Universiti Kuala Lumpur

Malaysian Institute of Aviation

Technology

AKD10203: ELECTRICAL FUNDAMENTAL 2

CLASS: 2 AEM1 (Group 4)

PRACTICAL REPORT # 2

Practical on DC Generator and Cable & Connector

LIST OF STUDENTS

1. HARITH TSAQIF BIN AHMAD YUSRI

2. AHMED SHARIN HAMZA
3. MUHAMMAD SAIFUL IZZAT BIN HISHAM
4. MUHAMMAD NABIL NA’AIM BIN ABDULLAH

Designation/Position: Deputy Dean

 Universiti Kuala Lumpur
Malaysian Institute of Aviation
Technology
WORKSHEET FOR PRACTICAL

TITLE: DC MOTOR AND GENERATOR

Subject Subject Name: Electrical Fundamental 2

AKD10203 C1-12 EWIS
Code:
Project Code: P-12A
EASA : 3. 12 DCAM 66 : 3. 12
Module: 3 ATA Chapter: 24
Sub-module: 12 DC Motor and Generator

GIVEN Students are give this workshop practical sheet

The objectives of this practical session are:
1. Expose the students to the practical skills utilsed on
the aircraft and its components.
2. Reinforce the lecture on the above subject.
OBJECTIVE
NOTE: The Practical is NOT intended to train the students to
repair or overhaul Generators.
Students are required to be able to perform the followings:
1- list and identify the major parts of a DC generator and the
functions of individual components.
PERFORMANCE 2- Quote the major defects of the major components.
STANDARD 3- Conduct the inspections and the major tests on the field and
armature windings.

The following skills are required:

1- use of industrial growler to test armature
STANDARD
PRACTICE 2- use of multimeter to check for continuity and short circuit.

No ID NUMBER STUDENT NAME CLASS

1 53106221022 Harith Tsaqif Bin Ahmad Yusri 2AEM1
2 53106221054 Ahmed Sharin Hamza 2AEM1
3 53106221020 Muhammad Nabil Na’aim Bin Abdullah 2AEM1
4 53106221002 Muhammad Saiful Izzat Bin Hisham 2AEM1

Prepared by: Approved by:

Sign/ Date Sign/ Date:

Name: JAMALULAIL HAMZAH

Designation/Position: Deputy Dean

 Universiti Kuala Lumpur
Malaysian Institute of Aviation

1. Reference Data:
Generator Service Manual – Delco – Remy
Course Note of Generator Maintenance.

2. Required Tools & Equipments:

Growler Units of suitable size for the armatures.
Small hacksaw blade 12” x 0.5”
Multimeters to read ohms and AC voltage.

3. Required Materials
DC generators. A stripped set with yoke, 2 end assy and the armature.
The generators must have complete field windings and armature assy and yoke to have the attached field coils.

4. Required Manpower
Max 2 students per group.

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 Universiti Kuala Lumpur
Malaysian Institute of Aviation
5. Procedure

A-Preparation
1. The equipments to be positioned on the tables for students.
2. Students will be divided into groups. Two per group.
B-Identify the parts
1. Each group is given This Task Sheet.
2. Students have to identify the main parts of the generator and their
functions. Take photo of the parts for report, photo from internet is also
acceptable.
3. Identify the stator’s parts: yoke, the salient poles, the field windings, the
2 end assy, the brush assy, bearings, air-intake.
4. Identify the parts of the rotor: the armature, armature windings,
commutators and commutator insulator, the armature core.
5. Identify the armature assy, the commutators and the insulation , windings,
core and shalf.
The report should contain the functions of the yoke, field winding,
salient poles, both the end assy, the commutators, the armature
windings and the armature core

C- Inspection.
1. Inspect the yoke and the poles and the field windings for damages,
overheating and the insulation and wiring. Identify the interpoles and
compensating windings, if any.
2. Inspect (a) condition of the commutator sign of overheating, pitting and cut.
(b) count the number of commutator segments (c) count the number of
slots in the core.
3. Check the mica insulation between the commutator, it should be below the
height of commutators.
4. Check the condition of the armature winding for sign of overheat,
mechanical damages and damage to the insulation.
D.Testings.
1. Field windings.
a. Using the suitable range of ohmmeter, check and report the resistance of
the field and its insulation to the yoke.
b. Check the continuity of the field winding and report it.

2. Armature Windings
a-Using ohmmeter, check the resistance between two adjacent commutator. If
it is a wave winding,check resistance between the opposite commutators.
b-Check the resistance from the commutators the shaft.
c. Check for armature Open Circuit - Put the armature on the growler,
switch it ON, check the AC voltage/curent between adjacent
commutators and record the voltages or current.
d. check for short circuit - with growler on, put the hacksaw blade parallel
to the shaft near the winding. The hacksaw should not vibrate.

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 Universiti Kuala Lumpur
Malaysian Institute of Aviation
6.REPORTS
Format
1. Introduction
a. The report is to examine and test the given DC generator. The work
was done in a team of 2 students.
2. Objectives
3. Safety precaution
4. Tools and Equipment
5. Identification of the generator Parts
Parts (examples) Picture Function
Yoke
Notes :The report should contain the functions of the yoke, field winding,
salient poles, both the end assy, the commutators, the armature windings
and the armature core.

6. The Inspection and Test

The following are the result of the inspections and test.
Parts(examples) Inspection/Test/methods Results
Check for burn and pitting There is slight burn mark.
No Pitting
Field Windings
Insulation Test –between the High resistance indicating
winding and the shaft using a good insulation between
multimeter. the winding and ground.

Virtual check on the The winding found to be in

condition of the winding good condition, except
one wire was cut.
Armature Winding
Check for insulation to
ground using a resistance
meter.

7. Conclusion
Give the status of the various part, whether they are serviceable or not.
If not, what are the defects.

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 Universiti Kuala Lumpur
Malaysian Institute of Aviation

6. Grading/ MOE

TASK/ITEM PERCENTAGE SCORE

Prompt & successful completion of project 70%

Safety Attitude & Team Work 10%
Proper Usage & Availability of hand tools 10%
Appropriate Reference 05%
Cleanliness 05%
Total Practical Grade 100%

7. Grading/ DCAM

Competency Level (Competent or Not Competent)

The following students’ competency are as follows:

Names Competent/ Not

Competent

Signature:

Instructor’s name: JAMALULAIL HAMZAH

Date:

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 Universiti Kuala Lumpur
Malaysian Institute of Aviation

DC Motor and Generator

Electrical Fundamental 2
AKD10203

Introduction
Growler is an electrical device used for testing insulation of a motor for shorted coils. A growler
consists of a coil of wire wrapped around an iron core and connected to a source of alternating
current. When placed on the armature or stator core of a motor the growler acts as the primary of
a transformer and the armature coils act as the secondary. A "feeler", a thin strip of steel also
known as hacksaw blade can be used as the short detector.

Objective
To inspect the armature in dc motor and generator for short in winding, ground or shaft and open
circuit.

Safety precaution
1. Wear proper attire during handling with dc generator such as googles, safety boots, gloves, etc.
2. Before inspection make sure the surrounding is clear and prepared for inspection
3. During inspection deactivate all power to the generator to avoid electrical shock
4. make sure to handle the component with care and make sure hands are dry or with gloves.
5. do a final inspection before switching the generator on.

Tools and equipments

 Growler units of suitable size for the armatures.
 Small hacksaw blade 12” x 0.5”
 Multimeters to read ohms and AC voltage.

Identification of the generator parts

Parts Picture Function

It is a magnetic frame
Yoke made of cast iron or
sometimes steel, which
works as a protector. This
protective cover keeps the
inner parts of the motor
safe and sound and also
supports the armature.
Yoke also houses the
magnetic poles and field
windings of a DC motor to
help supporting
the field system.

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EF2 Practical Apr
 Universiti Kuala Lumpur
Malaysian Institute of Aviation
It produces the magnetic
Field Winding field needed to excite a
generator or motor

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EF2 Practical Apr
 Universiti Kuala Lumpur
Malaysian Institute of Aviation

Salient Poles It is a magnet pole that

project toward the
armature of an electric
machine

Commutator It converts AC to
pulsating DC

Armature winding It is responsible for the

production of armature flux.
A commutator consists of
some segments that collect
the current from the
armature. It is responsible
for the conversion of
alternating current to direct
current.

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EF2 Practical Apr
 Universiti Kuala Lumpur
Malaysian Institute of Aviation
The central mass of iron
Armature cord on which the insulated wire,
to be rotated in the field of
an electrical current
generator or motor

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EF2 Practical Apr
 Universiti Kuala Lumpur
Malaysian Institute of Aviation
The inspection of the generator parts

Parts Inspection/test/methods Results

Field winding Check for burn Slight burn marks visible
Insulation test High resistance indicating a
good insulation between the
winding and ground.
Armature winding Check the condition of The winding founding to be
the winding in good condition.
Check insulated ground using To avoid any short circuit
resistance meter
Brush Replacing brushes that are half To ensure that pieces are
worn. not embedded in brush and
 Place new brush in collected copper
seated/contoured to
max the contact area
on commutator.
 Inspect spring tension
using spring scale.
Commutator inspection  Inspect for Commutator is in good
irregularities and condition and visibly appealed
pitting
 Avoid used of emery
cloth or conductive
material as these
could
cause short circuit.
Armature coil testing  Test each Electrical sparks is caused
commutator using by bad insulation
test lamp to inspect
open coil failure.
 Inspect for
shorting failure
using hacksaw blade
and place on
armature/rotated
armature
 Inspect for ground
failure using
ohmmeter on the
commutator
segment.
Field coil testing  Inspect field coil and
generator frame
using test lamp for
shorting failure.
 Test lamp will
indicate signs for
short failure
 Ohmmeter are used on
field coils terminals to

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EF2 Practical Apr
 Universiti Kuala Lumpur
Malaysian Institute of Aviation
inspect for continuity
Growler machine test  Armature is placed The metal strips will stick to
on growler machine any of the tooth, this will
indicate

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EF2 Practical Apr
 Universiti Kuala Lumpur
Malaysian Institute of Aviation
 Activate growler that the armature insulation is
machine with damaged
metal strips on
each stack
tooth
Multimeter test  Activate the multimeter The reading will show equal
and placed 2 pins on amount for all, thus the
the commutator bars armature is in good condition
at 180 degree in terms of continuity and
opposite to each other balancing.
 Repeat the step
above for each
equally opposite
pairs of
commutator bars

Conclusion
The inspection is to ensure that the DC generator is in good and working condition. During
the inspection, the growler machine is used to indicate problem that are involved in the DC
generator.

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 AKD10203: ELECTRICAL FUNDAMENTAL 2

CLASS: 2AEM1 (Group 4)

PRACTICAL REPORT # 2

CABLE AND CONNECTORS - EWIS

(PWS P7.7A, P7.7B, P7.7C, P7.7D, P7.7E)

LIST OF STUDENTS

1. HARITH TSAQIF BIN AHMAD YUSRI

2. AHMED SHARIN HAMZA
3. MUHAMMAD SAIFUL IZZAT BIN HISHAM
4. MUHAMMAD NABIL NA’AIM BIN ABDULLAH

DATE OF SUBMISSION: 2nd DIS 2021

P7.7A Crimping and Splicing of Wire Terminals:

• Do not cut the wire using a knife or side cutter as it can damage the wires and it will not
give you a clean cut
• The numbers on the wire strippers are the gauge for the wire
• To use the wire stripper, squeeze it and pull the wire stripper to give you a clean cut
• To connect the wires together, do not twist the wires together and wrap it with
electrical tape. If it is used on a high current application, the connection can heat up
and start a fire
• To crim wires, twist the wire a little bit and place the wire inside the insulated
butt connector and squeeze the crimper.
• To use an extra wire, crim the wire to the butt connector and twist the extra wire
together with the second wire and crim them using the crimper
• If we want to use the wire without cutting it, we can use the T – tabs.
• To use the T – tabs, place the wire into the T – tabs and close it and squeeze it
with the crimper.

Picture during the process:

Video Reference:

https://www.youtube.com/watch?v=rju7Md-7GTo

7.7 B Installation of Solder Sleeve-Insertion and Extraction:

• To use the solder sleeve, insert the wire and line it up in the centre of the solder
sleeve on the solder.
• To melt the solder sleeve and solder, we can use heat gun
• The dark coloured loop goes back towards the insulation
• In case that there is no pre – inserted wire, insert the wire we need and line
it up underneath the line of solder
• The red side of the pin is to insert the wire while the white side of the pin is to
remove the wire
• To remove a pin, slide the wire into the valley of the pin and slide the tool into the
connector. Wiggle it until you hear a pop sound and give a gentle tug to the wire and
both wire and the pin will come out
 • To insert it on the other hand, use the red side of the pin and place it over the wire until
you hear a pop sound

Pictures during the process:

Video Reference:

https://www.youtube.com/watch?v=XEYXlgnSyhA

https://www.youtube.com/watch?v=uhRCUAYoSXg
7.7 C Crimping of connector Pin and Socket.
• First strip the insulation from the wire
• Choose the correct dive for the size of wire
• Assemble the props needed
• Silicon rubber seals are fitted first by pushing them over the wire and line up with the
edge of insulation
• There are two clamps on the metal connector and the larger clamp fits over the silicone
seal the smaller will crimp directly onto the exposed wire
• Once assembled in the crimping tool just one crimping action is necessary to
professionally crimp the pin
• After both pins are crimped, it is pushed into the body of the connector and then the
plastic locking tab is inserted to line up the pins and lock them in place
• The female pins are also crimped the same
way Pictures during process

Video reference.

https://www.youtube.com/watch?v=SyhOZLVMWjQ
7.7 D Cable Looming and Binding.
• Tie the wires waxed linen or nylon cord
• Protect wires from abrasion and heat
• Choose the correct diameter of loom for the wire bundles you want to protect
• There are different variety of cable looms suitable for different situations
• Slit the loom and slide the cables inside the loom
• Cable looming is inexpensive and easy to install

Video reference.

h ttps://www.youtube.com/watch?v=zQaB7WYRp8E https://www.youtube.com/watch?v=W0_jzlnmLS8
7.7 E Soldering Wire ln A Connector

 Use the wire stripper to strip adequate insulation from the end of each wire
 Apply a small amount of solder to the stripped portion of wire.
 Pre tinned the connector
 Cut a little bit heat shrink tubing and insert at the end of the wire
 Heat both the wire and connector at the same time
 Once it solder on both of them are molten, put the wire at the top of the connector and
hold
still for a couple second
 Do the same thing at the other connector
 Shrink the heat shrink tubing using heat gun
Reference:
Soldering Deans Connectors - YouTube