Aircraft Alternator Maintenance Manual TABLE OF CONTENTS Airworthiness Limitations ........................A-1 General Information ........................... A-1 Airworthiness Limitations Statement ....................A-1 Life Limits ............................A-2 CHAPTER 1 - INTRODUCTION ........................1-1 General Information ..........................1-1 General Specification (manual) ......................1-2 How to use the manual ........................1-2 Measurements ............................1-3 Units of Measure ..........................1-3 Abbreviations ............................1-4...
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Aircraft Alternator Maintenance Manual CHAPTER 4 - CHECK ..........................4-1 General ...............................4-1 Inspection Checks ..........................4-1 CHAPTER 5 - INSPECTION & TESTING ....................5-1 General ...............................5-1 A. Equipment ............................5-1 B. Precautions ..........................5-2 Inspection ............................5-2 A. Arc Marks on Terminals (Visual Inspection): ................5-2 B. Bearing Inspection (For Troubleshooting Purposes): ..............5-2 C.
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Aircraft Alternator Maintenance Manual 6.11 Materials ............................6-12 A. Hardware .............................6-12 B. Specific Items ..........................6-12 C. Special Items ..........................6-12 6.12 Applying Safety Wire .........................6-13 6.13 Applying Safety Cable ........................6-13 6.14 Installation on the Aircraft (Gear Drive) .....................6-13 6.15 Installation on the Aircraft (Belt Drive)....................6-13 6.16 Special Conditions: ..........................6-14 A.
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Aircraft Alternator Maintenance Manual Thank you for purchasing a PlanePower* alternator. We encourage you to read this manual thoroughly. It contains a wealth of information about how to properly install and maintain your alternator so that it may give you many years of safe and reliable service. Should you have a question regarding your alternator that is not covered in the manual, Hartzell Engine Technologies Product Support is ready to assist you.
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Change SI Units: Ah to A ∙ h, N.m to N ∙ m; Change U.S. Units: lbf/in to lbf ∙ in, lb/ft to lbf ∙ ft; Para. 1.9, change ES-10024B-( ) to ES-10024B-1 thru -5 and 5LS; Update Operational Data and Dimensions paragraphs;...
Aircraft Alternator Maintenance Manual AIRWORTHINESS LIMITATIONS General Information CAUTION: THE AIRWORTHINESS LIMITATIONS HEREIN ARE THOSE MANDATED BY HARTZELL ENGINE TECHNOLOGIES. THESE LIMITATIONS ARE THE MINIMUM REQUIRED TO MEET CONTINUED AIRWORTHINESS BUT MAY BE SUPERSEDED BY MORE STRINGENT REQUIREMENTS AS PUBLISHED BY THE FAA, AIRCRAFT, ROTORCRAFT OR OTHER MANUFACTURERS THAT USE THESE COMPONENTS IN THEIR APPLICATIONS.
Aircraft Alternator Maintenance Manual Life Limits A. The FAA establishes specific life limits for certain component parts as well as the complete starter adapter. Such limits require replacement of the identified parts after a specified number of cycles or hours of use. B.
Aircraft Alternator Maintenance Manual CHAPTER 1 - INTRODUCTION General Information WARNING: IMPROPER OR UNAUTHORIZED APPLICATIONS OF THE INFORMATION CONTAINED IN THE MANUAL MAY RENDER THE AIRCRAFT OR THE COMPONENT UNAIRWORTHY AND RESULT IN LOSSES, DAMAGES, OR INJURY TO THE USER. DO NOT USE OBSOLETE OR OUTDATED INFORMATION.
A. This manual follows general GAMA guidelines using ATA 100 identification as required. Principle units of measure used in the manual are U.S. units with International System of Units (SI) in parentheses. B. The ALV-9610, ES-10024, ES-10024B-1 thru -5 and 5LS, and ES-6024D series (24v) alternator models are considered herein.
Aircraft Alternator Maintenance Manual Measurements The measurements given in this manual are taken from original manufacturing drawings. Units of Measure A. SI Units Ampere A ∙ h Ampere hours Gram Newton N ∙ m Newton meter Volt °C Degree Celsius Ω...
Aircraft Alternator Maintenance Manual Abbreviations A. The abbreviations given below are used in the manual: (upper or lower case) Alternator Control Unit Aircraft Flight Manual Alternator Air Transport Association of America Continental Motors, Inc. Drive End (housing) Diameter Federal Aviation Administration (USA) FIG.
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Aircraft Alternator Maintenance Manual BRUSH HOLDER: Device that retains multiple brush assemblies and is comprised of a holder, contacts, and terminals. CONTINUITY: The continuous path for the flow of current in an electrical circuit. COOLING COVER: Device attached to the alternator to provide cooling air from an external source. May be provided with alternator or required by the airframe manufacturer.
Aircraft Alternator Maintenance Manual CHAPTER 2 - DESCRIPTION OF OPERATION Description A. General Hartzell Engine Technologies (HET) small frame, gear and belt driven alternators have been designed and constructed to provide extended periods of trouble-free operation with a minimum amount of maintenance.
Aircraft Alternator Maintenance Manual B. Operational Data Gear Driven Air Cooled Belt Driven (ES10024B) External fan cooling (ES10024B) Operating Speed (Minimum for Regulation): 2,200 RPM Maximum Continuous Operating Speed: 10,000 RPM Operating Output (Rated): 28.0 volts, 100 amps Maximum Operating Altitude: 31,900 feet MSL (9,723 meters MSL) Weight: See Table 2-1, this chapter...
Aircraft Alternator Maintenance Manual Basic Component Description A. The principle components of the aircraft alternators described herein are the slip ring end housing assembly with bearing, the rectifier assembly, the stator, the rotor, the drive end housing assembly with bearing and the brush holder assembly with spring and brushes.
Aircraft Alternator Maintenance Manual Physical Detail A. The brush holder assembly consists of a brush holder housing and two brush assemblies. The brush assemblies are made from a carbon-graphite brush having a flexible braided copper wire lead fitted to a coil spring.
Aircraft Alternator Maintenance Manual CHAPTER 3 - TROUBLESHOOTING General In the event of malfunction in electrical power, it should not be assumed to be an alternator fault before employing proper troubleshooting procedures. The overall objective of trouble-shooting is to find the cause of trouble and take corrective action to prevent a recurrence. Even perfectly operational alternators cannot compensate for improper adjustments, corroded or worn parts, and improper installation or lack of maintenance.
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Aircraft Alternator Maintenence Manual 3.2 Continued Table 3.1 Loose terminal connections: Inspect the terminals, if they will tighten, do so, if not the alternator may need to be disassembled to replace studs or receptacles. Also observe the wire terminal ends to assure they are crimped properly on the wire with no corrosion or burns present.
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Aircraft Alternator Maintenance Manual 3.2 Continued Table 3.2 Shorted or leaking RFI capacitor (airframe, engine, HET external filter): Remove capacitor and perform capacitance check and wire lead to case resistance check. Replace filter capacitor if failed (external filter only). If an internal PCB type filter, replace or overhaul alternator if failed.
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Aircraft Alternator Maintenence Manual 3.2 Continued Table 3.3 Failed battery: Determine battery age and check for expected life. If near or beyond normal life, replace battery. If battery discharges frequently, check for dead or shorted cells, if found replace battery. Voltage regulator set too high for aircraft operating conditions: Check the voltage regulator setting per the aircraft service manual.
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Aircraft Alternator Maintenance Manual 3.2 Continued Table 3.4 Drive coupler slipping: Inspect the condition of the drive clutch. (as applicable) This part is supplied by the engine manufacturer. Improper tension supplied by this clutch will allow slippage during high alternator output. Drive Belt slipping: Inspect the condition of the pulley belt.
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Aircraft Alternator Maintenence Manual 3.2 Continued Table 3.5 Brush arcing: Remove and examine brush material, spring, and leads. If spring in broken or the lead is coming out of brush, or if brush is chipped or worn past 50% replace brush. Examine slip ring surface for condition. Rough or damaged slip ring surface: If the slip rings show minor surface roughness they may be polished.
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Aircraft Alternator Maintenance Manual 3.2 Continued Table 3.6 Damaged alternator or voltage regulator wiring harness: Check wiring harness for damage and repair. If damage is found, check voltage regulator for function and replace if necessary. Dirty or rough rotor slip rings: If dirty, the slip rings may be cleaned. Take care not to scratch the surface. If the slip rings are worn beyond limits, replace or overhaul alternator (see section 6).
Aircraft Alternator Maintenence Manual Alternator Drive Coupling Troubleshooting The alternator drive coupling is provided by the airframe or engine manufacturer and those manufacturers normally issue instructions regarding maintenance and installation. The alternator drive coupling is fundamental to the operation of Hartzell Engine Technologies (HET) gear driven alternator.
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Aircraft Alternator Maintenance Manual Continued If an alternator is determined to be at fault, note that HET sells alternators with or without a pulley due to the desire of engine and airframe manufacturers to sometimes use their own custom pulley and belt arrangements. The HET alternator designated ES10024B-1 is delivered without a pulley.
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Aircraft Alternator Maintenence Manual Continued Whenever the pilot notes belt noise, it is important to determine the type of noise and under what circumstances it occurs. Repairing a drive misalignment (chirp) is not likely to resolve a slip noise (squeal) that may be caused by insufficient tension. (1) Check if the problem is more noticeable when starting and while the engine is cool (cool wet belt).
Aircraft Alternator Maintenance Manual CHAPTER 4 - CHECK General A. This section defines the various checks and inspections needed to assure reliable and safe operation of the alternator while in service. They are listed in hours time in service (TIS) or in calendar time, whichever is applicable and are the first to occur when offered a choice.
Aircraft Alternator Maintenance Manual CHAPTER 5 - INSPECTION & TESTING General This chapter outlines the tests and inspections required to determine the condition of the alternator removed for scheduled and unscheduled maintenance. Refer to the procedures given in the TROUBLESHOOTING Chapter prior to applying any test for maintenance.
Aircraft Alternator Maintenance Manual B. Precautions Regular maintenance must be accomplished per this manual and per the applicable aircraft and/or engine service manuals and publications. In addition, observe the following precautions: DISCONNECT THE BATTERY before connecting or disconnecting test instruments (except voltmeter), or before removing or replacing any unit or wiring.
Aircraft Alternator Maintenance Manual Grasp the drive component (pulley or coupling) and push-pull the shaft in a direction parallel to the axis. Movement should be small, less than .0062 inch (.1575 mm). Grasp the drive component (pulley or coupling) and push-pull the shaft in a direction perpendicular to the axis.
Aircraft Alternator Maintenance Manual G. Pulley Run Out Check: Note: A pulley runout check must be done with the pulley installed on the alternator. Consult the aircraft and/or engine maintenance manuals for procedures to perform the pulley runout check while on the aircraft engine.
Aircraft Alternator Maintenance Manual D. Test Setup For gear driven alternators, install a fabricated test pulley (Fig. 5.1), washer, and nut onto the alternator shaft. All ES-10024B models shall be tested with the original manufacturer installed pulley. If testing a gear driven alternator, torque nut to 30 ft-lbs max to secure the fabricated test pulley. Mount the alternator to a test bench that is capable of turning the rotor shaft 10,000 RPM in combination with drive pulley and alternator pulley.
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Aircraft Alternator Maintenance Manual Order of Tests Output Voltage Min. Output Amps Max Alternator RPM Test #1 28.0 ± .5 8000 Test #2 28.0 ± .5 4000 Test #3 28.0 ± .5 2500 Table 5.1 - ES- 10024 & ALV-9610 Test Parameters Order of Tests Output Voltage Min.
Aircraft Alternator Maintenance Manual Alternator Self Excitation Test (-5 & -5LS only) A. Self-excitation ability is derived from residual magnetism in the rotor pole pieces, which provides the minimum generated voltage necessary to power the ACU and begin producing power. (This provision only on the ES- 10024B-5 or -5LS alternator.) B.
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Aircraft Alternator Maintenance Manual Field 2 Terminal Field 1 Terminal to Ground Jumper to DC Output Jumper (switched) Ground Terminal DC Output 24v Battery DC Load Bank Figure 5.5 - ALV-9610, ES-10024B, and ES-6024D Test Setup (ALV-9610 Shown) ES1031 24-30-01 Rev.
Aircraft Alternator Maintenance Manual CHAPTER 6 - MAINTENANCE General A. This section contains information regarding recommended maintenance for all alternators listed in this manual. These recommendations assure reliable and safe operation of the alternator while in service. Maintenance is listed in hours time in service (TIS) or calendar time, whichever is applicable but each are the first to occur.
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Aircraft Alternator Maintenance Manual Alternator Drive Coupling Inspection & Maintenance (cont’d) B. To remove the gear driven alternator from a specific engine, refer to the aircraft and/or engine service and maintenance manuals for detailed instructions. C. General Removal - Gear Driven Alternator Make sure external power has been disconnected.
Aircraft Alternator Maintenance Manual Alternator Belt & Pulley Inspection & Maintenance A. Although the alternator belt is provided by the airframe or engine manufacturer and those manufacturers normally issue manuals or instructions regarding their maintenance, the belt is fundamental to the operation of Hartzell Engine Technologies LLC (HET) alternator.
Aircraft Alternator Maintenance Manual Alternator Belt & Pulley Inspection & Maintenance (cont’d) Alternator Maximum with Pulley Belt Tension ES-10024B-2 76 lbs / 34.5 kg ES-10024B-3 80 lbs / 36.3 kg ES-10024B-4 79 lbs / 35.8 kg ES-10024B-5 80 lbs / 36.3 kg Table 6.2 - Alternator Maximum Belt Tension Removal from the Aircraft (Belt Drive) A.
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Aircraft Alternator Maintenance Manual Problem Possible Cause Corrective Action Belt Slippage Lack of tension Increase tension Overloaded drive Reduce load or check pulley size Worn pulley or V grooves Replace pulley Oily drive conditions Clean drive, resolve oil leak Belt turn over Misaligned drive Realign shafts and pulleys Worn pulley or V grooves...
Aircraft Alternator Maintenance Manual Brush Removal and Installation NOTE: Brushes must be replaced in pairs. If replacing brushes only, order two (2) each, HET P/N ALE-13A brushes through an authorized HET distributor. HET recommends replacing the brush holder ass’y HET P/N ALU-3045BS or ALE-3045BS as applicable.
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Aircraft Alternator Maintenance Manual A. Inspect the through bolts while installed, they must not be bent, cracked, or damaged. B. If any through bolt is bent, cracked, damaged or housings are loose, the alternator should be replaced or overhauled. (Loose and damaged through bolts may indicate serious internal damage in the alternator.) C.
Aircraft Alternator Maintenance Manual 6.10 Terminal Hardware Removal and Installation A. Removal AUX Terminal: Using a thin 3/8 wrench, hold the bottom nut and loosen the top nut as shown in Figure 6.4 AUX Terminal. This is required to prevent the loss of the factory torque of the bottom nut. Remove and discard lockwasher.
Aircraft Alternator Maintenance Manual 6.11 Materials This section presents the current materials available for maintenance. Items are available through an HET autho- rized distributor and are the only parts available at this time. Some parts such as OEM pulleys alternator belt, and drive coupling may only be available from aircraft/engine OEM.
Aircraft Alternator Maintenance Manual 6.12 Applying Safety Wire A. If applying safety wire, use .032 stainless steel per the standards outlined in AC43.13.1b or NASM-33540 of the latest revision. (Safety wire does not maintain fastener torque.) 6.13 Applying Safety Cable A.
Aircraft Alternator Maintenance Manual (4) Re-connect the blast air tube if required. (5) If pulley is to be installed, torque pulley nut 55 to 65 ft-lbs (74.6 Nm to 88.1 Nm) and check pulley run out per section 5.2.G. (Use pulley wrench to hold pulley, later units use 5/16 inch hex key to hold shaft while applying torque to output shaft nut.) CAUTION: DO NOT EXCEED TENSION LIMITS.
Aircraft Alternator Maintenance Manual If “sudden stoppage” as defined by the engine manufacturer has occurred or if a sudden stoppage has caused the belt to twist or come off, the alternator must be inspected. Refer to the appropriate engine or airframe manuals to remove the alternator. Check the following: (a) Belt - remove belt - check for flat spots, cuts, or broken fabric.
Aircraft Alternator Maintenance Manual (3) If a strike has occurred, (especially if arc burns appear on the propeller) remove the alternator and inspect for arc marks. If gear driven, observe the drive coupling teeth as an arc here may leave raised metal which will also cause further damage when running.
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