F0296 41 boulevard de la Rpublique 78401 Chatou Cedex France Tel : + 33 (0)1 34 80 73 00 Fax : + 33 (0)1 30 71 01 40 ORIGINAL ISSUE: DEC. 15/85TITLE PAGE 1 MAY 19/08 24-32-61COMPONENT MAINTENANCE MANUAL WITH ILLUSTRATED PARTS LIST 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. 2007 THALES AVIONICS ELECTRICAL SYSTEMS SA. All rights reserved. TITLE PAGE 2 MAY 19/08 Use or disclosure of this data is subject to the restrictions on the cover page of this Component Maintenance Manual with IPL. 24-32-61PAGE LEFT BLANK INTENTIONALLY SWLA PAGE 1 MAY 19/08 Use or disclosure of this data is subject to the restrictions on the cover page of this Component Maintenance Manual with IPL. 24-32-61SAFETY ADVISORY WARNING: MAKESUREALLPERSONSKNOWANDOBEYTHEPRECAUTIONS RECOMMENDEDBYTHEMANUFACTURERORSUPPLIERFOREACHMATERIAL BEFORE IT IS USED. REFER TO THE MANUFACTURER / SUPPLIER DATA FOR THE PROCEDURESTODISCARDTHESEMATERIALS.IFTHEMANUFACTURERSOR SUPPLIERSINSTRUCTIONSARENOTOBEYED,INJURYTOPERSONSCAN OCCUR. WARRANTY / LIAIBILITY / ADVISORY WARNING Theuseofanynon-specifiedpartsorpartswhichdonotstrictlyconformtothe manufacturerspecificationanddrawingsforSTARTERGENERATORP/N8260-12* and/ornotrepairedormadebyfacilitiesapprovedbyTHALESAVIONICS ELECTRICALSYSTEMScancauseproductmalfunctionswhichcouldresultin damageto,ordestructionof,equipmentandinjurytopersonnelandcancancel warranties underwritten by THALES AVIONICS ELECTRICAL SYSTEMS.UseonlythereplacementpartsspecifiedintheillustratedPartsListpageblockof thecorrespondingCMMorreplacementpartsproventostrictlyconformto applicablemanufacturerspecificationsanddrawingsforSTARTERGENERATOR P/N 8260-12*.THALESAVIONICSELECTRICALSYSTEMSisnotresponsibleforSTARTER GENERATOR P/N 8260-12* that is not maintained and/or repaired in accordance with THALESAVIONICSELECTRICALSYSTEMSpublishedinstructions.THALES AVIONICSELECTRICALSYSTEMSisnotresponsibleforspecialtoolsandtest equipment made by other companies. SWLA PAGE 2 MAY 19/08 Use or disclosure of this data is subject to the restrictions on the cover page of this Component Maintenance Manual with IPL. 24-32-61 PAGE LEFT BLANK INTENTIONALLY THALES AVIONICS ELECTRICAL SYSTEMS COMPONENT MAINTENANCE MANUAL P/N 8260-12* RR PAGE 1 MAY 19/08 Use or disclosure of this data is subject to the restrictions on the cover page of this Component Maintenance Manual with IPL. 24-32-61 1MAR. 15/87 2FEB. 15/88 3SEP. 15/90 4JUN. 15/93 5DEC. 15/93 6FEB. 15/99 7FEB. 28/00 8MAR. 12/01 9MAY 19/08 RECORD OF REVISIONS REV No.ISSUE DATE DATE INSERTED REV No. ISSUE DATE DATE INSERTED BYBY THALES AVIONICS ELECTRICAL SYSTEMS COMPONENT MAINTENANCE MANUAL P/N 8260-12* RR PAGE 2 MAY 19/08 Use or disclosure of this data is subject to the restrictions on the cover page of this Component Maintenance Manual with IPL. 24-32-61 PAGE LEFT BLANK INTENTIONALLY THALES AVIONICS ELECTRICAL SYSTEMS COMPONENT MAINTENANCE MANUAL P/N 8260-12* RTR PAGE 1 MAY 19/08 Use or disclosure of this data is subject to the restrictions on the cover page of this Component Maintenance Manual with IPL. 24-32-61RECORD OF TEMPORARY REVISIONS TEMPORARY REVISIONS PAGE NO. ISSUE DATE NO.DATE INSERTED BYDATE PERMANENT REVISION NO. BY CANCELLED THALES AVIONICS ELECTRICAL SYSTEMS COMPONENT MAINTENANCE MANUAL P/N 8260-12* RTR PAGE 2 MAY 19/08 Use or disclosure of this data is subject to the restrictions on the cover page of this Component Maintenance Manual with IPL. 24-32-61 PAGE LEFT BLANK INTENTIONALLY THALES AVIONICS ELECTRICAL SYSTEMS COMPONENT MAINTENANCE MANUAL P/N 8260-12* LEP PAGE 1 MAY 19/08 Use or disclosure of this data is subject to the restrictions on the cover page of this Component Maintenance Manual with IPL. 24-32-61Title Page1MAY 19/08 2BLANK Safety Warranty 1MAY 19/08 Liability Advisory2BLANK Record of Revisions1MAY 19/08 2BLANK Record of1MAY 19/08 Temporary2BLANK Revisions List of Effective Pages1MAY 19/08 2MAY 19/08 Service Bulletin List1MAY 19/08 2MAY 19/08 List of Amendments1MAY 19/08 2MAY 19/08 Table of Contents1MAY 19/08 2MAY 19/08 Introduction1MAY 19/08 2MAY 19/08 3MAY 19/08 4MAY 19/08 5MAY 19/08 6BLANK Description and1MAY 19/08 Operation2MAY 19/08 3MAY 19/08 4MAY 19/08 5MAY 19/08 6MAY 19/08 Testing and1001MAY 19/08 Fault Isolation1002MAY 19/08 1003MAY 19/08 1004MAY 19/08 1005MAY 19/08 1006MAY 19/08 Disassembly3001MAY 19/08 3002MAY 19/08 3003MAY 19/08 3004MAY 19/08 3005MAY 19/08 3006MAY 19/08 3007MAY 19/08 3008MAY 19/08 3009MAY 19/08 3010MAY 19/08 Cleaning4001MAY 19/08 4002MAY 19/08 4003MAY 19/08 4004MAY 19/08 4005MAY 19/08 4006MAY 19/08 Inspection/Check5001MAY 19/08 5002MAY 19/08 5003MAY 19/08 5004MAY 19/08 5005MAY 19/08 5006MAY 19/08 5007MAY 19/08 5008MAY 19/08 Repair6001MAY 19/08 6002MAY 19/08 6003MAY 19/08 6004MAY 19/08 6005MAY 19/08 6006MAY 19/08 Assembly7001MAY 19/08 7002MAY 19/08 7003MAY 19/08 7004MAY 19/08 7005MAY 19/08 7006MAY 19/08 7007MAY 19/08 7008MAY 19/08 7009MAY 19/08 7010MAY 19/08 7011MAY 19/08 7012MAY 19/08 7013MAY 19/08 7014MAY 19/08 7015MAY 19/08 7016MAY 19/08 7017MAY 19/08 7018BLANK Fits and Clearances8001MAY 19/08 8002MAY 19/08 LIST OF EFFECTIVE PAGES SUBJECTPAGEDATE PAGESUBJECTDATE SUBJECTPAGEDATELEP PAGE 2 MAY 19/08 Use or disclosure of this data is subject to the restrictions on the cover page of this Component Maintenance Manual with IPL. THALES AVIONICS ELECTRICAL SYSTEMS COMPONENT MAINTENANCE MANUAL P/N 8260-12* 24-32-61Special Tools9001MAY 19/08 Fixtures 9002MAY 19/08 Equipment and9003MAY 19/08 Consumables9004MAY 19/08 9005MAY 19/08 9006MAY 19/08 9007MAY 19/08 9008MAY 19/08 9009MAY 19/08 9010MAY 19/08 9011MAY 19/08 9012MAY 19/08 9013MAY 19/08 9014MAY 19/08 Illustrated1MAY 19/08 Parts List2BLANK TP 10001 INTRO 100011MAY 19/08 2MAY 19/08 3MAY 19/08 4BLANK VCI 100011MAY 19/08 2MAY 19/08 NI ALPHA 100011MAY 19/08 2MAY 19/083MAY 19/08 4BLANK NI NUM 100011MAY 19/08 2MAY 19/08 Detailed Parts List10001MAY 19/08 10001-0MAY 19/08 10001-1MAY 19/08 10001-2MAY 19/08 10001-3MAY 19/08 10002-0MAY 19/08 10002-1MAY 19/08 10002-2MAY 19/08 10002-3MAY 19/08 10002-4MAY 19/08 10002-5BLANK 10003-0MAY 19/08 10003-1MAY 19/08 10003-2BLANK Storage15001MAY 19/08 (including15002MAY 19/08 Transportation)15003MAY 19/08 15004BLANK THALES AVIONICS ELECTRICAL SYSTEMS COMPONENT MAINTENANCE MANUAL P/N 8260-12* SBL PAGE 1 MAY 19/08 Use or disclosure of this data is subject to the restrictions on the cover page of this Component Maintenance Manual with IPL. 24-32-618260-120-24-001*AJUL. 87Ball bearings : change in grease grade.Valid for version 8260-120 which is deleted to the CMM. 8260-120-24-002*BJAN. 90Baffle added to armature for ballbearing protection on drive end.Valid for version 8260-120 which is deleted to the CMM. 8260-120-24-003*CJUL. 87Flanged bearing changed.Valid for version 8260-120 which is deleted to the CMM. 8260-120-24-0048260-121JUL. 88Mounting of an oil screen. 8260-120-24-005FMAR. 91An insulated deflector is fitted at commutator end part of laminatedcircuit. 8260-120-24-006ESEP. 90Metallic part used to secure electricleads from stator windings and from brushes is isolated from brush holder case. 8260-120-24-007DFEB. 92Replacement of four screws securingthe flange and improvement of the tightening torque. 8260-12*-24-008HDEC. 98The shape and the material of the terminal block are different. The capacitors, the terminals and the nutsare kept (for S. G. P/N 8260-120/121). ADEC. 98The shape and the material of the terminal block are different. The capacitors, the terminals and the nutsare kept (for S. G. P/N 8260-123). 8260-12*-24-009JDEC. 98Replacement of the speed sensor P/N P058067 by the speed sensor P/N P609742 (for S. G. P/N 8260-120/121). BDEC. 98Replacement of the speed sensor P/N P058067 by the speed sensor P/N P609742 (for S. G. P/N 8260-123). SERVICE BULLETIN LIST DESCRIPTIONDATE MOD. STATE IDENT. SERVICE BULLETIN THALES AVIONICS ELECTRICAL SYSTEMS COMPONENT MAINTENANCE MANUAL P/N 8260-12* SBL PAGE 2 MAY 19/08 Use or disclosure of this data is subject to the restrictions on the cover page of this Component Maintenance Manual with IPL. 24-32-61 8260-12*-24-010KOCT. 97The insulator P/N P714615 becomes P/N P721751. 8260-12*-24-0118260-123DEC. 98Brushes P/N P601952 are replaced by brushes P/N P607965. 8260-12*-24-012MDEC. 98Lining P/N P714154 is replaced by lining P/N P714154-1 (for S. G. P/N 8260-120/121). DDEC. 98Lining P/N P714154 is replaced by lining P/N P714154-1 (for S. G. P/N 8260-123). 8260-12*-24-013NDEC. 02Bearing 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). EDEC. 02Bearing 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*-24-014MAY 03Guarantee the reliability of the Starter Generator by a correct application of the overhaul procedures in accordance with specification. 8260-12*-24-016PDEC. 04Obsolescence 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 8260-121).FDEC. 04Obsolescence 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). DESCRIPTIONDATE MOD. STATE IDENT. SERVICE BULLETIN THALES AVIONICS ELECTRICAL SYSTEMS COMPONENT MAINTENANCE MANUAL P/N 8260-12* LOA PAGE 1 MAY 19/08 Use or disclosure of this data is subject to the restrictions on the cover page of this Component Maintenance Manual with IPL. 24-32-61 ABall bearings : change in grease grade.8260-120 Version Deleted BBaffle added to armature for ball 8260-120 bearing protection on drive end.Version Deleted CFlanged bearing changed.8260-120 Version Deleted Mounting of an oil screen.8260-121 FAn insulated deflector is fitted at commutator 8260-121 end part of laminatedcircuit. EMetallic part used to secure electric 8260-121 leads from stator windings and from brushesis isolated from brush holder case. DReplacement of four screws securing 8260-121 the flange and improvement of the tighteningtorque. GReplacement of the terminal block P/N 8260-121 P604100 by the terminal block P/N P608636. HReplacement of the terminal block P/N 8260-121 P608636 by the terminal block P/N P608636-1. JReplacement of the speed sensor 8260-121 P/N P058067 by the speed sensorP/N P609742. KThe insulator P/N P714615 becomes 8260-121 P/N P721751. MLining P/N P714154 is replaced by lining 8260-121 P/N P714154-1. NBearing reliability improvement. Bearing P/N 8260-121 410964 becomes P/N B320050L andBearing P/N 410965 becomes P/N B320250L. PObsolescence of the commutator. The8260-121 commutator P/N P057017-1 is replaced byP/N P500315, the armature P604823-3becomes P/N P604823-4 or P/N P604823-4Rwhen the armature is rewound or recomm. LIST OF AMENDMENTS AMDTBRIEF DESCRIPTIONAPPLICABLE TO VERSION LOA PAGE 2 MAY 19/08 Use or disclosure of this data is subject to the restrictions on the cover page of this Component Maintenance Manual with IPL. THALES AVIONICS ELECTRICAL SYSTEMS COMPONENT MAINTENANCE MANUAL P/N 8260-12* 24-32-61 AThe shape and the material of the terminal 8260-123 block are different. The capacitors,the terminals and the nutsare kept. BReplacement of the speed sensor 8260-123 P/N P058067 by the speed sensorP/N P609742. DLining P/N P714154 is replaced by lining 8260-123 P/N P714154-1. EBearing reliability improvement. Bearing P/N 8260-123 410964 becomes P/N B320050L andBearing P/N 410965 becomes P/N B320250L. FObsolescence of the commutator. The8260-123 commutator P/N P057017-1 is replaced byP/N P500315, the armature P604823-3becomes P/N P604823-4 or P/N P604823-4Rwhen the armature is rewound or recomm. AMDTBRIEF DESCRIPTIONAPPLICABLE TO VERSION THALES AVIONICS ELECTRICAL SYSTEMS COMPONENT MAINTENANCE MANUAL P/N 8260-12* TC PAGE 1 MAY 19/08 Use or disclosure of this data is subject to the restrictions on the cover page of this Component Maintenance Manual with IPL. 24-32-61 Page INTRODUCTION.......................................................................................................... INTRO 1 1. INTRODUCTION.................................................................................................................. 1 2. SHOP CHECK ..................................................................................................................... 5 3. REVISIONS.......................................................................................................................... 5 4. LIST OF ABBREVIATIONS.................................................................................................. 5 DESCRIPTION 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 GENERATOR 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 TABLE OF CONTENTS TC PAGE 2 MAY 19/08 Use or disclosure of this data is subject to the restrictions on the cover page of this Component Maintenance Manual with IPL. THALES AVIONICS ELECTRICAL SYSTEMS COMPONENT MAINTENANCE MANUAL P/N 8260-12* 24-32-61SPECIAL TOOLS, FIXTURES, EQUIPMENT AND CONSUMABLES .............................. 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 AVIONICS ELECTRICAL SYSTEMS COMPONENT MAINTENANCE MANUAL P/N 8260-12* INTRO PAGE 1 MAY 19/08 Use or disclosure of this data is subject to the restrictions on the cover page of this Component Maintenance Manual with IPL. 24-32-61 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 Rpublique 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.INTRODUCTION INTRO PAGE 2 MAY 19/08 Use or disclosure of this data is subject to the restrictions on the cover page of this Component Maintenance Manual with IPL. THALES AVIONICS ELECTRICAL SYSTEMS COMPONENT MAINTENANCE MANUAL P/N 8260-12* 24-32-61(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 INTRODUCTIONINTRO 1199 DESCRIPTION AND OPERATION11999 TESTING AND FAULT ISOLATION 100010011999 SCHEMATIC AND WIRING DIAGRAMS 200020012999 DISASSEMBLY300030013999 CLEANING400040014999 CHECK500050015999 REPAIR600060016999 ASSEMBLY700070017999 FITS AND CLEARANCES800080018999 SPECIAL TOOLS, FIXTURES, EQUIPMENT AND CONSUMABLES 900090019999 SPECIAL PROCEDURES110001100111999 REMOVAL120001200112999 INSTALLATION130001300113999 SERVICING140001400114999 STORAGE (including TRANSPORTATION) 150001500115999 REWORK (Service Bulletin accomplishment) 160001600116999 ILLUSTRATED PARTS LIST100001000110999 THALES AVIONICS ELECTRICAL SYSTEMS COMPONENT MAINTENANCE MANUAL P/N 8260-12* INTRO PAGE 3 MAY 19/08 Use or disclosure of this data is subject to the restrictions on the cover page of this Component Maintenance Manual with IPL. 24-32-61(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 stepbystep 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 stepbystep 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 necessary to restore a worn or damaged part to serviceable condition. (10) Assembly This page block gives stepbystep assembly instructions in a logical sequence, references to the figure item numbers from the IPL illustration(s) where applicable. INTRO PAGE 4 MAY 19/08 Use or disclosure of this data is subject to the restrictions on the cover page of this Component Maintenance Manual with IPL. THALES AVIONICS ELECTRICAL SYSTEMS COMPONENT MAINTENANCE MANUAL P/N 8260-12* 24-32-61(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 selfcontained 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 original 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* INTRO PAGE 5 MAY 19/08 Use or disclosure of this data is subject to the restrictions on the cover page of this Component Maintenance Manual with IPL. 24-32-61 TASK 24-32-61-879-801-A01 2.SHOP CHECK A.Themanufacturerhascheckedthattheproceduresdescribedinthepageblocksofthe manualarecorrect.Forthispurpose,ithasperformedthedisassembly,assemblyand 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 ATAAir Transport Association of America DPLDetailed Parts List IPLIllustrated Parts List LEPList of Effective Pages LOAList Of Amendments NI/ALPHANumerical Index ALPHAbetical NI/NUMNumerical Index NUMeric RORRecord Of Revisions RTRRecord of Temporary Revisions SBService Bulletin SBLService Bulletin List TCTable of Contents VVolt VAVolt Ampere VCIVendor Code Index VDCVolt Direct Current INTRO PAGE 6 MAY 19/08 Use or disclosure of this data is subject to the restrictions on the cover page of this Component Maintenance Manual with IPL. THALES AVIONICS ELECTRICAL SYSTEMS COMPONENT MAINTENANCE MANUAL P/N 8260-12* 24-32-61 PAGE LEFT BLANK INTENTIONALLY THALES AVIONICS ELECTRICAL SYSTEMS COMPONENT MAINTENANCE MANUAL P/N 8260-12* PAGE 1 MAY 19/08 Use or disclosure of this data is subject to the restrictions on the cover page of this Component Maintenance Manual with IPL. 24-32-61 TASK 24-32-61-872-801-A01 1.GENERAL (REF. IPL, FIGURES 1 AND 2) NOTE:This manual covers the maintenance of starter-generator P/N 8260-12*. This starter-generatorisprovidedwithacoverfittedwiththreestudsforattachmentofa 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) DESCRIPTION AND OPERATION PAGE 2 MAY 19/08 Use or disclosure of this data is subject to the restrictions on the cover page of this Component Maintenance Manual with IPL. THALES AVIONICS ELECTRICAL SYSTEMS COMPONENT MAINTENANCE MANUAL P/N 8260-12* 24-32-61 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 DC THALES AVIONICS ELECTRICAL SYSTEMS COMPONENT MAINTENANCE MANUAL P/N 8260-12* PAGE 3 MAY 19/08 Use or disclosure of this data is subject to the restrictions on the cover page of this Component Maintenance Manual with IPL. 24-32-61 GRAPHIC 24-32-61-991-001-A01 OVERALL DIMENSIONS FIGURE 1 PAGE 4 MAY 19/08 Use or disclosure of this data is subject to the restrictions on the cover page of this Component Maintenance Manual with IPL. THALES AVIONICS ELECTRICAL SYSTEMS COMPONENT MAINTENANCE MANUAL P/N 8260-12* 24-32-61 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). Theterminalblockissecuredtotheframebyscrews(300)andtabwashers(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). Aconnector(130)issecuredtotheframe(270)byscrews(150)andwashers(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) Theflangedbearing(220),fittedatthefrontwithabaffleforcoolingairexhaust,fitsinto the frame to which it is secured by screws (230). Alocatingpinisprovidedatthefronttocorrectlypositionthestarter-generatoronits mount. Theflangedbearingisprovidedwithacentralboreaccommodatingaballbearing(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) Thecommutatorbearingassembly(1-180)fitsintotheframetowhichitissecuredby 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 (1-60)appliedagainstthecommutatorbybrushsprings(1-310)retainedontheirpins(1-250)byspacers(1-320)and(1-330)andretainingrings(1-340).Thebrushshuntsare 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 commutator bearing assembly to permit rapid checking of the brushes. D.Armature (REF. IPL, Figures. 1 and 2) Thearmature(2-240)isdrivenbyatorqueshaft(1-90)whosevisibleportionisprovided with a splined drive end. THALES AVIONICS ELECTRICAL SYSTEMS COMPONENT MAINTENANCE MANUAL P/N 8260-12* PAGE 5 MAY 19/08 Use or disclosure of this data is subject to the restrictions on the cover page of this Component Maintenance Manual with IPL. 24-32-61 E.Fan (REF. IPL, Figure 1) Thefan(1-140),whichbearsagainsttheinnerraceringoftheballbearing(1-470),is securedtothearmatureshaftbyakey(1-150)andanut(1-160)fittedwithawasher (1-170), for self-cooling purposes. Itdrawstheairthroughaventilationnozzlesecuredtoacover(1-30)by3studs,and expelsitintothestarter-generatortoprovideadequatecooling.Thecoverissecuredby screws (1-40) and washers (1-50). F.Vibration absorber (REF. IPL, Figures 1 and 2) The starter-generatoris fitted witha torque shaft vibration damper consisting of two discs (2-10) and (2-30) driven in rotation by the armature and the torque shaft, respectively. Intheeventoftorqueshaftvibration,thesediscsrubagainstalining(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 seriesbetweentheterminal(A)andthenegativeterminal(E)andfourcommutatingand compensatingcoilsconnectedinseriesbetweenterminal(E)andthenegativebrushes.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. PAGE 6 MAY 19/08 Use or disclosure of this data is subject to the restrictions on the cover page of this Component Maintenance Manual with IPL. THALES AVIONICS ELECTRICAL SYSTEMS COMPONENT MAINTENANCE MANUAL P/N 8260-12* 24-32-61 GRAPHIC 24-32-61-991-002-A01 OPERATION FIGURE 2 THALES AVIONICS ELECTRICAL SYSTEMS COMPONENT MAINTENANCE MANUAL P/N 8260-12* PAGE 1001 MAY 19/08 Use or disclosure of this data is subject to the restrictions on the cover page of this Component Maintenance Manual with IPL. 24-32-61 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 QTYNAME No specific1Voltage regulator identical to that installed in the aircraft or equivalent No specific1Starter-generator drive stand capable of a driving speed of 14000 rpm No specific1Load resistor (RC) capable of 500 A at 30 V No specific1Moving-coil ammeter (A1), class 0.5, with 20 A shunt No specific1Moving-coil ammeter (A2), class 0.5, with 500 A shunt No specific1Moving-coil voltmeter (V1), class 0.5, rating: 40 V DC No specific1Megger for measuring the insulating resistance at 45-50 V DC No specific1SPST switch (IC) No specific1Resistor 0.4 , 50 W No specific1Vibrotest 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 TESTING AND FAULT ISOLATION PAGE 1002 MAY 19/08 Use or disclosure of this data is subject to the restrictions on the cover page of this Component Maintenance Manual with IPL. THALES AVIONICS ELECTRICAL SYSTEMS COMPONENT MAINTENANCE MANUAL P/N 8260-12* 24-32-61 PART NUMBERQTYNAME VCF02GE1Switch I1: 10A or equivalent 350X4033R1Rheostat Rh1: 315 W, 33 , 5 % or equivalent Plate shunt 100 A1Shunt: 100 A, 75 mV or equivalent 30243STPA-2091Contactor 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 k 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* PAGE 1003 MAY 19/08 Use or disclosure of this data is subject to the restrictions on the cover page of this Component Maintenance Manual with IPL. 24-32-61 Check that the insulation resistance of the starter-generator is 100 k with 45-50 V DC applied for an overhaul. Check that the insulation resistance of the starter-generator is 10 M 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 10 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 m. The vibration on NDE (Not Drive End) (see figure 1001) is 15 m. Reset the rheostat (Rh1) to a minimum and open switch I1 to stop the starter generator. Decrease the voltage of the variable DC power supply at the minimum value. PAGE 1004 MAY 19/08 Use or disclosure of this data is subject to the restrictions on the cover page of this Component Maintenance Manual with IPL. THALES AVIONICS ELECTRICAL SYSTEMS COMPONENT MAINTENANCE MANUAL P/N 8260-12* 24-32-61 GRAPHIC 24-32-61-991-1001-A01 VIBRATION TEST FIGURE 1001 THALES AVIONICS ELECTRICAL SYSTEMS COMPONENT MAINTENANCE MANUAL P/N 8260-12* PAGE 1005 MAY 19/08 Use or disclosure of this data is subject to the restrictions on the cover page of this Component Maintenance Manual with IPL. 24-32-61TASK 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 FAULTPOSSIBLE CAUSECORRECTION 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. PAGE 1006 MAY 19/08 Use or disclosure of this data is subject to the restrictions on the cover page of this Component Maintenance Manual with IPL. THALES AVIONICS ELECTRICAL SYSTEMS COMPONENT MAINTENANCE MANUAL P/N 8260-12* 24-32-61 FAULTPOSSIBLE CAUSECORRECTION GENERATOR OPERATION Zero output voltage.Torque shaft broken.Replace the torque shaft. Shunt winding shorted or opened. Replace the frame. Incorrect commutationBrushes 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 :Theregulatorusedinthisset-upisanTHALESA.E.S.generatorcontrolunitP/N102-003-** GRAPHIC 24-32-61-991-1002-A01 TEST SET-UP DIAGRAM FIGURE 1002 THALES AVIONICS ELECTRICAL SYSTEMS COMPONENT MAINTENANCE MANUAL P/N 8260-12* PAGE 3001 MAY 19/08 Use or disclosure of this data is subject to the restrictions on the cover page of this Component Maintenance Manual with IPL. 24-32-61 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 CBA8260-123 (brush change). Clean the armature (Refer to Subtask 24-32-61-160-003-A01). Assembly (Refer to page block ASSEMBLY). CBR8260-121andCBR8260-123:brushandbearingreplacementforSG8260-121and 8260-123 Bedding the brushes is recommended to avoid problems 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 KIT P/N CBR8260-121 AND CBR8260-123 FIGUREITEMQTYDESCRIPTION 1608Brush 1808Springwasher 11001Nut 11101Washer 11701Washer lock 12004Tabwasher 12104Washer 14701Bearing 14904Screw 2501Tabwasher 2701Bearing 2904Screw DISASSEMBLY PAGE 3002 MAY 19/08 Use or disclosure of this data is subject to the restrictions on the cover page of this Component Maintenance Manual with IPL. THALES AVIONICS ELECTRICAL SYSTEMS COMPONENT MAINTENANCE MANUAL P/N 8260-12* 24-32-61 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) FIGUREITEMQTYDESCRIPTION 1808Springwasher 11001Nut 11101Washer 11701Tabwasher 12004Tabwasher 12104Washer 14701Bearing 14904Screw 2501Tabwasher 2701Bearing 2904Screw CBA8260-121 and CBA8260-123 : brush replacement for SG 8260-121 and 8260-123 Bedding the brushes is recommended to avoid problems during the first start (Refer Subtask 24-32-61-420-014-A01). DETAIL KIT P/N CBA8260-121 AND CBA8260-123 (BRUSH CHANGE) FIGUREITEMQTYDESCRIPTION 1608Brush 1808Springwasher 11001Nut 11701Washer lock THALES AVIONICS ELECTRICAL SYSTEMS COMPONENT MAINTENANCE MANUAL P/N 8260-12* PAGE 3003 MAY 19/08 Use or disclosure of this data is subject to the restrictions on the cover page of this Component Maintenance Manual with IPL. 24-32-61Overhaul (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 SMALLERTHANTHELIMITORDAMAGED,THEREPAIREDARMATURE 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). PAGE 3004 MAY 19/08 Use or disclosure of this data is subject to the restrictions on the cover page of this Component Maintenance Manual with IPL. THALES AVIONICS ELECTRICAL SYSTEMS COMPONENT MAINTENANCE MANUAL P/N 8260-12* 24-32-61 DETAIL KIT P/N RGN8260-120, RGN8260-121 AND RGN8260-123 FIGUREITEMQTYDESCRIPTION 1504Washer 1608Brush 1708Screw 1808Springwasher 11001Nut 11701Washer lock 12004Tabwasher 12104Washer 14701Bearing 14904Screw 2501Washer lock 2701Bearing 2904Screw 21404Washer 21702Tabwasher 21901Lug 22001Springwasher 22308Screw 22501Gasket 22902Tabwasher 23101Springwasher 23301Springwasher 23501Springwasher 23701Springwasher Item not Illustrated4Sleeve THALES AVIONICS ELECTRICAL SYSTEMS COMPONENT MAINTENANCE MANUAL P/N 8260-12* PAGE 3005 MAY 19/08 Use or disclosure of this data is subject to the restrictions on the cover page of this Component Maintenance Manual with IPL. 24-32-61 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: Mandatorydiscardalllockingparts.Duringanoverhaul,alsodiscardthe 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 QTYNAME E42761Brush hook E48201Disc removing tool E42331Pin E33961Wrench E4148-1J1Slotted nut socket E60721Commutator bearing extractor E73511Bearing pusher E118751Speed sensor tightening tool E15526-21Base E59801Vee E59811Support No specific1Soldering iron (2) Referenced information REFERENCEDESIGNATION IPLFigures1, 2 and 3 Starter generator PAGE 3006 MAY 19/08 Use or disclosure of this data is subject to the restrictions on the cover page of this Component Maintenance Manual with IPL. THALES AVIONICS ELECTRICAL SYSTEMS COMPONENT MAINTENANCE MANUAL P/N 8260-12* 24-32-61C.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) Using the tool P/N E4820, separate the disc (2-10) from the torque shaft (1-90). THALES AVIONICS ELECTRICAL SYSTEMS COMPONENT MAINTENANCE MANUAL P/N 8260-12* PAGE 3007 MAY 19/08 Use or disclosure of this data is subject to the restrictions on the cover page of this Component Maintenance Manual with IPL. 24-32-61 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 (1-190) fitted with the tab washers (1-200) 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: WiththetoolP/NE6072fittedondriveflangeseparatethestarter-generator intotwoparts,thearmatureandcommutatorbearingassemblyononeside, and the frame assembly and flanged bearing housing, on the other side. NOTE:Handlethisassemblybythearmatureandnotbythecommutatorbearing assembly. Do not touch the commutator with the fingers. PAGE 3008 MAY 19/08 Use or disclosure of this data is subject to the restrictions on the cover page of this Component Maintenance Manual with IPL. THALES AVIONICS ELECTRICAL SYSTEMS COMPONENT MAINTENANCE MANUAL P/N 8260-12* 24-32-61 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:DONOTEXERTTENSIONONTHELEADSOFSPEEDDETECTOR ASSEMBLY (100). THALES AVIONICS ELECTRICAL SYSTEMS COMPONENT MAINTENANCE MANUAL P/N 8260-12* PAGE 3009 MAY 19/08 Use or disclosure of this data is subject to the restrictions on the cover page of this Component Maintenance Manual with IPL. 24-32-61 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:Donotremovethespeedsensorassembly(2-100)fromitssupporton flange(2-80)tocarryoutamaintenanceorrepairoperation:leavethe 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). PAGE 3010 MAY 19/08 Use or disclosure of this data is subject to the restrictions on the cover page of this Component Maintenance Manual with IPL. THALES AVIONICS ELECTRICAL SYSTEMS COMPONENT MAINTENANCE MANUAL P/N 8260-12* 24-32-61 Remove the screws (2-210) and discard the washer (2-200). Remove the speed sensor assembly (2-100). E.Close-up Not applicable. THALES AVIONICS ELECTRICAL SYSTEMS COMPONENT MAINTENANCE MANUAL P/N 8260-12* PAGE 4001 MAY 19/08 Use or disclosure of this data is subject to the restrictions on the cover page of this Component Maintenance Manual with IPL. 24-32-61 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:Usethespecialtoolsandequipmentgiveninthelistinthepageblock SPECIAL TOOLS, FIXTURES, EQUIPMENT AND CONSUMABLES. PART NUMBER QTYNAME No specific1Cabinwithsuctionandwaterscreenfunctions,typeCORAL MINIVELO series No specific1Ultrasonic cleaning machine, FISA type, series 3 FR 34 No specific1Megger for measuring the insulation resistance at 45-50 V DC No specific1Compressedairwithacapacityof7,5bar(108psi)withtool P/N 506277-1 No specific1Stiff nylon bristle brush No specific1Oven 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 NUMBERNAME 90017838Washing liquid FIMM M18 or equivalent 90017839Washing liquid FIMM M36 or equivalent 7954A009Red anti-flash varnish type 2407 or equivalent No specificAdhesive cloth No specificBrush No specificFine emery cloth to get a very clean surface (3) Referenced information REFERENCEDESIGNATION IPL Figure 2Starter generator CLEANING PAGE 4002 MAY 19/08 Use or disclosure of this data is subject to the restrictions on the cover page of this Component Maintenance Manual with IPL. THALES AVIONICS ELECTRICAL SYSTEMS COMPONENT MAINTENANCE MANUAL P/N 8260-12* 24-32-61C.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 :ONCETHETERMINALBLOCKISREMOVED,THEVARIOUS CONNECTIONSWILLBEFREE.DURINGTHECLEANING OPERATIONS,TAKEALLTHENECESSARYSTEPSTOAVOIDANY 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 M. If not, do a new cleaning cycle. THALES AVIONICS ELECTRICAL SYSTEMS COMPONENT MAINTENANCE MANUAL P/N 8260-12* PAGE 4003 MAY 19/08 Use or disclosure of this data is subject to the restrictions on the cover page of this Component Maintenance Manual with IPL. 24-32-61 If after a complete cleaning cycle the insulation is less than 1 M: perform a new pre-cleaning cycle, brush vigorously the connections and then do another cleaning cycle of the frame assembly. NOTE:Doasmanycleaningcyclesasneededtogetaninsulationvalueof greater than 1 M. 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:Ifthepartstobecleanedareverydirty,pre-cleanthepartsinthecleaning 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:DURINGTHEPRE-CLEANINGANDCLEANINGOPERATIONS,DO NOTTOUCHTHECOMMUTATORWITHYOURFINGERSANDTAKE ALL NECESSARY STEPS TO AVOID DAMAGE TO THE MICA UNDER THE COMMUTATOR BLADES. (a)Pre-cleaningStart 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'TPOINTDIRECTLYTHEDRYCOMPRESSEDAIRSPRAY ON THE MICA (SEE FIGURE 4001). Press the blower trigger. PAGE 4004 MAY 19/08 Use or disclosure of this data is subject to the restrictions on the cover page of this Component Maintenance Manual with IPL. THALES AVIONICS ELECTRICAL SYSTEMS COMPONENT MAINTENANCE MANUAL P/N 8260-12* 24-32-61 Perform this operation blade by blade 360 around the commutator. CAUTION:BESURETOTAKEALLTHENECESSARYPRECAUTIONS 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:BESURETOTAKEALLTHENECESSARYPRECAUTIONS 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 M. 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 M. 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. Remove the adhesive cloth masks. THALES AVIONICS ELECTRICAL SYSTEMS COMPONENT MAINTENANCE MANUAL P/N 8260-12* PAGE 4005 MAY 19/08 Use or disclosure of this data is subject to the restrictions on the cover page of this Component Maintenance Manual with IPL. 24-32-61 Heat the varnish at 150 C (302 F) for about 2 hours to cure it. CAUTION:AFTERTHISOPERATIONITISNECESSARYTOPERFORMA DIAMONDSURFACINGOFTHEARMATURE(SEEPAGEBLOCK "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 M. 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 M. 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. PAGE 4006 MAY 19/08 Use or disclosure of this data is subject to the restrictions on the cover page of this Component Maintenance Manual with IPL. THALES AVIONICS ELECTRICAL SYSTEMS COMPONENT MAINTENANCE MANUAL P/N 8260-12* 24-32-61 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 FIGURE 4001 THALES AVIONICS ELECTRICAL SYSTEMS COMPONENT MAINTENANCE MANUAL P/N 8260-12* PAGE 5001 MAY 19/08 Use or disclosure of this data is subject to the restrictions on the cover page of this Component Maintenance Manual with IPL. 24-32-61 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:Usethespecialtoolsandequipmentgiveninthelistinthepageblock SPECIAL TOOLS, FIXTURES, EQUIPMENT AND CONSUMABLES. PART NUMBER QTYNAME No specific1Megger for measuring the insulating resistance at 45-50 V DC P6118451Brush Wear Checking Gauge No specific1Dynamometer No specific1Spring test machine No specific1Ohmmeter (Internal R: 20000 V) No specific1Micrometer internal 30-45 mm (1.181-1.771 in) No specific1Micrometer external 0-25 mm (0-0.984 in) No specific1Caliper square 0 to 250 mm (0 to 9.842 in) No specific2Measuring pin gages diameter 2,438 mm (0.0960 in) (2) Referenced information REFERENCEDESIGNATION 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. INSPECTION/CHECK PAGE 5002 MAY 19/08 Use or disclosure of this data is subject to the restrictions on the cover page of this Component Maintenance Manual with IPL. THALES AVIONICS ELECTRICAL SYSTEMS COMPONENT MAINTENANCE MANUAL P/N 8260-12* 24-32-61 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: Comparethedimensionsofpartswiththosespecifiedinthepageblock"FITS AND CLEARANCES". Discard all out-of-tolerance parts. NOTE: Certainsubassembliesshouldbesubjectedtospecialchecks,inadditiontothe 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 K. 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 0.1 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* PAGE 5003 MAY 19/08 Use or disclosure of this data is subject to the restrictions on the cover page of this Component Maintenance Manual with IPL. 24-32-61 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:Applythemeggertestspikestothesidesofthesegments,toavoidscoring them. Subtask 24-32-61-210-003-A01 (3) Checking the brushes (REF. to figures 5001 and 5002) CAUTION:NEVERREMOVETHEBRUSHESFROMTHEIRGUIDESTOCHECK THEM.ONLYREMOVETHEBRUSHESWENTHEYHAVETOBE REPLACED WITH NEW ONES. NOTE:Brushesmustbecheckedtodeterminethelimitofuseandconditionofthe startergenerator.Theprocedureisthesameforeachoneofbothengines andappliesonthetwobrushesofthethreeaccessiblebrushlines(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 be replaced as decribed in subtask 24-32-61-020-001-A01. PAGE 5004 MAY 19/08 Use or disclosure of this data is subject to the restrictions on the cover page of this Component Maintenance Manual with IPL. THALES AVIONICS ELECTRICAL SYSTEMS COMPONENT MAINTENANCE MANUAL P/N 8260-12* 24-32-61 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 FIGURE 5002 THALES AVIONICS ELECTRICAL SYSTEMS COMPONENT MAINTENANCE MANUAL P/N 8260-12* PAGE 5005 MAY 19/08 Use or disclosure of this data is subject to the restrictions on the cover page of this Component Maintenance Manual with IPL. 24-32-61 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:Foroptimumbrushlifealwaysverifythatallbrushspringtensionlevelsare symmetricalandwithinthelevelsspecified.Ifanyspringtensionisfoundto be outside the specified limit discard old spring and replace it with a new one. PAGE 5006 MAY 19/08 Use or disclosure of this data is subject to the restrictions on the cover page of this Component Maintenance Manual with IPL. THALES AVIONICS ELECTRICAL SYSTEMS COMPONENT MAINTENANCE MANUAL P/N 8260-12* 24-32-61 GRAPHIC 24-32-61-991-5002-A01 CHECK THE BRUSH SPRING TENSION FIGURE 5003 THALES AVIONICS ELECTRICAL SYSTEMS COMPONENT MAINTENANCE MANUAL P/N 8260-12* PAGE 5007 MAY 19/08 Use or disclosure of this data is subject to the restrictions on the cover page of this Component Maintenance Manual with IPL. 24-32-61 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:THEBALLBEARINGSARELUBRICATEDFORSERVICELIFE 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). If the measure value is lower than 18,631 mm (0.7335 in), replace the torque shaft. PAGE 5008 MAY 19/08 Use or disclosure of this data is subject to the restrictions on the cover page of this Component Maintenance Manual with IPL. THALES AVIONICS ELECTRICAL SYSTEMS COMPONENT MAINTENANCE MANUAL P/N 8260-12* 24-32-61 GRAPHIC 24-32-61-991-5004-A01 CHECKING OF THE TORQUE SHAFT FIGURE 5004 E.Close-up Not applicable THALES AVIONICS ELECTRICAL SYSTEMS COMPONENT MAINTENANCE MANUAL P/N 8260-12* PAGE 6001 MAY 19/08 Use or disclosure of this data is subject to the restrictions on the cover page of this Component Maintenance Manual with IPL. 24-32-61TASK 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:Usethespecialtoolsandequipmentgiveninthelistinthepageblock SPECIAL TOOLS, FIXTURES, EQUIPMENT AND CONSUMABLES. PART NUMBER QTYNAME Type R2B61SchenkbalancingmachineTypeR2B6withtwoaccessorykits M180 and M181 and a cell P44 8005011Repair kit No specific1Machine tool cutting lathe No specific1Indicator capable of measuring 0.008 mm (0.0003 in) No specific1Brush No specific1Oven with a capacity of 180 C (356 F) E29491Tool for reworking the chamfers No specific1Micrometer internal 30-45 mm (1.181-1.771 in) No specific1Micrometer external 0-25 mm (0-0.984 in) No specific1Stamp (2) Consumables NOTE:UsetheconsumablesgiveninthelistinthepageblockSPECIALTOOLS, FIXTURES, EQUIPMENT AND CONSUMABLES. PART NUMBER NAME 7954A009Red anti-flash varnish 2407 90003328Varnish ISOPOXY 433-37A NOTE :The brand name and the type of equipment are given for reference purposes only. Anyanotherequipmentwiththesamecharacteristicscanbeusedaswell. The products used are listed under page block "LIST OF PRODUCTS". REPAIR PAGE 6002 MAY 19/08 Use or disclosure of this data is subject to the restrictions on the cover page of this Component Maintenance Manual with IPL. THALES AVIONICS ELECTRICAL SYSTEMS COMPONENT MAINTENANCE MANUAL P/N 8260-12* 24-32-61 C.Job set-up Not applicable D.ProcedureNOTE:Thispageblockdescribesallrepairproceduretobeperformedfollowing inspection, disassembly and servicing. NOTE:Repairworkisundertakenonconditionthatthecomponentorassembly concernedisnototherwiseaffectedbydefectswhicharecauseforrejection.In this respect, it is advisable to complete all the checks required before undertaking any repair work. Subtask 24-32-61-350-001-A01 (1) Diamond surfacing of the commutator CAUTION:THIS OPERATION SHOULD ONLY BE PERFORMED IF NECESSARY (EG.: COMMUTATORBLADESCARRED)ANDNORMALLYONLYAFTER3 BRUSHES REPLACEMENT OPERATIONS. (a)Rounding off If the commutator shows deep marks or signs of wear, it is advisable to correct the roundness before carrying out diamond surfacing. Rounding off is performed in a lathe with a VIDIA tool, quality H1. The following operations should be performed after rounding off and prior to diamond surfacing: check that the concentricity between the commutator and the ball bearing seats is 0.008 mm (0.000315 in) (before SB 8260-12*-24-016). check that the concentricity between the commutator and the ball bearing seats is 0.006 mm (0.000236 in) (post SB 8260-12*-24-016). Turn the commutator to a width of 2 mm (0.0787 in) and to a depth of 1 mm (0.0394 in) (see detail A Fig. 6001). THALES AVIONICS ELECTRICAL SYSTEMS COMPONENT MAINTENANCE MANUAL P/N 8260-12* PAGE 6003 MAY 19/08 Use or disclosure of this data is subject to the restrictions on the cover page of this Component Maintenance Manual with IPL. 24-32-61 GRAPHIC 24-32-61-991-6001-A01 ROUNDING OFF FIGURE 6001 Undercut the mica between the commutator bars to a maximum width of 0.5 mm (0.1968 in) and to a maximum depth of 1 mm (0.0394 in). Rechamfer the chamfers of the commutator segments (0.2 mm at 45) (0.007 in at 45) with the tool for reworking the chamfers P/N E2949 (see figure 6002). GRAPHIC 24-32-61-991-6002-A01 TOOL FOR REWORKING THE CHAMFERS P/N E2949 FIGURE 6002 PAGE 6004 MAY 19/08 Use or disclosure of this data is subject to the restrictions on the cover page of this Component Maintenance Manual with IPL. THALES AVIONICS ELECTRICAL SYSTEMS COMPONENT MAINTENANCE MANUAL P/N 8260-12* 24-32-61 Scrape the grooves between the commutator segments in order to remove any loose matter in these grooves. After the above operations, check that the commutator diameter is greater than the minimum dimension specified in the page block "FITS AND CLEARANCES", then carry out diamond surfacing. (b)Diamond surfacing Diamond surfacing should be carried out in a precision lathe fitted with a compressible center to prevent overheating of the armature shaft (tallow the center). Drive the part to be surfaced at a speed of 3 000 rpm and take one or more very light cuts (maximum diametrical depth: 0.015 mm (0.00059 in)) with a cutting speed of approx. 0.05 mm (0.0019 in) per revolution. Take as many cuts as required to obtain a perfect commutator surface. After surfacing, clean the segments with a small brush made of very soft bristle. Check that the commutator diameter is not less than the minimum dimension specified in the page block "FITS AND CLEARANCES". Protect the commutator until the armature is to be installed in the starter-generator. NOTE:Never touch the commutator with the fingers after diamond surfacing. When reinstalling the armature after diamond surfacing of the commutator, it is advisable to operate the starter-generator for a few hours with light load applied in order to obtain a glossy finish, as this is the essential requirement to be met to obtain correct commutation and to limit brush wear. 1Final check a Total out of round Check that the total out of round of the commutator is 8 m (before SB 8260-12*-24-016). Check that the total out of round of the commutator is 6 m (post SB 8260-12*-24-016). b Bar to bar Check that the bar to bar of the commutator is 3 m (before SB 8260-12*-24-016). Check that the bar to bar of the commutator is 2 m (post SB 8260-12*-24-016). CAUTION:AFTERTHISOPERATIONOFDIAMONDSURFACING PERFORM SYSTEMATICALLY A NEW BALANCING. THALES AVIONICS ELECTRICAL SYSTEMS COMPONENT MAINTENANCE MANUAL P/N 8260-12* PAGE 6005 MAY 19/08 Use or disclosure of this data is subject to the restrictions on the cover page of this Component Maintenance Manual with IPL. 24-32-61 Subtask 24-32-61-350-002-A01 (2) Balancing the armature (See figure 6003) CAUTION:THISOPERATIONSHOULDBEPERFORMEDSYSTEMATICALLY AFTEREVERYDIAMONDSURFACINGANDORMAINTENANCE OPERATIONS. The dynamic balance of the armature should be checked in the event of vibration orafter rounding off. This operation is carried out with a balancing machine. The driving speed is according to the type of machine. Balancing is performed by adding balancing weights in the holes provided for this purpose on both ends of the armature, so as to obtain a permissible residual unbalance of 4.00 g.mm (0.1410 oz in) within each balancing plane: Front end of the armature (balancing plane 2): addition and stacking of 5 mm (0.196 in) dia. balancing weights. Commutator end (balancing plane 1) addition and stacking of 5 mm (0.196 in) dia. balancing weights. The result obtained should comply with group 2-5. NOTE :The balancing pellets are staked by three centre punch marks outside of the pellet. After balancing operations, apply red anti-flash varnish 2407 P/N 7954A009with a brush on the balancing pellets. GRAPHIC 24-32-61-991-6003-A01 BALANCING FIGURE 6003 PAGE 6006 MAY 19/08 Use or disclosure of this data is subject to the restrictions on the cover page of this Component Maintenance Manual with IPL. THALES AVIONICS ELECTRICAL SYSTEMS COMPONENT MAINTENANCE MANUAL P/N 8260-12* 24-32-61 Subtask 24-32-61-350-003-A01 (3) Impregnation of the stator (See figure 6003) Apply ISOPOXY varnish 433-37A P/N 90003328 with a brush on all the faces of the windings heads. NOTE :Forapplyingofthevarnishwiththebrushwatchnotanydrainingbe occasional inside the poles. Polymerisetheassemblyfor4hoursinanovenatatemperatureof180C (356 F). Subtask 24-32-61-350-004-A01 (4) Checking and readjustment of the bearing ball bores and the journals shaft on the armature P/N P604823 to P604823-4. The readjustment of the bearing ball bores and the journals shaft is performed by built-up of Nickel by electrochemistry process with a stamp (refer to page block FITS AND CLEARANCES for dimensions). E.Close-up Not applicable THALES AVIONICS ELECTRICAL SYSTEMS COMPONENT MAINTENANCE MANUAL P/N 8260-12* PAGE 7001 MAY 19/08 Use or disclosure of this data is subject to the restrictions on the cover page of this Component Maintenance Manual with IPL. 24-32-61TASK 24-32-61-400-801-A01 1.ASSEMBLY OF THE STARTER GENERATOR A.Reason for the job Self-explanatory B.Job set-up Information (1) Tools, fixtures and equipment NOTE:Usethespecialtoolsandequipmentgiveninthelistinthepageblock SPECIAL TOOLS, FIXTURES, EQUIPMENT AND CONSUMABLES. PART NUMBERQTYNAME No specific1Variable DC power supply, 0-50 A/0-30 V H3111Moving-coilDCammeter(A1),AOIPorequivalent,class0.5, with 50 A shunt No specific1Oscilloscope No specific10100mVcentre-zeromillivoltmeter(V1),class0.5, complete with leads and prods No specific1Dialindicator capable of measuring dimensionsfrom0.001 to 0.01 mm (0.0000393 to 0.000394 in) VCF02GE1Switch I1: 10A or equivalent 350X4033R1Rheostat Rh1: 315 W, 33 , 5 % or equivalent Plate shunt 100 A1Shunt: 100 A, 75 mV or equivalent 30243STPA-2091Contactor K1: 200 A, 28 V DC or equivalent No specific1Switch type APR 10-631 or equivalent (I3) E51061Spring fitting tool E118751Speed sensor tightening tool E4148-1J1Slotted nut socket E33961Wrench E42331Pin E42761Brush hook E59801Vee E59811Support No specific1DC power supply 28 V/200 A like P/N MTH 60-200 (CONVERGIE) or equivalent ASSEMBLY PAGE 7002 MAY 19/08 Use or disclosure of this data is subject to the restrictions on the cover page of this Component Maintenance Manual with IPL. THALES AVIONICS ELECTRICAL SYSTEMS COMPONENT MAINTENANCE MANUAL P/N 8260-12* 24-32-61 PART NUMBERQTYNAME E15526-21Support E39341Checking tool No specific1Soldering iron No specific1Compressedairwithacapacityof7,5bar(108psi)withtool P/N 506277-1 (2) Consumables NOTE:Use the consumables given in the list in the page block SPECIAL TOOLS, FIXTURES, EQUIPMENT AND CONSUMABLES. PART NUMBER NAME 90006113Loctite 932 90006118Blocking resin 90001529LUBRICOMET PA451 90000052Tinea solder 183-240 90006011Annealed stainless steel lockwire 0.6 mm dia (0.023622 in) E813634RSheath RNF 100 1/8 black dia. 3,2 mm (0.1259 in) (3) Referenced information REFERENCEDESIGNATION IPLFigures1, 2 and 3 Starter generator C.Job set-up Not applicable D.Procedure NOTE: For assembly tolerances and tightening torques, refer to the page block "FITS AND CLEARANCES". During each assembly operation, mandatory replace all locking parts. THALES AVIONICS ELECTRICAL SYSTEMS COMPONENT MAINTENANCE MANUAL P/N 8260-12* PAGE 7003 MAY 19/08 Use or disclosure of this data is subject to the restrictions on the cover page of this Component Maintenance Manual with IPL. 24-32-61 Subtask 24-32-61-420-001-A01 (1) Assembling the frame (a)Installing the terminal block Install the frame on the vee P/N E5980. Carefully move aside the electrical connections of the frame (2-260), then install the insulator (2-275). Install and secure the terminal block (2-280) with the screws (2-300) and the tab washers (2-290) which are also used to secure the grounding lugs of the terminal block. NOTE:Tighten the screws (2-300) to a torque of 0.25 m. daN (1.843 Ft. lb). NOTE:Ensurethatthesmalldiameterleads(terminalsAandD)arerouted betweenthelargeflatterminals(EandB)andterminalblockincavity provided at the base of terminal block. Lock the screws (2-300) by bending the tabwashers (2-290) onto them. Install the nuts (2-320) and (2-380) fitted with the washers (2-310) and (2370), and the nuts (2-340) and (2-360) fitted with the washers (2-330) and (2-350) (do not tighten the nuts). NOTE:Thenuts(2-320,2-380,2-340and2-360)willbetightenedupon installation of the starter-generator in the aircraft. Subtask 24-32-61-420-002-A01 (2) Assembling the Commutator bearing assembly Tension the first brush spring (1-310) using the tool P/N E5106 (See Figure 7001). CAUTION:RESPECTTHETENSIONANGLEOFTHESPRINGWHICHMUSTBE EQUAL TO 388. Install the first brush spring (1-310) using the tool P/N E5106 (See Figure 7001).Install the spacer (1-320). Tension the second brush spring (1-310) using the tool P/N E5106. CAUTION:RESPECTTHETENSIONANGLEOFTHESPRINGWHICHMUSTBE EQUAL TO 388. Install the second brush spring (1-310) using the tool P/N E5106.Install the spacer (1-330). Secure the springs with a new retaining ring (1-340). CAUTION:THEEDGEOFTHERETAININGRINGWILLBEONTHEEXTERNAL SIDE. PAGE 7004 MAY 19/08 Use or disclosure of this data is subject to the restrictions on the cover page of this Component Maintenance Manual with IPL. THALES AVIONICS ELECTRICAL SYSTEMS COMPONENT MAINTENANCE MANUAL P/N 8260-12* 24-32-61 Check the brush springs tension (Refer to Subtask 24-32-61-210-004-A01). GRAPHIC 24-32-61-991-7001-A01 INSTALLATION OF THE BRUSH SPRING FIGURE 7001 NOTE:Lightlysmeartheinnerandouterraceringsoftheballbearing(1-470)with compound LUBRICOMET PA451 P/N 90001529. Install the ball bearing (1-470). Install and secure the flange (1-480) with the screws (1-490). NOTE:Tighten the screws (490) to a torque of 0.12 m. daN (0.885 ft.lb). Subtask 24-32-61-420-003-A01 (3) Assembly the flanged bearing NOTE:Lightlysmeartheinnerandouterraceringsoftheballbearing(2-70)with compound LUBRICOMET PA451 P/N 90001529, side driving. Install the ball bearing (2-70). Install the speed sensor assembly (2-100) on the flange (2-80). Install and secure the flange (2-80) fitted with the speed sensor assembly (2-100) with the screws (2-90). NOTE:Tighten the screws (2-90) to a torque of 0.35 m. daN (2.581 ft.lb). Subtask 24-32-61-420-004-A01 (4) Assembling the speed sensor assembly (a)After maintenance or repair of a starter-generator component. CAUTION:DONOTEXERTTENSIONORTORSIONONTHELEADSOF SPEEDSENSORASSEMBLY(2-100)WHENREPLACINGTHE FLANGE (2-80) AND THE FLANGED BEARING (2-220). THALES AVIONICS ELECTRICAL SYSTEMS COMPONENT MAINTENANCE MANUAL P/N 8260-12* PAGE 7005 MAY 19/08 Use or disclosure of this data is subject to the restrictions on the cover page of this Component Maintenance Manual with IPL. 24-32-61 (b)After replacement of the speed sensor assembly (2-100) Install the sheath P/N E813634R on the speed sensor assembly (2-100). Install the lug (2-190). Secure the bonding jumper of the speed sensor assembly (2-100) with the screw (2-210) fitted with a new washer (2-200). NOTE:Tighten the screw (2-210) to a torque of 0.06 m. daN (0.442.Ft. lb). Install and secure the box (2-160) with the screws (2-180) and the new tab washers (2-170). NOTE:Checkthatthespeeddetectorconnectionsarenotwedgedunder connectorboxthentightenscrews(2-180)toatorqueof0.15m.daN (1.106 ft.lb). Lock the screws (2-180) with the new tab washers (2-170). Solder the connecting leads of the speed sensor assembly (2-100) to the pins of connector (2-130) with Tinea solder 183-240 P/N 90000052. NOTE:Do not cut the connecting leads of speed sensor assembly (2-100) ; if a lead is too long, make a loop within box (2-160). Bend the lead three two over itself before inserting it into the pin. Install the connector (2-130) as shown in figure 7002 by inserting it into its box (2-160). Install the screws (2-150) fitted with the new washers (2-140). NOTE:Tighten the screws (2-150) to a torque of 0.06 m. daN (0.442 ft.lb). Place the thumb nut (2-120) or a new thumb nut (2-120) and smaller in its housing in flange (2-80). Screw on the thumb nut (2-120) using the tool P/N E11875. After adjustment (Refer to Subtask 24-32-61-440-015-A01), lock thumb nut (2-120) with blocking resin P/N 90006118. GRAPHIC 24-32-61-991-7002-A01 FOOL PROOF DEVICES OF THE CONNECTOR FIGURE 7002 PAGE 7006 MAY 19/08 Use or disclosure of this data is subject to the restrictions on the cover page of this Component Maintenance Manual with IPL. THALES AVIONICS ELECTRICAL SYSTEMS COMPONENT MAINTENANCE MANUAL P/N 8260-12* 24-32-61 Subtask 24-32-61-420-005-A01 (5) Assembling the torque shaft Install the disc (2-10) on the torque shaft (1-90). Subtask 24-32-61-420-006-A01 (6) Installing the commutator bearing assembly NOTE:Lightly smear the journals of the armature (2-240) with LUBRICOMET PA451 P/N 90001529. Install the commutator bearing assembly (1-180) and engage the inner race ring of the ball bearing (1-470) onto the shaft of the armature (2-240) (on commutator end) according to the markings made upon disassembly. NOTE:Do not touch the commutator with the fingers. Install the slotted nut (1-160) to prevent the armature from failing during assembly operations (do not tighten). Subtask 24-32-61-420-007-A01 (7) Installing flanged bearing Install the frame on the support P/N E15526-2. Install the flanged bearing (2-220) on the frame assembly (2-260). Secure the flanged bearing with the screws (2-230) after smearing the screw threads with Loctite 932 P/N 90006113 and a soldering iron. NOTE:Tighten the screws (2-230) to a torque of 0.15 m. daN (1.106 ft.lb). Subtask 24-32-61-420-008-A01 (8) Installing the armature (fitted with the commutator bearing Refer to Subtask 24-32-61-420-006-A01) Install the gasket (2-250). Install the commutator bearing assembly fitted with the armature (2-240) in the frame fitted with the flanged bearing, and insert the front end of the armature shaft into the inner race ring of ball bearing (2-70). NOTE:Observe the markings made upon disassembly: on the inner race ring of ball bearing (2-70) and the front journal on the armature. on the frame assembly and the commutator bearing assembly. Remove the slotted nut (1-160). Secure the commutator bearing assembly with the screws (1-190) fitted with the new tab washers (1-200) and the washers (1-210). THALES AVIONICS ELECTRICAL SYSTEMS COMPONENT MAINTENANCE MANUAL P/N 8260-12* PAGE 7007 MAY 19/08 Use or disclosure of this data is subject to the restrictions on the cover page of this Component Maintenance Manual with IPL. 24-32-61 NOTE:Tighten the screws (1-190) to a torque of 0.200 m. da