Professional Documents
Culture Documents
r\n ~I lu-r
ru~ ru C E
For
I RCR
1\1 C~ I 1\1 E S
SSP -143rl -3
I\narch
1, 1985
Williemsport, Pennsylvsnisl7701
prP5to/ite.
SERVICE PUBLICATION
THE AIRCRAFT STARTING MOTOR USING GEAR REDUCTION DRIVE
with
minimum loss of
starting
motor
high cranking torque for a limited period of time when The starting motor has designed into it a means of engaging the starting switch is closed. its pinion with the flywheel ring gear on the engine with which it is used, and disengaging the pinion as soon as the engine starts.
The starting motor must
develop
DESCRIPTION The gear reduction starting motor consists of six major components: (1) The Commutator End Head Assembly, (2) The Armah~re, (3) The Frame and Field Assembly, (4) The
Gear
Drive
Assembly.
See
Figure
i.
9ET
VB~NDI
s~
OE*R
HOUSING ASSY.
.r.
BE*RINO:
Figure
Form L-649A
Exploded
OPERATION
energized, battery current is applied to the starting motor through the field coils creating a strong magnetic field. At the same time, current flows through the brushes to the commutator, through the armature windings to ground. The magnetic force created in the armature combined with that created in the field windings, begins to turn the armature.
terminal.
Current flows
When the
starting
circuit is
on
through
the gear
housing
where
supported by
on
roller
The gear mates with the teeth of the reduction gear that The shaft is keyed to the reduction gear. The Bendix drive is held
a
bearing.
position
the shaft
by a "spirol" pin. The shaft is supported in the gear housing by bearing and in the pinion housing by a graphitized bronze bearing.
wheel
When the armature turns the reduction gear, the Bendix drive pinion meshes with the flyring gear by inertia and action of the screw threads within the Bendix sleeve. A
detent pin engages in a notch in the screw threads which prevents fails to start when the starting circuit is de-energized.
When the
demeshing
if the
engine
engine reaches
screw
flywheel.
MAINTENANCE The
starting
circuit should be
inspected
at
regular intervals,
the
frequency
of which should
be determined ated.
by the amount of service and the conditions under which the vehicle is operIt is recommended that such inspection be made at least twice a year and should
include
1.
thg following:
The
Battery
battery should
be checked with
charged,
on
battery condition.
battery,
solution of
baking
Be
sure none
battery cells.
2.
Wiring
The
starting
circuit
connections
are
clean and
wiring should be inspected to be sure that all tight and that the insulation is sound. A voltage loss locate any high resistance connections that would affect
starting motor efficiency. This test is made with while cranking the engine or at approximately 100
limits should be used:
low
(A)
Voltage
battery post
to
starting
motor
terminal
(B)
Voltage loss
from
to starter frame
0. 1 volt maximum.
Form L-649A
If
voltage loss
is
each part of
high
resistance connections.
3.
Lubrication
of overhaul.
No lubrication is
required
on
the
sMrting
motor
Then lubricate the entire shaft under Bendix Drive, fill grooves 9 ounces of in armature shaft at drive end and pack gear box with 1.3 to 2. "O" or equivalent. Lithium Soap Base Grease #1925 Molytex
4.
seconds Operation The starting motor should be operated for a few with the ignition switch off to make sure that the pinion engages properly and that it turns freely without binding or excessive noise. Then the engine should be started two or three times to see that the pinion disengages properly Drive when the engine is turned off.
OVERHAUL
motor difficulty is noted, the If, during the above inspection, any indication of starting for the cleaning and repair. engine starting motor should be removed from
i.
Removal
the
To
remove
the
ground
starting motor from the engine, first disconnect battery post to prevent short circuiting. Dis-
connect the lead from the starting motor terminal, then take out the the bench for mounting bolts. The motor can then be lifted off and taken to
overhaul
2.
Disassembl3T Remove the frame screws from the commutator end and pull end head and armature from frame. Lift the brushes and lock the end in elevated position with brush springs. Use a puller to remove head from the armature. Use a special bearing puller to remove the
sealed ball bearing from the armature shaft.
head
housing to the frame. and Remove bolts and nuts holding the gear housing to the pinion housing Do not separate the two units. Pull Bendix shaft from pinion housing. Remove shaft. of the lose the steel spacer that is located on the pinion end
Remove the frame screws that secure the gear
pinion until it locks in the extended position. Locate "spirol" off the shaft. Do pin and use a pundh to remove. Slide drive assembly solvent. not attempt to disassemble the drive and do not dip it in cleaning
To remove the roller
use an
arbor press
should and the correct bearing arbor. DO NOT HAMMER OUT. Each part should for excessive wear or damage. Bearings be and evidence of roughness or galling. Oil clearance be che~ed for proper insulation and dirt should be removed from insulation and the condition of the checked.
Form L-649A
3.
Brushes
should be
see
freely
full contact
the commutator.
If
worn
to half their
original length
less, they
replaced.
Cheek the commutator for If
uneven
4.
Armature
wear, excessive
or
glazing
or
evidence
of excessive arcing.
can
discolored, the
commutator
or
be cleaned with 00
a
or
sandpaper.
worn, it
should be turned in
lathe.
Figure 2.
and
grounds,
h
probes
r,lt
connected in series
lln
one
Touch
probe
to
commutator seg-
I~
Figure
2
If the test
lamp lights,
the
armature is
grounded
and should be
replaced.
To test for shorted armature
coils,
growler
is used,
is
placed
over
on
the
rotated held
over
by
hand the
core
that it passes
slot. If
a
each armature
core
opens
can
be made
by inspecting
coloration.
an
open circuit.
Figure
6.
Field Coils
on
test
probe
the
starter terminal.
the
brushes fields
are
the frame.
are
If the
they
are
6.
To test brush
holders, plate
i
test
probe
to the brush
Figure
Form L-649A
Testing
The test
not
are
light
touched.
7.
Remove
Inspect housings for cracks and bearings for excessive Housing rust, paint or grease from mounting surfaces.
8.
Bendix Drive
wiped
clean with
dry cloth.
The pinion
Replace
as
above
or
are
excessively
worn or
damaged.
9.
assembling the starting motor, always use an arbor press and the The bronze and roller bearings. proper bearing arbor for installing graphitized Bendix Bendix shaft should have a thin film of Lubriplate #777~or equivalent on the portion of the shaft.
Assembly
When
properly seated when installing by wrapping a strip of 00 times sandpaper around the commutator (with the sanding side out) 1-1/4 to 1-1/2 the and armaturn commutator covered maximum. Drop brushes on sandpaper
New brushes should be
sure
properly
with the
flywheel ring
gear.
See
specifications
for
particular
BENCH TESTS
After the starting motor is reassembled, it should be tested to see that the no load current To make this test, connect as shown in at a certain voltage is within specifications. make sure 5. If current is too high, check the bearing alignment and end play to
Figure
there is
no
binding
or
interference.
to
~o or
on
rawhide
help
align
the
the armature.
If
difficulty is indicated in the above test, a stall torque test may be made to see shown starting motor is producing its rated cranking power. Make test connections as Figure 6.
no
if the
in
CI
KNIFE
KNIFE SWITCH
o
CARBON PILE
AMMETER
SWITCFI
CARBON PILE
?IPRINC
SCALE
BATTERY
~C1
STARTING MOTOR
BATTERY
TACnOMETER
STARTING MOTOR
Figure
Form L-649A
Figure
Stall-Torque Hookup
seating of the brushes and high resistance. If these checks are made and found to be in good order, replace frame and field assembly and retest starter.
internal connections for
are
not within
specifications, check
the
Inspect the control circuit wiring between the battery, solenoid and manual starting switches
for
breaks,
faulty
a
insulation.
Tighten
sure
firmly
good ground
connection.
voltage loss across the switch contacts during normal starting. of 0. 2 volts per 100 amperes, the solenoid should be replaced.
on or
If loss is in
If solenoid fails to operate when the manual switch is turned when the manual switch is either
if it fails to release
If
opening
or
released, it should be removed and tested to specifications. closing voltages are not as specified, replace the solenoid.
Form L-649A
December,
1965
presro/itP,
SERVICE PARTS LIST
MHB SERles
STARTING MOTORS ISSUEO:
9-25-79(Rev.)
ORIG.EaUIP. MOTOR
SERVICE MOTOR
PART NUMBER
PART NUMBER
USE USE USE
APPLICATION
MHB-4O16R
MHB-4017R MHB-4019R
MHB-4004
MHB-4005,R
MHB-4006 MHB-4006 MHB-4O18R MHB-4008R MHB-401 4R
Lycomin9
Continental
USE
MHB-4O16R MHB-4O17R
MHB-401 9R MHB-401 8R
Lycoming Lycomlng Lycoming Lycomlng Lycoming Lycomfng Lycoming Lycoming Lycoming Lycoming Lycomlng Lycoming Lycoming
USE
USE USE
USE
MHB-4O14R MMU-4001R
MHB-4O16R MHB-401 7R
USE
USE
MHB-4O18R MHB-4O19R
Lycoming only.
File in the
P.I11dinUJ*
OE-AI AIRCRAFIMANUAL
STARTING MOTOR
14
~-____ _1
19
17
16
L____
-T--
j
__J
------7---
Exploded View
of
Typical
MHB
Starting
Motor
ISSUED~3-13-81 (REV,)
C.E.
D. E. Head
or
SHEET 2
D. E.
Head
Bearing
Bearing
Hsg.
Assembly
Assembly
Pinion
O
MHB-4001,R MHB-4002, R MHB-4003, R
MHB-4004
MHB-4 005,R[* MHB-2399S
O
MHB-2012S
O
MHB-2397S
O
MHB-2400
O
X-3991
O
Ca]
O
[al
I I
MHB-2383 MHB-2399S
MHB-2420
I I
MHB-2012AS
I I
II
I I
MBP-2002CS MHB-2400A
I I
CNR]
X-3991
I I
Cb]
Cb]
[cl
MAB-124
II
Cc]
MZ-1147
MHB-2384S
I
MHB-2012S
MHB-2418S
MHB-2384AS
[NR]
MHB-2137[e] Cd]
CNR]
90-2118[f] Cd] ENRI [d]
MZ-298
MHS-4006
i MBP-2002CS
MHB-2400
CNR]
X-3991
MHB-4007,R
MHB-4008, R
MHB-4009,R
MHB-2399S
MHB-2397S
I
I
I I
I
I I
MHB-2012AS
MHB-2012S
I
I
I
II
I
I
I
i
I
I
I
[NRI Cd]
PS-1432C
PS-1437B
MHB-2397AS
MHB-2397S
MHD-4010,R
MHB-4011,R
MHB-4012,R
I j I
I I
I I I
II
I I I
I I I
I I I
II
PS-2432B PS-1432E
MHB-4013,K
MHB-4014,R
I
MMU-2386S MHB-2399S
MHB-2012AS
MHB-2397AS
MHB-4015, K
MHB-4016,R MHB-4017,R MHB-4018,R
I
MHB-EO1 25
MHB-2384BS
MHB-2337S
II
MBP-2002D
MHB-2400
[NR]
X-3991
PS-1435
MG-77A
MZ-298
PS-1432C
PS-1437B PS-1432E
MtlB-4019,d
II
PS-2432B
[e] CNR]
Shaft Pkg. must be used at time of first repair. Individual componentsPS-1432CS Housing PS-1432C Pinion Hsg.,MZ-298 Bearing, M2-326 Bendix Drive Shaft may be replaced thereafter. Shaft Pkg. must be used at time of first repair. Individual componentsPS-l437BS Housing PS-1437B Pinion Hsg.,MZ-298 Bearing, M2-326 Bendix Drive Shaft may be replaced thereafter. Shaft Pkg. must be used at time of first repair. Individual ComponentsPS-2432BS Housing PS-2432B Pinion Hsg.,MZ-298 Bearing,MZ-326 Bendix Drive Shaft may be replaced thereafter. Shaft Pkg. must be used at time of first repair. Individual CompOnentsPS-1432ES Housing PS-1432E Pinion Hsg.,MZ-298 Bearing, M2-326 Bendix Drive Shaft may be replaced thereafter. available. MZ-414S D.E. Mtg. Screw Gasket Pkg.(lOPcs.) and 90-2191 Mtg. Screw Pkg.(20Pcs.)also Seal Pkg. Available thru Lycoming only.
Not
Cf] Bearing
required.
File in the
Prlntd In U.S.A.
I
r
Intermed.
Brush
Bearing
Spring
t
Terminal Stud
Cover Band
Oil Seal
S~jtt
MHB-4001,R
MHB-4002, n MHB-4003, R
MHB-4004
Assgl?ply
Package
12
11
O
MZ-24A
EBB-75ACgl
Ca]
MZ-19S
90-2502
CNR]
I I
II
I I
I
I I I I I I I I I
I
I I I I I
I
i I I 1 I
CNR]
[NP.]
XA-560
EBB-133Ch]
I~NRI
MHB-4005,R[*ll
MHB-4006
CNR]
90-2118[f1 CNH]
ENR]
EBB-75ACgl
CNR]
[NRI
MHB-4007, R MHB-4O08,K
~NRI
[d3
Mi-326
I I
I i I I
I I
I I I j
i I
[NR] CNRI
I I
I I
I I
I I
ENR]
[NR] CNPl CNRI CNR] CNRI ENRI [NR] CNR] CNR]
I
I
I
i I
EBD-142AIgl
EBB-l
I
i I
I
UNRI
MZ-326A
I
1
i
i
I
i
MHB-4O15, R MHB-4016,R
MHB-4017,R
24A[h]
236Cj]
EBB-131AChl
CNRI
I I
I I I
I I I I
i i I I
I j I
I i I
i i I
CNRI
MHB-4018,R
CNP]
MHB-4019,R
CNR]
Ca] [b]
Cc]
Cd]
[f] [gl Ch] Cjl CNR]
Shaft Pkg. must be used at time of first repair. Individual Housing PS-1432C Pinion Hsg.,MZ-298 Bearing, M2-326 Bendix Drive Shaft may be replaced Shaft Pkg.must be used at time of first repair. Individual PS-1437BS Housing PS-1437B Pinion Hsg.,MZ-298 Bearing, M2-326 Bendix Drive Shaft may be replaced Shaft Pkg. must be used at time of first repair. Individual PS-2432BS Housing PS-2432B Pinion Hsg., MZ-298 Bearing,MZ-326 Bendix Drive Shaft may be replaced Shaft Pkg. must be used at time of first repair. Individual PS-1432ES Housing PS-1432E Pinion Hsg., MZ-298 Bearing,MZ-326 Bendix Drive Shaft may be replaced Seal Pkg. Bearing 90-2140 Bendix Pin Pkg.(25 Pcs.) also available. 90-2139 Bendix Pin Pkg. (25 Pcs.) also available. MZ-339 Bushing also available. Available thru Lycoming only. Not required. PS-1432CS
Componentsthereafter.
Componentsthereafter.
Componentsthereafter.
Componentsthereafter.
ISSUED: 8-3-81
Bearing
Retainer Plate
(REvl)
SHEET 3
Switch
Assembly
Gear
Housing
As1Y
fhrust Washer
Switch
Connector
O
MHB-4001,R MHB-4002, R MHB-4003, R
MHB-4004 MZ-396
O
Ck]
MZ-393 90-601
O
[NR] I [NR]
CNRI
MZ-144
MZ-1390
CNRI
[NR]
CNR~
I
[NRI CNR]
I
[NR]
I
90-2677 90-601 90-2232 90-601
Cm]
[NR] I~NR]
CNRI
MHB-4005,RC*]
MHB-4006
I MHB-1030[*]
i
MZ-396
[NR]
MZ-1390
[k]
CNR]
MZ-396
i
I I I
[NR~
MZ-393
I
i
[NR]
CNRI
[NR]
[NR~
CNR] CNR]
[NR]
CNR]
I I I I
I I I I
i I
[NR]
CNRI
[NR~
[NR] [NR] [NR~ [NR] CNR] [NR) CNR]
I I
CNRI
MZ-393
I I
90-2677
I I
[NR] [NAI
MHB-4015,R
MHB-4016,R MHB-4017,R MHB-4018,R
[NR]
MZ-396
[NR]
MZ-1390
[k]
1 I~k3 [k] [k] 1
90-601
[NR]
I I [NR] [NR] [NR]
i I
MHB-4019,R
Two used.
No
longer available.
CNR
Lycoming only.
Prinld In U.5.1.
PTP~rO/ltP:
SERVICE INFORMATION
GENERAL INFORMATION VOLTAGE ROTATION
24 Gear Reduction Units Except MHB-4005, Drive CCWDE Motor R R -4014, MHB-4005, Drive CWDE Motor
MHB
AIRCRAFT STARTING MOTORS
Issued
4/1/~3
R,-4009, R,-4014, R.
CWDE
CWDE
MHB-4009,
Drive CWDE
CCWDE
4 4
on
motor
DRIVE ASSEMBLY
Reduction gears, shafts, and drives used with the MHB-4005, 4005R, and 4006 are not manufactured or
supplied by
LUBRICATION
GEAR REDUCTION UNITS
Except
MHB-4006
Thoroughly clean and repack needle bearings with Shell A~vania #2 Pack gear box with 1-1/4 to or an equivalent bearing lubricant. 2 ounces of Texaco #1925 Molytex "O" or an equivalent Lithium soap base grease. (Also see Drive Assembly servicing.)
MHB-4006
Saturate the felt oiling pad in the commutator end head with SAE 20 oil. Allow excess oil to drain out before installing
end head on motor. Thoroughly clean and inspect the two needle bearings in the drive end head for wear or damage. Replace if necessary. Repack needle bearing with Shell Alvania #2 or an equivalent bearing lubricant.
Printed in U.S.A.
ec
Data
STARTING MOTORS
MHB
presto~te
SERVICE
Issued
4/1/83
5
I
Page 2 of
INFORMATION
DIRECT DRIVE UNITS Soak new absorbent bronze bearings in SAE 20 oil before installation. Saturate the felt oiling pad in the commutator end head with SAE 20 Allow excess oil to drain out before installing end head on oil. Put a light film of Lubriplate #777, or equivalent, on the motor. drive end of the armature shaft before installing the drive end head. (Also see Drive Assembly servicing.)
DRIVE ASSEMBLIES
The Drive Assembly should be throroughly cleaned and re-lubricated Do Not use carburetor cleaner or any when the motor is overhauled. cleaning solution that could damagethe rubber block inside the Use only clean petroleum base cleaners such as Drive Assembly. kerosene or "varsol". Thoroughly clean the drive to remove all dirt, grease, and contamination from the screwshaft threads and The drive cup may also be removed to insure a thorough control nut. cleaning job. Do Not attempt to remove the control nut. After the drive has been cleaned and blown dry with compressed air, lubricate the drive with a spray-on type silicone lubricant. Lubricate the motor shaft with the same silicone lubricant before installing the Drive Assembly. When reassembling the early style drive on the shaft, make sure the spirol pin does not project beyond the outside diameter of the pinion sleeve. When reassembling the late style drive, make sure the head washer covers both ends of the retaining pin. BEARING REPLACEMENT GEAR
PEDIICTIPN UNITS
When
Except MHB-4006
replacing needle bearings they must be pressed in flush with the edge casting. The armature bearing must be flush on the side toward the armature and the Drive Assembly shaft bearing flush on Press the pinion housing bearing the side toward the Drive Assembly. in flush with the outside edge of the casting.
of the
MHB-4006
Press the armature shaft bearing into the housing until it is flush Press the oil seal in until it is flush with with the bearing bore. Press the gear reduction shaft bearing in the edge of the casting. is with the edge of the casting. end flush so that the open DIRECT DRIVE UNITS Press the drive end bearing in flush with the outside Press the oil seal into the casting so that the oil
edge
casting. against
of the it bottoms
seal
counterbore.
prpstolifP,
SERVICE
~N FORM ATION
INTERMEDIATE BEARING PLATE
MHB
AIRCRAFT STARTING MOTORS
Issued
4/1/83
Page
3 of 5
MHB-4O15, R
on
Torque
threads of 35 in./lbs.
screws.
BRUSH REPLACEMENT
Brushes must be replaced when they have worn down to a length of Refer to service bulletin ASM-1 for brush replacement 1/4" or less.
procedure.
BRUSH SPRING TENSION Measure with a spring scale 32 to 40 ounces with new brushes. Pull on a line opposite the hooked under the spring at the brush. line of force exerted by the spring and take the reading just as the spring leaves the brush. END PLAY
Except MHB-4006
Make sure the fiber thrust No dimensional specification necessary. shaft and that a steel the end of armature drive washer is on the Drive the thrust washer is on each end of Assembly shaft. Refer to number. Parts List for thrust washer package MHB-4006
Adjust
.005" to .050" with thrust washers on the commutator end Refer to Parts List for thrust washer package number. of the shaft.
to
Adjust to .005" minimum with thrust washers. Maintain a clearance of 1/64" to 7/64" between the inside edge of the drive pinion and the outside edge of the drive end casting with the drive extended Refer to and the armature pushed toward the commutator end head. Parts List for thrust washer package number.
COMMUTATOR END HEAD
GEAR REDUCTION UNITS
Assemble the end head on the motor in line with the motor terminal.
is
directly
is
directly
Tech. Data
STARTING MOTORS
Printed in U.S.A.
BHMSROTOM
4/1/83
of 5
SERVICE
Page 4
INFORMATION
COMMUTATOR REFINISHING
bearing journals
TEST SPECIFICATION
See
(750F.)
Figures
1 and 2 for
no
20.0 volts, 35 max. amps., 4600 Min. Load Test (Motor Only) 20.0 volts, 35 max, amps., 5300 Min. Load Test (Complete Unit) 14.0 volts, 260 max. amps., 27.0 min. Ft. Lbs. Stall Torque Test
No No
RPM RPM
20.0 volts, 36 max, amps., 4600 min. 14.0 volts, 260 max. amps., 8.0 min.
Internal
Unit
Drive Type
Gear Reduction Gear Reduction Gear Reduction D~rect Gear Reduction Gear Gear Gear Gear Gear Gear Ge Gear
Wiring
Application
Lycoming Lycoming Lycoming
Franklin
MHB-4005, R
MHB-4006
R R R R
R R
Reduction
Reduction
ti
on
R
R
Reducti-~n
Gear Reduction
R R R
R
Fig. Fig. Pig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig.
3 3 3 4
4 3
3 3
Lycoming
Continental
4 3
3
3 3
4 4 3 3
3
F_ig.
F~g.
Lycoming Lycoming Lycomi n Lycomi ng Lycoming Ly comi n Ly comi n g Lycoming Lycoming Lycoming Lycoming Lycoming Lycoming
prpsto~-fP,
SERVICE
MHB
AIRCRAFT STARTING MOTORS Issued
4/1/83
INFORMATION
No Load
Page
5 of 5
Stall
Torque ~41
olU~k r~dh
mlrcn
UIOH C(~L
gb
cueol rrre
IlllWC
w*L~
~ffElll
~TTLI*
~LCWOU1EI 111171NC YOIOII
~*(ltlllb 1101011
Figure
Figure
TERMINAL
TERYIWAL
P6ST
INSULATED BRUSH
GROUNDED 8RU3H
CIK)UNDED BRUSH
SHUWT
WIWDIWG
INSULATED
BRUSH
SHUNT,
wlNDINC
//VY
INSULATED
BRUSH BRUSH
BRUSH
BRUSH
VIEWED FROY COYYUTAfOR EWD
Figure
Figure
File in the
Printed in U.5.n.
Tech. Data
STARTING MOTORS
prp~tp/itp,
SERVICE PARTS LIST
MHJ SERIES
STARTING MOTORS
ISSUED:
5~1 5-81
(Rev.)
ORIG.
EOUIP.MOTOR
PART
NUMBER
SE RVICE MOTOR
VOLTS:
24
APPLICATION
MHJ-4002
MHJ-4O03,S MHJ-4O04
MHJ-4O04R MHJ-4005 MHJ-40O5R
Teledyne Continental
Teledyne
Lycom~ng
Continental
Service Motor
MHJ-4005R MHJ-4005R
Lycoming
Service Motor
Note:- Due to production design of the assemblies listed here-in the Field Coils being varnished and baked in place within the Frame; we have followed the advice of our Production Engineering Dept. and have recalled the servicing of the individual Field Coi is. Commencing immediately, whenever Field Coils the complete Frame R Field Assy. will be supplied.
are
requi red,
PI.d In V.II.
I
I
MHJ Series
Starting
FI~
lil
I I
~I 1
2
[o~-
MHJ
Starting
Motor
MHJ
ISSUED:10-13-81(REV,)
D. E. Head
or
SHEET 2
Bendix
D.E.
Assembly
Armature
Set
Bearing
Hsg.
6
Drive
O
MHJ-4O02
O
MDL-2O12ES
ly
3
As 4
ly
Pini 5
O
CNR]
MHJ-2147S
MEX-2O92S
MDL-1002
MCL-2136
ML-18A
MHJ-4003,S
MHJ-4004
I
MHJ-3151S
I
MDZ-2012CS
MEX-2O92AS
I
I
I
I
MCL-2136A PS-1455
I
MHJ-36
CNR]
EBB-l 24A
MEX-3O31S
PS-1455A
CNR]
Not
required.
Bendix Pin Pkg.
Brush Plate As ly Brush Term. Stud Pac Oil Seal Pa Thru Bolt Thrust Washer Pac
Assembly
Spring
1 Iio\ 1
9\
1111
(12)
(13~
(14
90-2677
MHJ-4002
CNR]
MOL-1064ES
MZ-19S
90-726
XA-1024
GJ-Z0DS
MHJ-4003,S
MHJ-4004 MHJ-4004R
[NR]
90-2139
MDL-1064GS
I I
I I
I I
CNR]
CNR]
GJ-Z0S
90-2232
MHJ-4005
I
I
I
I
I
I
I
I
[NR]
[NR]
MHJ-40O5R
[NRINot required.
Gear Needle
Assembly
Gear
Housing
As sembl y
Bearing
Retainer Plate
I
1 (171 1 ~181
15)
MHJ-4002
(16) [NR]
(19
CNR]
CNR]
MZ-396
CNR]
CNR]
CNR] [NR]
MZ-393
CNR] CNR]
MHJ-44
MHJ-4003,S
MHJ-4004
MHJ-4004R MHJ-4005 MHJ-4005R
CNR]
MHJ-1045
Ca]
I
I I
I
1 I
I
I I
Cal
Two used
(XA-997) 1/2"
I.D.
and
(XA-998) 13/16"
I.D.
CNRI
Not
required.
File in the
Prln)d In U.S.~.
I
L
presto/ifP,
SERVICE
IN FORM ATION
GENERAL INFORMATION
M HJ
Aircraft Issued:
Starting Motors
4/1/83
Page
1 of 4
VOLTAGE ROTATION
24
Motor CCWDE,
Drive CWDE
BRUSHES
Separate
MHJ-4OO4, R, 4005, R
Rubber Folo Thru
Type
MH3-4004, R, 4005, R
SERVICE LUBRICATION
INFORMATION
MHJ-4002, 4003
bearings in SAE 20 oil before installation. Saturate pad in the commutator end head with SAE 20 oil. to drain out before installing end head on Put motor. a light film of Lubriplate #777 on the armature before shaft assembling motor.
Soak
new
MHJ-4004, R, 4005, R
Thoroughly clean and repack needle bearings with Shell Alvania #2 or an equivalent bearing lubricant with 1-1/4 to 2 ounces or Texaco #1925 Molytex "O" or an equivalent Lithium soap base grease. (Alsosee Drive Assembly servicing).
DRIVE ASSEMBLY
The Drive Assembly should be thoroughly cleaned and relubricated Do Not use carburetor cleaner or when the motor is overhauled. any cleaning solution that coulddamage the rubber block inside Use only clean petroleum base cleaners such the Drive Assembly. Thoroughly clean the Drive Assembly to as kerosene or "varsol". remove all dirt, grease, and contamination from the screwshaft The drive cup may also be removed to threads and control nut. Do Not attempt to remove the insure a thorough cleaning job.
control nut.
Printed in U.S.A.
Tech. Data
STARTING MOTORS
MHJ
prPst~ite.
SERVICE
4/1/83
Page
2 of 4
INFORMATION
After the Drive
Assembly has been cleaned and blown dry with compressed air, lubricate the drive with a spray on type
Lubricate the motor shaft with the same silicone lubricant. When silicone lubrcant before installing the Drive Assembly. make head washer the the drive on sure shaft, reassembling covers both ends of the retaining pin.
BEARING REPLACEMENT
MHJ-4OO2, 4003
The drive end bearing must be pressed in flush with the oil The oil seal must bottom against the counterseal counterbore.
bore.
MHJ-4004, R, 4005, R
Press the armature shaft needle bearing in approximately 3/16" below the edge of the casting on the side toward the armature. Press the Drive Assembly shaft needle bearing in flush with the casting on the side toward the Drive Assembly. Press the in flush with the outside edge of the pinion housing bearing
casting.
BRUSH REPLACEMENT Brushes must be of 1/4" or less.
replacement procedure.
BRUSH SPRING TENSION
32 to 40
Measure with a spring Pull on a line opposite the line of force exerted by the spring and take a reading just as the spring leaves the brush.
ounces
new
with
brushes.
spring
at the brush.
END PLAY
(Armature
Shaft
to
Only)
Adjust
.005" to .050" with thrust washers on the commuRefer to Parts List for thrust tator end of the shaft. washer package number.
POLE SHOE
INSTALLATION The pole shoes must be installed so that the longer pointing in the same direction as armature rotation.
tip
is
COMMUTATOR REFINISHING Di Mi
ame
te r
i. 50"
.003" max. .002" max. measure from bearing journal 50 microinch max.
IEST
MHJ-4002, 4003
No Load Test
SPECIFICATIONS
(750F)
max.
43 210
max.
SERVICE INFORMATION
MHJ-4004, R, 4005,~P
No Load Test No Load Test
See
Aircraft Issued:
Starting
4/1/83
Motors
Page
3 of 4
Figures
1 and 2 for test connections. 20.0 volts, 43 max. amps, 6200 min. 20.0 volts, 43 max, amps, 1800 min. 8.0 volts, 210 max. amps, 27.0 min.
Lbs.
Internal Unit
MHJ-4002
Wiri?g
Figure 3
Application
3 4 4 Continental Continental
Lycoming Lycoming
INSTALLATION NOTE
Prior to starting motor installation, clean any rust, corrosion or dirt from Also check all ground the mounting surfaces of the starting motor and engine. strap connections to make sure they are clean and tight.
nU1FC ~V(TEI(
IIWITE
9;$
CIII~OL( ~LE
C,
AUUCTLe
]It~
~WITCH
L*neON GILL
1PIWIC
~CUE
GIOVUO
V/r$~
T4CnOYEIER
IT*RTINC UOTOR
Figure
Figure
Printed in U.S.A.
Tech.
Data
4/1/83
SERVICE
Page 4 of 4
INFORMATION
BRUSH\
INSULATED BRUY(
INSULATED BRUSn
GROUNDED ~RUSW
INSULATED
GROUNDED
eRUsH
DRuSH
VIEWED CA#I
COMMUTATOR
END
VIEWED FROM
COMMUIATOF~
END
Figure
Figzire
presro/itP,
SERVICI: PARTS LIST
MMU SERIES
STARTING MOTORS
ISSUED:
6-1-79
ORIG.EQUIP.MOTOR
PART NUMBER
SERVICE MOTOR
PART NUMBER
USE
APPLICATION
MMU-4001,R
MMU-4001R
Lycoming
Prln)d In U.S.A.
STARTING MOTOR
SECTION
MMU Series
Starting
ld-
\uJ
5
J9
8
--_~ug/
d
3Y
0, 3
Q)
Exploded
View of
Typical
MMU
Starting
Motor
SHEET 2
Assembly
ISSUED: 10-13-81(REV,)
Armature
Brush Set Frame
MIIIIU SERIES
Field
As
Comm.End Head
Pinion
D.E.
Brush
Housing
Assembl y
5
Bearing
Spring
O
MMU-4001,R
MMU-2386S
O
MHB-2012AS
Assembly
MHB-2384BS
MBP-2002D
PS-1435
MG-77A
MZ-19S
Intermediate
Intermed.
Assembly
Bearing As~
Bearing
Bendix Drive
Cover Band
Terminal Stud
O
MZ-339
Pac_kage
O
90-2502
MMU-4001,R
M2-1236
EBB-124ACa]
MZ-24A
90-2677
[a]
Package(25 Pcs.)
also available.
File in the
Prlntd In U.s.A.
I
r
STARTING MOTOR
SECTION
MMU presto/ire.--------
SERVICE
INFORM ATION
24
CWDE 4
BRUSHES
DRIVE ASSEMBLY
4
Rubber Folo-Thru
Type
SERVICE INFORMATION
LUBRICATION
Soak new absorbent bronze bearings in SAE 20 oil before installation. Saturate the felt oiling pad in the commutator end head with SAE 20 Allow excess oil to drain out before installing end head on oil. Put a light film of Lubriplate #777 on the drive end of the motor. (Also armature shaft before installing the intermediate bearing.
see
Drive
Assembly.)
DRIVE ASSEMBLY The Drive Assembly should be thoroughly cleaned and re-lubricated Do not use carburetor cleaner or any when the motor isoverhauled. could that solution damage the rubber block inside the cleaning clean Use petroleum base cleaners such as Drive Assembly. only "Varsol". Thoroughly clean the Drive Assembly to remove kerosene or from the screwshaft threads and contamination and all dirt, grease, be removed to insure a thorough also drive The control nut. cup may the control nut. to remove Do not attempt cleaning job.
After the Drive Assembly has been cleaned and blown dry with compressed air, lubricate the drive with a spray-on type silicone Lubricate the motor shaft with the same silicone lubrilubricant. When reassembling the cant before installing the Drive Assembly. washer covers both ends of head the make sure Drive on the shaft, the retaining pin.
BEARING REPLACEMENT
Press the drive end Press the casting.
bearing in flush with the outside edge of the intermediate bearing in flush to the side
File in the
Printad in U.S.A.
Tech. Data
STARTING MOTORS
MMII
presr~tP.
SERVICE
Issued 4/1/83
Page 2 of 3
INFORMATION
I
on
threads of
screws.
Torque
BRUSH REPLACEMENT
to 25
35
in/lbs.
Brushes must be replaced when they have worn down to a length of 1/4" or less. Refer to service ASM-1 for brush replacement procedure. BRUSH SPRING TENSION
32 to 40 ounces with new brushes. Measure with a spring scale hooked under the spring at the brush. Pull on a line opposite the line of force exerted by the spring and take the reading just as the spring leaves the brush. END PLAY
Adjust
to
.005" minimum with thrust washers on the commutator end of Refer to Parts List for thrust washer package
COMMUTATOR END HEAD Assemble the end head on the motor in line with the motor terminal.
COMMUTATOR REFINISHING Minimum Diameter Undercut Total Indicator Runout Surface Finish 1.50" .003" max. .002" max. measure from 50 microinch max.
so
is
directly
bearing journals
TEST SPECIFICATIONS
No Load Test
Stall
Torque
Test
35 250
max. max.
Ft.
Lbs.
MMU-4001, R
Application Lycomi ng
fe.
SERVICE
MMU
AIRCRAFT STARTING MOTOR
Issued 4/1/83
INFORMATION
Page
3 of 3
TERMINAL
POST GROUNDED
BRUSH
INSULATED
BRUSH
SHUNT
WINDING
INSULATED~
BRUSH
~YJ\GROUNDED
\BRUSH
File in the
Printed in U.S.A.
I I
Tech. Da ta
STARTING MOTORS
prpsr~/itP,
SERVICE PARTS LIST
MZSE~1ES
STARTING MOTORS
ISSUEO:12-31-80(Rev.)
ORIG.EOUIP.MOTOR
PART NUMBER
M2-4203
Franklin
MZ-4204,R
MZ-4205,R MZ-4206,R
MZ-4207;R
MZ-4208,R
M2-4214
MZ-4216,R MZ-4217,R
MZ-422OR MZ-4221R
MZ-4218,R
MZ-4219,R
MZ-422ZR
Lycoming Lycoming Lycomi ng Lycoming Lycomi ng Lycoming Lycoming Lycoming Lycoming Lycoming
MZ-4220,R MZ-4221,R
MZ-4222,R
MZ-4223R
MZ-4220R MZ-4221R
MZ-4222R
MZ-4223R
MZ-4224R
MZ-4225R
p,.., mUI*.
I
I
MZ Series
Starting
_____i
19)-~--
Q;
\L: 16
L-----~O
-----T--
_J
eo~$
~-o
i
s---
__.J
Exploded View
of
Typical
MZ
Starting
Motor
ISSUED:10-13-81(REV,)
Brush Set Frame& Field As ly Comm. End Head
SHEET 2
D.E.
C.E.
D. E. Head
or
Bearing
1 (5) 1
Bearing Hsg.
1 1 7
O
#2-4203 #2-2383 MZ-2386S MZ-2399S
O
MZ-201 2AS
MBG-2012S MZ-l
ly
1 (4)
Pinio
31
161
005ASC*~
MZ-20O2F MZ-2002U
MZ-2400
[NR]
[NR]
X-3991
MZ-1147 PS-1435
MZ-46A MG-77A
MZ-4204,R
MZ-42O5,R
MZ-2385S
I
MZ-2397S
Cal
MZ-4206,R
MZ-4207,R MZ-4208,R
M2-4214
I I I
MZ-2412S
MZ-2399S
I I I
MBG-2012CS MBG-2012S
I I I
MZ-2022DS
I I I
MZ-2002VS
I I I [NR]
X-3991
I I I
[NR]
90-2018[e1
MZ-4216,R MZ-4217,R
MZ-4218,R
MZ-2397S
MZ-2400
[b]
i
PS-2432B
[bl
MZ-298
I
I I
j
I
I
i
I
I
I
I
PS-1432C
PS-1437B PS-1432C PS-2432B PS-1432C
I 1
I
I I
I
I I
I
I I
I
I I
i
I
I
MZ-4223,R
PS-1437B
PS-1432C
MZ-4224,R
MZ-4225,R
I I I I
I I I
PS-1432F
[X1 Ea]
Es~
Field Assembly not available. Field Coil Pkg. Complete Frame Shaft Pkg. must be used at time of first repair. Individual ComponentsPS-2432BS Housing PS-24328 Pinion Hsg.,MZ-298 Bearing,Mt-326 Bendix Drive Shaft may be replaced thereafter. Shaft Pkg. must be used at time of first repair. Individual Components[b] PS-1432CS.Housing PS-1432C Pinion Hsg.,MZ-298 Bearing,MZ-326 Bendix Drive Shaft may be replaced thereafter. Shaft Pkg. must be used at time of first repair. Individual Components[c] PS-1437BS Housing PS-1437B Pinion Hsg.,MZ-298 Bearing,MZ-326 Bendix Drive Shaft may be replaced thereafter. MZ-414S D.E. Mounting Screw Gasket Package is also available. Seal Package. Bearing [NRI Not required.
Prln)d In V.S.A.
I
r
Bearing AssemblY
Spring
Terminal Stud
Cover Band
Oil Seal
Pa~age
O
MZ-24A
~2-4203
EBB-l EBB-1
33[f]
24A~f]
[NRI
CNR]
CNRI
MZ-l 236
MZ-l 9S
90-716
XA-560
M2-4204,R
90-877
ENR~
MZ-4205,R
EBB-75ACgl
Ca]
CNRI
90-876
MZ-4206,R
MZ-4207,R MZ-4208,R
~2-4214
j
I
CNRJ
I
I
Cb] [cl
CNR]
CNRI
j
I I
I
I I
I
I I
90-877 90-876
I
I i
CNK] CNR]
Chi
I
[hl
[bl
MZ-3%S
[NR]
[NRI [NR]
~NR]
I
I I
1
1 I
1
1 I
I
j I
I_NR]
INR~
MZ-4216,R
EBB-142A[gl EBB-75ATgl
MZ-4217, R
MZ-4218,n
CNR]
CIIIR~
j 1
EBR-1~2Argj
MZ-326A
I I j
I
I I I
I
I I I
I
i I I
I
MZ-4219, R
MZ-4220,R M2-4221,R #2-4222,R M2-/1223,R MZ-4224, R
I I
[NR] CNR]
[i\lR]
j 1 I
EBH-131P,[jl
I I I
I j j
CNR]
I I I
I I
I I I
[NR] [NR]
MZ-4225,H
[NR]
Ca]
Cb] Cc]
Shaft Pkg. must be used at time of first repair. Individual componentsPS-2432BS Housing PS-24328 Pinion Hsg.,MZ-298 Bearing,MZ-326 Bendix Drive Shaft may be replaced thereafter. Shaft pky. must be used at time of first repair. Individual ComponentsPS-1432CS Housing PS-1432C Pinion Hsg.,MZ-298 Bearing,MZ-326 Bendix Drive Shaft may be replaced thereafter. Shaft Pkg. must be used at time of first repair. Individual ComponentsPS-1437BS Housing PS-1437B Pinion Hsg.,MZ-298 Bearing,MZ-326 Bendix Drive Shaft may be replaced thereafter.
Cf] 90-2139 Bendix PinPackage(E5Pcs.) also available. Cgl 90-2140 Bendix Pin Package(E5Pcs.) also available. Chi Not part of this Motor; available thru Continental only Cjl X-5384 Bendix Pin also available. [NRI Not required.
#639153.
ISSUED: 8-3-81
Needle
Retainer
Plate
(REV,
SHEET 3
Switch
Thrust
Washer Connector
Assembly
Gear
Housing Assembly
16
Bearing
Package
O
M2-4203
O
[NR1 [NR]
Cm3
I
[NRI [NR]
MZ-393 90-2677
90-2271 MZ-144
[NR]
[NR]
MZ-396
[NR]
[NR]
MZ-1390
[n] [NR]
[NR]
MZ-4204,R
MZ-4205,R MZ-4206,R M2-4207, R MZ-4208,R
M2-42l4
[NR]
[NR]
90-601
I
[NR] [k]
MZ-396
I
I
I
[NR]
MZ-1390
[m]
Cm3
I
I
[NR] [NRI
MZ-393
I
I
I
90-2006
I
I
I
[NR]
[NR]
L~NR]
CNR]
[NR]
[NR]
[NR] [NR]
[NR] [NR]
MZ-4216,R
90-601
[NR]
I I I 1 I 1 I
I
I I I
I I I I I j
I I I I I I I I
I
I I I I I I I
I
I I I I I I I I
i
[NR]
[NR] [NR]
[NR]
I I
I I
[m]
[k] [m]
Used with but not part of this Motor, available thru Continental XA-998 is 13/16 I.D. Two used- XA-997 is 1/2" I.D.
#639153.
[NR[n 7
trequired. oN
File in the
Prinld
In U.s.A.
STARTING MOTOR
r
SECTION
MZ
AIRCRAFT STARTING MOTOR
Issued 4/1/83
Page 1 of
VOLTAGE ROTATION
12 All Gear Reduction units except MZ-4216, Motor CCWDE, Drive CWDE
R, 4220, R
M2-4216, R, 4220, R
All BRUSHES
POLES
4
SWITCH
on
motor
DRIVE
M2-4214
All
uses
others
use
GEAR REDUCTION 7 to 1 Gear ratio M2-4214 All others 3.38 to 1 Gear ratio
SERVICE INFORMATION
LUBRICATION
GEAR REDUCTION UNITS
Except M2-4214
or
Thoroughly clean and repack needle bearings with Shell Alvania #2 Pack gear box with 1-1/4 to 2 an equivalent bearing lubricant. ounces of Texaco #1925 Molytex "O" or an equivalent Lithium soap base grease. (Also see Drive Assembly servicing.)
DIRECT DRIVE UNITS AND M2-4214
Soak new absorbent bronze bearings in SAE 20 oil before instal~ation. Saturate the felt oiling pad in the commutator end head with SAE 20 Allow excess oil to drain out before installing end head on oil. Put a light film of Lubriplate P777, or equivalent, on the motor. drive end of thearmature shaft before installing the intermediate (Also see Drive Assembly servicing.) bearing or drive end head.
File in the
Printed in U.S.A.
Tech. Data
STARTING MOTORS
AIRCRAFT STARTING
Issued 4/1/83
ZMROTOM
2 of 5
prpst~te
SERVICE
Page
INFORMATION
FORMSPRAG DRIVE
If the drive feels rough when These units are not serviceable. rotated in its free direction, or if the gear rotates in both Never submerge the drive directions, the drive should be replaced. assembly in a cleaning solution. To do so will destroy or contaminate the internal lubrication which cannot be replaced. DRIVE ASSEMBLY
The Drive Assembly should be thoroughly cleaned and re-lubricated when the motor is overhauled. Do not use carburetor cleaner or any cleaning solution that could damage the rubber block inside the drive assembly. Use only clean petroleum base cleaners such as kerosene or "Varsol". Thoroughly clean the Drive Assembly to remove all dirt, grease, and contamination from the screwshaft The drive cup may also be removed to threads and control nut. insure a thorough cleaning job. Do not attempt to remove the control nut. After the Drive Assembly has been cleaned and blown dry with compressed air, lubricate the drive with a spray-on type silicone lubricant. Lubricate the motor shaft with the same silicone lubricant before installing the drive assembly. When reassembling the early style drive on the shaft, make sure the spirol pin does not project beyond the outside diameter of the When reassembling the late style drive, make pinion sleeve. sure the head washer covers both ends of the retaining pin.
BEARING REPLACEMENT
GEAR REDUCTION UNITS When replacing needle bearings they must be pressed in flush with the edge of the casting. The armature bearing must be flush on the side toward the armature and the Drive Assembly shaft bearing flush
the side toward the Drive Assembly. Press the pinion bearing in flush with the outside edge of the casting.
on
housing
casting. against
the drive end bearing in flush with the outside edge of the Press the oil seal into the casting so that it bottoms the oil seal counterbore.
M2-4204, R
Torque
screws.
prp~fO/lfP,
SERVICE
IMFORM ATION
BRUSH REPLACEMENT
MZ
AIRCRAFT STARTING MOTOR Issued 4/1/83
Page
3 of 5
Brushes must be replaced when they have worn down to a length of Refer to Service Bulletin ASM-1 for brush replace1/4" or less.
ment
procedure.
Except M2-4214
Make sure the fibre thrust No dimensional specification necessary. shaft and that a steel armature end the of drive the washer is on Drive the of end each is on Assembly shaft. Refer to thrust washer
package
number.
Maintain a of the drive inside the edge clearance of 1/64" to 7/64" between with the drive end drive the casting pinion and the outside edge of head. end commutator the toward extended and the armature pushed number. washer package Refer to Parts List for thrust
M2-4204 and M2-4214, adjust to .005" minimum with thrust washers on Refer to Parts List for the commutator end of the armature shaft. thrust washer package number.
COMMUTATOR END HEAD
GEAR REDUCTION
UNITS
Assemble the end head on the motor in line with the motor terminal.
DIRECT DRIVE UNITS AND
MZ-4216, R, 4220,
R
so
Assemble the end head on the motor in line with the motor terminal.
directly
Printed in U.S.A.
Tech. Data
STARTING MOTORS
AIRCRAFT STARTING
Issued 4/1./83
ZMROTOM
SERVICE
4 of 5
Page
I
INFORMATION
I
COMMUTATOR REFINISHING
1.50" .003"
max.
bearing journals
TEST SPECIFICATION
(750
F.)
torque
test
(See Figures
1 and 2
for
no
connections.)
GEAR REDUCTION UNITS No Load Test (Motor Only) No Load Test (Complete Unit) Stall Torque Test
RPM RPM
Ft.
Lbs.
75 560
max,
max,
RPM
Ft.
Lbs.
M2-4214
50 560
max.
max.
RPM Ft.
Lbs.
Internal
Unit M2-4203 Drive Type Di rect
R
R R R R
R
MZ-4216, M2-4217, M2-4218, MZ-4219, M2-4220, M2-4221, M2-4222, M2-4223, M2-4224, M2-4225,
R R R R
R
R
R R R
Wiring Fig. 3 Fig. 3 Fig. 4 Fig. 4 Fig. 4 Fig. 4 Pig. 4 Fig. 3 Fig. 4 Fig. 4 Fig. 4 Fig. 3 Fig. 4 Pig. 4 Fig. 4 Fig. 4 Fig. 4
a
Application
Fran kl in
Lycoming Lycoming Lycoming Lycoming Lycoming Lycoming Lycoming Lycoming Lycoming Lycoming
part of, this
INSTALLATION NOTE
starting motor installation, clean any rust, corrosion or dirt mounting surfaces of the starting motor and engine. Also check all ground connections to make sure they are clean and tight.
the
Prior to
from
ZM___.~
SERVICE
AIRCRAFT STARTING MOTOR
Issued 4/1/83
____.._
INFORMATION
Page
5 of 5
~WICE
o
L*I(MN CIIL
~s
lulrr
olCl~sC,
CAIWY e(LL
IYITCH
)MIUG
YUE
;1:
e*rrrlr
I)*fTERI
II/
T4CnOYETER
)~RTING UOTOR
GIIWIIO
ST*ITIWC YOTOI)
Figure
Figure
TERMINAL
POST
~R
INSULATED
BRUSH
~ca
GROUNDED
BRUSH
GROUNDED BRUSH
INSULATED BRUSH
GROUNDED
BRUSH
GROUNDED BRUSH
INSULATED BRUSH
VIEWED FROM
COMMUTATOR
END
VIEWED FROM
COMMUTATOR END
Figure 3
Figure 4
Printed in U.S.A.
ec
Data
STARTING MOTORS
AIRCRAFT
ALTERNATORS
(Figure 1)
have been
designed
operation
with
minimum
amount of maintenance.
They
have i~so
been
designed
changes
encountered in aircraft
applications.
DESCRIPTION
principal components 1Figure 2) of the alternator are (1) the stator, (2) the rotor, (3) the slip ring end head, (4) the drive end
The
head and
(51
the reotifiers.
Figure
111III
oI$ P9 T
-PL.
O
i.
(((II)
Figure
laminated iron
core on
windings
are
Leads
~haae windings
pair of rectifiers,
one
negative and
2.
one
positive.
a
single field
the shaft.
four-poled,
interleaved
a
on
are
connected to
pair
of
slip rings
3.
which
are
slip ring end head supports the rectifier mounting plate and rectifiers, a preLubricated bearing in which the rotor shaft rotates, the brush holders and brushes, the
T~e
blast tube
assembly.
4.
5.
are
The negative rectifiers are pressed into the pressed into the rectifier mounting plate and
are
slip ring
are
rectifiers
voltage protection.
only
be necessary to
complete disassembly may not be required. In some cases perform those operations which are required to effect the repair.
However, in this section, the complete overhaul is covered step by step to provide detailed information on each operation. In actual service practice, these operations may be used as
required.
DISASSEMBLY
CAUTION:
To
prevent damage
assembly,
servicing is attempted.
i.
Using
strap wrench,
remove
the
pulley
nut.
The
pulley
puller.
Now remove the four through Remove the fan, woodruff key, and spacer from the shaft. bolts. Tap the drive end head lightly with a rawhide hammer and separate the end head and
slip ring
end head.
springs
2.
when
plate mounting screw. Note carefully the correct assembly of the insulator washers and bushings. Using the same special tools shown in Figure 3, support Thestatorcannowbe separated theend head andpress outthe three negative rectifiers.
the rectifier mounting from the
slip ring
end head.
3.
To remove the
Figure
Figure
4.
as
shown in Figure 3.
touch
To
disconnect the rectifier from the stater the soldered end of the connector with three leads when the solder is melted.
leads, use pliers to grip the rectifier leads and Pull the connector off the a hot soldering iron.
5.
To
remove
use a
puller
that grips
on
the the
bearing
retainer
plate pressing
shown in
Figure
as
5.
Do not
attempt to
remove
by supporting
or
the
shaft,
plate
screws.
plate
screws
and press
bearing
Figure
6.
Figure
i"
Figure
Upon completion of the disassemhly, all parts should be cleaned and visually inspected for
cracks,
i.
wear or
signs
of
overheating
or
mechanioal interference.
Rotor
or
grounded
test
can
shortedwindings.
a
The ground
probes, connected
in series with
lamp,
tester.
an
ohm7.
meter
or
any type
Figure
between the
slip
poles.
winding,
voltmeter,
shown
inFigure 8,
ohmmeter.
are
listed
individual
apecificatlon
or a
pages.
Excessive
current draw
low ohmmeter
reading
indicates shorted
or
an
an
open
2.
Rectifiers
pinpoint open or shorted rectifiers without going through the operation of disconnecting the stater leads. However, if a
tester is not
detect and
available,
test
probes
a
and
#57
bulb, connected
AMMETER
in series with
12 volt
battery,
Touch
RHEOSTAT
can
be used in the
one
test
following manner. probe to a rectifier heat sink test probe to a lead from one of
Then
reverse
VOLTMETER)
should
light
in
one
light
in
lights
in
directions,
one or more
of the rectifiers
To
pinpoint
the
defective rectifier, the stater leads must be disconnected and the above test
each rectifier.
Open rectifiers
Figure
light
rectifier is open.
grounded windings with a 12 volt test bulb, ohmmeter, in the following manner. Separate the section, stater from the slip ring end head just far enough to insert a couple of rags or blocks of wood. In other words, insulate the stater from the end~head. To test for grounded windings, touch one test bulb or ohmmeter probe to ~nv stater lead, and the other test bulb or ohmmeter probe to the stater frame. If the test bulb lights, or the ohmmeter indicates continuity, the stater is grounded. To test for open windings, connect one test probe to
3.
Stater
The stater
can
or
the stater
must
continuity.
windings, shorted windings are almost impossible to locate. However, shorted stater windings will usually cause the alternator to "growl" or be noisy duringoperation and will usually show some signs of overheating.
Due to the low resistance inthe stater
are
replaced
to determine whether
not it is the
replaced.
Note:
New
roughness or excessive clearance to determine if they should be bearings are prelubricated; additional lubrication is not required.
a
cloth
dampened
in solvent.
1.
bearing
using
race
flat block
square
the outer
of the
retainer
plate.
on
use a
tool that
race
against
hearing
against
To
Figure 9.
or
2;
rectifier mounting
a
plate, support
in with
special
driver tool.
Figure
10.
(Uae
hammer.)
Figure
Figure
on
10
Strip
approximately 1/4"
CONNECTIONS,
rectifiers.
USE PLIERS AS A HEAT-DAM ON THE LEAD TOO MUCH HEAT WILL DAMAGE
3.
To
spread
use an
installing
the
HOLE
rotor,
Alien wrench
equivalent
to
USE STIFF WIRE WITH ro HOLD
BRUSH
H001(
LEID
Figure 11.
4.
m9
press the
stater and
together.
locator pina
through bolts.
to be
or
E(IUIV*LENT
BRUSH
sure
freely
Figure
11
when rotated
by
5.
Tighten
nut
using
strap wrench.
been bench
(Do
assembly
tested.)
Upon completion of assembly, the alternator should be teated for output. This test is made The alternator to determine whether the alternator is capable of delivering rated output:
must meet
tests
are
attempted.
Wiring connections for bench testing the alterRefer to the nator are shown in Figure 12. for Individual specification pages output teet:
figures.
to obtain the
eaaaaa
C,
if necessary,
\j
After bench
O
tell
safety
wire in the
on
the
alternator
the engine.
Note:
era
or
AlwaylS refer to the airframe manufacturwiring diagram when installing the alternator
on
t~,t
vauut~l
the aircraft.
Figure
12
BATTERY, before connecting or diaconnectit~g test instruments (except voltmeter) or before removing or replacing any unit or wiring. Accidental grounding or shorting at the regulator, alternator, ammeter or accessorfes, will cause severe damage to the units and/or wiring.
DISCONNECT THE
2.
THE OUTPUT LEAD MUST NOT BE REMOVED FROM THE ALTERNATOR WHILE THE ROTOR WINDING fS ENERGIZED AND THE ALTERNATOR fS OPERATING
DO NOT ATTEMPT TO POLARIZE THE ALTERNATOR.
3.
Any attempt
4.
to do
so
is
required.
circuits.
~GROUNDING OF THE ALTERNATOR OUTPUT TERMINAL MAY DAMAGE THE ALTERNATOR AND/OR CIRCUIT AND COMPONENTS.
REVERSED BATTERYCONNECTIONS MAY DAMAGE THE RECTIFIERS, VEHICLE Battery polarity WIRING OR OTHER COMPONENTS OF THE CHARGING SYSTEM. should be checked with
ARE NEGATIVE
a
f,.
battery.
MOST VEHICLES
GROUND.
C,.
fF A BOOSTER BATTERY OR FAST CHARGER IS USED, fTS POLARITY MUST BE CONNECTED CORRECTLY TO PREVENT DAMAGE TO THE ELECTRICAL SYSTEM
COMPONENTS.
SOLID STATE
A I R C R A FT A LT E R N AT OR
REGULATOR
Alternator output
be controlled and the
voltage can, within the limits of the design capability of the alternator, by properly varying the average level of current flow in the rotor winding PRESTOLITE full electronic solid state regulator is well suited for this purpose.
alternator, due to its design, has self-limiting current-limiting unit in the regulator.
THE REGULATOR COMPONENTS
current characteristics
The Prestolite
and needs
no
THE TRANSISTOR
The transistor is
in
an
an
can
or
turn
on
electric circuit.
mechanical
moving parts
out.
one
direction
and in
compared
to
passing current in the forward direction, will pass current a Particular value of voltage is applied in the reverse only direction. It is this Zener action which makes it adaptable for use as a voltage sensing device in the regulator.
in the
reverse
The Zener
diode,
in addition to
direction
when
THE RESISTOR
The resistor is
When of the
is turned on,
battery voltage
is
applied
to the "I"
(ignition)
terminal
r-,-
iu
S
F
TI
R4
ALTERNATOR
I
ZI
PI
RO
iLn
-------III e, 13
_____
_I
REGULATOR
IGNITION SWITCH
BATTERY
Figure i.
The NPN power transistor, T3, is turned on by current flow from the ignition terminal through R-6 and the collector emitter junction of T2 through D2 through the base emitter
junction of T3
to
ground.
on
Whenever the power transistor, T3, is on, T2 is also from the ignition terminal, through the field winding,
T3 to
and T1 is
off,
through
the collector
emitter of
ground.
regulator ground
This network dereverse con-
With the ignition switch on, current will flow from the "I" terminal through a voltage dividing network consisting of R-l, R-2 and P-l.
voltage connected
diode connected to the divider network conducts, current will flow from the "I" terminal through R-l through Z1 and through the base emitter junction of T1 to ground. This
junction of T1 to conduct which diverts the base current of T2 flowing from "I" terminal through R-4 to ground, turning off T2 which turns off T3, de-energizing the rotor winding; then, when the alternator output voltage falls to a value which permits Z1 to cease conduction, T1 will turn off which turns on T2 and T3, reenergizing the rotor winding.
causes
This sequence is performed so rapidly that the rotor current average appears as a value usually less than full rotor current depending on rotor RPM and system load connected.
Each time the power transistor, T3, is turned off, current flow in the rotor winding is reduced. This causes the rotor magnetic field to collapse which would generate high voltage at the power transistor, T3, if a path were not provided so that the field current this path, thus procan decay at a slower rate, field suppression diode, D1, provides
tecting
the
the
regulator
increase
or
regulator
uses
Capacitor, C1 is used to filter ripple and alternator diode switching spike ating batteryless.
Neon
as a
surge suppressor.
limited range of
voltage adjustment.
This will
destroy regulator
and void
warranty.
1.
or
specialist,
must disconnect
battery before connecting or disconnecting a test other test equipment or before making wiring changes in the electrical
at the
system.
2.
When
voltmeter
3.
When
is in
installing
a
a
so
battery
in
vehicle, be
can
that the
position
be connected to the
for negative
4.
ground systems.
area,
The
and in
regulator, when installed in a vehicle, should be mounted on a metal a place where it will not be subjected to excessive temperature.
a
5.
To insure
between the
6.
good regulator ground, a permanent ground lead should regulator mounting bolt and the alternator frame.
therefore,
never
or as
be connected
connect
ground,
the
momentarily,
Do not
to either the
regulator
field terminal
terminals.
interchange
I and F leads to
regulator
this will
destroy
regulator
7.
The alternator should be in good condition and capable of producing full output, and the alternator drive belt must be adjusted tight enough to prevent slippage.
The
8.
battery
must be in
good
9.
10.
the
battery
charging
circuit
i.
on
the vehicle
or on
the test
bench,
2.
remains the
as
shown in
Fig.
2.
tight.
or
loose
open the
charging circuit
at any
system
is
operating.
*LTERNP~TOR
REGULATOR
TEST AMMETER
CARBON
PILE
zn
AMMETER
ALTERNATOR SWITCH
ON TEST VOLTMETER OFF
BATTERY
Figure
2.
3.
regulator setting
until the
regulator
4.
shown in
Figure
2.
Start the
Turn
on
engine
across
adjust
battery
its
speed
to obtain 3, 000 to
4,
accessories
or use a
carbon-pile
the
charge
rate.
5.
voltage.
indicated After 1 minute operating time, check the regulator operating voltage as correct the for operating by the voltmeter. SEE THE SERVICE SPECIFICATIONS The voltage is shown for the ambient temperature in which the
regulator
6.
is
operating operating.
reading indicates that the operating voltage is not within limits, lift the plastic plug from top of regulator and adjust the voltage to the desired value. Replace the plug after adjustment. Before condemning the regulator, recheck the altenrator and the battery; making sure that they are in good condition. Recheck all circuit connections and all wiring for unwanted resistance the entire (voltage drop test). Recheck the voltmeter for accuracy and repeat
If the voltmeter
operating~test.
L-652A
10/68
Toledo, Ohio
43601
BELT DRIVEN
AIRCRAFT
ALTERNATORS
and construoted to
of trouble-free
minimum
amount of maintenance.
They
have also
been
designed
changes encountered
in aircraft
applications.
DESCRIPTION
principle components (Figure 2) of the Aircraft Alternator are (1) the Brush Holder Assembly, (2) the Slip Ring End Head, (3)
The the Reetifiers, and
(4)
the Stater,
(5)
the Rotor
(6)
Figure
Figure
i.
assembly
contains huo
brushes,
two brush
springs,g
brush holder
and insulators. Each brush is connected to a separate terminal sb~dand is insulated from ground. The brush and holder assembly can easily be removed for inspection or brush
replacement
2.
The
slip ring
provides
assembly.
a
The
slip
assembly
and
grease seal.
are are
voltage
negative rectifiers
a
are
mounted in the
mounted in the rectifier mounting plate slip ring end head. Each pair of rectifiers is
while the
connected to
the rectifier
are
anchored to
mounting plate
a
protection.
lead which is connected to the center of the three phase The stater has or relays. wind ings and is used to activate low voltage warning systems resistance. been treated with a special epoxy varnish for high temperature
4.
special
5.
provide temperature epoxy cement to secure the winding leads used is High temperature solder
6.
and spacer on the slip ring end The rotor contains the slip ring end bearing inner race been specially treated with a high of the shaft. The rotor winding and winding leads have vibration and temperature resistance characteristics. to
to the
slip rings.
supports
OVERHAUL
not be required. repairing the alternator, complete disassembly may which are required to will only be necessary to perform those operations In
some cases
When
it
effect the
repair.
overhaul is covered step by step to provide detailed However, in this section, the complete these operations may be used as information on each operation. In actual service practice,
required.
DISASSEMBLY
i.
screws
holding
assembly
in the
head.
2.
assembly
safety wire from the through bolts. Hold The pulley must be removed with remove the pulley nut. woodruff key and spacer from the shaft.
Remove the
pulley puller.
with
3.
through bolts
as
the drive tap the drive end head lightly to separate unit, from the stater and slip ring end head.
and
4.
terminal studs.
assembly of the insulator washers and bushings. the end head and press out the three Using the special tools shown in Figure 3, support be separated from the stater assembly. negative rec~ifiers. The end head can now
Note
from the output and auxiliary nuts, lock washers, flatwashers and insulators
carefully
the correct
5.
To
or
remove
type
slip ring end bearing and grease seal, 4. impact type bearing puller as shown in Figure
the
is necessary.
hook
bearing unless
replacement
Figure
The inner
race
of the slip ring end bearing is pressed onto the rotor shaft. When bearing
6.
To
remove
Figure
shaft, use a puller that grips on the bearing retainer plate as shown in Figure 5. Do not attempt to remove by supporting the end head and pressing on the shaft, as this may result in distortion of the end head or stripping of the retainer plate sorews. Remove the three retainer plate sorews and press the bearing
rotor out of the end head.
Figure
6.
Figure
Figure
5
CPMPONENTS
cleaned and visually inspected for Upon completion of the disassembly, all parts should be cracks, wear or distortion and any signs of overheating or mechanical interference.
i.
can or
Rotor
grounded
any
type
slip
rings and
in
windings. The ground test series with a 110 volt test lamp, an ohmmeter There must not be any continuity bet~ueen the
or
shorted
winding,
connect
voltmeter,
or a
or use an
ohmmeter.
listed
indicates shorted
indicate
an
infinite ohmmeter
reading
would
~MMETER
RHEOST~T
8*TTERY
ROTOR
Figure
2.
Figure
or
A diode rectifier tester will detect and pinpoint open without going through the operation of disconnecting the stater leads. is not available, test probes and a #57 bulb, connected in series with
Reotifiers
shorted rectifiere
a
However, if
a
tester
can
12 volt
battery,
be used in the
test
following
manner.
one
Touch
one
test
probe
to
probe
to
lead from
of the
rectifiers
in
one
Then
reverse
We position
light
light
lights
in both
directions,
one or more
repeated on each rectifier. Open rectifiers can only he detected, when using either bulb, by disconnecting the stater leads. The test bulb will fail to light in
8.
Stater
foropenorgroundedwindInga
ohmmeter,
in the
with
12 volttestbulb,
or an
following
a
manner.
Separate We
blocks of
slip ring
or
end head
just
far
enough
to insert
couple
or
of rage
or
wood. touch
In other
one
To test for
test bulb
ohmmeter
probe
If the test
test
probe
to the
auxiliary
terminal
or
The test
grounded. To test for open windings, connect winding center oonnectlon and touch bulb must light, or the ohmmeter must show
the stater
continuity.
windings, shorted windings are almost impossible to locate. However, shorted stater windings will usually cause the alternator to "growl" or be noisy during operation and will usually show some signs of overheating.
Due to the low resistance in the stater
are
replaced
to determine whether
not it is the
Whenever the alternator is overhauled, new bearings and oil or Bearings and Seals grease seals are reoommended, even though the bearings and seals appear to be in good condition. A faulty seal can cause an alternator to fail within a very short period of time. 4.
ASSEMBLY
i.
so
bearing
using
flat block
approximately
tool that fits
race
2" square
the outer
race on
of the bearing.
plate.
the
the
place
the rotor
shaft,
over
against
bearing
race,
bearing
is
against
ring retainer
Figure 9.
or
2.
Carefully install
by
supporting the
unit and
1 Figure
10
do not
SOLDERING THESE
hammer.) CONNECTIONS,
WHEN
USE PLIERS AS A HEAT DAM ON THE LEAD BETWEEN TOO MUCH HEAT WILL DAMAGE THE
sure
they
are
in the
Figure
11.
and rectifier leads must be After the slip ring end head is completely assembled, the stater leads are secured to the rectifier mounting plate with epoxy. Make sure the stater rotor. so that they do not interfere with the
positioned
3.
Make
sure
the
lip of
bearing.
assembly
of
bearing, seal,
inner
race
Figure
12.
LOCKWPASHER
LT~
-FIBERWASHER
~ENO HEAD
SEAL-INSTALL SEAL
WITH LIP TOWARD BEARING
INNER
RACE
AUXILIARY TERMINAL
FLATWASHERc~
END
NUTC~
LOCKWASHER
c~Ly
FIBERWASHER
GREASE
CAVITY
HEAD(
~cNsuLnToR
Z
~L, 1
SPAC ER
~TERYIN*L STVD
BEARING
OUTPUT(+)
TERMINAL
t
Figure
4. is
11
Figure
Spin the
12
rotor to make
sure
there
mechanical interference.
Safety
wire
Install spacer, woodruff should be installed after the unit has been bench tested for output. to 35 Ft. Lbs. using a strap wrench key, fan, pulley, lockwasher and nut. Torque the nut tube assembly until after the unit has been bench Do not install the blast to hold the pulley. tested.
the rotor and check Install the brush and holder assembly and retaining screws. Spin the field terminals for interference between the brush holder and rotor. Check across
5.
with
an
ohmmeter.
on
the individual
specification
TESTING
IcAReoN
PILE
.JIMCER
WIRE
Wiring connections for bench testing the alterRefer to the nator are shown in Figure 13. individual specification pages for output test
I
I I
I
+I
I
figures.
to obtain
if necessary,
ILn
TE~MIIEfER
After bench testing the alternator, install the safety wire and blast tube and install the alternator
on
the
engine.
__
_,_
Figure
13
Note:
Always
or
wiring diagram
when
installing
the
alternator
testing
the alternator
on
the aircraft.
(exceptvoltmeter)
BATTERY, before connecting or disconnecting test Instruments betore removing or replacing any unit or wiring. Accidental grounding or shorting at the regulator, alternator, ammeter or accessories, will cause severe damage to the units and/or wiring.
DISCONNECT THE
or
2.
THE OUTPUT LEAD MUST NOT BE REMOVED FROM THE ALTERNATOR WHILE
Any
4.
attempt to do
so
may result in
damage
to
ALTERNATOR
5.
AND/OR CIRCUIT
AND COMPONENTS.
6.
USED,
COMPONENTS.
AIRCRAFT
ALTER NATO RS
Prestolite
Alternators
and constructed to
changes
encountered in aircraft
applications.
DESCRIPTION
The
of the
(1) The drive end The head, (2) rotor, (3) The stater, (4) The rectifiers, (5) The slip ring end head and
Aircraft Alternator
(6) The
assembly.
Figure
1
90
O
c
oooa
Figure
1)
and
prelubricated bearing,
an
oil
seal, collar
2)
the
ventilating
inner
race
fan
an
(ALX
series
only)
and
slip ring
end
hearing
and spacer
The rotor
winding and winding leads have been specially treated with a high temperature epoxy cement to provide vibration and temperature resistance characteristics. High temperature solder is used to secure the winding leads to the slip rings.
3) The stater contains a special lead which is connected to the center of the three phase windings and is used to activate low voltage warning systems or relays. The stater has been treated with a special epoxy varnish for high temperature resistance.
4)
are
voltage
Three positive rectifiers are mounted in the rectifier mounting plate while the Each pair of rectifiers is three negative rectifiers are mounted in the slip ring end head.
protection.
connected to
are
anchored to the
5) The slip ring end head provides the mounting for the rectifiers and rectifier mounting plate, output and auxiliary terminal studs, and the brush and holder assembly. The slip ring end head contains a roller bearing and outer race assembly and a grease seal.
6) The brush
and holder
assembly
contains two
a
brushes,
two brush
springs,
brush holder
and insulators.
ground. replacement
assembly
can
easily be removed
for
inspection
or
brush
OVERHAUL
only
be
alternator, complete disassembly may not be required. In some cases necessary to perform those operations which are required to effect the repair.
However, in this section, the complete overhaul is covered step by step to provide detailed information on each operation. In actual service practice, these operations may be used as
required.
DISASSEMBLY
1.
screws
head.
brush holder
assembly
in the
slip ring
end
2.
Remove the
safety
remove
3.
Tap the drive end head lightly and separate the drive end head and rotor,
as a
unit, from
slip ring
end head.
4.
terminal studs.
the
Note
carefully the
assembly
bushings.
special tools shown in Figure 3, support the end head and press out the three Using negative rectifiers. The end head can now be separated from the stater assembly.
Fd
Figure
6.
To remove the
slip ring
end
bearing
and
a
grease
hook
seal,
or
type
as
shown in Figure 4.
of the
slip ring
end
bearing
is
pressed onto the rotor shaft. When bearing replacement is necessary, always replace the complete bearing assembly, including
the inner
race.
Figure
6.
Clamp engine
vise and
remove
assembly
and
woodruff key.
the
The drive gear assembly is not a Prestolite part and is serviced manufacturer. Support the drive end head and carefully press out the rotor
Remove the retainer
by
assembly.
pressed
plate
screws
and retainer
plate.
bearing.
Once the
bearing
is
removed,
be knocked
or
housing.
Upon completion of the disassembly, all parts should be cleaned and visually inspected for
cracks,
i.
can
wear or
signs of overheating
or
Rotor
grounded
or
shorted winding.
a
ground
an
test
probes,
lamp,
ohmmeter
or
any
slip rings
Figure poles.
5.
winding,
connect
voltmeter,
shown in Figure 6,
or use an
ohmmeter.
listed
on
*MMETER
RHEOSTAT YOLTMETER
I*TTERI
RoTon
Figure
Figure
Excessive current draw
or or a
open
windings. winding.
No current draw
an
2.
Rectifiers
or
out not
going through
the operation of
used in the
test
However, if
a
tester is
can
12 volt
battery,
the
be
to
lead from
one
position
of the leads.
lights in bath directions, one or more of the rectifiers in that heat sink is shorted. To pinpoint the defective rectifier, the stater leads must be disoonnected and the shove test repeated on eaoh rectifier. Open rectifiers can only be detected, when using the test bulb, by disconnecting the stater leads. The test bulb will fail to light in either
Lf the test bulb direction if the rectifier is open.
grounded windings with a 12 volt test bulb, ohmmeter, in the following manner. Separate the stator from the slip ring end head just far enough to insert a couple of rags or blacks of wood. In other words, insulate the stator from the end head. To test for grounded windings, touch one test bulb or ohmmeter probe to the auxiliary terminal or any stater lead, and the other test bulb or ohmmeter probe to the stater frame. If the test bulb lights, or the ohmmeter indicates continuity, the stater is grounded. To test for open windings, connect one test probe to the auxiliary terminal or the stater winding center connection and touch The test bulb must light, or the ohmmeter must show each of the three stater leads.
3. Stater
or
continuity.
locate.
However, sharted
and
windings, shorted windins~s are almost impossible to stater windings will usually cause the alternator to "growl" or be will usually shaw same signs of overheating.
are
replaced
to determine whether
not it is the
Whenever the alternator is overhauled, new bearings and oil or grease recommended, even though the bearings and seals appear to be in good canditian.
can cause an
faulty
seal
very short
period
of time.
ASSEMBLY
Install the oil seal with the lip toward the outside of the end head.
below the
Press
approximately 1/16"
edge
of the
casting.
Press
only
on
the outer
of the
race and press in bearing Reassemble oil seal collar, "0" ring seal, woodruff key, drive gear assembly, nut rotor. and cotter pin. Torque rotor shaft nut to 31 to 41 Ft. Lbs. Correct assembly of drive end
installing.
screws.
Support the
inner
Carefully
or
by
supporting the unit and using the special tools illustrated in Figure 8.
lr
OIL
SE*L
nd
BELW
CIISTING
DE
HEPID
sELLEo
OF
9DE
COLLI\R
BE*RINF ROTOR
SH~FT
~D
~d
IAJ~
o"
BE*RN6
nlNo
SELL
BEIRING
C~S"
L~R
RET~INER
CORRECT
ASSEMBLY
OF
OIL
SEALS
Figure 7
Figure
(Use arbor
press
SOLDERING
do not
WHEN
USE PLIERS AS A HEAT DAM ON THE LEAD BETWEEN TOO MUCH HEAT WILL DAMAGE THE
RECTIFIERS.
sure
they
are
in the
Figure
9.
After the slip ring end head is completely assembled, the stater and rectifier leads must be secured to the rectifier mounting plate with epoxy. Make sure the stater leads are positioned
so
that
they
Make
inner
sure race
the
lip of
bearing.
Correct
assembly
of
bearing, seal,
Figure
10.
NVT
END HEI\D
INSULAT
RECTIFIER
TERMINAL
STVD/
AUXILIARY TERMINAL
MOUNTING PLATE
NUT
LOCKWASHER BERWASHER
GREASE
CAVITY
END
HEAD(
UL~TOR
SPACER
~TERMINAL STUD
RECTIFIER
MOUNTING PLATE
BEARING
OUTPUT(+)
TERMINAL
Figure
Figure
10
sure
Assemble the alternator and install the through bolts. Spin the rotor to make is no mechanical interference. Torque the through bolts to 30 to 35 in. Ibs. should be installed after the unit has been bench tested for output.
there
wire
Safety
screws.
Spin the
Check
across
an
ohmmeter.
the individual
specification
TESTING
Upon completion of assembly, the alternator should be tested to determine if it is capable Caution: All flange mounted alternators require a source of delivering its full rated output. of ventilation. Do not test these alternators at full rated output for more than 30 seconds
unless adequate air pressure for
cooling
is
supplied.
some
on
provides
same
rule
applies
to these units.
Wiring
nator
Figure Ii. Refer to the individual specification pages for output test figures. Adjust the carbon pile, if necessary, to obtain the specified voltage.
are
CARBON
P"E
safety
wire in the
on
alternator
the
engine.
Note:
Always refer to the airframe manufacturers wiring diagram when installing the alternator or testing the alternator on the aircraft. I I
+I
I
ILD
TEST AMMETER
/II~(/+
___
_TEST_V~L_TM_ETER
Figure
11
1.
before
connecting or disconnecting test instruments replacing any unit or wiring. Accidental removing the regulator, alternator, ammeterpr accessories, will
or
units
and/or wiring.
3.
Any attempt
4.
to do
so
may result in
damage
to the
is
required.
circuits.
ALTERNATOR
AND/OR
5.
Battery polarity
MOST VEHICLES
6.
BE
COMPONENTS.
prPSfCl/l~ti?l
24 VO LT
100 AMPERE
AIRCRAFT
ALTERNATOR
(Figure 1)
manufactured for
flange
are
foot, hinge
Both
provide types for extended periods of heavy duty service trouble-free operation with a minimum amount designed
of maintenance.
and constructed to
They
are
construoted to
withstand the vibration and Extreme temperature changes encountered in airoraft applications.
DESCRIPTION
are
by
the
prefix
num-
Figure
r
oooa
goe eo-~1I
I
QO.p
BBB
O
oe
Q!
~cb
P
Figure
nange mounted,
principle components: (Figure 2) of these alternators are (1) the slip ring head, (2) the assemblies, (3) the stater, (4) the rotor and (5) the drive end head
assembly. slip ring end head provides the mounting for the rectifier-heat sink assemblies, the output, auxiliary and ground terminal studs, brush holder and brush assemblies and the slip ring end bearing. The 8000 series unite attach the blast tubs assembly to the slip ring
(1)
The end head.
(2)
(Flgure 3),
are
different in
has six
(6)
rectifiers of
one
polarity
attached to it.
(1)
OUTPUT
FI
FIELD
GROUND
nuxlLlnRv
Figure
rectifiers
Figure
(two positive and two negative). This can best be illustrated with an internal wiring diagram. (Figure 4). Each rectifier is rated at 150 P. I. V. minimum for transient voltage protection. All soldered connections are made with high temperature solder. The stater and rectifier leads are anchored to the heat sink with epoxy cement to provide vibraBecause of this construction, special service procedures must be followed. tion protection. Refer to the rectifier section of Inspection and Testing of Components.
(3) The stater contains a center tap lead which is connected to the center of the three phase windings and is used to activate low voltage warning systems or relays. The stater has been treated with a special epoxy varnish for high temperature resistance and vibration protection.
winding leads have been specially treated with a high temperature varnish and epoxy cement to provide vibration and temperature resistant characteristics. High temperature solder is used to secure the winding leads to the slip rings.
(4) The
rotor
wldding
and
(5)
on
prelubricated bearing.
seal, and
a
an
oil
seal, collar
and shaft
ventilation
OVERHAUL
When repairing the alternator,
complete disassembly may not be required. In some cases, the repair. it will be necessary to perform only those operations ~hich arerequired to effect to provide detailed However, in this section, the complete overhaul is covered step by step these operations may be used information on each operation. In actual service practice,
as
required.
OVERHAUL NOTE recommend the following components be
When
overhauling
the alternator,
we
replaced:
(2)
i.
2.
Brushes.
3. 4. 5.
6.
bearing. bearing. Slip seal Series). (9000 Oil Shaft seal "0" ring (9000 Series).
ring end
Lack tab washers.
Drive end
DISASSEMBLY
(1)
ears on
remove
the three
through
(2)
ears on
remove
bolts.
cover.
This
or
chisel
accomplished by wedging a smi\ll, imife blade, between the cover and the slip
can
be
(4) Use a puller, as shown in Figure 5, to press the rotor shaft out of the slip ring end bearing. Separate thedrive endhead and rotor, as aunit, from thestatar and slip ring end head, being careful not to lose the brush springs while separating the units.
(5)
and
Remove the nuts,
auxiliary terminal
The
be
separated
sink assemblies.
slip ring
bearing
head.
(6) Each
slip ring
brush is connected to
terminal
through
come
the
Service brushes
and
can
he
slip easily
alternator is disassembled.
Clamp
drive
the rotor in
poles,
the
components from
The
NOTE:
pulley,
units,
used
an
assembly,
are
the
or
are
not manufactured
available from
Figure
the
on
puller
as
Figure
6.
Do not
attempt
separated
pressing
(3)
Remove the
hearing
retainer
plate
screws
and
retainer.
carefully
on
The oilseal,
the press-
then be knocked
or
thoroughly
cleaned and
visually
in-
spected for cracks, wear or distortion, and any signs of overheating or mechanical interferenoe.
The ratar should be teated far a (1) Rotor grounded, shorted, or open winding. The ground test can be made with a 110 volt test lamp, an
ohmmeter,
or
any
type
of
continuity
teeter.
Figure
There must not be any continuity (Flgure from the slip rings to the rotor shaft or pales.
winding,
connect
an
accurate
voltmeter,
ammeter and
re-
oruse an
accurate ohmmeter.
listed
on
the individual
ohmmeter
readingwould
an
indicate shorted
open
low
an
infinite ohmmeter
(2)
Reotifiers
A rectifier tester
pairs of
reotifiers. The canstructian of the alternator (two rectifiers connected to one stater lead) makes it impossible to check for a single open rectifier without going through the operation
of
the When soldering and unsoldering the rectifier connections, use pliers as a heat dam on rectifiers. will heat much damage rectifier leads, between the solder joint and rectifier. Too
IU.ETER
ROTOR
(i~7 CI
VOLTMETER
I
8
BP~TTERY
Figure
Figure
(4)
If
shorted
or
open rectifier is
located,
must be
replaced.
The
indivihual
rectifiers
not
rectifier should be
(S)
Stater
The stater
can
12
grounded windings with test probes and volt battery, an ohmmeter, or any type continuity
or
except
To test for
stater
grounded windings,
indicated, the
connect
one
test
probe
to the
auxiliary
terminal stud
test bulb
or
or
any any
lead.
is
continuity
lights
windings,
connect
test
each stater connectianwith the other test be indloated between all connections.
probe to the auxiliary terminal stud and touch probe. The testbulb must light or continuity must
replaced.
Check
possible
opens before
replacing
the stater.
windings, shorted windings are almost impossible to locate. However, shorted stater windings will usually cause the alternator to be noisy or "growl" during operation and will usually show signs of overheating.
If all other eleetrioal cheeks
the stater should be
are
replaced
to determine
not it is the
And/Or Rectifier Heat Sink Replacement When soldering or unsoldering the rectifier connections, pliers should be used as a heat dam behueen the solder joint and We rectlfiers. Too much heat will damage rectlfiers.
(4)
Stater
ILSSEMBLY
thoroughly cleaning, inspecting, testing, and replacing any faulty components, assemble and test the unit. Reassembly is, basically, the reverse of disassembly.
After
re-
However, the
bled unit.
Install
bearing with the sealed side toward the by pressing on the outer race only.
screws.
Sup-
part the
Do not
rotor shaft and press the end head onto the shaft using the tool shown in Figure 9.
attempt
the end head and bearing may be damaged. Install the spacer, fan, woodruff key, pulley, lockwasher, and nut. Torque the pulley re-
taining
nut to 35 to 45 Ft.
Lbs.
Figure
(5)
Install the oil seal with the lip toward the outside of the
the outside
edge of the casting. Install the bearing When installing the bearing, press only on the outer race. Install the bearing retainer and screws. Support the rotor shaft and press the end head assembly onto the shaft, using the same tool shown in Figure 9 and being careful not to damage the oil seal.
with the sealed side toward the rotor.
BELOV C*PTINO
end head.
Reassemble the oil seal collar, being careful lip under. A small
amount of oil
on
D. E.
HEAD07
rH
/OlL
SEnL
tion easier.
SEALED
SIDE
OF BEARING
,COLLAR
cROTOR SHAFT
careful not to cut the "0" ring on the shaft keyway. Use a small, blunt instrument to push the "0" ring seal into the shaft collar. A small
amount of oil
on
the "0"
ring seal
will make
installation easier.
"O" RING SEAL
BEARING
assembling the assembly. Figure 10 shows the correct assembly of the drive end head components. Torque the drive retaining
remainder of the drive
nut to 37 to 42 Ft.
seal is
fully
installed before
RETAINER
CORRECT
ASSEMBLY OF
OIL
SEALS
Figure
10
assembling the
brush holder
sure
retaining
screws
are
tight.
A small amount of Lock-Tite
on
the
retaining
screw
threads, prior
to
assembly,
will pro-
Assemble the stater and rectifier heat sink assemblies in the end head, insulators
are
making
certain the
correctly
assembled
as
shown in
Figures
11 and 12.
so
they
was so
necessary to replace the stater or either rectifier heat sink, position the they will not interfere with the rotor and secure the leads to the heat sinks
ring,
in the end
head,
so
that
one
of the holes is
directly
brushes.
springs
Insert
small drill
~---NUTc----\
~---NUT
F LA TWASHER~
/~2\ LATWASHERC--~2: F
I-----
c~
3---FBERWASHER
------INSULATORc-~-----~ENO HEBDc----
~FLATWASHER
~--MEAT
SINK
---//E
AUX. TERM.
~HEAT
ALL EXCEPT AUX. TERM.
SINKc--~C-AUX. TERM.
INSULATORC/
INSULATORc/
Figure
11
(8000 Series)
(6)
Figure
12
(9000 Series)
or
metal rod
through the
snap
ring hole
a
place.
through bolts to hold the unit together. Reare contacting the slip rings. Visucheck to make the brush leads sure freeand are cannot bind against anything. ally Make sure the shaft snap ring retainer is in place and install the slip ring end bearing. The bearinstalled be with the must sealed side toward the tool rotor. ing that fits against the Use a bearing inner race and press the bearing onto the rotor shaft while supporting the drive end
move the brush
couple
sure
of
holding
the brushes
of the shaft.
through bolts.
assembly
on
Units,
or secure
the lock tab washers until the unit has been tested.
After the alternator is fully assembled, the components should be Torquing Specifications torqued to the listed specifications:
Through Bolts
30-35 In.
70-85 In.
Lbs.
1/4
Lbs.
Lbs. Lbs.
Upon completion of assembly, the alternator should be tested to determine if the unit is
capable
of
delivering
output.
mounted units,
more
flange
require
a source
of ventilation.
Do Not
output for
adequate
air pressure
for
cooling
is
supplied.
testing the alternator
are
Wiring
must meet
obtain the
shown in
Volts
25.8 28.4
10.
Output
RPM
100.0
2000 5000
TEST VOLTMETER
TEST
PIMMETER
After bench
testing
blast tube
on
engine, making mounting surfaces, especially on the 9000 Series, are free of corrosion or foreign mate~ials. Torque the alternator retaining bolts to the specifications listed in the engine
on sure
the
-~JUMPER WIRES~
Figure
I
13
BATTERY
manufacturers manual.
(7)
NOTE:
Always
diagram
when instRllinr
nr
test-
the aircraft.
connecting
before
or
2. THE ALTERNATOR OUTPUT LEAD MUST NOT BE REMOVED FROM THE ALTER-
NATOR WITH THE FIELD CIRCUIT ENERGIZED AND THE ALTERNATOR OPERATING.
3. DO NOT ATTEMPT TO POLARIZE THE ALTERNATOR.
Any attempt to do
so
is
required.
circuits.
A~jD/OR
battery.
MOST VEHJCLES
MUST BE
ITY ARE SET TO CORRESPOND WITH THE VEHICLE SYSTEM VOLTAGE AND POLAR-
ITY.
(8)
A I R C RA FT A LT E R N ATO R
A LV-940 O S E R I ES
1.1
inspeotion
4.
1.1.1
Verify no damage Replace Hausings and Shaft shaft damaged). any damaged housings and rotor (if
Thru-Bolts and Loolt Tabs Verify installation of six thru-bolts and lock tabs. See Figure 2-12 far installation at one place and Figure 2-13 For the other five
1.1.2
Inspect bearing and shaft end for discoloration indicatingaverheating or wear (See Figure 1-3) ,,d if so, replace bearing and rotor inspect bearing inner race for evidence of turning onshsft (See Figure I-Sland iFso, replace bearing
and rotor
places. Bolt torque value is 3035 inch-pounds. Bolts are high strength type (120,000 psi) which can be identified by a raised "Y" mark an heads as shown in Figure 2-13.
1.1.3 Terminals and insulators Verify no damage and installation as per Figures 2-10 and 2-11 Refer to paragraph 2510 for terminal mounting nut torque values.
11.4
Shaft
Verify
no
damageiwear
worn
(20 micraor
parts.
1.1.6
Oil Seal
Verify
parts.
no
or wear
Figure
1-1 for
typical
installation
Replace damaged
or worn
ta
Figure
1-2
X;
s~r
Figure
1.1.6
1-1
Slip Ring
End
Figure
1-3
End Condition Remove bearing cover from end head as shown in 1 Figure 1-2. CARE MUST BE TAKEN NOT TO DAMAGE END HEAD. IF COVER IS DAMAGED A NEW COVER MUST BE INSTALLED
2
7.
Inspect
cover
on
inside
sur-
nea.oue.,
bssring.d
5.
Inspect end housing bearing bushing for signs of corrosion, gouges, scratches and burrs and if so, replace housing and bearing. (New bushing has 30
micro-inch surface finish).
Inspect bearing outer race For evidence of turning in housing bushing (See Figure 1-3) and if so, replace bearing and housing Inspect bearing for wear and grease mntnmin;,tion as indicated by darkening or change in arigipsni NIIC"Bpmlornndllrraonroordin.rmptol cles. The original Cheuren SRI #2 grease hasa dark green color. Replace bearing and housing if
bearing
grease is
so
contaminuted.
1.1.7
Hand spin the rotor shaft. A defecBearing Check tive bearing may be heard or felt. To determine which bearing is defective will require disassembly of alternator to separate the drive end head and rotor assembly from the slip ring end head and stater assembly. The check can then be repeated with the drive end
current of 83.0 amperes. Alternator must be connected as shown in Figure 1-4 for full field operation,
i.e. for
jumpered
or a
to the
the
field control
head and rotor assembly to determine which bearing is defective and should be replaced.
1.2
Electrical Checks
on room
1.2.1
Positive Rectifier Heat Sink Assembly: 1. Using a VOM on the RX1 range, make forward and reverse rectifier resistance measurements between the
temperature and extended test time will increase winding resistance, due to temperature increase, and prevent proper check to the stated limits. Also, the
alternator must not be operated without required air cooling for more than 20 seconds at the loaded condition or damage will result. Therefore, to minimize operation time required at the loaded condition, the following test sequence is suggested I. With field control switch open, adjust speed to specified value. 2. Close field switdh, adjust load to give specified output voltage at specified speed, record load current, open field switch and decrease load and speed
to
zero.
2. 3.
One
high
(no meter movement), Abnormal readings indicate one or more rectifiers are defective and the assembly must be replaced. Individual rectifiers are not replaceable.
to
1.2.2
Negative Rectifier Heat Sink Assembly: 1. Repeat test as in 1.2.1 with VOM connections
the
1.2.3
Field Circuit:
1.
Using VOM,
measure
3.
2.
F2 terminals, Resistance should be 9.9 to approximately 15 ohms at 20-27"C (70"-80"F). This resistance is measured through~the brushes and some variation is expected for the specified maximum value. An
1-1
as
required
for trouble
opencircuit will be much higher than this value. If measured resistance is less, this indicates possible shorted rotor, slip rings or RFI capacitor (ALV-9407 only, disconnect one lead for check). If
measured resistance is greater this indicates possible dirty slip rings, bad brushes or open rotor. Replace defective parts or clean slip rings as indicated.
1.2.4
TEST VOLTMETER
TEST
*IJMETER
Ground Checks: 1. Using VOM on RX100 range, make between the slip ring end housing and the AUX, F1, and F2 terminals. Meter should indicate infinite resistance (no
stnemerusaemecnatsiser
cnReou PILE
FIELD CDNTRO~
SWITCH
meter movement).
2.
Abnormal readings indicate a fault condition at terminal mounting interface or the housing internal to the alternator.
a test stand, verify alternator output perforof 28.0 volts at 6000 r/min for minimum output
~JUMPER WIRES/
BITIERY
1.2.5
Performance Test;
Using
mance
Figure
1-4
2.1
General This section contains information required to completely disassemble and reassemble the alternator. In addition, this section includes inspection and test procedures for the individual components and subassemblies. When repairing the alternator, complete disassembly may not be required. In some cases, it will be which are necessary to perform only those operations required to effect the repair.
2.2
Recommended Replacement Parts It is recommended that original equipment service parts be used for parts replacement. Refer to the Prestolite OE-A1 Aircraft Manual Alternator Section for available service parts.
2.3
2.3.1
Disassembly
Remove Rear Housing Stater and Rectifier Heat Sinks Assembly from Rotor Drive End
Housing Assembly.
1.
on a
2
3
thru
ground terminal.
lock tabs when reassembling) Using a socket wrench, remove the six (6) thru bolts and Lock tabs Inspect bolts for any damage.
auxiliary terminal
3.
Replace
if
required
at
reassembly
4.
NOTE Verify removed thru-bnltfi are higl, stlength boltp as identi8ed by tile raised "Y~ mark on the heads (See Figure 2-1$) If not, the bolts must be replaced
at
reassembly. Separate rectifier-stater assembly from the slip ring end housing, pushing terminals (step 2) through the housing and remove housing
Remove remaining insulators and washers from terminals and housing. Note location to facilitate
rDassembly
2.5.3
Remove Brush
4. 6.
reassembly with the required bolts. Remove the slip ring end head bearing cover (see
paragraph 1.16).
Place alternator on wood holding block having n clearance hole far the shaft diameter (including shaft spacer) and shaft length so that it rests on the front surface of the machined circular part of drive end
(ALVW07 only) from Slip Ring End Housing. I. Using socket wrench, remove outs, washers and insulgtors from 6eld terminals Note location to
2~
3
integral
brushes.
across
bousings
of
reas-
alignment
Co
for
reassembly
ease
i.
5
Using
puller (Proto
cause
#4029
recommended,
spine damage) installed on the head end housing as shown in Figure 2-1 slip ring to prevent damage to housing, separate the slip ring end housing and stator-reetifier ;lasembly. Retl.ieve brush springs if they fall out during this operation Place the removed slip ring end head and stater assembly on a pad to protect exposed stator winding pending further disassembly
othermay
O~ ALV-9407. remove capacitor clamp screw, clamp and capacitor. Removebrush holder Bstoning hardware, ineluding brush springs if not removed
2.3.4
Remove
1. 2.
Remove
Slip Ring End Head Bearing bearing snap ring retainer using required housing in a
press with
rear
removal pliers.
Position end of hous-
ingtowards press table. Using a ik inchdiameter x 8 inch long bar on inner race oEbearingand with the end housing bearing boss area supported by a
tube 2U inch O.D x I~B inch I.D x 2 inch long, NOT HAMpress bearing from housing (DO MER). Diseard bearing. Remove hearing O-ring seal From housing and disoard seal.
2.3.6 Rotor and Drive End
3.
Separate
i. 2. 3.
4.
Housing
key
and nut.
Remove shaft
er or
drive gear
Remove woodruff
Discard seal.
5.
6.
Position assembly vertically in a press with slip ring end towards press table and housing supported above press table by twoithree vertical support plates between housing and press table and press rotoroutor Applypressl.amtoshaftend NOT HAMMER), being careful not (DO housing
to allow
housing
or
rotor to
2.3.6
Bearing
)9l~b%irl
I/B
2.
Remove three screws that secure bearing retainer and remove retainer Place housing in press as shown in Figure 2-2 and using the bearing removal tools shown, press bearing from housing (DO NOT HAMMERI Discard
bearing.
231
Remove Oil Seal from Drive End Housing Position housing in press with front of housing 1 towards press table and supported on a 2H inch I.D pipe at housing ail Heal pocket 2.
Using
and
rear
lih inch diameter bar between press ram of oil seal, press oil seal from housing
Figure
i
2.32
2-1
2.3.8 Remove Rectifier
sembly
Heat Sinks ABRemove Stater and Reotifier From Slip RingEnd Head. I. Position the assembly on holding block 2 Using socket wrench, r~mave nuts, washers and insulators from the (t) output terminal,
Assembly
This
procedure applies
or
atator
replacement
th, stator leads. The other heat sink has similar type
eonneelions.
holding each
stator lead to
Removethe
the
RBM
2.4
3/16"
C
Refer to
inspection and Testing of Removed Components paragraph 2.6 far alternator servicing and
Front and Rear
1.
testing precautions.
Housing
Cleanboth housings using DowChemical-Chloro thane VG solvent to remove grease and dirt.
I 1
9.
dry with BLtered low pressure compressed dry wipe dry with clean cloth. Inspect both housings for stripped threads, cracks on exterior and interior surfaces, and wear and corrosion in the bearing mounting slee. if anyaf the above Replacehausingatreasaembly
air
or
Air
faults
are
noted.
\BED
OF PRESS 2-2
24.2
Mounting Hardware
i.
screws,
Figure
any removed metallic hardware, i.e., lockwashers, natwashers, nuts, bearing retainer plate. bearingsnap ring retainer, shaft
Inspect
spacer,
Replace
any
2.
Hardware that will be reused shall be cleaned as required, using Dow Chemical-Chlorothene VG Air dry parts using filtered low pressure eampressed dry air or wipe dry with clean, Lint free, cloth.
2.4.3
Inspect parts
are
SULATORS). Air dry parts with filtered low pressure compressed dry air or wipe dry with clean lint free cloth.
2.4.4
RFI Capacitor (ALV-84M only) 1. Inspect capacitor far cracks in insulation and
leads. Replace capacitor at reassembly if any faults are noted. Test capacitor for a short or leakage condition
broken/damaged
2.
using
an
shortedneaky.
2.4.5
Inspectbrushholder forcracks and breaks in plasReplace if damaged, at reassembly. Inspectthe two brushandterminal assemblies for damaged terminals, insulation damage,
tic and bent metal bracket.
or oil soaked brush material and minimum brush length of 0.45 inch. Replace brushes at reassembly if any of the above faults are noted.
2.
brokenicracked
Figure
2-3
NOTE
damage rectifier, or shorten their service life. Use long nose pliers between rectifiers and solder joint as a heat sink during soldering or unsoldering operations. Complete operation as quickly as possible. A 100 watt soldering iron with clean tip is adequate
Too much heat
can
NOTE It is advisable to change brushes if length is 0.5 i"ch or less to eliminate later disassembly for bUBh 5.
Wear
replacement
springs for any spring Force. free length of about 1.2
or
Inspect
Service
1.
Unsolder all stater Leads from both rectifier-heat sink assemblies. Tag stater leads and rectifier connection point to facilitate reassembly Remove and discard metal tubing used over each rectifier pair leads and stator Lead.
springs have a inches, 0.29 inch maximum diameter and a spring force of 0.54 pounds at compressed length of 087 inches. Replace springs if they are damaged.
2.4.6
Rotor
i.
Assembly
mtor for any of the allowing faults and rotor if any are detected (with the encep-
IL
in
Inspect
replace
tien of the
step C).
Worn andlorcorroded
drive end and Loose shaft.
bearingjournal surfaces
on
Oouged, bent, cracked or excessive eormsionaf pole pieces. Bent, gouged or excessive corrosion of shaft. Slip ringswhich are roughorout of round may
lathe (do not chuck shaft on bear of slip ring., with must not exceed to journal, bearing respect 0.001 inch total indicator reading Remove
be trued in
a
ingjournals) Concentricity
to
make
slip rings
Figure 2-4
smooth and round Final surface finish shall be 50 micro-inches maximum. The finished slip ring diameter must not be Less than 1.350
inches, otherwise
sure
rotor must be
there
are no
replaced. Lnparticles on or
Size: Contents:
/la Diameter
9535D/o Tin
Spool
between
slip rings.
Clean dirty slip ring using Dow Chemical Chlorothene VD and wipe residue away with a
H. clean lint free cloth. Rurned/diseolored coil (insulation will flake off burned coil) Damaged varnish ceating is
not
Temperature:
Liquid Temperature;
Vendo. Souroe:
Cinncinnati, Ohio
or
repairable,
a.
Rotor Resistance Test i\ Using a VOM measure resistance between slip ring terminals, point A and B of Figure 2-4. DO NOT CONNECT TO SLIP 81NG SURFACE. Coil resistance should be 9.9 to 118 ohms at 20~-270C (709-80T). If resistance is higher, inspect saldered connections at slip ring terminals. Repair if
necessary
Equivalent Figure
B
2-5
Looseicracked
epoxy,
securing
slater
leads.
B.
may be removed and now epoxy (3M Co Scotcheast #10 resin) applied.
using
hightemperature solder pr
shown in
Figure 2-5 with rosin and alcohol nux. Repeat test of Part A.
the
C
3
Damaged
3 to
speci8ention
testing
Replace
D.
Usings VOM on RXloO range, measure resislance between slip ring terminal and pole piece, points A and C of Figure 2-4 Na meter
movement
Discoloration of stater windings indicatex overheating that may be caused by shorted coils or grounded winding. Perform electrical
tests
on
stater
as
specified
in step 4.
should
occur
(infmite resistance),
3.
If stater shows wear or damage to epoxy eoating of windings, the stater must be replaced. Perform electrical tests of the Positive and Negative RectiBerBeat Sink Assemblies as noted in
E.
not
touching shaft
Re4.
pair
B.
and retest
as
required.
p.ragraphs disassembly
A.
Replace
tected.
Stater testing
Using
a
per
Follows ofter
2.4.7
Rectifier-Heat Sinks and Stator Assembly 1. Inspect terminals for stripped threads henWburnt shafts. Faulty terminals require replacement,
2.
RX100 range, measure resisstater lead and bare metal surface of stater core. No meter movement should occur (infinite resistance). If a alight VOM
tame between
atatar
movement i. detected
or
scale, the
B.
stater, must be
replaced.
UsingVOMonRX1
See A.
following
required
if faults
are
(continuity) between
detected.
Broken rectifier leads require replacement of the associated rectifier-heat sink assembly. RECTIFIERS ARE NOT SERVICEABLE INDIVIDUALLY.
ohm or less otherwise replace stater. Check flexible leads for possible opens before replac-
ing
stater
2.5 2.5.1
Assembly
install Drive End Oil 8eal
i. 2. 3. Position drive end
6.
Install
a new
O-ring
position
housing
on
press table, Positlan new oil seal squarely in housing with lip towards outside of end head,
housing
into gmove of shaft collar Use a small blunt instrument to push O-ring into groove. A small amount of Dow Coming DC4 grease an the O-ring
an
seal will make installation easier. Make certain th, seal is fully installed before assembling the remainder of the drive assembly Figure i-land 2~l.haw carrect assembly of oil seal and drive end
of 1~ inch diameter bar stack, press oil seal squarely into end head to a distance of approximately L/le inch from outside face ofeaat-
Using
length
head components.
I
D. E
C*STING
housing
2.
on
press table.
Position
st of
new
bearing squarely
into
bearing pock-
housing with SEALED SIDE OF BEARING TOWARDS iNSIDE OF HOUSING. CARE MUST
BE TAKEN TO PREVENT CONTAMINATION OF BEARING. Using a 2711e inch O.D, pipe withiJ2 inch wall, press bearing into housing up to the housing
SE~LED OF
SIDE
/OIL
SEIL
BEPIRINO
-COLLIIR
bearing stop. Apply pressure to outer race only. Pressure on inner raoe will damage bearing. DO NOT HAMMER. install bearing retainer and screws Torque 25-30 inch-pounds
to Rotor
/I
jcROTOR
RING
SHPIFT
I
BEPIRINO
SE*L
2.53
Install Drive End Housing Assembly i. Lubricate oilseal lipwithChevronSRI #2 grease. 2. Position rotor assembly in press with net surface at slip ring end of shaft against a flat and true
a
surface of press. Position drive end housing and bearing assembly on rotor shaft. The bearing must be square with rotor shaft. Take care not to damage oil seal as shah passes through oil seal. Install the shaft oil seel spacer (collar) on shaft, being careful not to fold the oil seal lip under, up to contact with the bearing inner race. The collar O-ring groove should be on the outside SURFACE DAMAGE NOT TOLERABLE, SURFACE HAS
10-20 MICRO-INCH FINISH, 2.5.4
BEI\RINO/
RET*INER
Figure
2-7
4.
procedure applies
when
5.
Position
bekiring
pipe
VI inch wall
2A inch
long)
on
shaft in
contact with end of shaft roller as shown in Figure 2-6 and press bearing onto the shaft up to shaft
heat sink assemblies andior the stater assembly. Applicable steps should be used if only one of the rectifier-heat sinks is being replaced Figure 2-3 shows typical completed assembly. Use previous tug ged connecting points to insure proper wiring of stater leads to rectifiers. INDIVIDUAII RECTIFIERS ARE NOT SERVICEABLE. NOTE:
stop.
damage reetifiers or shorten their service life. Use long nose pliers between reeti8ers and solderjoint as a heat sink during soldering operutions. Complete the operation us quickly as possible consistent with producing a good solder connection A 100 watt soldering iran with clean tip is adequate. Use a high temperature solder as per Figure 2-5 with rosin
Tao much heat
can
and alcohol nux. NEVER USE ACID CORE SOLDER FOR ELECTRICAL CONNECTIONS. THE U8E OF ANY OTHER FLUX OTHER THAN RO8IN 18 PROHIBITED. 1. Withreferenccto FigurePS. form statar leadsand rectifier-heat sink rectifier leads (minimum of inch bend radius) as shown, (pre-tin stator lends) install new solder tubing over leads (apply heat sink pliers between rectifier and joint to be sol dared) and solder Repeat this until all stator lends have been connected to the positive and negative heat sink rectifiers. NOTE: The stater leads will be cemented to the heat sinks using SM Company Scatchcast Xlo resin, at aa-
sembly
to the
Figure
2-8
sinks in
with heat
2.5.5
4.
With reference to
Figures
housing
Install brushholder in end head using screws and lockwashers. Ti.hten screws to 15-20 inch pounds,
using insulators and hardware shown. The RFI capacitor used on the ALV-9407 only, should also be installed at this time, as shown in Figures
shown in
2-10A
and B.
Figure 2-8.
CA PAC I TO R
HEX-NUT
LOCKWASHER
SPACER WASHER
FLATWASHER/
Figure
2-10A
Figure
3.
2-8
Install two brush springs and brushes into holder. Depress:brushes (with leads in holder slots) and insert a small drill or metal rod through the snap ring hole to hold the brushes in place (see Figure
2-9).
OI)CCIS(IO
FI
f\F2
ni
ill
III
I
1
lo
SCREW
I YLII
DRILL
Figure
5. 6.
2-108
OR ROD
Install capacitor clamp and mount ing screw. Torque screw to 15-20 inch pounds. (ALV-9407) Apply Dow Coming #1890 sealer to clamp as shown.to secure capacitor to clamp.
(ALV-9407)
BRUSH HOLDER
7.
2.5.6
lies to
Install Stater and Rectifier-Heat Sink AssembSlip Ring End Housing I. Assemble the stater and rectifier heat sink assemblies into the end head assembly of paragraph 2.5.5 makingcertain terminals, insulators and hardware are correctly assembled as shown in Figure 2-11. Align housing and stater with previthru-bolt ous scribe marks to insure alignment of holes. Final torque of terminal nuts will be done at
complete assembly
of alternator.
~NUT-
flBERWI\SHERSJ
~HEdll SINK
1NSUL*T
AUX, TERM.
Figure
2-11
NOTE:
A. Insure thatthe stater B.
are
mating surfaces oEhausing and clean and free of any dirt, burrs or
foreign material.
If it was necessary to replace the statorirectifier heat sink(s), position the stater leads so that they will not interfere with the rotor and secure leads at six places to heat sinks with SM Company Scotchcast X10
Figure
1-12
besin, following manufacturers instructions. See Figure 25 for typical epoxy application points.
2.6.7 Assemble Rear Drive End i.
Housing-ltator Assembly to Housing and Rotor Assembly Assemble the rear hausing-stator assembly to the drive end housing and rotor assembly, aligning
the sections with
tions
previous
NOTE:
scribe marks
on
sec-
mating surfaces of housing and clean and free of any dirt, burrs or
install two thru-boltti to hold unit
foreign material.
Temporarily
together.
verify
brushes seat againstslip ringe. Visually check that brush leeds are free and cannot bind against
anything.
4.
Install
into the
rear
housin~-
bearing sleeve graove. Lubricate O-ring with Dow Coming DC-4 grease before installation.
2.6.8 install
1
Figure
2-lj
2.5.1 in arbor
press ~th net surface of drive end shaft net and true surface of press. 2
against a
2.
F2 and passes through the blast tube of the drive ,,d housing. Tighten bolts evenly, while maintaining lack tab orientation each a little bit at a time in sequence until all are tight and torqued to 30-35 inch
pounds.
3
as
shown in
3.
applicable.
to the follow-
2.5.10
Terminal
i.
Torquing
outer
race
will
4.
bearing
Sorew Size
X10-32 #1032
Torque (inchpounds)
25-30
25-30 2530 ?0-85 10-85
2.5.9
Install Thru-Bolts and Lock Tabs i. Installthe six thru-bolts and new lack tabs. Figure
2-12 shows lock tab installation atdepressed position on end head. Figure 2-13 shows lack tab installation at the five other points. The longest thru-bolt i. installed in the hole between F1 and
#10-32 k..-28
/1"-28
U..-28
?0-85
2.5.11
3.
assembly
as
outlined in
4.
Alternator output lead MUST NOT be removed from alternator with field circuit energized and
unit operating. Do not attempt to
2.5.12
Installation of Drive Shaft Shipping Hardware 1. Install #5 woodruff key on shaft. 2. Install shipping washer (ALKdO) on shaft and flush to shaft collar. 3. Install shipping spacer (GJT40C) to shaft so spacer passes over and covers key. 4. Install retaining nut on shaft hand tight. Installation of Drive Coupling 1. Refer to engine manufacturers specifications. Note that shipping washer and shipping spacer must be removed.
Follow
polarization
is
2.5.13
SO MAY RESULT IN DAMAGE TO ALTERNATOR, REGULATOR OR CIRCUITS. 5. Grounding alternator output terminal may damage alternator and/or circuit and components. 6. Reversed battery connections will damage the rectifiers, wiring or other components of charging system. Battery polarity must be checked with a voltmeter before connecting battery. Most sys7.
2.5.14
2.6
Servicing and Testing Precautions Always refer to airframe manufacturers wiring diagram when installing or testing the alternator
on
8.
the aircraft.
negative ground. battery or fast charger is used, its polarity must be connected correctly to prevent damage to the battery and electrical system. Provide adequate ventilation around battery and keep sparks and flame away from batteries. When using auxiliary power unit, make sure voltage and polarity are set to correspond with vehide system voltage and polarity.
tems
are
If
booster
2.
connecting or disvoltmeter) or (except connecting replacing any unit or wiring. For negative ground applications, disconnect the negative lead first.
Disconnect the
battery,
before
9.
test instruments
Never use acid solder for electrical connections. Rosen flux is only type permitted.
PROBABLE CAUSE
Loose te~minal connections.
2. Wornmroken brush.
3.
4.
5. 6.
7.
8.
Dirty/worn rotor slip rings. Shortlleakage from field terminals to housing. Shorted/open rotor field. Shorted/open stater windings. Shorted/open rectifiers on positive and/or negative rectifier-heat sinks. Shorted/leaky RFI capacitor ton ALV-9407 only).
NOISY ALTERNAI~OR
i. Defective
bearings
(magnetic noise).
INTERMITTENT OUTPUT
1. Worn
ALE SERIES
SERVICE PARTS LIST ALTERNATOR ISSUED:
2-18-75(Rev.)
VOLTS-1P
ORIG. EOUIP.ALTERNATOR
ENG.
SERVICE ALTERNATOR
APPLICATION
USE
ALE-64O6R
ALE-6406R
Lycoming Lycoming
Service Service
ALE-64O6R
ALE-6406RG ALE-6420 ALE-6420G ALE-6420R ALE-6420RG USE USE
USE
ALE-6406R
ALE-6420R ALE-6420R
Lycoming Lycoming
Service
Service
ALE-6420R
USE USE
USE USE USE USE
ALE-8105A
ALE-8406
ALE-8406G
ALE-8406R ALE-8406RG
ALE-8406R
ALE-8408R ALE-8408R ALE-8420R ALE-8420R ALE-8420R
ALE-8420R
Service
ALE-8408
ALE-8408R ALE-8420 ALE-8420G ALE-8420R ALE-8420RG ALE-8421 ALE-8421R
Lycoming
Service
USE
USE
Lycoming Lycaming
Service
Service
USE
USE
ALE-8421R ALE-8421R
Lycoming
Service
p.ml, i. u.r.*
ALTERNATOR SECTION
/16
7t---~
/6
o--------l
0-------7~
Exploded
View of
Typical
A1E Alternator
ISSUED: 3-5-79
8rush,Holder
S
~REvl)
I
SHEET 2
D.E.
Brush
Slip Ring
End Head
S.R.E.
IDrlve End
Head
Assembly
Assembly
Spring
Bearing
Bearing
Assembly
Assembly
Assembly
O
ALE-6406,R ALE-6406G,RG ALE-6420,R ALE-2173S-1
ALE-1 01 345
8
1 I
ALU-1045BS[b]
0
90-2396[d]
O
90-2014Ca]
O
ALE-1003K
O
X-3416
90-2396[d]
ALU-1045BS
ALK-11328S-1
ALE-6420G,RG
ALE-8105A ALE-2016
ALE-1012LS[cll
I
ALU-10458S[b]
ALE-1002LS
X-3417
ALE-8406,R
90-2396Cd]
I
I
I
I
ALE-I 01 345
90-2396[d]
90-2014Ea]
ALE-8406G,RG
ALE-8408,R ALE-8420,R ALE-8420G,RG ALE-8421,R
I
ALE-2173S-1
ALE-1045BS[b]
ALU-I WSBS
ALK-11328S-:
ALE-1045BS
Eabj
Head Assy. Bearing 5 Seal Pkg. also included with Rotor 6 S.R.E. ALE-1013AS Captive Brush 6 Spring Set also individually available for the Complete units already having this design. Earlier units must replace Brush Holder Assy. if Brushes or Springs are required. [c] Brush Set only; Brush Spring Set ALA-19S also available. be used at time of first repair. [d] S.R.E.Head 6 Rotor Pkg. Complete Package must
be used thereafter. Individual Components(See Sheet W3 for contents of Pkg.) may 35-781 (GJC-498S) Cover Pkg, (10 Pcs,) also available,
FII In Ihe
Prlntd In U.S~.
I
I
ALTERNATOR SECTION
Assembly
Assembly
Nega ti ve Rectifier
Term. Stud
D.E. Retainer
Slip Ring
(Pkg.of3)
8
90-2030
O
GR-32
d
I
Eyelet Package
O
90-818
ALE-6406,R
ALE-2008AD
ALE-1 054A
XA- 94455
ALE-6406G,RG
ALE-6420,R
ALE-6420G,RG
ALE-81 05A
ALE-2008Z ALE-POOBAD
ALE-1004
ALE-1 054A
1 1
90-2359
ALE-1062
ALE-8406,R
90-2030
ALU-1062A
ALE-8406G,RG ALE-8408,R
ALE-8420,R
ALE-8420G,RG
ALE-8421,R
SHEET 3
Drive
Pulley
Regulator
20
Packa9e
Package
O
ALE-6406,R ALE-6406G,RG
ALE-6420,R
Beer
ALD-P1
(2 Pc.)
ALA-LOJS
90-33
90-2241
PU-672A
VSF-7203S
ALE-6420G,RG
ALE-8105A
ALE-8406,R ALE-8406G,RG
ALE-8408,R ALE-8420,R
FVR-4011A
VSF-7203S
ALE-8420G,RG ALE-8421,R
FYR-4011A
Cd]
Contents of S.R.E.
Head 5 Rotor Pk
90-2396
S.R.E.
Hd.
Rotor
Pkg.
90-2014 ALK-1132BS-1
ALE-2173S-1
Bearing Pkg.
Head Assy. S.R.E.
Rotor
File in )he
Prlnkd In V.S.A.
I
I
ALTERNATOR SECTION
1
IL!
prp~fD/Ifp,
SERVICE
INFORMATION
I
ALTERNATOR DESCRIPTION
RATED VOLTAGE 12
ALE
AIRCRAFT ALTERNATORS
Issued 4/1/83
Page 1 of 4
40
Amperes
ROTATION
Bi-Directional
See Tabulation
Negative
APPROXIMATE WEIGHT
SERVICE INFORMATION
procedures covering disassembly, component testing, component replacement, assembly, and bench testing, are contained in the service publiRefer to the following service cations in the front of the Alternator Section. is required. publications when detailed service information
Detailed service
ALTERNATOR SERIES SERVICE
PUBLICATION
L-651A
ALE 8100
ALE 6400
8400
L-655A
SERVICE BULLETINS
Refer to the Service Bulletin Section of this manual to the ALE series alternators.
SERVICE SPECIFICATIONS DRIVE PULLEY
for bulletins
pertaining
nut to 35
Ft.
Lbs.
minimum to
Lbs.
maximum.
temperature
700
to
800F.
2.
Ohmmeter must be accurate and batteries must be fresh. Frequently check ohmmeter accuracy by measuring a known resistance such as a 10.0 ohm resistor. Ohnrneter must be checked to
zero
3.
4.
Slip rings and ohmmeter test probes must be clean. test probe leads must be in good condition.
Ohmmeter
Prin~ad in U.S.A.
Tech. Data
ALTERNATORS
ALE
AIRCRAFT ALTERNATORS
k
SERVICE
Issued
4/1/83
Page 2 of 4
INFORMATION
Rotor
winding resistance
Rotor to be
room
temperature
700
to
800
F.
2.
3.
publication for
test
wiring diagram.
bearing journals
Alternator to be
room
temperature
700
to
800
F.
before
beginning
2.
test.
Alternator connected so it is supplying its own field current. Refer to service publicationfor bench test
wiring diagram.
3.
Output voltage
to be controlled
run
by
an
adjustable load.
4.
Alternator not to be
test
more
point.
VENTILATION
All units except the 6400 series, use a slip ring end cover that has a hose type connection for air pressure ventilation. Remove this cover when bench testing the alternator.
SERVICE
INFORM ATION
AIRCRAFT ALTERNATORS
Issued
4/1/83
Page 3 of 4
(Without Regulator)
Output Amperage
19 32 Minimum Alternator RPM
2000 4000
Output Voltage
14.0 14.0
and 8400
Alternator
Approx Weight
R
Internal
Orig. Equip.
Regulator
VSF-7201 7203
or
Replacement
Kegu
1 a~or
Wiring
6 Oz.
ALE-6406,
10 Lb.
Figure 1
VSF-7203S
ALE-6406G, kG ALE-6420,
R
Figure 1*
Figure
1
FVR-4004+
VSF-7203 VSF-7203S
ALE-6420G, RG
ALE-8105A
Figure 1*
FVR-4OO4+
Figure
12 Oz.
2
1
ALE-8406, R
Figure
VSF-7201 7203
or
VSF-7203S
ALE-8406G, RG
10 Lb. 10 Lb.
10 Lb.
12 Oz.
Figure
1*
FVR-4004+
ALE-8408, R ALE-8420,
R
120z.
12 Oz.
Figure
Figure
3
1
VSF-7203 FVR-4004+
VSF-7203S
ALE-8420G, RG
10 Lb.
10 Lb. 1
12 Oz.
12 Oz.
Figure
Figure
1*
3
ALE-8421,
Same
as
a
VSF-7203S
with
Wico
except field terminal F-2 externally grounded Lycoming applications only. strap connector.
Figure
File in the
Printed in U.S.A.
I
j
Tech.
Data
ALTERNATORS
4/ 1/83
of 4
SERVICE
Page 4
INFORMATION
OUTPUT
DIOOES
II
srnmR
t
,I
ii I
ROTOR WINDINa
1-11
C
II
GROUNDriL
Figure 1
Figure 2
Figure
prpsto/~te,
SERVICE PARTS LIST
ALT SERES
ALTERNATOR
ISSUED:
10-19-7~YRev.)
VOLTS-24
ORIG.EaUIP.ALTERNATOR
ENG.
NUMBER
SERVICE ALTERNATOR
ENG.
NUMBER APPLICATION Franklln
ALT-SIOIA
ALT-51 02S
USE
Frankl in
ALT-8420
ALT-8421R
ALT-0404LS ALT-8404R ALT-84O4RS ALT-8407 ALT-8420 ALT-8421 ALT-8421LS ALT-8421R ALT-8421RS ALT-94O5 ALT-9422
ALT-8421RS
ALT-B421R
ALT-84 21 RS ALT-8420 ALT-8420 AL~-8421R ALT-8421RS
ALT-8421R
Teledyne Continental
USE USE
Lycoming
Service Service
USE
File
in
the
171
-t~
6
rBS-s~i
ioY4
4
4~
~G L~3
ra-----
/4
I I
Exploded View
of
Typical
ALT Alternator
ISSUED:10-19-79 (REVI)
Brush,Holder 5 Spring Assembly
SHEET 2
O.E.
Brush
Set
Slip Ring
End Head
Assembly
Assembly
S.R.E. Beari ng
Bearing
Assembly
Assembly
O
ALT-5101A
ALT-51 025 ALT-8403 90- 2397 Cel ALT-2006
O
ALE-I D1 2LSCb~
O
CNA~ CNAI
ALU-1 ALH-I 00205 ALH-I 00205
O
X-3417
O
X5077
ALE-I 033
I ALE-1 01 385[5]
Ccl
04585Ccl
90-2397Ce~
(90-2014Cal
ALE-I 003K
X-3416
ALT-8404,R ALT-84WLS,R
ALT-8407 ALT-8420
I I I
ALU-21 285-1
Ccl
Ccl
I I
Ccl
ALE-1 01 3AS
ALU-I 04585
ALK-1132AS-1
ALT-8421,R
ALT-8421LS,RS
ALT- 9405
90-2398Ce]
ALU-21 385-1
Cc~
ALE-I 01 3AS
ALU-1
045B5Cc]
90-2398Ce~
ALE-I142AAS-I
I ALU-1043Cdl
X-4087
ALT-9422
ALU-I 04585
Cover Pkg. (10 Pcs.) Also available. also included with Rotor 5 Slip Ring End Head Assy. Pkg. ALA-19S Brush Spring Set Also available. Cc] ALE-1013AS Captive Brush 5 Spring Set also individually available for units already having this design. Earlier units must replace the Complete Brush Holder Assy. if Brushes or Springs are required.
C*] 35-781(65C-4985)
[b[a3
Bearing
5 Seal
[d] XA-1026 D.E. 0i1 Seal also available. Ce] S.R.E.Head 5 Rotor Pkg. Complete Package must be used at time of first repair. Individual Components(See Sheet #3 for contents of Pkg.)may be replaced thereafter. Tn91 Hot Available,
File in the
Prlntd
In
ALTERNATOR SECTION
U.S~.
Assembly
Assembly
Negative
Rectifier
Assembly
(Pkg,of3
Thru Bolt
Eyelet
Package
O
ALT-51 01A ALT-51 025 ALT-8403
ALE-2008AA
Package
13
ALE-2008R
ALE-1004
XA- 94405
90-2359
GGW- 91
ALA-EOES
90-818
I
ALE-I 054A
I
I
II
1
1
ALA-20GS
ALT-8404,R ALT-8404LS,RS
ALT-8407
ALT-8420
90-2043
ALT-8421,R ALT-8421LS,RS
ALT- 9405
90-2030
II
90-2043
ALT-9422
ISSUED: 10-19-79(REv,)
Rotor
SHEET 3
Nut
Yent
Drive
Assembly
Cover
Washer
Shaft
Fan
Pulley
Regul ator
O
ALT-5101A ALT-51 025
ALT-8403
~4
90-33
Sp~er
(2 PC.)
o
ALH-P1A
O
90-2241
O
PU-598E YSB-7401C VSF-7403S
CNA~
CNA~
ALU-I 062
I
1 I
II
II
CNAI
CNAI
PU-672A
I ALC-P1F IALD-21
90-2259
ALT-8404, R
ALU-1 062A
90-2241
ALT-8404LS,RS
ALT-8407 ALT-8420
I
ALU-I 062
I
1
I
I ALC-S1F
I
90-2259
CNAI
[NA]
I
ALU-1 062A
I
i
I
I ALD-21
I
90-2241
~NA]
PU-672A
ALT-8421,R
ALT-8421LS,RS
ALT-9405 ALT-9422
I
CNA] CNA]
I
8X-4075Cgl
I
ALU-23Cfl
I
CNAI
I,
CNA~
[e]
Contents of S.R.E.
S.
Head
Rotor
Pkg.
90-2397 90-2398
R.
E.Head
Rotor
Pkg.
Bearing Pkg.
Head
Rotor
90-2014
E. AL K-l 1 32AS-1
Assy.,S.R.
ALU-2128S-1
ALU-2138S-1
[f] [91
[NAI
XA-744AZ Shaft Spacer 0-Ring Seal available. Nut only; Washer not required. Not available.
File in the
Prlnkd In
I
I
ALTERNATOR SECTION
1
U.S~.
presz~fP,
SERVICE
INFORMATION
ALTERNATOR DESCRIPTION
RATED VOLTAGE
R OTAT I ON Bi
ALT
AIRCRAFT ALTERNATORS
Issued:
4/1/83
of 4
Page 1
24
Di
re ct
RATED
OUTPUI
50
Amperes
ve
i ona 1
See Tabulation
GROUNDED POLARITY
Ne g a t i
APPROXIMATE WEIGHT
SERVICE
INFORMATION
procedures covering disassembly, component testing, comporeplacement, assembly and bench testing are contained in the service publications in the front of the Alternator Section. Refer to the following service publication when detailed service information is required.
Detailed service
nent
ALTERNATOR
SERIES
ALT 5100
ALT 6400 ALT 9400
L-655A
L-663 SERVICE BULLETINS
Refer to the Service Bulletin Section of this manual to the ALT series alternators.
SERVICE SPECIFICATIONS
DRIVE PULLEY
for bulletins
pertaining
Torque
to 40 Ft.
retaining
nut to 35
Ft.
Lbs.
minimum
temperature
700
to
800F.
2.
Ohmmeter must be accurate and batteries must be fresh. Frequently check ohmmeter accuracy by measuring a known resistance such as a 10.0 ohm resistor.
3. 4.
zero
Slip rings and ohmmeter test probes must be test probe leads must be in good condition.
Printed in Usn.
OF-Al
Tech.
Data
ALTERNATORS
ALTAIRCRAFT
Page
ALTERNATORS
Issued 4/1/83 2 of 4
SERVICE
INFORMATION
winding resistance
temperature
700
to
800F.
2. 3.
publication for
test
wiring diagram.
Alternator to be
room
temperature
700
to
800F.
before
beginning
test.
2.
Alternator connected so it is supplying its own field current. to service publication for bench test wiring diagram.
Refer
3.
Output voltage
to be controlled
run
by
an
adjustable load.
4.
Alternator not to be
more
point.
VENTILATION
The 8400 series alternators use a slip ring end cover that has a hose type connection for air pressure ventilation. Remove this
cover
when bench
testing
the alternator,
The 9400 series alternators are cooled entirely by air pressure through a hose type connection on the drive end head. When bench testing this type of alternator, make output tests as short
as
possible
unless
adequate
cooling
is
supplied.
ALT
SERVI%E
INFORM ATION
AIRCRAFT ALTERNATORS
Issued:
4/1/83
Page
3 of 4
(Without Regulator)
Output Amperage
20 43 17 43 Minimum Alternator RPM 3000 6000
3000 6000
Output Voltage
28.0 28.0 28.0 28.0
:?tel;~al
Figure
1
Ri
VSB-7401C
VSF-7401
Figure 2
VSF-7403S
VSF-7403S
or
Figure
VSF-7404
VSF-7402S
2 Oz.
Figure 3
VSF-7403S
VSF-7404
ALT 8404, LS, R, RS, S ALT 8407 ALT 8420 ALT 8421, LS, R, RS, S ALT 9405 12 Lb.
2 Oz.
Figure
or
VSF-7403S
12 Lb.
12 Lb.
Figure
VSF-7403S VSF-7403S
VSF-7403S
Figure 3
12 Lb.
Figure
11 Lb.
6 Oz.
Figure
VSF-7401 or VSF-7403S
VSF-7403S
ALT 9422
11 Lb,
6 Oz.
Figure
VSF-7404
VSF-7403S
File in the
Printed in U.S.A.
Tech.
Data
A LT E RNATORS
ALT
AIRCRAFT ALTERNATORS
Issued:
4/1/83
of
SERVICE
Page 4
INFBRMATION
FIELD
FI
rlELD r2
DIODES
I_11Y II
STATOR
Ip/rl
II I II II I It
II
I I
id;
ROTOR
I-II
~U
~c____i
Figure
1
Figure 2
OUTPUT
FIELD
FIELD
STP~TOR
I I
AUXI
ROTOR
WINDING
I-JI
I
PI
II
II
GROUND~i-ce
Figure 3
prest~itP.
SERVICE PARTS LIST
ALU SERIES
ALTERNATOR
ISSUED:
2-27-75(Rev.)
VOLTS-24
ORIG.E9UIP.ALTERNATOR
ENG. NUMBER ALU-8403 ALU-84O3LS ALU-8403R ALU-84O3RS ALU-8421 ALU-8421LS
USE USE USE USE USE USE
SERVICE ALTERNATOR
ENG.
APPLICATION
Lycoming Lycoming
Service Service
ALU-8421RS ALU-8421R
Lycoming
ALU-8421RS
ALU-8421R
ALU-8421RS
Lycaming
Service
ALU-8421R
ALU-8421RS ALU-9404L ALU-9404R ALU-9422L
ALU-9422R USE
Service
ALU-9404R
ALU-9404R
Lycoming
Service
USE
ALU-9422R ALU-9422R
Lycoming
Service
File
Plmn~ i. v.l.*.
in
the
ALTERNATOR SECTION
AL
List
L__
-T
____J
LfO
r--
-I
Exploded View
of
SHEET 2
D.E.
~Assembly
Assembly
Set
o
ALU-8403,R
ALU-8403LS,
o
1----
Spring Assembly
5
S.R.E.
Drive End
Bearing
Seal
Head
Bearing
Assembly
Pkg.
o
ALU-1045Bqb]
O
ALE-I003K
X-3415
90-2397[dI
90-23971~13
90-2014 Ea]
ALU-2128S-1
ALE-1013AS
ALU-1 04585
ALK-1)32AS-1
90-2398[d]
ALU-2138S-1
j
ALE-1013AS
i ALU-1045BSI~b]
ALU-1045BS
90-2398[d]
ALE-l14EAAS-1
I ALU-1043[c]
X-4087
C*] 35-781 (GJC-49BS) Cover Pkg. (10 Pea.) Also available. Seal Pkg. also included,with Rotor 5 Slip Ring End Head Assy. ~a] Bearing [b] ALE-1013AS Captive Brush Spring Set also Individually available for units
already having this design. Earlier units must replace the Complete Brush Holder Assy. if Brushes or Springs are required.
also available.
Individual components
Complete PIQSee
Package must be used at time of first repair. Sheet #3 for contents of Pkg.)may be replaced thereafter.
Prlntd In U.S.*.
ALTERNATOR SECTION
Assembly
Assembly
Pes.Rect. Plate
Negative
Rectiffer
Term Stud
S.R.E. Cover
D.E. Retainer
Thru
Bolt
Assembly
9
Pac~gqee
O
90-2030 ALU-1 062A
OPa~age
GR-32 ALA-L0GS
ALU-8403,R ALU-8403LS,RS
ALE-2008AB
ALE-1054A
XA-944JS
ALU-8421,R ALU-8421LS,RS
ALU-9404L, R ALU-9422L,R
90-2043
ISSUED:2-27-75(REv,)
Rotor
Vent.
SHEET 3
Drive
Washer
Shaft
Fan
Pulley
Regulator
Package
00
ALU-0403,K ALU-R403LS,RS
AL.U-8421 ,H 90-818
90-33
B
AL0-21
(2 Pc.)
000
PU-672A
VSF-7403S
90-2241
PU-672A
I 8X-4075[f]
ALU-23[e]
Id]
Contents
of S.R.E.
Rotor
Head
Rotor
Pkg.
90-2390
S.R.E.Head
Pkg.
90-2397
Bearing Pkg.
Head
Rotor
90-2014
90-2014 ALE-1142AAS-1
I\LIl-21 385-1
Assy.,S.R.E.
ALK-1132AS-1
4LU-212AS-1
available. Ic] XA-744AZ Shaft Spacer O-Ring also not required. Washer Nut only; [f]
File in the
Prln,d
In U.S.~.
ALTERNATOR SECTION
SERVIcE
IN FORM ATION
fP~
ALU
AIRCRAFT ALTERNATORS
Issued:
4/1/83
Page
1 of 3
Amperes
Bi-Directional
See Tabulation SERVICE
Negative
APPROXIMATE WEIGHT
INFORMATION
nent
Detailed service procedures covering disassembly, component testing, comporeplacement, assembly, and bench testing are contained in the service publications in the front of the Alternator Section. Refer to the following service publication when detailed service information is required. ALTERNATOR
SERIES
ALU 6400
ALU 9400
Refer to the Service Bulletin Section of this manual to the ALU series alternators.
SERVICE SPECIFICATIONS DRIVE PULLEY
for bulletins
pertaining
Torque
to 40
retaining
nut to 35
Ft.
Lbs.
minimum
temperature
700
to
800F.
Ohmmeter must be accurate and batteries must be fresh. Frequently check ohmmeter accuracy by measuring a known resistance such as 10.0 ohm resistor. Ohmmeter must be checked to
zero
3. 4.
Slip rings and ohmmeter test probes must be test probe leads must be in good condition.
Printed in U.S.A.
OF-Al
a~a
ALTERNATORS
ALU
AIRCRAFT ALTERNATORS
Issued 4/1/83
kPresto~rp.
SERVICE
Fage 2 of 3
INFORMATION
to
12.5 ohms.
temperature
700
to
800F.
2.
3.
publication
for test
wiring diagram.
1.350"
.002" max. measure from bearing journals 50 microinch max.
temperature
700
to
800F.
before
beginning
test. Re fe r
2.
Alternator connected so it is supplying its own field curre?t. to service publication for bench test wiring diagram.
3. 4.
Output voltage
to be controlled
run more
by
an
Alternator not to be
VENTILATION
The 8400 series alternators use a slip ring end cover that has a Remove this hose type connection for air pressure ventilation. alternator. the bench when cover testing
The 9400 series alternators are cooled entirely by air pressure through a hose type connection on the drive end head. When bench testing this type of alternator, make output tests as short as possible unless adequate air pressure for cooling is supplied.
ALU
SERVICE
INFORM ATION
ALTERNATOR OUTPUT TEST SPECIFICATIONS
Alternator Series
4/1/83
Page
3 of 3
(Without Regulator)
Output
Amperage
23.0 61.0 21.0 60.0 Minimum Alternator RPM 4000 8000
Output
Voltage
28.0 28.0 28.0 28.0
ALU 9400
4000
8000
Alternator ALU-6404
ALU-8401
Approx. Weight
11 Lb.
Replacement Regulator
VSF-7403S
VSF-7404 VSF-7401
VSF-7403 VSF-7403 VSF-7403 VSF-7403
VSF-7403S VSF-7403S
VSF-7403S VSF-7403S VSF-7403S
ALU-94O4, L, R
ALU-9422, L, R
11 Lb.
6 Oz.
OUTPUT
DIODES
Inl
II;I
ST~mR
ROTORWINDING
I-t
Ij/ I I/I
)II
I
File in the
Printed in U.S.A.
Tech.
Data
ALTERNAIORS
prest~/itP,
SERVICE PARTS LIST
ALTERNATORS
ISSUEO:
11-10-82
(Rev.)
ORIG.E~UIP.ALTERNATOR
PART NUMBER
SERVICE ALTERNATOR
VOLTS-24
PART NUMBER
USE USE USE
APPLICATION
ALV-6403LS
ALV-6403RS
ALV-84O2 ALV-8402L
ALV-8511 ALV-8511R
Lycoming
Service Alternator
USE
USE
ALV-8511R
ALV-8511R
ALV-8511R
USE USE USE USE USE
ALV-8512 ALV-8512R
ALV-9401
ALV-8512R
Lycoming
Service Alternator
ALV-8512R
ALV-951OR ALV-9510R
ALV-951oR
ALV-9405R ALV-9405R
ALV-9406R ALV-9406R ALV-9510R ALV-9510R
Al ternator
Lycoming
Service Alternator
USE
Lycoming
Service Alternator
Teledyne Cent.
Service Alternator
USE
USE
ALV-9510R
ALV-9510R ALV-951OR
Lycoming
Service Alternator
ALV-951OR
NOTE:
SEE TABLE FOR ALTERNATOR BEING SERVICED WHEN COMPONENT PARTS ARE REOUIRED.
File in the
,1111 1 u.r.*.
ALTERNATOR SECTION
Ls
21
[a] -t~
5
22
L
I
_I
(18\
IOC~M
b~-"L
16
(ri\
0~
r\ 14
L~ G~
(4
3r
I3
1615
Exploded View
of
SHEET 2
Stater
Assembly
Assembly
Brush Set
Bearing
Assembly
D.E.
Bearing
Assembly
II
ALV-6403LS ALV-6403RS ALV-8402
ALV-8402L
(2)
ALV-1012S
(3)
ALV-1022S
(4)
X-4087
(5)
ALB-20D3A
(6)
X-4086
~7
ALV-2008AS
ALV-2026AS
ALV-1O22BS
X-3626A
ALE-20038
ALV-9401 ALV-9401L ALV-9401R ALV-9405L ALV-9405R ALV-9406L ALV-94O6R ALV-9407 ALV-9407S ALV-951a
ALV-9510L
ALV-2006AS
ALV-1O02S
X-4087
ALV-1003Ca]
ALV-1003A[a]
ALV-1003~a]
ALV-1002AS
ALV-1102AS
X-3626A
ALV-1003[a]
ALV-95l0R
[al
XA-l441
D.E.
File in the
Prlnld In V;S.~.
ALTERNATOR SECTION
Brush
Spring
Set
Neg. Rect.&
Plate
Vent. Cover
S.R.E.
I
1
Bearing
Co
S.R.E. Retainer
Assembly
AsLembly
Assembly
Assembly
121
8\
(9~
(10
O
ALV-1004A
(13
Ib]
GR-32
ALV-6403LS
ALV-1OI5
AMA-I 9S
ALV-1004
[NR]
GJT-47
ALV-6403RS
A~\l-8402
I
1
I
I
I
1
I
I
I
I
CNR]
ACV-I 031
ALV-8402L
ALV-8511
ALV-8511R
I i I
I I
I i
I~
I i
I
I I
~NRI
[NR] CNRI
CNR~
I
I I I
M
I
I I I I I
I
I I
~I
I
I I I
II
[NR~
[NR~
I I I I
I I
CNR]
GR-32
[NR]
CNRI [NR]
[NR]
ALV-1031
ALV-9405L
ALV-9405R ALV-9406L ALV-9406R ALV-9407
I
i
I I
i I
I I
CNRI
~NRI
ALV-9407S
ALV-95~0
ALV-9510L
i I
j I 1 I I
II
[NR~
INRI CNR]
I I
[NR]
ALV-9510R
[NR]
CNR]
Ib~
CNR~
at
Shaft.
SHEET 3
Nut
Washer Pa ge
Eyelet
Package
Pa
Thru
Bolt
Bearing
0
Ring
1
20
O
ALV-6403LS
ALV-6403RS
PacJ~pge
Pa~age
ge
O
90-2040
MES-98S
19
21
[NR] ~NR]
[NR] [NR]
90-818
ALB-POAS
XA-744AB
90-33
ALV-8402 ALV-8402L
ALV-8511
[NR] [NR]
XA- 540S
ALV-8511R ALV-8512
ALV-8512R ALV-9401
[NR]
[NR]
[NR]
90-2046
ALB-20AS-1
XA-744AB
8X-4075[c]
ALV-9401L
ALV-9401R ALV-9405L ALV-9405R
CNR]
CNR]
CNRI
[NRI
ALV-9406L
ALV-9406R
ALV-9407 ALV-9407S
[NR]
CNR]
ALV-1038S
90-2040
90-2046
ALV-9510
ALV-9510L ALV-9510R
ALV-1038S
XA-1540S
~cl [NR]
Nut Not
only; Washer
not
required.
required.
File in the
Prlntd In U.S.A.
ALTERNATOR SECTION
Regulator (24
22)
ALV-6403LS
ALE-21
(23)
PU-1609A
VSF-7403S
ALV-6403RS
ALV-8402
Cd]"
[NRI
I I I
N
I I I I I I
I
ALV-9406R
ALV-9407
ALV-9407S
90-2822[e1l
[NRI [NR]
I I
[NRI
Spacer only.
Seal
is also available.
~e] [NR]
required.
presto~-fP.
SERVICE
INFORM ATION
ALV
AIRCRAFT ALTERNATORS Issued:
4/1/83
Page
1 of 3
ALTERNATOR DESCRIPTION
24
RATED OUTPUT
100
Amperes
Bi-Directional
See Tabulation
GROUNDEDPOLARITY
Insulated System
APPROXIMATE WEIGHT
SERVICE INFORMATION
procedure covering disassembly, component testing, component replacement, assembly, and bench testing, are contained in the service publiRefer to the following cations in the front of the Alternator Section. is required. information service service publications when detailed
Detailed service ALTERNATOR SERIES SERVICE PUBLICATION 8400 L-664 L-670 L-68O
SERVICE BULLETINS
Refer to the Service Bulletin Section of this manual to the ALV series alternators. SERVICE SPECIFICATIONS
DRIVE PULLEY
for bulletins
pertaining
pulley retaining
Lbs.
gear
nut to 35
Ft.
Lbs.
maximum.
DRIVE GEAR
retaining
maximum.
nut to
37
Ft.
Lbs.
Lbs.
temperature
700
to
800F.
2.
Ohmmeter must be accurate and batteries must be fresh. Frequently check ohmmeter accuracy by measuring a known resistance such as a 10.0 ohm resistor.
Ohmmeter must be checked to
test.
zero
3.
File in the
Printed in U.S.A.
Tech.
Data
ALTERNATORS
ALVAIRCRAFT
Iss ued:
ALTERNATORS
411/83
SERVICE
Page 2 of 3
INFORMATION
Slip rings and ohmmeter test probes must probe leads must be in good condition.
be clean.
Ohmmeter test
winding resistance
Rotor to be
room
temperature
700
to
800F.
2. 3.
wiring diagram.
ROTOR CURRENT DRAW TEST SPECIFICATION Current draw at 24.0 volts SLIP RING REFINISHING
Alternator to be
room
temperature
700
to
800F.
before
beginning
test.
2.
Alternator connected so it is supplying its own field current. to service publication for bench test wiring diagram.
Refer
3.
Output voltage
to be controlled
by
an
adjustable load.
VENTILATION
The 8400 series alternators use a slip ring endcover that has a hose type connection for air pressure ventilation. Remove this
cover
The 9400 and 9500 series alternators are cooled entirely by air pressure through a hose type connection on the drive end head. When bench testing this type of alternator, make output tests as short as possible unless adequate air pressure for cooling is
supplied.
A LV
a
SERVICE
I N FO RMATI ON
ALTERNATOR OUTPUT TEST SPECIFICATIONS
4/1/83
Page
3 of 3
(Without Regulator)
Output Pn~perage
53.0 88.0 48.0 83.0 Minimum
Rlternator RPR
Outp
Yolt~ge
28.0 28.0
ALV 6400-8400-8500
3000 6000
ALV 9400
9500
28.0 28.0
3000 6000
Alternator
Approx. Weight
20 20 21 21 20 21 21 22 21 21
Lb. Lb. Lb. Lb. Lb.
Replacement Regulator
VSF-7403S VSF-7403S VSF-7403S VSF-7403S VSF-7403S VSF 7403S VSF-7403S VSF-7403S VSF-7403S VSF-7403S
ALV-6403LS, RS
ALV-64O4
ALV-8402, L ALV-8511, R
ALV-8512.
R
or
7404
10 10 10 10 10
or
7404
or
7404
OUTPUT
FIELD
F2
FIail
_j
Internal
GROUND
AUXILIARY
AU~J
Wiring Diagram
File in the
Printed in U.S.A.
Tech. Data
ALTERNATORS
presto/itP.
SERVICE PARTS LIST
ALX SERIES
ALTERNATOR
ISSUED:10-19-79
(Rev.)
ORIG.EOUIP. ALTERNATOR
ENG.
VOLTS-1P
NUMBER
APPLICATION
Lycoming
Lycoming Lycoming
Lycoming
Service Service Service Service
ALX-8421R
ALX-8421RS ALX-8421 RS ALX-8421R ALX-8421R ALX-8421RS
ALX-8403RS ALX-8403RSG
ALX-8421
ALX-8421G
USE
USE
USE
ALX-8421LS ALX-8421LSG ALX-8421R ALX-8421RG ALX-8421RS ALX-8421RSG ALX-9402 ALX-94O4L ALX-9404LG ALX-9404R ALX-9404RG ALX-9405
ALX-9422L
USE
USE
ALX-8421RS ALX-8421R
ALX-8421R ALX-8421RS
Service
ALX-9424
ALX-9422R
ALX-9422LG
ALX-9422R ALX-9422RG
ALX-9424
Lycoming
Service Service
ALX-9425 ALX-9425A
ALX-9425B
ALX-9421
ALX-9425R
Teledyne Continental
Teledvne Continental
File in the
Plilld In UI.*
20
17
Ed]~
14
16
~"10
hbb
io
o~
-------II I
r-
Qg~l
I I
Exploded View
of
ISSUED 110-19-79(REY,
Brush,Holder Spring
SHEET 2
D.E.
Brush
Set
Slip Ring
End Head
S.R.E.
Orive End
Head
Assembly
Assembly
Bearing&
Seal
Bearing
O
ALX-6408 ALX-6423
O
ALE-1013AS
*ri~bly
ALU-1O45BS
Asiy
Pkg.0
ALE-1003R
O
X-3416
90-2399[e]
ALH-L1 28S-1
90-2399[eI
90-2014[a]
I
Cc]
I
ALU-1045BSCc]
ALK-1132AS-1
ALX-8403,R ALX-8403G,RG
ALX-8403LS,RS
ALX-84O3LSG
90-2399Ce]
90-2399[e]
ALE-1003K
I I I I
ALH-2128S-1
I I I I
[c3
[c3
Ccl Cc]
ALE-1013AS
ALU-1045BS
ALX-8403RSG ALX-8421,R
ALK-1132AS-1
ALX-8421G,RG ALX-8421iS,RS
ALX-842LLSG ALX-8421RSG ALX-9402
90-2409[e] 90-2400[e]
1
[cl
I
ALU-1045BS[c]
90-2409[e]
1
1
j
I
ALU-1003
ALX-9404L,R ALX-9404LG,RG
ALX-9405
90-2400[e]
ALU-1O43[d]
X-4087
I
90-2401[e]
ALH-2138S-1
[c3
Cc]
ALE-1013AS
I
ALU-1O45BS
90-2401[e]
ALE-ll42AAS-1
ALX-9422L,R
ALX-9422LG,RG
ALX-9424 ALX-9425 ALX-9425A ALX-9425B
ALX-2138S-1
ALH-2206S-l[b]
~I
ALU-I 003
X-5398
Ea] b]
S.R.E.Head Assy. Seal Pkg. also included with Rotor Bearing Fan Assembly. Rotor,Bearing Spring Set also individually available for units re] ALE-1013AS Captive Brush the Complete Brush already having this design. Earlier units must replace Holder Assy. if Brushes or Springs are required. if required. [dl XA-1026 D.E. Oil Seal also individually available must be used at time of first repair. Package Rotor Complete Pkg. S.R.E.Head [e] of Pkg.)maybe replaced thereafter. Individual Components(See Sheet #3 for GJC-49BS Cover Pkg.
C*]
(10 Pc.)
Also available.
File in the
Prlnld In
ALTERNATOR SECTION
U.S~.
Assembly
Assembly
Pos.Rect. Plate
Negative
Rectifier
Term. Stud
S.R.E. Cover
Thru Bolt
D.E.
O
ALX-6408 ALX-6423
Assembly
(Pkg.of 3)
Retainer
O
ALE-1 054A
Package
O
XA-944JS
O
90-2043
O
[NA]
Package
O
ALA-POGS
O
GR-32
ALE-2008AB
I
I
I
I
I
1
90-2030
[NA]
ALU-1062A
ALX-8403,R
ALX-8403G,RG
ALX-8403LS,RS
ALX-8403LSG ALX-8403RSG
ALX-8421,R
ALX-8421G,RG
ALX-8421LS,RS
ALX-8421LSG
ALX-8421RSG ALX-9402
It
90-2043
ALX-1 062S
ALX-9404L, R ALX-9404LG,RG
ALX-9405
I I
I I
I I
I
I
I
I I
I
ALX-9422L, R
I I
I I I
11
I 1
I I
I I
I I
ALX-9422LG,RG
ALX-9424
ALX-9425
t
I
ALX-9425A
ALX-9425B
CNA]
Not Available.
ISSUED: 10-19-79(REv,)
Nut& Washer
Rotor Vent
SHEET 3
Regulator
Assembly
Ring
Seal
Eyelet Package
Drive
Shaft
Fan
Pulley
Package
Spacer
O
ALX-6408 ALX-6423
O
90-818
90-33
O
9n-2259Cf] [NA~ 1
O
VSF-7203S
ALC-ZIF
I
I
I
I
I
I
II
I
I I I
II
I
I I I
CNAI
PU-672A
II
ALX-8403,R
ALX-8403G,RG ALX-8403LS, RS
ALX-8403LSG ALX-9403RSG
ALD-21
II
90-2241[f]
II
I I I
I I I
I I I
II
II
[NA~ [NAI
II
II
[NA~ [NA]
[NA]
I
I I I I I
I
I
I I I I
I
I CNA] 8X-4075ChI
II
I
I I I I I
II
I
I I I
I
I I I I I
[NA~
PU-672A
ALX-8421,R ALX-8421G,RG
ALX-8421 LS,RS ALX-8421 LSG ALX-8421 RSG
ALX-9402
VSF-7203S
I
[NAI CNAI [NAI
CNA~
FYR-4011A VSF-7203S
FVR-4Dl1A
[NAI CNA]
CNA] [NA]
XA-744AZ
II
II
~I
CNA]
ALU-23
ALP-I
034[91
VSF-7204
VSF-7203S
ALX-9404L, R
ENAI
[NA] [NA]
ALX-9404LG,RG
ALX-9405
1
I
I
I
II
I
I
I
I
II
I I
[NA]
FVR-4011A VSF-7203S
II
II
II
I ALP-1034Cg]
[NA]
[NA]
ALX-94221., R
I I
I
CNA]
I I
I
I I
II
I
I
I I
II
I I
I
II
ALX-9422LG,RG
ALX-9424
ALX-9425
II
II
I
I
I I
FVR-4011A
VSF-72035
II
II
II
I ALP-1034Cgl
I
I I
[NAI
CNA]
[NAI [NA~
[NA]
CNAl
CNAI
ALX-9425A
ALX-9425B
[NA] [NA]
[NAI
[NA]
Cel
S.
Contents of S.R.E. R.
Head
Rotor Pk
E.Head
Rotor
Pkg.
90-2399
90-2400 90-2014
90-2401 90-2014
90-2409 90-2014
Bearing Pkg.
Head Assy.,S.R.E.
Rotor
90-2014
ALK-1132AS-1 ALH-2128S-1
ALE-1142AAS-I
ALH-2138S-1
ALE-ll4SAAS-1
ALX-2138S-1
ALE-ll4ZAAS-1
1ALH-2206S-1
CNAI Not Available. Cf] Two(Z) Piece Fan Assy. [gl Also included with Rotor. [h] Nut only; Washer not required.
File in the
Plin)d In U.S.*.
ALTERNATOR SECTION
1/
ALX SERVICE
AIRCRAFT ALTERNATORS
Issued:
4/1/83
INFORMATION
ALTERNATOR DESCRIPTION
RATED VOLTAGE
Page
1 of 4
12
RATED OUTPUT
70
Amperes
ROTATION
Bi-Directional
See Tabulation
GROUNDED POLARITY
Negative
APPROXIMATE WEIGHT
INFORMATION
procedures covering disassembly, component testing, comporeplacement, assembly and bench testing are contained in the service Refer to the following publications in the front of the Alternator Section. service publication when detailed service information is required.
nent
SERVICE
PUBLICATION
8400
L-655A
L-663
SERVICE BULLETINS
Refer to the Service Bulletin Section of this manual the ALX series alternators.
for bulletins
pertaining
to
SERVICE SPECIFICATIONS
DRIVE PULLEY
nut to 35
Ft.
Lbs.
minimum to
maximum.
Rotor to be
room
temperature
700
to
800F.
2.
Ohmmeter must be accurate and batteries must be fresh. Frequently check ohmmeter accuracy by measuring a known resistance such as 10.0 ohm resistor. Ohmmeter must be checked to
zero
3. 4.
and ohmmeter test probes must be clean. leads must be in good condition.
Ohmmeter
winding
resistance
Printed in U.S.A.
Tech.
Data
ALTERNATORS
Al X
k
SERVICE
4/1/83
Page
2 of 4
INFORMATION
CONDITI6NS
temperature
room
700
to
800F.
2.
3.
publication for
test
wiring diagram.
measure
max.
from
bearing journals
50 microinch
Alternator to be
room
temperature
700
to
800F.
before
beginning
test.
2.
Alternator connected so it is supplying its own field current. to service publication for bench test wiring diagram.
Refer
3.
Output voltage
to be controlled
run more
by
an
adjustable load.
4.
Alternator not to be
point.
VENTILATION
The 8400 series alternators use a slip ring end cover that has a hose type connection for air pressure ventilation. Remove this cover when bench testing the alternator. The 9400 series alternators are cooled entirely by air pressure through a hose type connection on the drive end head. When bench testing this type of alternator, make output tests as short as possible unless adequate air pressure for cooling is supplied.
(Without Regulator)
Output
Amperage
33.0 57.0
Output Voltage
14.0 14.0
prasto/ire.~--SERVICE
INFORM ATION
AIRCRAFT ALTERNATORS
Issued:
4/1/83
Page
3 of 4
Alternator
Approx. Weight
11 Lb. 12 Oz.
Origl Equip.
Regulator
VSF-7203S VSF-7204
VSF-7204
or
Keguia~or
ALX 6406
VSF-7203S
ALX 6408
11
11
Lb.
Lb.
12 Oz.
VSF-7203S
ALX 6423
ALX 8403, LS, R, RS
*ALX 84036, LSG, RG, RSG
12 Oz.
2 Oz.
VSF-7204
VSF-7201
or
VSF-7203S
VSF-7203S
12 Lb.
VSF-7203
12 Lb.
2 Oz.
FVR-4O04+
FVR-4011+
12
Lb.
2 Oz.
or
VSF-7203S
12 Lb.
2 Oz.
FVR-4011+
11
11
Lb. Lb.
6 Oz.
6 Oz.
VSF-7203S
or
VSF-7203S
RG
11 11
Lb.
Lb.
6 Oz.
6 Oz.
FVR-4011+
VSF-7203S
VSF-7204
ALX 9422L,
R 11
Lb. Lb.
6 Oz.
6 Oz. 6 Oz.
VSF-7203 FVR-4O04+
VSF-7204
RG
11
11 Lb.
ALX 9425, A, B
11 Lb.
same
6 Oz.
as
VSF-7204
VSF-7203S
Internal wiring
grounded with
Wico
Field terminal F-2 externally shown. Lycoming applications only. strap connector.
File in the
Printed in U.S.A.
TECH. DATA
ALTERNATORS
AZRCRAFT
Issued:
XLASRO~ANRETLA
4/1/83
4 of 4
presro/ite.
SERVICE
INFORMATION
Page
OUtPVT
FIELD rl
FIELD
DIODES
STITOII
I_ II
It
\rf
I
AUXIL~RJ,
II I It
ii
presto/ire,
SERVICE PARTS LIST
ALY-6403 To 642iP RG
ALTERNATOR ISSUED:
3-3-75(Rev.)
VOLTS-IF
ORIG.EOUIP.ALTERNATOR
ENG.
NUMBER
ALY-6403 ALY-6403G ALY-6403R ALY-64O3RG ALY-6406 ALY-64OSG ALY-640BR ALY-6406RG ALY-64O8
APPLICATION
Lycoming Lycomfng
Service Service
ALY-642OR
ALY-6406R
Lycoming Lycoming
Service Service
ALY-6406R
ALY-6406R ALY-6406R
ALY-64O9
ALY-6412
ALY-64F1 ALY-5422
ALY-64F5
ALY-6420R ALY-6420R
ALY-6420 ALY-642OG
ALY-6420R ALY-6420RG ALY-6421 ALY-6422
ALY-6425
ALY-6420R
USE ALY-6420R
ALY-6421
ALY-6422
ALY-6425 USE USE
Piper Piper
Teledyne Continental
ALY-6427
ALY-6427G ALY-6427R ALY-6427RG
Lycoming Lycoming
Service
Service
USE
File in the
Pas, in u.S.*.
ALTERNATOR SECTION
~-----O
B
10
g-@
II
0----------~
c/
Exploded View
of
ISSUED: 11-6-79(REVI)
Slip Ring
End Head
S.R.E.
Drive
SHEET 2
D.E.
Brush
Br.,Holder
Assembly
Assembly
Set
Spring Assembly
Assembly
End Head
Bearing
Assembly
O
ALY-6003,R
O
ALE-1013AS
O
ALU-1045BS
0
90-2396[c1
O
90-2014Ea]
O
ALE-1003K
O
X-3416
90-2396[c]
ALY-6403G,RG
ALY-6406,R
[5]
ALU-1
0458SCb]
ALY-6406G,RG
ALY-6408
I
I 90-2402[c~
I
I
~b]
Cb~ Cb~ [b]
ALE-1 01 3AS
ALE-I
0458SCbI
ALY-6409 ALr-6412
1
ALU-1
1
0458SCb]
90-2402[c] 90-2396[c~
ALK-1132BS-1
90-2396[c]
ALE-2173S-1
I
I
ALE-1003R ALE-1003K
ALY-6420,R
ALU-1 04585
ALY-6420G,RG
ALY-6421 ALY-6422 ALY-6425
I
ALE-2177S-1 ALE-2173S-1
AL E-l 04585
ALU-1045BS
ALE-1003R kLE-1003K
ALY-6427,R
ALY-6427G,RG
E:3
Cover Pkg.10 Pcs.) Also available. Pkg. also ~nclided with Rotor 8 S.R.E.Hd. Assy. Spring Set also individually available for [b] ALE-1013AS Captive Brush the units already having this design. Earlier units must replace Complete Brush Holder Assy. if Brushes or Springs are required. Rotor Pkg. complete Package must be used at time of [cl S.R.E.Head #3 for contents of Pkg.) first repair. Individual Components(See thereafter. may be replaced
35-781
(GJC-49BS)
Seal
Bearing
File in the
Printd In U.s.*.
ALTERNATOR SECTION
Assembly
Assembly
Pos.Rect. 6 Plate As
Negative
Rectifier
Terminal Stud
Thru Bolt
O
ALY-6403, R ALY-6403G,RG ALY-6406,R ALY-6406G,RG
ALY-6408 ALY-6409
(Pkg.of 3)
Eyelet Package
Package
8
ALE-1 054A XA-944JS
O
90-2030
Package
O
61-32
O
ALA-P0JS
O
90-818
ALE-2008AE
90-2043
ALY-6412
ALY-6420,R ALY-6420G,RG
ALY-6421 ALY-6422
90-2030
90-2043
ALY-6425
ALY-6427,R ALY-6427G,RG
90-2030
ISSUED: ll-6-79(REv,)
Rotor Shaft Vent. Fan Drive
SHEET 3
Assembly
Cover
Nut Washer
Pulley
Regulator
Package
Spacer
(2 Pc.)
18
O
ALY-6403,R
O
90-33
ENAI
ALD-LI
90-2241
PU-672A
VSF-7203S
ALY-6403G,RG
ALY-6406, R
ALY-64D6G,RG
ALY-6408 ALY-6409
[NA]
[NA: CNA~
I
I
I
I
I
I
I
I
PU-676A
FYR-4011A
YSF-7203S FVR-4011A
I
I I
I I
I
I
ALD-P1A ALC-21F
ALD-21
I
I I
90-2259 90-2241 PU-672A
PU-692A
[NAI [NA]
CNA] [NA] CNAI
I I
I I
FVR-4024 FVR-4324
ALY-6412
CNA]
PU-672A
VSF-7203S
VSF-7203S
ALY-6420, R ALY-6420G,RG
ALY-6421
ALY-6422
FVR-4011A FYR-4024
FVR-4324
VSF-7203S VSF-7203S
I
I j I
I
I I I
ALD-ZIA
ALC-PLF ALD-21
I
I
90-2259
I
I
PU-692A
ALY-6425
CNA]
PU-676A
ALY-6427,R ALY-6427G,RG
90-2241
FVR-4DllA
[c]
Contents of
S.R.E1
Rotor
Head
Rotor
Pkg.
90-2402 90-2014
S.R.E.Head
Pkg.
90-2396
Bearing Pkg.
Head
Rotor
Assy.,S.R.E.
ALK-1132BS-1 ALE-2177S-1
[NA]
Not Available.
File in the
Prlntd In U.S.~.
ALTERNATOR SECTION
prP~ro/ite,
SERVICF CARTS LIST
ALY-8402
ALTERNATOR
ISSUED:
To
8426RG
3-3-75(Rev.)
VOLTS-IE
ORIG.E4UIP.ALTERNATOR
ENG.
NUMBER ALY-8402 ALY-8403 ALY-8403G USE
USE
SERVICE ALTERNATOR
ENG.
NUMBER
ALY-8411
ALY-8420R
ALY-8403LS
ALY-8403LSG ALY-8403R
ALY-8420R
ALY-84O3RS
ALY-8403RS
ALY-8420R
ALY-8420R
ALY-8403RS
ALY-8403RS ALY-8426R
ALY-8426R
Lycoming
Lycoming
Service
ALY-8405RG ALY-8410
ALY-8410R
Service
Lycoming
Service
ALY-8411
USE USE
USE
ALY-8420R
ALY-8420R ALY-8420RS
USE
Lycoming
Service
USE
USE
ALY-8426R
ALY-8426R
ALY-8426R
ALY-8426RG
USE
ALY-8426R
Service
File in the
OE-AI AIRCRAFT MANUPIL
I,
~----O
io
9-@
II
0------------~
~3
;P7
ISSUED:II.-6-79(REV,
Slip Ring
End Head
S.R.E. Drive End
SHEET
D.E.
Br.,Holder
Assembly
Assembly
Set
Spring Assembly
O
ALY-8402
O
[b]
O
ALU-I045BS[b]
*i~,"
ly
Seal
Bearing Pkg.
Head
Bearing
Assembly
O
90-2014[a]
O
ALE-1 003K
O
X-3416
90-2396[c]
90-2396[c]
ALY-8403,R ALY-8403G,RG
I I I I
[b]
[b]
ALY-8403LS, RSI
ALY-8403LSG ALY-8403RSG ALY-8405,R
[b]
Cb]
[6] Cb] Cb] [b] [b]
ALE-1013AS ALE-1
I I
I I
I I I I
I
ALE-2173S-1
ALY-8405G,RG
ALY-8410, R
ALY-8411
04585[ b]
ALV-1045BS
ALY-8420,R
ALK-1132BS-1
ALY-8420G,RG
ALY-8420LS,
ALY-8420LSG
ALY-8420RSG
ALY-8423,R
ALY-8424
I
I
I
I
ALE-1045BS
I ALU-1045BS
ALY-8426,R
ALY-8426G,RG
Ea*3
[b] [c]
Cover Pkg. (10 Pee.) Also PKS. also Included with Rotor Spring Set also individually available for ALE-1013AS Captive Brush units already having this design. Earlier units must replace the Complete Brush Holder Assy. if Brushes or Springs are required. Rotor Pkg. Complete Package must be used at first repair. S.R.E.Head of Pkg.)may be Individual components(See Sheet #3 for 35-781
(GJC-49BS~
a seal
Bearing
replaced thereafter.
File in the
Pllnld In U.S.*.
ALTERNATOR SECTION
Assembly
Assembly
Negative
Rectifier
Terminal Stud
D.E. Retainer
Thru Bolt
Eyelet Package
Assembly
(Pkg.of3)
Package
8
ALY-8402 ALE-2008AE
ALE-1054A XA-944JS
O
GR-32
Package
O
ALA-PDJS
90-818
90-2043
ALY-8403,R
ALY-8403G,RG ALY-8403LS,RS
ALY-8403LSG
90-2030
ALY-8403RSG
ALY-8405,R
ALY-8405G,RG ALY-8410,R
ALY-8411
90-2043
90-2030
ALY-8420,R ALY-8420G,RG
ALY-8420LS,RS
ALY-8420LSG ALY-8420RSG
ALY-8423,R
ALY-8424
90-2043 90-2030
ALY-8426,R
ALY-8425G,RG
ISSUED: 11-6-79(REV,)
Vent. Drive
SHEET 3
Assembly
Cover
Washer
Shaft
Fan
Pulley
Regua Itor
Packagecer
(2 Pc.)
O
ALY-8402
O
90-2259 90-2241
O
VSF-7203S YSF-7203S
ALU-1 062
ALU-I 062A
90-33
ALC-P1F
CNAI
PU-672A
ALY-8403,R
ALY-8403G,RG ALY-8403LS,RS
ALY-8403LSG
ALY-8403RSG
I
II
ALD-P1
II
I
I
I
I
ALU-I 0620
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
II
I
I
I
I
I
I
CNAI
CNAI CNAI
PU-672A
n
FVR-4OI1A
VSF-7203S
II
I~
II
II
~I
II
FVR-4011 A
VSF-7203S
I
ALU-I 062A ALU-1 062 ALU-I 062A
I
I
1
I
f
I
I
I
I
I
I
I
FYR-4011A
FYR-4324
ALC-21F ALD-L1
I
90-2259
CNAI
PU-672A
VSF-7203S
VSF-7203S
ALY-8420,R
ALY-8420G,RG
90-2241
n
I I I I
I I I I
I I I I
I I I I
I I I I
CNA] CNAI
CNAI
PU-672A
FVR-4011A
VSF-7203S
ALY-8420LS,RS
ALY-8420LSG
FYR-4011A
ALY-8420RSG
ALY-8423, R
ALY-8424
I
ALU-1 062
I
1
1
I
I
I
ALC-21F
ALD-L1
II
I
90-2259
90-2241
FVR-4324
CNA~
i
PU-672A
YSF-7203S VSF-7203S
ALY-8426,R
ALU-I 0620
ALY-8426G,RG
II
FYR-4O11A
[cl
contents of S.R.E.
Head
Rotor
90-2396 90-2014
Bearing Pkg.
Head Rotor
Assy.,S.R.E.
ALK-ll3ZBS-I
ALE-2173S-1
CNAI
Not Available.
File in the
Plin~d In U.S~.
ALTERNATOR SECTION
presr~re.
SERVICE INFORMATION
ALY
AIRCRAFT ALTERNATORS
Issued:
4/1/83
Page
1 of 4
RATED
OUTPUT
60
Amperes
Bi-Directional
See Tabulation
GROUNDEDPOLARITY
Negative
APPROXIMATE WEIGHT
SERVICE INFORMATION
nent
covering disassembly, component testing, comporeplacement, assembly and bench testing are contained in the service publications in the front of the Alternator Section. Refer to the following service publication when detailed service information is required.
Detailed service procedures
ALTERNATOR SERIES
ALY 6400 8400 SERVICE PUBLICATION L-655A
SERVICE BULLETINS Refer to the Service Bulletin Section of this manual to the ALY series alternators. SERVICE SPECIFICATIONS DRIVE PULLEY
nut to 35
Ft.
Lbs.
minimum to
maximum.
Rotor to be
room
temperature
700
to
800F.
Ohmmeter must be accurate and batteries must be fresh. Frequently check ohmmeter accuracy by measuring a known resistance such as 10.0 ohm resistor. Ohmmeter must be checked to
zero
3.
4.
leads must
winding resistance
Printed in U.S.A.
Tech.
Data
ALTERNATORS
ALYAIRCRAFT
Issued:
ALTERNATORS
4/1/83
SERVICE INFORMATION
Page 2 of 4
temperature 700
to
800F.
2.
3.
publication
for test
wiring diagram.
measure max.
from
bearing journals
50 microinch
Alternator to be
room
temperature 700
to
800F.
before
beginning
test.
2.
Alternator connected so it is supplying its own field current. to service publication for bench test wiring diagram.
Refer
3. 4.
Output voltage
to be controlled
run more
by
an
adjustable load.
Alternator not to be
point.
VENTILATION
The 8400 series alternators use a slip ring end cover that has a Remove this hose type connection for air pressure ventilation.
cover
when bench
(Without Regulator)
Output era Amperage
13.0 47.0
Output o Voltage
14.0 14.0
ALY 6400-8400
4000
pres10,IIIpaAIV
SERVICE INFORMATION
Issued:
AIRCRAFT ALTERNATORS
4/1/83
of 4
Page
Alternator ALY ALY ALY ALY ALY ALY ALY ALY ALY ALY ALY ALY ALY ALY ALY ALY
Approx. Weight
10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10
Lb. Lb. Lb. Lb. Lb.
6 Oz.
Internal
Wirin_g
Figure 1 Figure 1" Figure 1 Figure 1* Figure 2 Figure 2 Figure 1 Figure 1 Figure 1* Figure 2 Figure 2 Figure 1 Figure 1 Figurel*
Replacement Regulator
VSF-7203S FVR-4O11+ VSF-7203S FVR-4O11+ X18150+ X16300B+ VSF-7203S
6420, R 64206, RG
6421 6422
6425
6427, R 64276, RG
8402
8403, LS, R, RS ALY 84036, LSG, 10 Lb. 12 Oz. RG, RSG 10 Lb. 12 Oz. ALY 8405, R ALY 84056, RG 10 Lb. 12 Oz.
ALY 8410, ALY 8411
R
Lb. Lb. Lb. Lb. Lb. Lb. Lb. Lb. Lb. Lb. Lb.
Oz.
Oz. Oz. Oz. Oz. Oz. Oz. Oz. 6 Oz. 12 Oz.--12 Oz.
FVR-4004+
X18150+ X16300B+ VSF-7204 VSF-7203 FVR-40O4+
Figure Figure
1 1
VSF-7204 VSF-7203
FVR-4004+ VSF-7203 FVR-4OO4+ X16300B+ VSF-7204 VSF-7203 FVR-4OO4+ X16300B+ VSF-7204 VSF-7203 FVR-4OO4+
Figure 1*
Figure 1 Figure 1*
ALY 8420, LS, R, RS ALY 84206, LSG, RG, RSG ALY 8423, R
2 1 1
1*
ALY 8424
ALY 8426, R ALY 84266, RG Same
as
12 12 12 12
strap
Wico
Figure
groiinded with
Printed in U.S.A.
Tech. Data
ALTERNATORS
ALY
AIRCRAFT ALTERNATORS
k presr~ite.
SERVICE
Issued:
4/1/83
Page 4 of 4
JNFORMArlON
OUTPUT_
FIELD
;vl
STATOR
II I
(I
ROTOR WINDING
1~\11
Figure 1
/C7
Figure
ALZ SERIES
SERVICE PARTS LIST
ALTERNATOR
ISSUED:
3-4-75(Rev.)
VOLTS-IL
ORIG.EOUIP.ALTERNATOR
ENG.
NUMBER ALZ-8401
ALZ-8401G ALZ-84O1R ALZ-8401RG
ALZ-8423
APPLICATION
Lycoming Lycoming
Service Service
ALZ-8423R
ALZ-8423R ALZ-8423R ALZ-8423R
Lycoming Lycoming
Service Service
USE USE
ALZ-8423R
File in the
P.lnldinU.I.*
ALTERNATOR SECTION
List
-I
C/
to
~a
----(13
C/
Exploded
View of
,a-
SHEET 2
D.E.
Brush
Set
Slip Ring
End Head
S.R.E.Bearing
L Seal
P
Drive End
Head
Assembly
Assembly
Bearing
O
ALZ-8401
ALZ-8401G
O
1
O
IALU-10458S[a]
"i~iy
90-2396[c]
n,i~gl,
ALE-1003K
O
X-3416
90-2396[c]
90-2014Cbl
ALZ-8401R
ALZ-8401RG ALZ-8423
ALZ-8423G
jALE-2173S-1
ALE-1 01 3AS
ALU-1045BS
ALK-1132BS-1
ALZ-8423R ALZ-8423RG
E~3
35-781
(GJC-49BS
Cover
Pkg
B~Spring
already having this design. Holder Assy.,ff Brushes or Springs are required. S.R.E. Seal Pkg. also included with Rotor [b] Bearing Rotor Pkg. Complete Package must be used [c] S.R.E.Head
Individual components
Also aval Ible, 10 Pcs. Set alsolndivi ually avallaole Tor un~rs Earlier units must replace the Complete Brush
Hd.
Assy.
at time of first
repair.
(See
File in the
Prlntd In V.S.*.
ALTERNATOR SECTION
Assembly
Assembly
Negative
Rectifier
S.R.E. Cover
D.E. Retainer
Term. Stud
Thru Bolt
(Pkg.of 3)
8
ALZ-8401 ALZ-8401G ALZ-8401R
ALZ-8401RG ALZ-8423
O
XA-944JS ALU-1 062A
O
GR-32
o
90-2030
ALE-2008AG
ALE-1D54A
ALA-20JS
ISSUED: 3-5-79(REv~)
Rotor
Vent.
SHEET 3
Eyelet Package
Nut 6
Drive
Washer Pac la
Sha~L It
Fan
Pulley
Regul ator
O
ALZ-8401 ALZ-8401G
ALZ-8401R
(;ZRc
.90-818
90-33
ALD-21
90-2241
PU-672A
VSF-7203S
FYR-4011A
YSF-7203S
ALZ-8401RG
ALZ-8423
FVR-(IO11A
VSF-7203S
FVR-4011A
YSF-7203S
FVR-4011A
[c]~Contents
of S.R.E.
Head 6 Rotor
90-2396
Bearing Pkg.
Head
Rotor
Assy.,S.R.E.
Pllntd In U.S.*.
ALTERNATOR SECTION
ALZ
SERVICE
AIRCRAFT ALTERNATORS
Issued:
4/1/83
INFORMATION
Page 1 of 3
RATED OUTPUT
50
Amperes
Bi -Di rectional
10 Lb.
GROUNDED
12 Oz.
POLARITY
Negative
APPROXIMATE WEIGHT
SERVICE
INFORMATION
replacement, assembly, and bench testing are contained in the service publications in the front of the Alternator Section. Refer to the following service publication when detailed service information is required.
nent
ALTERNATOR
SERIES
SERVICE PUBLICATION
ALZ 8400
for bulletins
pertaining
SERVICE SPECIFICATIONS
DRIVE
PULLEY
nut to 35
Ft.
Lbs.
minimum
Lbs.
maximum.
Rotor to be
room
temperature
700
to
800F.
2.
Ohmmeter must be accurate and batteries must be fresh. Frequently check ohmmeter accuracy by measuring a known resistance such as 10.0 ohm resistor. Ohmneter must be checked to
zero
3. 4.
ohmmeter test probes must be clean. leads must be in good condition. probe
Ohmmeter
Prin)ed in U.S.A.
Tech.
Data
ALTERNATORS
ALZ
SERVICE
Page 2 of 3
INFORMATION
winding
resistance
Rotor to be
room
temperature
700
to
800F.
2.
3.
Voltmeter and ammeter must be accurate. Refer to service publication for test
wiring diagram.
1.350"
.002"
max. measure max.
from
bearing journals
50 microinch
Alternator to be
room
temperature
700
to
800F.
before
beginning
current.
test.
2.
Alternator connected
to
service
so it is supplying its own field publication for bench test wiring diagram.
Refer
3.
Output voltage
to
be controlled
run more
by
an
adjustable load.
4.
Alternator not to be
VENTILATION
The 8400 series alternators use a slip ring end cover that has a hose type connection for air pressure ventilation. Remove this cover when bench testing the alternator.
ALZ
SERVICE
INFORMATION
ALTERNATOR OUTPUT TEST SPECIFICATIONS
Alternator Series ALZ 8400
AIRCRAFT AI~TFRNATORS
Issued:
4/1/83
Page
3 of 3
(Without Regulator)
Output Amperage
17.0 41.0
Output Voltage
14.0 14.0
Orig. Equip.
Alternator
Regulator
VSF-7203
Replacement Regulator
VSF-7203S
ALZ 8401, R
*ALZ 84016, RG
ALZ 8423, R *ALZ 84236,
RG
FVR-4004+
VSF-7203
FVR-4011+
VSF-7203S
FVR-4004+
FVR-4011+
Field terminal F-2 externally grounded Internal wiring same as shown. with a strap connector. Lycoming applications only. Wico
FIELD FI DIODES
C
ST~TO(1
II
I(\(I)
I I
It
II
ROtOl WIWDINO
1-11IJI
File in the
Printed in u.s.n.
Tech.
Data
ALTERNATORS
SERVICE
INFORMATION
VOLTS 12 GROUND
These units have
an
Page
Neg at i ve
external
ADJUSTMENT
the
The regulator has on top of the regulator. adjustment spread ranging from 13.0 volts to 15.0 volts. Output is increased by turning the adjustment
plastic plug
an
clockwise.
OPERATING VOLTAGE volts when con1 minute operation. trolling a load of 10 to 15 amps after The These units are not affected by ambient temperatures. "I" or ignition voltmeter must be connected from the
The
regulator should
be
adjusted
to 14.2
terminal
CAUTION NOTES
i.
2. 3.
Use
to
ground.
alternators.
Regulator base
Do not
have
good ground
connection.
the two
voltage
4.
Do not
system
with
polarity
reversed.
5.
6.
Do not This is
a
adjustment
screw.
Replace
with
new
VSF-7201uit-~
VSF-7202
VSFc7203,S
VSF-7204
II
zn~
aLGiiL1TPa
Rdl-FL 5r
rC*
Typical Schematic
Circuit of
Regulator
File in ~he
Printed
in
Tech.
Data.
U.S.A
REGULATORS
RELAYS
prest~tP.
SERVICE INFORMATION
VSF-7dOD
AIRCRAFT VOLTAGE REGULATOR
Issued:
10-5-72
Page 1 of 1
VOLTS
24
Negati ve
These units have
an external adjustment located under the The regulator has top of the regulator.
ADJUSTMENT
plastic plug
an
on
adjustment spread ranging from 26.0 volts to 30.0 increased by turning the adjustment
regulator should be adjusted to 28.4 volts when controlling a.load of 10 to 15 amps after 1 minute operation. These units are not affected by ambient temperatures. The voltmeter must be connected from the "I" or ignition terminal to ground.
i.
2.
3.
CAUTION NOTES
Use
only
(ungrounded)
a
field alternators.
connection.
Regulator
Do not
good ground
the two
voltage
4.
polarity
5.
Do
not
force the
a new
voltage adjustment
screw.
6.
This with
is
a
repairable.
Replace
Unit
;ti:
c~
alr "~n
VSF-7401 VSF-7402
i~Z
12
91
PI
VSF-7403,S
VSF-7404
i
~Fs
5*"~Y 3Y
C
Typical
File in the
Princd
in
Tech.
Data
REGULATORS R RELC\YS
US.*