Plane-Power ES-10024B-1 Maintenance Manual

Aircraft alternator

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Aircraft Alternator

Maintenance Manual

ES1031

Rev. B: 20 Apr. 2022

AIRCRAFT ALTERNATOR

MAINTENANCE MANUAL

P/N

ALTERNATOR

MODELS

ES-10024B-1

ES-10024B-2

ES-10024B-3

ES-10024B-4

ES-10024B-5

ES-10024B-5LS

ES-10024

ALV-9610

ES1031

ES-14024B-1

ES-14024B-2

ES-14024B-3

ES-14024B-4

ES-14024B-5

ES-14024B-1LS

ES-6024D

24-30-01

Page: i

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Page 1 Aircraft Alternator Maintenance Manual AIRCRAFT ALTERNATOR MAINTENANCE MANUAL ES1031 ALTERNATOR MODELS ES-10024B-1 ES-14024B-1 ES-10024B-2 ES-14024B-2 ES-10024B-3 ES-14024B-3 ES-10024B-4 ES-14024B-4 ES-10024B-5 ES-14024B-5 ES-10024B-5LS ES-14024B-1LS ES-10024 ES-6024D ALV-9610 ES1031 24-30-01 Rev. B: 20 Apr. 2022 Page: i © 2022 - Hartzell Engine Technologies - All rights reserved...
Page 3: Table Of Contents
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...
Page 4 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.
Page 5 Aircraft Alternator Maintenance Manual 6.11 Materials ............................6-12 6.12 Applying Safety Wire .........................6-14 6.13 Applying Safety Cable ........................6-14 6.14 Installation on the Aircraft (Gear Drive) .....................6-14 6.15 Installation on the Aircraft (Belt Drive)....................6-14 6.16 Special Conditions: ..........................6-15 A. Sudden Engine Stoppage (gear drive): ..................6-15 B.
Page 6 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.
Page 8 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;...
Page 9 Aircraft Alternator Maintenance Manual RECORD OF REVISIONS Revision Issue Page(s) Description Level Date Revised 4/20/22 Revision accepted via PCO-111097; Add alternator models ES-14024B-1 thru -5, & -1LS; Remove Copyright boilerplate; Add ES-14024B-1 thru -5, -1LS to para. 1.2 B.; Add ES-14024B-1 thru -5 to para. 1.9; Add ES-14024B Operational Data;...
Page 10 Aircraft Alternator Maintenance Manual RECORD OF TEMPORARY REVISIONS Issue Page Date Temporary Date Rev. Letter Number Removed 24-30-01 ES1031 Page: x Rev. B: 20 Apr. 2022 © 2022 - Hartzell Engine Technologies - All rights reserved...
Page 11: Airworthiness Limitations
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.
Page 12: Life Limits
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.
Page 13: Chapter 1 - Introduction
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.
Page 14: General Specification (Manual)
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, -5LS, ES-14024B-1 thru -5, -1LS, and ES-6024D series (24v) alternator models are considered herein.
Page 15: Measurements
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...
Page 16: Abbreviations
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.
Page 17 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.
Page 18: Disposal
Model Identification ALV-9610 Gear Driven (24 Volt) ES-10024 Gear Driven (24 Volt) ES-10024B-1 thru -5 and -5LS Belt Driven (24 Volt) ES-14024B-1 thru -5 and -1LS Belt Driven (24 Volt) ES-6024D Gear Driven (24 Volt) 1.10...
Page 19: Chapter 2 - Description Of Operation
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.
Page 20: Operational Data
Aircraft Alternator Maintenance Manual B. Operational Data Gear Driven (ES-10024, ALV-9610, ES-6024D) Air Cooled 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 Belt Driven (ES-10024B)
Page 21 Aircraft Alternator Maintenance Manual 8.63 4.122 .669 4.122 4.118 2.44 1.42 2.00 4.00 5.25 5.25 Figure 2.3 ES-10024/ALV-9610 Dimensions ES1031 24-30-01 Rev. B: 20 Apr. 2022 Page: 2-3 © 2022 - Hartzell Engine Technologies - All rights reserved...
Page 22 Aircraft Alternator Maintenance Manual 5.116 .112 .875 2.610 1.13 3.985 Figure 2.4 ES-10024B-1 & 10024B-5LS Dimensions 24-30-01 ES1031 Page: 2-4 Rev. B: 20 Apr. 2022 © 2022 - Hartzell Engine Technologies - All rights reserved...
Page 23 Aircraft Alternator Maintenance Manual Figure 2.5 ES-10024B-2 Dimensions 3.22 2.223 2.56 7.66 PK 6.73mm STD Figure 2.6 ES-10024B-3 Dimensions 2.97 1.517 2.40 7.50 ES1031 24-30-01 Rev. B: 20 Apr. 2022 Page: 2-5 © 2022 - Hartzell Engine Technologies - All rights reserved...
Page 24 Aircraft Alternator Maintenance Manual K 6.290 STD Figure 2.7 ES-10024B-4 Dimensions 3.00 1.978 2.52 7.61 J10 2.31 PITCH Ø 2.266 Figure 2.8 ES-10024B-5 Dimensions 1.883 2.44 9.393 24-30-01 ES1031 Page: 2-6 Rev. B: 20 Apr. 2022 © 2022 - Hartzell Engine Technologies - All rights reserved...
Page 25 Aircraft Alternator Maintenance Manual R3.50 Figure 2.9 ES-10024B-1 thru - 4 & -5LS ES-10024B-5 (Less blast tube cover) ES1031 24-30-01 Rev. B: 20 Apr. 2022 Page: 2-7 © 2022 - Hartzell Engine Technologies - All rights reserved...
Page 26 Aircraft Alternator Maintenance Manual 4.122 1.42 5.725 Figure 2.10 6024D Dimensions 24-30-01 ES1031 Page: 2-8 Rev. B: 20 Apr. 2022 © 2022 - Hartzell Engine Technologies - All rights reserved...
Page 28 Aircraft Alternator Maintenance Manual Ø 5.118 Ø 2.74 .112 1.13 .875 2.59 2.225 ±.015 3.968 ±.022 7.69 Figure 2.12 ES-14024B-1 (-1LS, Less Pulley) Dimensions 24-30-01 ES1031 Page: 2-10 Rev. B: 20 Apr. 2022 © 2022 - Hartzell Engine Technologies - All rights reserved...
Page 29 Aircraft Alternator Maintenance Manual Figure 2.13 ES-14024B-2 Dimensions 3.980 Ø 5.900 .600 4.106 Ø 3.17 Figure 2.14 ES-14024B-2 Dimensions 1.758 1.713 .130 3.00 7.190 ES1031 24-30-01 Rev. B: 20 Apr. 2022 Page: 2-11 © 2022 - Hartzell Engine Technologies - All rights reserved...
Page 30 Aircraft Alternator Maintenance Manual Figure 2.15 ES-14024B-3 Dimensions 3.980 4.106 .600 Shipping Spacer Figure 2.16 ES-14024B-3 Dimensions .130 3.00 7.516 24-30-01 ES1031 Page: 2-12 Rev. B: 20 Apr. 2022 © 2022 - Hartzell Engine Technologies - All rights reserved...
Page 31 Aircraft Alternator Maintenance Manual Figure 2.17 ES-14024B-4 Dimensions 3.980 4.106 .600 Figure 2.18 ES-14024B-4 Dimensions 1.158±.028 .130 3.00 7.516 ES1031 24-30-01 Rev. B: 20 Apr. 2022 Page: 2-13 © 2022 - Hartzell Engine Technologies - All rights reserved...
Page 32 Aircraft Alternator Maintenance Manual 21° 21° R3.50 Figure 2.19 ES-14024B-5 Dimensions .485 5.118 Figure 2.20 ES-14024B-5 Dimensions .113 1.13 .875 2.59 3.955±.022 24-30-01 ES1031 Page: 2-14 Rev. B: 20 Apr. 2022 © 2022 - Hartzell Engine Technologies - All rights reserved...
Page 33: Basic Component Description
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.
Page 34: Physical Detail
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.
Page 35: Theory Of Operation
Aircraft Alternator Maintenance Manual Drive End (DE) Bearing Rotor Assembly Stator Assembly Slip Ring End (SRE) Housing Brush Holder Shaft Spacer and Assembly O-Ring Assembly Drive End (DE) Housing Rectifier Assemby Figure 2.22 - Alternator Exploded View (typical) Theory of Operation A.
Page 36: Operational Data
Aircraft Alternator Maintenance Manual Operational Data Model ES-10024 ES-10024B ES-14024B ALV-9610 ES-6024D Drive Type Direct Belt Belt Direct Direct Cooling Through-flow Fan, External Fan, External Through-flow Through-flow Min Regulated Speed 2,200 RPM 2,200 RPM 3000 RPM 2,200 RPM 1,800 RPM Max Continuous 10,000 RPM 10,000 RPM...
Page 37: Chapter 3 - Troubleshooting
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.
Page 38 Aircraft Alternator Maintenance 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.
Page 39 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.
Page 40 Aircraft Alternator Maintenance 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.
Page 41 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.
Page 42 Aircraft Alternator Maintenance 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.
Page 43 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).
Page 44: Alternator Drive Coupling Troubleshooting
Aircraft Alternator Maintenance 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. Observe the following information when installing and using the drive coupling: If an alternator is determined to be at fault, note that the gear coupling is considered a part of the engine installation and should be removed from the alternator and properly installed on the replacement unit.
Page 45 Aircraft Alternator Maintenance Manual Continued Unusual belt condition, low belt tension, belt contamination, and belt vibration are other sources of belt noise. A screech or squeal that occurs when starting or increasing engine RPM rapidly typically indicates a lack of tension so check belt tension. A tapping or grinding sound caused by debris imbedded in the drive side of the belt can be the cause and should be checked.
Page 47: Chapter 4 - Check
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.
Page 49: Chapter 5 - Inspection & Testing
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.
Page 50: Precautions
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.
Page 51: Field Circuit Open Or Ground Test Procedure
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.
Page 52: Pulley Run Out Check
Indicator must be capable of measuring 0.0005 inch or better. Zero out the indicator and slowly rotate the pulley for each axis runout check. ES-10024B-1, thru -4 and ES-14024B-1, -2, -5, and -1LS series pulley assemblies must not exceed a runout of 0.008 inch on either axis.
Page 53: Order Of Tests
Aircraft Alternator Maintenance Manual C. Order of Tests To minimize the affects of heat, it is recommended to test the alternator at the highest RPM rating first (see Tables 5.1 thru 5.3). D. Test Setup For gear driven alternators, install a fabricated test pulley (Fig. 5.1), washer, and nut onto the alternator shaft.
Page 54 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.
Page 55: Alternator Self Excitation Test (-5 & -5Ls Only)
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.
Page 56 Aircraft Alternator Maintenance Manual Figure 5.1 - Test Pulley Fabrication Dimensions 24-30-01 ES1031 Page: 5-8 Rev. B: 20 Apr. 2022 © 2022 - Hartzell Engine Technologies - All rights reserved...
Page 57 Aircraft Alternator Maintenance Manual Fig. 5.3 - Gear Driven Alternator Alternator Mounting Fixture DC Load Bank Test Bench Surface Drive Motor - Mounted below Drive Belt alternator 24v Battery Figure 5.2 - Typical Test Bench Setup .385 x4 3.03 90° 4.14 Figure 5.3 - Gear Driven Alternator Mounting Fixture ES1031...
Page 58 Aircraft Alternator Maintenance Manual Field Terminal 1 to DC Output Jumper (switched) Ground Terminal DC Output 24v Battery DC Load Bank Figure 5.4 - ES-10024 Test Setup 24-30-01 ES1031 Page: 5-10 Rev. B: 20 Apr. 2022 © 2022 - Hartzell Engine Technologies - All rights reserved...
Page 59 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, ES-14024B and ES-6024D Test Setup (ALV-9610 Shown) ES1031 24-30-01 Rev.
Page 61: Chapter 6 - Maintenance
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.
Page 62: Torque Information
Aircraft Alternator Maintenance Manual Torque Information Reference Description Torque Value (US) Torque Value (SI) Figure 6.1 (gear) Output Shaft Nut 25-37.5 ft-lbs*** 33.9-50.8 Nm Figure 6.2 (belt) Output Shaft Nut* 55-65 ft-lbs*** 74.6-88.1 Nm Section 2.7 Through Bolts 45-50 in-lbs 5.08-5.65 Nm Section 2.7 (top &...
Page 63 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.
Page 64: Alternator Belt & Pulley Inspection & Maintenance
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.
Page 65: Removal From The Aircraft (Belt Drive)
Aircraft Alternator Maintenance Manual Alternator Belt & Pulley Inspection & Maintenance (cont’d) Alternator Maximum with Pulley Belt Tension ES-10024B-2 76 lbf / 338.06 N ES-10024B-3 80 lbf / 355.86 N ES-10024B-4 79 lbf / 351.41 N ES-10024B-5 80 lbf / 355.86 N ES-14024B-1 75 lbf / 333.62 N ES-14024B-2...
Page 66 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...
Page 67: Exterior Cleaning (Direct Drive Or Belt Drive)
Aircraft Alternator Maintenance Manual Exterior Cleaning (direct drive or belt drive) NOTE: Prior to cleaning the alternator whether mounted on the aircraft or as removed, observe and note condition. Look for any arcing, wear marks, fretting or other indica- tors of defect. CAUTION: DO NOT SPRAY CLEANING FLUIDS INTO THE ALTERNATOR HOUSING OPENINGS.
Page 68: Brush Removal And Installation
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.
Page 69 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.
Page 70: Terminal Hardware Removal And Installation
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.
Page 71 Aircraft Alternator Maintenance Manual Output (+) Terminal Stud AUX Terminal Stud Lock-washer Flat Washer Lock-washer Fiber Washer Washer Flat Washer Fiber Washer Rectifier Bushing Mounting Bushing Rectifier Plate Mounting Capacitor Plate Insulator Ring Terminal (ES-10024 Only) Aux Terminal Output (+) Terminal Ground Stud Brush Holder Assembly Cupped Nut 2 ea.
Page 72: Materials
Aircraft Alternator Maintenance Manual 6.11 Materials This section presents the current materials available for maintenance. Items are available through an HET authorized 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.
Page 73 Aircraft Alternator Maintenance Manual Alternator PN Part Number Description GBM-21B Nut, Output Shaft 8X-4075 Nut, Output Shaft 40523-4 Washer, Locking (Output Shaft) * 8X-0173 Nut, AUX Terminal 12X-0196 Lockwasher, AUX terminal * 8X-1063 Nut, Output Terminal 12X-0199 Lockwasher, Output Terminal * 40298 Cupped Nut, Ground terminal 8X-0140...
Page 74: Applying Safety Wire
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.
Page 75: Special Conditions
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.
Page 76: Lightning Strike
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.
Page 77: Storage And Shelf Life
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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Plane-Power ES-10024B-1 Maintenance Manual

Chapter 1 - Introduction

Chapter 2 - Description of Operation

Chapter 3 - Troubleshooting

Chapter 4 - Check

Chapter 5 - Inspection & Testing

Chapter 6 - Maintenance

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Summary of Contents for Plane-Power ES-10024B-1

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