Prestolite Maintenance Information

Transcription

PRt z;TO LITE
r\n ~I lu-r
ru~ ru C E
For
I RCR
C
1\1 C~ I 1\1 E S
I\narch
SSP -14’3rl -3
1, 1985
L;I~AVCO LYCOMING WILLIAMSPORT DIVISION
652 Oliver Street,
Williemsport, Pennsylvsnis’l7701
~AVCO LYCOMING ENGINE GRQUP
prP5to/ite.
SERVICE PUBLICATION
THE AIRCRAFT STARTING MOTOR USING GEAR REDUCTION DRIVE
designed to carry high current
battery, solenoid starting switch,
The starting circuit is
circuit includes the
motor, the connecting wiring and the vehicle frame.
for starting while the battery supplies the power.
with
a
minimum loss of
voltage. This
starting
cranks the engine
manual starting switch,
The
starting
motor
The manual switch and solenoid starting
switch control the operation.
THE STARTING MOTOR
high cranking torque for a limited period of time when
The starting motor has designed into it a means of engaging
the starting switch is closed.
its pinion with the flywheel ring gear on the engine with which it is used, and disengaging
the pinion as soon as the engine starts.
The starting motor must
develop
a
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
9ET
VB~NDI
1
s~
OE*R
HOUSING ASSY.
.r.
BE*RINO:
THRUST W*SHER PI(C.
Figure
Form L-649A
1
Exploded
View of Gear Reduction Starting Motor
i.
OPERATION
When the
circuit is
starting
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.
Current flows
terminal.
The gear cut
it is
on
the drive end of the armature shaft extends
supported by
roller
a
position
on
the gear
housing
where
bearing.
The gear mates with the teeth of the reduction gear that
The shaft is keyed to the reduction gear. The Bendix drive is held
drives the Bendix shaft.
in
through
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.
a
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
wheel
detent pin engages in a notch in the screw threads which prevents
fails to start when the starting circuit is de-energized.
When the
engine reaches
of the notch in the
screw
a
predetermined speed, centrifugal
demeshing
if the
engine
action forces the detent pin out
shaft and allows the pinion to demesh from the
flywheel.
MAINTENANCE
The
circuit should be
starting
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:
Battery
charged,
The
battery should
and filled to the proper level wit~
be made to determine
on
Be
2.
the
battery,
sure none
Wiring
be checked with
The
connections
battery condition.
it should be cleaned with
of the solution enters the
starting
are
hydrometer to be sure it is fully
approved water. A load test should
a
If dirt and corrosion have accumulated
a
solution of
baking
soda and water.
battery cells.
circuit
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
clean and
test should be made to
starting motor efficiency. This test is made with
while cranking the engine or at approximately 100
low
reading voltmeter
amperes, then the following
a
limits should be used:
(A)
Voltage
loss from insulated
terminal
(B)
Voltage loss
from
battery ground post
0. 1 volt maximum.
Form L-649A
battery post
to
starting
motor
0.3 volt maximum.
to starter frame
If
voltage loss
is
greater than the above limits,
additional tests should be made
the circuit to locate the
3.
Lubrication
No lubrication is
high
over
each part of
resistance connections.
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
of overhaul.
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
ground
To
remove
the
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.
head
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.
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
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
Turn the Bendix
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
Check the brushes to
full contact
should be
4.
on
If
worn
freely
to half their
in their holders and make
original length
or
less, they
replaced.
Armature
Cheek the commutator for
of excessive arcing.
If
be cleaned with 00
can
that they slide
see
the commutator.
should be turned in
a
wear, excessive
uneven
only slightly dirty. glazed
or
000
lathe.
or
glazing
discolored, the
If the commutator is rough
sandpaper.
or
evidence
commutator
or
worn, it
Figure 2.
The armature shaft should be inspeoted for
rough bearing surfaces
rough or damaged splines.
To test the armature far
set of test
probes
(1
lln
r,lt
Touch
one
probe
and
grounds,
a
connected in series
h´•
to
a
I~
commutator seg-
ment and the other to the armature
If the test
core.
armature is
lamp lights,
the
and should be
grounded
replaced.
To test for shorted armature
is
placed
rotated
held
on
by
the
hand
the
over
over
2
Figure
coils,
a
Turning Starting
is used,
growler
Figure
3.
Motor Commutator
The armature
growler and slowly
while a steel strip is
core
so
each armature
that it passes
core
slot.
If
a
coil is shorted, the steel strip will
vibrate.
A
quick check for
by inspecting
the
opens
can
be made
trailing edge tin
direction of rotation) of the
oommu-
tator segments for excessive dis-
coloration.
an
6.
This condition indicates
open circuit.
Field Coils
on
Figure
Cheek the field coils for
the frame and the other
starter terminal.
brushes
fields
are
sure
Testing Motor Armature for Shorts
grounds (Figure 4) by placing
one
test
probe
the
the
accidentally touching
lamp lights, the
grounded. Repair or
are
the frame.
Be
an
3
not
If the
replace.
Inspect all connections
to make
sure
clean and tight and inspect
insulation for deterioration.
they
6.
are
Brush Holders
touch
one
test
To test brush
probe
holders,
to the brush
plate
and the other to each brush holder.
i
Figure
Form L-649A
4
Testing
Motor Fields for Grounds
The test
not
light
lamp should light when the grounded brush holders
when the insulated brush holders
Gear and Pinion
7.
vrear.
Remove
touched and should
touched.
Inspect housings for cracks and bearings for excessive
Housing
rust, paint or grease from mounting surfaces.
The Bendix Drive should be
Bendix Drive
8.
are
are
should turn smoothly in
one
drive if it fails to check
as
wiped
clean with
a
dry cloth.
The pinion
direction and should lock in the other direction.
above
or
if the pinion teeth
are
excessively
Replace
worn or
damaged.
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
9.
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
Check the position of the pinion to be
flywheel ring
Dust should be blown out of the motor
the direction of rotation.
gear.
See
sure
specifications
for
the unit will mesh
particular
properly
with the
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
hammer will often
or
interference.
help
to
align
the
~o or
three sharp raps
bearings and free
on
the frame with
a
rawhide
the armature.
if the
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.
If
no
o
KNIFE
SWITCH
CI
KNIFE
in
AMMETER
CARBON PILE
SWITCFI
CARBON PILE
?IPRINC
SCALE
~C1
BATTERY
BATTERY
TACnOMETER
STARTING MOTOR
STARTING MOTOR
Figure
Form L-649A
5
No-Load Test Hook-up
Figure
6
Stall-Torque Hookup
If torque and current
are
not within
specifications, check
the
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
STARTING MOTOR CONTROL CIRCUIT
Inspect the control circuit wiring between the battery, solenoid and manual starting switches
for
breaks,
solenoid is
poor connections and
firmly
faulty
mounted and makes
a
insulation.
good ground
Tighten
all connections and make
Check the
excess
voltage loss across the switch contacts during normal starting.
of 0. 2 volts per 100 amperes, the solenoid should be
replaced.
If solenoid fails to operate when the manual switch is turned
on or
If loss is in
if it fails to release
when the manual switch is
either
opening
or
sure
connection.
released, it should be removed and tested to specifications.
closing voltages are not as specified, replace the solenoid.
If
Form L-649A
December,
1965
presro/itP,
SERVICE PARTS LIST
MHB SERles
STARTING MOTORS
ISSUEO:
SERVICE MOTOR
ORIG.EaUIP. MOTOR
PART NUMBER
APPLICATION
USE
MHB-4O16R
USE
USE
MHB-4017R
MHB-4019R
Lycoming
Lycoming
Lycoming
MHB-4004
Frankl in
PART NUMBER
MHB-4001,R
MHB-4002,R
MHB-4003,R
MHB-4004
Lycomin9
MHB-4005,R
MHB-4006
MHB-4OO7,R
MHB-4008, R
MHB-4009,R
MHB-4O10,R
MHB-4011, R
MHB-4012, R
MHB-4013,R
MHB-4014,R
MHB-4015,R
USE
MHB-4O17R
USE
USE
MHB-401 9R
MHB-401 8R
USE
MHB-4O14R
MMU-4001R
MHB-4016,R
MHB-4017,R
MHB-4018,R
MHB-4019,R
USE
USE
USE
USE
USE
Continental
MHB-4006
MHB-4O18R
MHB-4008R
MHB-401 4R
USE
Available thru
Lycoming
Lycomlng
Lycoming
Lycomlng
MHB-4O16R
USE
USE
USE
Lycoming
Lycomfng
Lycoming
Lycoming
Lycoming
Lycoming
Lycomlng
Lycoming
Lycoming
MHB-4O16R
MHB-401 7R
MHB-4O18R
MHB-4O19R
Lycoming only.
File in the
P.I11´•dinU´•J´•*´•
9-25-79(Rev.)
OE-AI AIRCRAF’IMANUAL
I
STARTING MOTOR
I
~P(B-4000 Series Starting Motor Parts List
6
6
14
17
~-’____ _1
19
16
L____
-T--
j
------7---
Exploded View
of
Typical
__J
MHB
Starting
Motor
ISSUED~3-13-81 (REV,)
MHB SERIES STARTING MOTOR PARTS LIST
Brush
Set
Armature
Assembly
O
O
I
I
I
MHB-4003, R
I
I
I
MHB-2383
MHB-4 005,R[*
MHB-2399S
MHS-4006
MHB-2420
MHB-4007,R
MHB-2399S
MHB-2012AS
I
j
MHB-2012S
I
I
I
MHB-4008, R
I
I
MHB-4009,R
I
I
Bearing
Assembly
Assembly
MHB-2400
II
II
I
MHB-4011,R
I
I
I
MHB-4012,R
j
I
I
MHB-4013,K
I
I
MHB-4015, K
MMU-2386S
MHB-4016,R
MHB-2399S
I
O
O
X-3991
Ca]
[al
I
I
I
Cb]
Cb]
I
I
I
Cc]
[cl
MHB-2418S
MHB-2400A
X-3991
MHB-2384AS
i MBP-2002CS
CNR]
MHB-2137[e]
90-2118[f]
MHB-2397S
MHB-2400
X-3991
Cd]
Cd]
ENRI
I
I’
II
I
II
II
MZ-1147
[NR]
I
I
[NRI
I
I
Cd]
I
PS-1432C
I
I
PS-1437B
I
I
I
PS-2432B
I
I
I
PS-1432E
I
I
I
i
I
MHB-EO1 25
I
MHB-2384BS
MBP-2002D
[a]
[b]
Ccl
[d]
[e]
CNR]
[d]
MZ-298
MHB-2337S
MHB-2400
II
PS-1435
MG-77A
1
PS-1432C
MZ-298
I
PS-1437B
[NR]
X-3991
I
PS-1432E
MHB-4018,R
MtlB-4019,d
MAB-124
CNR]
MHB-2397AS
MHB-2012AS
I
Hsg.
O
MBP-2002CS
I
MHB-4014,R
D. E.
Bearing
or
MHB-2384S
MHB-2397S
MHB-2012S
I
D. E. Head
Pinion
O
MHB-2397AS
MHB-2012AS
MHD-4010,R
MHB-4017,R
C.E.
Head
MHB-2397S
MHB-4002, R
MHB-4004
Comm. End
O
MHB-2012S
MHB-2399S
MHB-4001,R
Frame
Field
SHEET 2
I
I
I
II
I
I
I
PS-2432B
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.
Cf] Bearing
CNR]
Not
Prlnt´•d In U.S.A.
required.
File in the
I
STARTING MOTOR
OE-AI AIRCRAFT MANUAL
I
SECTION
r
r,
MHB SERIES STARTING MOTOR PARTS LIST
Bendix
Drive
Bendix
Drive
Assembly
Bearing
S~jtt
Assgl?ply
Ca]
CNR]
I
Cb]
[NR]
I
Cc]
[NR]
EBB-133Ch]
CNR]
CNR]
MHB-4005,R[*ll
I~NRI
CNR]
MHB-4006
ENR]
MHB-4007, R
MHB-4O08,K
EBB-75ACgl
MHB-4001,R
Brush
Intermed.
Oil
Seal
Cover
Band
Terminal
Stud
Spring
Package
t
11
O
12
MZ-19S
CNR]
MZ-24A
90-2502
I
I
CNR]
I
I
i
[NP.]
I
I
I
I
[NRI
I
I
I
I
CNR]
CNRI
CNR]
I
I
I
1
90-2118[f1
EBB-75ACgl
[d]
[NRI
I
I
I
I
CNH]
CNR]
~NRI
[NR]
I
I
I
I
[NR]
MHB-4009,R
EBB-142A[g3
[d3
CNR]
I
i
I
CNRI
MHB-4010, R
EBB-75A[gl
MHB-4002, n
I
MHB-4003, R
I
MHB-4004
II
Mi-326
I
XA-560
~NR]
I
I
I
I
ENR]
MHB-4011,R
I
I
I
CNR]
I
I
’I
j
[NR]
MHB-4012,R
I
i
i
CNR]
I
I
I
i
CNPl
I
I
CNR]
I
I
I
I
CNRI
I
I
CNR]
I
I
i
I
CNR]
i
i
CNRI
MHB-4013,R
MHB-4014,R
EBD-142AIgl
MHB-4O15, R
EBB-l
MHB-4016,R
EBB-131AChl
UNRI
24A[h]
MZ-l
MZ-326A
CNRI
I
I
I
i
ENRI
I
I
I
i
[NR]
I
I
I
CNR]
I
I
I
CNR]
MHB-4017,R
I
I
i
CNRI
MHB-4018,R
j
i
i
CNP]
MHB-4019,R
I
I
I
CNR]
Ca]
[b]
Cc]
Cd]
[f]
[gl
Ch]
Cjl
CNR]
1
236Cj]
I
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
PS-2432BS Housing
PS-2432B Pinion Hsg., MZ-298 Bearing,MZ-326 Bendix Drive Shaft may be replaced
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.
MHB SERIES STARTI~G MOTOR PARTS LIST
ISSUED: 8-3-81
Gear
Gear
Assembly
Housing
MZ-396
fhrust
Washer
Retainer
Plate
Bearing
As1Y
O
MHB-4001,R
Needle
(REvl)
Connector
O
Switch
O
Ck]
MZ-1390
SHEET 3
Switch
MZ-393
90-601
[NR]
CNRI
MHB-4002, R
I
I
[kl
i
I
I
[NR]
[NR]
MHB-4003, R
I
I
[kl
I
I
I
CNRI
CNR~
MZ-144
Cm]
[NRI
MHB-4004
CNR]
MHB-4005,RC*]
I MHB-1030[*]
MHB-4006
i
[NR]
[NR]
MZ-1390
[NR]
90-2677
~NRI
90-601
[NR]
[NR]
CNR]
CNH]
90-2232
[NR]
I~NR]
[k]
MZ-393
90-601
[NR]
CNRI
I
[NR]
[NR]
i
CNRI
[NR~
MHB-4007,R
MZ-396
MHB-4008,R
CNR]
i
L~kl
[NR~
MHB-4009,R
MZ-396
I
Ck]
MZ-393
I
I
Ek3
I
I
i
CNR]
[NR]
MHB-4011,R
I
I
I~kl
I
I
i
CNR]
CNR]
MHB-4012,R
I
I
[k]
I
[NR]
[NR~
I
I
Ek3
I
I
I
CNRI
[NR]
I
Ek]
I
I
I
[NR]
[NR]
90-2677
[NAI
[NR~
90-601
[NR]
[NR]
I
MHB-4010, R
I
MHB-4013, R
MHB-4014,R
MHB-4015,R
[NR]
MHB-4016,R
MZ-396
[NR]
MZ-1390
j
MHB-4019,R
I
Two used.
No
CNR
I
XA-997 is 1/2" O.D.
CNRI
[k]
MZ-393
1
I~k3
I
I
MHB-4017,R
MHB-4018,R
[NR]
1
I
i
I
[NR]
CNR]
[k]
I
I
[NR]
[NR)
[k]
I
[NR]
CNR]
and XA-998 is 13/16" O.D.
longer available.
Available thru
Not required.
Prinl´•d In U.5.1.
Lycoming only.
File in the
I
I
STARTING MOTOR
SECTION
PTP~rO/ltP:
MHB
AIRCRAFT STARTING MOTORS
SERVICE
Issued
4/1/~3
INFORMATION
GENERAL INFORMATION
VOLTAGE
24
ROTATION
Gear Reduction Units Except MHB-4005,
Drive
CCWDE
Motor
R
R
-4014,
MHB-4005,
Drive
CWDE
Motor
MHB-4009,
R,-4009, R,-4014, R.
CWDE
CWDE
R
CWDE
Motor
Direct Drive Units
CCWDE
Drive
CWDE
BRUSHES
4
POLES
4
SWITCH
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
presto~te´•
MHB
Issued
SERVICE
4/1/83
Page 2 of
INFORMATION
5
I
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.
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
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.
When
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
casting.
against
the oil
seal
counterbore.
edge
of the
it bottoms
prpstolifP,
MHB
SERVICE
Issued
~N FORM ATION
Page
4/1/83
3 of 5
I
INTERMEDIATE BEARING PLATE
MHB-4O15, R
Use "Loctite Grade A"
screws to 25
Torque
threads of
35 in./lbs.
on
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
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
.005" to .050" with thrust washers on the commutator end
Refer to Parts List for thrust washer package number.
of the shaft.
Adjust
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
Except MHB-4OO5, R, 4009, R, 4014,
Assemble the end head on the motor
in line with the motor terminal.
so
R
that the letter "R"
is
directly
is
directly
MHB-4005, R, 4009, R, 4014, R and DIRECT DRIVE UNITS
Printed in U.S.A.
File in the
so
that the letter "L"
Tech.
Data
STARTING MOTORS
BHMSROTOM
AIRCRAFT STARTING
Issued
Page 4
SERVICE
4/1/83
INFORMATION
of 5
COMMUTATOR REFINISHING
1.50"
.003" max.
.002" max. measure from
50 microinch max.
Minimum Diameter
Undercut
Total Indicator Runout
Surface Finish
TEST SPECIFICATION
See
Figures
1 and 2 for
no
load and stall
bearing journals
(750F.)
torque test connections.
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.
SHUNT FIELD CURRENT DRAW
8.7 to 10.4 amperes at 24.0 volts
RPM
Ft. Lbs.
Internal
Drive Type
Unit
MHB-4001, R
MHB-4002, R
MHB-4003, R
MHB-40O4
MHB-4005, R
Gear Reduction
Gear Reduction
Gear Reduction
D~rect
Gear Reduction
Reduction
Reduction
Reduction
Reduction
R
Gear
Gear
Gear
Gear
Gear
Gear
Ge
Gear
R
Gear Reduction
R
pi rect
Gear Reduction
Gear Reduction
Gear Reduction
Gear Reduction
MHB-4006
MHB-4007,
MHB-4008,
MHB-4009,
MHB-4010,
MHB-4O11,
R
MHB-4012,
MHB-4013,
MHB-4014,
MHB-4015,
MHB-4O16,
MHB-4017,
MHB-4018,
MHB-4019,
R
R
R
R
R
R
R
R
R
Reduction
Reduction
ti
on
Reduct’i-~n
Wiring
Fig.
Fig.
Pig.
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
3
3
3
4
F_ig.
3
F~g.
3
4
3
3
3
4
3
3
3
3
4
4
3
3
Application
Lycoming
Lycoming
Lycoming
Franklin
Lycoming
Continental
Lycoming
Lycoming
Lycomi n
Lycomi ng
Lycoming
Ly comi n
Ly comi n g
Lycoming
Lycoming
Lycoming
Lycoming
Lycoming
Lycoming
MHB
prpsto~-fP,
SERVICE
Issued
INFORMATION
Page
5 of 5
Stall
No Load
olU~k r~dh
4/1/83
Torque
~41
gb
I
cueol rrre
mlrcn
UI´•OH C(~L
IlllWC
w*L~
~TTLI*
~ffElll
~LCWOU1EI
~*(ltlllb 1101011
111171NC YOIOII
Figure
TERMINAL
Figure
1
2
TERYIWAL
A
P6ST
GROUNDED
8RU3H
INSULATED
BRUSH
SHUNT,
//VY
INSULATED
CIK)UNDED
BRUSH
BRUSH
SHUWT
wlNDINC
WIWDIWG
INSULATED
BRUSH
BRUSH
VIEWED FROY COYYUTAfOR EWD
VCWtD TROM cCMNUTATOR END
Figure
Printed in U.5.n.
‘BRUSH
BRUSH
Figure
3
File in the
I
I
Tech.
Data
4
STARTING MOTORS
prp~tp/itp,
SERVICE PARTS LIST
MHJ SERIES
STARTING MOTORS
ISSUED:
ORIG.
SE RVICE MOTOR
EOUIP.MOTOR
PART
NUMBER
PART
NUMBER
MHJ-4002
MHJ-4O03,S
MHJ-4O04
MHJ-4O04R
MHJ-4005
MHJ-40O5R
VOLTS:
USE
USE
USE
USE
5~1 5-81
(Rev.)
24
APPLICATION
MHP-4101S
MHP-IIOIS
MHJ-4004R
Teledyne Continental
MHJ-4004R
Service Motor
MHJ-4005R
Lycoming
MHJ-4005R
Service Motor
Teledyne
Continental
Lycom~ng
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.
PI’.’´•d In V.II.
File in the
are
requi red,
I
STARTING MOTOR
I
SECTION
MHJ Series
Starting
Motor Parts List
8
FI~
I
lil
a
I I
~I 1
2
[o~-
Q
Exploded View of Typical
MHJ
Starting
Motor
MHJ
Armature
Assembly
MHJ-4O02
I
Frame&
Comm. End
D. E. Head
Set
Field
Head
or
ly
I
MDZ-2012CS
Pini
ly
D.E.
Bendix
Bearing
Drive
Hsg.
5
4
O
6
MCL-2136
MDL-1002
MEX-2O92S
I
MHJ-3151S
MHJ-4004
As
3
MDL-2O12ES
MHJ-2147S
MHJ-4003,S
Brush
O
O
SHEET 2
ISSUED:10-13-81(REV,)
SERIES STARTING MOTOR PARTS LIST
MEX-2O92AS
I
I
MCL-2136A
MEX-3O31S
I
I
PS-1455
I
I
PS-1455A
ML-18A
I
CNR]
I
MHJ-36
CNR]
EBB-l 24A
MHJ-4004R
I
MHJ-4005
I
I
MHJ-4O05R
CNR]
Not
required.
Bendix
Pin Pkg.
Assembly
Brush
Plate
As
ly
9\
MHJ-4002
CNR]
MHJ-4003,S
[NR]
1
MDL-1064GS
Iio\
Oil
Seal
Term.
Stud
Pac
1
1111
Thru
Bolt
Thrust
Washer
Pac
Pa
1
(12)
XA-1024
90-726
MZ-19S
MOL-1064ES
90-2139
MHJ-4004
Brush
Spring
I
I
I
CNR]
MHJ-4004R
I
I
I
I
I
CNR]
MHJ-4005
I
I
I
I
I
[NR]
MHJ-40O5R
I
I
I
I
[NR]
I
Bendix
Drive
Shaft
1
(13~
1
(14
GJ-Z0DS
90-2677
GJ-Z0S
90-2232
[NRINot required.
Gear
Assembly
Gear
Bearing
As sembl y
15)
MHJ-4002
CNR]
MHJ-4003,S
CNR]
1
(16)
j
I
1
(171
CNR]
CNR]
CNR]
[NR]
CNR]
Ca]
I
I
Ca]
MHJ-4005
I
1
I
Ca]
MHJ-4005R
I
I
I
Ca3
Two used
Not
Prln)´•d In U.S.~.
(XA-997) 1/2"
I.D.
(19
CNR]
I
Cal
~181
CNR]
MHJ-4004R
CNRI
1
[NR]
MHJ-1045
MZ-396
MHJ-4004
Retainer
Plate
Needle
Housing
and
(XA-998) 13/16"
MHJ-44
MZ-393
I.D.
required.
File in the
I
STARTING MOTOR
L
SECTION
I
presto/ifP,
M HJ
SERVICE
Aircraft
Starting Motors
Issued:
4/1/83
IN FORM ATION
Page
1 of 4
GENERAL INFORMATION
VOLTAGE
24
ROTATION
CWDE
MHJ-4002, 4003
MHJ-4004, R, 4005, R
Motor CCWDE,
Drive CWDE
BRUSHES
4
POLES
4
SWITCH
Separate
DRIVE
MHJ-4OO4, R, 4005, R
Rubber Folo Thru
MH3-4004, R, 4005, R
3.38 to 1 Gear Ratio
Type
GEAR REDUCTION
SERVICE
INFORMATION
LUBRICATION
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
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
prPst~ite.
MHJ
Aircraft Starting Motors
Issued:
Page
SERVICE
4/1/83
INFORMATION
2 of 4
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.
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
with
new
scale hooked under the
END PLAY
(Armature
brushes.
spring
at the brush.
Only)
Shaft
.005" to .050" with thrust washers on the commuRefer to Parts List for thrust
tator end of the shaft.
washer package number.
Adjust
POLE SHOE
to
INSTALLATION
The pole shoes must be installed so that the longer
pointing in the same direction as armature rotation.
Di
Mi
ame
.003" max.
.002" max. measure from bearing journal
50 microinch max.
SPECIFICATIONS
(750F)
MHJ-4002, 4003
No Load Test
Stall Torque Test
20.0 volts,
8.0 volts,
is
i. 50"
te r
Undercut
Total Indicater Runout
Surface Finish
IEST
tip
43
210
max.
max.
amps, 6200 min.
8.0 min.
amps,
RPM
Ft. Lbs.
SERVICE
INFORMATION
See
MHJ-4004, R, 4005,~P
No Load Test
No Load Test
Figures
(Motor Only)
(Complete Unit)
Stall Torque Test
Aircraft
Starting
Issued:
4/1/83
Page
Motors
3 of 4
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
Wiri?g
Unit
Application
MHJ-4002
Figure 3
MHJ-4003,S
MHJ-4004, R
MHJ-4O05, R
Figure
Figure
Figure
Continental
Continental
3
4
4
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
C,
9;$
]It~
AUUCTLe
CIII~OL( ~LE
~WITCH
L*neON GILL
1PIWIC
~CUE
GIOVUO
V/r$~
CeOUt(D
T4CnOYEIER
571~1711YG YOTOII
IT*RTINC UOTOR
Figure
Printed in U.S.A.
Figure
1
File in the
2
Tech.
I
Data
START ING MOTORS
Aircraft Starting Motors
Issued:
SERVICE
4/1/83
INFORMATION
Page 4 of 4
TERMINAL
STUD
TEFMHK
POST
GROUNDED
BRUSn
INSULATED
bMUSH
GROUNDED
INSULATED
BRUY(
BRUSH\
I
SHUnt
O
O
INSULATED
BRUSn
GROUNDED
~RUSW
VIEWED CA#I
COMMUTATOR
Figure
3
END
GROUNDED
INSULATED
eRUsH’
I
VIEWED FROM
DRuSH
COMMUIATOF~
Figzire
4
END
presro/itP,
SERVICI: PARTS LIST
MMU SERIES
STARTING MOTORS
ISSUED:
SERVICE MOTOR
ORIG.EQUIP.MOTOR
PART NUMBER
MMU-4001,R
Prln)´•d In U.S.A.
6-1-79
USE
PART NUMBER
APPLICATION
MMU-4001R
Lycoming
Pile in the
STARTING MOTOR
SECTION
MMU Series
Starting
Motor Parts List
ld-
\uJ
5
J9
8
--_~ug/
d
3Y
3
0,
Q)
2
Exploded
View of
Typical
MMU
Starting
Motor
SHEET 2
Assembly
ISSUED: 10-13-81(REV,)
Armature
MIIIIU SERIES
Brush
Set
Frame
Field
As
O
MMU-4001,R
Assembly
MMU-4001,R
[a]
O
MMU-2386S
Intermed.
Bearing
As~’
Bearing
M2-1236
90-2139 Bendix Pin
Housing
Assembly
Assembl y
MHB-2384BS
Bendix
Drive
MBP-2002D
PS-1435
Cover
Band
Terminal
Stud
Pac_kage
O
MZ-339
Package(25 Pcs.)
EBB-124ACa]
O
MZ-24A
D.E.
Bearing
90-2502
MG-77A
Thrust
Washer
Packa
d
90-2677
also available.
File in the
Prlnt´•d In U.s.A.
Pinion
Brush
Spring
5
MHB-2012AS
Intermediate
Comm.End
Head
r
I
STARTING MOTOR
I
SECTION
MZ-19S
MMU
presto/ire.-------AIRCRAFT STARTING MOTOR
SERVICE
Issued 4/1/83
INFORM ATION
Page 1 of 3
GENERAL INFORMATION
VOLTAGE
24
ROTATION
CWDE
POLES
4
BRUSHES
4
Rubber Folo-Thru
DRIVE ASSEMBLY
Type
SERVICE INFORMATION
LUBRICATION
Soak new absorbent bronze bearings in SAE 20 oil before installation.
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.
Tech.
Data
STARTING MOTORS
MMII
presr~tP.
AIRCRAFT STARTING MOTOR
SERVICE
Issued 4/1/83
Page 2 of 3
INFORMATION
I
Use
"Loctite Grade A"
Torque
screws
to 25
on
threads of
35
in/lbs.
screws.
BRUSH REPLACEMENT
1/4" or less. Refer to service ASM-1 for brush replacement procedure.
line of force exerted by the spring and take the reading just as the
spring leaves the brush.
END PLAY
Adjust
to
.005" minimum with thrust washers on the commutator end of
Refer to Parts List for thrust washer package
the armature shaft.
number.
COMMUTATOR END HEAD
so
that the letter "L"
is
directly
Minimum Diameter
Undercut
Surface Finish
1.50"
.003" max.
50 microinch max.
bearing journals
TEST SPECIFICATIONS
No Load Test
Stall
Torque
Test
Unit
MMU-4001, R
20.0 volts,
14.0 volts,
35
250
max.
max.
amps., 3325 RPM
amps., 10.4 min.
8.8 to 10.4 amperes at 24.0 volts
Drive Type
Direct
Application
Lycomi ng
Ft.
Lbs.
fe.
MMU
SERVICE
Issued 4/1/83
INFORMATION
Page
3 of 3
TERMINAL
POST
INSULATED
GROUNDED
BRUSH
BRUSH
SHUNT
WINDING
INSULATED~
~YJ\GROUNDED
\BRUSH
BRUSH
VIEWED FROM COMMUTAfOR END
File in the
Printed in U.S.A.
I
I
Tech.
Da ta
STARTING MOTORS
prpsr~/itP,
SERVICE PARTS LIST
MZSE~1ES
STARTING MOTORS
ISSUEO:12-31-80(Rev.)
SERVICE MOTOR
ORIG.EOUIP.MOTOR
M2-4203
MZ-4205,R
MZ-4206,R
USE
USE
USE
MZ-4207;R
USE
MZ-4208,R
USE
MZ-4204,R
M2-4214
p,.., mUI*.
M2-4203
Franklin
MZ-4204R
MZ-4221R
MZ-4222R
MZ-4223R
Lycoming
Lycoming
Lycoming
Lycoming
MZ-4208R
M2-4214
Lycoming
Lycoming
Lycoming
Lycomi ng
MZ-4216,R
MZ-4217,R
USE
USE
MZ-422OR
MZ-4221R
MZ-4218,R
USE
MZ-422ZR
MZ-4219,R
USE
USE
MZ-4223R
USE
USE
MZ-4221R
MZ-4222,R
MZ-4223,R
USE
MZ-4223R
MZ-4224,R
MZ-4225,R
USE
MZ-4224R
USE
MZ-4225R
MZ-4220,R
MZ-4221,R
APPLICATION
PART
PART NUMBER
MZ-4220R
MZ-4222R
File in the
OE-PII AIRCRIFT MANVAL
Continental
Lycoming
Lycomi ng
Lycoming
Lycoming
Lycoming
Lycoming
Lycoming
I
I
STARTING MOTOR
SECTION
Starting
MZ Series
Motor Parts List
6
_____i
Q;
\L:
19)-~--
16
L-----~O
L
-----T--
_
_
_J
~-o
’eo~$
i
s---
__.J
Exploded View
of
Typical
MZ
Starting
Motor
Brush
Set
Armature
Assembly
O
SHEET 2
ISSUED:10-13-81(REV,)
MZ SERIES MOTOR PARTS LIST
Comm. End
Head
Frame&
Field
As
ly
O
#2-2383
MZ-201 2AS
MZ-l
MZ-4204,R
MZ-2386S
MBG-2012S
MZ-42O5,R
MZ-2399S
I
I
1
005ASC*~
(4)
Pinio
1
(5)
D.E.
Bearing
or
ly
31
#2-4203
D. E. Head
C.E.
Bearing
1
Hsg.
161
1
1 7
MZ-20O2F
[NR]
MZ-1147
MZ-46A
MZ-2385S
MZ-2002U
[NR]
PS-1435
MG-77A
MZ-2397S
MZ-2400
X-3991
Cal
~al
MZ-4206,R
I
I
I
I
I
I
Cb]
[bl
MZ-4207,R
I
I
I
I
I
I
Ccl
Ccl
MZ-4208,R
I
I
I
I
I
I
CNRI
[NR]
M2-4214
MZ-2412S
MBG-2012CS
MZ-2022DS
MZ-2002VS
MZ-4216,R
MZ-2399S
MBG-2012S
MZ-2397S
MZ-2400
MZ-4217,R
i
MZ-4218,R
MZ-2413Cdl
[NR]
[b]
X-3991
I
I
I
I
i
PS-2432B
I
j
I
I
I
PS-1432C
I
I
i
I
I
PS-1437B
I
I
I
I
PS-1432C
MZ-4219,R
I
MZ-4220,R
I
#2-4221,R
1
I
I
I
I
I
PS-2432B
MZ-4222,R
I
I
I
I
I
i
PS-1432C
MZ-4223,R
I
I
I
I
I
I
I
I
I
MZ-4224,R
MZ-4225,R
I
I
PS-1437B
PS-1432C
I
PS-1432F
[X1
Ea]
Field Assembly not available.
Field Coil Pkg. Complete Frame
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
MZ-414S D.E. Mounting Screw Gasket Package is also available.
Seal Package.
Bearing
[NRI Not required.
Es~
Prln)´•d In V.S.A.
File in the
r
I
STARTING MOTOR
I
SECTION
90-2018[e1
[bl
MZ-298
~2-4203
EBB-l
33[f]
[NRI
M2-4204,R
EBB-1
24A~f]
CNR]
MZ-4205,R
EBB-75ACgl
j
I
Cb]
MZ-4207,R
I
I
MZ-4208,R
~2-4214
I
MZ-4216,R
MZ-4218,n
j
MZ-4219, R
1
MZ-l 9S
Pa~age
I
j
1
90-876
1
I
[NRI
I
I
[NR]
[cl
CNK]
I
I
I
I
[NR]
CNRJ
CNR]
CNR]
I
I
I
i
CNRI
Chi
[hl
[NR]
I
1
90-877
1
I
I_NR]
EBB-142A[gl
[bl
[NRI
I
1
90-876
1
j
INR~
[NR]
I
I
I
I
CNR]
~NR]
I
I
I
i
CIIIR~
I
[NR]
I
I
‘I
I
[WR]
I
CNR]
j
I
I
I
CNR]
[i\lR]
I
I
I
I
CNR]
I
I
MZ-3%S
I
MZ´•-326A
I
I
CNR]
I
I
M2-/1223,R
1
I
j
[NR]
I
I
MZ-4224, R
I
I
j
[NR]
I
j
I
[NRI
Cc]
ENR~
90-877
j
Cb]
XA-560
1
#2-4222,R
Ca]
i
I
M2-4221,R
MZ-4225,H
MZ-24A
90-716
1
CNRI
O
j
EBR-1~2Argj
MZ-4220,R
CNRI
Oil
Seal
CNRI
EBB-75ATgl
MZ-42’17, R
Spring
MZ-l 236
Ca]
MZ-4206,R
Bearing
AssemblY
Cover
Band
Terminal
Stud
Brush
Intermed.
Bendix
Drive
Sft
Bendix
Drive
Assembly
EBH-131P,[jl
I
I
#639153.
[NR]
[NR]
j
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.
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.
CNR]
[NR]
ISSUED: 8-3-81
Switch
Connector
Washer
Plate
Bearing
Housing
Assembly
Gear
Assembly
SHEET 3
(REV,
Thrust
Retainer
Needle
Gear
Package
I
O
16
O
M2-4203
[NR]
[NR]
[NR1
[NRI
90-2677
MZ-144
MZ-4204,R
[NR]
[NR]
[NR]
[NR]
90-2271
[NR]
[NR]
MZ-4205,R
MZ-396
90-601
[NR]
[NR]
M2-4207, R
[NR]
MZ-4208,R
I
[m]
I
I
I
[NR]
L~NR]
I
Cm3
I
I
I
[NR]
CNR]
I
[m]
[NR]
I
I
[NR]
[NR]
[NR]
[NRI
90-2006
[NR]
[NR]
90-601
[NR]
[NR]
[NR]
[k]
M2-42l4
I
MZ-4218,R
[m]
MZ-1390
MZ-396
MZ-4216,R
MZ-4217,R
I
I
MZ-4206,R
MZ-393
Cm3
MZ-1390
[n]
MZ-393
I
I
[m]
I
I
I
[NR]
[NR]
I
I
[m3
I
I
I
[NR]
[NR]
I
I
[m]
I
I
[NR]
[NR]
MZ-4219,R
I
MZ-4220,R
I
I
Cm]
I
I
I
ENR]
[NR]
I
j
Cm]
I
I
I
I
[NR]
[m]
I
I
[NR]
MZ-4222,R
1
I
[NR]
[NRI
M2-4223,R
1
I
[m3
I
I
I
[NR]
[NR]
M2-4224, R
I
I
[ml
I
I
I
[NR]
[NR~
MZ-4225,R
I
I
[m]
I
I
i
[NR]
[NR]
M2-4221,R
[k]
[m]
[NR[n 7
I
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.
trequired.
oN•´’
STARTING MOTOR
File in the
Prinl´•d
In U.s.A.
r
I
SECTION
MZ
SERVICE
Issued 4/1/83
INFORMAT ION
Page 1 of
5
GENERAL INFORMATION
VOLTAGE
12
ROTATION
All Gear Reduction units except MZ-4216,
Motor CCWDE, Drive CWDE
M2-4216, R, 4220, R
All
Direct Drive units
Motor CWDE, Drive CCWDE.
CWDE.
BRUSHES
4
POLES
4
SWITCH
Gear Reduction Units
Separate
Switch mounted
Direct Drive Units
M2-4214
DRIVE
All
uses
others
a
use
R, 4220, R
on
motor
Formsprag, Torque Limiting Drive
Rubber Folo Thru Type Drives
GEAR REDUCTION
7 to 1 Gear ratio
M2-4214
All others 3.38 to 1 Gear ratio
SERVICE INFORMATION
LUBRICATION
Except M2-4214
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.
or
DIRECT DRIVE UNITS AND M2-4214
Soak new absorbent bronze bearings in SAE 20 oil before instal~ation.
oil.
Put a light film of Lubriplate P777, or equivalent, on the
motor.
drive end of thearmature shaft before installing the intermediate
bearing or drive end head.
File in the
Printed in U.S.A.
Tech.
Data
STARTING MOTORS
ZMROTOM
prp´•st~te´•
AIRCRAFT STARTING
SERVICE
Issued 4/1/83
Page
INFORMATION
2 of 5
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
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
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
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.
casting.
against
M2-4204, R
Use "Loctite Grade A" on threads of
screws to 25-35 in/lbs.
Torque
screws.
MZ
prp~fO/lfP,
SERVICE
Issued 4/1/83
IMFORM ATION
Page
3 of 5
BRUSH REPLACEMENT
Refer to Service Bulletin ASM-1 for brush replace1/4" or less.
ment
procedure.
take the reading just as the
and
the
exerted
force
line of
spring
by
brush.
the
spring leaves
END PLAY
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
number.
package
DIRECT DRIVE UNITS
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
M2-4203, adjust to .005" minimum with thrust washers.
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,
DIRECT DRIVE UNITS AND
MZ-4216, R, 4220,
Printed in U.S.A.
File in the
MANUAL
AIRCRAFT
OR-Al
so
R
that the letter "R" is directly
R
so
that the letter "L" is
Tech.
Data
directly
STARTING MOTORS
ZMROTOM
AIRCRAFT STARTING
SERVICE
Issued 4/1./83
Page
4 of 5
INFORMATION
I
I
Minimum Diameter
Undercut
Surface Finish
1.50"
.003"
max.
50 microinch max.
TEST SPECIFICATION
(See Figures
1 and 2
for
no
(750
F.)
load and stall
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
DIRECT DRIVE UNITS
No Load Test
Stall Torque Test
10.0 volts,
4.0 volts,
75
560
max,
MOTOR ONLY
No Load Test
Stall Torque Test
10.0 volts,
4.0 volts,
50
560
max.
max,
max.
max.
max,
bearing journals
torque
test
connections.)
amps., 8000 min.
amps., 1600 min.
amps., 37.5 min.
RPM
RPM
amps., 5500 min.
amps., 11.1 min.
RPM
amps., 8000 min.
amps., 11.1 min.
RPM
Ft.
Ft.
Lbs.
Lbs.
M2-4214
max.
Ft.
Lbs.
Internal
Drive Type
Di rect
Unit
M2-4203
MZ-4204,
M2-4205,
MZ-4206,
M2-4207,
M2-4208,
R
R
R
R
R
Direct
Gear Reduction
Gear Reduction
Gear Reduction
Gear Reduction
M2-4214
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
R
Gear Reduction
Gear Reduction
Gear Reduction
Gear
Gear
Gear
Gear
Gear
Gear
Gear
"Formsprag Torque Limiting
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
Drive used with, but not
Application
Fran kl in
Lycoming
Lycomi ng
Lycoming
Lycoming
Lycoming
Continental
Lycoming
Lycoming
Lycoming
Lycoming
Lycoming
Lycoming
Lycoming
Lycoming
Lycoming
Lycoming
a
part of, this
motor.
INSTALLATION NOTE
Prior to
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
from
ZM___.~
____.._
SERVICE
Issued 4/1/83
INFORMATION
5 of 5
olCl~sC,
lulrr
~s
o
~WICE
Page
CAIWY e(LL
IYITCH
L*I(MN CIIL
)MIUG
YUE
;1:
I
e*rrrlr
I
II/
I)*fTERI
T4CnOYETER
i
GIIWIIO
ST*ITIWC YOTOI)
)~RTING UOTOR
Figure
Figure
~ca
INSULATED
GROUNDED
BRUSH
BRUSH
GROUNDED
INSULATED
BRUSH
BRUSH
K
O
GROUNDED
INSULATED
BRUSH
I
VIEWED FROM
COMMUTATOR
‘BRUSH
END
File in the
O
INSULATED
BRUSH
GROUNDED
BRUSH
VIEWED FROM
COMMUTATOR END
Figure 4
Figure 3
Printed in U.S.A.
2
TERMINAL
POST
~R
TERMINAL
POST
1
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
been
designed
with
a
They
have i~so
operation
amount of maintenance.
minimum
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
oI$ P9 T
111III
O
1
(((II)
-PL.
Figure
i.
The stator consists of
a
laminated iron
core on
wound in slots around the inside clrctunferenee.
three points of the
negative and
2.
one
~haae windings
iron sections assembled
which
which the three phase
Leads
are
windings
are
connected to eachof the
and each lead is connected to
pair of rectifiers,
a
one
positive.
The rotor consists of
slip rings
2
are
a
on
single field
the shaft.
coil encased between two
The ends of the field coil
four-poled,
are
interleaved
connected to
a
pair
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
3.
T~e
field and output terminals, and
a
blast tube
assembly.
of
4.
The drive end head supports
a
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
rectifiers
slip ring
are
connected to the stater leads.
rated at 150 PIV minimum for transient
are
end head and the positive rectifiers
The
voltage protection.
OVERHAUL
complete disassembly may not be required. In some cases
perform those operations which are required to effect the repair.
When repairing the alternator,
it will
only
be necessary to
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
a
strap wrench,
remove
the
pulley
nut.
The
pulley
must be removed with
a
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
springs
2.
when
slip ring
end head.
Re careful not to lose the brush
separating the assemblies.
Remove the nuts,
lockwashers, and flatvashers from the output terminal and
remove
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
3.
slip ring
end head.
To remove the
slip ring bearing, support
the end head and press
bearing out, using
the proper tools shown in Figure 4.
Figure
3
Figure
4
9
If necessary, press the rectifiers out of the rectifier mounting plate
4.
as
shown in Figure 3.
leads, use pliers to grip the rectifier leads and
Pull the connector off the
a hot soldering iron.
disconnect the rectifier from the stater
the soldered end of the connector with
touch
three leads when the solder is melted.
5.
To
bearing
remove
the drive end head from the rotor shaft,
plate
pressing
retainer
end head and
as
on
stripping of the retainer
bearing
the
shown in
plate
as
Do not
use a
that grips
remove
Remove the three retainer
Figure
on
plate
the
by supporting
screws
the
or
and press
6.
Figure
i"
5
puller
attempt to
this may result in distortion of the end head
screws.
out of the end head.
Figure
Figure
shaft,
the
5.
6
INSPECTION AND TESTING OF COMPONENTS
Upon completion of the disassemhly, all parts should be cleaned and visually inspected for
cracks,
i.
grounded
can
or
shortedwindings.
be made with test
in series with
meter
or
lamp,
oontinuity
be any oontinui$
an
any type
or
a
shown
mechanioal interference.
voltmeter,
in´•Figure 8,
individual
current draw
Figure
7.
winding,
ammeter and rheostat
or use an
apecificatlon
or a
ohm-
between the
ohmmeter.
Rotor current draw and resistance
on
or
poles.
To test for shorted turns in the rotor
as
overheating
The ground
tester.
rings and the rotor shaft
connect
of
probes, connected
110 volt test
a
There must not
slip
signs
The rotor should be teated for
Rotor
test
distortion and any
wear or
pages.
low ohmmeter
are
listed
Excessive
reading
windings. No current draw
infinite ohmmeter reading would indicate
indicates shorted
or
an
an
open
winding.
Figure
7
To
Rectifiers
2.
A diode rectifier tester will
detect and
pinpoint open or shorted rectifiers
without going through the operation of disconnecting the stater leads. However, if a
available,
tester is not
bulb, connected
battery,
AMMETER
Touch
VOLTMETER)
I
a
position of the leads.
should
light
in
one
directions,
If the test bulb
one or more
in that heat sink is shorted.
BATTERY
Then
reverse
The test bulb
direction and not
the other direction.
both
#57
following manner.
probe to a rectifier heat sink
test probe to a lead from one of
the rectifiers in that heat sink.
the
a
12 volt
test
and the other
RHEOSTAT
and
probes
be used in the
can
one
test
in series with
light
in
lights
in
of the rectifiers
To
pinpoint
the
defective rectifier, the stater leads must be
ROTOR
repeated on
can only be
bulb, by
disconnected and the above test
each rectifier.
Figure
Open rectifiers
detected, when using the test
disconnecting the stater leads.
8
will fail to
light
The test bulb
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
described in the rectifier
or
or an
the stater
center connection and touch each of the three stater leads.
must
ohmmeter must show
winding
light, or the
The test bulb
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
i
If all other electrical checks
the stater should be
replaced
Check the bearings for
replaced.
Note:
New
are
normal and the alternator fails to
to determine whether
or
not it is the
supply its rated output,
faulty component.
roughness or excessive clearance to determine if they should be
bearings are prelubricated; additional lubrication is not required.
If excessively dirty, the end housings may be wiped clean with
a
cloth
dampened
in solvent.
ASSEMBLY
1.
Press the ball
square
so
bearing
into the drive end head
that the pressure is exerted
on
the outer
using
race
a
approximately 2"
bearing. Install the
flat block
of the
retainer
With the snap ring and retainer cup in place
plate.
fits over the shaft and
is
2;
against
To
(Uae
do not
arbor press
Figure
Strip
or
mounting plate and press the reetifiers
or
the insulation back
rectifier mounting
in with
a
special
Figure
9
approximately 1/4"
WHEN SOLDERING THESE
hearing
race
plate, support
driver tool.
hammer.)
CONNECTIONS,
10
the stater leads and reconnect them to the
on
The connector sleeves should be soldered
rectifiers.
tool that
use a
Figure 9.
install the rectifiers in the slip ring end head
10.
the rotor shaft,
the inner bearing race, and press until the inner
the snap ring retainer cup.
the end head
Figure
against
on
an
the rectifier and stater leads.
USE PLIERS AS A HEAT-DAM ON THE LEAD
BETWEEN THE SOLDER JOINT AND THE RECTIFIER.
TOO MUCH HEAT WILL DAMAGE
THE RECTIFIERS.
3.
To
rotor,
spread
the brushes when
Alien wrench
use an
hold insulated brush.
or
installing
equivalent
the
HOLE
to
USE STIFF WIRE WITH
(Use hole in the end
ro HOLD
BRUSH
H001(
LEID
headjustbelow thefield terminal.) T~egmund
brush is held with
a
hook made out of stiff wire
m9
Figure 11.
4.
Spread the brushes and manually
stater and
press the
end head assemblies and
slip ring
the drive end head and rotor assemblies
Be euro ths
are no
through bolts.
to be
or
sure
USE "LLEN
After releasing brushes, cheek
m HOLD
WRENCH OR
BRUSH
E(IUIV*LENT
LEID
that the rotor does not n~b the stater
brush leads and that the rotor b~ms
when rotated
5.
(Thare
used.) Install and tighten
through
locator pina
together.
~olt halse Une up.
by
been bench
11
hand.
Install spacer, woodnrff
strap wrench.
Figure
freely
(Do
tested.)
key, fan, pulley,
not install blast h~be
loekwasher and nut.
assembly
on
Tighten
nut
using
a
the alternator until after the unit has
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
Wiring connections for bench testing the alterRefer to the
nator are shown in Figure 12.
for
Individual specification pages
output teet:
figures.
Adjust the carbon pile,
specified voltage.
safety
eaaaaa
C,
I
on
through bolts and install
tell
or
O
the
the engine.
AlwaylS refer to the airframe manufacturwiring diagram when installing the alternator
Note:
era
\j‘
O
testing the alternator, install the
wire in the
alternator
attempted.
are
if necessary,
to obtain the
After bench
tests
testing the alternator
on
t~,t
vauut~l
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.
2.
THE OUTPUT LEAD MUST NOT BE REMOVED FROM THE ALTERNATOR WHILE
THE ROTOR WINDING fS ENERGIZED AND THE ALTERNATOR fS OPERATING
3.
DO NOT ATTEMPT TO POLARIZE THE ALTERNATOR.
DISCONNECT THE
Any attempt
4.
f,.
to do
so
may redult in damage to
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
C,.
polarization
the alternator, regulator or
No
a
voltmeter befor~ connecting the
battery.
MOST VEHICLES
GROU’ND.
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
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.
be controlled
and the
The Prestolite
and needs
no
alternator, due to its design, has self-limiting
current-limiting unit in the regulator.
current characteristics
THE REGULATOR COMPONENTS
THE TRANSISTOR
The transistor is
in
an
an
electronic switch which
electric circuit.
It has
no
mechanical
can
or
turn
on
and turn off the flow of current
moving parts
to
wear
out.
THE RECTIFIER DIODE
The rectifier diode will pass current in
this respect, it may be
compared
to
a
one
direction
only (fonvard direction);
and in
one-way check valve.
THE ZENER DIODE
The Zener
diode,
in addition to
passing current in the forward direction, will pass current
a Particular value of voltage is applied in the reverse
only
direction. It is this Zener action which makes it adaptable for use as a voltage sensing
device in the regulator.
in the
reverse
direction
when
THE RESISTOR
The resistor is
a
device which is used to limit currentflow.
HOW THE REGULATOR OPERATES
When
of the
ignition switch
regulator.
is turned on,
r-,-
battery voltage
is
applied
to the "I"
S
iu
F
F
R4
TI
ALTERNATOR
I
1
ZI
PI
iLn’
RO
-------III
e,
13
_____
REGULATOR
_I
IGNITION
SWITCH
Figure i.
BATTERY
(ignition)
terminal
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.
Whenever the power transistor, T3, is on, T2 is also
from the ignition terminal, through the field winding,
T3 to
on
off,
and T1 is
through
current will flow
the collector
emitter of
ground.
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
When the system
voltage connected
regulator ground
This network de-
relative to the Zene‘r diode, Z1,
to ’r" terminal reaches
a
reverse con-
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
4
the
system and regulator from possible damage.
Temperature compensation is flat which
output voltage constant with temperature
The PRESTOLITE solid state
regulator
means
the
increase
uses
regulator
or
Will hold the alternator
decrease after initial warm-up.
three NPN silicon transistors.
Capacitor, C1 is used to filter ripple and alternator diode switching spike
ating batteryless.
Neon
lamp, L-l, provides transient voltage protection acting
Control P1 is used to provide
a
limited range of
as a
when oper-
surge suppressor.
voltage adjustment.
PREPARATION FOR TESTING
Caution:
Do Not
Interchange Regulator Leads.
This will
destroy regulator
and void
warranty.
1.
The aircraft technician
the
or
battery ground cable
ammeter
or
other electrical systems
specialist,
must disconnect
at the
battery before connecting or disconnecting a test
other test equipment or before making wiring changes in the electrical
system.
2.
3.
When
voltmeter
only is to be
connected, provided caution is
When
is in
a
installing
a
position
for negative
4.
The
a
battery
in
a
used for circuit
used when
vehicle, be
that this terminal
so
can
testing, the battery need not be disconnecting or disconnecting the voltmeter.
sure
that the
battery negative terminal
battery ground cable
be connected to the
ground systems.
regulator, when installed in a vehicle, should be mounted on a metal
a place where it will not be subjected to excessive temperature.
area,
and in
5.
To insure
a
between the
6.
good regulator ground, a permanent ground lead should
regulator mounting bolt and the alternator frame.
The alternator does not need to be polarized;
even
momentarily,
terminals.
to either the
Do not
interchange
regulator
therefore,
never
field terminal
I and F leads to
or
regulator
as
be connected
connect
ground,
to the alternator field
this will
destroy
the
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.
8.
The
9.
The voltmeter and the ammeter should be of the best
10.
battery
must be in
good
condition and should be
carbon-pile connected across
while testing the regulator.
A
the
battery
fully charged.
quality
and should be accurate.
may be used to load the
charging
circuit
TESTING THIS REGULATOR
i.
The procedure for
bench,
2.
testing this regulator, whether
remains the
same.
Connect test meters
All circuit connections should be clean and
ment connections which must not
time while the
system
is
come
operating.
tight.
loose
or
on
as
the vehicle
shown in
Fig.
or on
the test
2.
This includes the test instru-
open the
charging circuit
at any
*LTERNP~TOR
REGULATOR
CARBON
TEST AMMETER
PILE
zn´•
AMMETER
BATTERY
ALTERNATOR
SWITCH
ON
OFF
TEST VOLTMETER
Figure
3.
2.
The voltmeter will not indicate the true
regulator setting
4.
Connect the voltmeter and the ammeter
and
as
the
5.
its
adjust
speed
to obtain 3, 000 to
as
4,
shown in
Figure
battery
to obtain this
charge
2.
000 alternator RPM.
needed to establish 10 to 15 ampere electrical load,
Start the
Turn
or use a
on
engine
accessories
carbon-pile
across
rate.
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
voltage.
regulator
6.
regulator
operating in the charging system or on
minute, at a charge rate of from 10 to 15 amperes.
has been
1
until the
the test bench for at least
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
(Figure 1) have been designed
provide extended periods
and construoted to
of trouble-free
operation with
been
designed
They
a
minimum
have also
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
(6)
(4)
the Stater,
(5)
the Rotor
the Drive End Head.
Figure
Figure
i.
The brush and holder
assembly
contains huo
1
2
brushes,
two brush
springs,g
brush holder
and insulators. Each brush is connected to a separate terminal sb~dand is insulated from
ground. The brush and holder assembly can easily be removed for inspection or brush
replacement
2.
The
purposes.
slip ring
end head
plate, outputand auxiliary
ring end
head oontains
a
provides
the mounting for the reotifiers and rectifier mounting
terminal studs, and thebrush and holder
roller bearing and outer
race
assembly
and
assembly.
a
The
grease seal.
slip
The rectifiers used in these units
protection. Three positive rectifiers
3.
three
negative rectifiers
are
a
the rectifier
mounting plate
are
rated at 150 P.I. V. minimum for transient
voltage
while the
mounted in the rectifier mounting plate
slip ring end head. Each pair of rectifiers is
mounted in the
stater lead with
connected to
are
high temperature solder.
The stater leads
with epoxy cement for vibration
are
anchored to
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
The stater contains
4.
a
special
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
5.
provide
temperature epoxy cement
to secure the winding leads
used
is
High temperature solder
supports
The drive end head
6.
a
to the
slip rings.
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
When
it
In
some cases
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
head.
screws
holding
Remove the brush and holder
the brush holder
assembly
3.
Remove the
Remove the four
end head and rotor,
4.
Remove the
a
slip ring end
pulley
puller.
the
a
strap wrench and
Remove the fan,
with
a
the drive
tap the drive end head lightly to separate
unit, from the stater and slip ring end head.
through bolts
as
in the
from the end head.
safety wire from the through bolts. Hold
The pulley must be removed with
remove the pulley nut.
woodruff key and spacer from the shaft.
2.
assembly
and
from the output and auxiliary
nuts, lock washers, flatwashers and insulators
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
terminal studs.
5.
type
To
or
Note
carefully
the correct
slip ring end bearing and grease seal,
4.
impact type bearing puller as shown in Figure
remove
replacement
the
is necessary.
it will be necessary to have
Do not remove the
a
hook
bearing unless
Figure
3
of the slip ring end bearing is
pressed onto the rotor shaft. When bearing
The inner
race
replacement is necessary, always replaoe
the complete bearing assembly, inoluding
the inner
6.
To
race.
remove
the drive end head from the
Figure
4
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
6
CPMPONENTS
INSPECTION AND TESTING OF
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.
The rotor should be teated for
i.
Rotor
can
be made with test
or
any
slip
type
of
rings and
as
on
in
probes, connected
continuity taster. Figure
the rotor shaft or poles.
To test far shorted turns in the rotor
shown in Figure 8,
or use an
shorted
a
Excessive current draw
specification pages.
windings. No current
open winding.
voltmeter,
ohmmeter.
draw
indicates shorted
an
or
connect
winding,
the individual
indicate
windings. The ground test
series with a 110 volt test lamp, an ohmmeter
There must not be any continuity bet~ueen the
grounded
or an
are
listed
low ahmmeter reading
or a
infinite ohmmeter
would
reading
~MMETER
RHEOST~T
8*TTERY
ROTOR
Figure
Figure
7
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
2.
Reotifiers
be used in the
test
probe
to
following
a
one
Touch
of the
If the test bulb
To
lights
in both
one
test
rectifiers
light
The test bulb should
of the leads.
shorted.
manner.
lead from
in
directions,
one
probe
to
a
However, if
a
Then
direction and not
pinpoint the defective rectifier, the
shorted rectifiere
or
12 volt
a
tester
battery,
can
rectifier heat sink and the other
in that heat sink.
one or more
8
light
reverse
We position
in the oWer direction.
of the rectifiers in that heat sink is
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
above teet
the test
direction if the rectifier is open.
8.
Stater
The statoroanbe tested
described in the rectifier section,
stater from the
wood.
touch
In other
one
slip ring
or an
just
words, insulate the
test bulb
other test bulb
end head
or
or
with
foropenorgroundedwindInga
ohmmeter,
far
enough
in the
to insert
following
a
stater from the end head.
couple
probe
to the stater frame.
12 volttestbulb,
manner.
of rage
or
or
If the test
Separate We
blocks of
grounded wlndinga,
lead, and the
bulb Hgbts, or the
To test for
ohmmeter probe to the auxiliary terminal
ohmmeter
a
am stater
grounded. To test for open windings, connect
winding center oonnectlon and touch
bulb must light, or the ohmmeter must show
ohmmeter indioates continuity, the stater is
one
test
probe
to the
auxiliary
eaoh of the three stater leads.
terminal
or
The test
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.
to the low resistance in the stater
Due
replaced
are
or
not it is the
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
into the drive end head
that the pressure is exerted
With the snap
shaft and
snap
2.
bearing
against
the inner
ring retainer
unit and
press
place
race,
using the special
of the bearing.
the rotor
shaft,
approximately
2" square
Install the retainer
use a
tool that fits
bearing
race
is
plate.
over
the
against
the
hammer.)
CONNECTIONS,
or
rectifier mounting plate
by
teals illustrated in Figure 10.
1 Figure
10
Reoonneot the stater leads to the rectifiers.
WHEN
USE PLIERS AS A HEAT DAM ON THE LEAD BETWEEN
THE SOLDER JOWT AND THE RECTIFIER.
RECTIFIERS.
on
and press until the inner
9
do not
SOLDERING THESE
bearing
race
flat block
the rectifiers in the slip ring end head
Figure
(Use arbor
the outer
a
Figure 9.
cup.
Carefully install
supporting the
on
ring and retainer cup in
using
TOO MUCH HEAT WILL DAMAGE THE
Reassemble the rectifier mounting plate studs and insulators, making
See
correct order.
Figure
sure
they
are
in the
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
bearing.
assembly
of
bearing, seal,
Make
inner
race
lip of
the
sure
the oil seal is toward t~
and spacer is shown in
12.
Figure
NUT
LOCKWPASHER
LT~
-FIBERWASHER
SEAL-INSTALL SEAL
WITH LIP
~ENO HEAD
TOWARD BEARING
~RECTIFIER
MOUNTING PLATE
INNER
TERMINAL
RACE
AUXILIARY
TERMINAL
NUT´•C~
FLATWASHERc~
LOCKWASHER
c~Ly
GREASE
FIBERWASHER
Z
CAVITY
END
HEAD(
~L,
~cNsuLnToR
RECTIFIER
MOUNTING PLATE
~TERYIN*L STVD
1
SPAC ER
BEARING
OUTPUT(+)
TERMINAL
Figure
t
4.
is
Figure
11
Assemble the alternator and install the through bolts.
no
mechanical interference.
Spin the
12
rotor to make
Torque the through bolts to 30 to 35 in. Ibs.
sure
Safety
there
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.
the individual
listed
The ohmmeter must indicate the amount of rotor resistance
specification
on
page.
TESTING
r
IcAReoN
.JIMCER
WIRE
PILE
Wiring connections for bench testing the alterRefer to the
nator are shown in Figure 13.
individual specification pages for output test
figures.
to obtain
pile,
Adjust
the specified voltage.
the carbon
After bench testing the alternator, install the
safety wire and blast tube and install the
alternator
on
the
engine.
I
I
if necessary,
I
+I
I I
I
ILn
TE~MIIEfER
I
_
__
_,_
_
_
_
_
Figure
13
7
Note:
Always
alternator
or
refer to the airframe manufacturers
testing
the alternator
on
wiring diagram
when
installing
the
the aircraft.
PRECAUTIONS TO BE OBSERVED WHEN TESTING OR SERVICING THE ELECTRICAL SYSTEM
1.
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
DISCONNECT THE
(except’voltmeter)
2.
or
THE OUTPUT LEAD MUST NOT BE REMOVED FROM THE ALTERNATOR WHILE
THE ROTOR WINDING IS ENERGIZED AND THE ALTERNATOR IS OPERATING
3.
Any
4.
attempt to do
so
may result in
damage
to
No
GROUNDING OF THE ALTERNATOR OUTPUT TERMINAL MAY DAMAGE THE
ALTERNATOR
5.
polarization is required.
the alternator, regulator or circuits.
AND/OR CIRCUIT
AND COMPONENTS.
RECTIFIERS, VEHICLE
Battery polarity
MOST
VEHICLES
battery.
REVERSED BATTERY CONNECTIONS MAY DAMAGE THE
a
voltmeter before connecting the
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 SYSTER´•I
COMPONENTS.
480 LT FLANGE MOUNT
AIRCRAFT
ALTER NATO RS
FLANGE MOUNTED AIRCRAFT ALTERNATOR
Prestolite
Flange Mounted Aircraft
(Figure 1) have been designed
Alternators
and constructed to
provide extended periods
of trouble-Iree operation with a minimum
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)
Aircraft Alternator
of the
(1) The drive end
The
head, (2)
rotor, (3) The stater, (4) The
rectifiers, (5) The slip ring end head and
(6) The
are
brush and holder
assembly.
Figure
1
90
O
oooa
c
Figure
1)
and
The drive end head contains
a
a
2
prelubricated bearing,
an
oil
seal, collar
and shaft seal
blast tube connection for ventilation.
2)
The rotor contains
the
slip ring
end
a
ventilating
hearing
inner
race
fan
an
the drive end of the shaft
and spacer
on
(ALX
series
the other end of the shaft.
only)
and
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
a
high temperature solder.
The stater leads
anchored to the
are
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
and insulators.
assembly
Each brush is c6nnected to
The brush and holder
ground.
replacement
contains two
assembly
two brush
springs,
a
brush holder
separate terminal stud and is insulated from
a
can
brushes,
easily be removed
for
inspection
or
brush
purposes.
OVERHAUL
alternator, complete disassembly may not be required. In some cases
necessary to perform those operations which are required to effect the repair.
When repairing the
it will
only
be
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
head.
Remove the brush and
safety
holding the
holder assembly
screws
brush holder
assembly
in the
wire from the thru bolts and
Remove the
3.
Tap the drive end head lightly and separate the drive end head and rotor,
4.
slip ring
Note
remove
as a
unit, from
end head.
Remove the nuts, lock
terminal studs.
end
the thru bolts.
2.
the stater and
slip ring
from the end head.
washers, flatwasher and insulators from the output and auxiliary
carefully the
correct
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.
the
Fd
Figure
6.
To remove the
grease
hook
or
bearing
impact type bearing puller
shown in Figure 4.
and
race
a
as
Do not remove the bear-
ing unless replacement
The inner
end
it will be necessary to have
seal,
type
slip ring
3
of the
is necessary.
slip ring
end
bearing
is
pressed onto the rotor shaft. When bearing
replacement is necessary, always replace
the complete bearing assembly, including
the inner
6.
Clamp
the rotor in
engine
assembly.
a
vise and
remove
the cotter pin, nut, drive gear
assembly
and
Note:
Remove the retainer
and press out the
pressed
4
The drive gear assembly is not a Prestolite part and is serviced
manufacturer. Support the drive end head and carefully press out the rotor
woodruff key.
the
Figure
race.
bearing.
plate
Once the
out from the inside of the
screws
bearing
and retainer
is
removed,
plate.
by
Support the drive end head
the oil seal
can
be knocked
or
housing.
WSPECTION AND TESTWO OF COMPONENTS
Upon completion of the disassembly, all parts should be cleaned and visually inspected for
cracks,
wear or
distortion and any
signs of overheating
The rotor should be tested for
i.
Rotor
can
be made with test
probes,
grounded
or
connected in series with
or
mechanical interference.
shorted winding.
a
110 volt test
The
lamp,
ground
an
test
ohmmeter
or
any
type of continuity tester.
slip rings
and the rotor shaft
or
Figure
poles.
as
shown in Figure 6,
or use an
5.
There must not be any continuity between the
winding,
ohmmeter.
connect
a
voltmeter,
I
are
listed
on
*MMETER
RHEOSTAT
YOLTMETER
I*TTERI
RoTon
Figure
5
Figure
individual specification pages.
indicates shorted
indicate
an
open
No current draw
the operation of
out
going through
not
available, teet probes and
following manner.
used in the
test
probe
to
of the leads.
or
an
or a
low ohmmeter reading
infinite ohmmeter reading would
A diode rectifier tester will detect and pinpoint open
Rectifiers
2.
windings.
winding.
a
lead from
one
the stater leads.
disconnecting
a #57 bulb, connected
Touch one test probe
to
a
one
or
shorted reotifiers wim-
However, if
in series with
a
12 volt
a
tester is
battery,
can
be
rectifier heat sink and the other
of the reotlfiers in that heat sink.
The test bulb should light in
6
Then
reverse
the
position
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
described in the rectifier section,
continuity.
or an
or
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.
Due to the low resistance in the stater
However, sharted
locate.
noisy during operation
and
replaced
are
or
not it is the
supply its’ rated output,
faulty component.
Whenever the alternator is overhauled, new bearings and oil or grease
recommended, even though the bearings and seals appear to be in good canditian.
4. Bearings and Seals
seals
A
are
faulty
seal
can cause an
alternator to fail within
a
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.
approximately 1/16"
below the
the seal toward the inside of the end head.
edge
Press
of the
only
casting.
on
Press
Install the ball
the outer
race
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.
inner
Support the
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
nd
SE*L
DE
sELLEo
OF
CIISTING
BELW
9DE
HEPID
COLLI\R
~D
BE*RINF
ROTOR
’o"
nlNo
~d
SH~FT
IAJ~
SELL
BE*RN6
BEIRING
C~S"
RET~INER
L~R
ASSEMBLY
CORRECT
OF
OIL
SEALS
Figure
Figure 7
(Use arbor
SOLDERING
do not
hammer.)
THESE CONNECTIONS,
press
Reoonnect the stater leads to the reotifiers.
WHEN
USE PLIERS AS A HEAT DAM ON THE LEAD BETWEEN
THE SOLDER OINT AND THE RECTIFIER.
RECTIFIERS.
8
TOO MUCH HEAT WILL DAMAGE THE
Reassemble the rectifier mounting plate studs and insulators, making
correct order.
See
sure
they
are
in the
9.
Figure
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.
Correct
bearing.
of
assembly
bearing, seal,
lip of
the oil seal is toward the
Make
sure
the
inner
race
and spacer is shown in
10.
Figure
NVT
LOCKWASHER
FLATWAS
SEAL- INSTALL SEAL
IBERWASHER
WITH LIP
TOWARD BEARING
END HEI\D
INSULAT
RECTIFIER
TERMINAL
INNER
MOUNTING PLATE
STVD/
RACE
AUXILIARY
TERMINAL
NUT
GREASE
LOCKWASHER
CAVITY
BERWASHER
END
HEAD(
SPACER
UL~TOR
RECTIFIER
BEARING
~TERMINAL STUD
MOUNTING PLATE
OUTPUT(+)
TERMINAL
Figure
Figure
9
10
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.
sure
there
Safety
wire
should be installed after the unit has been bench tested for output.
Install the brush and holder assembly and retaining
screws.
Spin the
rotor and check for
interference between the brush holder and rotor.
Check
across
the field terminals with
amount of rotor resistance listed
on
an
ohmmeter.
the individual
The ohmmeter must indicate the
specification
page.
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
1
The internal fan used
applies
to these units.
on
cooling
the ALX series
is
supplied.
provides
some
ventilation; however, the
same
rule
Wiring
connections for bench
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.
nator
are
shown in
CARBON
After bench testing the alternator, install the
safety
wire in the
alternator
on
the
P"E
8
through bolts and install the
engine.
Always refer to the airframe manufacturers wiring diagram when installing the alternator
or testing the alternator on the aircraft.
I I
Note:
t
_
+I
ILD
TEST AMMETER
/II~(/+
I
___
_
_
_
_
_
_
_TEST_V~L_TM_ETER
Figure
11
PRECAUTIONS TO BE OBSERVICED WHEN TESTING OR SERVICING THE ELECTRICAL SYSTEM
1.
connecting or disconnecting test instruments
replacing any unit or wiring. Accidental
removing
the regulator, alternator, ammeterpr accessories, will
DISCONNECT THE BATTERY, before
before
(except voltmeter) or
grounding or shorting at
cause severe damage to the
2.
units
or
and/or wiring.
THE ALTERNATOR MUST NOT BE OPERATED ON OPEN CIRCUIT WITH THE
ROTOR WINDING ENERTIZED.
3.
Any attempt
4.
to do
so
may result in
damage
to the
No
is
required.
circuits.
GROUNDING OF THE ALTERNATOR OUTPUT TERMINAL MAY DAMAGE THE
ALTERNATOR
5.
polarization
alternator, regulator or
AND/OR
CIRCUIT AND COMPONENTS.
REVERSED BATTERY CONNE’CTIONS MAY DAMAGE THE RECTIFIERS, VEHICLE
a
voltmeter before connecting the battery.
Battery polarity
MOST VEHICLES
6.
IF A BOOSTER BATTERY OR FAST CHARGER IS
USED, ITS POLARITY MUST
BE
COMPONENTS.
prPSfCl/l~ti?l
24 VO LT
100 AMPERE
AIRCRAFT
ALTERNATOR
THE PI1ESTOLITE 24 VOLT 100 AMPERE AIRCRAFT ALTERNATOR
100 ampere airoraft
The Prestolite 24 volt.
alternators
both
flange
(Figure 1)
are
manufactured for
mounting and double
foot, hinge
mounting, belt-driven applications.
Both
and constructed to
provide
types
for
extended
periods of
heavy duty service
trouble-free operation with a minimum amount
designed
are
of maintenance.
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.
by
the
prefix
ALV in the part
are
num-
The 8000 series identifies the double
Figure
1
r
oooa
goe
eo-~1I
I
QO.p
oe
BBB
O
Q!
~cb
Figure
feat, hinge mounted,
gear-driven units.
The
i
P
O
2
belt-driven units, while the 9000 series identifies the
nange mounted,
principle components: (Figure 2) of these alternators are (1) the slip ring head, (2) the
assemblies, (3) the stater, (4) the rotor and (5) the drive end head
heat sink and rectifier
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,
construction from those used in any other Prestolite aircraft alternator.
has six
(6)
rectifiers of
one
polarity
attached to it.
(1)
are
different in
Each heat sink
Each stater lead connects to four
I
OUTPUT
k
FI
FIELD
GROUND
j
nuxlLlnRv
Figure
Figure
3
4
(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.
rectifiers
(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.
wldding
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
(5)
rotor
and
The drive end head,
end head also contains
on
an
both series, contains
oil
seal, collar
a
and shaft
prelubricated bearing.
seal, and
a
The 9000 series
blast tube connection for
ventilation
OVERHAUL
complete disassembly may not be required. In some cases,
the repair.
it will be necessary to perform only those operations ~hich are’required 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,
When repairing the alternator,
as
required.
OVERHAUL NOTE
When
overhauling
the alternator,
we
recommend the following components be
(2)
replaced:
i.
Brushes.
2.
Drive end
5.
bearing.
bearing.
Slip
seal
Series).
(9000
Oil
Shaft seal "0" ring (9000 Series).
6.
Lack tab washers.
3.
4.
ring end
DISASSEMBLY
(1)
(8000 Series) Straighten the
assembly.
ears on
the lock tabwashers and
remove
the three
the
ears on
the lock tab washers and
remove
the six through
through
bolts and blast tube
(2)
(9000 Series) Straighten
bolts.
slip ring end bearing
sharp object, such as a small, sharp
(3)
Remove the
chisel
or
be
accomplished by wedging a smi\ll,
imife blade, between the cover and the slip
This
cover.
can
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)
Remove the nuts,
and
auxiliary terminal
The
sink assemblies.
lockwashers, net washers and insulators from the output, ground,
The end head
studs.
slip ring
end
bearing
can now
can
be
separated
from the stater and heat
be pushed out from the inside of the end
head.
(6) Each
brush is connected to
a
terminal
through
studthat is insulated and mounted
slip ring
Service brushes
end head.
The brush holder
attached to terminal studs.
is attached to the
screws
and
can
the
come
ring end head with two
slip
easily
he
serviced
the
once
alternator is disassembled.
Clamp
the rotor in
not to distort the rotor
drive
components from
NOTE:
The
pulley,
units, and the drive
9000 series
units,
a
vise, being careful
poles,
used
an
the
5
The drive end head and rotor
shown in
may be
Figure
6.
damaged.
by supporting the
Do not
on
end head and
pressing
separated
on
the 9000 series units
out the rotor.
(3)
an
the
not manufactured
to press the rotor out of the end head
The drive end head and rotor
used
are
or
available from
engine manufacturer.
the 8000 series units must be
attempt
the
the 8000 series
assembly,
are
remove
the rotor shaft.
serviced by Prestolite but
Figure
and
with
or
can
a
puller
as
the end head
be
separated
Remove the
hearing
retainer
Support the
bearing.
retainer.
can
and
screws
carefully
end head and
press out the
9000 series units,
plate
The oilseal,
on
then be knocked
the
or
press-
ed out from the inside of the end head.
INSPECTING AND TESTING COMPONENTS
Upon completion of disasaembly, all parts
thoroughly
should be
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,
Figure
6
rheostatas shown in Figure 8,
are
ohmmeter
listed
on
reading would indicate
(2)
Reotifiers
winding,
oruse an
connect
an
speoifioation pag-e.
windings. No
winding.
indicate shorted
open
an
type
A rectifier tester
can
accurate
accurate ohmmeter.
the individual
readingwould
any
of
continuity
teeter.
There must not be any continuity
(Flgure
from the slip rings to the rotor shaft or pales.
sistance
or
voltmeter,
ammeter and
Rotor currentdraw and
current draw
an
or
or a
re-
low
infinite ohmmeter
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
I
IU.ETER
ROTOR
I
(i~7 CI
I
VOLTMETER
Figure
Figure
(4)
8
BP~TTERY
If
a
shorted
must be
or
open rectifier is
replaced.
the heat sink
located,
indivihual
The
rectifiers
not
are
assembly containing that
replaceable and no attempt
rectifier
should be
made to unsolder them from the heat sink.
(S)
The stater
Stater
can
be tested for open
#57 bulb connected in series with
To test for
stater
grounded windings,
continuity
connect
one
test
probe
to the
auxiliary
Connect the other test
lead.
is
12
a
110 volt test bulb.
except
tester
a
grounded windings with test probes and
volt battery, an ohmmeter, or any type continuity
or
indicated, the
To test for open
windings,
probe to the stater frame. If the
is grounded and must be replaced.
stater
connect
lights
or
any
or
any
probe to the auxiliary terminal stud and touch
probe. The testbulb must light or continuity must
If the stater is open, it must be
be indloated between all connections.
possible
test bulb
test
one
each stater connectianwith the other test
flexible leads for
terminal stud
opens before
replacing
replaced.
Check
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
are
replaced
to determine
whether
or
not it is the
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
However, the
following assembly procedures
a properly assem-
1
must be observed to obtain
bled unit.
Drive End Head-8000 Series Unite
the
Install
bearing with the sealed side toward the
by pressing on the outer race only.
rotor
Install the bearing retainer and
screws.
Sup-
part the
rotor shaft and press the end head
onto the shaft using the tool shown in Figure 9.
Do not
attempt
to press the rotor into the end
head without supporting the bearing inner
race
the end head and bearing may be damaged.
Install the spacer, fan, woodruff key, pulley,
lockwasher, and nut. Torque the pulley re-
or
taining
nut to 35 to 45 Ft.
Lbs.
Figure
(5)
9
re-
Install the oil seal with the lip toward the outside of the
Drive End Head-9000 Series Units
Press the oil seal in
end head.
approximately 1/16" below
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
Reassemble the oil seal collar, being careful
lip under. A small
C*PTINO
not to fold the oil seal
amount of oil
HEAD07
D. E.
SEALED
rH
SIDE
the collar will make installa-
ring seal, being
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
SEnL
/OlL
OF BEARING
on
Install the "0"
tion easier.
,COLLAR
amount of oil
cROTOR SHAFT
on
the "0"
installation easier.
seal is
fully
will make
ring seal
Make certain the "0" ring
installed before
BEARING
assembling the
assembly. Figure 10
shows the correct assembly of the drive end
head components. Torque the drive retaining
RETAINER
nut to 37 to 42 Ft.
"O" RING SEAL
remainder of the drive
ASSEMBLY OF
CORRECT
OIL
SEALS
10
Figure
Lbs.
Slip Ring End Assembly
Assemble the brush
and terminal stud assemblies in the end head
assembling the
prior
to
Make
sure
brush holder
heat sinks and stater.
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
correctly
assembled
Position the stater leads
so
they
as
shown in
Figures
making
certain the
11 and 12.
will not interfere with the rotor.
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
NOTE: If it
was
stater leads
so
with epoxy cement.
Position the snap
brushes.
ring,
in the end
Install the brush
head,
springs
so
that
one
of the holes is
/~´•´•´•´•´•´•´•´•´•´•2\
F’LATWASHERC--~2:
I-----´•
c~
3---F’BERWASHER
11
F LA TWASHER~
~FLATWASHER
~FLAtWASHER
FIBERWASHERS
Figure
small drill
IN SULATOR-
---------´•INSULATORc~--_
~HEAT
---//E
INSULATORC/
a
----~END HEADc---
-----~ENO HEBDc----
ffLL EXCEPT
AUX. TERM.
Insert
~----´•INSULATOR-
------´•INSULATORc-~-
SINK
in line with the
~---´•NUT
~---´•NUTc----\
~--´•MEAT
directly
and brushes in the brush holder.
ALL EXCEPT
AUX. TERM.
AUX. TERM.
Figure
(8000 Series)
(6)
SINKc--~C--
INSULATORc/
12
AUX. TERM.
(9000 Series)
or
metal rod
through the
snap
ring hole
Assemble the alternator and install
to hold the brushes in
couple
place.
of
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
holding
a
tool and make
sure
the brushes
of the shaft.
Install the remaining
Units,
or secure
through bolts.
Do not install the blast tube
assembly
on
the 8000 Series
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.
Lbs.
1/4
70-85 In.
Lbs.
30-35 In.
Lbs.
37-42 Ft.
Lbs.
Inch Term. Stud Nuts
#10-32 Term. Stud Nuts
9000 Series
8000 Series
Coupling Retaining Nut
Pulley Retaining Nut
35-45 Ft. Lbs.
TESTING
Upon completion of assembly, the alternator should be tested to determine if the unit is
capable
of
delivering
its full rated
CAUTION: The 9000 Series,
test these units at full rated
for
cooling
Wiring
is
output.
flange
mounted units,
output for
more
testing the alternator
Volts
Output
25.8
10.
28.4
100.0
blast tube
Do Not
air pressure
the
shown in
RPM
OAmps. Min.
Amps. Min.
testing
on
of ventilation.
adequate
Figure 13. The alternator
Adjust carbon pile, if necessary, to
are
or exceed the specifications listed below.
specified voltage.
must meet
After bench
a source
supplied.
connections for bench
obtain the
require
than 20 seconds unless
2000
TEST VOLTMETER
5000
I
I
TEST
PIMMETER
alternator, install the
the 8000 Series Units and
secure
the lock tab washers.
CARBON
PILE
Install the alternator
the
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
sure
on
all
I
I
-~JUMPER WIRES~
I
manufacturer’s manual.
Figure
(7)
13
I
BATTERY
NOTE:
Always
refer to the airframe manufacturer’s wiring
ing the alternator
on
diagram
when instRllinr
nr
test-
the aircraft.
PRECAUTIONS TO BE OBSERVED WHEN TESTING OR SERVICING THE ELECTRICAL
SYSTEM
or disconnecting test instruments
replacing
removing
any unit or wiring. Accidental
(except voltmeter)
grounding or shorting at the regulator, alternator, ammeter, or accessories, will
1. DISCONNECT THE BATTERY, before
or
before
connecting
or
2. THE ALTERNATOR OUTPUT LEAD MUST NOT BE REMOVED FROM THE ALTER-
NATOR WITH THE FIELD CIRCUIT ENERGIZED AND THE ALTERNATOR OPERATING.
polarization
alternator, regulator or
3. DO NOT ATTEMPT TO POLARIZE THE ALTERNATOR.
Any attempt to do
so
may result in damage to the
No
is
required.
circuits.
4. GROUNDING OF THE ALTERNATOR OUTPUT TERMINAL MAY DAMAGE THE
ALTERNATOR
A~jD/OR
CIRCUIT AND COMPONENTS.
RECTIFIERS, VEHICLE
CHARGING SYSTEM. Battery polarity
5. REVERSED BATTERY CONNECTIONS MAY DAMAGE THE
WIRING OR OTHER COMPONENTS OF THE
a
voltmeter before connecting the
battery.
MOST VEHJCLES
6. IF A BOOSTER BATTERY OR FAST CHARGER IS
USED, ITS POLARITY
MUST BE
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
4.
inspeotion
1.1
Visual and Meohanioal
1.1.1
Verify no damage Replace
Hausings and Shaft
shaft damaged).
any damaged housings and rotor (if
1.1.2
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
5
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
11.4
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.
Replace damaged parts.
Shaft
Spaoer and O-Ring Seal
damageiwear
inch maximum) and
worn
1.1.6
Verify
to shaft spacer surface finish
no
(20 micra-
O-ring seal. Replace damaged
or
parts.
Verify
Oil Seal
Figure
1-1 for
or worn
no
typical
damage
or wear
installation
to oil seal. See
Replace damaged
parts.
ta
X;
Figure
1-2
Figure
1-3
´•s~r
Figure
1.1.6
Slip Ring
End
1-1
Bearing, Housing and Shaft
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
Inspect
cover
for rust accumulation
ullh
5.
on
nea.oue.,
inside
sur-
bssring´•.d
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).
6.
7.
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
current of 83.0 amperes. Alternator must be connected as shown in Figure 1-4 for full field operation,
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 alter-
field terminals F1 and F2
i.e.
jumpered
and(-) output terminals (use #16
nator 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
the
for
or
2-3 ampere field current and
to the
#18 AWG wire
a
field control
switch). Approximately 6 hp will be required to drive
head and rotor assembly to determine which bearing
is defective and should be replaced.
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
1.2
Electrical Checks
two
1.2.1
Positive Rectifier Heat Sink Assembly:
1. Using a VOM on the RX1 range, make forward
and reverse rectifier resistance measurements be-
temperature and extended test time will increase
winding resistance, due to temperature increase, and
prevent proper check to the stated limits. Also, the
tween the
2.
3.
1.2.2
One
high
(no meter movement),
Abnormal readings indicate one or more rectifiers
are defective and the assembly must be replaced.
Individual rectifiers are not replaceable.
Negative Rectifier Heat Sink Assembly:
1. Repeat test as in 1.2.1 with VOM connections
the
1.2.3
very
to
terminal and the AUX terminal,
Field Circuit:
1.
2.
Using VOM,
to
measure
The stated performance is based
on room
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
terminal and the AUX terminal.
reading should be low and the other
reasons.
resistance between Fl and
3.
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
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
zero.
Page 9, Table
analysis.
Refer to
TEST VOLTMETER
I
1-1
I
as
required
TEST
for trouble
*IJMETER
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
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
cnReou
PILE
stnemerusaemecnatsiser
FIELD CDNTRO~
SWITCH
meter movement).
2.
1.2.5
Abnormal readings indicate a fault condition at
terminal mounting interface or
the housing
internal to the alternator.
~JUMPER WIRES/
I
I
BITIERY
Performance Test;
Using
mance
a test stand, verify alternator output perforof 28.0 volts at 6000 r/min for minimum output
Figure
1-4
Section 2
’OVERHAUL PROCEDURE
2.1
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.
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 subas-
2.2
semblies.
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.
2.3
Disassembly
2.3.1
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.
Straightenthe locktabsoneachof the six(6)
2
3
Replace
if
auxiliary terminal
new
required
at
3.
reassembly
NOTE
Verify removed thru-bnltfi are higl, stl´•ength boltp
as identi8ed by tile raised "Y’~ mark on the heads
(See Figure 2-1$) If not, the bolts must be replaced
reassembly with the required bolts.
Remove the slip ring end head bearing cover (see
at
4.
4.
2.5.3
housing. Scribe mark
alignment
and stater to indicate
across
for
of
2~
facilitate reassembly
Remove terminals with
3
Remove internal insulators from brush terminals
i.
O~ ALV-9407. remove capacitor clamp screw,
clamp and capacitor.
Removebrush holder Bstoning hardware, ineluding brush springs if not removed
Using
a
puller (Proto
Co
#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
5
cause
2.3.4
Remove
1.
integral
brushes.
reassembly
Note location for
reas-
sembiv,
6.
Holder, Brushes and Capacitor
Remove Brush
bousings
ease
Remove remaining insulators and washers from
terminals and housing. Note location to facilitate
(ALVW07 only) from Slip Ring End Housing.
I. Using socket wrench, remove outs, washers and
insulgtors from 6eld terminals Note location to
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
reassembly.
Separate rectifier-stater assembly from the slip
ring end housing, pushing terminals (step 2)
through the housing and remove housing
rDassembly
paragraph 1.16).
6.
AUX terminal and the other
Note location to facilitate
ground terminal.
thru
lock tabs when reassembling)
Using a socket wrench, remove the six (6) thru
bolts and Lock tabs Inspect bolts for any damage.
bolts (Use
Slip Ring End Head Bearing
bearing snap ring retainer using required
Remove
removal pliers.
2.
Position end
housing in a
press with
rear
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
3.
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
Separate
Rotor and Drive End
i.
Remove shaft cotter
2.
Remove shaft
er or
key
Housing
and nut.
shipping sleeve and shipping wash-
drive gear
assembly if installed.
key
3.
Remove woodruff
4.
Remove rotor shaft spacer and
O-ring seal
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
2.3.6
i
)9l~b%irl
’I/B´•
housing
Remove Drive End
i.
2.
rotor to
drop and be damaged.
Bearing
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
bearing.
Discard
231
or
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
a
lih inch diameter bar between press ram
of oil seal, press oil seal from housing
rear
(DO NOT HAMMER). Disoard oil seal.
Figure
i
2.32
2-1
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,
sembly
2.3.8
Heat Sinks from Stater
Remove Rectifier
Assembly
This
procedure applies
assembly from the
replacement
or
to removal of either heat sink
assembly as required for
atator
testing of individual assemblies. Fig
2~Q showsone of the roctifierheatsintssrwired
to
th, stator leads. The other heat sink has similar type
eonneelions.
Remove epoxy cement
holding each
stator lead to
heat sink
4.
Removethe
the
RBM
3/16"
2.4
inspection and Testing of Removed Components
paragraph 2.6 far alternator servicing and
Refer to
DIA. BBR
STOCK
C
testing precautions.
2.4.1
Front and Rear
1.
a
I
9.
1
e 112" l.D. PIPE
4.
Air
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
or
faults
OF PRESS
24.2
are
noted.
Mounting Hardware
i.
Figure
Housing
Cleanboth housings using DowChemical-Chloro
thane VG solvent to remove grease and dirt.
air
I
\BED
AUXoutputterminal andspaeer from
negative heat sink assembly.
2-2
any removed metallic hardware, i.e.,
lockwashers, natwashers, nuts, bearing
retainer plate. bearingsnap ring retainer, shaft
Inspect
screws,
spacer,
bearing over, shaft key. etc.
age, wear, carrosion or distortion
faulty parts at reassembly.
2.
2.4.3
far any dam-
Replace
any
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.
(Washers and Spacers)
for cracks, deformation and burn
insulators
i.
Inspect parts
2.
marks.
Parts that
as
are
suitable for reuse, shall be cleaned
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
ohmmeter. Use meter RX100 scale and
to lead. Replace capacitor if it is
check hem lead
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.
´•P
2.
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.
brokenicracked
Figure
2-3
NOTE
It is advisable to change brushes if length is 0.5
i"ch or less to eliminate later disassembly for
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
1.
2
can
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.
b’UBh
5.
Wear
Inspect
replacement
springs for any
spring Force.
free length of about 1.2
two stainless steel brush
deformation, change in Length
Service
or
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
IL
mtor for any of the allowing faults and
rotor if any are detected (with the encep-
Inspect
replace
tien of the
slip ring repair noted
in
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.
Worn andlorcorroded
u
bearingjournal surfaces
slip ring end
slip ring assembly or pole pieces
drive end and
D
Loose
on
shaft.
E
F
G.
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
make
to
Figure 2-4
slip rings
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
there
between
are no
replaced. Lnparticles on or
rotor must be
burrs or metal
slip rings.
Size:
’/la Diameter
Contents:
9535D/o Tin
Clean dirty slip ring using Dow Chemical
Chlorothene VD and wipe residue away with a
clean lint free cloth.
Rurned/diseolored coil (insulation will flake
off burned coil) Damaged varnish ceating is
not
a.
Temperature:
23PC apprex
Liquid Temperature;
23bC approx
Vendo. Souroe:
J W
Phstia
repairable,
or
Equivalent
Figure
FACE. 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
using
a
B
3
speci8ention
Replace
hightemperature solder pr
C
shown in
D.
Usings VOM on RXloO range, measure resislance between slip ring terminal and pole
piece, points A and C of Figure 2-4 Na meter
should
Lnspect slip ring
make certain they
pair
B.
and retest
Replace
as
occur
are
not
touching shaft
rotor if any meter movement is de-
tected.
2.4.7
3.
to heat sinks) and discolorationof stater windings.
See
following
list far action
required
if faults
are
detected.
A.
Broken rectifier leads require replacement of
the associated rectifier-heat sink assembly.
RECTIFIERS ARE NOT SERVICEABLE
INDIVIDUALLY.
stater
as
specified
in step 4.
1.2.1 and 122.
Stater testing
disassembly
performed as
paragraph 2.3.8:
can
per
be
a
VOM
on
a
movement i. detected
scale, the
B.
Follows ofter
RX100 range, measure resisstater lead and bare metal
surface of stater core. No meter movement
should occur (infinite resistance). If a alight
Using
tame between
atatar
leeds, loose or cracked epoxy (securing stater leads
on
p.ragraphs
4.
A.
Inspect for broken rectifier leads, damaged
testing
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
Rectifier-Heat Sinks and Stator Assembly
1. Inspect terminals for stripped threads henWburnt
shafts. Faulty terminals require replacement,
2.
stater leads
Discoloration of stater windings indicatex
overheating that may be caused by shorted
coils or grounded winding. Perform electrical
tests
Re-
required.
leads.
E.
(infmite resistance),
NOTE;
and solder connections to
slater
require stator replucoas specified in step
determine possible damage to rectifiers.
Damaged
3 to
rotor if coil fails resistance test
movement
securing
epoxy,
ment and electrical
Rotor Ground Test
A
Looseicracked
2-5
may be removed and now epoxy (3M Co
Scotcheast #10 resin) applied.
Figure 2-5 with
rosin and alcohol nux. Repeat test of Part A.
the
C
Harris Co
Cinncinnati, Ohio
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 SUR-
B.
Spool
4.65Y´•o Silver (Minimun~l
NOTE:
H.
x
or
irmeter indicates full
stater, must be
UsingVOMonRX1
replaced.
range, measure resistance
(continuity) between
AUX terminal and each
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
6.
Assembly
Position drive end
2.
3.
housing
on
press with front of
press table,
Positlan new oil seal squarely in housing with lip
towards outside of end head,
housing
an
a
O-ring
seal onto shaft and
position
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
a new
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
install Drive End Oil 8eal
i.
Install
length
head components.
ing. DO NOT HAMMER.
25.2
Install Drive End Bearing
1. Position drive end housingon press with front of
2.
I
C*STING
press table.
housing
on
Position
new
bearing squarely
into
bearing pock-
housing with SEALED SIDE OF BEARING
TOWARDS iNSIDE OF HOUSING. CARE MUST
st of
3
4
2.53
D. E
BE TAKEN TO PREVENT CONTAMINATION
OF BEARING.
Using a 2711e inch O.D, pipe with’iJ2 inch wall,
press bearing into housing up to the housing
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
SE~LED
OF
SIDE
/OIL
BEPIRINO
I
SEIL
-COLLIIR
/I
n
I
jcROTOR
I
RING
SHPIFT
SE*L
to Rotor
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
4.
BEI\RINO/
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,
5.
BEPIRINO
Position
pipe
x
bekiring
installation tool(l9ls inch O.D.
VI inch wall
x
2’A 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
stop.
RET*INER
Figure
2.5.4
2-7
Assemble ReotiBer-Heat Sink Assemblies and
8tator Assembly
This
procedure applies
when
replacing the recti8er-
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:
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
Figure
2-8
sinks in
to the
slip ring end housing,
position in the end head.
with heat
2.5.5
Assemble Slip RingEnd Head, Brush Bolder and
4.
1.
Install brushholder in end head using screws and
lockwashers. Ti.hten screws to 15-20 inch pounds,
2.
Instailbearingsnap ringretainer, positioninggap
in retainer relative to brushholder
as
With reference to
Figures
2-10A and B, assemble
brush terminal insulators and install to
Brushes
housing
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
2-10A
shown in
and B.
Figure 2-8.
CA PAC I TO R
HEX-NUT
SPACER
LOCKWASHER
WASHER
FLATWASHER/
Figure
Figure
3.
2-10A
DOW CORNING
SEALER No.1890
2-8
Install two brush springs and brushes into holder.
Depress:´•brushes (with leads in holder slots) and
insert a small drill or metal rod through the snap
ring hole to hold the brushes in place (see Figure
LAMP
CAPACITOR
2-9).
OI)’CCIS(IO
f\F2
FI
BEARING
RETAINER
HOLE
I
ni
ill
I
I
lo
SCREW
I ’YLII
III
1
Figure
5.
DRILL
6.
OR
ROD
2-108
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.
SLIPRING END HOUSING
2.5.6
plication.
Torque field (brush) terminal
inch pounds.
stud nuts to 25-30
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
lies to
Figure
2-9
complete assembly
7
of alternator.
~NUT-
-INsuLaron--END HEIID´•
-2´•INSULIITORf-----FL*TWISHER
flBERWI\SHERSJ
~´•HEdll SINK´•
1NSUL*T
ALL EXCEPT
AUX. TERM.
Figure
AUX, TERM.
2-11
NOTE:
A.
mating surfaces oEhausing and
clean and free of any dirt, burrs or
Insure thatthe
stater
are
foreign material.
B.
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
Housing-ltator Assembly to
Housing and Rotor Assembly
Assemble the rear hausing-stator assembly to the
drive end housing and rotor assembly, aligning
Assemble Rear
Drive End
i.
the sections with
scribe marks
previous
on
sec-
tions
NOTE:
mating surfaces of housing and
clean and free of any dirt, burrs or
Insure that the
stater
are
foreign material.
a.
Temporarily
install two thru-boltti to hold unit
together.
3.
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
SUp Ring End Bearing.
Position assembly of paragraph
1
2.5.1 in arbor
press ~th net surface of drive end shaft
net and true surface of press.
2
3.
4.
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
2.5.9
Figure
2-lj
install
outer
race
NOT HAMMER.)
Install slip ring end
will
damage bearing. (110
bearing
cover.
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
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
2.5.10
as
Terminal
i.
as
shown in
Figure a-12 and
applicable.
Torquing
Tighten the terminal mauntingnuts
to the follow-
ing torque values:
Terminal
Sorew
Size
Torque
(inchpounds)
Fl
X10-32
25-30
F2
#1032
25-30
AUX
#10-32
k..-28
25´•30
’/1"-28
10-85
U..-28
?0-85
(f)
AUX
?0-85
2.5.11
2.5.12
2.5.13
2.5.14
Post Assembly Test
Perform test on completed
section 1, paragraph 1.2.5.
3.
assembly
as
outlined in
4.
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.
Servicing and Testing Precautions
Always refer to airframe manufacturer’s wiring
diagram when installing or testing the alternator
Alternator
on
8.
the aircraft.
connecting or disvoltmeter) or
(except
connecting
replacing any unit or wiring. For negative ground
applications, disconnect the negative lead first.
Disconnect the
battery,
polarize the alternator. No
required. ANY ATTEMPT TO DO
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
7.
Installation of Alternator to Engine
engine manufacturer’s instructions.
2.
is
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 sys-
Installation of Drive Coupling
1. Refer to engine manufacturer’s specifications.
Note that shipping washer and shipping
spacer must be removed.
1.
unit operating.
Do not attempt to
polarization
Follow
2.6
Alternator output lead MUST NOT be removed
from alternator with field circuit energized and
before
9.
test instruments
If
a
are
booster
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
LOW/NO ALTERNATOR OUTPUT
PROBABLE CAUSE
I
i.
Loose te~minal connections.
2. Wornmroken brush.
3.
4.
5.
6.
7.
8.
NOISY ALTERNA’I~OR
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).
i. Defective
bearings
at drive end and/or
2. Loose frame thru-bolts.
3. Shorted rectifiers
INTERMITTENT OUTPUT
1. Worn
(magnetic noise).
brushes/dirty slip rings.
2. Loose connections/corroded terminals.
slip ring end.
ALE SERIES
SERVICE PARTS LIST
ALTERNATOR
ISSUED:
ORIG. EOUIP.ALTERNATOR
ENG.
USE
ALE-6406R
USE
ALE-64O6R
ALE-64O6R
APPLICATION
Lycoming
Lycoming
ALE-6406RG
ALE-6420
USE
USE
ALE-6406R
Service
Service
ALE-6420R
Lycoming
ALE-6420G
ALE-6420R
ALE-6420RG
USE
ALE-6420R
Lycoming
ALE-6420R
ALE-6406R
Service
ALE-6420R
ALE-8408R
ALE-84O6R
Service
ALE-8105A
USE
USE
ALE-8406
USE
ALE-8406G
USE
ALE-8406R
ALE-8406R
Lycaming
USE
USE
ALE-8406R
Service
ALE-8408R
ALE-8408R
Lycoming
USE
ALE-8420R
ALE-8420R
ALE-8420R
Lycoming
Lycaming
USE
ALE-8420R
Service
USE
ALE-8421R
Lycoming
ALE-8421R
Service
ALE-8406R
ALE-8406RG
ALE-8408
ALE-8408R
ALE-8420
ALE-8420G
ALE-8420R
ALE-8420RG
ALE-8421
USE
ALE-8421R
p.ml, i. u.r.*
VOLTS-1P
ENG.
NUMBER
NUMBER
ALE-6406
ALE-6406G
SERVICE ALTERNATOR
2-18-75(Rev.)
File in the
OE-AI AIRCR*FT MANUAL
Lycomi ng
Lycoming
Service
Service
Service
I
ALTERNATOR SECTION
ALE Series Alternator Parts List
/16
7t---~
/6
o--------l
0-------7~
Exploded
View of
Typical
A1E Alternator
ISSUED: 3-5-79
ALE SERIES ALTERIIATOR PARTS LIST
Brush
Rotor
Spring
End Head
Bearing
Assembly
Assembly
90-2396[d]
1
I
O
90-2014Ca]
90-2396[d]
ALU-1045BS[b]
SHEET 2
~REvl)
IDrlve End
Head
D.E.
I
Bearing
Assembly
0´•
8
O
ALE-6406,R
S.R.E.
S
Assembly
Assembly
Slip Ring
8rush,Holder
O
O
ALE-1003K
X-3416
ALE-6406G,RG
ALE-6420,R
ALK-11328S-1
ALU-1045BS
ALE-2173S-1
ALE-1 01 345
ALE-2016
ALE-1012LS[cll
ALE-6420G,RG
ALE-8105A
90-2396Cd]
ALE-8406,R
I
I
I
ALU-10458S[b]
I
I
ALE-1045BS[b]
X-3417
ALE-1002LS
90-2014Ea]
90-2396[d]
ALE-8406G,RG
ALE-8408,R
I
ALU-I WSBS
ALE-I 01 345
ALE-2173S-1
ALE-8420,R
ALK-11328S-:
ALE-8420G,RG
ALE-8421,R
I
I
I
ALE-1045BS
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
Eabj
be used thereafter.
Individual Components(See Sheet W3 for contents of Pkg.) may
35-781 (GJC-498S) Cover Pkg, (10 Pcs,) also available,
Prlnt´•d In U.S~.
FII´• In Ihe
I
OE-AI AIRCMPt MANUAL
I
ALTERNATOR SECTION
ALE SERIES ALTERNATOR PARTS LIST
Stater
Assembly
Assembly
Pos.Rectf fier
8 Plate
As
ALE-6406,R
ALE-2008AD
ALE-1 054A
Nega ti ve
Rectifier
Term.
Stud
(Pkg.of3)
’8’
O
90-2030
GR-32
XA- 94455
Slip Ring
D.E.
Retainer
d´•
I
Eyelet
Package
O
90-818
ALE-6406G,RG
ALE-6420,R
ALE-6420G,RG
ALE-81 05A
ALE-2008Z
ALE-1004
1
90-2359
ALE-1062
ALE-8406,R
ALE-POOBAD
ALE-1 054A
1
90-2030
ALU-1062A
ALE-8406G,RG
ALE-8408,R
ALE-8420,R
ALE-8420G,RG
ALE-8421,R
A
ISSUED: 3-5-79 (REV.)
ALE SERIES ALTERWATOR PARTS LIST
Packa9e
Rotor
Shaft
Nut
Washer
Thru
Bolt
Assembly
Package
’Beer
O
ALE-6406,R
I
ALA-LOJS
ALD-P1
90-33
Vent
Drive
Fan
Pulley
SHEET 3
Regulator
(2 Pc.)
20
PU-672A
90-2241
VSF-7203S
FVR-4011A
ALE-6406G,RG
YSF-7203S
ALE-6420,R
FVR-4011A
ALE-6420G,RG
ALE-8105A
ALA-20FS
ALE-8406,R
ALA-2(X1S
YSF-7203S
FVR-4011A
ALE-8406G,RG
ALE-8408,R
VSF-7203S
ALE-8420,R
FYR-4011A
ALE-8420G,RG
ALE-8421,R
Cd]
Contents of S.R.E.
90-2396
90-2014
Head 5 Rotor Pk
S.R.E.
Hd.
Rotor
Pkg.
Bearing Pkg.
ALK-1132BS-1
Head Assy. S.R.E.
ALE-2173S-1
Rotor
Prlnkd In V.S.A.
File in )he
I
I
ALTERNATOR SECTION
1
IL!
ALE
prp~fD/Ifp,
AIRCRAFT ALTERNATORS
SERVICE
Issued 4/1/83
INFORMATION
Page 1 of 4
I
ALTERNATOR DESCRIPTION
GROUNDED POLARITY
Bi-Directional
ROTATION
APPROXIMATE WEIGHT
40
RATED OUTPUT
12
RATED VOLTAGE
Amperes
Negative
See Tabulation
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
SERVICE
ALTERNATOR
SERIES
PUBLICATION
L-651A
ALE 8100
ALE 6400
L-655A
8400
SERVICE BULLETINS
Refer to the Service Bulletin Section of this manual
to the ALE series alternators.
for bulletins
pertaining
SERVICE SPECIFICATIONS
DRIVE PULLEY
Torque the drive pulley retaining
40 Ft.
Lbs.
nut to 35
Ft.
Lbs.
minimum to
maximum.
ROTOR OHMMETER TEST CONDITIONS
Prin~ad in U.S.A.
700
to
800F.
1.
Rotor to be room
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.
Ohnrneter must be checked to
4.
Slip rings and ohmmeter test probes must be clean.
test probe leads must be in good condition.
temperature
File in the
zero
before and after rotor test.
Tech.
Data
Ohmmeter
ALTERNATORS
k
ALE
Issued
SERVICE
4/1/83
INFORMATION
Page 2 of 4
ROTOR OHMMETER TEST SPECIFICATION
Rotor
winding resistance
3.0 to 5.0 ohms.
ROTOR CURRENT DRAW TEST CONDITIONS
700
800
i.
Rotor to be
2.
Voltmeter and ammeter must be accurate.
3.
Refer to service
temperature
room
publication for
to
test
F.
wiring diagram.
ROTOR CURRENT DRAW TEST SPECIFICATION
Current draw at 12.0 volts
2.4 to 4.0 amperes.
SLIP RING REFINISHING
Minimum Diameter
Surface Finish
1.350"
.002" max, measure from
50 microinch max.
bearing journals
ALTERNATOR OUTPUT TEST CONDITIONS
i.
Alternator to be
beginning
2.
room
temperature
700
to
800
F.
before
test.
Alternator connected so it is supplying its own field
current.
Refer to service publicationfor bench test
wiring diagram.
3.
Output voltage
4.
Alternator not to be
test
to be controlled
run
more
by
an
adjustable load.
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
Issued
INFORM ATION
ALTERNATOR OUTPUT TEST SPECIFICATIONS
Alternator
Series
Series
(Without Regulator)
Output
Amperage
Minimum
Alternator RPM
14.0
14.0
19
32
2000
4000
and 8400
Orig. Equip.
Internal
Approx
Weight
Wiring
Regulator
10 Lb.
6 Oz.
Figure 1
VSF-7201
7203
10 Lb.
6 Oz.
Figure 1*
FVR-4004+
10 Lb.
6 Oz.
Figure
ALE-6420G, RG
10 Lb.
6 Oz.
Figure 1*
ALE-8105A
10 Lb.
ALE-8406, R
10 Lb.
ALE-8406G, RG
ALE-6406,
R
ALE-6406G, kG
ALE-6420,
R
or
12 Oz.
Figure
1
VSF-7201
7203
10 Lb.
12 Oz.
Figure
1*
FVR-4004+
ALE-8408, R
10 Lb.
120z.
Figure
3
R
10 Lb.
12 Oz.
Figure
1
VSF-7203
10 Lb.
12 Oz.
Figure
1*
FVR-4004+
10 Lb.
12 Oz.
Figure
3
ALE-8421,
Same
as
with
a
Wico
R
VSF-7203S
FVR-4OO4+
2
ALE-8420G, RG
or
1
Prestolite part number.
File in the
I
Tech.
I
Data
j
VSF-7203S
VSF-7203S
VSF-7203S
except field terminal F-2 externally grounded
Lycoming applications only.
strap connector.
Figure
1 a~or
VSF-7203S
VSF-7203
1
Replacement
Kegu
Figure
ALE-8420,
Printed in U.S.A.
Page 3 of 4
Output
Voltage
ALE 6400, 8100,
Alternator
4/1/83
ALTERNATORS
ALE
AIRCRAFT ALTERNATOR
Issued
Page 4
SERVICE
4/ 1/83
of 4
INFORMATION
OUTPUT
II
DIOOES
’t
I
srnmR
ii I
ROTOR
WINDINa
,I
1
1-11
II
C
GROUNDriL
Figure 2
Figure 1
Figure
3
prpsto/~te,
SERVICE PARTS LIST
ALT SER’ES
ALTERNATOR
ISSUED:
10-19-7~YRev.)
SERVICE ALTERNATOR
ORIG.EaUIP.ALTERNATOR
VOLTS-24
ENG.
ENG.
NUMBER
NUMBER
ALT-SIOIA
ALT-51 02S
ALT-8403
ALT-SIOIA
Franklln
ALT-51 02S
Frankl in
USE
ALT-8420
USE
USE
ALT-8421R
Lycoming
Lycoming
ALT-8404
ALT-0404LS
ALT-8421RS
APPLICATION
ALT-8404R
ALT-84O4RS
ALT-8407
ALT-8420
ALT-8421
USE
USE
USE
ALT-84 21 RS
ALT-8420
ALT-8420
AL~-8421R
ALT-8421LS
ALT-8421R
ALT-8421RS
ALT-94O5
ALT-9422
USE
ALT-8421RS
Lycoming
ALT-8421R
Service
Service
File
USE
USE
in
the
OE-AI AIRCR*FT MANUAL
ALT-B421R
ALT-8421RS
ALT-9422
ALT-9422
Service
Service
Lycoming
ALTERNATOR
~LTEINIIOR SECTION
IICIION
I
ALT Series Alternator Parts List
-t~
171
6
rBS-s~i´•
ioY4
4
a
4~
5’
~G L~3
’I
ra-----
/4
I I
Exploded View
of
Typical
ALT Alternator
ISSUED:10-19-79 (REVI)
ALT SERIES ALTERNATOR PARTS LIST
Brush
Rotor
Assembly
Assembly
Set
O
O
ALT-51 025
ALT-8404,R
CNAI
ALH-I 00205
Ccl
I
Ccl
I
I
Ccl
ALT-8407
I
I
Ccl
ALU-21 285-1
ALE-1 01 3AS
O
O
I ALE-1 01 385[5]
ALU-1
04585Ccl
ALU-I 04585
90-2397Ce~
Drive End
Head
Assembly
Assembly
ALH-I 00205
ALT-84WLS,R
ALT-8420
End Head
CNA~
90- 2397 Cel
ALT-8403
Slip Ring
ALE-I D1 2LSCb~
ALT-2006
ALT-5101A
Brush,Holder
5 Spring
Assembly
S.R.E.
Beari ng
X-3417
(90-2014Cal
6
SHEET 2
O.E.
Bearing
O
ALE-I 033
X5077
ALE-I 003K
X-3416
I ALU-1043Cdl
X-4087
ALK-1132AS-1
ALT-8421,R
ALT-8421LS,RS
ALT- 9405
90-2398Ce]
ALT-9422
ALU-21 385-1
Cc~
ALE-I 01 3AS
ALU-1
045B5Cc]
ALU-I 04585
90-2398Ce~
I
ALE-I142AAS-I
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
Prlnt´•d
In
U.S~.
I
ALTERNATOR SECTION
ALT SERIES ALTER~ATOR PARTS LIST
Sta tor
Assembly
Pos. Rectifi er
Plate
Assembly
Negative
Termi nal
Stud
Rectifier
Assembly
D.E.
Petal ner
(Pkg,of3
O
ALT-51 01A
ALE-2008R
ALE-1004
XA- 94405
I
ALT-51 025
ALT-8403
ALE-2008AA
ALT-8404,R
I
ALE-I 054A
I
I
90-2359
1
90-990
I
1
90-2043
I
1
90-2030
1
90-2043
II
ALT-8404LS,RS
ALT-8407
ALT-8420
ALT-8421,R
I
I
90-2030
ALT-8421LS,RS
ALT- 9405
ALT-9422
1
I
II
1
90-2043
Thru
Bolt
Eyelet
Package
Package
13
GGW- 91
ALA-EOES
6b32
ALA-20GS
90-818
ISSUED: 10-19-79(REv,)
ALT SERIES ALTERNATOR PARTS LIST
I
S.R.E.
Cover
Assembly
O
I
Washer
Shaft
’~4’
Sp~er
90-33
CNA~
ALT-5101A
Rotor
Nut
Yent
Drive
Fan
Pulley
(2 PC.)
o
O
O
ALH-P1A
90-2241
PU-598E
CNA~
I
I
ALT-8403
ALU-I 062
1
I ALC-P1F
90-2259
ALT-8404, R
ALU-1 062A
I
IALD-21
90-2241
I
I
1
I ALC-S1F
I
I
i
I ALD-21
I
I
ALT-51 025
ALT-8404LS,RS
I
ALU-I 062
ALT-8407
I
ALT-8420
ALU-1 062A
ALT-8421,R
ALT-8421LS,RS
I
ALT-9405
CNA]
ALT-9422
CNA]
[e]
Head
Contents of S.R.E.
S.
R.
E.Head
Rotor
Bearing Pkg.
Head
Rotor
[f]
[91
[NAI
Prlnkd In
Assy.,S.R.
E.
Pkg.
II
I
YSB-7401C
VSF-7403S
PU-672A
CNAI
[NA]
~NA]
I
PU-672A
90-2241
I
Regul ator
CNAI
90-2259
I
I,
CNAI
I
I
I
I
Rotor
I
ALU-23Cfl
8X-4075Cgl
I
II
SHEET 3
[NAI
I
CNAI
CNA]
CNA~
CNA]
Pkg.
90-2397
90-2398
90-2014
90-2014
AL K-l 1 32AS-1
ALE-1 142AAS-1
ALU-2128S-1
ALU-2138S-1
XA-744AZ Shaft Spacer 0-Ring Seal available.
Nut only; Washer not required.
Not available.
U.S~.
File in the
I
I
ALTERNATOR SECTION
1
ALT
presz~fP,
SERVICE
Issued:
INFORMATION
Page 1
4/1/83
of 4
R OTAT I ON
Bi
Di
re ct
Amperes
Ne g a t i
GROUNDED POLARITY
i ona 1
APPROXIMATE WEIGHT
50
OUTPUI
RATED
24
RATED VOLTAGE
ve
See Tabulation
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
SERVICE
PUBLICATION
ALTERNATOR
SERIES
L-651A
ALT 5100
L-655A
8400
ALT 6400
L-663
ALT 9400
SERVICE BULLETINS
to the ALT series alternators.
for bulletins
pertaining
DRIVE PULLEY
Torque
the drive pulley
Lbs. maximum.
retaining
nut to 35
Ft.
Lbs.
minimum
to 40 Ft.
to
800F.
Rotor to be
2.
3.
Ohnmeter must be checked to
4.
Slip rings and ohmmeter test probes must be
OF-Al
room
the
e
l
i
F
L
A
U
NAM
AIRCRAFT
in
Printed in Usn.
700
i.
temperature
zero
clean.
Ohmmeter
Tech.
Data
ALTERNATORS
ALTAIRCRAFT
k
ALTERNATORS
SERVICE
Issued 4/1/83
Page
INFORMATION
2 of 4
Rotor
winding resistance
10.5 to 12.5 ohms,
700
800F.
i.
Rotor to be
2.
3.
Refer to service
room
temperature
to
publication for
test
wiring diagram.
1.9 to 2.3 amperes.
Minimum Diameter
Surface Finish
1.350"
.002" max, measure from bearing journals
50 microinch max.
700
800F.
i.
Alternator to be
2.
Alternator connected so it is supplying its own field current.
to service publication for bench test wiring diagram.
3.
Output voltage
4.
room
temperature
to be controlled
run
more
by
an
to
before
beginning
test.
Refer
adjustable load.
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
Issued:
INFORM ATION
Page
3 of 4
(Without Regulator)
Minimum
Alternator RPM
Output
Amperage
Alternator
Series
Output
Voltage
ALT 5100, 6400,
and 8400
28.0
28.0
20
43
3000
6000
ALT 9400
28.0
28.0
17
43
3000
6000
Ri
:?tel;~al
Alternator
4/1/83
VSB-7401C
1
ALT 5101A, S
12 Lb.
2 Oz.
Figure
ALT 5102S
12 Lb.
2 Oz.
Figure 2
VSF-7401
VSF-7403S
ALT 6408
11 Lb.
12 Oz.
Figure
VSF-7404
VSF-7403S
ALT 8403
12 Lb.
2 Oz.
Figure 3
3
VSF-7402S
or
VSF-7403S
VSF-7404
12 Lb.
2 Oz.
Figure
3
VSF-7401
VSF-7403
ALT 8407
12 Lb.
2 Oz.
Figure
3
VSF-7404
VSF-7403S
ALT 8420
12 Lb.
2 Oz.
Figure 3
VSF-7404
VSF-7403S
ALT 8421, LS,
R, RS, S
12 Lb.
2 Oz.
Figure
3
VSF-7403
VSF-7403S
ALT 9405
11 Lb.
6 Oz.
Figure
3
VSF-7401 or
VSF-7403S
VSF-7403S
ALT 9422
11 Lb,
6 Oz.
Figure
3
VSF-7404
VSF-7403S
or
Tech.
File in the
Printed in U.S.A.
VSF-7403S
ALT 8404, LS,
R, RS, S
I
Data
A LT E RNATORS
t
ALT
Issued:
Page 4
SERVICE
4/1/83
of
g
INFBRMATION
FIELD
Ip/rl
FI
rlELD r2
I_11Y II
DIODES
STATOR
I
I
id’;
I-II
ROTOR
1
Figure 2
OUTPUT
FIELD
FIELD
I
STP~TOR
I
AUXI
I-JI
ROTOR
WINDING
I
GROUND~i-´•ce
Figure 3
II
~U
~c____i
Figure
II I II
II I It
I
PI
II
II
prest~itP.
SERVICE PARTS LIST
ALU SERIES
ALTERNATOR
ISSUED:
SERVICE ALTERNATOR
ORIG.E9UIP.ALTERNATOR
VOLTS-24
ENG.
ENG.
NUMBER
NUMBER
ALU-8403
ALU-84O3LS
ALU-8403R
ALU-84O3RS
ALU-8421
USE
ALU-8421LS
USE
USE
USE
USE
USE
APPLICATION
ALU-8421R
ALU-8421RS
Lycoming
Lycoming
ALU-8421R
Service
Service
ALU-8421RS
ALU-8421R
Lycoming
ALU-8421RS
Lycaming
ALU-8421R
ALU-8421R
Service
ALU-8421RS
ALU-9404L
ALU-9404R
ALU-8421RS
Service
USE
ALU-9422L
USE
ALU-9422R
File
Plmn~ i. v.l.*.
2-27-75(Rev.)
in
the
OGAI AIRCRAFT MANVAL
ALU-9404R
Lycoming
ALU-9404R
Service
ALU-9422R
ALU-9422R
Lycoming
Service
ALTERNATOR SECTION
AL
Series Alternator Parts
L__
-T
List
____J
8
LfO
r--
Exploded View
of
-I
Typical ALU Alternator
ALU SERIES ALTERNATOR PARTS LIST
Rotor
~Assembly
ALU-8403,R
ISSUED: 3-5-79 (REv.)
Brush
Br.,Holder
Assembly
Set
o
o
Spring
Assembly
1----
90-2397[dI
5
Slip Ring
End Head
S.R.E.
Bearing
Assembly
Seal
Drive End
L
Head
90-23971~13
D.E.
Bearing
Pkg.
O
o
ALU-1045Bqb]
SHEET 2
90-2014 Ea]
ALE-I003K
X-3415
I ALU-1043[c]
X-4087
ALU-8403LS,
ALU-8421,R
ALU-2128S-1
ALE-1013AS
ALU-1 04585
ALK-1)32AS-1
ALU-8421LS,
ALU-9404LIR
90-2398[d]
ALU-9422L,R
ALU-2138S-1
j
i ALU-1045BSI~b]
ALE-1013AS
ALU-1045BS
90-2398[d]
1
ALE-l14EAAS-1
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
[c] XA-1D25 D.E.O11 Seal
[d] S.R.E.Hwd P1 Rotor
also available.
Package must be used at time of first repair.
Sheet #3 for contents of Pkg.)may be replaced thereafter.
PIQSeeComplete
Individual components
Prlnt´•d In U.S.*.
File in the
ALTERNATOR SECTION
ALU SERIES ALTERMATOR PARTS LIST
Stater
Assembly
Pes.Rect.
Plate
Assembly
Negative
Term
Stud
Rectiffer
Assembly
Pac~gqee
O
9
ALU-8403,R
ALE-2008AB
ALE-1054A
XA-944JS
90-2030
ALU-8403LS,RS
ALU-8421,R
ALU-8421LS,RS
ALU-9404L, R
ALU-9422L,R
I
I
S.R.E.
Cover
1
90-2043
ALU-1 062A
D.E.
Retainer
Thru
Bolt
OPa~age
GR-32
ALA-L0GS
ISSUED:2-27-75(REv,)
ALU SERIES ALTERNATOR PARTS LIST
Rotor
Nut
Eyelet
Washer
Package
Assembly
Package
00
’B’
AL0-21
90-33
90-818
ALU-0403,K
Shaft
SHEET 3
Drive
Vent.
Pulley
Fan
Regulator
(2 Pc.)
000
90-2241
PU-672A
VSF-7403S
ALU-R403LS,RS
PU-672A
AL.U-8421 ,H
ALU-8421LS,RS
I 8X-4075[f]
ALU-9404L,R
ALU-23[e]
ALU-9422L,K
Id]
Contents
of S.R.E.
Head
Rotor
Pkg.
S.R.E.Head
Bearing Pkg.
Head
Rotor
Assy.,S.R.E.
Rotor
Pkg.
90-2397
90-2390
90-2014
90-2014
ALK-1132AS-1
ALE-1142AAS-1
4LU-´•212AS-1
I\LIl-21 385-1
available.
Ic] XA-744AZ Shaft Spacer O-Ring also
not
required.
Washer
Nut
only;
[f]
File in the
Prln,´•d
In U.S.~.
I
ALTERNATOR SECTION
ALU
fP~
SERVIcE
Issued:
IN FORM ATION
Page
4/1/83
1 of 3
RATED OUTPUT
24
RATED VOLTAGE
APPROXIMATE WEIGHT
Amperes
Negative
GROUNDED POLARI~ITY
Bi-Directional
ROTATION
70
See Tabulation
SERVICE
INFORMATION
Detailed service procedures covering disassembly, component testing, comporeplacement, assembly, and bench testing are contained in the service
nent
SERVICE
PUBLICATION
ALTERNATOR
SERIES
ALU 6400
L-655A
8400
L-663
ALU 9400
SERVICE BULLETINS
to the ALU series alternators.
for bulletins
pertaining
DRIVE PULLEY
Torque
to 40
the drive pulley
Ft. Lbs. maximum.
retaining
nut to 35
Ft.
Lbs.
minimum
to
800F.
Rotor to be
2.
resistance such as 10.0 ohm resistor.
3.
Ohmmeter must be checked to
4.
Slip rings and ohmmeter test probes must be
OF-Al
room
the
e
l
i
F
L
A
U
NAM
AIRCRAFT
in
Printed in U.S.A.
700
i.
temperature
zero
I
clean.
a~a´•
Ohmmeter
ALTERNATORS
kPresto~rp.
ALU
SERVICE
Issued 4/1/83
INFORMATION
Fage 2 of 3
Rotor
winding resistance -´•10.5
12.5 ohms.
to
temperature
700
to
800F.
i.
Rotor to be
2.
3.
Refer to service
room
publication
for test
wiring diagram.
1.9 to 2.3 amperes.
1.350"
Minimum Diameter
Surface Finish
.002" max. measure from bearing journals
50 microinch max.
be room
temperature
700
to
800F.
before
beginning
i.
Alternator to
2.
Alternator connected so it is supplying its own field curre?t.
3.
Output voltage
4.
to be controlled
run
more
by
an
test.
Re fe r
adjustable load.
point.
VENTILATION
Remove this
alternator.
the
bench
when
cover
testing
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
AIKCRAFT ALTERNATORS
SERVICE
Issued:
INFORM ATION
Alternator
Series
Page
4/1/83
3 of 3
(Without Regulator)
Output
Output
Voltage
Amperage
Minimum
Alternator RPM
ALU 6400, 8400
28.0
28.0
23.0
61.0
4000
8000
ALU 9400
28.0
28.0
21.0
60.0
8000
4000
Replacement
Regulator
Orig. Equip.
Regulator
Alternator
Approx.
Weight
ALU-6404
11 Lb.
12 Oz.
VSF-7404
VSF-7403S
ALU-8401
12 Lb.
2 Oz.
VSF-7401
VSF-7403S
ALU-84O3, LS, R, RS, S
12 Lb.
2 Oz.
VSF-7403
VSF-7403S
ALU-8421, LS, R, RS, S
12 Lb.
2 Oz.
VSF-7403
VSF-7403S
ALU-94O4, L, R
11
Lb.
6 Oz.
VSF-7403
VSF-7403S
ALU-9422, L, R
11 Lb.
6 Oz.
VSF-7403
VSF-7403S
OUTPUT
II;I
DIODES
Inl
)II
ST~mR
ROTORWINDING
I-t
Ij/ I I/I
I
Internal Wiring Diagram
File in the
Printed in U.S.A.
Tech.
Data
ALTERNAIORS
prest~/itP,
SERVICE PARTS LIST
ALTERNATORS
11-10-82
ISSUEO:
ORIG.E~UIP.ALTERNATOR
PART NUMBER
SERVICE ALTERNATOR
VOLTS-24
PART NUMBER
APPLICATION
Lycoming
ALV-6403LS
USE
ALV-6403RS
USE
ALV-84O2
ALV-8402L
USE
ALV-8512R
ALV-8512R
ALV-BSI1R
USE
ALV-8511R
ALV-8511
USE
ALV-8511R
Teledyne Cont.,Service
Lycoming
Lycomi n 9
ALV-8511R
Service Alternator
ALV-8512R
Lycoming
ALV-8511R
ALV-8512
ALV-8512R
USE
ALV-9401
USE
ALV-94OiL
Service Alternator
ALV-8512R
Service Alternator
USE
ALV-951OR
ALV-9510R
Teledyne Cent.
Lycoming
ALV-940LR
ALV-9405L
ALV-9405R
USE
ALV-951oR
Se rvi
USE
ALV-9405R
ALV-9405R
Lycoming
ALV-94O6L
USE
ALV-9406R
ALV-9406R
Lycoming
Teledyne Cent.
USE
ALV-9510R
ALV-9510R
ALV-9406R
ALV-9407
ALV-9407S
ALV-951O
USE
USE
ALV-9510R
ALV-9510L
USE
ALV-9510R
ALV-951OR
ALV-951OR
NOTE:
ce
Al ternator
Service Alternator
Service Alternator
Service Alternator
Lycoming
Service Alternator
SEE TABLE FOR ALTERNATOR BEING SERVICED
WHEN COMPONENT PARTS ARE REOUIRED.
File in the
,11´•1´•´•1 1´• u.r.*.
(Rev.)
OCAI AIRCRAFT MANVAL
ALTERNATOR SECTION
ALV Series Alternator Parts List
Ls
21
[a] -t~
22
5
5
L
_I
I
(18\
IOC~M
b~-"L
16
(ri\
0~
L~ G~
r\
14
(4
I3
3r
1615
Exploded View
of
Typical ALV Alternator
ISSUED: 11-10-82 (KEV,)
ALV SERIES ALTERNATOR PARTS LIST
Brush
Set
Rotor
Assembly
Assembly
Slip Ring
S.R.E.
End Head
Bearing
Drive End
Head
As
ly
Assembly
II
1
1
ALV-1012S
ALV-2026AS
ALV-6403LS
(2)
(3)
1
(4)
1
(5)
1
ALV-1022S
X-4087
ALB-20D3A
SHEET 2
D.E.
Stater
Bearing
Assembly
(6)
X-4086
1
~7
ALV-2008AS
ALV-6403RS
ALV-8402
ALV-8402L
ALV-8511
I
I
I
ALV-1O22BS
X-3626A
ALE-20038
I
I
ALV-1O02S
X-4087
ALV-1003Ca]
I
I
I
I
ALV-8511R
ALV-8512
ALV-8512R
ALV-2006AS
ALV-9401
ALV-9401L
ALV-9401R
ALV-9405L
I
I
I
ALV-1003A[a]
I
ALV-1003~a]
ALV-9405R
ALV-9406L
ALV-94O6R
ALV-9407
I
I
ALV-1002AS
I
ALV-1102AS
ALV-9407S
ALV-951a
I
I
X-3626A
ALV-1003[a]
ALV-9510L
ALV-95l0R
[al
XA-l441
D.E.
Oil Seal also available.
File in the
Prlnld In V;S.~.
I
ALTERNATOR SECTION
Brush
Br.Holder
Bkt.
Assembly
Spring
Set
Assembly
8\
(9~
Neg. Rect.&
AsLembly
Assembly
Vent.
Cover
Plate
S.R.E.
I
Bearing
1
[NR]
ALV-6403RS
I
I
I
I
I
CNR]
A~\l-8402
1
I
1
I
I
ACV-I 031
ALV-8511
I
I
I
I
ALV-8511R
i
I
i
i
ALV-8512
I
ALV-8512R
I
I
I
ALV-9401
I
I
I
ALV-9401L
I
I
I
ALV-9401R
I
S.R.E.
Retainer
Co
121
ALV-1004A
ALV-1004
I
Assembly
O
(10
AMA-I 9S
ALV-1OI5
ALV-6403LS
Pos. Rect.&
Plate
Ib]
(13
GR-32
GJT-47
ALV-8402L
I~
M
I
ALV-9405R
ALV-9406L
I
I
II
I
I
[NR]
I
CNRI
~NRI
CNR~
[NR~
[NR~
I
I
CNR]
I
I
[NR]
I
I
CNRI
I
I
[NR]
i
I
[NR]
I
I
ALV-1031
I
I
CNRI
I
~NRI
~I
I
I
ALV-9405L
I
’I
I
I
GR-32
ALV-9406R
ALV-9407
I
i
ALV-9407S
I
I
ALV-95~0
i
ALV-9510L
ALV-9510R
Ib~
CNR~
Used only on
Not required.
j
I
[NR~
I
I
1
I
Early Production units having Snap Ring
II
at
I
[NR]
I
[NR]
Slip Ring End of Rotor
I
INRI
CNR]
I
Shaft.
I
CNR]
ISSUED: 11-10-82 (REV~)
ALV SERIES ALTERWATOR PARTS LIST
Capacitor
Assemb~y
Assembly
[NR]
ALV-6403RS
~NR]
ALV-8402
[NR]
ALV-8402L
[NR]
ALV-8511
[NR]
ALV-8511R
[NR]
Eyelet
Thru
Package
Bolt
Pa
Pa~age
I
0
1
20
XA-744AB
ALB-POAS
90-818
I
I
I
1
I
I
I
I
Ring
ge
19
MES-98S
90-2040
Bearing
Washer
Pa
ge
21
90-33
XA-’ 540S
[NR]
ALV-8512R
[NR]
ALV-9401
[NR]
ALV-9401L
CNR]
ALV-9401R
CNR]
ALV-9405L
CNRI
ALV-9405R
[NRI
ALV-9406L
[NR]
ALV-9406R
CNR]
90-2046
XA-744AB
ALB-20AS-1
8X-4075[c]
90-2040
90-2046
ALV-1038S
ALV-9407
Tab
O
ALV-6403LS
I
Lock
Stud
PacJ~pge
O
ALV-8512
Term.
SHEET 3
Nut
ALV-9407S
ALV-1038S
ALV-9510
I
I
XA-1540S
ALV-9510L
ALV-9510R
~cl
[NR]
Nut
Not
only; Washer
not
required.
required.
File in the
Prlnt´•d In U.S.A.
I
ALTERNATOR SECTION
Rotor
Shaft
Assembly
Vent.
Fan
22)
ALV-6403LS
1
ALE-21
(23)
PU-1609A
Regulator
(24
VSF-7403S
ALV-6403RS
ALV-8402
ALV-8402L
ALV-8511
ALV-8511R
ALV-8512
ALV-0512R
ALV-9401
ALV-21
Cd]"
[NRI
ALV-9401L
I
I
eNRI
ALV-940LR
I
I
CNR]
ALV-9405L
I
I
[NRI
I
[NRI
ALV-9405R
N
I
[NRI
ALV-9406R
I
I
ENRI
ALV-9407
I
[NR]
ALV-94061
ALV-9407S
[NRI
ALV-9510
90-2822[e1l
ALV-9510L
I
ALV-9510R
I
n
[NRI
[NR]
I
[NRI
Spacer only.
[d] XA-744AZ Shaft Spacer O-Ring
~e]
[NR]
Includes XA-744AZ Shaft
Not
required.
Seal
is also available.
Spacer 0-Ring Seal.
ALV
presto~-fP.
SERVICE
Issued:
INFORM ATION
Page
4/1/83
1 of 3
RATED OUTPUT
24
RATED VOLTAGE
APPROXIMATE WEIGHT
Amperes
Insulated System
GROUNDEDPOLARITY
Bi-Directional
ROTATION
100
See Tabulation
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
SERVICE
PUBLICATION
ALTERNATOR
SERIES
L-664
L-670
L-68O
8400
ALV-6400
ALV-94OO
ALV-95OO
SERVICE BULLETINS
to the ALV series alternators.
for bulletins
pertaining
DRIVE PULLEY
DRIVE GEAR
Torque the drive
minimum to 45 Ft.
pulley retaining
Torque the drive
gear
minimum to 42 Ft.
nut to 35
Ft.
Lbs.
maximum.
Lbs.
retaining
Lbs.
nut to
37
Ft.
Lbs.
maximum.
700
to
800F.
i.
Rotor to be
2.
3.
room
temperature
zero
before and after rotor
test.
Printed in U.S.A.
File in the
Tech.
Data
ALTERNATORS
ALVAIRCRAFT
ALTERNATORS
Iss ued:
411/83
SERVICE
INFORMATION
Page 2 of 3
ROTOR OHMMETER TEST CONDITIONS CONT’D.
4.
Slip rings and ohmmeter test probes must
probe leads must be in good condition.
be clean.
Ohmmeter test
Rotor
winding resistance
9.9 to 11.8 ohms.
700
800F.
i.
Rotor to be
2.
3.
Refer to
room
temperature
to
service publication for test
wiring diagram.
2.03 to 2.42 amperes.
Minimum Diameter
Surface Finish
1.350"
.002" max. measure from bearing journals
50 microinch max.
700
800F.
i.
Alternator to be
2.
3.
Output voltage
room
temperature
to be controlled
by
an
to
before
beginning
adjustable load.
VENTILATION
The 8400 series alternators use a slip ring end’cover that has a
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.
test.
Refer
A LV
a
SERVICE
Issued:
I N FO RMATI ON
9500
ALV 9400
ALV-64O4
ALV-8402, L
ALV-8511, R
ALV-8512.
R
ALV-9401, L, R
ALV-9405L, R
ALV-9406L, R
ALV-9407, S
ALV-951O, L, R
Minimum
28.0
28.0
53.0
88.0
3000
6000
28.0
28.0
48.0
83.0
3000
6000
20
20
21
21
20
21
21
22
21
21
ALV-6403LS, RS
(Without Regulator)
Output
Pn~perage
t
Approx.
Weight
Alternator
3 of 3
Yolt~ge
Outp
ALV 6400-8400-8500
Page
Lb.
Lb.
Lb.
Lb.
Lb.
Lb.
Lb.
Lb.
Lb.
Lb.
10
10
10
10
10
Oz.
Oz.
Oz.
Oz.
Oz.
4/1/83
Rlternator RPR
Orig. Equip.
Regulator
Replacement
Regulator
VSF-7403
VSF-7404
VSF-7403
VSF-7403
VSF-7403
VSF-7403
VSF-7403
VSF-7403
VSF-7404
VSF-7403
VSF-7403S
VSF-7403S
VSF-7403S
VSF-7403S
VSF-7403S
VSF 7403S
VSF-7403S
VSF-7403S
VSF-7403S
VSF-7403S
or
7404
or
7404
or
7404
OUTPUT
FIELD
FIail
F2
GROUND
AUXILIARY
AU~J
_j
Internal
File in the
Printed in U.S.A.
Wiring Diagram
Tech.
Data
ALTERNATORS
ALX SERIES
presto/itP.
ALTERNATOR
SERVICE PARTS LIST
ISSUED:10-19-79
ORIG.EOUIP. ALTERNATOR
ENG.
ENG.
NUMBER
NUMBER
ALX-6408
ALX-6423
ALX-8403
ALX-8403G
ALX-8403LS
ALX-8403LSG
ALX-8403R
ALX-8403RG
ALX-8403RS
ALX-8403RSG
USE
USE
USE
USE
USE
USE
USE
USE
USE
ALX-8421R
ALX-8421RS
Lycoming
Lycoming
ALX-8421RS
ALX-8421R
Lycoming
ALX-8421R
ALX-8421RS
ALX-8421 RS
USE
USE
ALX-8421LS
ALX-8421LSG
ALX-8421R
USE
ALX-8421RG
ALX-8421RS
ALX-8421RSG
ALX-9402
ALX-94O4L
USE
ALX-8421R
ALX-8421RS
USE
USE
USE
ALX-8421RS
ALX-9425J
ALX-9422R
USE
ALX-9422R
ALX-9422R
ALX-9422L
USE
USE
USE
USE
ALX-9422LG
USE
ALX-9422R
ALX-9422RG
APPLICATION
ALX-8421
USE
VOLTS-1P
ALX-6423
ALX-6423
ALX-8421R
ALX-8421G
ALX-9404LG
ALX-9404R
ALX-9404RG
ALX-9405
ALX-8421R
ALX-8421R
ALX-8421RS
ALX-8421RS
ALX-8421R
Lycoming
Service
Service
Service
Service
Lycomlng
Lycoming
Lycoming
Lycomlng
Service
Service
Service
Service
Lycoming
Lycoming
Service
ALX-9422R
Service
ALX-9424
Lycoming
ALX-9422R
Lycoming
USE
ALX-9422R
ALX-9422R
ALX-9422R
ALX-9425
USE
ALX-9424
ALX-9425R
ALX-9425A
USE
ALX-9424
ALX-9425B
File in the
Plill´•d In U´•I.*´•
SERVICE ALTERNATOR
OE-AI AIRCRAFT MANVAL
(Rev.)
Service
Service
ALX-9421
ALX-9425R
Teledvne Continental
I
ALTERNATOR
norRNlroRrrcnoN
SECTION
I
ALX Series Alternator Parts List
20
17
Ed]~
6
14
8
~"10
16
hbb
o~’
8
r-
Qg~l
I I
Exploded View
of
Typical ALX Alternator
io
‘-------II I
5
ISSUED 110-19-79(REY,
ALX SERIES ALTERIIATDR PARTS ?IST
Assembly
Assembly
O
ALX-6408
90-2399[e]
ALX-6423
ALH-L1 28S-1
Asiy
O
*ri~bly
ALU-1O45BS
90-2399[eI
I
I
ALX-8403G,RG
I
I
[c3
ALX-8403LS,RS
I
I
[c3
ALX-84O3LSG
I
I
Ccl
ALX-8403RSG
I
I
Cc]
Seal
D.E.
Pkg.0’
Bearing
O
90-2014[a]
ALE-1003R
X-3416
ALK-1132AS-1
90-2399[e]
ALU-1045BSCc]
I
ALE-1003K
ALK-1132AS-1
ALU-1045BS
ALE-1013AS
ALH-2128S-1
ALX-8421,R
Head
Bearing&
End Head
I
Cc]
90-2399Ce]
ALX-8403,R
Brush,Holder
Spring
ALE-1013AS
S.R.E.
Slip Ring
Set
Brush
Rotor
SHEET 2
Orive End
ALX-8421G,RG
ALX-8421iS,RS
ALX-842LLSG
ALX-8421RSG
ALX-9402
90-2409[e]
ALX-9404L,R
90-2400[e]
ALX-9404LG,RG
ALX-9405
ALX-9422L,R
I
1
I
[cl
I
ALU-1045BS[c]
90-2409[e]
1
j
ALU-1003
90-2400[e]
1
I
ALU-1O43[d]
X-4087
I
I
ALU-I 003
X-5398
[c3
Cc]
90-2401[e]
ALH-2138S-1
1
I
1
ALE-ll42AAS-1
ALU-1O45BS
ALE-1013AS
90-2401[e]
ALX-9422LG,RG
ALX-9424
ALX-2138S-1
ALX-9425
ALH-2206S-l[b]
I
I
~I
ALX-9425A
ALX-9425B
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
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
Ea]b]
C*]
GJC-49BS Cover Pkg.
(10 Pc.)
Also available.
File in the
Prlnld In
U.S~.
I
ALTERNATOR SECTION
ALX SERIES ALTERNATOR PARTS LIST
Stater
Assembly
Pos.Rect.
Plate
Assembly
O
ALE-2008AB
ALX-6423
ALX-8403,R
S.R.E.
Cover
Package
O
ALE-1 054A
I
Term.
Stud
(Pkg.of 3)
Assembly
O
ALX-6408
Negative
Rectifier
O
XA-944JS
O
[NA]
90-2043
I
I
I
I
I
1
I
[NA]
90-2030
ALU-1062A
90-2043
ALX-1 062S
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
I
ALX-9404L, R
I
I
I
ALX-9422L, R
I
ALX-9422LG,RG
I
ALX-9424
I
ALX-9425
ALX-9425A
ALX-9425B
CNA]
Not Available.
1
I’
I
ALX-9404LG,RG
ALX-9405
I
It
[NA]
I
[NA]
I
I
[NA]
I
I
[NA]
1
t
I
[NAI
I
I
I
CNA]
I
ALX-1 0625
I
I
I
I
I
I
I
11
I
I
Thru
Bolt
D.E.
Retainer
Package
O
O
ALA-POGS
GR-32
Nut&
Washer
Rotor
Vent
Drive
Shaft
Fan
Pulley
Seal
Package
Spacer
O
O
Eyelet
Package
"O"
Ring
Assembly
O
[NA~
9n-2259Cf]
[NA]
ALX-6423
[NA~
I
I
I
ALX-8403,R
CNA~
I
I
I
ALX-8403G,RG
[NAI
I
I
I
ALX-8403LS, RS
[NA]
I
I
I
ALX-8403LSG
CNA]
I
I
I
ALX-9403RSG
[NA~
I
I
I
ALX-8421,R
[NA]
I
I
I
I
I
ALX-8421G,RG
[NA]
I
I
I
I
I
ALX-8421 LS,RS
[NAI
I
I
I
ALX-8421 LSG
CNA]
I
ALX-8421 RSG
CNA]
I
I
ALX-9402
[NA]
I
I
I
1
I
ALX-9405
I
I
ALX-94221., R
I
I
ALX-9422LG,RG
I
I
ALX-9424
I
I
I
II
90-2241[f]
ALD-21
II
II
II
II
II
I
II
I
II
II
II
I
I
I
I
II
I
II
II
I
II
I
II
I
II
II
II
[NA~
VSF-7203S
I
II
I
[NAI
FVR-4011A
I
[NA~
I
r
I
II
I
[NAI
VSF-7203S
I
CNAI
FVR-4Dl1A
I
[NAI
CNA~
VSF-7204
ENAI
[NA]
VSF-7203S
[NA]
[NA]
FVR-4011A
I ALP-1034Cg]
[NA]
VSF-7203S
I
[NA]
[NA]
I
[NA]
[NA]
FVR-4011A
[NA]
VSF-72035
ALP-I
I
034[91
I ALP-1034Cgl
I
I
[NAI
[NAI
I
I
CNAl
ALX-9425A
[NA]
I
I
CNA]
[NA~
I
I
CNAI
ALX-9425B
[NA]
I
I
[NAI
[NA]
I
I
[NA]
S.
R.
E.Head
Rotor
Head
FYR-4011A
I
CNA]
Contents of S.R.E.
VSF-7203S
PU-672A
ALX-9425
Cel
FYR-4011A
I
ALU-23
I
II
I
CNAI
II
CNA]
8X-4075ChI
VSF-7203S
I
~I
CNA]
II
II
II
I
1
PU-672A
I
II
I
XA-744AZ
ALX-9404LG,RG
ALC-ZIF
90-33
90-818
Regulator
O
ALX-6408
ALX-9404L, R
SHEET 3
ISSUED: 10-19-79(REv,)
ALX SERIES ALTERiJATOR PARTS LIST
Rotor Pk
Pkg.
Bearing Pkg.
90-2399
90-2400
90-2401
90-2409
90-2014
90-2014
90-2014
90-2014
Head Assy.,S.R.E.
ALK-1132AS-1
ALE-1142AAS-I
ALE-ll4SAAS-1
Rotor
ALH-2128S-1
ALH-2138S-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.*.
I
ALTERNATOR SECTION
1/
ALX
SERVICE
Issued:
INFORMATION
Page
4/1/83
1 of 4
RATED OUTPUT
12
RATED VOLTAGE
APPROXIMATE WEIGHT
Amperes
Negative
GROUNDED POLARITY
Bi-Directional
ROTATION
70
See Tabulation
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.
Detailed service
nent
SERVICE
ALTERNATOR
SERIES
PUBLICATION
ALX 6400
L-655A
8400
L-663
ALX 9400
SERVICE BULLETINS
the ALX series alternators.
for bulletins
pertaining
to
DRIVE PULLEY
40 Ft.
Lbs.
nut to 35
Ft.
Lbs.
minimum to
maximum.
700
to
800F.
i.
Rotor to be
2.
3.
4.
Slip rings
test probe
room
temperature
zero
and ohmmeter test probes must be clean.
leads must be in good condition.
Ohmmeter
Rotor
Printed in U.S.A.
winding
resistance
File in the
3.5 to 5.0 ohms.
Tech.
Data
ALTERNATORS
k
Al X
Page
SERVICE
4/1/83
Issued:
INFORMATION
2 of 4
ROTOR CURRENT DRAW TEST
CONDITI6NS
700
800F.
i.
Rotor to be
2.
3.
Refer to service
room
temperature
to
publication for
wiring diagram.
test
2.4 to 4.0 amperes.
1.350"
.002" max.
Minimum Diameter
Surface Finish
measure
50 microinch
from
bearing journals
max.
700
800F.
Alternator to be
2.
3.
Output voltage
4.
room
temperature
to be controlled
run
more
by
to
an
before
beginning
i.
test.
Refer
adjustable load.
point.
VENTILATION
Remove this
cover when bench testing the alternator.
through a hose type connection on the drive end head. When bench
testing this type of alternator, make output tests as short as
possible unless adequate air pressure for cooling is supplied.
(Without Regulator)
Alternator
Series
Output
Voltage
Amperage
ALX 6400-8400
and 9400
14.0
14.0
33.0
57.0
Output
Minimum
Alternator RPM
3000
6000
prasto/ire.~--AIRCRAFT ALTERNATORS
SERVICE
Issued:
INFORM ATION
Page
4/1/83
3 of 4
Origl Equip.
Alternator
Approx.
Weight
ALX 6406
11
Lb.
12 Oz.
VSF-7203S
VSF-7204
ALX 6408
11
Lb.
12 Oz.
VSF-7204
VSF-7203S
ALX 6423
11
Lb.
12 Oz.
VSF-7204
VSF-7203S
ALX 8403, LS,
R, RS
12 Lb.
2 Oz.
VSF-7201
*ALX 84036, LSG,
RG, RSG
12 Lb.
2 Oz.
FVR-4O04+
ALX 8421, LS,
R, RS
12
Lb.
2 Oz.
VSF-7201
VSF-7203
XALX 84216, LSG,
RG, RSG
12 Lb.
2 Oz.
FVR-4004+
FVR-4011+
ALX 9402
11
Lb.
6 Oz.
VSF-7204
VSF-7203S
11
Lb.
6 Oz.
VSF-7201
VSF-72O3
11
Lb.
6 Oz.
FVR-4004+
11
Lb.
6 Oz.
VSF-7203
ALX 9404L,
or
VSF-7203S
VSF-7203S
or
VSF-7203
R
*ALX 9404LG,
Keguia~or
Regulator
RG
ALX 9405
FVR-4011+
VSF-7203S
or
or
VSF-7203S
FVR-4011+
VSF-7203S
or
VSF-7204
11
Lb.
6 Oz.
VSF-7203
~SF-7203S
11
Lb.
6 Oz.
FVR-4O04+
FVR-4011+
ALX 9424
11 Lb.
6 Oz.
VSF-7204
VSF-7203S
ALX 9425, A, B
11 Lb.
6 Oz.
VSF-7204
VSF-7203S
ALX 9422L,
R
*ALX 9422L6,
RG
Internal wiring
grounded with
Wico
a
Field terminal F-2 externally
shown.
strap connector.
same
as
File in the
Printed in U.S.A.
TECH.
DATA
ALTERNATORS
XLASRO~ANRETLA
presro/ite.
AZRCRAFT
Issued:
Page
SERVICE
4/1/83
INFORMATION
4 of 4
OUtPVT
FIELD rl
FIELD
It
DIODES
STITOII
I_
II
\rf
I
ii
II I It
AUXIL~RJ,
ALY-6403 To 642iP RG
presto/ire,
ALTERNATOR
SERVICE PARTS LIST
ISSUED:
ORIG.EOUIP.ALTERNATOR
SERVICE ALTERNATOR
ENG.
VOLTS-IF
ENG.
NUMBER
NUMBER
APPLICATION
ALY-6403
ALY-6403G
ALY-6403R
ALY-64O3RG
ALY-6406
USE
USE
USE
ALY-642OR
ALY-6420R
ALY-6420R
USE
USE
ALY-642OR
Service
Service
ALY-6406R
Lycoming
ALY-64OSG
ALY-640BR
ALY-6406RG
ALY-64O8
USE
ALY-6406R
Lycoming
USE
ALY-6406R
ALY-6406R
Service
Service
ALY-64O9
USE
ALY-64F1
ALY-5422
Piper
Piper
ALY-6412
USE
USE
USE
ALY-64F5
ALY-6420
ALY-642OG
Lycoming
Lycomrng
ALY-6420R
ALY-6420RG
USE
USE
Lycoming
Lycomfng
ALY-6420R
ALY-6420R
ALY-6420R
ALY-6421
ALY-6422
Service
Service
ALY-6420R
ALY-6421
ALY-6425
ALY-6422
Piper
Piper
ALY-6425
ALY-6427G
USE
USE
ALY-6427R
ALY-6427R
Lycoming
Lycoming
ALY-6427R
ALY-6427RG
ALY-6427R
ALY-6427R
Service
USE
ALY-6427
File in the
Pas, in u.S.*.
3-3-75(Rev.)
Service
I
ALTERNATOR SECTION
I
ALY-6403 to 6427R6 Alternator Parts List
h
~-----O
B
10
g-@
II
5
0----------~
c/
Exploded View
of
Typical ALY Alternator
ISSUED: 11-6-79(REVI)
ALY-61103 TO 61127RG ALTERNATOR PARTS LIST
Brush
Rotor
Assembly
Assembly
Set
O
O
Slip Ring
Spring
Assembly
End Head
ALU-1045BS
End Head
Bearing 8
Seal Pkg.
Assembly
O
ALE-1013AS
90-2396[c]
ALY-6003,R
Br.,Holder
Drive
S.R.E.
SHEET 2
D.E.
Bearing
Assembly
0´•
O
O
O
90-2396[c1
90-2014Ea]
ALE-1003K
X-3416
ALY-6403G,RG
ALY-6406,R
I
I
[5]
ALY-6406G,RG
I
I
~b]
ALY-6408
I
I
Cb~
ALY-6409
90-2402[c~
Cb~
ALr-6412
90-2396[c]
[b]
0458SCb]
ALE-I
0458SCbI
1
1
ALU-1
0458SCb]
ALU-1 04585
ALE-1 01 3AS
ALE-2173S-1
ALY-6420,R
ALU-1
90-2402[c]
90-2396[c~
I
ALE-1003R
ALK-1132BS-1
I
ALE-1003K
I
ALE-1003R
ALY-6420G,RG
ALY-6421
I
ALY-6422
ALE-2177S-1
ALY-6425
ALE-2173S-1
I
I
AL E-l 04585
I
I
ALU-1045BS
I
I
kLE-1003K
ALY-6427,R
ALY-6427G,RG
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
E:3
35-781
Bearing
(GJC-49BS)
Seal
File in the
Print´•d In U.s.*.
I
ALTERNATOR SECTION
ALY-6403 TO 6427R6 ALTERIIATOR PARTS LIST
Stater
Assembly
Pos.Rect.
6 Plate
As
Assembly
Negative
(Pkg.of 3)
O
ALY-6403, R
Terminal
Stud
Rectifier
Package
8
ALE-2008AE
ALE-1 054A
D.E.
Retai ner
O
XA-944JS
90-2030
Thru
Bolt
Eyelet
Package
Package
O
61-32
O
ALA-P0JS
O
90-818
ALY-6403G,RG
ALY-6406,R
ALY-6406G,RG
I
ALY-6408
I
1
90-2043
ALY-6409
ALY-6412
ALY-6420,R
I
I
I
90-2030
ALY-6420G,RG
ALY-6421
I
1
90-2043
ALY-6422
ALY-6425
ALY-6427,R
I
I
1
90-2030
ALY-6427G,RG
h
ISSUED: ll-6-79(REv,)
ALY-64O3 TO 6427RG ALTERNATOR PARTS LIST
Nut
Washer
Rotor
Shaft
Package
Spacer
S.R.E.
Cover
Assembly
Drive
Vent.
Fan
Regulator
Pulley
(2 Pc.)
O
O
18
VSF-7203S
PU-672A
90-2241
ALY-6403,R
ENAI
ALY-6403G,RG
[NA]
I
I
I
I
ALY-6406, R
[NA:
I
I
I
I
ALY-64D6G,RG
CNA~
I
I
I
ALY-6408
[NAI
I
I
I
I
PU-672A
FVR-4024
ALY-6409
[NA]
I
I
ALD-P1A
I
I
PU-692A
FVR-4324
ALY-6412
CNA]
I
I
ALC-21F
90-2259
CNA]
VSF-7203S
ALY-6420, R
[NA]
I
I
ALD-21
90-2241
PU-672A
VSF-7203S
ALY-6420G,RG
CNAI
I
I
I
I
I
FVR-4011A
ALY-6421
CNA]
I
I
I
I
I
FYR-4024
ALY-6422
CNA~
I
I
ALD-ZIA
I
I
ALY-6425
CNA]
j
I
ALC-PLF
90-2259
CNA]
VSF-7203S
ALY-6427,R
~NA]
I
I
ALD-21
90-2241
PU-676A
VSF-7203S
ALY-6427G,RG
CNAI
I
I
[c]
Contents of
S.R.E.Head
S.R.E1
Head
Rotor
Bearing Pkg.
Head
Assy.,S.R.E.
Rotor
[NA]
ALD-LI
90-33
Pkg.
Rotor
SHEET 3
I
I
FYR-4011A
YSF-7203S
PU-676A
FVR-4011A
FVR-4324
PU-692A
I
I
FVR-4DllA
Pkg.
90-2396
90-2402
90-2014
90-2014
ALK-1132BS-1
ALK-1132BS-1
ALE-2173S-1
ALE-2177S-1
Not Available.
File in the
Prlnt´•d In U.S.~.
I
ALTERNATOR SECTION
I
prP~ro/ite,
ALY-8402
ISSUED:
SERVICE ALTERNATOR
ENG.
ENG.
NUMBER
NUMBER
ALY-8402
ALY-8403
ALY-8403G
ALY-8403LS
ALY-8403LSG
ALY-8403R
ALY-8403RG
ALY-8403RS
ALY-8403RSG
ALY-8405
VOLTS-IE
APPL ICAT ION
ALY-8411
USE
ALY-8420R
USE
USE
USE
ALY-8420R
ALY-8403RS
Lycoming
Lycoming
Lycoming
Lycoming
USE
USE
ALY-8420R
Service
ALY-8420R
Service
Service
Service
ALY-8403RS
USE
USE
ALY-8403RS
ALY-8426R
Lycoming
ALY-8405G
ALY-8405R
USE
ALY-8426R
Lycoming
USE
Service
ALY-8405RG
ALY-8410
USE
USE
ALY-8410R
USE
ALY-8426R
ALY-8426R
ALY-8423R
ALY-8423R
ALY-8411
ALY-8420
ALY-842OG
ALY-8420LS
ALY-8420LSG
ALY-8411
ALY-8423R
ALY-8424
ALY-8426
ALY-8426G
Lycoming
Service
USE
ALY-8420R
ALY-8420RS
USE
ALY-8420RS
USE
ALY-8420R
ALY-8420R
ALY-8420RS
Service
Service
Service
ALY-8420RS
Service
ALY-8423R
Lycoming
ALY-8423R
ALY-8424
Service
USE
USE
ALY-8420R
USE
ALY-8426R
USE
ALY-8426R
Lycoming
Lycoming
ALY-8426R
Service
ALY-8426R
Service
ALY-8426R
ALY-8426RG
Service
Lycoming
Lycoming
Lycomlng
USE
USE
ALY-8420R
ALY-8420RG
ALY-8420RS
ALY-8420RSG
ALY-8423
3-3-75(Rev.)
USE
ALY-84O3RS
USE
File in the
OE-AI AIRCRAFT MANUPIL
8426RG
ALTERNATOR
SERVICF CARTS LIST
ORIG.E4UIP.ALTERNATOR
To
I
SECTION
ALTERNATOR slcnon
aurlwroa
I
ALY-8402 to 8426RG Alternator Parts List
I,
v
~----O
io
9-@
0------------~
II
5
~3
;P7
Exploded View of Typical ALY Alternator
ALY-8402 TO 8426RG ALTERNATOR PARTS LIST
Rotor
Assembly
Assembly
O
Br.,Holder
Set
Spring
Assembly
O
90-2396[c]
ALY-8402
Brush
[b]
I
I
[b]
ALY-8403LS, RSI
I
[b]
ALY-8403LSG
I
I
Cb]
ALY-8403RSG
I
I
[6]
I
Cb]
I
Cb]
I
[b]
ALE-1
I
[b]
ALV-1045BS
ALY-8403G,RG
ALY-8405,R
I
ALY-8405G,RG
ALY-8410, R
I
ALY-8411
ALE-1013AS
ALE-2173S-1
ALY-8420,R
End Head
*’i~,"
SHEET
Drive End
D.E.
Head
Bearing
Pkg.
Assembly
O
O
90-2014[a]
ALE-1 003K
Seal
ly
90-2396[c]
ALU-I045BS[b]
[b]
I
ALY-8403,R
Slip Ring
O
ISSUED:II.-6-79(REV,
S.R.E.
Bearing
04585[ b]
I
I
ALK-1132BS-1
ALY-8420G,RG
ALY-8420LS,
ALY-8420LSG
ALY-8420RSG
ALE-1045BS
ALY-8423,R
I
I
I
ALY-8424
I
I
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
Bearing
(GJC-49BS~
a seal
replaced thereafter.
File in the
Pllnld In U.S.*.
I
I
ALTERNATOR SECTION
O
X-3416
ALY-8402 TO 8~26RG ALTERNATOR PARTS
Stater
Assembly
Assembly
Pos. Rect.
Plate
Rectifier
Terminal
Stud
Assembly
(Pkg.of3)
Package
Negative
O
8
ALE-1054A
ALE-2008AE
ALY-8402
I
ALY-8403,R
90-2043
XA-944JS
I
I
90-2030
ALY-8403G,RG
ALY-8403LS,RS
ALY-8403LSG
ALY-8403RSG
ALY-8405,R
ALY-8405G,RG
ALY-8410,R
I
ALY-8411
I
I
ALY-8420,R
1
90-2043
1
90-2030
ALY-8420G,RG
ALY-8420LS,RS
ALY-8420LSG
ALY-8420RSG
ALY-8423,R
ALY-8424
I
I
I
1
90-2043
ALY-8426,R
I
I
I
1
90-2030
ALY-8425G,RG
D.E.
Retainer
O
GR-32
Thru
Bolt
Eyelet
Package
Package
O
ALA-PDJS
90-818
ISSUED: 11-6-79(REV,)
ALY-8402 TO 8112611(3 ALTERIJATOR PARTS LIST
Rotor
Nut
S.R.E.
(2 Pc.)
Packagecer
ALU-1 062
ALY-8403,R
ALU-I 062A
90-33
I
I
ALY-8403G,RG
I
I
ALY-8403LS,RS
I
I
II
ALY-8403LSG
I
I
II
ALY-8403RSG
I
I
I
ALY-84056,RG
I
90-2259
CNAI
VSF-7203S
ALD-P1
90-2241
PU-672A
YSF-7203S
I
II
I
I~
I
~I
I
I
ALU-I 0620
ALY-8405, R
ALC-P1F
I
II
I
II
I
ALY-8410, R
ALU-I 062A
I
f
ALY-8411
ALU-1 062
1
I
ALC-21F
ALY-8420,R
ALU-I 062A
I
I
ALD-L1
FVR-4OI1A
I
I
CNAI
VSF-7203S
I
II
I
CNAI
FVR-4011 A
I
CNAI
I
I
n
I
II
I
I
o
O
O
O
ALY-8402
Regua Itor
Pulley
Fan
Shaft
Washer
Cover
Assembly
I
n
I
90-2259
I
FYR-4011A
I
FYR-4324
CNAI
VSF-7203S
VSF-7203S
PU-672A
90-2241
I
I
I
ALY-8420LS,RS
I
I
I
I
I
CNA]
VSF-7203S
ALY-8420LSG
I
I
I
I
I
CNAI
FYR-4011A
ALY-8420RSG
I
I
I
I
I
CNAI
ALY-8423, R
I
I
I
I
I
n
ALY-8424
ALU-1 062
1
I
ALC-21F
90-2259
ALY-8426,R
ALU-I 0620
1
I
ALD-L1
90-2241
ALY-8426G,RG
[cl
I
I
contents of S.R.E.
Head
S.R.E.Head 6 Rotor Pkg.
Assy.,S.R.E.
Rotor
CNAI
I
II
I
FVR-4324
PU-672A
CNA~
YSF-7203S
VSF-7203S
PU-672A
i
I
I
FYR-4O11A
Rotor
90-2396
90-2014
Bearing Pkg.
Head
II
I
FVR-4011A
ALY-8420G,RG
I
I
VSF-7203S
PU-672A
I
n
I
1
SHEET 3
Drive
Vent.
ALK-ll3ZBS-I
ALE-2173S-1
Not Available.
File in the
Plin~d In U.S~.
I
ALTERNATOR SECTION
ALY
presr~re.
SERVICE
Issued:
INFORMATION
Page
4/1/83
1 of 4
RATED
12
RATED VOLTAGE
GROUNDEDPOLARITY
Bi-Directional
ROTATION
APPROXIMATE WEIGHT
60
OUTPUT
Amperes
Negative
See Tabulation
SERVICE INFORMATION
covering disassembly, component testing, comporeplacement, assembly and bench testing are contained in the service
Detailed service procedures
nent
SERVICE
PUBLICATION
ALTERNATOR
SERIES
ALY 6400
L-655A
8400
SERVICE BULLETINS
to the ALY series alternators.
for bulletins pertaining
DRIVE PULLEY
40 Ft.
Lbs.
nut to 35
Ft.
Lbs.
minimum to
maximum.
700
to
800F.
i.
Rotor to be
2.
3.
4.
Slip rings
test probe
room
temperature
zero
probes must be clean.
be in good condition.
and ohmmeter test
leads must
Ohmmeter
Rotor
Printed in U.S.A.
winding resistance
File in the
3.5 to 5.0 ohms.
Tech.
Data
ALTERNATORS
ALYAIRCRAFT
ALTERNATORS
Issued:
4/1/83
SERVICE
INFORMATION
Page 2 of 4
temperature 700
to
800F.
i.
Rotor to be
2.
3.
Refer to service
room
publication
for test
wiring diagram.
2.4 to 4.0 amperes.
Minimum Diameter
Surface Finish
1.350"
.002" max.
measure
50 microinch
from
bearing journals
max.
temperature 700
to
800F.
before
beginning
i.
Alternator to be
2.
3.
Output voltage
4.
room
to be controlled
run
more
by
an
test.
Refer
adjustable load.
point.
VENTILATION
Remove this
cover
when bench
testing the alternator.
(Without Regulator)
Alternator
Series
Output
o
Voltage
Output
era
Amperage
ALY 6400-8400
14.0
14.0
13.0
47.0
Minimum
RPM
Alternator
erna or R
2000
4000
pres10,III’paAIV
SERVICE
Issued:
INFORMATION
ALY
ALY
ALY
ALY
ALY
ALY
ALY
ALY
ALY
ALY
ALY
ALY
ALY
ALY
ALY
ALY
Internal
Approx.
Weight
Alternator
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
6403, R
64036, RG
6406, R
64066, RG
6408
6409
6412
6420, R
64206, RG
6421
6422
6425
6427, R
64276, RG
8402
Wirin_g
Lb.
Lb.
Lb.
Lb.
Lb.
6 Oz.
Lb.
Lb.
Lb.
Lb.
Lb.
Lb.
Lb.
Lb.
Lb.
Lb.
Lb.
6
6
6
6
6
6
6
6
6 Oz.
6 Oz.
6 Oz.
6 Oz.
Oz.
Oz.
Oz.
Oz.
Oz.
Oz.
Oz.
Oz.
6 Oz.
12 Oz.--12 Oz.
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
ALY 8420, LS,
R, RS
ALY 84206, LSG,
RG, RSG
ALY 8423, R
ALY 8424
ALY 8426, R
ALY 84266, RG
Same
strap
Wico
Printed in U.S.A.
Page
Orig. Equip.
Regulator
of 4
Replacement
Regulator
VSF-7203S
FVR-4O11+
VSF-7203S
FVR-4O11+
X18150+
X16300B+
VSF-7203S
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*
VSF-7203
FVR-4004+
VSF-7203
FVR-4004+
X18150+
X16300B+
VSF-7204
VSF-7203
Figure
Figure
VSF-7204
VSF-7203
X16300B+
VSF-7203S
VSF-7203S
FVR-4011+
VSF-7203S
VSF-7203S
Figure 1*
FVR-4004+
FVR-4011+
Figure 1
Figure 1*
VSF-7203S
FVR-4O11+
X16300B+
VSF-7203S
1
1
FVR-4004+
X18150+
X16300B+
VSF-7204
VSF-7203
FVR-40O4+
VSF-7203S
FVR-4O11+
X18150+
10 Lb.
10 Lb.
10 Lb.
12 Oz.
12 Oz.
12 Oz.
Figure
Figure
Figure
2
1
1
VSF-7203
FVR-4OO4+
X16300B+
VSF-7204
VSF-7203
10 Lb.
12 Oz.
Figure
1*
FVR-4OO4+
FVR-4O11+
10 Lb.
10 Lb.
10 Lb.
10 Lb.
12
12
12
12
Figure 2
Figure 1
Figure 1
Figure 1*
X16300B+
VSF-7204
VSF-7203
FVR-4OO4+
X16300B+
VSF-7203S
VSF-7203S
FVR-4011+
Oz.
Oz.
Oz.
Oz.
1 except field terminal F-2 externally
connector.
as
3
4/1/83
Figure
VSF-7203S
groiinded with
File in the
Tech.
Data
ALTERNATORS
a
k presr~ite.
ALY
Issued:
SERVICE
4/1/83
JNFORMArlON
Page 4 of 4
OUTPUT_
;vl
FIELD
II I
STATOR
ROTOR
WINDING
(I
1~\11
Figure 1
/C7
Figure
2
ALZ SERIES
ALTERNATOR
SERVICE PARTS LIST
ISSUED:
ENG.
NUMBER
ENG.
NUMBER
ALZ-8423R
ALZ-84L3R
ALZ-8423R
APPLICATION
Lycoming
Lycoming
ALZ-8401
USE
ALZ-8401G
ALZ-84O1R
ALZ-8401RG
USE
USE
USE
ALZ-8423R
Service
Service
ALZ-8423
USE
ALZ-8423R
Lycoming
ALZ-8423G
ALZ-8423R
ALZ-8423RG
USE
ALZ-8423R
ALZ-8423R
Lycoming
USE
File in the
P.lnl´•dinU.I.*
VOLTS-IL
SERVICE ALTERNATOR
ORIG.EOUIP.ALTERNATOR
OE´•AI AIRCRAFT MANUAL
ALZ-8423R
3-4-75(Rev.)
Service
Service
I
ALTERNATOR SECTION
ALZ-8000 Series Alternator Parts
List
-I
C/
to
----(13
~a
C/
Exploded
View of
Typical ALZ Alternator
,a-
ISSUED: 3-5-79 (REV,)
ALZ SERIES ALTERNATOR PARTS LIST
Brush
Rotor
Assembly
Set
Assembly
O
O
ALZ-8401
1
90-2396[c]
S.R.E.Bearing
Slip Ring
Br.,Holder
Spring
Assembly
L Seal
End Head
"’i~iy
O
P
5
90-2014Cbl
90-2396[c]
IALU-10458S[a]
SHEET 2
D.E.
Drive End
Head
Bearing
n,i~gl,
O
ALE-1003K
X-3416
ALZ-8401G
ALZ-8401R
ALZ-8401RG
ALZ-8423
ALE-1 01 3AS
jALE-2173S-1
ALK-1132BS-1
ALU-1045BS
ALZ-8423G
ALZ-8423R
ALZ-8423RG
E~3
35-781
(GJC-49BS
Cover
ALE-1013AS Captive Brush
Pkg
Also aval Ible,
10 Pcs.
Set alsolndivi ually avallaole Tor un~rs
Earlier units must replace the Complete 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
(See
Sheet #3 for contents of
File in the
Prlnt´•d In V.S.*.
Hd.
Assy.
at time of first
repair.
Pkg. )maybe replaced thereafter.
I
ALTERNATOR SECTION
nLz SERIES ALTER~ATOA PARTS LIST
Stater
Assembly
Assembly
Pos.Rect.
8 Plate
Assembl y
Negative
Rectifier
ALZ-8401G
ALZ-8401R
ALZ-8401RG
ALZ-8423
ALZ-8423G
ALZ-8423R
ALZ-8423RG
ALE-2008AG
ALE-1D54A
D.E.
Retainer
Term.
Stud
Thru
Bolt
(Pkg.of 3)
8
ALZ-8401
S.R.E.
Cover
XA-944JS
O
O
ALU-1 062A
GR-32
o
90-2030
ALA-20JS
ISSUED: 3-5-79(REv~)
ALZ SERIES ALTERNATDR PARTS LIST
Assembly
Eyelet
Package
O
ALZ-8401
Nut 6
Rotor
Vent.
Washer
Pac
Sha~L
Fan
la
.90-818
90-33
ALD-21
PU-672A
VSF-7203S
YSF-7203S
FVR-(IO11A
VSF-7203S
ALZ-8423
FVR-4011A
ALZ-8423G
YSF-7203S
ALZ-8423R
FVR-4011A
ALZ-8423RG
of S.R.E.
Head 6 Rotor
S.R.E.Hd. 6 Rotor Pkg.
90-2396
90-2014
Bearing Pkg.
Pllnt´•d In U.S.*.
90-2241
FYR-4011A
ALZ-8401RG
Rotor
Regul ator
It
ALZ-8401R
Head
Drive
Pulley
(;ZRc´•
ALZ-8401G
[c]~Contents
SHEET 3
Assy.,S.R.E.
ALK-11328S-1
ALE-2173S-1
File in th´•
OE-AI AIRCIIAFt MANUAL
ALTERNATOR SECTION
ALZ
SERVICE
Issued:
INFORMATION
4/1/83
Page 1 of 3
ROTATION
RATED OUTPUT
12
RATED VOLTAGE
GROUNDED
Bi -Di rectional
10 Lb.
APPROXIMATE WEIGHT
50
Amperes
Negative
POLARITY
12 Oz.
SERVICE
INFORMATION
Detailed service procedures covering disassembly, component testing, compo-
replacement, assembly, and bench testing are contained in the service
nent
SERVICE
PUBLICATION
ALTERNATOR
SERIES
L-655A
ALZ 8400
SERVICE BULLETINS
for bulletins
pertaining
to the ALZ series alternators.
DRIVE
PULLEY
to 40 Ft.
Lbs.
nut to 35
Ft.
Lbs.
minimum
maximum.
to
800F.
Rotor to be
2.
3.
Ohmneter must be checked to
4.
room
temperature
zero
ohmmeter test probes must be clean.
leads
must be in good condition.
probe
Slip rings and
test
Prin)ed in U.S.A.
700
i.
File in the
OE-AI AIRCRAFt MANUAL
Ohmmeter
Tech.
Data
ALTERNATORS
ALZ
SERVICE
Issued 4/1/83
INFORMATION
Page 2 of 3
winding
Rotor
resistance
3.5 ’to 5.0 ohms.
700
800F.
i.
Rotor to be
2.
3.
Refer to service publication for test
room
temperature
to
wiring diagram.
2.4 to 4.0 amperes.
1.350"
Minimum Diameter
Surface Finish
.002"
max.
measure
50 microinch
from
bearing journals
max.
i.
Alternator to be
2.
Alternator connected
to
service
room
temperature
700
to
800F.
before
so it is supplying its own field
publication for bench test wiring diagram.
3.
Output voltage
4.
to
be controlled
run
more
by
an
beginning
test.
current.
Refer
adjustable load.
than 2 minutes for each test point.
VENTILATION
Remove this
cover when bench testing the alternator.
ALZ
AIRCRAFT AI~TFRNATORS
SERVICE
Issued:
INFORMATION
2000
4000
17.0
41.0
14.0
14.0
ALZ 8400
Minimum
Alternator RPM
Output
Amperage
Output
Voltage
Replacement
Regulator
Orig. Equip.
Regulator
Alternator
3 of 3
(Without Regulator)
Alternator
Series
Page
ALZ 8401, R
VSF-7203
VSF-7203S
*ALZ 84016, RG
FVR-4004+
FVR-4011+
ALZ 8423, R
VSF-7203
VSF-7203S
FVR-4004+
FVR-4011+
*ALZ 84236,
RG
4/1/83
Field terminal F-2 externally grounded
Internal wiring same as shown.
with a strap connector.
Wico
FIELD FI
C
DIODES
ST~TO(1
I(\(I)
II
I
I
It
II
1-11IJI
ROtOl WIWDINO
Printed in u.s.n.
File in the
I
Tech.
L-600 SERVICE MANUAL
I
Data
ALTERNATORS
AIRCRAFT VOLTAGE REGULATOR
SERVICE
INFORMATION
VOLTS
Page
have
These units
ADJUSTMENT
1
of 1
Neg at i ve
GROUND
12
10-5-72
Issued:
external
an
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
terminal
CAUTION NOTES
to
be
adjusted
to 14.2
ground.
only with insulated (ungrounded) field
i.
Use
2.
Regulator base
3.
Do not
4.
Do not
must
have
connection.
good ground
a
(even momentarily) connect
regulator terminals together.
connect battery into
the two
system
alternators.
with
voltage
polarity
reversed.
5.
Do not
6.
This
with
is
a
force the voltage
a
new
adjustment
screw.
sealed unit and not repairable.
Replace
unit.
VSF-7201u´•it-~
VSF-7202
II
VSFc7203,S
zn~
VSF-7204
aLGiiL1TPa
Rdl-FL
I
5r
Typical Schematic
File in ~he
Printed
in
U.S.A
OE-AI AIRCRAFT MANUAI
I
rC*
Circuit of
Tech.
Data.
1
Regulator
REGULATORS
RELAYS
VSF-7dOD
prest~tP.
AIRCRAFT VOLTAGE REGULATOR
SERVICE
Issued:
INFORMATION
Page 1 of 1
Negati ve
24
VOLTS
10-5-72
These units have
ADJUSTMENT
plastic plug
an
on
an external adjustment located under the
The regulator has
top of the regulator.
adjustment spread ranging from 26.0 volts to 30.0
increased by turning the adjustment
volts.
Output is
clockwise.
OPERATING VOLTAGE
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.
CAUTION NOTES
i.
Use
2.
Regulator
3.
Do not
4.
Do not connect battery into system with
The
(ungrounded)
with insulated
only
base must have
a
field alternators.
good ground
(even momentarily) connect
regulator terminals together.
connection.
the two
voltage
polarity
reversed.
force the
not
5.
Do
6.
This
with
is
screw.
repairable.
sealed unit and not
a
new
a
voltage adjustment
Replace
unit.
’I
al´•r "~n´•
;ti:
Unit
VSF-7401
VSF-7402
c~
I
PI
u
i~Z
12
91
VSF-7403,S
~Fs
VSF-7404
i
u
5*"~Y
3Y
Typical
File in the
Princ´•d
in
US.*
OE-AI AIRCRAFf MANUAL
’C
Schematic Circuit of Regul~tor
Tech.
Data
REGULATORS R RELC\YS

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