What was found
23-80.001 COMMUNICATIONS DISC EXCESS STATIC IN HEADSET INTERMITTNETLY ((YD5R)) INTERFERES WITH RECEPTION ON BOTH COMS. ISOLATED NOISE TO BE FROM ALTERNATOR (1) (NOISE GOES AWAY WHEN UNIT IS TURNED OFF). PERFORMED INSP IAW (KAES SIL-A-135). FOUND INBD BRUSH SPRING TO BE COLLAPSED. IT WAS NOT APPLYING ANY FORCE ON BRUSH TO KEEP POSITIVE CONTACT AGAINST COMMUTATOR RING. (BRUSH APPEARED TO BE FLOATING) THIS LIKELY HAD CAUSED EXCESS ARCING EVEN THOUGH POWER OUTPUT WAS NORMAL. IT WAS ALSO FOUND THAT 75 PERCENT OF THE WIRE STANDS WIRE BROKEN ON BOTH BRUSHES. REPLACEMENT OF BRUSH HOLDER ASSY FIXED EMI NOISE ISSUE. THE FRAGILE NATURE OF THE BRUSH DESIGN APPEARS TO BE THE MAIN ISSUE AND NEEDS TO BE ADDRESSED BY MFG TO CREATE A MORE ROBUST DESIGN.