushes are removed from the
brush holders, be sure to return each brush to the brush
holder from which it was removed.
4-4.

Stall Torque Test

a. Mount the starter generator on starter

torque tester, type B1.
b. Connect the spline coupling of the torque
coupling arm to the spline of drive shaft assembly (22, figure 31) and place one of the notched
ends of the torque coupling arm in the shackle
suspended from the scale.

Figure 4-1. Typical Brush Seating.

TM 55-2925-236-40

c. Connect the starter generator to the varidrive and start the vari-drive.
d. Set the main switch to ON.
e. Set the VOLTAGE INPUT GENERATOR
AND SUPPLY switch to SUPPLY. The voltage
indicated is the field voltage applied to the starter generator.
f. Turn the LINE AMPERE ADJUSTMENT
control to obtain a current reading between 500
and 800 amperes. The stall torque as indicated
by the stall torque test stand scale, at any point
within this 500- to 800-ampere range, must comply with the values indicated by figure 4-2.
g. If the specified stall torque cannot be obtained within the current range indicated in step
f, turn end bell assembly (30, figure 3-1) until
the correct torque is obtained.
h. Set the VOLTAGE INPUT GENERATOR
AND SUPPLY switch to VOLTAGE INPUT
GENERATOR and read and record the starter
generator voltage. The voltage reading should be
in accordance with values given in figure 4-2.
i. If for any reason the position of end bell
assembly (30, figure 31 ) was shifted, allow the
starter generator to run for 1/2 hour and repeat
the test.
4-5. Dielectric Strength
a. Perform this test before any of the final

tests.
b. Using insulation breakdown test set 137001C, apply 250 volts, 60 cps for one minute between each terminal post and the frame
(ground).
c. A current. flow of more than 15 milliamperes
indicates insulation breakdown.
4-6. Final Tests
a. General. Mount the starter generator on the
test stand, as described in paragraph 4-1a(4).
b. Maximum Speed for Regulation.
Note. The starter generator must not be given
an operational warm-up prior to this test.

(1) Turn on the test stand controls and increase the drive motor speed to 10,000 rpm.
(2) Adjust the regulator until the output
voltage is 30 volts.
(3) Record the field voltage (Ef) and field
current (If ).
(4) Calculate the external resistance in the
field circuit by dividing the field voltage by the
field current.
(5) The external resistance in the shunt
field must not exceed 35 ohms.

c. Heating, Commutation, Minimum Speed an

Equalizing Voltage.
(1) For heating, commutation, minimum
speed, and equalizing voltage tests, the following
is considered as a continuous operating condi
tion: While the starter generator is cold, the re
sistance and temperature of the shunt field must
be determined for use in calculating the averag
field temperature rise used during continuous op
eration at full load. The starter generator is considered to have reached its continuous operating
condition when the rate of rise of the shunt field
temperature does not increase more than 2F
(1 C) during a five-minute period.
(2) Start the blower and drive motor. In
crease the drive motor speed to operate the start
er generator at 8000 rpm. Close suitable switches
of the load bank to apply 300 amperes d-c load
When the starter generator reaches its continuous operating condition as described in step a
proceed as follows:
(a) Check the readings of the instruments. During the heat run, readings must be
limited to those shown in table 42.
Table 4-2. Heating Test Readings
Shunt Field
Load Ammeter
Line Voltage

8 amperes (max)

300 amperes

30 volts

(b) Measure the equalizing voltage across

terminals D and E on terminal board (49, figure
3-1 ). The voltage must be between 1.9 and 2.1
volts.
(3) After completing the previous test, de
crease the speed of the motor until the minimum
rated speed of 4000 rpm is measured on the ta
chometer. Adjust the voltage regulator until a 26volt reading is obtained. The starter generator
must deliver rated current of 300 amperes, as
read on the ammeter.
Note. At no time during the above heat runs
should the required resistance external to the shunt field
be less than 1.25 ohms. Refer to paragraph 4-6b t o
calculate the external shunt field resistance.

(4) Readjust the regulator until a 30-volt

reading is obtained.
d. Commutation. Immediately following the
previous heat runs, with the starter generator
hot, observe the commutation of the starter generator over the speed range 4400 to 8000 rpm
for no load (all load switches off), half load
(suitable load switches turned onto give 150 amperes), and rated load (suitable switches turned
on to give 300 amperes). Table 4-3 lists the vari4-3

TM 55-2925-236-40

Figure4-2. Stall Torque Curve.

4 - 4

TM 55-2925-236-40

ous conditions. There should be no sparking except for the fine pinpoint sparking at the generator brushes.
Note. For any speed within the speed range,
the field current must increase with increases in load.
Table 4-3. Commutation Test Readings
Line
Voltage

4400
4400
4400

30
30
30

0
150
300

6000
6000
6000

30
30
30

0
150
300

8(MO
8000
8000

30
30
30

0
150
300

e. Overspeed.
(1) Perform this test while the starter generator is hot as a result of testing.
(2) Open all load switches and the field
switch. Operate the generator at no load.

(3) Increase the speed of the driving motor

to 11,000 rpm. The generator must operate al
this speed for five minutes without mechanical
failure, the throwing of varnish, or impairment
of electrical performance.
(4) At the end of the five-minute overspeed
run, reduce the speed to 6000 rpm. Apply rated
load of 300 amperes.

(5) Operate the starter generator for one

minute and check the electrical performance. The
results should compare with those observed in
paragraph 46c.
f. Polarity Check.
(1) Operate the starter generator at rated
speed and load conditions. Connect the voltmeter
leads to starter generator terminals B+ and Eobserving proper polarity.
(2) If the voltmeter connections must be reversed to obtain a reading, the polarity of the
starter generator is reversed. In this case, flash
the field in the proper direction as described in
paragraph 42.

4-5

TM 55-2925-236-40

APPENDIX A
REFERENCES
MS33540 (ASG)
QQ-S-571
TM 33-750
TM 55-405-10

Safety Wiring, General Practices for

Solder, Soft
Army Equipment Record System
Ground Handling and Service Equipment

By Order of the Secretary of the Army:

W. C. WESTMORELAND,
Official:

General, United States Army,

Chief of Staff.

KENNETH G. WICKHAM,

Major General, United States Army,

The Adjutant General.
Distribution:
To be distributed in accordance with DA Form 12-31 requirements for Direct and General Support Maintenance
Instructions for UH-1C, UH-1D, and AH-1G Aircraft

A-1

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