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PRt z;TO LITE

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

L;I~AVCO LYCOMING WILLIAMSPORT DIVISION


652 Oliver Street,

Williemsport, Pennsylvsnisl7701

~AVCO LYCOMING ENGINE GRQUP

prP5to/ite.
SERVICE PUBLICATION
THE AIRCRAFT STARTING MOTOR USING GEAR REDUCTION DRIVE

The starting circuit is


circuit includes the

designed to carry high current battery, solenoid starting switch,

with

minimum loss of

manual starting switch, The

motor, the connecting wiring and the vehicle frame.


for starting while the battery supplies the power. switch control the operation.
THE STARTING MOTOR

starting

motor

voltage. This starting cranks the engine

The manual switch and solenoid starting

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

Housing, (5) The Pinion Housing, and (6) The Bendix

Drive

Assembly.

See

Figure

i.

9ET

VB~NDI

s~
OE*R

HOUSING ASSY.

.r.
BE*RINO:

THRUST W*SHER PI(C.

Figure
Form L-649A

Exploded

View of Gear Reduction Starting Motor

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

The gear cut


it is

on

the drive end of the armature shaft extends


a

through

the gear

housing

where

supported by
on

roller

drives the Bendix shaft.


in

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

closed end roller

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

predetermined speed, centrifugal

action forces the detent pin out

of the notch in the

shaft and allows the pinion to demesh from the

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

and filled to the proper level wit~

hydrometer to be sure it is fully approved water. A load test should


a

be made to determine the

battery condition.

If dirt and corrosion have accumulated


a

battery,

it should be cleaned with

solution of

baking

soda and water.

Be

sure none

of the solution enters the

battery cells.

2.

Wiring

The

starting

circuit

connections

are

clean and

test should be made to

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:

reading voltmeter amperes, then the following


a

low

(A)

Voltage

loss from insulated

battery post

to

starting

motor

terminal

0.3 volt maximum.

(B)

Voltage loss

from

battery ground post

to starter frame

0. 1 volt maximum.

Form L-649A

If

voltage loss

is

greater than the above limits,


over

additional tests should be made


the circuit to locate the

each part of

high

resistance connections.

3.

Lubrication
of overhaul.

No lubrication is

required

on

the

sMrting

motor

except at the time

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

cable from the

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

reduction gear, woodruff


Turn the Bendix

key and steel spacer from shaft.

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

bearings from the gear housing,

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

Check the brushes to


on

see

that they slide

freely

in their holders and make


or

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

only slightly dirty. glazed


000

discolored, the

commutator
or

be cleaned with 00
a

or

sandpaper.

If the commutator is rough

worn, it

should be turned in

lathe.

Figure 2.
and

The armature shaft should be inspeoted for

rough bearing surfaces rough or damaged splines.


To test the armature far set of test
(1

grounds,
h

probes
r,lt

connected in series

lln
one

Touch

probe

to

commutator seg-

ment and the other to the armature


core.

I~
Figure
2

If the test

lamp lights,

the

armature is

grounded

and should be

replaced.
To test for shorted armature

Turning Starting Figure


3.

Motor Commutator The armature

coils,

growler

is used,

is

placed
over

on

the

rotated held
over

by

hand the

growler and slowly while a steel strip is


so

core

that it passes
slot. If
a

each armature

core

coil is shorted, the steel strip will vibrate.

quick check for


the

opens

can

be made

by inspecting

trailing edge tin


oommu-

direction of rotation) of the

tator segments for excessive dis-

coloration.
an

This condition indicates

open circuit.

Figure

Testing Motor Armature for Shorts


one

6.

Field Coils
on

Cheek the field coils for


an

grounds (Figure 4) by placing

test

probe

the frame and the other Be


sure

the

starter terminal.

the

brushes fields

are

the frame.
are

accidentally touching lamp lights, the grounded. Repair or


not

If the

replace. Inspect all connections


to make
sure

clean and tight and inspect insulation for deterioration.

they

are

6.

Brush Holders touch


one

To test brush

holders, plate
i

test

probe

to the brush

and the other to each brush holder.

Figure
Form L-649A

Testing

Motor Fields for Grounds

The test
not

lamp should light when the grounded brush holders


when the insulated brush holders
are

are

touched and should

light

touched.

7.

Gear and Pinion


vrear.

Remove

Inspect housings for cracks and bearings for excessive Housing rust, paint or grease from mounting surfaces.

8.

Bendix Drive

The Bendix Drive should be


one

wiped

clean with

dry cloth.

The pinion

should turn smoothly in


drive if it fails to check

direction and should lock in the other direction.

Replace

as

above

or

if the pinion teeth

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

slowly in after sanding.


ture

the direction of rotation.

Dust should be blown out of the motor

Check the position of the pinion to be

sure

the unit will mesh

properly

with the

flywheel ring

gear.

See

specifications

for

particular

unit for correct dimensions.

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

three sharp raps

on

the frame with

rawhide

hammer will often

help

align

the

bearings and free

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

No-Load Test Hook-up

Figure

Stall-Torque Hookup

If torque and current

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

STARTING MOTOR CONTROL CIRCUIT

Inspect the control circuit wiring between the battery, solenoid and manual starting switches
for

breaks,

poor connections and

faulty
a

insulation.

Tighten

all connections and make

sure

solenoid is Check the


excess

firmly

mounted and makes

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-4001,R MHB-4002,R MHB-4003,R


MHB-4004

MHB-4O16R
MHB-4017R MHB-4019R

Lycoming Lycoming Lycoming


Frankl in

MHB-4004

MHB-4005,R
MHB-4006 MHB-4006 MHB-4O18R MHB-4008R MHB-401 4R

Lycomin9
Continental

MHB-4OO7,R MHB-4008, R MHB-4009,R MHB-4O10,R

USE

USE USE USE USE


USE USE

MHB-4O16R MHB-4O17R
MHB-401 9R MHB-401 8R

Lycoming Lycomlng Lycoming Lycomlng Lycoming Lycomfng Lycoming Lycoming Lycoming Lycoming Lycomlng Lycoming Lycoming

MHB-4011, R MHB-4012, R MHB-4013,R MHB-4014,R MHB-4015,R


MHB-4016,R MHB-4017,R MHB-4018,R MHB-4019,R
Available thru

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

~P(B-4000 Series Starting Motor Parts List

14

~-____ _1
19

17

16

L____

-T--

j
__J

------7---

Exploded View

of

Typical

MHB

Starting

Motor

MHB SERIES STARTING MOTOR PARTS LIST


Assembly
Armature
Brush Set Frame Field
Comm. End

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

[a] [b] Ccl [d]

[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

STARTING MOTOR SECTION


r,

OE-AI AIRCRAFT MANUAL

MHB SERIES STARTING MOTOR PARTS LIST


Assembly
Bendix Drive Bendix Drive

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]

CNR] [NR] [NR] CNR]


[NRI

MZ-19S

90-2502

CNR]

I I

II

I I

Cb] Cc] CNR]


CNR] CNRI [d]

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

CNR] EBB-142A[g3 EBB-75A[gl

~NRI
[d3
Mi-326

[NR] CNR] ~NR]

I I

I i I I
I I

I I I j
i I

[NR] CNRI

MHB-4009,R MHB-4010, R MHB-4011,R MHB-4012,R


MHB-4013,R MHB-4014,R

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

CNR] CNR] CNR] CNR]


MZ-l

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.

MHB SERIES STARTI~G MOTOR PARTS LIST


Gear Needle

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

[kl [kl [NR]

[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[*]

~NRI CNR] CNH]


MZ-393

[NR] [NR] [NR]

i
MZ-396

[NR]
MZ-1390

MHB-4007,R MHB-4008,R MHB-4009,R


MHB-4010, R MHB-4011,R MHB-4012,R MHB-4013, R MHB-4014,R

[k]

CNR]
MZ-396

i
I I I

L~kl Ck] Ek3


I~kl

[NR~
MZ-393

I
i

[NR]
CNRI

[NR]
[NR~

CNR] CNR]

[NR]
CNR]

I I I I

I I I I

i I

[k] Ek3 Ek] [NR]

[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

XA-997 is 1/2" O.D.

and XA-998 is 13/16" O.D.

longer available.

CNR

Available thru Not required.

Lycoming only.

Prinld In U.5.1.

File in the OE-AI AIRCRAFT MANUAL

STARTING MOTOR SECTION

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,

CWDE Motor Direct Drive Units

Drive CWDE

CCWDE

BRUSHES POLES SWITCH

4 4

Gear Reduction Units Separate switch mounted Direct Drive Units

on

motor

DRIVE ASSEMBLY

Rubber Folo Thru Type


GEAR REDUCTION 3.38 to
1 Gear Ratio

(see following note).

DRIVE AND GEAR NOTE

Reduction gears, shafts, and drives used with the MHB-4005, 4005R, and 4006 are not manufactured or

supplied by

Prestolite. SERVICE INFORMATION

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.

File in the OF-Al AIRCRAFT MANUAL

ec

Data

STARTING MOTORS

MHB

AIRCRAFT STARTING MOTORS

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

Use "Loctite Grade A" screws to 25

threads of 35 in./lbs.

bearing plate retaining

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

GEAR REDUCTION UNITS

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

DIRECT DRIVE UNITS

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

Except MHB-4OO5, R, 4009, R, 4014,


so

Assemble the end head on the motor in line with the motor terminal.

that the letter "R"

is

directly

MHB-4005, R, 4009, R, 4014, R and DIRECT DRIVE UNITS


Assemble the end head on the motor in line with the motor terminal.
File in the OF-Al AIRCRAFT MANUAL
so

that the letter "L"

is

directly

Tech. Data

STARTING MOTORS

Printed in U.S.A.

AIRCRAFT STARTING Issued

BHMSROTOM
4/1/83
of 5

SERVICE

Page 4

INFORMATION

COMMUTATOR REFINISHING

Minimum Diameter Undercut Total Indicator Runout Surface Finish

1.50" .003" max. .002" max. measure from 50 microinch max.

bearing journals

TEST SPECIFICATION
See

(750F.)

Figures

1 and 2 for

no

load and stall

torque test connections.

GEAR REDUCTION UNITS

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

DIRECT DRIVE UNITS


No Load Test Stall Torque Test

20.0 volts, 36 max, amps., 4600 min. 14.0 volts, 260 max. amps., 8.0 min.

RPM Ft. Lbs.

SHUNT FIELD CURRENT DRAW

8.7 to 10.4 amperes at 24.0 volts

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-4001, R MHB-4002, R MHB-4003, R


MHB-40O4

MHB-4005, R
MHB-4006

MHB-4007, MHB-4008, MHB-4009, MHB-4010, MHB-4O11,

R R R R
R R

Reduction Reduction Reduction Reduction

Reduction
Reduction
ti
on

MHB-4012, MHB-4013, MHB-4014, MHB-4015, MHB-4O16, MHB-4017, MHB-4018, MHB-4019,

R
R

Reducti-~n

Gear Reduction

R R R
R

pi rect Gear Reduction Gear Reduction Gear Reduction Gear Reduction

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

VCWtD TROM cCMNUTATOR END

Figure

Figure

File in the
Printed in U.5.n.

OF-Al AIRCRAFT MANUAL

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

PART NUMBER USE USE USE USE

APPLICATION

MHJ-4002

MHJ-4O03,S MHJ-4O04
MHJ-4O04R MHJ-4005 MHJ-40O5R

MHP-4101S MHP-IIOIS MHJ-4004R


MHJ-4004R

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.

File in the OF-Al AIRCRAFT MANUAL

I
I

STARTING MOTOR SECTION

MHJ Series

Starting

Motor Parts List

FI~

lil

I I

~I 1
2

[o~-

Exploded View of Typical

MHJ

Starting

Motor

MHJ

SERIES STARTING MOTOR PARTS LIST


Brush Frame& Field Comm. End Head

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

MHJ-4004R MHJ-4005 MHJ-4O05R

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

Bendix Drive Shaft

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

Ca] Ca] Ca3

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

STARTING MOTOR SECTION

OF-Al AIRCRAFT MANUAL

presto/ifP,
SERVICE
IN FORM ATION
GENERAL INFORMATION

M HJ
Aircraft Issued:

Starting Motors
4/1/83

Page

1 of 4

VOLTAGE ROTATION

24

CWDE MHJ-4002, 4003 MHJ-4004, R, 4005, R


4 4

Motor CCWDE,

Drive CWDE

BRUSHES

POLES SWITCH DRIVE


GEAR REDUCTION

Separate
MHJ-4OO4, R, 4005, R
Rubber Folo Thru

Type

MH3-4004, R, 4005, R
SERVICE LUBRICATION

3.38 to 1 Gear Ratio

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

the felt oiling Allow excess oil

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.

File in the OE-AI AIRCRAFf MANUAL

Tech. Data

STARTING MOTORS

MHJ

Aircraft Starting Motors


Issued:

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.

replaced when they have

worn down to a length Refer to Service Bulletin ASM-1 for brush

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.

scale hooked under the

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"

Undercut Total Indicater Runout Surface Finish

.003" max. .002" max. measure from bearing journal 50 microinch max.

IEST
MHJ-4002, 4003
No Load Test

SPECIFICATIONS

(750F)
max.

Stall Torque Test

20.0 volts, 8.0 volts,

43 210

max.

amps, 6200 min. 8.0 min. amps,

RPM Ft. Lbs.

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

(Motor Only) (Complete Unit)

Stall Torque Test


SHUNT FIELD CURRENT DRAW

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.

RPM RPM Ft.

Lbs.

4.8 to 6.0 amperes at 24.0 volts.

Internal Unit
MHJ-4002

Wiri?g
Figure 3

Application
3 4 4 Continental Continental

MHJ-4003,S MHJ-4004, R MHJ-4O05, R

Figure Figure Figure

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

CeOUt(D 571~1711YG YOTOII

Figure

Figure

Printed in U.S.A.

File in the OF-Al AIRCRAFT MANUAL

Tech.

Data

START ING MOTORS

Aircraft Starting Motors


Issued:

4/1/83

SERVICE

Page 4 of 4

INFORMATION

TERMINAL STUD GROUNDED BRUSn INSULATED bMUSH


SHUnt

TEFMHK POST GROUNDED

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.

Pile in the OF-Al AIRCRAFT MANUAL

STARTING MOTOR
SECTION

MMU Series

Starting

Motor Parts List

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

Thrust Washer Packa

O
90-2502

MMU-4001,R

M2-1236

EBB-124ACa]

MZ-24A

90-2677

[a]

90-2139 Bendix Pin

Package(25 Pcs.)

also available.

File in the
Prlntd In U.s.A.

I
r

STARTING MOTOR

OF-Al AIRCRAFT MANUAL

SECTION

MMU presto/ire.--------

SERVICE
INFORM ATION

AIRCRAFT STARTING MOTOR Issued 4/1/83 Page 1 of 3

GENERAL INFORMATION VOLTAGE ROTATION


POLES

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

toward the armature.

File in the
Printad in U.S.A.

OF-Al AIRCRAFT MANUAL

Tech. Data

STARTING MOTORS

MMII

AIRCRAFT STARTING MOTOR

presr~tP.
SERVICE

Issued 4/1/83

Page 2 of 3

INFORMATION
I

INTERMEDIATE BEARING PLATE


Use

"Loctite Grade A"


screws

on

threads of

bearing plate retaining

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

the armature shaft. number.

.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

that the letter "L"

is

directly

bearing journals

TEST SPECIFICATIONS
No Load Test

Stall

Torque

Test

20.0 volts, 14.0 volts,

35 250

max. max.

amps., 3325 RPM amps., 10.4 min.

Ft.

Lbs.

SHUNT FIELD CURRENT DRAW Unit

8.8 to 10.4 amperes at 24.0 volts

MMU-4001, R

Drive Type Direct

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

VIEWED FROM COMMUTAfOR END

File in the
Printed in U.S.A.

OE-AI AIRCRAFT MANUAL

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

SERVICE MOTOR APPLICATION

PART M2-4203 USE USE USE USE USE USE USE


USE

M2-4203

Franklin

MZ-4204,R

MZ-4205,R MZ-4206,R

MZ-4207;R
MZ-4208,R
M2-4214

MZ-4204R MZ-4221R MZ-4222R MZ-4223R


MZ-4208R M2-4214

Lycoming Lycoming Lycoming Lycoming


Lycoming
Continental

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

USE USE USE USE USE USE USE

MZ-4223R
MZ-4220R MZ-4221R

MZ-4222R
MZ-4223R

MZ-4223,R MZ-4224,R MZ-4225,R

MZ-4224R
MZ-4225R

p,.., mUI*.

File in the OE-PII AIRCRIFT MANVAL

I
I

STARTING MOTOR SECTION

MZ Series

Starting

Motor Parts List

_____i
19)-~--

Q;

\L: 16

L-----~O

-----T--

_J

eo~$

~-o

i
s---

__.J

Exploded View

of

Typical

MZ

Starting

Motor

MZ SERIES MOTOR PARTS LIST


Assembly
Armature

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

~al [bl Ccl

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

Cb] Ccl CNRI MZ-2413Cdl

[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

MZ-4219,R MZ-4220,R #2-4221,R


MZ-4222,R

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.

File in the OE-AI AIRCRAFT MANUAL

I
r

STARTING MOTOR SECTION

MZ SERIES MOTOR PARTS LIST


Assembly
Bendix Drive Bendix Drive Sft Intermed.
Brush

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

[NRI [NR] [NR]


CNRI

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]

[WR] CNR] CNR]


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] [NRI

[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.

MZ SERIES MOTOR PARTS LIST


Gear

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]

[m] [NR] [m]

[NR]
[NR]

[NR] [NR]
[NR] [NR]

MZ-4216,R

90-601

[NR]

MZ-4217,R MZ-4218,R MZ-4219,R MZ-4220,R M2-4221,R


MZ-4222,R M2-4223,R M2-4224, R
MZ-4225,R

I I I 1 I 1 I
I

I I I

I I I I I j

[m] [m3 [m] Cm] Cm] [m] [m3


[ml

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]


ENR] [NR] [NR]

[NR]
[NR] [NR]
[NR]

[NRI [NR] [NR~ [NR]

I I
I I

[NR] [NR] [NR]

[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

OF-Al AIRCRAFT MANUAL

SECTION

MZ
AIRCRAFT STARTING MOTOR

SERVICE INFORMAT ION


GENERAL INFORMATION

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

Motor CWDE, Drive CCWDE.


CWDE.

Direct Drive units

SWITCH

Gear Reduction Units Separate Switch mounted Direct Drive Units

on

motor

DRIVE

M2-4214
All

uses

Formsprag, Torque Limiting Drive


Rubber Folo Thru Type Drives

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.

OF-Al AIRCRAFT MANUAL

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

DIRECT DRIVE UNITS


Press

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.

INTERMEDIATE BEARING PLATE

M2-4204, R

Torque

Use "Loctite Grade A" on threads of screws to 25-35 in/lbs.

bearing plate retaining

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.

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. take the reading just as the and the exerted force line of spring by brush. the spring leaves END PLAY

GEAR REDUCTION UNITS

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

Parts List for thrust washer


DIRECT DRIVE UNITS

package

number.

M2-4203, adjust to .005" minimum with thrust washers.

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

Except MZ-4216, R, 4220,


so

Assemble the end head on the motor in line with the motor terminal.
DIRECT DRIVE UNITS AND

that the letter "R" is directly

MZ-4216, R, 4220,

R
so

Assemble the end head on the motor in line with the motor terminal.

that the letter "L" is

directly

Printed in U.S.A.

File in the MANUAL AIRCRAFT OR-Al

Tech. Data

STARTING MOTORS

AIRCRAFT STARTING
Issued 4/1./83

ZMROTOM
SERVICE
4 of 5

Page
I

INFORMATION
I

COMMUTATOR REFINISHING

Minimum Diameter Undercut Total Indicator Runout Surface Finish

1.50" .003"

max.

.002" max. measure from 50 microinch max.

bearing journals

TEST SPECIFICATION

(750

F.)
torque
test

(See Figures

1 and 2

for

no

load and stall

connections.)

GEAR REDUCTION UNITS No Load Test (Motor Only) No Load Test (Complete Unit) Stall Torque Test

10.0 volts, 50 10.0 volts, 75 4.0 volts, 560

max, max. max.

amps., 8000 min. amps., 1600 min. amps., 37.5 min.

RPM RPM
Ft.

Lbs.

DIRECT DRIVE UNITS No Load Test Stall Torque Test


MOTOR ONLY No Load Test Stall Torque Test

10.0 volts, 4.0 volts,

75 560

max,
max,

amps., 5500 min. amps., 11.1 min.

RPM
Ft.

Lbs.

M2-4214

10.0 volts, 4.0 volts,

50 560

max.

max.

amps., 8000 min. amps., 11.1 min.

RPM Ft.

Lbs.

Internal
Unit M2-4203 Drive Type Di rect
R

MZ-4204, M2-4205, MZ-4206, M2-4207, M2-4208,


M2-4214

R R R R
R

Direct Gear Reduction Gear Reduction Gear Reduction Gear Reduction


Gear Reduction Gear Reduction Gear Reduction

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

Gear Gear Gear Gear Gear Gear Gear

Reduction Reduction Reduction Reduction Reduction Reduction Reduction

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 Lycomi ng Lycoming Lycoming Lycoming


Continental

Lycoming Lycoming Lycoming Lycoming Lycoming Lycoming Lycoming Lycoming Lycoming Lycoming
part of, this

"Formsprag Torque Limiting


motor.

Drive used with, but not

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

TERMINAL POST INSULATED BRUSH

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.

File in the OE-AI AIRCRAFT MANUAL

ec

Data

STARTING MOTORS

(Early Produ ction Type)


BE LT DRIVEN

AIRCRAFT

ALTERNATORS

BELT DRIVEN AIRCRAFT ALTERNATOR

Prestolite Belt Driven Aircraft


Alternators

(Figure 1)

have been

designed

and constructed to provide extended periods


of trouble-free

operation

with

minimum

amount of maintenance.

They

have i~so

been

designed

and constructed to withstand

the vibration and extreme temperature

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

The stator consists of

laminated iron

core on

which the three phase


are

windings

are

wound in slots around the inside clrctunferenee.

Leads

connected to eachof the


a

three points of the

~haae windings

and each lead is connected to

pair of rectifiers,

one

negative and
2.

one

positive.
a

The rotor consists of

single field
the shaft.

coil encased between two

four-poled,

interleaved
a

iron sections assembled

on

The ends of the field coil

are

connected to

pair

of

slip rings
3.

which

are

from the shaft. insulated from each other and

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

field and output terminals, and

blast tube

assembly.

4.

The drive end head supports

sealed, prelubrioated ball bearing

in which the drive end

of the rotor shaft rotates.

5.
are

The negative rectifiers are pressed into the pressed into the rectifier mounting plate and
are

slip ring
are

end head and the positive rectifiers The

connected to the stater leads.

rectifiers

rated at 150 PIV minimum for transient

voltage protection.

OVERHAUL When repairing the alternator,


it will

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

to the blast tube

assembly,

it should be removed before any

servicing is attempted.
i.

Using

strap wrench,

remove

the

pulley

nut.

The

pulley

must be removed with

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

rotor assemblies from the stater and

slip ring

end head.

Re careful not to lose the brush

springs
2.

when

separating the assemblies.


lockwashers, and flatvashers from the output terminal and
remove

Remove the nuts,

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

slip ring bearing, support

the end head and press

bearing out, using

the proper tools shown in Figure 4.

Figure

Figure

4.

If necessary, press the rectifiers out of the rectifier mounting plate

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

the drive end head from the rotor shaft,


as on

use a

puller

that grips

on

the the

bearing

retainer

end head and

plate pressing

shown in

Figure
as

5.

Do not

attempt to

remove

by supporting
or

the

shaft,

this may result in distortion of the end head


Remove the three retainer

stripping of the retainer


the

plate

screws.

plate

screws

and press

bearing

out of the end head.

Figure

6.

Figure

i"

Figure

INSPECTION AND TESTING OF COMPONENTS

Upon completion of the disassemhly, all parts should be cleaned and visually inspected for

cracks,
i.

wear or

distortion and any

signs

of

overheating

or

mechanioal interference.

Rotor
or

The rotor should be teated for

grounded
test
can

shortedwindings.
a

The ground

be made with test

probes, connected

in series with

110 volt test

lamp,
tester.

an

ohm7.

meter

or

any type

There must not

oontinuity be any oontinui$


or

Figure

between the

slip

rings and the rotor shaft

poles.
winding,

To test for shorted turns in the rotor


connect
as
a

voltmeter,

ammeter and rheostat


or use an

shown

inFigure 8,

ohmmeter.
are

Rotor current draw and resistance


on

listed

individual

apecificatlon
or a

pages.

Excessive

current draw

low ohmmeter

reading

indicates shorted
or

an

windings. No current draw infinite ohmmeter reading would indicate


winding. Figure
7

an

open

2.

Rectifiers

A diode rectifier tester will

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

and the other

following manner. probe to a rectifier heat sink test probe to a lead from one of
Then
reverse

VOLTMETER)

the rectifiers in that heat sink. the

position of the leads.

The test bulb

should

light

in

one

direction and not

light

in

the other direction. both


BATTERY
ROTOR

If the test bulb

lights

in

directions,

one or more

of the rectifiers
To

in that heat sink is shorted.

pinpoint

the

defective rectifier, the stater leads must be disconnected and the above test
each rectifier.

Open rectifiers

Figure

detected, when using the test disconnecting the stater leads.


will fail to

repeated on can only be bulb, by


The test bulb

light

in either direction if the

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

be tested for open


or an

or

described in the rectifier

the stater
must

winding light, or the

center connection and touch each of the three stater leads.

The test bulb

ohmmeter must show

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

If all other electrical checks


the stater should be

are

normal and the alternator fails to


or

replaced

to determine whether

not it is the

supply its rated output, faulty component.

Check the bearings for

replaced.

Note:

New

roughness or excessive clearance to determine if they should be bearings are prelubricated; additional lubrication is not required.
a

If excessively dirty, the end housings may be wiped clean with


ASSEMBLY

cloth

dampened

in solvent.

1.

Press the ball


so

bearing

into the drive end head


on

using
race

flat block

square

that the pressure is exerted

the outer

of the

approximately 2" bearing. Install the

retainer

plate.

With the snap ring and retainer cup in place

on

the rotor shaft,

use a

tool that
race

fits over the shaft and


is

against

the inner bearing race, and press until the inner

hearing

against
To

the snap ring retainer cup.

Figure 9.
or

2;

install the rectifiers in the slip ring end head


or

rectifier mounting
a

plate, support

the end head

mounting plate and press the reetifiers


arbor press do not

in with

special

driver tool.

Figure

10.

(Uae

hammer.)

Figure

Figure
on

10

Strip

the insulation back

approximately 1/4"
CONNECTIONS,

the stater leads and reconnect them to the


an

rectifiers.

The connector sleeves should be soldered

the rectifier and stater leads.

WHEN SOLDERING THESE

USE PLIERS AS A HEAT-DAM ON THE LEAD TOO MUCH HEAT WILL DAMAGE

BETWEEN THE SOLDER JOINT AND THE RECTIFIER.


THE RECTIFIERS.

3.

To

spread
use an

the brushes when


or

installing

the

HOLE

rotor,

Alien wrench

equivalent

to
USE STIFF WIRE WITH ro HOLD
BRUSH

hold insulated brush.

(Use hole in the end

H001(

LEID

headjustbelow thefield terminal.) T~egmund


brush is held with
a

hook made out of stiff wire

Figure 11.
4.

m9
press the

Spread the brushes and manually

stater and

slip ring through

end head assemblies and

the drive end head and rotor assemblies


Be euro ths
are no

together.

locator pina

(Thare used.) Install and tighten


USE "LLEN
m HOLD WRENCH OR LEID

~olt halse Une up.

through bolts.
to be
or

After releasing brushes, cheek

E(IUIV*LENT

BRUSH

sure

that the rotor does not n~b the stater

brush leads and that the rotor b~ms

freely

Figure

11

when rotated

by

hand. loekwasher and nut.


on

5.

Install spacer, woodnrff

key, fan, pulley,

Tighten

nut

using

strap wrench.
been bench

(Do

not install blast h~be

assembly

the alternator until after the unit has

tested.)

ALTERNATOR BENCH TEST

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

output specifications before regulator

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,

Adjust the carbon pile, specified voltage.

if necessary,

\j

After bench

testing the alternator, install the

O
tell

safety

wire in the
on

through bolts and install

the

alternator

the engine.

Note:
era
or

AlwaylS refer to the airframe manufacturwiring diagram when installing the alternator
on

t~,t

vauut~l

testing the alternator

the aircraft.

Figure

12

PRECAUTIONS TO BE OBSERVED WHEN TESTING OR SERVICING THE ELECTRICAL SYSTEM


1.

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

may redult in damage to

polarization the alternator, regulator or


No

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,.

voltmeter befor~ connecting the

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

THE AIRCRAFT ALTERNATOR 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

electronic switch which


It has
no

can
or

turn

on

and turn off the flow of current


to
wear

electric circuit.

mechanical

moving parts

out.

THE RECTIFIER DIODE

The rectifier diode will pass current in this respect, it may be


THE ZENER DIODE

one

direction

only (fonvard direction);

and in

compared

to

one-way check valve.

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

device which is used to limit currentflow.


HOW THE REGULATOR OPERATES

When of the

ignition switch regulator.

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,

current will flow

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.

system operating voltage ducting voltage.


termines the

relative to the Zener diode, Z1,

When the system

voltage connected

to r" terminal reaches

value at which the Zener

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

the collector emitter

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

system and regulator from possible damage.


means

Temperature compensation is flat which output voltage constant with temperature


The PRESTOLITE solid state

the

regulator

Will hold the alternator

increase

or

decrease after initial warm-up.

regulator

uses

three NPN silicon transistors.


when oper-

Capacitor, C1 is used to filter ripple and alternator diode switching spike ating batteryless.
Neon

lamp, L-l, provides transient voltage protection acting


a

as a

surge suppressor.

Control P1 is used to provide

limited range of

voltage adjustment.

PREPARATION FOR TESTING


Caution:
Do Not

Interchange Regulator Leads.

This will

destroy regulator

and void

warranty.
1.

The aircraft technician


the
ammeter

or

other electrical systems

specialist,

must disconnect

battery ground cable


or

battery before connecting or disconnecting a test other test equipment or before making wiring changes in the electrical

at the

system.
2.

When

only is to be connected, provided caution is


a

voltmeter

used for circuit used when

testing, the battery need not be disconnecting or disconnecting the voltmeter.


sure

3.

When
is in

installing
a

a
so

battery

in

vehicle, be
can

that the

position

that this terminal

be connected to the

battery negative terminal battery ground cable

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

The alternator does not need to be polarized;


even

connect

ground,
the

momentarily,
Do not

to either the

regulator

field terminal

to the alternator field

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

condition and should be

fully charged. quality


and should be accurate.

9.

The voltmeter and the ammeter should be of the best

10.

carbon-pile connected across while testing the regulator.


A

the

battery

may be used to load the

charging

circuit

TESTING THIS REGULATOR

i.

The procedure for

testing this regulator, whether


same.

on

the vehicle

or on

the test

bench,
2.

remains the

Connect test meters

as

shown in

Fig.

2.

All circuit connections should be clean and


ment connections which must not
come

tight.
or

This includes the test instru-

loose

open the

charging circuit

at any

time while the

system

is

operating.

*LTERNP~TOR

REGULATOR
TEST AMMETER
CARBON

PILE

zn
AMMETER

ALTERNATOR SWITCH
ON TEST VOLTMETER OFF

BATTERY

Figure

2.

3.

The voltmeter will not indicate the true


has been
1

regulator setting

until the

regulator

operating in the charging system or on minute, at a charge rate of from 10 to 15 amperes.


as

the test bench for at least

4.

Connect the voltmeter and the ammeter and


as

shown in

Figure

2.

Start the
Turn
on

engine
across

adjust
battery

its

speed

to obtain 3, 000 to

4,

000 alternator RPM.

accessories

needed to establish 10 to 15 ampere electrical load,


to obtain this

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

Prestolite Technical Service

Toledo, Ohio

43601

BELT DRIVEN

AIRCRAFT

ALTERNATORS

BELT DRIVEN AIRCRAFT ALTERNATOR

Prestolite Belt Driven Aircraft Alternators

and construoted to
of trouble-free

(Figure 1) have been designed provide extended periods


operation with
a

minimum

amount of maintenance.

They

have also

been

designed

and constructed to withstand

the vibration and extreme temperat~re

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)

the Drive End Head.

Figure

Figure
i.

The brush and holder

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.

purposes. end head

The

slip ring

provides

the mounting for the reotifiers and rectifier mounting

plate, outputand auxiliary


ring end
head oontains
a

terminal studs, and thebrush and holder


race

assembly.
a

The

slip

roller bearing and outer

assembly

and

grease seal.

The rectifiers used in these units protection. Three positive rectifiers


3. three

are are

rated at 150 P.I. V. minimum for transient

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

stater lead with

high temperature solder.

The stater leads

are

anchored to

mounting plate
a

with epoxy cement for vibration

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.

The stater contains

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.

The drive end head

supports

drive end sealed, prelubricated ball bearing in which the

of the rotor shaft rotates.

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.

Remove the two H10-24

screws

holding

the brush holder

assembly

in the

slip ring end

head.
2.

Remove the brush and holder

assembly

from the end head. the


a

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

strap wrench and Remove the fan,


a

3.

Remove the four

through bolts
as

end head and rotor,


Remove the

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.

it will be necessary to have Do not remove the

hook

bearing unless

replacement

Figure
The inner
race

of the slip ring end bearing is pressed onto the rotor shaft. When bearing

replacement is necessary, always replaoe the complete bearing assembly, inoluding


the inner
race.

6.

To

remove

the drive end head from the

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

INSPECTION AND TESTING OF

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

The rotor should be teated for


of

grounded

be made with test

any

type

slip

rings and

probes, connected continuity taster. Figure the rotor shaft or poles.

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

To test far shorted turns in the rotor


as
on

winding,

connect

voltmeter,
or a

ammeter and rheostat


are

shown in Figure 8, the individual

or use an

ohmmeter.

Rotor current draw and resistance

listed

indicates shorted

indicate

an

specification pages. windings. No current open winding.

Excessive current draw draw


or an

low ahmmeter reading

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

rectifier heat sink and the other

probe

to

lead from

of the

rectifiers
in
one

in that heat sink.

Then

reverse

We position

of the leads. shorted.


above teet the test

The test bulb should

light

direction and not

light

in the oWer direction.

If the test bulb


To

lights

in both

directions,

one or more

of the rectifiers in that heat sink is

pinpoint the defective rectifier, the

stater leads must be disconnected and the

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

direction if the rectifier is open. The statoroanbe tested

8.

Stater

foropenorgroundedwindInga
ohmmeter,
in the

with

12 volttestbulb,

described in the rectifier section,


stater from the

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

words, insulate the


or

stater from the end head.

To test for

test bulb

ohmmeter probe to the auxiliary terminal

other test bulb

ohmmeter

probe

to the stater frame.

If the test

grounded wlndinga, lead, and the bulb Hgbts, or the


am stater

ohmmeter indioates continuity, the stater is


one

test

probe

to the

auxiliary

terminal

or

eaoh of the three stater leads.

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

If all other electrical checks the stater should be

are

normal and the alternator fails to


or

replaced

to determine whether

not it is the

supply its rated output, faulty component.

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

Press the ball

bearing

into the drive end head


on

using

flat block

approximately
tool that fits
race

2" square

that the pressure is exerted

the outer

race on

of the bearing.

Install the retainer


use a

plate.
the
the

With the snap shaft and


snap

ring and retainer cup in


the inner cup.

place

the rotor

shaft,

over

against

bearing

race,

and press until the inner

bearing

is

against

ring retainer

Figure 9.
or

2.

Carefully install

the rectifiers in the slip ring end head

rectifier mounting plate

by

supporting the

unit and

using the special

teals illustrated in Figure 10.

Figure (Use arbor


press

1 Figure

10

do not

SOLDERING THESE

hammer.) CONNECTIONS,

Reoonneot the stater leads to the rectifiers.

WHEN

USE PLIERS AS A HEAT DAM ON THE LEAD BETWEEN TOO MUCH HEAT WILL DAMAGE THE

THE SOLDER JOWT AND THE RECTIFIER. RECTIFIERS.

Reassemble the rectifier mounting plate studs and insulators, making


correct order.
See

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.

Install the slip ring end hearing and oil seal.


Correct
NUT

Make

sure

the

lip of

the oil seal is toward t~

bearing.

assembly

of

bearing, seal,

inner

race

and spacer is shown in

Figure

12.

LOCKWPASHER
LT~

-FIBERWASHER
~ENO HEAD

SEAL-INSTALL SEAL
WITH LIP TOWARD BEARING

~RECTIFIER MOUNTING PLATE TERMINAL

INNER

RACE

AUXILIARY TERMINAL

FLATWASHERc~
END

NUTC~

LOCKWASHER
c~Ly

FIBERWASHER

GREASE
CAVITY

HEAD(
~cNsuLnToR

Z
~L, 1
SPAC ER

RECTIFIER MOUNTING PLATE

~TERYIN*L STVD

BEARING

OUTPUT(+)
TERMINAL
t

Figure
4. is

11

Figure
Spin the

12

Assemble the alternator and install the through bolts.


no

rotor to make

sure

there

mechanical interference.

Torque the through bolts to 30 to 35 in. Ibs.

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.

listed The ohmmeter must indicate the amount of rotor resistance


page.

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

pile, Adjust the specified voltage.


the carbon

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

refer to the airframe manufacturers

wiring diagram

when

installing

the

alternator

testing

the alternator

on

the aircraft.

PRECAUTIONS TO BE OBSERVED WHEN TESTING OR SERVICING THE ELECTRICAL SYSTEM


1.

(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

THE ROTOR WINDING IS ENERGIZED AND THE ALTERNATOR IS OPERATING


3.

DO NOT ATTEMPT TO POLARIZE THE ALTERNATOR.

Any
4.

attempt to do

so

may result in

damage

to

polarization is required. the alternator, regulator or circuits.


No

GROUNDING OF THE ALTERNATOR OUTPUT TERMINAL MAY DAMAGE THE

ALTERNATOR
5.

AND/OR CIRCUIT

AND COMPONENTS.

REVERSED BATTERY CONNECTIONS MAY DAMAGE THE should be checked with

WIRING OR OTHER COMPONENTS OF THE CHARGING SYSTEM.


a

voltmeter before connecting the

RECTIFIERS, VEHICLE Battery polarity MOST VEHICLES battery.

ARE NEGATIVE GROUND.

6.

IF A BOOSTER BATTERY OR FAST CHARGER IS

USED,

ITS POLARITY MUST RE

CONNECTED CORRECTLY TO PREVENT DAMAGE TO THE ELECTRICAL SYSTERI

COMPONENTS.

480 LT FLANGE MOUNT

AIRCRAFT

ALTER NATO RS

FLANGE MOUNTED AIRCRAFT ALTERNATOR

Prestolite

Alternators

Flange Mounted Aircraft (Figure 1) have been designed


provide extended periods

and constructed to

of trouble-Iree operation with a minimum amount of maintenance. They have also

been designed and constructed to withstand


the vibration and extreme temperature

changes

encountered in aircraft

applications.

DESCRIPTION

The

principle components (Figure 2)


are

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

brush and holder

assembly.
Figure
1

90
O
c
oooa

Figure

1)
and

The drive end head contains


a

prelubricated bearing,

an

oil

seal, collar

and shaft seal

blast tube connection for ventilation.

2)
the

The rotor contains

ventilating
inner
race

fan

an

the drive end of the shaft


on

(ALX

series

only)

and

slip ring

end

hearing

and spacer

the other end of the shaft.

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)

The rectifiers used in these units

are

rated at 150 P. I. V. minimum for transient

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

stater lead with

high temperature solder.

The stater leads

are

anchored to the

rectifier mounting plate with epoxy cement for vibration protection.

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.

Each brush is c6nnected to

separate terminal stud and is insulated from

ground. replacement

The brush and holder


purposes.

assembly

can

easily be removed

for

inspection

or

brush

OVERHAUL

When repairing the


it will

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.

Remove the two #10-24

screws

head.

Remove the brush and

holding the holder assembly

brush holder

assembly

in the

slip ring

end

from the end head.

2.

Remove the

safety

wire from the thru bolts and

remove

the thru bolts.

3.

Tap the drive end head lightly and separate the drive end head and rotor,

as a

unit, from

the stater and

slip ring

end head.

4.

Remove the nuts, lock

washers, flatwasher and insulators from the output and auxiliary


correct

terminal studs.
the

Note

carefully the

assembly

of the insulator washers and

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

it will be necessary to have

type

impact type bearing puller


is necessary.

as

shown in Figure 4.

Do not remove the bear-

ing unless replacement


The inner
race

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

the rotor in Note:

vise and

remove

the cotter pin, nut, drive gear

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.

Support the drive end head


can

and press out the

bearing.

Once the

bearing

is

removed,

the oil seal

be knocked

or

out from the inside of the

housing.

WSPECTION AND TESTWO OF COMPONENTS

Upon completion of the disassembly, all parts should be cleaned and visually inspected for

cracks,
i.
can

wear or

distortion and any

signs of overheating

or

mechanical interference. The

Rotor

The rotor should be tested for

grounded

or

shorted winding.
a

ground
an

test

be made with test

probes,

connected in series with

110 volt test

lamp,

ohmmeter

or

any

type of continuity tester.


and the rotor shaft
or

slip rings

Figure poles.

5.

There must not be any continuity between the

To test for shorted turns in the rotor


as

winding,

connect

voltmeter,

ammeter and rheostat


are

shown in Figure 6,

or use an

ohmmeter.

Rotor current draw and resistance

listed

on

*MMETER

RHEOSTAT YOLTMETER

I*TTERI
RoTon

Figure

Figure
Excessive current draw
or or a

individual specification pages. indicates shorted


indicate
an

low ohmmeter reading

open

windings. winding.

No current draw

an

infinite ohmmeter reading would

2.

Rectifiers

A diode rectifier tester will detect and pinpoint open

or

shorted reotifiers wima

out not

going through

the operation of

used in the
test

available, teet probes and following manner.


probe
to
a

disconnecting a #57 bulb, connected Touch one test probe


one

the stater leads.


in series with

However, if
a

tester is
can

12 volt

battery,
the

be

to

rectifier heat sink and the other Then


reverse

lead from

one

of the reotlfiers in that heat sink.

position

of the leads.

The test bulb should light in

direction and not Light in the other direction.

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

The stater can be tested for open


or an

or

described in the rectifier section,

continuity.

Due to the low resistance in the stater

locate.

However, sharted
and

noisy during operation

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

If all other electrical checks the stater should be

normal and the alternator fails to


or

replaced

to determine whether

not it is the

supply its rated output, faulty component.

4. Bearings and Seals seals A


are

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

alternator to fail within

very short

period

of time.

ASSEMBLY

1. Drive End Head the oil seal in

Install the oil seal with the lip toward the outside of the end head.
below the

Press

approximately 1/16"

edge

of the

casting.

Install the ball


race

the seal toward the inside of the end head.

Press

only

on

the outer

of the

bearing with bearing when

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.

Install bearing retainer and

screws.

Support the

inner

oil seals is shown in Figure 7.


2.

Carefully

install the rectifiers in the slip ring end head

or

rectifier mounting plate

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

hammer.) THESE CONNECTIONS,

do not

Reoonnect the stater leads to the reotifiers.

WHEN

USE PLIERS AS A HEAT DAM ON THE LEAD BETWEEN TOO MUCH HEAT WILL DAMAGE THE

THE SOLDER OINT AND THE RECTIFIER.

RECTIFIERS.

Reassemble the rectifier mounting plate studs and insulators, making


correct order. See

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

do not interfere with the rotor.

Install the slip ring end bearing and oil seal.

Make
inner

sure race

the

lip of

the oil seal is toward the

bearing.

Correct

assembly

of

bearing, seal,

and spacer is shown in

Figure

10.

NVT

LOCKWASHER FLATWAS IBERWASHER

SEAL- INSTALL SEAL


WITH LIP

END HEI\D

TOWARD BEARING INNER


RACE

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

Install the brush and holder assembly and retaining


interference between the brush holder and rotor.

screws.

Spin the

rotor and check for

Check

across

the field terminals with


on

an

ohmmeter.

The ohmmeter must indicate the page.

amount of rotor resistance listed

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

The internal fan used

on

the ALX series

provides

ventilation; however, the

same

rule

applies

to these units.

Wiring
nator

connections for bench shown in

testing the alter-

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

After bench testing the alternator, install the

P"E

safety

wire in the
on

through bolts and install the

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

PRECAUTIONS TO BE OBSERVICED WHEN TESTING OR SERVICING THE ELECTRICAL SYSTEM

1.

DISCONNECT THE BATTERY, before

(except voltmeter) or grounding or shorting at cause severe damage to the


2.

before

connecting or disconnecting test instruments replacing any unit or wiring. Accidental removing the regulator, alternator, ammeterpr accessories, will
or

units

and/or wiring.

THE ALTERNATOR MUST NOT BE OPERATED ON OPEN CIRCUIT WITH THE

ROTOR WINDING ENERTIZED.


DO NOT ATTEMPT TO POLARIZE THE ALTERNATOR.

3.

Any attempt
4.

to do

so

may result in

damage

to the

polarization alternator, regulator or


No

is

required.

circuits.

GROUNDING OF THE ALTERNATOR OUTPUT TERMINAL MAY DAMAGE THE

ALTERNATOR

AND/OR

CIRCUIT AND COMPONENTS.

5.

REVERSED BATTERY CONNECTIONS MAY DAMAGE THE RECTIFIERS, VEHICLE


WIRING OR OTHER COMPONENTS OF THE CHARGING SYSTEM. should be checked with
a

Battery polarity
MOST VEHICLES

voltmeter before connecting the battery.

ARE NEGATIVE GROUND.


IF A BOOSTER BATTERY OR FAST CHARGER IS

6.

USED, ITS POLARITY MUST

BE

CONNECTED CORRECTLY TO PREVENT DAMAGE TO THE ELECTRICAL SYSTEM

COMPONENTS.

prPSfCl/l~ti?l

24 VO LT

100 AMPERE

AIRCRAFT

ALTERNATOR

THE PI1ESTOLITE 24 VOLT 100 AMPERE AIRCRAFT ALTERNATOR


100 ampere airoraft
are

The Prestolite 24 volt.


alternators both

(Figure 1)

manufactured for

flange
are

mounting and double

foot, hinge
Both

mounting, belt-driven applications.

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

All 100 amp, 24 volt aircraft alternators


identified ber.

are

by

the

prefix

ALV in the part

num-

The 8000 series identifies the double

Figure

r
oooa

goe eo-~1I
I
QO.p

BBB
O

oe

Q!

~cb
P

Figure

feat, hinge mounted, gear-driven units.


The

belt-driven units, while the 9000 series identifies the

nange mounted,

heat sink and rectifier

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)

The rectifier and heat sirk assemblies

(Flgure 3),

used in these units,

are

different in

construction from those used in any other Prestolite aircraft alternator.

Each heat sink

has six

(6)

rectifiers of

one

polarity

attached to it.

Each stater lead connects to four

(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)

The drive end head,

on

both series, contains

prelubricated bearing.
seal, and
a

The 9000 series

end head also contains

an

oil

seal, collar

and shaft

blast tube connection for

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)

bolts and blast tube

(8000 Series) Straighten the assembly. (9000 Series) Straighten


the

ears on

the lock tabwashers and

remove

the three

through

(2)

ears on

the lock tab washers and

remove

the six through

bolts.

slip ring end bearing sharp object, such as a small, sharp


(3)
Remove the

cover.

This
or

chisel

accomplished by wedging a smi\ll, imife blade, between the cover and the slip
can

be

ring end head.

(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,

lockwashers, net washers and insulators from the output, ground,


studs.

auxiliary terminal
The

The end head


end

can now can

be

separated

from the stater and heat

sink assemblies.

slip ring

bearing

be pushed out from the inside of the end

head.

(6) Each
slip ring

brush is connected to

terminal

studthat is insulated and mounted end head.

through
come

the

Service brushes

attached to terminal studs.


is attached to the
screws

The brush holder


the

and

can

he

slip easily

ring end head with two


serviced
once

alternator is disassembled.

Clamp
drive

the rotor in

vise, being careful


and
remove

not to distort the rotor

poles,

the

components from
The

the rotor shaft.

NOTE:

pulley,
units,

used

an

the 8000 series used


an

units, and the drive


9000 series

assembly,
are

the
or

are

not manufactured

serviced by Prestolite but

available from

Figure

the

engine manufacturer. separated


with
or can a

The drive end head and rotor shown in may be

on

the 8000 series units must be

puller

as

Figure

6.

Do not

attempt

to press the rotor out of the end head


on

the end head be

damaged. by supporting the

The drive end head and rotor


end head and

the 9000 series units

separated

pressing

out the rotor.

(3)

Remove the

hearing

retainer

plate

screws

and

retainer.

press out the

Support the bearing.


can

end head and

carefully
on

The oilseal,

the press-

9000 series units,

then be knocked

or

ed out from the inside of the end head.

INSPECTING AND TESTING COMPONENTS

Upon completion of disasaembly, all parts


should be

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.

To test for shorted turns in the rotor

winding,

connect

an

accurate

voltmeter,

ammeter and
re-

rheostatas shown in Figure 8,


sistance
are

oruse an

accurate ohmmeter.

Rotor currentdraw and


or a

listed

on

the individual

ohmmeter

readingwould
an

indicate shorted
open

reading would indicate

speoifioation pag-e. windings. No winding.


can

Excessive current draw


current draw
or

low

an

infinite ohmmeter

(2)

Reotifiers

A rectifier tester

be used to detect shorted rectifiers and open

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

unsaldering and separating

the rectifier leads.

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,

the heat sink


are

must be

replaced.

The

indivihual

rectifiers

not

assembly containing that replaceable and no attempt

rectifier should be

made to unsolder them from the heat sink.

(S)

Stater

The stater

can

be tested for open


a

#57 bulb connected in series with


tester

12

grounded windings with test probes and volt battery, an ohmmeter, or any type continuity
or

except

110 volt test bulb.

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

Connect the other test stater

continuity

probe to the stater frame. If the is grounded and must be replaced.


one

lights

To test for open

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

If the stater is open, it must be

replaced.

Check

flexible leads for

possible

opens before

replacing

the stater.

Due to the low resistance of the statar

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

normal and the alternator fails to whether


or

replaced

to determine

not it is the

supply its rated output, faulty component.

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.

must be observed to obtain

following assembly procedures a properly assem-

Drive End Head-8000 Series Unite


the
rotor

Install

bearing with the sealed side toward the by pressing on the outer race only.

Install the bearing retainer and

screws.

Sup-

part the
Do not

rotor shaft and press the end head onto the shaft using the tool shown in Figure 9.

attempt

to press the rotor into the end


race

head without supporting the bearing inner


or

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)

Drive End Head-9000 Series Units

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.

Press the oil seal in

approximately 1/16" below

not to fold the oil seal

Reassemble the oil seal collar, being careful lip under. A small
amount of oil
on

the collar will make installa-

D. E.

HEAD07

rH
/OlL
SEnL

tion easier.

Install the "0"

ring seal, being

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

Make certain the "0" ring

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

Lbs. Assemble the brush


heat sinks and stater.

CORRECT

ASSEMBLY OF

OIL

SEALS

Slip Ring End Assembly


prior
Make
to

and terminal stud assemblies in the end head

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-

vide additional-vibration protection.

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.

Position the stater leads


NOTE: If it
stater leads

so

they

will not interfere with the rotor.

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

with epoxy cement. Position the snap

ring,

in the end

head,

so

that

one

of the holes is

directly

in line with the


a

brushes.

Install the brush

springs

and brushes in the brush holder.

Insert

small drill

~---NUTc----\

~---NUT
F LA TWASHER~

/~2\ LATWASHERC--~2: F
I-----

c~

3---FBERWASHER
------INSULATORc-~-----~ENO HEBDc----

~----INSULATOR----~END HEADc--IN SULATOR-

---------INSULATORc~--_ ~FLAtWASHER FIBERWASHERS

~FLATWASHER

~--MEAT

SINK

---//E
AUX. TERM.

~HEAT
ALL EXCEPT AUX. TERM.

SINKc--~C-AUX. TERM.

ffLL EXCEPT AUX. TERM.

INSULATORC/

INSULATORc/

Figure

11

(8000 Series)
(6)

Figure

12

(9000 Series)

or

metal rod

through the

snap

ring hole
a

to hold the brushes in

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

Assemble the alternator and install

couple
sure

of

holding

tool and make

the brushes

of the shaft.

Install the remaining

through bolts.

Do not install the blast tube

assembly

on

the 8000 Series

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

Inch Term. Stud Nuts

Lbs.
Lbs. Lbs.

#10-32 Term. Stud Nuts


9000 Series 8000 Series

30-35 In. 37-42 Ft.

Coupling Retaining Nut Pulley Retaining Nut


TESTING

35-45 Ft. Lbs.

Upon completion of assembly, the alternator should be tested to determine if the unit is

capable

of

delivering

its full rated

output.
mounted units,
more

CAUTION: The 9000 Series,


test these units at full rated

flange

require

a source

of ventilation.

Do Not

output for

than 20 seconds unless

adequate

air pressure

for

cooling

is

supplied.
testing the alternator
are

Wiring

connections for bench

must meet

obtain the

or exceed the specifications listed below. specified voltage.

Figure 13. The alternator Adjust carbon pile, if necessary, to

shown in

Volts
25.8 28.4
10.

Output

RPM

100.0

OAmps. Min. Amps. Min.


the

2000 5000
TEST VOLTMETER

TEST

PIMMETER

After bench

testing

alternator, install the


secure

blast tube

on

the 8000 Series Units and

the lock tab washers.


CARBON PILE

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

Install the alternator


all

the

-~JUMPER WIRES~
Figure

I
13

BATTERY

manufacturers manual.

(7)

NOTE:

Always

refer to the airframe manufacturers wiring


on

diagram

when instRllinr

nr

test-

ing the alternator

the aircraft.

PRECAUTIONS TO BE OBSERVED WHEN TESTING OR SERVICING THE ELECTRICAL


SYSTEM
1. DISCONNECT THE BATTERY, before
or
or disconnecting test instruments replacing removing any unit or wiring. Accidental (except voltmeter) grounding or shorting at the regulator, alternator, ammeter, or accessories, will cause severe damage to the units and/or wiring.

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

may result in damage to the

polarization alternator, regulator or


No

is

required.

circuits.

4. GROUNDING OF THE ALTERNATOR OUTPUT TERMINAL MAY DAMAGE THE ALTERNATOR

A~jD/OR

CIRCUIT AND COMPONENTS.

5. REVERSED BATTERY CONNECTIONS MAY DAMAGE THE

WIRING OR OTHER COMPONENTS OF THE

RECTIFIERS, VEHICLE CHARGING SYSTEM. Battery polarity

should be checked with

voltmeter before connecting the

battery.

MOST VEHJCLES

ARE NEGATIVE GROUND.

6. IF A BOOSTER BATTERY OR FAST CHARGER IS

USED, ITS POLARITY

MUST BE

CONNECTED CORRECTLY TO PREVENT DAMAGE TO THE ELECTRICAL SYSTEM


COMPON E NTS

7. WHEN USING AN AUXILIARY POWER

UNIT, MAKE SURE THE VOLTAGE AND POI,AR-

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

24 VO LT, 1 00 AM PE RE OVERHAUL PROCEDURES

Section 1 ELECTRICAL CHECKS AND INSPECTION

1.1

Visual and Meohanioal

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

Replace damaged parts. Spaoer and O-Ring Seal

Shaft

Verify

no

damageiwear
worn

to shaft spacer surface finish

(20 micraor

inch maximum) and

O-ring seal. Replace damaged damage

parts.

1.1.6

Oil Seal

Verify
parts.

no

or wear

to oil seal. See

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

Bearing, Housing and Shaft


6.

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

for rust accumulation


ullh

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

field terminals F1 and F2

jumpered
or a

to the

and(-) output terminals (use #16

#18 AWG wire

the

2-3 ampere field current and

field control

switch). Approximately 6 hp will be required to drive


the alternator at the specified load condition. Prepare test setup so that operation time at the loaded condition does not exceed 20 seconds. This is required for
two
reasons.

head and rotor assembly to determine which bearing is defective and should be replaced.
1.2

Electrical Checks

The stated performance is based

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.

terminal and the AUX terminal.


very

2. 3.

One

reading should be low and the other

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

terminal and the AUX terminal, resistance between Fl and

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

Page 9, Table analysis.


Refer to

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

Section 2 OVERHAUL PROCEDURE

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.

Place the alternator

on a

wood "V" block stand.

2
3

Straightenthe locktabsoneachof the six(6)


bolts (Use
new

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.

AUX terminal and the other Note location to facilitate

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

Holder, Brushes and Capacitor

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

facilitate reassembly Remove terminals with Note location for

integral

brushes.

Remove internal insulators from brush terminals

housing. Scribe mark

across

bousings
of
reas-

and stater to indicate sembiv,


6.

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

Remove shaft cotter

key

and nut.

Remove shaft
er or

shipping sleeve and shipping washassembly if installed. key


O-ring seal

drive gear

Remove woodruff

Remove rotor shaft spacer and

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

drop and be damaged.

2.3.6

Remove Drive End


i.

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

(DO NOT HAMMER). Disoard oil seal.

Figure
i
2.32

2-1
2.3.8 Remove Rectifier

Heat Sinks from Stater


to removal of either heat sink assembly as required for
to

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

assembly from the

atator

replacement

testing of individual assemblies. Fig

2~Q showsone of the roctifierheatsintssrwired

th, stator leads. The other heat sink has similar type
eonneelions.

Remove epoxy cement


heat sink 4.

holding each

stator lead to

Removethe
the

AUXoutputterminal andspaeer from

RBM

negative heat sink assembly.

2.4

3/16"
C

DIA. BBR STOCK


2.4.1

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.

e 112" l.D. PIPE


4.

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,

bearing over, shaft key. etc.

far any dam-

age, wear, carrosion or distortion faulty parts at reassembly.

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

insulators i. 2. marks. Parts that


as

Inspect parts

(Washers and Spacers) for cracks, deformation and burn


suitable for reuse, shall be cleaned

are

required using isoprapyl alcohol. (CAUTION:

ANYOTHER CLEANER MAY DAMADE IN-

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

check hem lead

ohmmeter. Use meter RX100 scale and to lead. Replace capacitor if it is

shortedneaky.
2.4.5

Brushholder, Brushes and Springs


i.

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

two stainless steel brush

deformation, change in Length

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

slip ring repair noted

step C).

ROTORS NOT SERVICEABLE IN PARTS AND


MUST BE REPLACED AS A WHOLE A. Stripped shaft threads B. Worn key slotsiholes (woodrnff and cotter). C.
D E F G.

Worn andlorcorroded
drive end and Loose shaft.

bearingjournal surfaces
on

slip ring end slip ring assembly or pole pieces

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

only enough material

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

burrs or metal NOTE:

replaced. Lnparticles on or

Size: Contents:

/la Diameter
9535D/o Tin

Spool

between

slip rings.

4.65Yo Silver (Minimun~l Phstia

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:

23PC apprex 23bC approx J W Harris Co

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

ment and electrical

require stator replucoas specified in step determine possible damage to rectifiers.


stater leads

testing

Replace

rotor if coil fails resistance test

D.

Rotor Ground Test A

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.

Lnspect slip ring make certain they

NOTE; and solder connections to


are

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.

1.2.1 and 122.


can

Replace
tected.

rotor if any meter movement is de-

Stater testing
Using
a

per

performed as paragraph 2.3.8:


be
on a

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

Inspect for broken rectifier leads, damaged

atatar

movement i. detected

or

irmeter indicates full

leeds, loose or cracked epoxy (securing stater leads


to heat sinks) and discolorationof stater windings.

scale, the
B.

stater, must be

replaced.

UsingVOMonRX1

range, measure resistance

See A.

following

list far action

required

if faults

are

(continuity) between

AUX terminal and each

detected.
Broken rectifier leads require replacement of the associated rectifier-heat sink assembly. RECTIFIERS ARE NOT SERVICEABLE INDIVIDUALLY.

stator lead (6 tatal). Resistance should be (1.6

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

seal onto shaft and

position

housing

on

press with front of

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.

ing. DO NOT HAMMER.


25.2 Install Drive End Bearing 1. Position drive end housingon press with front of

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.

Assemble ReotiBer-Heat Sink Assemblies and 8tator Assembly


This

procedure applies

when

replacing the recti8er-

5.

Position

bekiring

installation tool(l9ls inch O.D.


x

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

slip ring end housing, position in the end head.

with heat

2.5.5

Assemble Slip RingEnd Head, Brush Bolder and


Brushes
1.
2.

4.

With reference to

Figures

2-10A and B, assemble

brush terminal insulators and install to

housing

Install brushholder in end head using screws and lockwashers. Ti.hten screws to 15-20 inch pounds,

Instailbearingsnap ringretainer, positioninggap


in retainer relative to brushholder
as

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

DOW CORNING SEALER No.1890 LAMP CAPACITOR

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

BEARING RETAINER HOLE

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)

Follow manufacturers instructions for sealer ap-

BRUSH HOLDER

7.

plication. Torque field (brush) terminal inch pounds.

stud nuts to 25-30

SLIPRING END HOUSING


Figure
2-9

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-

-INsuLaron--END HEIID -2INSULIITORf-----FL*TWISHER

flBERWI\SHERSJ
~HEdll SINK

ALL EXCEPT AUX. TERM.

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-

Insure that the stater a. 3.


are

mating surfaces of housing and clean and free of any dirt, burrs or
install two thru-boltti to hold unit

foreign material.

Temporarily
together.

Remove the brush retraction teal and

verify

brushes seat againstslip ringe. Visually check that brush leeds are free and cannot bind against

anything.
4.

Install

bearing O-ring seal

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

SUp Ring End Bearing. Position assembly of paragraph

2.5.1 in arbor

press ~th net surface of drive end shaft net and true surface of press. 2

against a
2.

intobearingpocket Positionnewbearingsquarsly of housing with SEALED SIDE OF BEARING


TOWARDS ROTOR. CARE MUST BE TAKEN TO PREVENT CONTAMINATION OF BEARING. Use a lengthof W inch diameter bar stock to press bearing into housing onto shaft and up to shaft stop. Apply pressure to inner race only. Pressure on

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

Bend six (B) lack tabs


2-13
as

as

shown in

Figure a-12 and

3.

applicable.
to the follow-

2.5.10

Terminal
i.

Torquing

Tighten the terminal mauntingnuts


ing torque values:
Terminal
Fl F2

outer

race

will

damage bearing. (110


cover.

4.

NOT HAMMER.) Install slip ring end

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

AUX (f) AUX

#10-32 k..-28
/1"-28

U..-28

?0-85

2.5.11

Post Assembly Test Perform test on completed section 1, paragraph 1.2.5.

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

polarize the alternator. No required. ANY ATTEMPT TO DO

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

Installation of Alternator to Engine engine manufacturers instructions.


Alternator
1.

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.

CAUTION: ALWAYS RECONNECT BATTERY PRIOR TO OPERATING ALTERNATOR.

TABLE I-1 TROUBLE SHOOTING CHART


TROUBLE
I i.

PROBABLE CAUSE
Loose te~minal connections.

LOW/NO ALTERNATOR OUTPUT

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

at drive end and/or

slip ring end.

2. Loose frame thru-bolts. 3. Shorted rectifiers

(magnetic noise).

INTERMITTENT OUTPUT

1. Worn

brushes/dirty slip rings.

2. Loose connections/corroded terminals.

ALE SERIES
SERVICE PARTS LIST ALTERNATOR ISSUED:

2-18-75(Rev.)
VOLTS-1P

ORIG. EOUIP.ALTERNATOR
ENG.

SERVICE ALTERNATOR

NUMBER ALE-6406 ALE-6406G


USE

ENG. NUMBER ALE-6406R

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-6420R ALE-8408R ALE-84O6R ALE-8406R ALE-8406R

Lycomi ng Lycoming Lycaming


Service

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.*

File in the OE-AI AIRCR*FT MANUAL

ALTERNATOR SECTION

ALE Series Alternator Parts List

/16

7t---~

/6

o--------l

0-------7~

Exploded

View of

Typical

A1E Alternator

ALE SERIES ALTERIIATOR PARTS LIST


Rotor

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

OE-AI AIRCMPt MANUAL

ALE SERIES ALTERNATOR PARTS LIST


Stater

Assembly

Assembly

Pos.Rectf fier 8 Plate


As

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

ALE SERIES ALTERWATOR PARTS LIST


Assembly
Thru Bolt Nut Washer Rotor Shaft

ISSUED: 3-5-79 (REV.)


Vent
Fan

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

FVR-4011A YSF-7203S FVR-4011A


ALA-20FS ALA-2(X1S YSF-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

OF-Al AIRCRAFT MANUAL

IL!

prp~fD/Ifp,
SERVICE
INFORMATION
I
ALTERNATOR DESCRIPTION
RATED VOLTAGE 12

ALE
AIRCRAFT ALTERNATORS

Issued 4/1/83

Page 1 of 4

RATED OUTPUT GROUNDED POLARITY

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

Torque the drive pulley retaining


40 Ft.

nut to 35

Ft.

Lbs.

minimum to

Lbs.

maximum.

ROTOR OHMMETER TEST CONDITIONS


1.
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 a 10.0 ohm resistor. Ohnrneter must be checked to
zero

3.

before and after rotor test.

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.

File in the OF-Al AIRCRAFT MANUAL

Tech. Data

ALTERNATORS

ALE
AIRCRAFT ALTERNATORS

k
SERVICE

Issued

4/1/83

Page 2 of 4

INFORMATION

ROTOR OHMMETER TEST SPECIFICATION

Rotor

winding resistance

3.0 to 5.0 ohms.

ROTOR CURRENT DRAW TEST CONDITIONS i.

Rotor to be

room

temperature

700

to

800

F.

2.
3.

Voltmeter and ammeter must be accurate.


Refer to service

publication for

test

wiring diagram.

ROTOR CURRENT DRAW TEST SPECIFICATION

Current draw at 12.0 volts

2.4 to 4.0 amperes.

SLIP RING REFINISHING

Minimum Diameter Total Indicator Runout Surface Finish

1.350" .002" max, measure from 50 microinch max.

bearing journals

ALTERNATOR OUTPUT TEST CONDITIONS


i.

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

than 2 minutes for each

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

ALTERNATOR OUTPUT TEST SPECIFICATIONS

(Without Regulator)
Output Amperage
19 32 Minimum Alternator RPM
2000 4000

Alternator Series Series


ALE 6400, 8100,

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

10 Lb. 10 Lb. 10 Lb. 10 Lb. 10 Lb.

6 Oz. 6 Oz. 6 Oz.

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

Prestolite part number.

File in the
Printed in U.S.A.

I
j

Tech.
Data

OF-Al AIRCRAFT MANUAL

ALTERNATORS

ALE AIRCRAFT ALTERNATOR Issued

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 ALT-8403


ALT-8404

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

USE USE USE USE


USE

ALT-8421RS

Teledyne Continental Lycoming Lycoming


Service Service

ALT-B421R
ALT-84 21 RS ALT-8420 ALT-8420 AL~-8421R ALT-8421RS
ALT-8421R

Teledyne Continental

USE USE

Teledyne Continental Lycoming

Lycoming
Service Service

USE

ALT-8421RS ALT-9422 ALT-9422

Teledyne Continental Teledyne Continental

File

in

the

ALTERNATOR ~LTEINIIOR SECTION IICIION

OE-AI AIRCR*FT MANUAL

ALT Series Alternator Parts List

171

-t~
6

rBS-s~i
ioY4
4

4~

~G L~3

ra-----

/4

I I

Exploded View

of

Typical

ALT Alternator

ALT SERIES ALTERNATOR PARTS LIST


Rotor

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

Drive End Head

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~.

OF-Al AIRCRAFT MANUAL

ALT SERIES ALTER~ATOR PARTS LIST


Sta tor

Assembly

Assembly

Pos. Rectifi er Plate

Negative
Rectifier

Termi nal Stud

D.E. Petal ner

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

90-990 90-2043 90-2030


6b32

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

ALT SERIES ALTERNATOR PARTS LIST


S.R.E.

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

[NAI CNA] CNA]

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

90-2014 ALE-1 142AAS-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~.

OE-AI AIRCRAFT MANUAL

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

SERVICE PUBLICATION L-651A 8400

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.

the drive pulley Lbs. maximum.

retaining

nut to 35

Ft.

Lbs.

minimum

ROTOR OHMMETER TEST CONDITIONS


i. 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 a 10.0 ohm resistor.

3. 4.

Ohnmeter must be checked to

zero

before and after rotor test. clean. Ohmmeter

Slip rings and ohmmeter test probes must be test probe leads must be in good condition.

Printed in Usn.

OF-Al

the e l i F L A U NAM AIRCRAFT


in

Tech.
Data

ALTERNATORS

ALTAIRCRAFT
Page

ALTERNATORS

Issued 4/1/83 2 of 4

SERVICE

INFORMATION

ROTOR OHMMETER TEST SPECIFICATION


Rotor

winding resistance

10.5 to 12.5 ohms,

ROTOR CURRENT DRAW TEST CONDITIONS


i. Rotor to be
room

temperature

700

to

800F.

2. 3.

Voltmeter and ammeter must be accurate.


Refer to service

publication for

test

wiring diagram.

ROTOR CURRENT DRAW TEST SPECIFICATION


Current draw at 24.0 volts 1.9 to 2.3 amperes.

SLIP RING REFINISHING

Minimum Diameter Total Indicator Runout Surface Finish

1.350" .002" max, measure from bearing journals 50 microinch max.

ALTERNATOR OUTPUT TEST CONDITIONS


i.

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

than 2 minutes for each test

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.

ALT

SERVI%E
INFORM ATION

AIRCRAFT ALTERNATORS
Issued:

4/1/83

Page

3 of 4

ALTERNATOR OUTPUT TEST SPECIFICATIONS


Alternator Series ALT 5100, 6400, and 8400 ALT 9400

(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

Alternator ALT 5101A, S


ALT 5102S 12 Lb. 12 Lb. 11 Lb. 12 Lb. 2 Oz. 2 Oz.
12 Oz.

:?tel;~al
Figure
1

Ri

VSB-7401C
VSF-7401

Figure 2

VSF-7403S
VSF-7403S
or

ALT 6408 ALT 8403

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

VSF-7401 VSF-7403 VSF-7404 VSF-7404 VSF-7403

or

VSF-7403S

12 Lb.
12 Lb.

2 Oz. 2 Oz. 2 Oz.

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.

OF-Al AIRCRAFT MANUAL

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.

NUMBER ALU-8421R ALU-8421RS


ALU-8421R

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

OGAI AIRCRAFT MANVAL

AL

Series Alternator Parts

List

L__

-T

____J

LfO

r--

-I

Exploded View

of

Typical ALU Alternator

ALU SERIES ALTERNATOR PARTS LIST


Rotor
Brush

ISSUED: 3-5-79 (REv.)


Br.,Holder

SHEET 2
D.E.

~Assembly

Assembly

Set

o
ALU-8403,R
ALU-8403LS,

o
1----

Spring Assembly
5

Slip Ring End Head

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-8421,R ALU-8421LS, ALU-9404LIR ALU-9422L,R

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.

[c] XA-1D25 D.E.O11 Seal [d] S.R.E.Hwd P1 Rotor

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.*.

File in the OF-Al AIRCRAFT MANUAL

ALTERNATOR SECTION

ALU SERIES ALTERMATOR PARTS LIST


Stater

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

ALU SERIES ALTERNATOR PARTS LIST


Eyelet
Assembly
Package
Nut

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

ALU-8421LS,RS ALU-9404L,R ALU-9422L,K

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

OF-Al AIRCRAFT MANUAL

SERVIcE
IN FORM ATION

fP~

ALU
AIRCRAFT ALTERNATORS

Issued:

4/1/83

Page

1 of 3

ALTERNATOR DESCRIPTION RATED VOLTAGE ROTATION 24 RATED OUTPUT GROUNDED POLARI~ITY 70

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

SERVICE PUBLICATION 8400 L-655A


L-663 SERVICE BULLETINS

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

the drive pulley Ft. Lbs. maximum.

retaining

nut to 35

Ft.

Lbs.

minimum

ROTOR OHMMETER TEST CONDITIONS


i. 2.
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.

before and after rotor test. clean. Ohmmeter

Slip rings and ohmmeter test probes must be test probe leads must be in good condition.

Printed in U.S.A.

OF-Al

the e l i F L A U NAM AIRCRAFT


in

a~a

ALTERNATORS

ALU

AIRCRAFT ALTERNATORS
Issued 4/1/83

kPresto~rp.
SERVICE

Fage 2 of 3

INFORMATION

ROTOR OHMMETER TEST SPECIFICATION


Rotor

winding resistance -10.5

to

12.5 ohms.

ROTOR CURRENT DRAW TEST CONDITIONS


i. Rotor to be
room

temperature

700

to

800F.

2.
3.

Voltmeter and ammeter must be accurate. Refer to service

publication

for test

wiring diagram.

ROTOR CURRENT DRAW TEST SPECIFICATION


Current draw at 24.0 volts

1.9 to 2.3 amperes.

SLIP RING REFINISHING

Minimum Diameter Total Indicator Runout Surface Finish

1.350"
.002" max. measure from bearing journals 50 microinch max.

ALTERNATOR OUTPUT TEST CONDITIONS


i. Alternator to
be room

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

adjustable load. point.

Alternator not to be

than 2 minutes for each test

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

AIKCRAFT ALTERNATORS Issued:

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 6400, 8400

ALU 9400

4000
8000

Alternator ALU-6404
ALU-8401

Approx. Weight
11 Lb.

Orig. Equip. Regulator


12 Oz.
2 Oz. 2 Oz. 2 Oz.
6 Oz.

Replacement Regulator
VSF-7403S

VSF-7404 VSF-7401
VSF-7403 VSF-7403 VSF-7403 VSF-7403

12 Lb. 12 Lb. 12 Lb.


11 Lb.

VSF-7403S VSF-7403S
VSF-7403S VSF-7403S VSF-7403S

ALU-84O3, LS, R, RS, S


ALU-8421, LS, R, RS, S

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

Internal Wiring Diagram

File in the
Printed in U.S.A.

Tech.

OF-Al AIRCRAFT MANUAL

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

ALV-8512R ALV-8512R ALV-BSI1R

Lycoming
Service Alternator

USE
USE

ALV-8511R
ALV-8511R

Teledyne Cont.,Service Lycoming Lycomi n 9


Service Alternator

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-94OiL ALV-940LR ALV-9405L ALV-9405R


ALV-94O6L

Teledyne Cent. Lycoming


Se rvi
ce

ALV-951oR
ALV-9405R ALV-9405R
ALV-9406R ALV-9406R ALV-9510R ALV-9510R

Al ternator

Lycoming
Service Alternator

USE

Lycoming
Service Alternator

ALV-9406R ALV-9407 ALV-9407S ALV-951O


ALV-9510L USE
USE

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.*.

OCAI AIRCRAFT MANVAL

ALTERNATOR SECTION

ALV Series Alternator Parts List

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

Typical ALV Alternator

ALV SERIES ALTERNATOR PARTS LIST


Rotor

ISSUED: 11-10-82 (KEV,)


Slip Ring
End Head
S.R.E.

SHEET 2
Stater

Assembly

Assembly

Brush Set

Bearing

Assembly

Drive End Head As ly

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-8511 ALV-8511R ALV-8512


ALV-8512R

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.

Oil Seal also available.

File in the
Prlnld In V;S.~.

ALTERNATOR SECTION

OF-Al AIRCRAFT MANUAL

ALV SERIES ALTERNATOR PARTS LIST


Assembly
Br.Holder Bkt.

Brush

Spring
Set

Pos. Rect.& Plate

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~

ALV-8512 ALV-8512R ALV-9401 ALV-9401L ALV-9401R

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~

Used only on Not required.

Early Production units having Snap Ring

at

Slip Ring End of Rotor

Shaft.

ALV SERIES ALTERWATOR PARTS LIST


Capacitor
Assembly Assemb~y
Term.
Stud

ISSUED: 11-10-82 (REV~)


Lock
Tab

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

OE-AI AIRCRAFT MANUAL

ALV SERIES ALTERNATOR PARTS LIST


Assembly
Rotor Shaft Vent. Fan

Regulator (24

22)
ALV-6403LS
ALE-21

(23)
PU-1609A

VSF-7403S

ALV-6403RS
ALV-8402

ALV-8402L ALV-8511 ALV-8511R


ALV-8512

ALV-0512R ALV-9401 ALV-9401L ALV-940LR ALV-9405L


ALV-9405R ALV-94061 ALV-21

Cd]"

[NRI

I I I
N

I I I I I I
I

eNRI CNR] [NRI [NRI


[NRI ENRI [NR] [NRI

ALV-9406R
ALV-9407

ALV-9407S

ALV-9510 ALV-9510L ALV-9510R

90-2822[e1l

[NRI [NR]

I I

[NRI

Spacer only.

[d] XA-744AZ Shaft Spacer O-Ring

Seal

is also available.

~e] [NR]

Includes XA-744AZ Shaft Not

Spacer 0-Ring Seal.

required.

presto~-fP.
SERVICE
INFORM ATION

ALV
AIRCRAFT ALTERNATORS Issued:

4/1/83

Page

1 of 3

ALTERNATOR DESCRIPTION

RATED VOLTAGE ROTATION

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

ALV-6400 ALV-94OO ALV-95OO

SERVICE BULLETINS

Refer to the Service Bulletin Section of this manual to the ALV series alternators. SERVICE SPECIFICATIONS
DRIVE PULLEY

for bulletins

pertaining

Torque the drive minimum to 45 Ft. Torque the drive


minimum to 42 Ft.

pulley retaining
Lbs.
gear

nut to 35

Ft.

Lbs.

maximum.

DRIVE GEAR

retaining
maximum.

nut to

37

Ft.

Lbs.

Lbs.

ROTOR OHMMETER TEST CONDITIONS


i.
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 a 10.0 ohm resistor.
Ohmmeter must be checked to
test.
zero

3.

before and after rotor

File in the
Printed in U.S.A.

Tech.

OF-Al AIRCRAFT MANUAL

Data

ALTERNATORS

ALVAIRCRAFT
Iss ued:

ALTERNATORS

411/83

SERVICE

Page 2 of 3

INFORMATION

ROTOR OHMMETER TEST CONDITIONS CONTD.


4.

Slip rings and ohmmeter test probes must probe leads must be in good condition.

be clean.

Ohmmeter test

ROTOR OHMMETER TEST SPECIFICATION Rotor

winding resistance

9.9 to 11.8 ohms.

ROTOR CURRENT DRAW TEST CONDITIONS


i.

Rotor to be

room

temperature

700

to

800F.

2. 3.

Voltmeter and ammeter must be accurate.


Refer to

service publication for test

wiring diagram.

ROTOR CURRENT DRAW TEST SPECIFICATION Current draw at 24.0 volts SLIP RING REFINISHING

2.03 to 2.42 amperes.

Minimum Diameter Total Indicator Runout Surface Finish

1.350" .002" max. measure from bearing journals 50 microinch max.

ALTERNATOR OUTPUT TEST CONDITIONS


i.

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

when bench testing the alternator.

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

AIRCRAFT ALTERNATORS Issued:

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.

Orig. Equip. Regulator


VSF-7403 VSF-7404 VSF-7403 VSF-7403 VSF-7403 VSF-7403 VSF-7403 VSF-7403 VSF-7404 VSF-7403

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

ALV-9401, L, R ALV-9405L, R ALV-9406L, R ALV-9407, S ALV-951O, L, R

Lb. Lb. Lb.


Lb. Lb.

10 10 10 10 10

Oz. Oz. Oz. Oz. Oz.

or

7404

or

7404

OUTPUT

FIELD

F2

FIail
_j
Internal

GROUND

AUXILIARY

AU~J

Wiring Diagram

File in the
Printed in U.S.A.

OF-Al AIRCRAFT MANUAL

Tech. Data

ALTERNATORS

presto/itP.
SERVICE PARTS LIST

ALX SERIES
ALTERNATOR

ISSUED:10-19-79

(Rev.)

ORIG.EOUIP. ALTERNATOR
ENG.

SERVICE ALTERNATOR ENG.

VOLTS-1P

NUMBER ALX-6408 ALX-6423 ALX-8403 ALX-8403G ALX-8403LS ALX-8403LSG ALX-8403R ALX-8403RG


USE USE USE USE USE USE USE USE

NUMBER

APPLICATION

ALX-6423 ALX-6423 ALX-8421R


ALX-8421R ALX-8421RS ALX-8421RS ALX-8421R

Teledyne Continental Teledyne Continental

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

Lycomlng Lycoming Lycoming Lycomlng


Service

USE USE USE USE


USE

ALX-8421RS ALX-9425J ALX-9422R


ALX-9422R ALX-9422R
ALX-9422R

Service Service Service

Teledyne Continental Lycoming Lycoming


Service

USE USE USE USE USE USE USE USE

Service

ALX-9424
ALX-9422R

Teledyne Continental Lycoming

ALX-9422LG
ALX-9422R ALX-9422RG
ALX-9424

ALX-9422R ALX-9422R ALX-9422R


ALX-9424 ALX-9425R

Lycoming
Service Service

ALX-9425 ALX-9425A
ALX-9425B

Teledyne Continental Teledyne Continental

ALX-9421
ALX-9425R

Teledyne Continental
Teledvne Continental

File in the
Plilld In UI.*

OE-AI AIRCRAFT MANVAL

ALTERNATOR norRNlroRrrcnoN SECTION

ALX Series Alternator Parts List

20

17

Ed]~

14

16

~"10
hbb
io

o~

-------II I

r-

Qg~l
I I

Exploded View

of

Typical ALX Alternator

ALX SERIES ALTERIIATDR PARTS ?IST


Rotor

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~.

OE-AI AIRCRAFT MANUAL

ALX SERIES ALTERNATOR PARTS LIST


Stater

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

[NA] [NA] [NA] [NA] [NAI CNA]


ALX-1 0625

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.

ALX SERIES ALTERiJATOR PARTS LIST


"O"

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

[NA] [NA~ CNA~ [NAI [NA]


CNA]

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

FYR-4011A VSF-7203S FVR-4011A

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]

[NA] [NA] [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

OF-Al AIRCRAFT MANUAL

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

SERVICE Detailed service

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

ALTERNATOR SERIES ALX 6400


ALX 9400

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

Torque the drive pulley retaining


40 Ft.
Lbs.

nut to 35

Ft.

Lbs.

minimum to

maximum.

ROTOR OHMMETER TEST CONDITIONS


i.

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.

before and after rotor test.

Slip rings test probe

and ohmmeter test probes must be clean. leads must be in good condition.

Ohmmeter

ROTOR OHMMETER TEST SPECIFICATION


Rotor

winding

resistance

3.5 to 5.0 ohms.

Printed in U.S.A.

File in the OF-Al AIRCRAFT MANUAL

Tech.
Data

ALTERNATORS

Al X

AIRCRAFT ALTERNATORS Issued:

k
SERVICE

4/1/83

Page

2 of 4

INFORMATION

ROTOR CURRENT DRAW TEST


i. Rotor to be

CONDITI6NS
temperature

room

700

to

800F.

2.
3.

Voltmeter and ammeter must be accurate. Refer to service

publication for

test

wiring diagram.

ROTOR CURRENT DRAW TEST SPECIFICATION


Current draw at 12.0 volts SLIP RING REFINISHING

2.4 to 4.0 amperes.

Minimum Diameter Total Indicator Runout Surface Finish


ALTERNATOR OUTPUT TEST CONDITIONS
i.

1.350" .002" max.

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

than 2 minutes for each test

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.

ALTERNATOR OUTPUT TEST SPECIFICATIONS


Alternator Series ALX 6400-8400 and 9400

(Without Regulator)
Output
Amperage
33.0 57.0

Output Voltage
14.0 14.0

Minimum Alternator RPM


3000 6000

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+

ALX 8421, LS, R, RS


XALX 84216, LSG, RG, RSG ALX 9402 ALX 9404L,
R

12

Lb.

2 Oz.

VSF-7201 VSF-7203 FVR-4004+

or

VSF-7203S

12 Lb.

2 Oz.

FVR-4011+

11
11

Lb. Lb.

6 Oz.
6 Oz.

VSF-7204 VSF-7201 VSF-72O3


FVR-4004+ VSF-7203
or

VSF-7203S
or

VSF-7203S

*ALX 9404LG, ALX 9405

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

~SF-7203S FVR-4011+ VSF-7203S

*ALX 9422L6, ALX 9424

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.

Prestolite part number.

File in the
Printed in U.S.A.

OF-Al AIRCRAFT MANUAL

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

Internal Wiring Diagram

presto/ire,
SERVICE PARTS LIST

ALY-6403 To 642iP RG
ALTERNATOR ISSUED:

3-3-75(Rev.)
VOLTS-IF

ORIG.EOUIP.ALTERNATOR
ENG.

SERVICE ALTERNATOR ENG. NUMBER USE USE USE USE USE


USE USE USE

NUMBER
ALY-6403 ALY-6403G ALY-6403R ALY-64O3RG ALY-6406 ALY-64OSG ALY-640BR ALY-6406RG ALY-64O8

APPLICATION

ALY-642OR ALY-6420R ALY-6420R

Lycoming Lycomfng
Service Service

ALY-642OR
ALY-6406R

Lycoming Lycoming
Service Service

ALY-6406R
ALY-6406R ALY-6406R

ALY-64O9
ALY-6412

USE USE USE USE

ALY-64F1 ALY-5422

Piper Piper Teledyne Continental Lycoming Lycomrng


Service Service

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

ALY-6427R ALY-6427R ALY-6427R ALY-6427R

Lycoming Lycoming
Service
Service

USE

File in the
Pas, in u.S.*.

OE-AI AIRCRAFT MANUAL

ALTERNATOR SECTION

ALY-6403 to 6427R6 Alternator Parts List

~-----O

B
10

g-@

II

0----------~
c/

Exploded View

of

Typical ALY Alternator

ALY-61103 TO 61127RG ALTERNATOR PARTS LIST


Rotor

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

Bearing 8 Seal Pkg.

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

OE-AI AIRCRAFT MANUAL

ALY-6403 TO 6427R6 ALTERIIATOR PARTS LIST


Stater

Assembly

Assembly

Pos.Rect. 6 Plate As

Negative
Rectifier

Terminal Stud

D.E. Retai ner

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

ALY-64O3 TO 6427RG ALTERNATOR PARTS LIST


S.R.E.

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

CNA] CNA~ CNA]


~NA] CNAI

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

90-2014 ALK-1132BS-1 ALE-2173S-1

Assy.,S.R.E.

ALK-1132BS-1 ALE-2177S-1

[NA]

Not Available.

File in the
Prlntd In U.S.~.

ALTERNATOR SECTION

OF-Al AIRCRAFT MANUAL

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

APPL ICAT ION

ALY-8411
ALY-8420R

ALY-8403LS
ALY-8403LSG ALY-8403R

USE USE USE USE USE USE USE


USE USE

ALY-8420R

ALY-84O3RS
ALY-8403RS

Teledyne Continental Lycoming Lycoming Lycoming Lycoming


Service
Service Service Service

ALY-8420R
ALY-8420R

ALY-8403RG ALY-8403RS ALY-8403RSG ALY-8405


ALY-8405G ALY-8405R

ALY-8403RS
ALY-8403RS ALY-8426R
ALY-8426R

Lycoming
Lycoming
Service

ALY-8405RG ALY-8410
ALY-8410R

USE USE USE

ALY-8426R ALY-8426R ALY-8423R ALY-8423R

Service

Lycoming
Service

ALY-8411 ALY-8420 ALY-842OG ALY-8420LS ALY-8420LSG


ALY-8420R

ALY-8411
USE USE
USE

ALY-8420R
ALY-8420R ALY-8420RS

USE

ALY-8420RS ALY-8420R ALY-8420R ALY-8420RS


ALY-8420RS

Teledyne Continental Teledyne Continental Lycoming Lycoming Lycomlng


Service Service Service
Service

ALY-8420RG ALY-8420RS ALY-8420RSG ALY-8423 ALY-8423R ALY-8424 ALY-8426 ALY-8426G


ALY-8426R

USE USE USE

ALY-8423R ALY-8423R ALY-8424

Lycoming
Service

USE
USE

ALY-8426R

ALY-8426R
ALY-8426R

Teledyne Continental Lycoming Lycoming


Service

ALY-8426RG

USE

ALY-8426R

Service

File in the
OE-AI AIRCRAFT MANUPIL

SECTION ALTERNATOR slcnon aurlwroa

ALY-8402 to 8426RG Alternator Parts List

I,

~----O

io

9-@

II

0------------~

~3
;P7

Exploded View of Typical ALY Alternator

ALY-8402 TO 8426RG ALTERNATOR PARTS LIST


Rotor Brush

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

OF-Al AIRCRAFT MANUAL

ALY-8402 TO 8~26RG ALTERNATOR PARTS


Stater

Assembly

Assembly

Pos. Rect. Plate

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

ALY-8402 TO 8112611(3 ALTERIJATOR PARTS LIST


S.R.E. Nut
Rotor

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

ALY-8405, R ALY-84056,RG ALY-8410, R


ALY-8411

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

S.R.E.Head 6 Rotor Pkg.

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

OF-Al AIRCRAFT MANUAL

presr~re.
SERVICE INFORMATION

ALY
AIRCRAFT ALTERNATORS

Issued:

4/1/83

Page

1 of 4

ALTERNATOR DESCRIPTION RATED VOLTAGE ROTATION


12

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

for bulletins pertaining

Torque the drive pulley retaining


40 Ft. Lbs.

nut to 35

Ft.

Lbs.

minimum to

maximum.

ROTOR OHMMETER TEST CONDITIONS i.


2.

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.

before and after rotor test. Ohmmeter

4.

Slip rings test probe

and ohmmeter test

leads must

probes must be clean. be in good condition.

ROTOR OHMMETER TEST SPECIFICATION


Rotor

winding resistance

3.5 to 5.0 ohms.

Printed in U.S.A.

File in the OF-Al AIRCRAFT MANUAL

Tech.
Data

ALTERNATORS

ALYAIRCRAFT
Issued:

ALTERNATORS

4/1/83

SERVICE INFORMATION

Page 2 of 4

ROTOR CURRENT DRAW TEST CONDITIONS


i. Rotor to be
room

temperature 700

to

800F.

2.
3.

Voltmeter and ammeter must be accurate. Refer to service

publication

for test

wiring diagram.

ROTOR CURRENT DRAW TEST SPECIFICATION


Current draw at 12.0 volts SLIP RING REFINISHING

2.4 to 4.0 amperes.

Minimum Diameter Total Indicator Runout Surface Finish


ALTERNATOR OUTPUT TEST CONDITIONS
i.

1.350" .002" max.

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

than 2 minutes for each test

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

testing the alternator.

ALTERNATOR OUTPUT TEST SPECIFICATIONS


Alternator Series

(Without Regulator)
Output era Amperage
13.0 47.0

Output o Voltage
14.0 14.0

Minimum RPM Alternator erna or R


2000

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*

Orig. Equip. Regulator


VSF-7203 FVR-4004+ VSF-7203 FVR-4004+ X18150+ X16300B+ VSF-7204 VSF-7203

Replacement Regulator
VSF-7203S FVR-4O11+ VSF-7203S FVR-4O11+ X18150+ X16300B+ VSF-7203S

6403, R 64036, RG 6406, R 64066, RG


6408 6409 6412

6 Oz. 6 Oz. 6 Oz. 6 Oz. 6 6 6 6 6 6 6 6

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+

VSF-7203S FVR-4O11+ X18150+


X16300B+ VSF-7203S VSF-7203S FVR-4011+ VSF-7203S VSF-7203S FVR-4011+

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

10 Lb. 10 Lb. 10 Lb.


10 Lb.

12 Oz. 12 Oz. 12 Oz.


12 Oz.

Figure Figure Figure


Figure

2 1 1

VSF-7203S FVR-4O11+ X16300B+ VSF-7203S


VSF-7203S

1*

FVR-4O11+ X16300B+ VSF-7203S VSF-7203S FVR-4011+

ALY 8424
ALY 8426, R ALY 84266, RG Same
as

10 Lb. 10 Lb. 10 Lb. 10 Lb.

12 12 12 12

Oz. Oz. Oz. Oz.

Figure 2 Figure 1 Figure 1 Figure 1*

strap
Wico

1 except field terminal F-2 externally connector. Lycoming applications only.

Figure

groiinded with

Prestolite part number.

Printed in U.S.A.

File in the OE-AI AIRCRAFT MANUAL

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.

SERVICE ALTERNATOR ENG. NUMBER USE


USE USE USE
USE

NUMBER ALZ-8401
ALZ-8401G ALZ-84O1R ALZ-8401RG
ALZ-8423

APPLICATION

ALZ-8423R ALZ-84L3R ALZ-8423R

Lycoming Lycoming
Service Service

ALZ-8423R
ALZ-8423R ALZ-8423R ALZ-8423R

Lycoming Lycoming
Service Service

ALZ-8423G ALZ-8423R ALZ-8423RG

USE USE

ALZ-8423R

File in the
P.lnldinU.I.*

ALTERNATOR SECTION

OEAI AIRCRAFT MANUAL

ALZ-8000 Series Alternator Parts

List

-I

C/

to

~a

----(13

C/

Exploded

View of

Typical ALZ Alternator

,a-

ALZ SERIES ALTERNATOR PARTS LIST


Rotor

ISSUED: 3-5-79 (REV,)


Br.,Holder Spring Assembly

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

ALE-1013AS Captive Brush

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

Sheet #3 for contents of

Pkg. )maybe replaced thereafter.

File in the
Prlntd In V.S.*.

ALTERNATOR SECTION

OE-AI AIRCRAFT MANUAL

nLz SERIES ALTER~ATOA PARTS LIST


Stater

Assembly

Assembly

Pos.Rect. 8 Plate Assembl y

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

ALZ-8423G ALZ-8423R ALZ-8423RG

ALZ SERIES ALTERNATDR PARTS LIST


Assembly

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

ALZ-8423G ALZ-8423R ALZ-8423RG

FVR-4011A
YSF-7203S

FVR-4011A

[c]~Contents

of S.R.E.

Head 6 Rotor

S.R.E.Hd. 6 Rotor Pkg.

90-2396

Bearing Pkg.
Head
Rotor

90-2014 ALK-11328S-1 ALE-2173S-1

Assy.,S.R.E.

Pllntd In U.S.*.

File in th OE-AI AIRCIIAFt MANUAL

ALTERNATOR SECTION

ALZ
SERVICE
AIRCRAFT ALTERNATORS

Issued:

4/1/83

INFORMATION

Page 1 of 3

ALTERNATOR DESCRIPTION RATED VOLTAGE ROTATION


12

RATED OUTPUT

50

Amperes

Bi -Di rectional
10 Lb.

GROUNDED
12 Oz.

POLARITY

Negative

APPROXIMATE WEIGHT

SERVICE

INFORMATION

Detailed service procedures covering disassembly, component testing, compo-

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

L-655A SERVICE BULLETINS

Refer to the Service Bulletin Section of this manual


to the ALZ series alternators.

for bulletins

pertaining

SERVICE SPECIFICATIONS
DRIVE

PULLEY

Torque the drive pulley retaining


to 40 Ft.

nut to 35

Ft.

Lbs.

minimum

Lbs.

maximum.

ROTOR OHMMETER TEST CONDITIONS


i.

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.

before and after rotor test.

Slip rings and


test

ohmmeter test probes must be clean. leads must be in good condition. probe

Ohmmeter

Prin)ed in U.S.A.

File in the OE-AI AIRCRAFt MANUAL

Tech.
Data

ALTERNATORS

ALZ

AIRCRAFT ALTERNATORS Issued 4/1/83

SERVICE

Page 2 of 3

INFORMATION

ROTOR OHMMETER TEST SPECIFICATION


Rotor

winding

resistance

3.5 to 5.0 ohms.

ROTOR CURRENT DRAW TEST CONDITIONS


i.

Rotor to be

room

temperature

700

to

800F.

2.
3.

Voltmeter and ammeter must be accurate. Refer to service publication for test

wiring diagram.

ROTOR CURRENT DRAW TEST SPECIFICATION

Current draw at 12.0 volts SLIP RING REFINISHING

2.4 to 4.0 amperes.

Minimum Diameter Total Indicator Runout Surface Finish

1.350"
.002"
max. measure max.

from

bearing journals

50 microinch

ALTERNATOR OUTPUT TEST CONDITIONS


i.

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

than 2 minutes for each test 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.

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

Minimum Alternator RPM 2000 4000

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

Prestolite part number.

FIELD FI DIODES

C
ST~TO(1

II

I(\(I)
I I

It
II

ROtOl WIWDINO

1-11IJI

Internal Wiring Diagram

File in the
Printed in u.s.n.

Tech.
Data

L-600 SERVICE MANUAL

ALTERNATORS

SERVICE
INFORMATION
VOLTS 12 GROUND
These units have
an

AIRCRAFT VOLTAGE REGULATOR Issued:


10-5-72
of 1

Page

Neg at i ve
external

ADJUSTMENT

adjustment located under

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.

only with insulated (ungrounded) field


must

Regulator base
Do not

have

good ground

connection.

(even momentarily) connect regulator terminals together.


connect battery into

the two

voltage

4.

Do not

system

with

polarity

reversed.
5.
6.
Do not This is
a

force the voltage


a

adjustment

screw.

sealed unit and not repairable.


unit.

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

OE-AI AIRCRAFT MANUAI

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

volts. Output is clockwise. OPERATING VOLTAGE


The

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

with insulated base must have

(ungrounded)
a

field alternators.
connection.

Regulator
Do not

good ground

(even momentarily) connect regulator terminals together.


reversed.

the two

voltage

4.

Do not connect battery into system with

polarity

5.

Do

not

force the
a new

voltage adjustment

screw.

6.

This with

is
a

sealed unit and not


unit.

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

Schematic Circuit of Regul~tor

File in the
Princd
in

Tech.
Data

REGULATORS R RELC\YS

US.*

OE-AI AIRCRAFf MANUAL

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