sky-tec 122-12HT User manual

AIRCRAFT STARTER
MAINTENANCE MANUAL
P/N ST1005
STARTER MODELS
122-12HT 122-24HT
122-HT/EC 149-24HT
149-12HT 149-24HTL
149-HT/EC 149-24HT-NC
149-12HTL 149-24HT-H
149-12HT-H 149-24HT-H4
149-12HT-H2
ST1005 80-10-01
Rev. NEW: 05 Dec. 2022 Page: i
© 2022 - Hartzell Engine Technologies - All rights reserved
Aircraft Starter
Maintenance Manual

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80-10-01 ST1005
Page: ii Rev. NEW: 05 Dec. 2022
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Aircraft Starter
Maintenance Manual

Table of Contents
Record of Revisions.....................................................................................................................................vii
Service Documents..................................................................................................................................... viii
Airworthiness Limitations ............................................................................................................................A-1
A.1 General Information................................................................................................................A-1
A.2 Airworthiness Limitations Statement ......................................................................................A-1
A.3 Life Limits ...............................................................................................................................A-2
CHAPTER 1 - INTRODUCTION.........................................................................................................1-1
1.1 General Information.......................................................................................................................1-1
1.2 General Specification (manual) .....................................................................................................1-2
1.3 How to use the manual..................................................................................................................1-2
1.4 Measurements ...............................................................................................................................1-3
1.5 Units of Measure ...........................................................................................................................1-3
A. SI Units...................................................................................................................................1-3
B. U.S. Units ...............................................................................................................................1-3
C. Multiplying Prefixes.................................................................................................................1-3
1.6 Abbreviations .................................................................................................................................1-4
1.7 Definitions ......................................................................................................................................1-4
1.8 Disposal .........................................................................................................................................1-5
1.9 Model Identification........................................................................................................................1-5
1.10 Serial number Identification ...........................................................................................................1-6
1.11 Warranties .....................................................................................................................................1-6
1.12 Storage and Shelf Life...................................................................................................................1-6
A. Recommended Storage..........................................................................................................1-6
B. Shelf Life.................................................................................................................................1-7
CHAPTER 2 - DESCRIPTION OF OPERATION .............................................................................. 2-1
2.1 General ..........................................................................................................................................2-1
2.2 Basic Component Description .......................................................................................................2-1
2.3 Technical Purpose.........................................................................................................................2-1
2.4 Physical Detail ...............................................................................................................................2-1
2.5 Theory of Operation.......................................................................................................................2-1
2.6 Operational Data............................................................................................................................2-2
A. 122-12HT / 149-12HT ............................................................................................................2-2
B. 122-24HT / 149-24HT ............................................................................................................2-2
C. Duty Cycle ..............................................................................................................................2-2
ST1005 80-10-01
Rev. NEW: 05 Dec. 2022 Page: iii
© 2022 - Hartzell Engine Technologies - All rights reserved
Aircraft Starter
Maintenance Manual

CHAPTER 3 - TROUBLESHOOTING ...............................................................................................3-1
3.1 General ..........................................................................................................................................3-1
3.2 Procedure ......................................................................................................................................3-1
CHAPTER 4 - CHECK ...........................................................................................................................4-1
4.1 General ..........................................................................................................................................4-1
4.2 Inspection Checks .........................................................................................................................4-1
CHAPTER 5 - TEST & CHECK ...........................................................................................................5-1
5.1 General ..........................................................................................................................................5-1
5.2 Testing ...........................................................................................................................................5-1
A. Equipment ..............................................................................................................................5-1
B. Test conditions .......................................................................................................................5-1
C. Precautions.............................................................................................................................5-2
5.3 Starter Bench Testing (no-load) ....................................................................................................5-2
A. Starter Test Conditions...........................................................................................................5-2
B. Test Set-up.............................................................................................................................5-2
CHAPTER 6 - MAINTENANCE ...........................................................................................................6-1
6.1 General ..........................................................................................................................................6-1
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Aircraft Starter
Maintenance Manual

Thank you for purchasing a Sky-Tec* starter. We encourage you to read this manual
thoroughly. It contains a wealth of information about how to properly install and maintain your
starter so that it may give you many years of safe and reliable service.
Should you have a question regarding your sterter that is not covered in the manual, Hartzell
Engine Technologies Product Support is ready to assist you. We may be reached at the fol-
lowing contact information:
Phone: [phone], option 2
E-mail: [email protected]
Fax: [phone]
Web: www.Hartzell.aero/contact/
*Sky-Tec is a trademark of Hartzell Engine Technologies LLC
ST1005 80-10-01
Rev. NEW: 05 Dec. 2022 Page: v
© 2022 - Hartzell Engine Technologies - All rights reserved
Aircraft Starter
Maintenance Manual

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Maintenance Manual

Record of Revisions
Revision
Letter
Issue
Date
Page
Revised Description Date
New IR N/A New Release 12/05/2022
ST1005 80-10-01
Rev. NEW: 05 Dec. 2022 Page: vii
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Aircraft Starter
Maintenance Manual

Service Documents
Service
Document
Number
Description
Service
Document
Revision
Date
Incorporated
80-10-01 ST1005
Page: viii Rev. NEW: 05 Dec. 2022
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Aircraft Starter
Maintenance Manual

AIRWORTHINESS LIMITATIONS
A.1 General Information
CAUTION!
THE AIRWORTHINESS LIMITATIONS HEREIN ARE THOSE MANDATED BY
HARTZELL ENGINE TECHNOLOGIES. THESE LIMITATIONS ARE THE MINIMUM
REQUIRED TO MEET CONTINUED AIRWORTHINESS BUT MAY BE SUPERSEDED
BY MORE STRINGENT REQUIREMENTS AS PUBLISHED BY THE FAA, AIRCRAFT,
ROTORCRAFT OR OTHER MANUFACTURERS THAT USE THESE COMPONENTS
IN THEIR APPLICATIONS. FAILURE TO OBSERVE THESE LIMITATIONS MAY
COMPROMISE THE COMPONENT OR THE APPLICATION IT IS USED IN.
A.2 Airworthiness Limitations Statement
A. The Airworthiness Limitations section is FAA approved and species maintenance required under § 43.16 and
§ 91.403 of the Federal Aviation Regulations unless an alternative program has been FAA approved.
AIRWORTHINESS
LIMITATIONS
Revision Number Description of Revision
Airworthiness Limitation Revisions Log
ST1005 80-10-01
Rev. NEW: 05 Dec. 2022 Page: A-1
© 2022 - Hartzell Engine Technologies - All rights reserved
Aircraft Starter
Maintenance Manual

A.3 Life Limits
A. The FAA establishes specic life limits for certain component parts as well as the complete starter assembly. Such
limits require replacement of the identied parts after a specied number of cycles or hours of use.
B. Additions of, or changes to, any life limit for starter components will be noted in the Airworthiness Limitation
Revision Log.
C. Life Limits
(1) Starter models and their component parts affected by this manual currently do not have any life limited
parts.
(2) There are no new (or additional) Airworthiness Limitation associated with this equipment.
80-10-01 ST1005
Page: A-2 Rev. NEW: 05 Dec. 2022
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Aircraft Starter
Maintenance Manual

CHAPTER 1 -INTRODUCTION
1.1 General Information
WARNING!
IMPROPER OR UNAUTHORIZED APPLICATIONS OF THE INFORMATION
CONTAINED IN THE MANUAL MAY RENDER THE AIRCRAFT OR THE
COMPONENT UNAIRWORTHY AND RESULT IN LOSSES, DAMAGES,
OR INJURY TO THE USER.
DO NOT USE OBSOLETE OR OUTDATED INFORMATION. PERFORM
ALL INSPECTIONS OR WORK IN ACCORDANCE WITH THE MOST
RECENT REVISION OF THE APPLICABLE AIRCRAFT/ENGINE SERVICE
OR MAINTENANCE MANUAL. INFORMATION CONTAINED IN THESE
MANUALS MAY BE SIGNIFICANTLY CHANGED FROM EARLIER
REVISIONS. USE OF OBSOLETE INFORMATION MAY CREATE AN
UNSAFE CONDITION THAT MAY RESULT IN DEATH, SERIOUS BODILY
INJURY, AND/OR SUBSTANTIAL PROPERTY DAMAGE.
The accuracy and applicability of this manual has not been veried for any assembly, component or part
not manufactured by Hartzell Engine Technologies LLC (HET). Any use of the manual for other than its
intended or implied purpose is prohibited. The use of the manual for the purpose of performing any
installation, maintenance, replacement, adjustment, or inspection of any assembly, component or part not
manufactured by HET is not approved, endorsed, or sanctioned by HET.
This manual has been approved by Hartzell Engine Technologies LLC as the proper methods and
procedures that FAA or other airworthiness authority Certicated Repair Stations and A/P Mechanics
should use in the inspection and maintenance of Hartzell Engine Technologies LLC starters.
No liability will be assumed by Hartzell Engine Technologies LLC for actual, consequential, incidental or
other types of damages directly or indirectly resulting from the unauthorized use of this manual for other
than its stated purposes.
The liability for use of the authorized data herein for the maintenance, or return to service is limited to
the specic terms and conditions stated under the applicable Limited Warranty in e󰀨ect for each piece
part, component, assembly or whole unit sold by HET.
Because of the numerous modications, Supplemental Type Certicates (STC), Parts Manufacturing
Approvals (PMA), or Form 337 Field Approvals that may apply, it is the responsibility of the repairman,
mechanic or maintenance facility to determine the proper engine or aircraft application of this starter
assembly. Please refer to the appropriate aircraft Type Certicate (TC), Supplemental Type Certicate
(STC), aircraft equipment list, maintenance manuals, and/or Log Book entries for determination.
When performing installation, maintenance, replacement, adjustment, or inspection of any HET assembly,
component or part, it is imperative that the latest revision of this HET manual or other product support
document be referenced. Reference the HET website to be sure you have the latest revision before
performing any work. (https://skytec.aero/aircraft-starter-support/maintenance-manuals/)
All reasonable attempts were made to make this manual as complete and accurate as possible. If you
have any questions, comments, corrections or require clarication of any information contained herein,
please write to Hartzell Engine Technologies LLC, 2900 Selma Highway, Montgomery, Alabama, 36108
USA. TEL [phone], FAX [phone], or https://hartzell.aero/contact/.
ST1005 80-10-01
Rev. NEW: 05 Dec. 2022 Page: 1-1
© 2022 - Hartzell Engine Technologies - All rights reserved
Aircraft Starter
Maintenance Manual

1.2 General Specification (manual)
A. This manual follows general GAMA guidelines using ATA 100 identication as required. Principle units of
measure used in the manual are U.S. units with International System of Units (SI) in parentheses.
B. The 122-12HT, 122-24HT, 122-HT/EC, 149-12HT, 149-24HT, 149-12HTL, 149-24HTL, 149-HT/EC, 149-
12HT-H, 149-24HT-H, 149-24HT-NC, 149-12HT-H2, and 149-24HT-H4 starter models are considered
herein. Variations of these starters may be noted as applicable.
C. All aircraft, rotorcraft, or engine applications are limited to the holder of the TC, STC, PMA or TSO and only
at the date of that document publication or revision.
D. Only approved, competent persons with the necessary skills may do maintenance tasks described in the
manual. This may include a certied pilot doing “preventative maintenance” as dened in FAR 43, Appendix
A, paragraph C with guidance from AC 43.12A of latest change.
E. The manual describes maintenance on components as they are installed on aircraft and tasks that should
be accomplished in a properly equipped service facility.
F. Maintenance tasks and subtasks are referenced in the manual but will have no specic identication
numbers.
G. The manual contains: Description of operation, Troubleshooting, Instruction for Continued Airworthiness
(ICA) and Maintenance information along with part numbers required for basic maintenance tasks.
H. Changes and updates to this manual can be found at www.SkyTec.aero. Revisions will be tracked and
recorded in the Record of Revisions section of this document.
1.3 How to use the manual
A. Make sure the manual contains information applicable to your aircraft, engine, or replacement starter. Look
for the model number on the Title Page and if applicable, the part number of the replacement or superseded
component.
B. It is imperative that you read, understand, and observe all the applicable WARNINGS and CAUTIONS
before you do any work on this component.
C. Use only the sections needed, use the check section to determine what actions may be needed periodically
and the maintenance sections for servicing the starter.
D. If you need to identify a part or nd a part number, refer to illustrations herein or the applicable aircraft or
engine service or maintenance manual.
E. Refer to the troubleshooting section to assure that the observed or reported condition lies with the starter.
F. Fully test the starter per the instructions in this manual when running the aircraft. Utilize the aircraft and/
or engine manufacturer’s service manuals and publications before returning the aircraft to service. Use the
AFM or POH for aircraft operations.
G. Some sections in this manual apply to all starters considered herein. Other sections will contain information
specic to a particular starter model or variation of a model.
80-10-01 ST1005
Page: 1-2 Rev. NEW: 05 Dec. 2022
© 2022 - Hartzell Engine Technologies - All rights reserved
Aircraft Starter
Maintenance Manual

1.4 Measurements
The measurements given in this manual are taken from original manufacturing drawings.
1.5 Units of Measure
A. SI Units
A Ampere
A ∙ h Ampere hours
g Gram
N Newton
N ∙ m Newton meter
V Volt
°C Degree Celsius
Ω Ohm
W Watt
Hz Hertz
m Meter
cm Centimeter
kg Kilogram
B. U.S. Units
ft Foot
in Inch
lb Pound
lbf ∙ in Pound-force inch
lbf ∙ ft Pound-force foot
°F Degree Fahrenheit
C. Multiplying Prexes
μ Micro
m Milli
k Kilo
M Mega
p Pico
ST1005 80-10-01
Rev. NEW: 05 Dec. 2022 Page: 1-3
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Aircraft Starter
Maintenance Manual

1.6 Abbreviations
A. The abbreviations given below are used in the manual: (upper or lower case)
ATA Air Transport Association of America
DE Drive End (housing)
DIA Diameter
FAA Federal Aviation Administration (USA)
FIG. Figure
GAMA General Aviation Manufacturers Association
IPC Illustrated Parts Catalog
ID Inside Diameter
HET Hartzell Engine Technologies LLC
MAX Maximum
MFR Manufacturer
MIN Minimum
NO. Number
N/A Not Applicable
OD Outside Diameter
P/N Part Number
PARA. Paragraph
POH Pilots Operating Handbook
REF. Refer To
S/N Serial Number
1.7 Definitions
A. This paragraph denes the warnings and notications used in this manual. WARNINGS place critical attention
to use of tools, materials, procedures, or limitations, which must be followed without deviation to avoid injury to
the technician or other persons. CAUTIONS place immediate attention to use of tools and procedures which
must be followed to avoid injury, damage to equipment and/or facilities. Notes call attention to procedures
which make the job easier.
B. The following are basic denitions of the terms used herein: (as related to this manual)
AMMETER: The device for measuring current in amperes.
ARMATURE: Rotating electro magnet used to create a magnetic eld.
BRUSH: Device for conducting current to the commutator. It is a composite carbon block which includes a
spring and lead.
BRUSH HOLDER: Device that retains multiple brush assemblies and is comprised of a holder, contacts, and
terminals.
COMMUTATOR: Coverts AC current to DC current and ensures the torque acting on the armature is in the
same direction.
CONTINUITY: The continuous path for the ow of current in an electrical circuit.
EMI: Electro Magnetic Interference. A disturbance in the radio-frequency spectrum that is generated by an
external source that a󰀨ects electrical devices or circuits by electromagnetic induction, electrostatic coupling, or
conduction.
FRONT HOUSING: Part of the external housing which contains the components of the starter. This end has
structure typically used for mounting. It may also be referred to as the Drive End Housing or D.E.
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Aircraft Starter
Maintenance Manual

INSULATOR: Component that does not allow electricity to ow through it easily. Insulators do not allow
electricity to ow through them easily because the electrons in their atoms do not move easily from atom to
atom.
MULTIMETER: Device for the measurement of voltage, current, or resistance.
OPEN: Electrical term for a complete disruption of a conductive path in an electrical circuit. Will read innite
resistance.
REAR HOUSING: Part of the external housing which contains the components of the starter. It may also be
referred to as the Commutator End.
RFI: Radio Frequency Interference. Electromagnetic energy in the radio-frequency spectrum. Electrical
interference may be created by arcing between the brush and commutator during operation.
SHORT: Common term for an electrical circuit that allows a current to travel along an unintended path with
no or very low electrical impedance that can be seen using an Ohmmeter, resulting in an excessive current
owing through the circuit which becomes an undesirable condition.
TEST BENCH: Device so constructed as to allow testing of the starter or component parts.
TERMINALS: Studs, screws or other devices that provide connections for electrical power.
VOLT/OHM METER: Device for the measurement of voltage or resistance.
1.8 Disposal
A. The starter assembly is designed to allow for re-use of many starter sub-assemblies and components.
Disposal of unairworthy parts and assemblies as well as required replacement parts should be as follows:
Rejected parts should be tagged and scrapped per FAA requirements. Any part deemed unairworthy must be
rendered unusable prior to discard.
1.9 Model Identification
122-12HT 122-24HT
122-HT/EC 149-24HT
149-12HT 149-24HTL
149-HT/EC 149-24HT-NC
149-12HTL 149-24HT-H
149-12HT-H 149-24HT-H4
149-12HT-H2
ST1005 80-10-01
Rev. NEW: 05 Dec. 2022 Page: 1-5
© 2022 - Hartzell Engine Technologies - All rights reserved
Aircraft Starter
Maintenance Manual

1.10 Serial number Identification
HET H- K 05 001
Year Code
Month Code
Batch Code
Example above: 2010, May, rst unit of the month (batch). The year code advances one letter in alphabetical
order for each succeeding year.
1.11 Warranties
A. Hartzell Engine Technologies LLC (HET) o󰀨ers a Limited warranty with each new or rebuilt starter assembly
or component (parts) it sells through it’s distribution system. NO expressed or implied warranty exists when
repairing, or rebuilding any assembly or component using this manual except as it may apply to any new HET
replacement part purchased. If you suspect that any warranty applies to the starter assembly, it must be returned
through an authorized HET distributor in a manner prescribed by that specic distributor. The a󰀨ected starter
must be received by the factory fully assembled and not altered in any way for disposition by the HET warranty
department. (Warranty shall be denied for any starter received altered, modified, or disassembled.)
B. The HET Limited warranty policy in a󰀨ect for your starter was delivered with the unit at the time of purchase. (As
the Warranty policy is revised from time to time, you must check the policy delivered with your unit for specic
terms and conditions should a warranty condition occur. If needed for reference, obtain the most current policy
by visiting our website at www.hartzell.aero.
1.12 Storage and Shelf Life
A. RECOMMENDED STORAGE
When storing a new starter, there are two categories to consider, short term storage or a
long term storage on or o󰀨 the aircraft. Short term storage will be considered as storage up to but not
exceeding thirty-six (36) calendar months. Long term storage picks up at thirty-six (36) calendar months
but does not exceed twelve (12) calendar years. There is no special environment required except the
storage space should be clean and covered.
Short term, if on the shelf, requires only that the unit be kept in it original packaging. If unit is being
stored on the aircraft, start engine using starter at an interval of sixty (60) days.
Long term, if on the shelf, requires that the starter be removed from the packaging and examined on an
annual basis. Remove from the plastic bag as originally packaged and discard the bag as long term use
may allow condensation in bag. (If bag contains a desiccant and color does not indicate moisture, unit
may be kept in original bag.) If removed from bag, wipe or lightly spray outside with preservative oil and
wrap tightly with a waxed type paper. Place back into original shipping container.
80-10-01 ST1005
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© 2022 - Hartzell Engine Technologies - All rights reserved
Aircraft Starter
Maintenance Manual

If it is anticipated or determined that the aircraft will be in a long term storage situation, as soon as
practicable, wipe and spray the outside of the starter with preservative oil, start engine using starter at
an interval of sixty (60) days. (Engine must start to unwind adapter spring.)
B. SHELF LIFE
All starters have a shelf life of up to, but not to exceed twelve (12) calendar years at which time the unit must
replaced. (Does not express a warranty.)
ST1005 80-10-01
Rev. NEW: 05 Dec. 2022 Page: 1-7
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Aircraft Starter
Maintenance Manual

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Aircraft Starter
Maintenance Manual

CHAPTER 2 - DESCRIPTION OF OPERATION
2.1 General
A. Sky-Tec starters listed herein are designed as lightweight, direct-mounting, and energy-e󰀩cient. These
starters reduce current draw which attributes to the long life of the starter. The internal gear drive multiplies
armature torque and employs a slip disc clutch design for kickback protection.
2.2 Basic Component Description
A. The principle components of HT starters described herein are (1) mount assembly (2), drive assembly (3),
idler gear and clutch assembly, and (4) solenoid/motor assembly, see Fig. 2.1.
2.3 Technical Purpose
A. The purpose of the aircraft starter is to convert electrical power to mechanical power in order to start the
engine. The starter rotates the engine until the engine is able to operate under its own power.
(1) The battery is the source of electrical power whenever the BAT Master Switch is ON and is the source
of power for starting the aircraft.
2.4 Physical Detail
A. The mount assembly (1) provides the mounting ange for attachment of the starter to the engine and supports
the bearing through which the pinion shaft protrudes to expose the pinion gear.
B. The solenoid/motor assembly (4) is the rotating element of the starter. Its comprised of a shaft upon which are
mounted a lamination stack, conductors that form the winding and a commutator to which the windings are
electrically connected.
C. Brushes, located in the solenoid/motor assembly (4), provides a rotating connection through which the
armature assembly may be electrically energized.
D. Basic dimensions for the 122-( ) and 149-( ) HT series starters are found in Fig. 2.2A thru 2.2C. The 12 volt
and 24 volt HT series starters share like dimensions.
E. Starting motor pinions are specically designed to match the engine ring gear for proper mesh and cranking
performance. It is therefore important to ensure correct tooth count of ring gear. One quick and easy way is
to use HET’s ring gear check gage (Fig. 2-3). Running correctly matched gears will guarantee proper engine
cranking speed and service life for your starter.
CAUTION!
TO PREVENT DAMAGE TO THE STARTER AND/OR THE ENGINE FLYWHEEL RING
GEAR, ENSURE THE STARTER’S PINION GEAR TOOTH-COUNT MATCHES THE
ENGINE FLYWHEEL RING GEAR TOOTH-COUNT.
2.5 Theory of Operation
A. When the starting circuit is energized, battery current is applied to the starting motor terminal. At the same
time, current ows to the starter solenoid causing the the solenoid armature to extend axially and close the
internal electrical contacts. Current ows to the starter motor and extends the pinion gear for engagement
with the engine ywheel ring gear.
ST1005 80-10-01
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Aircraft Starter
Maintenance Manual

B. Starter motor engagement occurs when the pinion gear meshes with the ywheel ring gear. On the engine is
a ywheel with a ring gear attached around its edge. This ywheel is tted to the end of the crankshaft. On
the starter, the pinion is designed to t into the grooves of the ring gear. The starter motor is powered by the
solenoid, which helps to push the starter gear forward to mesh with the engine ywheel. As the starter motor
spins it turns the ywheel, which turns the crankshaft to initiate the rst engine combustion cycle. As soon as
the engine starts, the pinion disengages from the ywheel and remains dormant until the next starting event is
requested.
2.6 Operational Data
A. 122-12HT / 149-12HT
Weight 8.9 lbs
Voltage 12 volts
Power 1.7 kW
B. 122-24HT / 149-24HT
Weight 8.9 lbs
Voltage 24 volts
Power 3.2 kW
C. Duty Cycle
(1) 10 seconds of power (start), 20 seconds cool down (rest) for up to 6 starts.
(2) 30 minutes cool down before next start attempt.
80-10-01 ST1005
Page: 2-2 Rev. NEW: 05 Dec. 2022
© 2022 - Hartzell Engine Technologies - All rights reserved
Aircraft Starter
Maintenance Manual