COMMONWEALTH OF AUSTRALIA (Civil Aviation Regulations 1998), PART 39 - 107 CIVIL AVIATION SAFETY AUTHORITY
SCHEDULE OF AIRWORTHINESS DIRECTIVES
Electrical Equipment
AD/ELECT/28
Amdt 3
Prestolite Alternator SRE Bearing Inspection 9/79
Applicability: Prestolite ALV-9400 to ALV-9410 series gear driven alternators.
Requirement: Remove the slip ring and bearing cover by using a small sharp chisel, knife blade, or screwdriver to pry it out of the alternator slip ring head. Care must be taken not to damage the end head or bearing cover. If the bearing cover is damaged during removal it must be replaced.
Without further disassembly visually inspect the bearing and shaft end for discoloration or any sign of overheating or wear. Pay particular attention to the bearing inner and outer race.
If there is any sign of overheating or an indication that the rotor shaft has been turning in the inner race or the outer race turning in the end head, the alternator must be removed and repaired.
If the rotor shaft has been turning in the bearing inner race, the rotor and bearing must be replaced. If the bearing outer race has been turning in the end head, the bearing and end head must be replaced.
Check the bearing grease for any sign of overheating or contamination such as dirt, or metal filings. If the grease is a dark brown or black colour, or is so contaminated, the alternator must be removed and the bearing replaced.
If the bearing shows no sign of discoloration, overheating, wear or contamination the bearing only (not the entire cavity) should be regreased with Caltex RPM Grease SRI- 2 only.
Note. The following SBs refer to this inspection: Prestolite ASMIO, Rolls Royce T- 324, Continental TCM M75-30 and FAA AD 76-02-07.
Compliance: Within 100 hours time in service after 30 July 1976 and thereafter at intervals not exceeding 100 hours time in service or 500 hours time in service for alternators modified as per Rex Aviation Modification RA-C-1541.
Overview
The Civil Aviation Regulations 1998, as amended, under the authority of the Civil Aviation Act 1988, were enacted to address the need for comprehensive regulations governing aviation safety in Australia. The specific legislative instrument in question, F2006B09411, pertains to Part 39 - 107 of the Civil Aviation Regulations, which focuses on airworthiness directives for electrical equipment, particularly the inspection of Prestolite alternator SRE bearings. The instrument was introduced to mitigate risks associated with the malfunction of electrical equipment in aircraft, ensuring that such equipment meets safety standards to prevent in-flight failures. The objective is to maintain the highest safety standards by mandating regular inspections and necessary repairs of critical components such as alternator bearings, which are essential for the reliable operation of aircraft electrical systems.
Scope and Application
The Civil Aviation Regulations 1998, specifically Part 39 - 107 Civil Aviation Safety Authority Schedule of Airworthiness Directives, governs the maintenance and safety standards of aircraft electrical equipment, including the mandatory inspection of certain alternators. This directive applies to aircraft equipped with Prestolite ALV-9400 to ALV-9410 series gear-driven alternators. The inspection requirements must be adhered to by the operators, maintenance personnel, and other entities responsible for the upkeep of these aircraft components. The directive applies across the Commonwealth of Australia, ensuring a uniform approach to aircraft safety throughout the nation. The regulation is clear in its exclusions, focusing solely on the specified alternators and does not extend to other types of electrical equipment unless similarly identified in other directives. The application of these safety measures is not restricted by subordinate instruments but is mandatory as outlined within the primary regulations. Compliance with these directives is essential, with inspections mandated within 100 hours of service after 30 July 1976 and at intervals not exceeding 100 hours or 500 hours for modified alternators.
Key Provisions
The Civil Aviation Regulations 1998, specifically Part 39 - 107, under the Civil Aviation Safety Authority (CASA) Schedule of Airworthiness Directives, includes AD/ELECT/28 Amendment 3 concerning the inspection of Prestolite Alternator SRE bearings. This directive applies to a specific series of alternators, namely the Prestolite ALV-9400 to ALV-9410. The key requirement (under AD/ELECT/28Amdt 3) is that the slip ring and bearing cover must be removed using a small sharp chisel, knife blade, or screwdriver, taking care not to damage the end head or the bearing cover. If the bearing cover is damaged during removal, it must be replaced. After removal, the bearing and shaft end must be visually inspected for any signs of discoloration, overheating, or wear, particularly focusing on the bearing inner and outer race. If there is any indication of overheating or improper rotation of the rotor shaft or the bearing races, the alternator must be removed and repaired, with specific components such as the rotor, bearing, or end head being replaced as necessary. The bearing grease must also be checked for overheating or contamination, and if it appears dark brown, black, or contaminated, the alternator must be removed and the bearing replaced. If the bearing shows no signs of damage, it should only be regreased with Caltex RPM Grease SRI-2.
The obligations imposed by this directive require operators of the specified alternators to perform regular inspections as mandated. Compliance with the directive includes ensuring that inspections are conducted within 100 hours of service after 30 July 1976 and then at intervals not exceeding 100 hours of service or 500 hours of service for alternators modified as per Rex Aviation Modification RA-C-1541. The directive also references several Service Bulletins (SBs) that provide additional information on this inspection, including Prestolite ASMIO, Rolls Royce T-324, Continental TCM M75-30, and FAA AD 76-02-07. These references underscore the importance of following specific maintenance procedures to ensure the safety and reliability of the alternators.
Failure to comply with these requirements can result in serious consequences. The Civil Aviation Regulations do not explicitly state the penalties for non-compliance with this specific directive, but non-compliance with general CASA regulations can lead to substantial penalties. These can include fines, enforcement notices, and in severe cases, suspension or revocation of an aircraft's Certificate of Airworthiness. Additionally, any failure to comply with airworthiness directives can lead to criminal charges if it results in an aviation accident or incident, potentially leading to imprisonment, reflecting the critical nature of adhering to these safety standards.