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OBJECTIVES
To understand the usage of aircraft maintenance manuals.
To ensure the selections of appropriate tools during the removal and
installation of aircraft components.
Student needs to identify and follow the safety precaution during the process
of component removal and installation.
TOOLS REQUIRED
Set of Sockets Wire Cutter
Set of Spanners Multimeter
Wire Twister Meter Rule
Torque Wrench “ C Spanner
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!hilip screw driver Torch light
Step down socket adapter
REFERENCES
• "S#$%&'(() maintenance manual chapter $' * $+
STARTER GENERATOR INSPECTION
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SYSTEM OPERATION
,ircraft starter generator -asically a dc generator that can -e used as
starter motor
uring starting/ the -attery power is connected to the starter&gen. 0t will -ecome a motor and crank the engine
,t certain speed/ the -attery will disengage and it will -e riven -y the
engine and turn to generator
PROCEDURE TO REMOVE STARTER GENERATOR
#. 0solate relevant electrical circuits 1 chapter $'/ 2eneral 3
$. 4pen -ottom engine cowls.+. isconnect starter 5 generator cooling air inlet hose.
'. isconnect -reather hose from -ottom front coil. 1right engine& 6one M$3
%. Remove -ottom cowl.
7. Remove overheat switch from stater generator 1chapter $'/ 2enerator
4verheat Switch3
8. isconnect electrical ca-les from starter 5 generator.
WARNING 9 ST,RT:R 5 2:;:R,T4R W:02"T ,!!R4<. %'=).
>. Support weight of starter 5 generator/ release clamp ring and report starter 5
generator
Picture of t!rter "e#er!tor !fter $ei#" re%o&e
INSPECTION OF T'E CARBON BRUS'
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#. Remove -rush gear cover -and.
$. Remove the two suppressor -o? cover/ secured -y slot headed screw.
+. isconnect lead from terminal on choke assem-ly.
'. isconnect leads from the small capacitors on either side of choke
assem-ly.
%. Slacken the two screws securing the suppressor tray saddle to the field
coil yoke.
7. Slide complete suppressor -o? assem-ly toward the -rushgear end of the
unit and carefully lift clear.
8. Withdraw -rushes from holders and measure the length of the longest
side of each pair -rushes. 0f this measurement is #.## inch or a-ove/ the
-rushes may -e fitted for a futher routine check period.
>. 0f the measurement is less then #.## inch/ the -rushes may -e refitted -ut
must -e renewed -efore the minimum -rush length of (.>% inch has -een
reached.
INSPECTIONS ON CARBON BRUS'
INSTALLATION OF STARTER GENERATOR
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#. Make sure that the gear-o? e?tension drive shaft grease sleeve is
lu-ricated with clean approved lu-ricant. 0f necessary/ wash out all
trace of old contaminated using white spirit and dry off with clean
compress air. !ack the e?tension drive shaft grease sleeve with
approved fresh lu-ricant.
$. Make sure that the starter generator locating dowel holes in the engine
air outlet casing are clean and that mounting flanges and clamping
surfaces are free from -urrs and foreign matter.
+. =u-ricate thread of clamp ring -olt/ inside faces of clamp ring/ and
starter generator splines with grease. =u-ricate and fit new o&ring seal
to starter generator drives shaft shroud.
'. 4ffer out starter generator/ check that mounting flange mate and fully
engage starter generator with engine gear-o?.
%. @it starter generator clamp ring/ and torque tighten -olt to #$( l- inch/
loosen and re&torque to #$( l- inch. Repeat sequence until -olt ceases
to advance. When finally torqued to correct loading the gap -etween
clamp end must -e (.(%$ inch to (.$>% inch.
7. Connect and secure electrical ca-les to starter generator.
8. Connect and secure overheat switch electrical leads to terminal -lock
== or M=.
>. @it -ottom front cowl.
A. Connect and secure starter generator air cooling inlet hose.
#(. Connect and secure the -reather hose to -ottom front cowl.
##. Close and secure all cowls
#$. Restore all relevant electrical circuit
#+. @unctional test for starter generator -efore install into aircraft.
SAFETY PRECAUTIONS
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a3 Wear proper attire and use the right tools -efore removing and installing the
starter generator.
-3 Starter generator weighs appro?imately %' =).
c3 0n the following operation ensure that fle?i-le pipe @.##&$$+ is not under
tension and does not foul the starter generator.
d3 Care must -e taken not to damage drive end sealing ring/ when fitting starter
generator to engine.
e3 =ocate -ottom front cowl and check alignment of air inlet prior to torque
loading.
f3 =eft&hand starter generator only/ ensures that the ca-le terminal lugs do not foul
the cowling.
DEFECT
• Stand on M$ cowling missing
• Ca-el on car-on -rush # worn out
• Suppresser -o? cover have a lot of corrosion
• Two screw missing
• Wire at voltage regulator missing
ACTION
@itted stand at M$ cowling
Replaced ca-el of car-on -rush #
Replaced -o? cover Replaced the missing screw
0nstalled new wire at voltage regulator
CIRCUIT BREA(ER INSPECTIONS
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SBST:M 4!:R,T04;
• 0t is commonly used in aircraft to protect the circuit from e?cessive current
•
0t is resetta-le once the circuit is cools• ,ircraft circuit -reakers are trip&free type which means that once the -reaker
opens/ the circuit remains open until the circuit cools regardless of the
position of the operating control.
• Circuit -reakers operate on either thermal or magnetic principles.
• Thermal -reakers open a circuit when e?cess current heats an element in the
-reaker causing the contacts to open.
• Magnetic -reakers utili6e the magnetic field caused -y the current in the
circuit to open the contacts
PROCEDURE
#. @irst/ shut down all aircraft electrical system.
$. Remove two circuit -reaker with different ampere.
+. Check continuity using multimeter 1analogue3.
!icture of circuit -reaker
SAFETY PRECAUTION
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a3 :nsure power supply has -een removed -efore remove the circuit -reakers.
-3 :nsure that the circuit -reakers that has -een removed must -e tag to ensure
correct location when installing the -reakers.
c3 0f the circuit -reakers need to -e replace/ ensure that circuit -reakers must -ecorrect current rating as -efore.
Defect
Contacter damage
Circuit -reaker is not connected with wire
Actio#
Replaced the circuit -reaker Connect the wire to the circuit -reaker contacter
BATTERY INSPECTIONS
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SBST:M 4!:R,T04;
• The "awker $'&volts $%&,h lead&acid -attery is a sealed/ valve regulated
system which allows the -attery to -e oriented and operated in any attitude
or position without spillage of electrolyte• 0t comprises two #$&volts sealed mono&-locks connected in series/ which are
tightly enclosed in a polyester -onded fi-er glass which incorporates the
-attery main terminal connector.
• :ach mono&-locks incorporates a resealing safety valve to guard against the
effects of a-usive use of the -attery.
• The mono&-locks are e?ternally connected -y multiple copper strip
lamination and to the main -attery terminals.
PROCESS OF REMOVING T'E BATTERY
• disconnect venting pipes
• disconnect -attery connector
• release wing -olt securing -attery mounting tray assem-ly to -attery shelf
• remove -attery from -attery mounting tray
INSPECTIONS
:nsure the -attery trays are clean/ and drip tray -locks and pad are securely
-onded in position
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• Remove -attery hold&down cover/ and check that the -attery vent plugs are
secure and free from o-struction.
PROCESS OF INSTALLING T'E BATTERY
• =ocate the -attery on drip tray in mounting tray assem-ly/ fit and tighten
wing -olts and locking nuts to secure -attery to tray assem-ly
• !osition the -attery complete with mounting tray assem-ly in the aircraft
ensuring that the dowels on mounting tray locate in holes in mounting
structure. Tighten wing -olt to secure.
• Connect and secure -attery connection.
• @it and secure -attery vent pipes.
•@unctionally test -attery supply circuit 1 see chapter $'/ C 2:;:R,T4R 3
DEFECTS
)attery terminal connector corrode
)attery terminal ingress or dirt
)attery venting pipe damage
ACTIONS
Replaced the -attery terminal with new one
Replace the venting pipe
CONCLUSIONS
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Trainee must -e use appropriate tools during removal and installation of
aircraft components.
Safety precaution must -e identified and followed during the process of
component removal and installation.
:very defect must have its own action so that it can -e solved -efore the
aircraft is -eing released.
:very maintenance work must -e done according to the maintenance
manual.
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UNIVERSITY (UALA LUMPUR
MALAYSIAN INSTITUTE OF AVIATION TEC'NOLOGY
PRACTICAL REPORT
'S )*+ COMPONENT REMOVAL AND INSTALLATION
INSTRUCTOR , Mr- F!i.!/ S0!riff
TRAINEE , Mo01 S2!.3!# $i# F!1.i/ +4)+5)6764+
, C0e Mo01 Fir1!u $i# C0e Mo01 '!#!fi +4)+5)67))8
, Mo0!%!1 Fir1!u $i# A1#!# +4)+5)676*)
CLASS , 9 'e/ico:ter
SUBJECT , Aircr!ft E/ectric!/ S2te%
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