F0296
41 boulevard de la République 78401 Chatou Cedex France Tel : + 33 (0)1 34 80 73 00
Fax : + 33 (0)1 30 71 01 40
COMPONENT MAINTENANCE MANUAL
WITH
ILL USTRATED PARTS L IST
STARTER GENERATOR
P/N: 8260-121
P/N: 8260-123
This document and all information contained herein, is the sole property of THALES AVIONICS ELECTRICAL SYSTEMS SA. No intellectual property rights are granted by the delivery of this document or the disclosure of its content. This document shall not be reproduced, duplicated or disclosed to a third party without the express written consent of THALES AVIONICS ELECTRICAL SYSTEMS SA. This document and its consent shall not be used for any other purpose other than that for which it is supplied.
SAFETY ADVISORY
WARNING:
MAKE SURE ALL PERSONS KNOW AND OBEY THE PRECAUTIONS
RECOMMENDED BY THE MANUFACTURER OR SUPPLIER FOR EACH MATERIAL
BEFORE IT IS USED. REFER TO THE MANUFACTURER / SUPPLIER DATA FOR THE PROCEDURES TO DISCARD THESE MATERIALS. IF THE MANUFACTURER’ S OR SUPPLIER’ S INSTRUCTIONS ARE NOT OBEYED, INJURY TO PERSONS CAN OCCUR.
WARRANTY / LIAIBILITY / ADVISORY
WARNING
The use of any non-specified parts or parts which do not strictly conform to the manufacturer specification and drawings for STARTER GENERATOR P/N 8260-12* and / or not repaired or made by facilities approved by THALES AVIONICS ELECTRICAL SYSTEMS can cause product malfunctions which could result in damage to, or destruction of, equipment and injury to personnel and can cancel warranties underwritten by THALES AVIONICS ELECTRICAL SYSTEMS. Use only the replacement parts specified in the illustrated Parts List page block of the corresponding CMM or replacement parts proven to strictly conform to applicable manufacturer specifications and drawings for STARTER GENERATOR P/N 8260-12*.
THALES AVIONICS ELECTRICAL SYSTEMS is not responsible for STARTER GENERATOR P /N 8260-12* that i s no t m aintained and/or repaired i n acco rdance w ith THALES AVIONICS ELECTRICAL SYSTEMS published instructions. THALES AVIONICS ELECTRICAL SYSTEMS is no t res po ns ib le fo r sp eci al to ol s and tes t
THALES A VIONICS ELECTRICAL SYSTEMS
COMPONENT MAINTENANCE MANUAL
P/N 8260-12*
1 MAR. 15/87 2 FEB. 15/88 3 SEP. 15/90 4 JUN. 15/93 5 DEC. 15/93 6 FEB. 15/99 7 FEB. 28/00 8 MAR. 12/01 9 MAY 19/08RECORD OF REVISIONS
REV No. ISSUE DATE DATE
INSERTED REV No. ISSUE DATE
DATE
INSERTED BY
THALES AVIONICS ELECTRICAL SYSTEMS
COMPONENT MAINTENANCE MANUAL
P/N 8260-12*
THALES A VIONICS ELECTRICAL SYSTEMS
COMPONENT MAINTENANCE MANUAL
P/N 8260-12*
RECORD OF TEMPORARY REVISIONS
TEMPORARY REVISIONS PAGE NO. ISSUE DATE NO. DATE INSERTED BY DATE PERMANENT REVISION NO. BY CANCELLED
THALES AVIONICS ELECTRICAL SYSTEMS
COMPONENT MAINTENANCE MANUAL
P/N 8260-12*
THALES A VIONICS ELECTRICAL SYSTEMS
COMPONENT MAINTENANCE MANUAL
P/N 8260-12*
Title Page 1 MAY 19/08
2 BLANK
Safety Warranty 1 MAY 19/08
Liability Advisory 2 BLANK
Record of Revisions 1 MAY 19/08
2 BLANK
Record of 1 MAY 19/08
Temporary 2 BLANK
Revisions
List of Effective Pages 1 MAY 19/08
2 MAY 19/08
Service Bulletin List 1 MAY 19/08
2 MAY 19/08
List of Amendments 1 MAY 19/08
2 MAY 19/08
Table of Contents 1 MAY 19/08
2 MAY 19/08 Introduction 1 MAY 19/08 2 MAY 19/08 3 MAY 19/08 4 MAY 19/08 5 MAY 19/08 6 BLANK
Description and 1 MAY 19/08
Operation 2 MAY 19/08
3 MAY 19/08
4 MAY 19/08
5 MAY 19/08
6 MAY 19/08
Testing and 1001 MAY 19/08
Fault Isolation 1002 MAY 19/08
1003 MAY 19/08 1004 MAY 19/08 1005 MAY 19/08 1006 MAY 19/08 Disassembly 3001 MAY 19/08 3002 MAY 19/08 3003 MAY 19/08 3004 MAY 19/08 3005 MAY 19/08 3006 MAY 19/08 3007 MAY 19/08 3008 MAY 19/08 3009 MAY 19/08 3010 MAY 19/08 Cleaning 4001 MAY 19/08 4002 MAY 19/08 4003 MAY 19/08 4004 MAY 19/08 4005 MAY 19/08 4006 MAY 19/08 Inspection/Check 5001 MAY 19/08 5002 MAY 19/08 5003 MAY 19/08 5004 MAY 19/08 5005 MAY 19/08 5006 MAY 19/08 5007 MAY 19/08 5008 MAY 19/08 Repair 6001 MAY 19/08 6002 MAY 19/08 6003 MAY 19/08 6004 MAY 19/08 6005 MAY 19/08 6006 MAY 19/08 Assembly 7001 MAY 19/08 7002 MAY 19/08 7003 MAY 19/08 7004 MAY 19/08 7005 MAY 19/08 7006 MAY 19/08 7007 MAY 19/08 7008 MAY 19/08 7009 MAY 19/08 7010 MAY 19/08 7011 MAY 19/08 7012 MAY 19/08 7013 MAY 19/08 7014 MAY 19/08 7015 MAY 19/08 7016 MAY 19/08 7017 MAY 19/08 7018 BLANK
Fits and Clearances 8001 MAY 19/08
8002 MAY 19/08
LIST OF EFFECTIVE PAGES
SUBJECT PAGE DATE SUBJECT PAGE DATE
THALES AVIONICS ELECTRICAL SYSTEMS
COMPONENT MAINTENANCE MANUAL
P/N 8260-12*
Special Tools 9001 MAY 19/08
Fixtures 9002 MAY 19/08
Equipment and 9003 MAY 19/08
Consumables 9004 MAY 19/08 9005 MAY 19/08 9006 MAY 19/08 9007 MAY 19/08 9008 MAY 19/08 9009 MAY 19/08 9010 MAY 19/08 9011 MAY 19/08 9012 MAY 19/08 9013 MAY 19/08 9014 MAY 19/08 Illustrated 1 MAY 19/08
Parts List 2 BLANK
TP 10001 INTRO 10001 1 MAY 19/08 2 MAY 19/08 3 MAY 19/08 4 BLANK VCI 10001 1 MAY 19/08 2 MAY 19/08 NI ALPHA 10001 1 MAY 19/08 2 MAY 19/08 3 MAY 19/08 4 BLANK NI NUM 10001 1 MAY 19/08 2 MAY 19/08
Detailed Parts List 10001 MAY 19/08
10001-0 MAY 19/08 10001-1 MAY 19/08 10001-2 MAY 19/08 10001-3 MAY 19/08 10002-0 MAY 19/08 10002-1 MAY 19/08 10002-2 MAY 19/08 10002-3 MAY 19/08 10002-4 MAY 19/08 10002-5 BLANK 10003-0 MAY 19/08 10003-1 MAY 19/08 10003-2 BLANK Storage 15001 MAY 19/08 (including 15002 MAY 19/08 Transportation) 15003 MAY 19/08 15004 BLANK
THALES A VIONICS ELECTRICAL SYSTEMS
COMPONENT MAINTENANCE MANUAL
P/N 8260-12*
8260-120-24-001* A JUL. 87 Ball bearings : change in grease grade.
Valid for version 8260-120 which is deleted to the CMM.
8260-120-24-002* B JAN. 90 Baffle added to armature for ball
bearing protection on drive end. Valid for version 8260-120 which is deleted to the CMM.
8260-120-24-003* C JUL. 87 Flanged bearing changed.
Valid for version 8260-120 which is deleted to the CMM.
8260-120-24-004 8260-121 JUL. 88 Mounting of an oil screen.
8260-120-24-005 F MAR. 91 An insulated deflector is fitted at
commutator end part of laminated circuit.
8260-120-24-006 E SEP. 90 Metallic part used to secure electric
leads from stator windings and from brushes is isolated from brush holder case.
8260-120-24-007 D FEB. 92 Replacement of four screws securing
the flange and improvement of the tightening torque.
8260-12*-24-008 H DEC. 98 The shape and the material of the
terminal block are different. The capacitors, the terminals and the nuts are kept (for S. G. P/N 8260-120/121).
A DEC. 98 The shape and the material of the
terminal block are different. The capacitors, the terminals and the nuts are kept (for S. G. P/N 8260-123).
8260-12*-24-009 J DEC. 98 Replacement of the speed sensor
P/N P058067 by the speed sensor P/N P609742 (for S. G. P/N 8260-120/121).
B DEC. 98 Replacement of the speed sensor
P/N P058067 by the speed sensor P/N P609742 (for S. G. P/N 8260-123).
SERVICE BULLETIN LIST
DESCRIPTION
DATE
MOD. STATE
IDENT.
SERVICE
BULLETIN
THALES AVIONICS ELECTRICAL SYSTEMS
COMPONENT MAINTENANCE MANUAL
P/N 8260-12*
8260-12*-24-010 K OCT. 97 The insulator P/N P714615 becomes
P/N P721751.
8260-12*-24-011 8260-123 DEC. 98 Brushes P/N P601952 are replaced by
brushes P/N P607965.
8260-12*-24-012 M DEC. 98 Lining P/N P714154 is replaced by lining
P/N P714154-1 (for S. G. P/N 8260-120/121).
D DEC. 98 Lining P/N P714154 is replaced by lining
P/N P714154-1 (for S. G. P/N 8260-123).
8260-12*-24-013 N DEC. 02 Bearing P/N 410964 is replaced by
bearing P/N B320050L, Bearing P/N 410965 is replaced by bearing P/N B320250L (for S. G. P/N 8260-121).
E DEC. 02 Bearing P/N 410964 is replaced by
bearing P/N B320050L, Bearing P/N 410965 is replaced by bearing P/N B320250L (for S. G. P/N 8260-123).
8260-12*-24-014 MAY 03 Guarantee the reliability of the Starter
Generator by a correct application of the overhaul procedures in accordance with specification.
8260-12*-24-016 P DEC. 04 Obsolescence of the commutator. The
commutator P/N P057017-1 is replaced by P/N P500315, the armature P604823-3 becomes P/N P60482P604823-3-4 or P/N P604823-4R when the armature is rewound or recomm (for S. G. P/N 8260-121).
F DEC. 04 Obsolescence of the commutator. The
commutator P/N P057017-1 is replaced by P/N P500315, the armature P604823-3 becomes P/N P604823-4 or P/N P604823-4R when the armature is rewound or recomm (for S. G. P/N 8260-123).
DESCRIPTION
DATE
MOD. STATE
IDENT.
SERVICE
BULLETIN
THALES A VIONICS ELECTRICAL SYSTEMS
COMPONENT MAINTENANCE MANUAL
P/N 8260-12*
A Ball bearings : change in grease grade. 8260-120
Version Deleted
B Baffle added to armature for ball 8260-120
bearing protection on drive end. Version Deleted
C Flanged bearing changed. 8260-120
Version Deleted
Mounting of an oil screen. 8260-121
F An insulated deflector is fitted at commutator 8260-121
end part of laminated circuit.
E Metallic part used to secure electric 8260-121
leads from stator windings and from brushes is isolated from brush holder case.
D Replacement of four screws securing 8260-121
the flange and improvement of the tightening torque.
G Replacement of the terminal block P/N 8260-121
P604100 by the terminal block P/N P608636.
H Replacement of the terminal block P/N 8260-121
P608636 by the terminal block P/N P608636-1.
J Replacement of the speed sensor 8260-121
P/N P058067 by the speed sensor P/N P609742.
K The insulator P/N P714615 becomes 8260-121
P/N P721751.
M Lining P/N P714154 is replaced by lining 8260-121
P/N P714154-1.
N Bearing reliability improvement. Bearing P/N 8260-121
410964 becomes P/N B320050L and Bearing P/N 410965 becomes P/N B320250L.
P Obsolescence of the commutator. The 8260-121
commutator P/N P057017-1 is replaced by P/N P500315, the armature P604823-3 becomes P/N P604823-4 or P/N P604823-4R when the armature is rewound or recomm.
LIST OF AMENDMENTS
THALES AVIONICS ELECTRICAL SYSTEMS
COMPONENT MAINTENANCE MANUAL
P/N 8260-12*
A The shape and the material of the terminal 8260-123
block are different. The capacitors, the terminals and the nuts are kept.
B Replacement of the speed sensor 8260-123
P/N P058067 by the speed sensor P/N P609742.
D Lining P/N P714154 is replaced by lining 8260-123
P/N P714154-1.
E Bearing reliability improvement. Bearing P/N 8260-123
410964 becomes P/N B320050L and Bearing P/N 410965 becomes P/N B320250L.
F Obsolescence of the commutator. The 8260-123
commutator P/N P057017-1 is replaced by P/N P500315, the armature P604823-3 becomes P/N P604823-4 or P/N P604823-4R when the armature is rewound or recomm.
THALES AVIONICS ELECTRICAL SYSTEMS
COMPONENT MAINTENANCE MANUAL
P/N 8260-12*
Page INTRODUCTION... ... ... ... ... ... INTRO 1 1. INTRODUCTION... ... ... ... ... .... 1 2. SHOP CHECK ... ... ... ... ... ... 5 3. REVISIONS... ... ... ... ... ... 5 4. LIST OF ABBREVIATIONS... ... ... ... ... 5DESCRIPTION AND OPERATION ... ... ... ... 1
1. GENERAL ... ... ... ... ... ... 1
2. CHARACTERISTICS ... ... ... ... ... 1
3. DETAILED DESCRIPTION ... ... ... ... .... 4
4. OPERATION ... ... ... ... ... ... 5
TESTING AND FAULT ISOLATION ... ... ... . 1001
1. STARTER GENERATOR TEST ... ... ... ... 1001
2. STARTER GENERATO R FAULT ISOLATION ... ... ... 1004
SCHEMATIC AND WIRING DIAGRAMS ... ...NOT APPLICABLE DISASSEMBLY... ... ... ... ... 3001
1. DISASSEMBLY OF THE STARTER GENERATOR ... . 3001
CLEANING... ... ... ... ... ... ... ... 4001
1. CLEANING OF THE STARTER GENERATOR ... ... ... 4001
INSPECTION/CHECK... ... ... ... ... 5001
1. VISUAL INSPECTION OF THE STARTER GENERATOR... ... 5001
REPAIR... ... ... ... ... ... ... 6001
1. REPAIR OF THE STARTER GENERATOR ... ... ... 6001
ASSEMBLY... 7001
1. ASSEMBLY OF THE STARTER GENERATOR ... ... 7001
FITS AND CLEARANCES ... ... ... ... . 8001
1. FITS AND CLEARANCES ... ... ... ... 8001
2. TORQUE VALUE TABLE... ... ... ... ... 8002
THALES AVIONICS ELECTRICAL SYSTEMS
COMPONENT MAINTENANCE MANUAL
P/N 8260-12*
SPECIAL TOOLS, FIXTURES , EQUIPMENT AND CONS UMABLES ... 9001
1. LIST OF APPROVED REPAIR FACILITIES ... ... 9001
2. SPECIAL TOOLS, FIXTURES AND EQUIPMENT ... 9002
3. CONSUMABLES ... ... ... ... 9006
SPECIAL PROCEDURES ... ... ... ...NOT APPLICABLE INSTALLATION ... ... ... ...NOT APPLICABLE SERVICING ... ... ... ... ... ... NOT APPLICABLE STORAGE (INCLUDING TRANSPORTATION) ... ... ... 15001
1. STORAGE INSTRUCTIONS ... ... ... ... ... 15001
REWORK... ... ... ... ... ... NOT APPLICABLE Illustrated parts list... ... ... ... ...TP 10001 INTRODUCTION ... ... ... .... IPL INTRO 1 1. GENERAL... ... ... ... ... ... ...IPL INTRO 1 2. UTILISATION OF THE DETAILED PARTS LIST ... ...IPL INTRO 1 3. TERMS AND ABBREVIATIONS USED... ... ...IPL INTRO 3 4. UPDATING ... ... ... ... ...IPL INTRO 4 VENDOR CODE INDEX ... ... ... ... .. VCI 1 ALPHA NUMERICAL INDEX ... NI/ALPHA 1 NUMERICAL INDEX... ... ... ... ... ...NI/NUM 1 DETAILED PARTS LIST... ... ... ... ... 10001
THALES A VIONICS ELECTRICAL SYSTEMS
COMPONENT MAINTENANCE MANUAL
P/N 8260-12*
TASK 24-32-61-871-801-A01 1. INTRODUCTION
A. General
(1) This component maintenance manual (CMM) agrees with the Air Transport Association (ATA) Spec 100 revision 37.
(2) This CMM gives the procedures necessary to do easy checks and replacement of parts and components manufactured by THALES AVIONICS ELECTRICAL SYSTEMS S. A., 41 Boulevard de la République BP 53- 78401 CHATOU Cedex-FRANCE. It also
gives the procedures for maintenance. The maintenance procedures given in this CMM are only for approved persons with the necessary skills.
(3) This CMM gives the shop maintenance procedures of the component.
(4) This manual uses the identification of the tasks and subtasks which as specified in the Maintenance Task Oriented Support System (MTOSS). The maintenance tasks and other data have special MTOSS numbers for the use of Electronic Data Processing (EDP). The user of the manual can ignore the MTOSS numbers.
(5) This manual contains:
− the technical data for the component,
− the maintenance and repair procedures for the component,
− an Illustrated Parts List (IPL) with the data for the component parts. The IPL Figure and the item number identify the parts in all the Page Blocks of the manual.
(6) A check of the DISASSEMBLY, TESTING and ASSEMBLY procedures was done in a workshop.
B. How to Use the Manual
(1) Make sure the manual contains the applicable data for your component. Look for the part number on the Title Page.
(2) To identify a part or to find a part number, refer to the IPL, which has an Introduction to show the procedure.
(3) You must use the instructions in this manual, for all the maintenance steps of a component. Read all the applicable WARNINGS and CAUTIONS before you do the work on the component.
(4) When you use consumable materials, a part number, which is shown in the list of the Consumable Materials Table, identifies these materials.
THALES AVIONICS ELECTRICAL SYSTEMS
COMPONENT MAINTENANCE MANUAL
P/N 8260-12*
(5) When you use special tools, a part number, which is shown in the list of the Special Tools Table, identifies these tools.
(6) For the tightening torque values of the parts, refer to the Table of Tightening Torques. C. CMM Page Blocks (Page blocks)
(1) The information for each component in the CMM is divided into specific Page Blocks. Each Page Block has its specified subject matter and its specified page numbers. These Page Blocks have these titles:
PAGE BLOCK Type PAGE BLOCK
Number
PAGE BLOCK Pagination
INTRODUCTION INTRO 1 1−99
DESCRIPTION AND OPERATION 1 1−999
TESTING AND FAULT
ISOLATION 1000 1001−1999
SCHEMATIC AND WIRING
DIAGRAMS 2000 2001−2999 DISASSEMBLY 3000 3001−3999 CLEANING 4000 4001−4999 CHECK 5000 5001−5999 REPAIR 6000 6001−6999 ASSEMBLY 7000 7001−7999
FITS AND CLEARANCES 8000 8001−8999
SPECIAL TOOLS, FIXTURES, EQUIPMENT AND CONSUMABLES 9000 9001−9999 SPECIAL PROCEDURES 11000 11001−11999 REMOVAL 12000 12001−12999 INSTALLATION 13000 13001−13999 SERVICING 14000 14001−14999 STORAGE (including TRANSPORTATION) 15000 15001−15999
REWORK (Service Bulletin
accomplishment) 16000 16001−16999
THALES AVIONICS ELECTRICAL SYSTEMS
COMPONENT MAINTENANCE MANUAL
P/N 8260-12*
(2) The Introduction explains the organization of the data in the CMM and the use of the data (DO and MP parts only).
− For IPL part: see IPL INTRO (PAGE BLOCK 10000).
− The introduction includes a glossary of non standard abbreviations.
(3) Description and Operation
− This page block gives general overall information. − It gives a mechanical and an electrical description.
− It explains the configuration and the operation of the component. − It explains external connector interconnections in the component.
(4) Testing and Fault Isolation
− This page block contains specific tests and procedures required to determine the condition of a component.
− It includes fault isolation data.
(5) Schematic and Wiring Diagrams
− This page block contains contains all schematic diagrams, wiring and interconnecting diagrams of cards, chassis wiring, modules, subassemblies.
(6) Disassembly
− This page block gives step−by−step disassembly instructions in a logical sequence (in the order of IPL item numbers). It includes references to the figure item numbers from the IPL illustration(s) where applicable.
(7) Cleaning
− This page block gives step−by−step description of the cleaning operations for the component and its parts.
(8) Check
− This page block gives all the check procedures that are necessary during shop maintenance.
(9) Repair
− This page block contains detailed repair procedures and specifications necessaryto restore a worn or damaged part to serviceable condition.
(10) Assembly
− This page block gives step−by−step assembly instructions in a logical sequence, references to the figure item numbers from the IPL illustration(s) where applicable.
THALES AVIONICS ELECTRICAL SYSTEMS
COMPONENT MAINTENANCE MANUAL
P/N 8260-12*
(11) Fits and Clearances
− This page block provides the fits and clearances data, in one or more tables, and torque tightening figures if applicable.
(12) Special Tools, Fixtures, Equipment and Consumables
− This page block lists all special tools, fixtures, equipment and consumables necessary for maintenance actions given in the other page blocks. (13) Illustrated Parts List
− This page block contains the complete list of all the parts of the component (For detailed description of the IPL, see IPL INTRO).
(14) Special Procedures
− This page block contains tasks which are not part of the other page blocks, but are necessary as a result of other maintenance tasks.
− These tasks are self −contained repairs or preventive maintenance. (15) Removal − Not applicable. (16) Installation − Not applicable. (17) Servicing − Not applicable. (18) Storage
− This page block contains requirements related to preparation for transportation, special handling, packaging, storage and preservation requirements of the component after assembly or test.
(19) Rework
− Not applicable.
(20) Measurements
− The measurements, which are given in this manual, come from the srcinal manufacturing drawings.
− This CMM uses the "System International"(S.I.) units for quantities and values. It also gives the imperial units in parentheses.
THALES AVIONICS ELECTRICAL SYSTEMS
COMPONENT MAINTENANCE MANUAL
P/N 8260-12*
TASK 24-32-61-879-801-A01
2. SHOP CHECK
A. The manufacturer has checked that the procedures described in the page blocks of the manual are correct. For this purpose, it has performed the disassembly, assembly and check procedures.
TASK 24-32-61-879-802-A01
3. REVISIONS
A. With each revision written for the manual, full instructions are supplied. These refer to the related page numbers for insertion and deletion.
B. Revised, added or deleted material is identified by a vertical black line or the letter R in the left-hand margin of the page.
TASK 24-32-61-879-803-A01
4. LIST OF ABBREVIATIONS
ATA Air Transport Association of America
DPL Detailed Parts List
IPL Illustrated Parts List
LEP List of Effective Pages
LOA List Of Amendments
NI/ALPHA Numerical Index ALPHAbetical
NI/NUM Numerical Index NUMeric
ROR Record Of Revisions
RTR Record of Temporary Revisions
SB Service Bulletin
SBL Service Bulletin List
TC Table of Contents
V Volt
VA Volt Ampere
VCI Vendor Code Index
THALES AVIONICS ELECTRICAL SYSTEMS
COMPONENT MAINTENANCE MANUAL
P/N 8260-12*
THALES AVIONICS ELECTRICAL SYSTEMS
COMPONENT MAINTENANCE MANUAL
P/N 8260-12*
TASK 24-32-61-872-801-A01
1. GENERAL (REF. IPL, FIGURES 1 AND 2)
NOTE: This manual covers the maintenance of generator P/N 8260-12*. This
starter-generator is provided with a cover fitted with three studs for attachment of a ventilation nozzle.
The starter-generator mainly comprises: − a frame (2-260),
− a flanged bearing (2-220),
− a commutator bearing assembly (1-180), − an armature (2-240),
− a speed sensor (2-100).
The assembly is cooled by a fan (1-140) protected by a cover (1-30).
TASK 24-32-61-872-802-A01
2. CHARACTERISTICS
The starter-generator is a shielded unit having the following characteristics:
A. General characteristics
− Overall dimensions : See figure 1
− Maximum altitude : 10 600 m (35 000 ft)
− Cooling : self-cooling and forced air cooling
− Rotational direction : counter clockwise (as seen from drive
shaft end)
− Attachment : quick-release system (taper
mounting flange)
− Weight : 18.350 kg (40.45 Ib)
THALES AVIONICS ELECTRICAL SYSTEMS
COMPONENT MAINTENANCE MANUAL
P/N 8260-12*
B. Detailed characteristics − Generator operation: • voltage : 30 V DC • rated current : 400 A • power : 12 kW • speed range : 7 200 to 12 000 rpm − Starter operation: • torque : 3.6 m.kg (126.03 ft.lb) • speed : 1 750 rpm • current : 800 A • voltage : 16 V DCTHALES AVIONICS ELECTRICAL SYSTEMS
COMPONENT MAINTENANCE MANUAL
P/N 8260-12*
GRAPHIC 24-32-61-991-001-A01 OVERALL DIMENSIONS
THALES AVIONICS ELECTRICAL SYSTEMS
COMPONENT MAINTENANCE MANUAL
P/N 8260-12*
TASK 24-32-61-872-803-A01
3. DETAILED DESCRIPTION
A. Frame (REF. IPL, Figure 2)
The frame (260) houses a set of field coils whose output leads, protected by a gasket (250) and an insulator (275), are connected to a terminal block (280).
The terminal block is secured to the frame by screws (300) and tabwashers (290). It comprises two main terminals (E and B) to which the connecting leads are secured by nuts (340 and 360) and washers (330 and 350), and two auxiliary terminals (A and D) to which the connecting leads are secured by nuts (320 and 380) and washers (310 and 370). A connector (130) is secured to the frame (270) by screws (150) and washers (140) by
means of a box (160) secured by screws (180) and tabwashers (170).
The identification plate (390), the modification plate (410) and the indicating plate (430) are secured by rivets (400, 420 and 430) to the external surface of the frame.
B. Flanged bearing (REF. IPL, Figure 2)
The flanged bearing (220), fitted at the front with a baffle for cooling air exhaust, fits into the frame to which it is secured by screws (230).
A locating pin is provided at the front to correctly position the starter-generator on itsmount. The flanged bearing is provided with a central bore accommodating a ball bearing (70). This ball bearing is retained in the flanged bearing by a flange (80) secured by screws (90) and on the armature shaft by a key (40).
C. Commutator bearing assembly (REF. IPL, Figures 1 and 2)
The commutator bearing assembly (1-180) fits into the frame to which it is secured by screws (1-190) fitted with tabwashers (1-200) and plain washers (1-210).
It is fitted with a central bore accommodating a ball bearing (1-470) whose outer race ring is retained by a flange (1-480) secured by screws (1-490).
The commutator bearing assembly comprises four guides (1-410) accommodating brushes 60) applied against the commutator by brush springs 310) retained on their pins (1-250) by spacers (1-320) and (1-330) and retaining rings (1-340). The brush shunts are connected to the windings of the set of field coils by screws (1-70) and washers (1-80).
A removable brush cover (1-10) fitted with a screw (1-20) is placed around the commutatorbearing assembly to permit rapid checking of the brushes.
D. Armature (REF. IPL, Figures. 1 and 2)
The armature (2-240) is driven by a torque shaft (1-90) whose visible portion is provided with a splined drive end.
THALES AVIONICS ELECTRICAL SYSTEMS
COMPONENT MAINTENANCE MANUAL
P/N 8260-12*
E. Fan (REF. IPL, Figure 1)
The fan (1-140), which bears against the inner race ring of the ball bearing (1-470), is secured to the armature shaft by a key (1-150) and a nut (1-160) fitted with a washer (1-170), for self-cooling purposes.
It draws the air through a ventilation nozzle secured to a cover (1-30) by 3 studs, and expels it into the starter-generator to provide adequate cooling. The cover is secured by screws (1-40) and washers (1-50).
F. Vibration absorber (REF. IPL, Figures 1 and 2)
The starter-generator is fitted with a torque shaft vibration damper consisting of two discs (2-10) and (2-30) driven in rotation by the armature and the torque shaft, respectively. In the event of torque shaft vibration, these discs rub against a lining (2-20) placed between them until vibration is suppressed. A spring (1-120), clamped by a nut (1-100) and a bearing against washers (1-110) and (1-130), is used to adjust the operating clearance of the vibration damper.
G. Speed sensor (REF. IPL, Figure 2)
The speed sensor (100) is located at the front of the starter-generator and is secured to the flanged bearing (220) by a nut (120) fitted with a washer (110).
TASK 24-32-61-872-804-A01
4. OPERATION (REF. FIGURE 2)
The starter-generator comprises a four-pole magnetic circuit with four shunt coils connected in series between the terminal (A) and the negative terminal (E) and four commutating and compensating coils connected in series between terminal (E) and the negative brushes. The terminal (D) is connected to the negative brushes.
A. Starter operation
The starter-generator operates as a series-wound DC motor capable of providing a torque of 3.6 m.kg (26.03 ft.lb).
B. Generator operation
The starter-generator generates a DC voltage of 30 V and is capable of providing a power of 12 kW for driving speeds ranging from 7 200 to 12 000 rpm.
THALES AVIONICS ELECTRICAL SYSTEMS
COMPONENT MAINTENANCE MANUAL
P/N 8260-12*
GRAPHIC 24-32-61-991-002-A01 OPERATION
THALES AVIONICS ELECTRICAL SYSTEMS
COMPONENT MAINTENANCE MANUAL
P/N 8260-12*
TASK 24-32-61-700-801-A01
1. STARTER GENERATOR TEST
A. Reason for the job Self-explanatory
B. Job set-up Information
(1) Tools, fixtures and equipment
NOTE: You can use equivalent alternatives for the items given in the list.
NOTE: Refer to the page block “SPECIAL TOOLS, FIXTURES, EQUIPMENT AND CONSUMABLES” for full data about the special tools in this list.
NOTE: The tests must be performed at a temperature of + 20 °C (68 °F). NOTE: During the tests the starter generator must be self-cooled.
NOTE: Generator brushes must be seated 100 % in the direction of rotation and 80% minimum in the axial direction.
NOTE: Connect the various test set-up components as shown on the test set-up figure 1002.
PART NUMBER
QTY NAME
No specific 1 Voltage regulator identical to that installed in the aircraft or equivalent
No specific 1 Starter-generator drive stand capable of a driving speed of 14000 rpm
No specific 1 Load resistor (RC) capable of 500 A at 30 V
No specific 1 Moving-coil ammeter (A1), class 0.5, with 20 A shunt
No specific 1 Moving-coil ammeter (A2), class 0.5, with 500 A shunt No specific 1 Moving-coil voltmeter (V1), class 0.5, rating: 40 V DC
No specific 1 Megger for measuring the insulating resistance at 45-50 V DC
No specific 1 SPST switch (IC)
No specific 1 Resistor 0.4 Ω, 50 W
No specific 1 Vibrotest Schenk 60 equipped with captor AS.065 x 107 x, 3
kHz high-pass band filter and 1 kHz low-pass band filter or equivalent
THALES AVIONICS ELECTRICAL SYSTEMS
COMPONENT MAINTENANCE MANUAL
P/N 8260-12*
PART NUMBER QTY NAME
VCF02GE 1 Switch I1: 10A or equivalent
350X4033R 1 Rheostat Rh1: 315 W, 33 Ω, 5 % or equivalent
Plate shunt 100 A 1 Shunt: 100 A, 75 mV or equivalent
30243STPA-209 1 Contactor K1: 200 A, 28 V DC or equivalent
C. Job set-up Not applicable.
D. Procedure
Subtask 24-32-61-750-001-A01
(1) Maximum regulation speed test (For overhaul only) − Gradually start the drive stand.
− Drive the starter-generator at a speed of 12 000 rpm.
− Check the voltage on V1 is 29 V DC ± 0.3 V DC at 20 °C (68 °F) or 29 V DC ± 0.5 V DC full temp range.
• the field current is : 1 A ≤ I ≤ 2.1 A as read on A1. Subtask 24-32-61-750-002-A01 (For overhaul only)
(2) Minimum regulation speed test (For overhaul only) − Gradually start the drive stand.
− Drive the starter-generator at a speed of 7200 rpm. − Set the voltage reading on V1 to 29 V.
− Set the load resistance reading on A1 is 400 A. − Check the field current measured is : I < 11 A. Subtask 24-32-61-750-003-A01
(3) Insulation test
− Check that the insulation resistance of the starter-generator is ≥ 20 kΩ with 45-50 V DC between terminal E and frame, applied for a brush change or a brush and bearing change.
THALES AVIONICS ELECTRICAL SYSTEMS
COMPONENT MAINTENANCE MANUAL
P/N 8260-12*
− Check that the insulation resistance of the starter-generator is ≥ 100 kΩ with 45-50 V DC applied for an overhaul.
− Check that the insulation resistance of the starter-generator is ≥ 10 MΩ with 45-50 V DC between pin 1 of the speed sensor and the frame and between pin 2 of the speed sensor and the frame.
NOTE: Discharge the spark capacitors before carrying out the insulation test. Subtask 24-32-61-750-004-A01
(4) Resistance value of the speed sensor
− Check that the resistance value is 115 Ω ± 10 Ω with 45-50 V DC between pins 1 and 2 of the speed sensor connector.
Subtask 24-32-61-750-005-A01
(5) Vibration test
This test has to be carried out under no load, at a speed of 6000 rpm in starter operating mode and without the torque shaft (1-90) and vibration damper (2-30) fitted on the machine.
− Connect the starter generator as shown in figure 7008.
− Set the excitation rheostat (Rh1) to its munimum resistance value. − Set the voltage of the variable DC power supply at the munimum value. − Close switch I1 and gradually increase the voltage up to 30 V DC.
− Increase the resistance (Rh1) to obtain a rotational speed of approximately 6000 rpm.
− Using a vibrotest, check that:
• The vibration on DE (Drive End) (see figure 1001) is ≤ 15 μm. • The vibration on NDE (Not Drive End) (see figure 1001) is ≤ 15 μm. − Reset the rheostat (Rh1) to a minimum and open switch I1 to stop the starter
generator.
THALES AVIONICS ELECTRICAL SYSTEMS
COMPONENT MAINTENANCE MANUAL
P/N 8260-12*
GRAPHIC 24-32-61-991-1001-A01 VIBRATION TEST
THALES AVIONICS ELECTRICAL SYSTEMS
COMPONENT MAINTENANCE MANUAL
P/N 8260-12*
TASK 24-32-61-700-802-A01
2. STARTER GENERATOR FAULT ISOLATION A. Reason for the job
Self-explanatory
B. Job set-up Information Not applicable C. Job set-up
Not applicable D. Procedure
FAULT POSSIBLE CAUSE CORRECTION
− Fan rubbing against the cover.
− Check the fan and the cover, replace the defective part. − Vibration and abnormal
noises.
− Rear ball bearing defective.
− Replace the ball bearing and refer to page block «FITS AND CLEARANCES » for
assembly. STARTER OPERATION
− The starter generator fails to rotate.
− Torque shaft broken. − Brush shunt open.
− Replace the torque shaft. − Replace the brushes. − At rated loads, the
starter-generator does not rotate at normal speed and does not apply the rated torque of 3.6 m.daN (26.55 ft.lb).
− Worn brushes.
− Partial short-circuit in the inductor.
− Measure the brush length and replace them if out of tolerance.
− Replace the frame.
− Excessive current consumption.
− Short-circuit in the commutator or armature windings.
− Clean the commutator. If the trouble persists, replace the armature.
THALES AVIONICS ELECTRICAL SYSTEMS
COMPONENT MAINTENANCE MANUAL
P/N 8260-12*
FAULT POSSIBLE CAUSE CORRECTION
GENERATOR OPERATION
− Zero output voltage. − Torque shaft broken. − Replace the torque shaft.
− Shunt winding shorted or opened.
− Replace the frame.
− Incorrect commutation − Brushes not sliding
correctly in their guides.
− Clean the brush guides.
− The residual measurement must be performed after a heating test at 6400 rpm. It must not be less than 0.8 V.
TABLE 24-32-61-992-101-A01
NOTE : The regulator used in this set-up is an «THALES A.E.S.» generator control unit P/N 102-003-**
GRAPHIC 24-32-61-991-1002-A01 TEST SET-UP DIAGRAM
THALES AVIONICS ELECTRICAL SYSTEMS
COMPONENT MAINTENANCE MANUAL
P/N 8260-12*
TASK 24-32-61-000-801-A01
1. DISASSEMBLY OF THE STARTER GENERATOR
Disassemble the starter-generator only to the extent necessary to repair or replace defective parts.
In programmed maintenance, two types of operations are possible.
NOTE :For the two types of operation, discard systematically all locking parts. − Brushes and / or Bearings replacement (Ref. IPL, Figures. 1 and 2)
• Disassembly (Refer to page block ″DISASSEMBLY″).
• Replace components detailed in the Kit P/N CBR8260-121, CBR8260-123, CRR8260-123 (bearing change), CBA8260-121 and CBA8260-CRR8260-123 (brush change).
• Clean the armature (Refer to Subtask 24-32-61-160-003-A01″). • Assembly (Refer to page block ″ ASSEMBLY″).
CBR8260-121 and CBR8260-123 : brush and bearing replacement for SG 8260-121 and 8260-123
− Bedding the brushes is recommended to avoid problem’s during the first start (Refer Subtask 24-32-61-420-014-A01).
− Effect the speed sensor adjustment (Refer Subtask 24-32-61-420-013-A01). − Effect the vibration test (Refer Subtask 24-32-61-750-005-A01)
DETAIL K IT P/N CBR8260-12 1 AND CB R8260-123
FIGURE ITEM QTY DESCRIPTION
1 60 8 Brush 1 80 8 Springwasher 1 100 1 Nut 1 110 1 Washer 1 170 1 Washer lock 1 200 4 Tabwasher 1 210 4 Washer 1 470 1 Bearing 1 490 4 Screw 2 50 1 Tabwasher 2 70 1 Bearing 2 90 4 Screw
DISASSEMBLY
THALES AVIONICS ELECTRICAL SYSTEMS
COMPONENT MAINTENANCE MANUAL
P/N 8260-12*
CRR8260-123 : bearing replacement for SG 8260-121 and 8260-123.
CAUTION: : EACH BRUSHES MUST BE REFIT IN THE SAME LOCATION LIKE BEFORE DISASSEMBLY.
− Effect the speed sensor adjustment (Refer Subtask 24-32-61-420-013-A01). − Effect the vibration test (Refer Subtask 24-32-61-750-005-A01)
DETAIL KIT P/N CRR8260-123 (BEARING CHANGE)
FIGURE ITEM QTY DESCRIPTION
1 80 8 Springwasher 1 100 1 Nut 1 110 1 Washer 1 170 1 Tabwasher 1 200 4 Tabwasher 1 210 4 Washer 1 470 1 Bearing 1 490 4 Screw 2 50 1 Tabwasher 2 70 1 Bearing 2 90 4 Screw
CBA8260-121 and CBA8260-123 : brush replacement for SG 8260-121 and 8260-123 − Bedding the brushes is recommended to avoid problem’s during the first start (Refer
Subtask 24-32-61-420-014-A01).
DETAIL KIT P/N CBA8260-121 AND CBA8260-123 (BRUSH CHANGE)
FIGURE ITEM QTY DESCRIPTION
1 60 8 Brush
1 80 8 Springwasher
1 100 1 Nut
THALES AVIONICS ELECTRICAL SYSTEMS
COMPONENT MAINTENANCE MANUAL
P/N 8260-12*
− Overhaul (Ref. IPL, Figs. 1 and 2) POST SB 8260-12*-24-014
• Disassembly (Refer to page block ″DISASSEMBLY″).
• Replace components as detailed in the Kit P/N RGN8260-120, RGN8260-121 and RGN8260-123.
• Clean all parts (Refer to page block ″CLEANING″).
• Check all parts (mechanical, visual inspection and electrical) (Refer to page block ″CHECK″ and “TABLE OF FITS AND CLEARANCES”).
• Apply systematically varnish 433-37A on all the faces of the windings heads . • Apply systematically anti-flash varnish 2407 on commutator bearing (1-180), armature
(2-240) (Refer to page block ″REPAIR″).
• Turn systematically the commutator diameter (minimum diameter = 67 mm (2.637 in) (Refer to page block ″REPAIR″).
CAUTION : IF THE ARMATURE MUST BE REPLACED DUE TO COMMUTATOR DIAMETER SMALLER THAN THE LIMIT OR DAMAGED, THE REPAIRED ARMATURE MUST BE FULLY COMPLIANT WITH THE TAES ARMATURE P604823-4. • Turn the commutator to a width of 2 mm (0.078 in) and to a depth of 1 mm (0.039 in)
(Refer to page block ″REPAIR″).
• Mill the micas to a depth of 0.5 to 1 mm maximum (Refer to page block ″REPAIR″). • Diamond the commutator (Refer to page block ″REPAIR″).
(a) Check that the total out of round of the commutator is ≤ 0.008 mm (0.000314 in) (before SB 8206-12*-24-016).
(b) Check that the total out of round of the commutator is ≤ 0.006 mm (0.000236 in) (post SB 8206-12*-24-016).
(c) Check that the bar to bar of the commutator is ≤ 0.003 mm (0.0001181 in) (before SB 8206-12*-24-016).
(d) Check that the bar to bar of the commutator is ≤ 0.002 mm (0.0000787 in) (post SB 8206-12*-24-016).
• Balance the armature (2-240) (Refer to page block ″REPAIR″). • Assembly (Refer to page block ″ ASSEMBLY″).
THALES AVIONICS ELECTRICAL SYSTEMS
COMPONENT MAINTENANCE MANUAL
P/N 8260-12*
DETAIL KIT P/N RGN8260-120, RGN8260-121 AND RGN8260-123
FIGURE ITEM QTY DESCRIPTION
1 50 4 Washer 1 60 8 Brush 1 70 8 Screw 1 80 8 Springwasher 1 100 1 Nut 1 170 1 Washer lock 1 200 4 Tabwasher 1 210 4 Washer 1 470 1 Bearing 1 490 4 Screw 2 50 1 Washer lock 2 70 1 Bearing 2 90 4 Screw 2 140 4 Washer 2 170 2 Tabwasher 2 190 1 Lug 2 200 1 Springwasher 2 230 8 Screw 2 250 1 Gasket 2 290 2 Tabwasher 2 310 1 Springwasher 2 330 1 Springwasher 2 350 1 Springwasher 2 370 1 Springwasher
THALES AVIONICS ELECTRICAL SYSTEMS
COMPONENT MAINTENANCE MANUAL
P/N 8260-12*
A. Reason for the job Self-explanatory
B. Job set-up Information
(1) Tools, fixtures and equipment
NOTE: Refer to the page block “TESTING AND FAULT ISOLATION” or
“INSPECTION/CHECK” to find the cause of a malfunction, or the condition of the equipment.
NOTE: Mandatory discard all locking parts. During an overhaul, also discard the brushes (1-60), the ball bearings (1-260) and (2-70) and the lining (2-20). NOTE: Refer to the page block SPECIAL TOOLS, FIXTURES, EQUIPMENT AND
CONSUMABLES for full data about the special tools in this list.
PART NUMBER
QTY NAME
E4276 1 Brush hook
E4820 1 Disc removing tool
E4233 1 Pin
E3396 1 Wrench
E4148-1J 1 Slotted nut socket
E6072 1 Commutator bearing extractor
E7351 1 Bearing pusher
E11875 1 Speed sensor tightening tool
E15526-2 1 Base
E5980 1 Vee
E5981 1 Support
No specific 1 Soldering iron
(2) Referenced information
REFERENCE DESIGNATION
IPL Figures 1, 2 and 3
THALES AVIONICS ELECTRICAL SYSTEMS
COMPONENT MAINTENANCE MANUAL
P/N 8260-12*
C. Job set-up Not applicable
D. Procedure
Subtask 24-32-61-020-001-A01
(1) Removing of the protection covers
− Remove the clamp (3-20) and the cover (3-10) from the starter generator. − Remove the cover (3-30) from the connector of the starter generator. Subtask 24-32-61-020-002-A01
(2) Removing the brushes
− Install the starter generator on the vee P/N E5980.
− Unlock and unscrew the screw (1-20) to remove the cover band (1-10). − Carefully mark the positions of brushes (1-60) and the associated shunts. − Remove the screws (1-70) fitted with the washers (1-80), lift brush springs (1-310)
using the brush dog hook P/N E4276 and remove the brushes (1-60). Subtask 24-32-61-020-003-A01
(3) Removing the cover
− Unlock and remove the four screws (1-40) fitted with the washers (1-50), then remove the cover (1-30).
Subtask 24-32-61-020-004-A01
(4) Removing the torque shaft
− Prevent the torque shaft (1-90) from rotating holding it with the disc (2-10), remove and discard the nut (1-100), then remove the plate washer (1-110), the spring (1-120) and the washer (1-130).
− Remove the torque shaft fitted with the disc (2-10). − Remove the lining (2-20).
Subtask 24-32-61-020-005-A01
(5) Removing disc (2-10)
THALES AVIONICS ELECTRICAL SYSTEMS
COMPONENT MAINTENANCE MANUAL
P/N 8260-12*
Subtask 24-32-61-020-006-A01
(6) Removing disc (2-30)
− Unlock the nut (2-60), then prevent the armature (2-240) from rotating with the tool P/N E3396 fitted with the pin P/N E4233 and remove the nut (2-60) with the tool P/N E4148-1J.
NOTE: Fit the tool P/N E3396 into the splines of armature (2-240) from the fan end. − Discard the washer (2-50).
− Remove the disc (2-30) and the recover key (2-40). Subtask 24-32-61-020-007-A01
(7) Removing the fan
− Unlock the nut (1-160), then prevent the armature (2-240) from rotating with the wrench P/N E3396 fitted with the pin P/N E4233 and remove the nut (1-160) with the tool P/N E4148-1J.
NOTE: Fit the tool P/N E3396 into the armature (2-240) from the flanged bearing end. − Discard the washer (1-170).
− Remove the fan (1-140) and the recover key (1-150). Subtask 24-32-61-020-008-A01
(8) Removing the commutator bearing assembly
− Unlock and remove the screws (1-490) and remove the flange (1-480). − Unlock the screws (1-190).
− Remove the screws 190) fitted with the tab washers 200) and the washers (1-210).
− Remove the screws (2-90).
− Move aside the flange (2-80) fitted with the speed sensor assembly (2-100). NOTE: With the tool P/N E6072 fitted on drive flange separate the starter-generator
into two parts, the armature and commutator bearing assembly on one side, and the frame assembly and flanged bearing housing, on the other side. NOTE: Handle this assembly by the armature and not by the commutator bearing
assembly.
THALES AVIONICS ELECTRICAL SYSTEMS
COMPONENT MAINTENANCE MANUAL
P/N 8260-12*
− Remove the gasket (2-250).
− Protect the commutator with ice paper if the latter must not machined. − With the tool P/N E6072 remove the commutator bearing assembly from the
armature by pulling it exactly in line with the armature axis, in order to avoid commutator damages.
NOTE: Do not touch the commutator with the fingers. Subtask 24-32-61-020-009-A01
(9) Removing the ball bearing − Remove the screws (1-490).
− Remove the flange (1-480) then extract the ball bearing (1-470). − Remove the ball bearing (1-470) with the tool P/N E7351. Subtask 24-32-61-020-010-A01
(10) Removing the brush springs
− Release the brush springs (1-310). − Remove the ring retaining (1-340). − Remove the spacer (1-330).
− Remove the first brush spring (1-310). − Remove the spacer (1-320).
− Remove the second brush spring (1-310). Subtask 24-32-61-020-011-A01
(11) Removing the flanged bearing
− Install the starter generator on the support P/N E5981.
− Remove the screws (2-230), then move aside the flanged bearing (2-220) fitted with the flange (2-80) and the speed sensor assembly (2-100).
− Install the starter generator on the support P/N E15526-2. − Remove the screws (2-90).
− Move aside the flange (2-80) fitted with the speed sensor assembly (2-100). − Remove the ball bearing (2-70) with the tool P/N E7351.
CAUTION: DO NOT EXERT TENSION ON THE LEADS OF SPEED DETECTOR ASSEMBLY (100).
THALES AVIONICS ELECTRICAL SYSTEMS
COMPONENT MAINTENANCE MANUAL
P/N 8260-12*
Subtask 24-32-61-020-012-A01 (12) Disassembling the frame
− Install the frame on the base P/N E15526-2. (a) Removing the terminal block
− Remove the nuts (2-320) and (2-380) fitted with the washers (2-310) and (2-370), then the nuts (2-340) and (2-360) fitted with the washers (2-330) and (2-350).
NOTE : Use the pipe wrenches to avoid damaging the sides of the terminal block. − Unlock and remove the screws (2-300), discard the tab washers (2-290) and
remove the terminal block (2-280) being careful not to damage the connecting leads.
− If the sleeves (2-395) are loose discard them.
− Carefully move aside the electrical connections of the frame and remove the insulator (2-275).
Subtask 24-32-61-020-013-A01
(13) Removing the speed sensor assembly
(a) For maintenance of repair of a starter-generator component.
NOTE: Do not remove the speed sensor assembly (2-100) from its support on flange (2-80) to carry out a maintenance or repair operation: leave the detector assembly attached to the starter-generator by connector (2-130). (b) For replacement of the speed sensor assembly
− Unscrew the thumb nut (2-120) using the tool P/N E11875.
− Disengage the speed sensor assembly (2-100) from its support on the flange (2-180).
− Remove and discard the washer (2-110).
− Remove the thumb nut (2-120) and discard it if serial number is 81 and smaller.
− Remove the screws (2-150) and discard the washers (2-140). − Disengage the connector (2-130) from its box (2-160).
− Mark the electrical leads of speed detector assembly (2-100) and unsolder them from the connector (2-130) with a soldering iron.
− Move aside the connector (2-130).
− Unlock the screws (2-180) and discard the tab washers (2-170). − Remove the box (2-160).
THALES AVIONICS ELECTRICAL SYSTEMS
COMPONENT MAINTENANCE MANUAL
P/N 8260-12*
− Remove the screws (2-210) and discard the washer (2-200). − Remove the speed sensor assembly (2-100).
E. Close-up
THALES AVIONICS ELECTRICAL SYSTEMS
COMPONENT MAINTENANCE MANUAL
P/N 8260-12*
TASK 24-32-61-100-801-A01
1. CLEANING OF THE STARTER GENERATOR A. Reason for the job
Self-explanatory B. Job set-up Information
(1) Tools, fixtures and equipment
NOTE: Use the special tools and equipment given in the list in the page block “SPECIAL TOOLS, FIXTURES, EQUIPMENT AND CONSUMABLES”. PART
NUMBER
QTY NAME
No specific 1 Cabin with suction and water screen functions, type CORAL MINIVELO series
No specific 1 Ultrasonic cleaning machine, FISA type, series 3 FR 34 No specific 1 Megger for measuring the insulation resistance at 45-50 V DC No specific 1 Compressed air with a capacity of 7,5 bar (108 psi) with tool
P/N 506277-1
No specific 1 Stiff nylon bristle brush
No specific 1 Oven with a capacity of 180 °C (356 °F)) (2) Consumables
NOTE: Use the special tools and equipment given in the list in the page block “SPECIAL TOOLS, FIXTURES, EQUIPMENT AND CONSUMABLES”.
PART NUMBER NAME
90017838 Washing liquid FIMM M18 or equivalent
90017839 Washing liquid FIMM M36 or equivalent
7954A009 Red anti-flash varnish type 2407 or equivalent
No specific Adhesive cloth
No specific Brush
No specific Fine emery cloth to get a very clean surface
(3) Referenced information
REFERENCE DESIGNATION
IPL Figure 2 Starter generator
THALES AVIONICS ELECTRICAL SYSTEMS
COMPONENT MAINTENANCE MANUAL
P/N 8260-12*
C. Job set-up Not applicable D. Procedure
NOTE: The purpose of this page block is to specify the methods to be used to clean the mechanical parts and the windings of the starter generator.
Subtask 24-32-61-160-001-A01
(1) Cleaning of the frame assembly
The cleaning operation is performed in two stages: − pre-cleaning.
− cleaning.
− It is mandatory, before starting this operation to remove:
• the terminal block (2-280) as detailed in the page block DISASSEMBLY, Subtask 24-32-61-040-011-A01.
CAUTION : ONCE THE TERMINAL BLOCK IS REMOVED, THE VARIOUS
CONNECTIONS WILL BE FREE. DURING THE CLEANING
OPERATIONS, TAKE ALL THE NECESSARY STEPS TO AVOID ANY DAMAGE TO THE FIBREGLASS INSULATING SLEEVES.
• the speed detector (2-100) as detailed in the page block DISASSEMBLY,Subtask 24-32-61-040-012-A01.
NOTE : Following this operation, recover the insulating sleeves.
(a) Pre-cleaning the frame assembly
− Start up the cleaning cabin (suction syste, pump for water screen, washing liquid FIMM M18 P/N 90017838 and M36 P/N 90017839).
− Place the frame assembly in the cleaning cabin.
− Blow the inside of the frame to remove any carbon dust (pressure provide P=7,5 bar (108 PSI).
(b) Cleaning the frame assembly
− Place the frame assembly in the tank of the ultrasonic cleaning machine. − Start up the machine.
− Do a complete cleaning cycle (duration 1 hour).
− Install the frame assembly in an oven at a temperature of 180 °C (356 °F) for 4 hours.
− At the end of the operation, examine that the insulation between the negative connection and ground is greater than 1 MΩ. If not, do a new cleaning cycle.
THALES AVIONICS ELECTRICAL SYSTEMS
COMPONENT MAINTENANCE MANUAL
P/N 8260-12*
− If after a complete cleaning cycle the insulation is less than 1 M Ω: • perform a new pre-cleaning cycle,
• brush vigorously the connections and then do another cleaning cycle of the frame assembly.
NOTE: Do as many cleaning cycles as needed to get an insulation value of greater than 1 MΩ.
Subtask 24-32-61-160-002-A01
(2) Cleaning the mechanical parts
− Place the parts to be cleaned in the tank of the ultrasonic cleaning machine. NOTE: If the parts to be cleaned are very dirty, pre-clean the parts in the cleaning
cabin.
− Start up the machine.
− Do a complete cleaning cycle (duration 1 hour). Subtask 24-32-61-160-003-A01
(3) Cleaning of the armature
This operation is performed in two stages: − pre-cleaning,
− cleaning.
CAUTION: DURING THE PRE-CLEANING AND CLEANING OPERATIONS, DO NOT TOUCH THE COMMUTATOR WITH YOUR FINGERS AND TAKE ALL NECESSARY STEPS TO AVOID DAMAGE TO THE MICA UNDER
THE COMMUTATOR BLADES.
(a) Pre-cleaning
− Start up the cleaning cabin (suction system, power for water screen, washing liquid FIMM M18 P/N 90017838 and M36 P/N 90017839).
− Using the standard blower connected to a dry compressed air generator, clean all the cavities in the armature.
• on the commutator, insert the tool nozzle roller bearing side, • Examine that the air compressor provides 2,06 bar (30 PSI).
CAUTION: DON'T POINT DIRECTLY THE DRY COMPRESSED AIR SPRAY ON THE MICA (SEE FIGURE 4001).
THALES AVIONICS ELECTRICAL SYSTEMS
COMPONENT MAINTENANCE MANUAL
P/N 8260-12*
− Perform this operation blade by blade 360° around the commutator.
CAUTION: BE SURE TO TAKE ALL THE NECESSARY PRECAUTIONS MENTIONED ABOVE.
− Insert the blower nozzle P/N 506277-1 between the radial connections connecting the commutator blades to the armature conductors as shown in the Figure 4001.
− Ensure the dry compressed air generator provides a pressure of 7,5 bar (108 PSI).
− Press the blower trigger.
− Perform this operation 360° around the rotor.
− Complete the pre-cleaning operation by using the nozzle to blow all the accessible external parts of the armature.
CAUTION: BE SURE TO TAKE ALL THE NECESSARY PRECAUTIONS MENTIONED ABOVE.
(b) Cleaning
− Put the rotor vertically in the tank of the ultrasonic cleaning machine. − Do a complete cleaning cycle (time 1 hour).
− Install the armature in an oven at a temperature of 180 °C (356 °F) for 4 hours. − At the end of the cleaning operation, check that the insulation between the
commutator and the metal part is greater than 1 MΩ. If not, repeat the cleaning cycle.
NOTE : Do the cleaning cycle as many times as necessary to get the necessary insulation value greater than 1 MΩ.
After cleaning operation, check that all the periphery surface of the armature is coat with red anti-flash varnish 2407 P/N 7954A009.
If there is some faults carry out the touching up with a brush. If the faults are more important:
− Scrape varnish flakes and slightly sand with a fine emery cloth to get a very clean surface.
− Protect the unvarnished areas with adhesive cloth.
− Use a spray gun to apply red anti-flash varnish 2407 P/N 7954A009 on the armature.
THALES AVIONICS ELECTRICAL SYSTEMS
COMPONENT MAINTENANCE MANUAL
P/N 8260-12*
− Heat the varnish at 150 °C (302 °F) for about 2 hours to cure it.
CAUTION: AFTER THIS OPERATION IT IS NECESSARY TO PERFORM A DIAMOND SURFACING OF THE ARMATURE (SEE PAGE BLOCK "REPAIR”).
Subtask 24-32-61-160-004-A01
(4) Cleaning the commutator bearing assembly This operation is performed in two stages: − pre-cleaning,
− cleaning.
(a) Pre-cleaning
− Start up the cleaning cabin (suction system, pump for water screen, washing liquid FIMM M18 P/N 90017838 and M36 P/N 90017839).
− Place the commutator bearing assembly in the cleaning cabin.
− Blow the inside of the commutator bearing assembly to remove any carbon dust pressure provide P = 7,5 bar (108 PSI).
(b) Cleaning
− Put the commutator bearing assembly in the tank of the ultrasonic cleaning machine.
− Start up the machine.
− Do a complete cleaning cycle (duration 1 hour).
− Install the commutator bearing assembly in an oven at a temperature of 180 °C (356 °F) for 4 hours.
− At the end of the operation, examine that the insulation between the brushes guide and ground is greater than 1 MΩ. If not, do a new cleaning cycle. NOTE : Do the cleaning cycle as many times as necessary to get the necessary
insulation value greater than 1 MΩ.
After cleaning operation, check that all the periphery surface of the commutator bearing assembly is coat with red anti-flash varnish 2407 P/N 7954A009.
If there is some faults carry out the touching up with a brush. If the faults are more important:
− Scrape varnish flakes and slightly sand with a fine emery cloth to get a very clean surface.
THALES AVIONICS ELECTRICAL SYSTEMS
COMPONENT MAINTENANCE MANUAL
P/N 8260-12*
− Protect the unvarnished areas with the adhesive cloth.
− Use a spray gun to apply red anti-flash varnish 2407 P/N 7954A009 on the commutator bearing assembly.
− Remove the adhesive cloth masks.
− Heat the varnish at 150 °C (302 °F) for about 2 hours to cure it. Subtask 24-32-61-160-005-A01
(5) Speed detector assembly
− Using a stiff nylon bristle brush, remove all the adhesive residues, from the speed detector body at the nut locations and on the flange.
E. Close-up Not applicable.
GRAPHIC 24-32-61-991-4001-A01 CLEANING
THALES AVIONICS ELECTRICAL SYSTEMS
COMPONENT MAINTENANCE MANUAL
P/N 8260-12*
TASK 24-32-61-200-801-A01
1. VISUAL INSPECTION OF THE STARTER GENERATOR
A. Reason for the job Self-explanatory
B. Job set-up Information
(1) Tools, fixtures and equipment
NOTE: Use the special tools and equipment given in the list in the page block “SPECIAL TOOLS, FIXTURES, EQUIPMENT AND CONSUMABLES”. PART
NUMBER
QTY NAME
No specific 1 Megger for measuring the insulating resistance at 45-50 V DC
P611845 1 Brush Wear Checking Gauge
No specific 1 Dynamometer
No specific 1 Spring test machine
No specific 1 Ohmmeter (Internal R: 20000 ΩV)
No specific 1 Micrometer internal 30-45 mm (1.181-1.771 in) No specific 1 Micrometer external 0-25 mm (0-0.984 in) No specific 1 Caliper square 0 to 250 mm (0 to 9.842 in)
No specific 2 Measuring pin gages diameter 2,438 mm (0.0960 in)
(2) Referenced information
REFERENCE DESIGNATION
IPL Figure 1 Starter generator
C. Job set-up Not applicable
D. Procedure
NOTE: During the checks, visually inspect the unit to distinguish the parts which are to be reused from those which are to be replaced.
THALES AVIONICS ELECTRICAL SYSTEMS
COMPONENT MAINTENANCE MANUAL
P/N 8260-12*
NOTE: Carefully check for:
- Cleanness of the unit and condition of protective coatings. - Cracks, scoring or pitting.
- Signs of wear or attrition. - Condition of threads and teeth.
NOTE: Compare the dimensions of parts with those specified in the page block "FITS AND CLEARANCES". Discard all out-of-tolerance parts.
NOTE: Certain subassemblies should be subjected to special checks, in addition to the above ones.
NOTE: The insulation tests should be carried out with 45-50 V DC applied. The insulation resistance of the component parts should be ≥ 300 KΩ.
Subtask 24-32-61-210-001-A01
(1) Checking the frame
− Carry out an insulation test, if the test is unsatisfactory, refer to the page block "CLEANING", subtask 24-32-61-160-001-A01.
− Measure the resistance of the excitation winding between the terminals (A and E) with an ohmmeter.
− The measured value should be 2.03 Ω ± 0.1 Ω at 20 °C (68 °F) ; if not, discard the frame or send it for repair.
− Check the commutating and compensating winding (equalizer winding) for electrical continuity between terminals (D and E). If no continuity exists, discard the frame.
Subtask 24-32-61-210-002-A01
(2) Checking the armature
The commutator segments should have a uniform glossy with light circumferential scores, and should be noticeable projecting or recessed: if not, carry out diamond surfacing (See page block "REPAIR").
NOTE: Do not touch the commutator with the fingers.
The uniform, light circumferential scores caused by the use of cored carbon brushes for operation at high altitude are normal and do not affect the operation of the starter-generator.
− If the segments have blackened, check that the armature is not shorted or the winding is not opened.
THALES AVIONICS ELECTRICAL SYSTEMS
COMPONENT MAINTENANCE MANUAL
P/N 8260-12*
− Measure the insulation resistance between the commutator and the shaft ; if the measured value is incorrect, refer to, Subtask 24-32-61-160-003-A01.
NOTE: Apply the megger test spikes to the sides of the segments, to avoid scoring them.
Subtask 24-32-61-210-003-A01
(3) Checking the brushes (REF. to figures 5001 and 5002)
CAUTION: NEVER REMOVE THE BRUSHES FROM THEIR GUIDES TO CHECK THEM. ONLY REMOVE THE BRUSHES WEN THEY HAVE TO BE REPLACED WITH NEW ONES.
NOTE: Brushes must be checked to determine the limit of use and condition of the starter generator. The procedure is the same for each one of both engines and applies on the two brushes of the three accessible brush lines (six brushes have to be checked).
CAUTION: DO NOT TOUCH THE COMMUTATOR WITH THE BRUSH GAUGE P/N P611845.
− Unlock and remove the screw (1-20) to remove the cover band (1-10). − Move apart the brush wires (item 7, figure 5002) to clear the upper part of the
brushes (item 6, figure 5002).
− Install the brush gauge P/N P611845 between the two brush springs (item 5, figure 5002).
− Set the brush wear checking gauge P/N P611845 (See figure 5001) in contact against the brush guide (reference face) and against the brush to be checked. − Set the the brush gauge P/N P611845 in contact with the brush spring (item 5,
figure 5002).
− Record the result for each brush of the three accessible brush lines. − If at 500 FH
• All brushes checked are in green area, the brushes can be kept on the Starter Generator until the next brush check (300 FH later).
• One or several brushes checked are in yellow area, the brushes can be kept on the Starter Generator until the next brush check (150 FH later). • One or several brushes checked are in red area, all the brushes have to
THALES AVIONICS ELECTRICAL SYSTEMS
COMPONENT MAINTENANCE MANUAL
P/N 8260-12*
− If at 800 FH
• All brushes checked are in green area, the brushes can be kept on the Starter Generator until the next maintenance step i.e. bearing change or overhaul (1200 FH or 2400 FH).
• One or several brushes checked are in yellow area, the brushes can be kept on the Starter Generator until the next brush check (150 FH later). • One or several brushes checked are in red area, all the brushes have to
be replaced as decribed in subtask 24-32-61-020-001-A01.
GRAPHIC 24-32-61-991-5001-A01 BRUSH WEAR CHECKING GAUGE
FIGURE 5001
GRAPHIC 24-32-61-991-5002-A01 BRUSH CHECK
THALES AVIONICS ELECTRICAL SYSTEMS
COMPONENT MAINTENANCE MANUAL
P/N 8260-12*
Subtask 24-32-61-210-004-A01
(4) Checking the brush spring tension (REF. to figure 5003)
− Using a strip of sheet metal fabricate a spring finger lifter (1).
− Using a strain gauge (Dynamometer) (2) pull at right angle to brush top and always square with brush box.
− Spring tension level should always be recorded at the point where the brush spring finger has just lifted from the top of the brush.
− To determine exactly when the brush is released, place a piece of paper (3) between the brush spring finger and the brush top it self.
− Slightly pull the paper in direction (F2).
− Record spring tension level when brush spring finger pressure has just allowed the paper to move freely with a spring test machine.
The angle at which the strain gauge is pulled is extremely important. The line of force must always be square with the brush box.
Brush spring tension should be within the following limits : − new springs
• F1 = 1925 g (4.25 lbs )
− old springs
• F1 > 1700 g (3.75 lbs)
NOTE: For optimum brush life always verify that all brush spring tension levels are symmetrical and within the levels specified. If any spring tension is found to be outside the specified limit discard old spring and replace it with a new one.
THALES AVIONICS ELECTRICAL SYSTEMS
COMPONENT MAINTENANCE MANUAL
P/N 8260-12*
GRAPHIC 24-32-61-991-5002-A01 CHECK THE BRUSH SPRING TENSION
THALES AVIONICS ELECTRICAL SYSTEMS
COMPONENT MAINTENANCE MANUAL
P/N 8260-12*
Subtask 24-32-61-210-005-A01
(5) Checking the pin spring holder
− Check the pin spring holder. If it has been damaged or bent at the time of the disassembly, send the commutator bearing to THALES A.E.S. for replacement. Subtask 24-32-61-210-006-A01
(6) Checking the ball bearings
− Check that the ball bearings rotate freely without any friction spot or play and also that the ball bearing packings are not damaged, otherwise, discard them.
CAUTION: THE BALL BEARINGS ARE LUBRICATED FOR SERVICE LIFE
RELUBRICATION BY OPERATOR IS PROHIBITED. Subtask 24-32-61-210-007-A01
(7) Checking the lining
− Check that the lining is not dirty and its thickness is ≥ 2,5 mm (0.0984 in) otherwise, discard it.
Subtask 24-32-61-210-008-A01
(8) Checking the commutator bearing assembly
− Check the brush guides for distortion and for smooth internal surface ; otherwise, discard the Commutator bearing assembly.
Subtask 24-32-61-210-009-A01
(9) Checking of the torque shaft
− Install the measuring pin gages A diameter 2,438 mm (0.0960 in) as shown on the figure 5004.
− Measure the length B between both pin gages.
− Compare that the length B is upper than 18,631 mm (0.7335 in).
THALES AVIONICS ELECTRICAL SYSTEMS
COMPONENT MAINTENANCE MANUAL
P/N 8260-12*
GRAPHIC 24-32-61-991-5004-A01 CHECKING OF THE TORQUE SHAFT
FIGURE 5004
E. Close-up
THALES AVIONICS ELECTRICAL SYSTEMS
COMPONENT MAINTENANCE MANUAL
P/N 8260-12*
TASK 24-32-61-300-801-A01
1. REPAIR OF THE STARTER GENERATOR A. Reason for the job
Self-explanatory
B. Job set-up Information
(1) Tools, fixtures and equipment
NOTE: Use the special tools and equipment given in the list in the page block SPECIAL TOOLS, FIXTURES, EQUIPMENT AND CONSUMABLES. PART
NUMBER
QTY NAME
Type R2B6 1 Schenk balancing machine Type R2B6 with two accessory kits M180 and M181 and a cell P44
800501 1 Repair kit
No specific 1 Machine tool cutting lathe
No specific 1 Indicator capable of measuring 0.008 mm (0.0003 in)
No specific 1 Brush
No specific 1 Oven with a capacity of 180 °C (356 °F)
E2949 1 Tool for reworking the chamfers
No specific 1 Micrometer internal 30-45 mm (1.181-1.771 in) No specific 1 Micrometer external 0-25 mm (0-0.984 in)
No specific 1 Stamp
(2) Consumables
NOTE: Use the consumables given in the list in the page block SPECIAL TOOLS, FIXTURES, EQUIPMENT AND CONSUMABLES.
PART NUMBER
NAME
7954A009 Red anti-flash varnish 2407
90003328 Varnish ISOPOXY 433-37A
NOTE : The brand name and the type of equipment are given for reference purposes only. Any another equipment with the same characteristics can be used as well.
The products used are listed under page block "LIST OF PRODUCTS".