PrestoliteStarterAlternatorManual PDF
PrestoliteStarterAlternatorManual PDF
PrestoliteStarterAlternatorManual PDF
For
The starting circuit is designed to carry high current with a minimum loss of voltage. This
circuit includes the battery, solenoid starting switch, manual starting switch, starting
motor, the connecting wiring and the vehicle frame. The starting motor cranks the engine
for starting while the battery supplies the power. The manual switch and solenoid starting
switch control the operation.
The starting motor must high cranking torque for a limited period of time when
develop a
the starting switch is closed. The starting motor has designed into it a means of engaging
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.
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
See i.
Gear Housing, (5) The Pinion Housing, and (6) The Bendix Drive Assembly. Figure
9ET
1
VB~NDI
s~
.r.
BE*RINO:
Form L-649A
OPERATION
windings to ground. The magnetic force created in the armature combined with that created
in the’ field windings, begins to turn the armature.
The gear cut on the drive end of the armature shaft extends through the gear housing where
it is supported by a roller bearing.The gear mates with the teeth of the reduction gear that
drives the Bendix shaft. The shaft is keyed to the reduction gear. The Bendix drive is held
in position on the shaft by a "spirol" pin. The shaft is supported in the gear housing by a
closed end roller bearing and in the pinion housing by a graphitized bronze bearing.
When the armature turns the reduction gear, the Bendix drive pinion meshes with the fly-
wheel ring gear by inertia and action of the screw threads within the Bendix sleeve. A
detent pin engages in a notch in the screw threads which prevents demeshing if the engine
fails to start when the starting circuit is de-energized.
When the engine reaches a predetermined speed, centrifugal action forces the detent pin out
of the notch in the screw shaft and allows the pinion to demesh from the flywheel.
MAINTENANCE
The starting circuit should be inspected at regular intervals, the frequency of which should
be determined by the amount of service and the conditions under which the vehicle is oper-
ated. It is recommended that such inspection be made at least twice a year and should
include thg following:
Form L-649A
If voltage loss is greater than the above limits,
additional tests should be made over each part of
the circuit to locate the high resistance connections.
OVERHAUL
i. Removal To remove the starting motor from the engine, first disconnect
the ground cable from the 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
head
2. Disassembl3T Remove the frame screws from the commutator end
and pull end head and armature from frame. Lift the brushes and lock
the end
in elevated position with brush springs. Use a puller to remove
head from the armature. Use a special bearing puller to remove the
sealed ball bearing from the armature shaft.
Remove the frame screws that secure the gear 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.
lose the steel spacer that is located on the pinion end
of the shaft. Remove
Turn the Bendix pinion until it locks in the extended position. Locate "spirol"
off the shaft. Do
pin and use a pundh to remove. Slide drive assembly
not attempt to disassemble the drive and do not dip it in cleaning
solvent.
Form L-649A
3. Brushes Check the brushes to see that they slide freely in their holders and make
full contact on the commutator. If worn to half their original length or less, they
should be replaced.
4. Armature Cheek the commutator for uneven wear, excessive glazing or evidence
of excessive arcing. If only slightly dirty. glazed or discolored, the commutator
can be cleaned with 00 or 000 sandpaper. If the commutator is rough or worn, it
should be turned in a lathe. Figure 2.
The armature shaft should be inspeot-
ed forrough bearing surfaces and
rough or damaged splines.
To test for shorted armature coils, a growler is used, Figure 3. The armature
is placed on the growler and slowly
rotated by hand while a steel strip is
held over the core so that it passes
over each armature core slot. If a
6. Field Coils Cheek the field coils for grounds (Figure 4) by placing one test probe
on the frame and the other an the
starter terminal. Be sure the
brushes are notaccidentally touching
the frame. If the
lamp lights, the
fields are grounded. Repair or
replace.
7. Gear and Pinion Housing Inspect housings for cracks and bearings for excessive
vrear. Remove rust, paint or grease from mounting surfaces.
The Bendix Drive should be wiped clean with a dry cloth. The pinion
8. Bendix Drive
should turn smoothly in one direction and should lock in the other direction. Replace
drive if it fails to check as above or if the pinion teeth are excessively worn or
damaged.
9. Assembly assembling the starting motor, always use an arbor press and the
When
bronze and roller bearings. The
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.
ture slowly in the direction of rotation. Dust should be blown out of the motor
after sanding.
Check the position of the pinion to be sure the unit will mesh properly with the
BENCH TESTS
After the starting motor is reassembled, it should be tested to see that the no load current
at a certain voltage is within specifications. To make this test, connect as shown in
5. If current is too high, check the bearing alignment and end play to
make sure
Figure
interference. three sharp raps on the frame with a rawhide
there is no binding or ~o or
hammer will often help to align the bearings and free the armature.
if the
If difficulty is indicated in the above test, a stall torque test may be made to see
no
shown in
starting motor is producing its rated cranking power. Make test connections as
Figure 6.
KNIFE
o AMMETER
CI SWITCH
KNIFE CARBON PILE
SWITCFI
CARBON PILE
?IPRINC
SCALE
BATTERY
~C1 TACnOMETER
BATTERY
STARTING MOTOR
STARTING MOTOR
Form L-649A
If torque and current are not within specifications, check the
seating of the brushes and
internal connections for
high resistance. If these checks are made and found to be in good
order, replace frame and field assembly and retest starter.
Inspect the control circuit wiring between the battery, solenoid and manual starting switches
for breaks, poor connections and faulty insulation. Tighten all connections and make sure
solenoid is firmly mounted and makes a good ground connection.
Check the voltage loss across the switch contacts during normal starting. If loss is in
excess 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 it fails to release
when the manual switch is released, it should be removed and tested to specifications. If
either opening or closing voltages are not as specified, replace the solenoid.
Form L-649A
December, 1965
MHB SERles
presro/itP,
STARTING MOTORS
SERVICE PARTS LIST
ISSUEO: 9-25-79(Rev.)
P.I11´•dinU´•J´•*´•
File in the
OE-AI AIRCRAF’IMANUAL I STARTING MOTOR
I
~P(B-4000 Series Starting Motor Parts List
14 17
~-’____ _1
19 16
L____
-T--
__J
------7---
O O O O O O O
MHB-4001,R MHB-2399S MHB-2012S MHB-2397S MHB-2400 X-3991 Ca] [al
MHB-4002, R I I I II
I I I Cb] Cb]
MHB-4003, R I I I II
I I I Cc] [cl
MHB-4008, R I I I I’
I II
I I [NRI ENRI
MHB-4011,R I I I II
I I I PS-1437B
j I I II
I I I PS-2432B
MHB-4012,R
I I I I I PS-1432E
MHB-4013,K
I I II
I I PS-1437B
MHB-4017,R
PS-1432E
MHB-4018,R
I I I II
I I I PS-2432B
MtlB-4019,d
[a] PS-1432CS Housing Shaft Pkg. must be used at time of first repair. Individual components-
PS-1432C Pinion Hsg.,MZ-298 Bearing, M2-326 Bendix Drive Shaft may be replaced thereafter.
[b] PS-l437BS Housing Shaft Pkg. must be used at time of first repair. Individual components-
PS-1437B Pinion Hsg.,MZ-298 Bearing, M2-326 Bendix Drive Shaft may be replaced thereafter.
Ccl PS-2432BS Housing Shaft Pkg. must be used at time of first repair. Individual Components-
PS-2432B Pinion Hsg.,MZ-298 Bearing,MZ-326 Bendix Drive Shaft may be replaced thereafter.
[d] PS-1432ES Housing Shaft Pkg. must be used at time of first repair. Individual CompOnents-
PS-1432E Pinion Hsg.,MZ-298 Bearing, M2-326 Bendix Drive Shaft may be replaced thereafter.
MZ-414S D.E. Mtg. Screw Gasket Pkg.(lOPcs.) and 90-2191 Mtg. Screw Pkg.(20Pcs.)also
available.
[e]
Cf] Bearing Seal Pkg.
Available thru Lycoming only.
CNR] Not required.
MHB-4002, n I II
I Cb] [NR] I I I CNR]
Ca] PS-1432CS Housing Shaft Pkg. must be used at time of first repair. Individual Components-
PS-1432C Pinion Hsg.,MZ-298 Bearing, M2-326 Bendix Drive Shaft may be replaced thereafter.
[b] PS-1437BS Housing Shaft Pkg.must be used at time of first repair. Individual Components-
PS-1437B Pinion Hsg.,MZ-298 Bearing, M2-326 Bendix Drive Shaft may be replaced thereafter.
Cc] PS-2432BS Housing Shaft Pkg. must be used at time of first repair. Individual Components-
PS-2432B Pinion Hsg., MZ-298 Bearing,MZ-326 Bendix Drive Shaft may be replaced thereafter.
Cd] PS-1432ES Housing Shaft Pkg. must be used at time of first repair. Individual Components-
PS-1432E Pinion Hsg., MZ-298 Bearing,MZ-326 Bendix Drive Shaft may be replaced thereafter.
[f] Bearing Seal Pkg.
[gl 90-2140 Bendix Pin Pkg.(25 Pcs.) also available.
Ch] 90-2139 Bendix Pin Pkg. (25 Pcs.) also available.
Cjl MZ-339 Bushing also available.
Available thru Lycoming only.
CNR] Not required.
MHB SERIES STARTI~G MOTOR PARTS LIST ISSUED: 8-3-81 (REvl) SHEET 3
Gear Needle Retainer fhrust Switch
Assembly Gear Housing Bearing Plate Washer Connector Switch
As1Y
O O O
MHB-4001,R MZ-396 MZ-1390 Ck] MZ-393 90-601 [NR] CNRI
GENERAL INFORMATION
VOLTAGE 24
BRUSHES 4
POLES 4
DRIVE ASSEMBLY
Rubber Folo Thru Type
GEAR REDUCTION
3.38 to 1 Gear Ratio (see following note).
SERVICE INFORMATION
LUBRICATION
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.
ec
File in the
Data STARTING MOTORS
Printed in U.S.A. OF-Al AIRCRAFT MANUAL
MHB
presto~te´•
AIRCRAFT STARTING MOTORS
Issued 4/1/83 SERVICE
Page 2 of 5 INFORMATION
I
DRIVE ASSEMBLIES
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 reassem-
bling the late style drive, make 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 on
the side toward the Drive Assembly. Press the pinion housing bearing
in flush with the outside edge of the casting.
MHB-4006
Press the armature shaft bearing into the housing until it is flush
with the bearing bore. Press the oil seal in until it is flush with
the edge of the casting. Press the gear reduction shaft bearing in
so that the open end is flush with the edge of the casting.
Press the drive end bearing in flush with the outside edge of the
casting. Press the oil seal into the casting so that it bottoms
against the oil seal counterbore.
prpstolifP, MHB
AIRCRAFT STARTING MOTORS
SERVICE Issued 4/1/83
~N FORM ATION Page 3 of 5
BRUSH REPLACEMENT
END PLAY
MHB-4006
Assemble the end head on the motor so that the letter "R" is directly
in line with the motor terminal.
Assemble the end head on the motor so that the letter "L" is directly
in line with the motor terminal.
Tech.
File in the
Data STARTING MOTORS
Printed in U.S.A. OF-Al AIRCRAFT MANUAL
BHMSROTOM
AIRCRAFT STARTING
Issued 4/1/83 SERVICE
Page 4 of 5 INFORMATION
COMMUTATOR REFINISHING
No Load Test (Motor Only) 20.0 volts, 35 max. amps., 4600 Min. RPM
No Load Test (Complete Unit) 20.0 volts, 35 max, amps., 5300 Min. RPM
Stall Torque Test 14.0 volts, 260 max. amps., 27.0 min. Ft. Lbs.
Internal
Unit Drive Type Wiring Application
gb ~41
olU~k r~dh I
cueol rrre
mlrcn
UI´•OH C(~L
IlllWC
w*L~
~ffElll ~TTLI*
~LCWOU1EI
1 Figure 2
Figure
TERMINAL TERYIWAL
A
P6ST
INSULATED
BRUSH BRUSH BRUSH ‘BRUSH
Figure 3 Figure 4
PART PART
NUMBER NUMBER APPLICATION
FI~
a lil
I I
~I 1
2
[o~- Q
MHJ-4004R
MHJ-4005 I I I I I PS-1455A
MHJ-4O05R
MHJ-4003,S [NR]
GJ-Z0S 90-2232
MHJ-4004 90-2139 MDL-1064GS 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]
[NRINot required.
MHJ-4004R I I I Ca]
MHJ-4005 I 1 I Ca]
MHJ-4005R I I I Ca3
Cal Two used (XA-997) 1/2" I.D. and (XA-998) 13/16" I.D.
CNRI Not required.
GENERAL INFORMATION
VOLTAGE 24
BRUSHES 4
POLES 4
SWITCH Separate
GEAR REDUCTION
MH3-4004, R, 4005, R 3.38 to 1 Gear Ratio
SERVICE INFORMATION
LUBRICATION
MHJ-4002, 4003
MHJ-4004, R, 4005, R
DRIVE ASSEMBLY
Tech.
File in the
Data STARTING MOTORS
Printed in U.S.A. OE-AI AIRCRAFf MANUAL
MHJ
prPst~ite.
Aircraft Starting Motors
Issued: 4/1/83 SERVICE
Page 2 of 4 INFORMATION
After the Drive Assembly has been cleaned and blown dry with
compressed air, lubricate the drive with a spray on type
silicone lubricant. Lubricate the motor shaft with the same
silicone lubrcant before installing the Drive Assembly. When
reassembling the drive on the shaft, make sure head washer
covers both ends of the retaining pin.
BEARING REPLACEMENT
MHJ-4OO2, 4003
The drive end bearing must be pressed in flush with the oil
seal counterbore. The oil seal must bottom against the counter-
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
pinion housing bearing in flush with the outside edge of the
casting.
BRUSH REPLACEMENT
Brushes must be replaced when they have worn down to a length
of 1/4" or less. Refer to Service Bulletin ASM-1 for brush
replacement procedure.
COMMUTATOR REFINISHING
Mi Di ame te r i. 50"
Undercut .003" max.
Total Indicater Runout .002" max. measure from bearing journal
Surface Finish 50 microinch max.
Internal
Unit Wiri?g Application
INSTALLATION NOTE
Prior to starting motor installation, clean any rust, corrosion or dirt from
the mounting surfaces of the starting motor and engine. Also check all ground
strap connections to make sure they are clean and tight.
9;$ C, ]It~
nU1FC AUUCTLe
~V(TEI(
IIWITE CIII~OL( ~LE
~WITCH
L*neON GILL
1PIWIC
~CUE
GIOVUO
V/r$~
T4CnOYEIER CeOUt(D
571~1711YG YOTOII
IT*RTINC UOTOR
Figure 1 Figure 2
Page 4 of 4 INFORMATION
TERMINAL TEFMHK
STUD POST
GROUNDED INSULATED GROUNDED INSULATED
BRUSn bMUSH BRUSH\ BRUY(
I
SHUnt
O O
Figure 3 Figzire 4
MMU SERIES
presro/itP,
STARTING MOTORS
SERVICI: PARTS LIST
ISSUED: 6-1-79
STARTING MOTOR
Pile in the
SECTION
Prln)´•d In U.S.A. OF-Al AIRCRAFT MANUAL
MMU Series Starting Motor Parts List
ld- \uJ
J9
8
--_~ug/
d
3Y 3
0, Q)
O O 5
O O d
MMU-4001,R M2-1236 MZ-339 EBB-124ACa] MZ-24A 90-2502 90-2677
GENERAL INFORMATION
VOLTAGE 24
ROTATION CWDE
POLES 4
BRUSHES 4
SERVICE INFORMATION
LUBRICATION
DRIVE ASSEMBLY
After the Drive Assembly has been cleaned and blown dry with
compressed air, lubricate the drive with a spray-on type silicone
lubricant. Lubricate the motor shaft with the same silicone lubri-
cant before installing the Drive Assembly. When reassembling the
Drive on the shaft, make sure the head washer covers both ends of
BEARING REPLACEMENT
Press the drive end bearing in flush with the outside edge of the
casting. Press the intermediate bearing in flush to the side
toward the armature.
BRUSH REPLACEMENT
END PLAY
Assemble the end head on the motor so that the letter "L" is directly
in line with the motor terminal.
COMMUTATOR REFINISHING
TEST SPECIFICATIONS
INFORMATION Page 3 of 3
TERMINAL
POST
GROUNDED INSULATED
BRUSH BRUSH
SHUNT
WINDING
INSULATED~ ~YJ\GROUNDED
BRUSH \BRUSH
_____i Q; \L:
19)-~-- 16
L-----~O
L _ _
_J
-----T--
’eo~$~-o
i
s---
__.J
#2-4203 #2-2383 MZ-201 2AS MZ-l 005ASC*~ MZ-20O2F [NR] MZ-1147 MZ-46A
MZ-4218,R I j I I I PS-1432C
MZ-4219,R I I I i I I PS-1437B
MZ-4220,R I I I I I PS-1432C
#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 PS-1437B
MZ-4224,R I I PS-1432C
MZ-4225,R I I I I I PS-1432F
[X1 Field Coil Pkg. Complete Frame Field Assembly not available.
Ea] PS-2432BS Housing Shaft Pkg. must be used at time of first repair. Individual Components-
PS-24328 Pinion Hsg.,MZ-298 Bearing,Mt-326 Bendix Drive Shaft may be replaced thereafter.
[b] PS-1432CS.Housing Shaft Pkg. must be used at time of first repair. Individual Components-
PS-1432C Pinion Hsg.,MZ-298 Bearing,MZ-326 Bendix Drive Shaft may be replaced thereafter.
[c] PS-1437BS Housing Shaft Pkg. must be used at time of first repair. Individual Components-
PS-1437B Pinion Hsg.,MZ-298 Bearing,MZ-326 Bendix Drive Shaft may be replaced thereafter.
MZ-414S D.E. Mounting Screw Gasket Package is also available.
Es~ Bearing Seal Package.
[NRI Not required.
MZ-4216,R
I
EBB-142A[gl [bl [NRI I 1 90-876 1 j INR~
Ca] PS-2432BS Housing Shaft Pkg. must be used at time of first repair. Individual components-
PS-24328 Pinion Hsg.,MZ-298 Bearing,MZ-326 Bendix Drive Shaft may be replaced thereafter.
Cb] PS-1432CS Housing Shaft pky. must be used at time of first repair. Individual Components-
PS-1432C Pinion Hsg.,MZ-298 Bearing,MZ-326 Bendix Drive Shaft may be replaced thereafter.
Cc] PS-1437BS Housing Shaft Pkg. must be used at time of first repair. Individual Components-
PS-1437B Pinion Hsg.,MZ-298 Bearing,MZ-326 Bendix Drive Shaft may be replaced thereafter.
Cf] 90-2139 Bendix PinPackage(E5Pcs.) also available.
Cgl 90-2140 Bendix Pin Package(E5Pcs.) also available.
Chi Not part of this Motor; available thru Continental only #639153.
Cjl X-5384 Bendix Pin also available.
[NRI Not required.
MZ SERIES MOTOR PARTS LIST ISSUED: 8-3-81 (REV, SHEET 3
Gear Needle Retainer Thrust
Plate Washer Connector Switch
Assembly Gear Housing Bearing
Assembly Package
O 16
O I
M2-4203 [NR] [NR] [NR1 [NRI 90-2677 MZ-144 [n]
Used with but not part of this Motor, available thru Continental #639153.
[k]
[m] Two used- XA-997 is 1/2" I.D. XA-998 is 13/16 I.D.
[NR[n 7 trequired.
oN•´’
STARTING MOTOR
File in the
Prinl´•d In U.s.A. OF-Al AIRCRAFT MANUAL r I SECTION
MZ
AIRCRAFT STARTING MOTOR
SERVICE Issued 4/1/83
GENERAL INFORMATION
VOLTAGE 12
BRUSHES 4
POLES 4
GEAR REDUCTION
SERVICE INFORMATION
LUBRICATION
File in the
Tech.
Data STARTING MOTORS
Printed in U.S.A. OF-Al AIRCRAFT MANUAL
ZMROTOM
AIRCRAFT STARTING
prp´•st~te´•
SERVICE
Issued 4/1/83
Page 2 of 5 INFORMATION
FORMSPRAG DRIVE
These units are not serviceable. If the drive feels rough when
rotated in its free direction, or if the gear rotates in both
directions, the drive should be replaced. Never submerge the drive
assembly in a cleaning solution. To do so will destroy or contaminate
the internal lubrication which cannot be replaced.
DRIVE ASSEMBLY
BEARING REPLACEMENT
Press the drive end bearing in flush with the outside edge of the
casting. Press the oil seal into the casting so that it bottoms
against the oil seal counterbore.
BRUSH REPLACEMENT
END PLAY
Assemble the end head on the motor so that the letter "R" is directly
in line with the motor terminal.
Assemble the end head on the motor so that the letter "L" is directly
in line with the motor terminal.
(See Figures 1 and 2 for no load and stall torque test connections.)
Internal
Unit Drive Type Wiring Application
M2-4203 Di rect Fig. 3 Fran kl in
MZ-4204, R Direct Fig. 3 Lycoming
M2-4205, R Gear Reduction Fig. 4 Lycomi ng
MZ-4206, R Gear Reduction Fig. 4 Lycoming
M2-4207, R Gear Reduction Fig. 4 Lycoming
M2-4208, R Gear Reduction Fig. 4 Lycoming
M2-4214 Pig. 4 Continental
MZ-4216, R Gear Reduction Fig. 3 Lycoming
M2-4217, R Gear Reduction Fig. 4 Lycoming
M2-4218, R Gear Reduction Fig. 4 Lycoming
MZ-4219, R Gear Reduction Fig. 4 Lycoming
M2-4220, R Gear Reduction Fig. 3 Lycoming
M2-4221, R Gear Reduction Fig. 4 Lycoming
M2-4222, R Gear Reduction Pig. 4 Lycoming
M2-4223, R Gear Reduction Fig. 4 Lycoming
M2-4224, R Gear Reduction Fig. 4 Lycoming
M2-4225, R Gear Reduction Fig. 4 Lycoming
"Formsprag Torque Limiting Drive used with, but not a part of, this
motor.
INSTALLATION NOTE
Prior to starting motor installation, clean any rust, corrosion or dirt from
the mounting surfaces of the starting motor and engine. Also check all
ground connections to make sure they are clean and tight.
ZM___.~
AIRCRAFT STARTING MOTOR
____.._
INFORMATION Page 5 of 5
lulrr
olCl~sC,
o ~s
~WICE CAIWY e(LL
IYITCH
L*I(MN CIIL
)MIUG
YUE
;1:
e*rrrlr I I II/
I)*fTERI
i GIIWIIO
T4CnOYETER
ST*ITIWC YOTOI)
)~RTING UOTOR
Figure 1 Figure 2
TERMINAL ~R TERMINAL
POST ~ca POST
GROUNDED
GROUNDED INSULATED INSULATED
BRUSH
BRUSH BRUSH BRUSH
K
O O
INSULATED
GROUNDED GROUNDED
INSULATED BRUSH
‘BRUSH BRUSH
BRUSH I
Figure 3 Figure 4
ec
File in the
Data STARTING MOTORS
Printed in U.S.A. OE-AI AIRCRAFT MANUAL
(Early Produ ction Type)
BE LT DRIVEN
AIRCRAFT
ALTERNATORS
BELT DRIVEN AIRCRAFT ALTERNATOR
DESCRIPTION
(3) the slip ring end head, (4) the drive end
head and (51 the reotifiers.
Figure 1
111III
oI$ P9 T
O (((II)
-PL.
Figure 2
i. The stator consists of a laminated iron core on which the three phase windings are
wound in slots around the inside clrctunferenee. Leads are connected to eachof the
three points of the ~haae windings and each lead is connected to a pair of rectifiers, one
2. The rotor consists of a single field coil encased between two four-poled, interleaved
iron sections assembled on the shaft. The ends of the field coil are connected to a pair of
3. T~eslip ring end head supports the rectifier mounting plate and rectifiers, a pre-
Lubricated bearing in which the rotor shaft rotates, the brush holders and brushes, the
field and output terminals, and a blast tube assembly.
4. The drive end head supports a sealed, prelubrioated ball bearing in which the drive end
of the rotor shaft rotates.
5. The negative rectifiers are pressed into the slip ring end head and the positive rectifiers
are pressed into the rectifier mounting plate and are connected to the stater leads. The
rectifiers are rated at 150 PIV minimum for transient voltage protection.
OVERHAUL
When repairing the alternator, complete disassembly may not be required. In some cases
it will only be necessary to perform those operations which are required to effect the repair.
However, in this section, the complete overhaul is covered step by step to provide detailed
information on each operation. In actual service practice, these operations may be used as
required.
DISASSEMBLY
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.
Remove the fan, woodruff key, and spacer from the shaft. Now remove the four through
bolts. Tap the drive end head lightly with a rawhide hammer and separate the end head and
rotor assemblies from the stater and slip ring end head. Re careful not to lose the brush
2. Remove the nuts, lockwashers, and flatvashers from the output terminal and remove
the rectifier mountingplate mounting screw. Note carefully the correct assembly of the
insulator washers and bushings. Using the same special tools shown in Figure 3, support
theend head andpress outthe three negative rectifiers. Thestatorcannowbe separated
from the slip ring end head.
3. To remove the slip ring bearing, support the end head and press bearing out, using
the proper tools shown in Figure 4.
3 Figure 4 9
Figure
4. If necessary, press the rectifiers out of the rectifier mounting plate as shown in Figure 3. To
disconnect the rectifier from the stater leads, use pliers to grip the rectifier leads and touch
the soldered end of the connector with a hot soldering iron. Pull the connector off the
5. To remove the drive end head from the rotor 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 screws. Remove the three retainer plate screws and press
Figure 5 i"
Figure 6
Upon completion of the disassemhly, all parts should be cleaned and visually inspected for
cracks, wear or distortion and any signs of overheating or mechanioal interference.
Figure 7
2. Rectifiers A diode rectifier tester will
detect and pinpoint open or shorted rectifiers
without going through the operation of dis-
3. Stater The stater can grounded windings with a 12 volt test bulb,
be tested for open or
described in the rectifier section, ohmmeter, in the following manner. Separate the
or an
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
the stater winding center connection and touch each of the three stater leads. The test bulb
Due to the low resistance inthe stater windings, shorted windings are almost impossible to
locate. However, shorted stater windings will usually cause the alternator to "growl" or be
If all other electrical checks are normal and the alternator fails to supply its rated output,
the stater should be replaced to determine whether or not it is the faulty component.
Check the bearings for roughness or excessive clearance to determine if they should be
replaced. Note: New 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 bearing into the drive end head using a flat block approximately 2"
square so that the pressure is exerted on the outer race of the bearing. Install the
With the snap ring and retainer cup in place on the rotor shaft, use a tool that
retainer plate.
fits over the shaft and against the inner bearing race, and press until the inner hearing race
2; To install the rectifiers in the slip ring end head or rectifier mounting plate, support
the end head or mounting plate and press the reetifiers in with a special driver tool.
Figure 9 Figure 10
Strip the insulation back approximately 1/4" on the stater leads and reconnect them to the
rectifiers. The connector sleeves should be soldered an the rectifier and stater leads.
5. Install spacer, woodnrff key, fan, pulley, loekwasher and nut. Tighten nut using a
strap wrench. (Do not install blast h~be assembly on the alternator until after the unit has
been bench tested.)
ALTERNATOR BENCH TEST
Upon completion of assembly, the alternator should be’ teated for output. This test is made
to determine whether the alternator is capable of delivering rated output: The alternator
must meet output specifications before regulator tests are attempted.
2. THE OUTPUT LEAD MUST NOT BE REMOVED FROM THE ALTERNATOR WHILE
THE ROTOR WINDING fS ENERGIZED AND THE ALTERNATOR fS OPERATING
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,
be controlled by properly varying the average level of current flow in the rotor winding
and the PRESTOLITE full electronic solid state regulator is well suited for this purpose.
The Prestolite alternator, due to its design, has self-limiting current characteristics
and needs no current-limiting unit in the regulator.
THE TRANSISTOR
The transistor is an electronic switch which can turn on and turn off the flow of current
in an electric circuit. It has no mechanical or moving parts to wear out.
direction. It is this Zener action which makes it adaptable for use as a voltage sensing
device in the regulator.
THE RESISTOR
The resistor is a device which is used to limit currentflow.
When ignition switch is turned on, battery voltage is applied to the "I" (ignition) terminal
of the regulator.
r-,-
iu S
F
R4 F
TI ALTERNATOR
I
1
ZI
iLn’
PI RO
-------III
e, 13
_____
_I
REGULATOR IGNITION BATTERY
SWITCH
Figure i.
The NPN power transistor, T3, is turned on by current flow from the ignition terminal
through R-6 and the collector emitter junction of T2 through D2 through the base emitter
junction of T3 to ground.
Whenever the power transistor, T3, is on, T2 is also on and T1 is off, current will flow
from the ignition terminal, through the field winding, through the collector emitter of
T3 to ground.
With the ignition switch on, current will flow from the "I" terminal regulator ground
through a voltage dividing network consisting of R-l, R-2 and P-l. This network de-
termines the system operating voltage relative to the Zene‘r diode, Z1, reverse con-
ducting voltage.
When the system voltage connected to ’r" terminal reaches a 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
causes junction of T1 to conduct which diverts the base current of
the collector emitter
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, re-
energizing the rotor winding.
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
can decay at a slower rate, field suppression diode, D1, provides
this path, thus pro-
Temperature compensation is flat which means the regulator Will hold the alternator
output voltage constant with temperature increase or decrease after initial warm-up.
4
The PRESTOLITE solid state regulator uses three NPN silicon transistors.
when oper-
Capacitor, C1 is used to filter ripple and alternator diode switching spike
ating batteryless.
Neon lamp, L-l, provides transient voltage protection acting as a surge suppressor.
Caution: Do Not Interchange Regulator Leads. This will destroy regulator and void
warranty.
2. When a voltmeter
only is to be used for circuit testing, the battery need not be dis-
connected, provided caution is used when connecting or disconnecting the voltmeter.
3. When installing a battery in a vehicle, be sure that the battery negative terminal
is in a position so that this terminal can be connected to the battery ground cable
for negative ground systems.
6. The alternator does not need to be polarized; therefore, never connect ground,
even momentarily, to either the regulator field terminal or to the alternator field
terminals. Do not interchange I and F leads to regulator as 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.
9. The voltmeter and the ammeter should be of the best quality and should be accurate.
10. A carbon-pile connected across the battery may be used to load the charging circuit
while testing the regulator.
i. The procedure for testing this regulator, whether on the vehicle or on the test
bench, remains the same. Connect test meters as shown in Fig. 2.
2. All circuit connections should be clean and tight. This includes the test instru-
ment connections which must not come loose or open the charging circuit at any
time while the system is operating.
*LTERNP~TOR
REGULATOR
CARBON
TEST AMMETER
PILE
zn´•
AMMETER
BATTERY
ALTERNATOR
SWITCH
ON OFF
TEST VOLTMETER
Figure 2.
3. The voltmeter will not indicate the true regulator setting until the regulator
has been operating in the charging system or on the test bench for at least
Connect the voltmeter and the ammeter as shown in Figure 2. Start the engine
4.
to obtain 3, 000 to 4, 000 alternator RPM. Turn on accessories
and adjust its speed
as needed to establish 10 to 15 ampere electrical load, or use a carbon-pile across
indicated
5. After 1 minute operating time, check the regulator operating voltage as
by the voltmeter. SEE THE SERVICE SPECIFICATIONS for the correct operating
voltage. The voltage is shown for the ambient temperature in which the
operating
regulator is operating.
6. If the voltmeter 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 con-
dition. Recheck all circuit connections and all wiring for unwanted resistance
the entire
(voltage drop test). Recheck the voltmeter for accuracy and repeat
operating~test.
DESCRIPTION
Figure 1
Figure 2
i. The brush and holder assembly contains huo brushes, two brush springs,g brush holder
and insulators. Each brush is connected to a separate terminal sb~dand is insulated from
ground. The brush and holder assembly can easily be removed for inspection or brush
replacement purposes.
2. The slip ring end head provides the mounting for the reotifiers and rectifier mounting
plate, outputand auxiliary terminal studs, and thebrush and holder assembly. The slip
ring end head oontains a roller bearing and outer race assembly and a grease seal.
The rectifiers used in these units are rated at 150 P.I. V. minimum for transient voltage
3.
mounted in the rectifier mounting plate while the
protection. Three positive rectifiers are
three negative rectifiers are mounted in the slip ring end head. Each pair of rectifiers is
The stater leads anchored to
connected to a stater lead with high temperature solder. are
the rectifier mounting plate with epoxy cement for vibration protection.
4. The stater contains alead which is connected to the center of the three phase
special
or relays. The stater has
wind ings and is used to activate low voltage warning systems
resistance.
been treated with a special epoxy varnish for high temperature
drive end
6. The drive end head supports a sealed, prelubricated ball bearing in which the
of the rotor shaft rotates.
OVERHAUL
DISASSEMBLY
Remove the two H10-24 screws holding the brush holder assembly in the slip ring end
i.
head. Remove the brush and holder assembly from the end head.
the drive
3. Remove the four through bolts tap the drive end head lightly to separate
and
end head and rotor, as a unit, from the stater and slip ring end head.
Figure 6
Figure 5
INSPECTION AND TESTING OF CPMPONENTS
i. Rotor The rotor should be teated for grounded or windings. The ground test
shorted
can be made with test probes, connected in series with a 110 volt test lamp, an ohmmeter
or any type of continuity taster. Figure There must not be any continuity bet~ueen the
To test far shorted turns in the rotor winding, connect a voltmeter, ammeter and rheostat
shown in Figure 8, or use an ohmmeter. Rotor current draw and resistance are listed
as
the individual specification pages. Excessive current draw or a low ahmmeter reading
on
~MMETER
RHEOST~T
8*TTERY
ROTOR
Figure 7 Figure 8
2. ReotifiersA diode rectifier tester will detect and pinpoint open or shorted rectifiere
without going through the operation of disconnecting the stater leads. However, if a tester
is not available, test probes and a #57 bulb, connected in series with a 12 volt battery, can
be used in the following manner. Touch one test probe to a rectifier heat sink and the other
lead from of the rectifiers in that heat sink. Then reverse We position
test probe to a one
of the leads. The test bulb should light in one direction and not light in the oWer direction.
If the test bulb lights in both directions, one or more of the rectifiers in that heat sink is
shorted. To pinpoint the defective rectifier, the stater leads must be disconnected and the
above teet repeated on each rectifier. Open rectifiers can only he detected, when using
either
the test bulb, by disconnecting the stater leads. The test bulb will fail to light in
direction if the rectifier is open.
wood. In other words, insulate the stater from the end head. To test for grounded wlndinga,
touch one test bulb or ohmmeter probe to the auxiliary terminal or am stater lead, and the
ohmmeter probe to the stater frame. If the test bulb Hgbts, or the
other test bulb or
ohmmeter indioates continuity, the stater is grounded. To test for open windings, connect
one test probe to the auxiliary terminal or the stater winding center oonnectlon and touch
eaoh of the three stater leads. The test bulb must light, or the ohmmeter must show
continuity.
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.
If all other electrical checks are normal and the alternator fails to supply its rated output,
the stater should be replaced to determine whether or not it is the faulty component.
4. Bearings and Seals Whenever the alternator is overhauled, new bearings and oil or
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.
ASSEMBLY
i. Press the ball bearing into the drive end head using a flat block approximately 2" square
so that the pressure is exerted on the outer race of the bearing. Install the retainer plate.
With the snap ring and retainer cup in place on the rotor shaft, use a tool that fits over the
shaft and against the inner bearing race, and press until the inner bearing race is against the
2. Carefully install the rectifiers in the slip ring end head or rectifier mounting plate by
supporting the unit and using the special teals illustrated in Figure 10.
Figure 9 1 Figure 10
(Use arbor press do not hammer.) Reoonneot the stater leads to the rectifiers. WHEN
SOLDERING THESE CONNECTIONS, USE PLIERS AS A HEAT DAM ON THE LEAD BETWEEN
THE SOLDER JOWT AND THE RECTIFIER. TOO MUCH HEAT WILL DAMAGE THE
RECTIFIERS.
they in the
Reassemble the rectifier mounting plate studs and insulators, making sure are
Install the slip ring end hearing and oil seal. Make sure the lip of the oil seal is toward t~
3.
and spacer is shown in Figure 12.
bearing. Correct assembly of bearing, seal, inner race
NUT
LOCKWPASHER
LT~
-FIBERWASHER
SEAL-INSTALL SEAL
~ENO HEAD WITH LIP
TOWARD BEARING
~RECTIFIER
MOUNTING PLATE
TERMINAL INNER RACE
AUXILIARY
TERMINAL
NUT´•C~
FLATWASHERc~ c~Ly
LOCKWASHER
GREASE
Z
FIBERWASHER
CAVITY
END HEAD(
~cNsuLnToR ~L, 1 SPAC ER
RECTIFIER ~TERYIN*L STVD
MOUNTING PLATE BEARING
OUTPUT(+)
TERMINAL
11 Figure 12
t Figure
Safety wire
is no mechanical interference. Torque the through bolts to 30 to 35 in. Ibs.
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
to hold the pulley. Do not install the blast tube assembly until after the unit has been bench
tested.
Figure 13 7
Note: Always refer to the airframe manufacturers wiring diagram when installing the
alternator or testing the alternator on the aircraft.
2. THE OUTPUT LEAD MUST NOT BE REMOVED FROM THE ALTERNATOR WHILE
THE ROTOR WINDING IS ENERGIZED AND THE ALTERNATOR IS OPERATING
AIRCRAFT
ALTER NATO RS
FLANGE MOUNTED AIRCRAFT ALTERNATOR
DESCRIPTION
Figure 1
90
O oooa
Figure 2
1) The drive end head contains a prelubricated bearing, an oil seal, collar and shaft seal
and a blast tube connection for ventilation.
2) The rotor contains a ventilating fan an the drive end of the shaft (ALX series only) and
the slip ring end hearing inner race and spacer on the other end of the shaft. The rotor
winding and winding leads have been specially treated with a high temperature epoxy cement
to provide vibration and temperature resistance characteristics. High temperature solder
is used to secure the winding leads to the slip rings.
3) The stater contains a special lead which is connected to the center of the three phase
windings and is used to activate low voltage warning systems or relays. The stater has
been treated with a special epoxy varnish for high temperature resistance.
4) The rectifiers used in these units are rated at 150 P. I. V. minimum for transient voltage
protection. Three positive rectifiers are mounted in the rectifier mounting plate while the
three negative rectifiers are mounted in the slip ring end head. Each pair of rectifiers is
connected to a stater lead with high temperature solder. The stater leads are anchored to the
rectifier mounting plate with epoxy cement for vibration protection.
5) The slip ring end head provides the mounting for the rectifiers and rectifier mounting
plate, output and auxiliary terminal studs, and the brush and holder assembly. The slip
ring end head contains a roller bearing and outer race assembly and a grease seal.
6) The brush and holder assembly contains two brushes, two brush springs, a brush holder
and insulators. Each brush is c6nnected to a separate terminal stud and is insulated from
ground. The brush and holder assembly can easily be removed for inspection or brush
replacement purposes.
OVERHAUL
When repairing the alternator, complete disassembly may not be required. In some cases
it will only be necessary to perform those operations which are required to effect the repair.
However, in this section, the complete overhaul is covered step by step to provide detailed
information on each operation. In actual service practice, these operations may be used as
required.
DISASSEMBLY
1. Remove the two #10-24 screws holding the brush holder assembly in the slip ring end
head. Remove the brush and holder assembly from the end head.
2. Remove the safety wire from the thru bolts and remove the thru bolts.
3. Tap the drive end head lightly and separate the drive end head and rotor, as a unit, from
the stater and slip ring end head.
4. Remove the nuts, lock washers, flatwasher and insulators from the output and auxiliary
terminal studs. Note carefully the correct assembly of the insulator washers and bushings.
Using special tools shown in Figure 3, support the end head and press out the three
the
negative rectifiers. The end head can now be separated from the stater assembly.
Fd
Figure 3
6. Clamp the rotor in a vise and remove the cotter pin, nut, drive gear assembly and
woodruff key. The drive gear assembly is not a Prestolite part and is serviced
Note: by
the engine manufacturer. Support the drive end head and carefully press out the rotor
assembly. Remove the retainer plate screws and retainer plate. Support the drive end head
and press out the bearing. Once the bearing is removed, the oil seal can be knocked or
Upon completion of the disassembly, all parts should be cleaned and visually inspected for
cracks, wear or distortion and any signs of overheating or mechanical interference.
i. Rotor The rotor should be tested for grounded or shorted winding. The ground test
can be made with test probes, connected in series with a 110 volt test lamp, an ohmmeter
or any type of continuity tester. Figure 5. There must not be any continuity between the
slip rings and the rotor shaft or poles.
To test for shorted turns in the rotor winding, connect a voltmeter, ammeter and rheostat
as shown in Figure 6, or use an ohmmeter. Rotor current draw and resistance are listed on
I *MMETER
RHEOSTAT
YOLTMETER
I*TTERI
RoTon
Figure 5 Figure 6
2. Rectifiers A diode rectifier tester will detect and pinpoint open or shorted reotifiers wim-
out going through the operation of disconnecting the stater leads. However, if a tester is
not available, teet probes and a #57 bulb, connected in series with a 12 volt battery, can be
used in the following manner. Touch one test probe to a rectifier heat sink and the other
test probe to a lead from one of the reotlfiers in that heat sink. Then reverse the position
of the leads. The test bulb should light in one direction and not Light in the other direction.
Lf the test bulblights 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
direction if the rectifier is open.
described in the rectifier section, ohmmeter, in the following manner. Separate the
or an
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
each of the three stater leads. The test bulb must light, or the ohmmeter must show
continuity.
Due to the low resistance in the stater windings, shorted windins~s are almost impossible to
locate. However, sharted stater windings will usually cause the alternator to "growl" or be
noisy during operation and will usually shaw same signs of overheating.
If all other electrical checks are normal and the alternator fails to supply its’ rated output,
the stater should be replaced to determine whether or not it is the faulty component.
4. Bearings and Seals Whenever the alternator is overhauled, new bearings and oil or grease
seals are recommended, even though the bearings and seals appear to be in good canditian.
A faulty seal can cause an alternator to fail within a very short period of time.
ASSEMBLY
1. Drive End Head Install the oil seal with the lip toward the outside of the end head. Press
the oil seal in approximately 1/16" below the edge of the casting. Install the ball bearing with
the seal toward the inside of the end head. Press only on the outer race of the bearing when
installing. Install bearing retainer and bearing
screws. race and press in
Support the inner
rotor. Reassemble oil seal collar, "0" ring seal, woodruff key, drive gear assembly, nut
and cotter pin. Torque rotor shaft nut to 31 to 41 Ft. Lbs. Correct assembly of drive end
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.
nd BELW CIISTING
OIL SE*L
lr DE HEPID
BEIRING C~S"
RET~INER
L~R
Figure 7 Figure 8
SOLDERING THESE CONNECTIONS, USE PLIERS AS A HEAT DAM ON THE LEAD BETWEEN
THE SOLDER OINT AND THE RECTIFIER. TOO MUCH HEAT WILL DAMAGE THE
RECTIFIERS.
Reassemble the rectifier mounting plate studs and insulators, making sure they are in the
After the slip ring end head is completely assembled, the stater and rectifier leads must be
secured to the rectifier mounting plate with epoxy. Make sure the stater leads are positioned
so that they do not interfere with the rotor.
Install the slip ring end bearing and oil seal. Make sure the lip of the oil seal is toward the
bearing. Correct assembly of bearing, seal, inner race and spacer is shown in Figure 10.
NVT
LOCKWASHER
SEAL- INSTALL SEAL
FLATWAS IBERWASHER
WITH LIP
END HEI\D TOWARD BEARING
INSULAT
RECTIFIER
MOUNTING PLATE
INNER RACE
TERMINAL STVD/
AUXILIARY
TERMINAL
NUT
LOCKWASHER GREASE
BERWASHER CAVITY
RECTIFIER
MOUNTING PLATE
~TERMINAL STUD BEARING
OUTPUT(+)
TERMINAL
Figure 9 Figure 10
Assemble the alternator and install the through bolts. Spin the rotor to make sure there
is no mechanical interference. Torque the through bolts to 30 to 35 in. Ibs. 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
Check across the field terminals with an ohmmeter. The ohmmeter must indicate the
amount of rotor resistance listed on the individual specification page.
TESTING
The internal fan used on the ALX series provides some ventilation; however, the same rule
1 applies to these units.
Wiring connections for bench testing the alter-
nator are Figure Ii. Refer to the
shown in
individual specification pages for output test
figures. Adjust the carbon pile, if necessary,
to obtain the specified voltage.
CARBON
P"E
8
After bench testing the alternator, install the
safety wire in the through bolts and install the
alternator on the engine.
t _ ___ _ _ _ _ _ _
_TEST_V~L_TM_ETER
Figure 11
24 VO LT 100 AMPERE
AIRCRAFT
ALTERNATOR
THE PI1ESTOLITE 24 VOLT 100 AMPERE AIRCRAFT ALTERNATOR
cations.
DESCRIPTION
r
oooa
goe I
eo-~1I
QO.p
BBB
oe
O
Q! ~cb
P i O
Figure 2
feat, hinge mounted, belt-driven units, while the 9000 series identifies the nange mounted,
gear-driven units.
The principle components: (Figure 2) of these alternators are (1) the slip ring head, (2) the
heat sink and rectifier assemblies, (3) the stater, (4) the rotor and (5) the drive end head
assembly.
(1) slip ring end head provides the mounting for the rectifier-heat sink assemblies, the
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
end head.
(2) The rectifier and heat sirk assemblies (Flgure 3), used in these units, are different in
construction from those used in any other Prestolite aircraft alternator. Each heat sink
has six (6) rectifiers of one polarity attached to it. Each stater lead connects to four
(1)
I
OUTPUT
k
FI
FIELD
GROUND
nuxlLlnRv j
3 Figure 4
Figure
rectifiers (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 vibra-
tion protection. Because of this construction, special service procedures must be followed.
Refer to the rectifier section of Inspection and Testing of Components.
(3) The stater contains a center tap lead which is connected to the center of the three phase
windings and is used to activate low voltage warning systems or relays. The stater has
been treated with a special epoxy varnish for high temperature resistance and vibration
protection.
(4) The rotor wlddingwinding leads have been specially treated with a high temperature
and
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.
The drive end head, both series, contains a prelubricated bearing. The 9000 series
(5) on
end head also contains an oil seal, collar and shaft seal, and a blast tube connection for
ventilation
OVERHAUL
When repairing the alternator, complete disassembly may not be required. In some cases,
it will be necessary to perform only those operations ~hich are’required to effect
the repair.
to provide detailed
However, in this section, the complete overhaul is covered step by step
information on each operation. In actual service practice, these operations may be used
as required.
OVERHAUL NOTE
(2)
i. Brushes.
2. Drive end bearing.
3. Slip ring endbearing.
4. Oil seal (9000 Series).
5. Shaft seal "0" ring (9000 Series).
6. Lack tab washers.
DISASSEMBLY
(1) (8000 Series) Straighten the ears on the lock tabwashers and remove the three through
bolts and blast tube assembly.
(2) (9000 Series) Straighten the ears on the lock tab washers and remove the six through
bolts.
(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, lockwashers, net washers and insulators from the output, ground,
and auxiliary terminal studs. The end head can now be separated from the stater and heat
sink assemblies. The slip ring end bearing can be pushed out from the inside of the end
head.
The drive end head and rotor on the 8000 series units must be separated with a puller as
shown in Figure 6. Do not attempt to press the rotor out of the end head or the end head
may be damaged. The drive end head and rotor on the 9000 series units can be separated
by supporting the end head and pressing out the rotor.
(3)
Remove the hearing retainer plate screws and
rheostatas shown in Figure 8, oruse an accurate ohmmeter. Rotor currentdraw and re-
(2) Reotifiers A rectifier tester can 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
rectifier leads, between the solder joint and rectifier. Too much heat will damage rectifiers.
I IU.ETER
ROTOR
(i~7 CI I BP~TTERY
VOLTMETER
Figure 8
Figure
(4)
If a shorted or open rectifier is located, the heat sink assembly containing that rectifier
must be replaced. The indivihual rectifiers are not replaceable and no attempt should be
made to unsolder them from the heat sink.
(S) Stater The stater can be tested for open grounded windings with test probes and
or a
#57 bulb connected in series with a 12 volt battery, an ohmmeter, or any type continuity
tester except 110 volt test bulb.
To test for grounded windings, connect one test probe to the auxiliary terminal stud or any
stater lead. Connect the other test probe to the stater frame. If the test bulb lights or any
continuity is indicated, the stater is grounded and must be replaced.
To test for open windings, connect one test probe to the auxiliary terminal stud and touch
each stater connectianwith the other test probe. The testbulb must light or continuity must
be indloated between all connections. If the stater is open, it must be replaced. Check
flexible leads for possible opens before replacing the stater.
If all other eleetrioal cheeks are normal and the alternator fails to supply its rated output,
the stater should be replaced to determine whether or not it is the faulty component.
(4) And/Or Rectifier Heat Sink Replacement When soldering or unsoldering the
Stater
rectifier connections, pliers should be used as a heat dam behueen the solder joint and We
rectlfiers. Too much heat will damage rectlfiers.
ILSSEMBLY
Afterthoroughly cleaning, inspecting, testing, and replacing any faulty components, re-
assemble and test the unit. Reassembly is, basically, the reverse of disassembly.
bled unit.
(5)
Drive End Head-9000 Series Units Install the oil seal with the lip toward the outside of the
end head. Press the oil seal in approximately 1/16" below
edge of the casting. the outside
Install the bearing with the sealed side toward the rotor.
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.
Reassemble the oil seal collar, being careful
BELOV C*PTINO
not to fold the oil seal
lip under. A small
amount of oil on the collar will make installa-
D. E.
HEAD07 rH tion easier. Install the "0" ring seal, being
careful not to cut the "0" ring on the shaft
SEALED SIDE /OlL SEnL keyway. Use a small, blunt instrument to push
OF BEARING the "0" ring seal into the shaft collar. A small
,COLLAR
amount of oil on the "0" ring seal will make
cROTOR SHAFT
installation easier. Make certain the "0" ring
"O" RING SEAL seal is fully installed before
assembling the
remainder of the driveassembly. Figure 10
BEARING
shows the correct assembly of the drive end
head components. Torque the drive retaining
RETAINER nut to 37 to 42 Ft. Lbs.
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, making certain the
Position the stater leads so they will not interfere with the rotor.
NOTE: If it was necessary to replace the stater or either rectifier heat sink, position the
stater leads so they will not interfere with the rotor and secure the leads to the heat sinks
with epoxy cement.
Position the snap ring, in the end head, so that one of the holes is directly in line with the
brushes. Install the brush springs and brushes in the brush holder. Insert a small drill
~---´•NUTc----\ ~---´•NUT
/~´•´•´•´•´•´•´•´•´•´•2\
F’LATWASHERC--~2:
I-----´• c~ F LA TWASHER~
3---F’BERWASHER ~----´•INSULATOR-
------´•INSULATORc-~- ----~END HEADc---
-----~ENO HEBDc---- IN SULATOR-
---------´•INSULATORc~--_
~FLATWASHER
~FLAtWASHER
FIBERWASHERS ~HEAT
~--´•MEAT SINK ---//E SINKc--~C--
INSULATORc/
INSULATORC/ ALL EXCEPT AUX. TERM.
ffLL EXCEPT AUX. TERM.
AUX. TERM.
AUX. TERM.
Figure 11 (8000 Series) Figure 12 (9000 Series)
(6)
or metal rod through the snap ring hole to hold the brushes in place.
move the brush holding tool and make sure the brushes
are contacting the slip rings. Visu-
ally check to make sure the brush leads are freeand cannot bind against anything. Make
sure the shaft snap ring retainer is in place and install the slip ring end
bearing. The bear-
ing must be installed with the sealed side toward the rotor. Use a tool that fits against the
bearing inner race and press the bearing onto the rotor shaft while supporting the drive end
of the shaft.
Install the remaining through bolts. Do not install the blast tube assembly on the 8000 Series
Units, or secure the lock tab washers until the unit has been tested.
Torquing Specifications After the alternator is fully assembled, the components should be
torqued to the listed specifications:
TESTING
Upon completion of assembly, the alternator should be tested to determine if the unit is
capable of delivering its full rated output.
CAUTION: The 9000 Series, flange mounted units, require a source of ventilation. Do Not
test these units at full rated output for more than 20 seconds unless adequate air pressure
for cooling is supplied.
Wiring connections for bench testing the alternator are shown in Figure 13. The alternator
must meet or exceed the specifications listed below. Adjust carbon pile, if necessary, to
obtain the specified voltage.
manufacturer’s manual.
Figure 13
(7)
refer to the airframe manufacturer’s wiring diagram when instRllinr nr test-
NOTE: Always
ing the alternator on the aircraft.
2. THE ALTERNATOR OUTPUT LEAD MUST NOT BE REMOVED FROM THE ALTER-
NATOR WITH THE FIELD CIRCUIT ENERGIZED AND THE ALTERNATOR OPERATING.
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
INSPECTION AND ELECTRICAL CHECKS
1.1 Visual and Meohanioal inspeotion 4. Inspect bearing and shaft end for discoloration
indicatingaverheating or wear (See Figure 1-3)
1.1.1 Hausings and Shaft Verify no damage Replace ,,d if so, replace bearing and rotor
shaft damaged).
any damaged housings and rotor (if 5 inspect bearing inner race for evidence of turning
Thru-Bolts and Loolt Tabs Verify installation of onshsft (See Figure I-Sland iFso, replace bearing
1.1.2
six thru-bolts and lock tabs. See Figure 2-12 far instal- and rotor
lation at one place and Figure 2-13 For the other five
places. Bolt torque value is 3035 inch-pounds. Bolts
are high strength type (120,000 psi) which can be
worn parts.
1.1.6 Oil Seal Verify no damage or wear to oil seal. See
ta
Figure 1-2
X; ´•s~r
Figure 1-1
Figure 1-3
1.1.6 Slip Ring End Bearing, Housing and Shaft
End Condition
1 Remove bearing cover from end head as shown in 6. Inspect bearing outer race For evidence of turning
Figure 1-2. CARE MUST BE TAKEN NOT TO in housing bushing (See Figure 1-3) and if so,
DAMAGE END HEAD. IF COVER IS DAM- replace bearing and housing
AGED A NEW COVER MUST BE INSTALLED 7. Inspect bearing for wear and grease mntnmin;,-
for rust accumulation inside tion as indicated by darkening or change in arigi-
2 Inspect cover on sur-
1.2.1 Positive Rectifier Heat Sink Assembly: temperature and extended test time will increase
1. Using a VOM on the RX1 range, make forward winding resistance, due to temperature increase, and
and reverse rectifier resistance measurements be- prevent proper check to the stated limits. Also, the
alternator must not be operated without required air
tween the terminal and the AUX terminal.
2. One reading should be low and the other high cooling for more than 20 seconds at the loaded condi-
very
tion or damage will result. Therefore, to minimize
(no meter movement),
3. Abnormal readings indicate one or more rectifiers operation time required at the loaded condition, the
are defective and the assembly must be replaced.
following test sequence is suggested
I. With field control switch open, adjust speed to
Individual rectifiers are not replaceable.
specified value.
1.2.2 Negative Rectifier Heat Sink Assembly: 2. Close field switdh, adjust load to give specified
1. Repeat test as in 1.2.1 with VOM connections to
the terminal and the AUX terminal, output voltage at specified speed, record load cur-
rent, open field switch and decrease load and speed
1.2.3 Field Circuit: to zero.
1. Using VOM, measure resistance between Fl and 3. Refer to Page 9, Table 1-1 as required for trouble
F2 terminals, analysis.
2. 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
I I TEST *IJMETER
(ALV-9407 only, disconnect one lead for check). If TEST VOLTMETER
Figure 1-4
Section 2
’OVERHAUL PROCEDURE
pletely disassemble and reassemble the alternator. In parts be used for parts replacement. Refer to the
Prestolite OE-A1 Aircraft Manual Alternator Section
addition, this section includes inspection and test pro-
for available service parts.
cedures for the individual components and subas-
semblies. 2.3 Disassembly
When repairing the alternator, complete disassem-
2.3.1 Remove Rear Housing Stater and Rectifier
bly may not be required. In some cases, it will be
which are Heat Sinks Assembly from Rotor Drive End
necessary to perform only those operations
required to effect the repair. Housing Assembly.
1. Place the alternator on a wood "V" block stand.
thru ground terminal. AUX terminal and the other
2 Straightenthe locktabsoneachof the six(6)
bolts (Use lock tabs when reassembling)
new auxiliary terminal Note location to facilitate
and stater assembly on a pad to protect exposed ingtowards press table. Using a ik inchdiameter
x 8 inch long bar on inner race oEbearingand with
stator winding pending further disassembly
the end housing bearing boss area supported by a
tube 2U inch O.D x I~B inch I.D x 2 inch long,
NOT HAM-
press bearing from housing (DO
MER). Diseard bearing.
3. Remove hearing O-ring seal From housing and
disoard seal.
i Assembly
2.32 Remove Stater and Reotifier Heat Sinks AB- to removal of either heat sink
This procedure applies
sembly From Slip RingEnd Head. assembly from the atator assembly as required for
I. Position the assembly on holding block testing of individual assemblies. Fig
replacement or
2 Using socket wrench, r~mave nuts, washers and 2~Q showsone of the roctifierheatsintssrwired to
insulators from the (t) output terminal, th, stator leads. The other heat sink has similar type
eonneelions.
Remove epoxy cement holding each stator lead to
heat sink
4. Removethe AUXoutputterminal andspaeer from
the negative heat sink assembly.
RBM
2.4 inspection and Testing of Removed Components
3/16" DIA. BBR Refer toparagraph 2.6 far alternator servicing and
STOCK testing precautions.
C 2.4.1 Front and Rear Housing
1. Cleanboth housings using DowChemical-Chloro
thane VG solvent to remove grease and dirt.
I a Air dry with BLtered low pressure compressed dry
I air wipe dry with clean cloth.
or
NOTE
NOTE It is advisable to change brushes if length is 0.5
i"ch or less to eliminate later disassembly for
Too much heat damage rectifier, or shorten their
can
service life. Use long nose pliers between rectifiers b’UBh Wear replacement
and solder joint as a heat sink during soldering or
5. Inspect two stainless steel brush springs for any
unsoldering operations. Complete operation as deformation, change in Length orspring Force.
Service springs have a free length of about 1.2
quickly as possible. A 100 watt soldering iron with
clean tip is adequate inches, 0.29 inch maximum diameter and a spring
1. Unsolder all stater Leads from both rectifier-heat force of 0.54 pounds at compressed length of 087
sink assemblies. Tag stater leads and rectifier inches. Replace springs if they are damaged.
shaft.
E Oouged, bent, cracked or excessive eormsionaf
pole pieces.
F Bent, gouged or excessive corrosion of shaft.
G. Slip ringswhich are roughorout of round may
be trued in lathe (do not chuck shaft on bear´•
a
INDIVIDUALLY.
2.5 Assembly 6. Install a new O-ring seal onto shaft and position
into gmove of shaft collar Use a small blunt in-
2.5.1 install Drive End Oil 8eal
strument to push O-ring into groove. A small
i. Position drive end housing on press with front of amount of Dow Coming DC4 grease an the O-ring
housing press table,
an
seal will make installation easier. Make certain
2. Positlan new oil seal squarely in housing with lip th, seal is fully installed before assembling the
towards outside of end head, remainder of the drive assembly Figure i-land
3. Using a of 1~ inch diameter bar stack,
length 2~l.haw carrect assembly of oil seal and drive end
press oil seal squarely into end head to a distance head components.
of approximately L/le inch from outside face ofeaat-
ing. DO NOT HAMMER.
25.2 Install Drive End Bearing
1. Position drive end housingon press with front of I C*STING
CA PAC I TO R
HEX-NUT
LOCKWASHER SPACER
FLATWASHER/ WASHER
Figure 2-10A
OI)’CCIS(IO
FI f\F2
BEARING I ni ill I I lo
RETAINER
SCREW
HOLE
I ’YLII III 1 Figure 2-108
SLIPRING END HOUSING 2.5.6 Install Stater and Rectifier-Heat Sink Assemb-
lies toSlip Ring End Housing
I. Assemble the stater and rectifier heat sink as-
Figure 2-9 semblies 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 previ-
ous scribe marks to insure alignment of
thru-bolt
holes. Final torque of terminal nuts will be done at
complete assembly of alternator.
7
~NUT-
-INsuLaron--
-END HEIID´•
-2´•INSULIITORf-----
-FL*TWISHER
flBERWI\SHERSJ
~´•HEdll SINK´•
1NSUL*T
ALL EXCEPT AUX, TERM.
AUX. TERM.
Figure 2-11
NOTE:
A. Insure thatthe mating surfaces oEhausing and
stater are clean and free of any dirt, burrs or
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 Figure 1-12
rotor and secure leads at six places to heat
sinks with SM Company Scotchcast X10
besin, following manufacturers instructions.
See Figure 25 for typical epoxy application
points.
2.6.7 Assemble Rear Housing-ltator Assembly to
Drive End Housing and Rotor Assembly
i. Assemble the rear hausing-stator assembly to the
drive end housing and rotor assembly, aligning
the sections with previous scribe marks on sec-
tions
NOTE:
Insure that the mating surfaces of housing and
stater are clean and free of any dirt, burrs or
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-lj
Figure
2.6.8 install SUp Ring End Bearing.
1 Position assembly of paragraph 2.5.1 in arbor
F2 and passes through the blast tube of the drive
press ~th net surface of drive end shaft against a ,,d housing.
net and true surface of press.
2. Tighten bolts evenly, while maintaining lack tab
2 Positionnewbearingsquarsly intobearingpocket orientation each a little bit at a time in sequence
of housing with SEALED SIDE OF BEARING until all are tight and torqued to 30-35 inch
TOWARDS ROTOR. CARE MUST BE TAKEN
pounds.
TO PREVENT CONTAMINATION OF BEAR- 3 Bend six (B) lack tabs as shown in Figure a-12 and
ING. 2-13 as applicable.
3. Use a lengthof W inch diameter bar stock to press
bearing into housing onto shaft and up to shaft 2.5.10 Terminal Torquing
i. Tighten the terminal mauntingnuts to the follow-
stop. Apply pressure to inner race only. Pres-
sure on outer race will damage bearing. (110 ing torque values:
NOT HAMMER.) Sorew Torque
Install slip ring end Terminal Size (inchpounds)
4. bearing cover.
Fl X10-32 25-30
2.5.9 Install Thru-Bolts and Lock Tabs F2 #1032 25-30
i. Installthe six thru-bolts and new lack tabs. Figure AUX #10-32 25´•30
2-12 shows lock tab installation atdepressed posi- k..-28 ?0-85
tion on end head. Figure 2-13 shows lack tab in- (f) ’/1"-28 10-85
stallation at the five other points. The longest AUX U..-28 ?0-85
thru-bolt i. installed in the hole between F1 and
2.5.11 Post Assembly Test 3. Alternator output lead MUST NOT be removed
Perform test on completed assembly as outlined in from alternator with field circuit energized and
section 1, paragraph 1.2.5. unit operating.
ISSUED: 2-18-75(Rev.)
/16
7t---~ /6
o--------l
0-------7~
O 8 0´• O O O
90-2014Ca] ALE-1003K X-3416
ALE-6406,R 90-2396[d] 1 I ALU-1045BS[b] 90-2396[d]
ALE-6406G,RG
ALE-6420G,RG
ALE-8406G,RG
ALE-8408,R I I I ALE-1045BS[b]
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.
EabjALE-1013AS Captive Brush 6 Spring Set also individually available for
the Complete
units already having this design. Earlier units must replace
Brush Holder Assy. if Brushes or Springs are required.
[c] Brush Set only; Brush Spring Set ALA-19S also available.
be used at time of first repair.
[d] S.R.E.Head 6 Rotor Pkg. Complete Package must be used thereafter.
Individual Components(See Sheet W3 for contents of Pkg.) may
35-781 (GJC-498S) Cover Pkg, (10 Pcs,) also available,
ALE-6406G,RG
ALE-6420,R
ALE-6420G,RG
ALE-8406G,RG
ALE-8408,R
ALE-8420,R
ALE-8420G,RG
ALE-8421,R
A
ISSUED: 3-5-79 (REV.) SHEET 3
ALE SERIES ALTERWATOR PARTS LIST
Thru Nut Rotor Vent Drive
Assembly Bolt Washer Shaft Fan Pulley Regulator
Package (2 Pc.)
Packa9e
O ’Beer 20
FVR-4011A
ALE-6406G,RG
YSF-7203S
ALE-6420,R
FVR-4011A
ALE-6420G,RG
ALE-8105A ALA-20FS
YSF-7203S
ALE-8406,R ALA-2(X1S
FVR-4011A
ALE-8406G,RG
ALE-8408,R
VSF-7203S
ALE-8420,R
FYR-4011A
ALE-8420G,RG
ALE-8421,R
ALE-2173S-1 Rotor
INFORMATION Page 1 of 4
I
ALTERNATOR DESCRIPTION
SERVICE INFORMATION
ALTERNATOR SERVICE
SERIES PUBLICATION
SERVICE BULLETINS
Refer to the Service Bulletin Section of this manual for bulletins pertaining
to the ALE series alternators.
SERVICE SPECIFICATIONS
DRIVE PULLEY
AIRCRAFT ALTERNATORS
k SERVICE
Issued 4/1/83
Page 2 of 4 INFORMATION
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.
AIRCRAFT ALTERNATORS
SERVICE Issued 4/1/83
Output Minimum
Alternator Output
Amperage Alternator RPM
Series
Series Voltage
14.0 19 2000
ALE 6400, 8100,
14.0 32 4000
and 8400
Figure 1* FVR-4004+
ALE-6406G, kG 10 Lb. 6 Oz.
AIRCRAFT ALTERNATOR
OUTPUT
DIOOES
II
’t srnmR
I
ii I
II
ROTOR ,I 1 1-11
WINDINa
C
GROUNDriL
Figure 1 Figure 2
Figure 3
ALT SER’ES
prpsto/~te,
SERVICE PARTS LIST ALTERNATOR
ISSUED: 10-19-7~YRev.)
ENG. ENG.
NUMBER NUMBER APPLICATION
File in
OE-AI AIRCR*FT MANUAL
the ALTERNATOR
~LTEINIIOR SECTION
IICIION
I
ALT Series Alternator Parts List
171 -t~
rBS-s~i´•
ioY4
4 a
4~
5’
~G L~3 ’I
/4
ra-----
I I
O O O O 6 O
ALT-5101A ALT-2006 ALE-I D1 2LSCb~ CNA~ ALH-I 00205 X-3417 ALE-I 033 X5077
ALT-8403 90- 2397 Cel Ccl ALU-1 04585Ccl 90-2397Ce~ (90-2014Cal ALE-I 003K X-3416
ALT-8404,R I Ccl
ALT-84WLS,R I I Ccl
ALT-8407 I I Ccl
ALT-8421,R
ALT-8421LS,RS
ALT-51 01A ALE-2008R ALE-1004 XA- 94405 90-2359 GGW- 91 ALA-EOES 90-818
ALT-51 025 I I II
1 90-990
ALT-8404,R I I I 1 90-2030
ALT-8404LS,RS
ALT-8407 1 90-2043
ALT-8420
ALT-8421,R I I 90-2030
ALT-8421LS,RS
ALT- 9405 1 I II
1 90-2043
ALT-9422
ALT SERIES ALTERNATOR PARTS LIST ISSUED: 10-19-79(REv,) SHEET 3
S.R.E. I Nut Rotor Yent Drive
ALT-8404LS,RS I I I I I CNAI
ALT-8420 I I I I I ~NA]
ALT-8421LS,RS I I I I I [NAI
ALT-9422 CNA] I I I,
I CNA~ CNA]
ALTERNATOR DESCRIPTION
SERVICE INFORMATION
ALTERNATOR SERVICE
SERIES PUBLICATION
SERVICE BULLETINS
Refer to the Service Bulletin Section of this manual for bulletins pertaining
to the ALT series alternators.
SERVICE SPECIFICATIONS
DRIVE PULLEY
the Tech.
Printed in Usn. OF-Al
e l
AIRCRAFTi F L
in
A U NAM Data ALTERNATORS
ALTAIRCRAFT ALTERNATORS k SERVICE
Issued 4/1/83
Page 2 of 4 INFORMATION
4. Alternator not to be run more than 2 minutes for each test point.
VENTILATION
The 8400 series alternators use a slip ring end cover that has a
hose type connection for air pressure ventilation. Remove this
cover when bench testing the alternator,
Ri t
Alternator
:?tel;~al
ALT 5101A, S 12 Lb. 2 Oz. Figure 1 VSB-7401C
R, RS, S VSF-7403
R, RS, S
AIRCRAFT ALTERNATORS
Issued: 4/1/83 SERVICE
Page 4 of g INFBRMATION
FIELD FI
Ip/rl
rlELD r2 DIODES I_11Y II
STATOR II I II
I id’; II I It
I ROTOR I-II II
~U
~c____i
Figure 1 Figure 2
OUTPUT
FIELD
FIELD
AUXI
ROTOR
WINDING
STP~TOR
I-JI
I
I
I
PI
II
II
I
GROUND~i-´•ce
Figure 3
ALU SERIES
prest~itP.
ALTERNATOR
SERVICE PARTS LIST
ISSUED: 2-27-75(Rev.)
ENG. ENG.
NUMBER NUMBER APPLICATION
File in the
ALTERNATOR SECTION
Plmn~ i. v.l.*. OGAI AIRCRAFT MANVAL
AL Series Alternator Parts List
L__ ____J
-T
LfO
r-- -I
ALU-8403LS,
ALU-8421LS,
File in the
ALTERNATOR SECTION
Prlnt´•d In U.S.*. OF-Al AIRCRAFT MANUAL
ALU SERIES ALTERMATOR PARTS LIST
Stater Pes.Rect. Negative Term S.R.E. D.E. Thru
Assembly Assembly Plate Rectiffer Stud Cover Retainer Bolt
Assembly Pac~gqee
9
O OPa~age
ALU-8403,R ALE-2008AB ALE-1054A XA-944JS 90-2030 ALU-1 062A GR-32 ALA-L0GS
ALU-8403LS,RS
ALU-8421,R
ALU-8421LS,RS
ALU-9404L, R I I 1 90-2043
ALU-9422L,R
ALU SERIES ALTERNATOR PARTS LIST ISSUED:2-27-75(REv,) SHEET 3
Rotor Vent. Drive
Eyelet Nut
Washer Shaft Fan Pulley Regulator
Assembly Package
(2 Pc.)
00
Package
’B’ 000
AL0-21 90-2241 PU-672A VSF-7403S
ALU-0403,K 90-818 90-33
ALU-R403LS,RS
PU-672A
AL.U-8421 ,H
ALU-8421LS,RS
ALU-9422L,K
90-2014 90-2014
Bearing Pkg.
ALK-1132AS-1 ALE-1142AAS-1
Head Assy.,S.R.E.
available.
Ic] XA-744AZ Shaft Spacer O-Ring also
[f] Nut only; Washer not required.
Issued: 4/1/83
IN FORM ATION Page 1 of 3
ALTERNATOR DESCRIPTION
SERVICE INFORMATION
ALTERNATOR SERVICE
SERIES PUBLICATION
SERVICE BULLETINS
Refer to the Service Bulletin Section of this manual for bulletins pertaining
to the ALU series alternators.
SERVICE SPECIFICATIONS
DRIVE PULLEY
e l i F L
in
A Uthe
NAM I a~a´• ALTERNATORS
Printed in U.S.A. OF-Al AIRCRAFT
ALU
AIRCRAFT ALTERNATORS
kPresto~rp. SERVICE
Issued 4/1/83
Fage 2 of 3 INFORMATION
4. Alternator not to be run more than 2 minutes for each test point.
VENTILATION
The 8400 series alternators use a slip ring end cover that has a
hose type connection for air pressure ventilation. Remove this
cover when bench testing the alternator.
OUTPUT
DIODES
II;I
Inl ST~mR )II
ROTORWINDING I-t Ij/ I I/I I
Tech.
File in the
Data ALTERNAIORS
Printed in U.S.A. OF-Al AIRCRAFT MANUAL
prest~/itP,
ALTERNATORS
SERVICE PARTS LIST
File in the
ALTERNATOR SECTION
,11´•1´•´•1 1´• u.r.*. OCAI AIRCRAFT MANVAL
ALV Series Alternator Parts List
Ls 21
22
[a] -t~
5 5
L _I
I
(18\ IOC~M
b~-"L
16
(ri\
0~
r\
14
L~ G~
(4
3r I3
1615
ALV-6403RS
ALV-8402
ALV-8402L
ALV-8511R
ALV-8512
ALV-8512R
ALV-9401L
ALV-9401R
ALV-9405L I I I I I ALV-1003A[a]
ALV-9405R
ALV-9406L I I I ALV-1003~a]
ALV-94O6R
ALV-9407 I I ALV-1002AS
ALV-9407S
ALV-9510L
ALV-95l0R
ALV-6403RS I I I I I CNR]
ALV-8402L
ALV-8511 I I I I I [NR]
ALV-8511R i I i i ’I
I I I CNRI
ALV-8512 I I~
~NRI CNR~
ALV-9401 I I I ~I
I I CNR] I I GR-32
ALV-9401L I M
I I I I [NR]
ALV-9401R I I I I CNRI
ALV-9405L I I II
I I [NR]
ALV-9405R i I [NR]
ALV-9406L I I I ALV-1031
ALV-9406R
ALV-9407 I i I I CNRI
ALV-9407S I I I ~NRI
ALV-9510L I I I II
I [NR] CNR]
Ib~ Used only on Early Production units having Snap Ring at Slip Ring End of Rotor Shaft.
CNR~ Not required.
ALV SERIES ALTERWATOR PARTS LIST ISSUED: 11-10-82 (REV~) SHEET 3
O O 19 20 21
ALV-6403RS ~NR]
ALV-8402 [NR]
ALV-8402L [NR]
ALV-8511R [NR]
ALV-8512 I [NR]
ALV-8512R [NR]
ALV-9401L CNR]
ALV-9401R CNR]
ALV-9405L CNRI
ALV-9405R [NRI
ALV-9406R CNR]
ALV-9407S
ALV-9510L
ALV-9510R
ALV-6403RS
ALV-8402
ALV-8402L
ALV-8511
ALV-8511R
ALV-8512
ALV-0512R
Spacer only.
ALTERNATOR DESCRIPTION
SERVICE INFORMATION
ALTERNATOR SERVICE
SERIES PUBLICATION
SERVICE BULLETINS
Refer to the Service Bulletin Section of this manual for bulletins pertaining
to the ALV series alternators.
SERVICE SPECIFICATIONS
DRIVE PULLEY Torque the drive pulley retaining nut to 35 Ft. Lbs.
minimum to 45 Ft. Lbs. maximum.
DRIVE GEAR Torque the drive gear retaining nut to 37 Ft. Lbs.
minimum to 42 Ft. Lbs. maximum.
Page 2 of 3 INFORMATION
4. Slip rings and ohmmeter test probes must be clean. Ohmmeter test
probe leads must be in good condition.
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 and 9500 series alternators are cooled entirely by air
pressure through a hose type connection on the drive end head.
When bench testing this type of alternator, make output tests as
short as possible unless adequate air pressure for cooling is
supplied.
A LV
a
AIRCRAFT ALTERNATORS
SERVICE Issued: 4/1/83
I N FO RMATI ON Page 3 of 3
OUTPUT
FIELD
FIail
F2
GROUND
AUXILIARY
AU~J _j
Tech.
File in the
Data ALTERNATORS
Printed in U.S.A. OF-Al AIRCRAFT MANUAL
ALX SERIES
presto/itP.
SERVICE PARTS LIST ALTERNATOR
ISSUED:10-19-79 (Rev.)
ENG. ENG.
NUMBER NUMBER APPLICATION
Plill´•d In U´•I.*´•
File in the
OE-AI AIRCRAFT MANVAL I ALTERNATOR
norRNlroRrrcnoN
SECTION
I
ALX Series Alternator Parts List
20
17
Ed]~
14
~"10
16
hbb io
o~’ ‘-------II I
8 5
r-
Qg~l
I I
O O *ri~bly Pkg.0’ O
90-2399[eI 90-2014[a] ALE-1003R X-3416
ALX-6408 90-2399[e] ALE-1013AS ALU-1O45BS
ALX-8403G,RG I I [c3
ALX-8403LS,RS I I [c3
ALX-84O3LSG I I Ccl
ALX-8403RSG I I Cc]
ALX-8421G,RG
ALX-8421iS,RS
ALX-842LLSG
ALX-8421RSG
ALU-1003
ALX-9402 90-2409[e] 1 I 1 90-2409[e] 1 j
90-2400[e] 1 I ALU-1O43[d] X-4087
ALX-9404L,R 90-2400[e] [cl ALU-1045BS[c]
ALX-9404LG,RG I I [c3
ALX-9422LG,RG
ALX-9424 ALX-2138S-1
X-5398
ALX-9425 ALH-2206S-l[b] I I ~I
I I ALU-I 003
ALX-9425A
ALX-9425B
ALX-6423 I I I I I [NA]
ALX-8403,R I I 1 90-2030 ALU-1062A
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 I It
I I’
1 90-2043 ALX-1 062S
ALX-9404L, R I I I I [NA]
ALX-9404LG,RG I I I [NA]
ALX-9405 I I I I I [NA]
ALX-9422L, R I I I [NA]
ALX-9422LG,RG I 1 t I [NAI
ALX-9424 I I I I I CNA]
ALX-9425 I 11
I I ALX-1 0625
ALX-9425A
ALX-9425B
O O O O
ALX-6408 [NA] 90-818 90-33 ALC-ZIF 9n-2259Cf] [NA~ 1 VSF-7203S
ALX-6423 [NA~ I I I II
I II
I CNAI
FYR-4011A
ALX-8403G,RG [NAI I I I II
I II
I II
I
ALX-8403LS, RS [NA] I I I II
I II
I [NA~ VSF-7203S
[NAI FVR-4011A
ALX-8403LSG CNA] I I I II
I II
I
ALX-9403RSG [NA~ I I I II
I r
I [NA~
VSF-7203S
ALX-8421,R [NA] I I I I I PU-672A
FYR-4011A
ALX-8421G,RG [NA] I I I I I I
ALX-8421 LS,RS [NAI I I I II
I II
I [NAI VSF-7203S
[NA] FVR-4011A
ALX-9404LG,RG 1 I II
I II
I II
I [NA]
ALX-9405 I I II
I II
I II
I ALP-1034Cg] [NA] VSF-7203S
ALX-94221., R I I II
I II
I I [NA] [NA]
[NA] FVR-4011A
ALX-9422LG,RG I I II II
I II
I [NA]
ALX-9424 I I II
I II
I II
I ALP-1034Cgl [NA] VSF-72035
ALTERNATOR DESCRIPTION
SERVICE INFORMATION
ALTERNATOR SERVICE
SERIES PUBLICATION
SERVICE BULLETINS
Refer to the Service Bulletin Section of this manual for bulletins pertaining
to the ALX series alternators.
SERVICE SPECIFICATIONS
DRIVE PULLEY
4. Alternator not to be run more than 2 minutes for each test point.
VENTILATION
The 8400 series alternators use a slip ring end cover that has a
hose type connection for air pressure ventilation. Remove this
cover when bench testing the alternator.
TECH.
File in the
DATA ALTERNATORS
Printed in U.S.A. OF-Al AIRCRAFT MANUAL
XLASRO~ANRETLA
AZRCRAFT
presro/ite.
SERVICE
Issued: 4/1/83
Page 4 of 4 INFORMATION
OUtPVT
FIELD rl
FIELD DIODES I_
It \rf
I
STITOII II ii
II I It
AUXIL~RJ,
ISSUED: 3-3-75(Rev.)
ENG. ENG.
NUMBER NUMBER APPLICATION
Pas, in u.S.*.
File in the
OE-AI AIRCRAFT MANUAL I ALTERNATOR SECTION
I
ALY-6403 to 6427R6 Alternator Parts List
~-----O
B
10
g-@ II
0----------~
c/
O O O 0´• O O O
ALE-1013AS ALU-1045BS 90-2396[c1 90-2014Ea] ALE-1003K X-3416
ALY-6003,R 90-2396[c]
ALY-6403G,RG
ALY-6406G,RG I I ~b]
ALY-6420G,RG
ALY-6422 ALE-2177S-1
I I ALU-1045BS I I I ALE-1003R
ALY-6425 ALE-2173S-1
kLE-1003K
ALY-6427,R
ALY-6427G,RG
ALY-6403G,RG
ALY-6406,R
ALY-6406G,RG
ALY-6408 I 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
ALY-64O3 TO 6427RG ALTERNATOR PARTS LIST ISSUED: ll-6-79(REv,) SHEET 3
S.R.E. Nut Rotor Vent. Drive
Assembly Cover Washer Shaft Fan Pulley Regulator
Package Spacer (2 Pc.)
O O 18
ISSUED: 3-3-75(Rev.)
ENG. ENG.
NUMBER NUMBER APPL ICAT ION
File in the
OE-AI AIRCRAFT MANUPIL I ALTERNATOR slcnon
aurlwroa SECTION
I
ALY-8402 to 8426RG Alternator Parts List
I,
~----O
io
9-@ II
5
0------------~ ~3
;P7
O O O *’i~," O O O
ALU-I045BS[b] 90-2396[c] 90-2014[a] ALE-1 003K X-3416
ALY-8402 90-2396[c] [b]
ALY-8403,R I [b]
ALY-8403G,RG I I [b]
ALY-8403RSG I I [6]
ALY-8405,R I Cb]
ALY-8405G,RG I I Cb]
ALY-8420G,RG
ALY-8420LS,
ALY-8420LSG
ALY-8420RSG
ALY-8423,R I I I ALE-1045BS
ALY-8424 I I I ALU-1045BS
ALY-8426,R
ALY-8426G,RG
[b] ALE-1013AS Captive Brush Spring Set also individually available for
units already having this design. Earlier units must replace the
Complete Brush Holder Assy. if Brushes or Springs are required.
[c] S.R.E.Head Rotor Pkg. Complete Package must be used at first repair.
Individual components(See Sheet #3 for of Pkg.)may be
replaced thereafter.
ALY-8403,R I I I 90-2030
ALY-8403G,RG
ALY-8403LS,RS
ALY-8403LSG
ALY-8403RSG
ALY-8405,R
ALY-8405G,RG
ALY-8410,R
ALY-8411 I I 1 90-2043
ALY-8420,R I 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
ALY-8402 TO 8112611(3 ALTERIJATOR PARTS LIST ISSUED: 11-6-79(REV,) SHEET 3
S.R.E. Nut Rotor Vent. Drive
Assembly Cover Washer Shaft Fan Pulley Regua Itor
Packagecer (2 Pc.)
O O O
ALY-8402 ALU-1 062 90-33 ALC-P1F 90-2259 CNAI VSF-7203S
ALY-8403G,RG I I II
I II
I II
I I FVR-4OI1A
ALY-8403LS,RS I I II
I I~
I II
I CNAI VSF-7203S
ALY-8403LSG I I II
I ~I
I II
I CNAI FVR-4011 A
ALY-8403RSG I I I I I CNAI
ALY-84056,RG I I o
I n
I n
I n
I FYR-4011A
ALY-8420G,RG I I I I
I
n
I I FVR-4011A
ALY-8420RSG I I I I I CNAI
ALY-8426G,RG I I II
I
II
I I FYR-4O11A
Rotor ALE-2173S-1
ALTERNATOR DESCRIPTION
SERVICE INFORMATION
ALTERNATOR SERVICE
SERIES PUBLICATION
SERVICE BULLETINS
Refer to the Service Bulletin Section of this manual for bulletins pertaining
to the ALY series alternators.
SERVICE SPECIFICATIONS
DRIVE PULLEY
4. Alternator not to be run more than 2 minutes for each test point.
VENTILATION
The 8400 series alternators use a slip ring end cover that has a
hose type connection for air pressure ventilation. Remove this
cover when bench testing the alternator.
OUTPUT_
FIELD
;vl
STATOR II I (I
ROTOR
WINDING
1~\11
Figure 1
/C7
Figure 2
ALZ SERIES
ALTERNATOR
SERVICE PARTS LIST
ISSUED: 3-4-75(Rev.)
ENG. ENG.
NUMBER NUMBER APPLICATION
-I
C/
to
----(13
~a
C/
,a-
ALZ SERIES ALTERNATOR PARTS LIST ISSUED: 3-5-79 (REV,) SHEET 2
Slip Ring S.R.E.Bearing Drive End D.E.
Rotor Brush Br.,Holder
Set Spring End Head L Seal Head Bearing
Assembly Assembly
O O
Assembly
O "’i~iy P
5 n,i~gl, O
90-2014Cbl ALE-1003K X-3416
ALZ-8401 90-2396[c] 1 IALU-10458S[a] 90-2396[c]
ALZ-8401G
ALZ-8401R
ALZ-8401RG
ALZ-8423G
ALZ-8423R
ALZ-8423RG
ALZ-8401G
ALZ-8401R
ALZ-8401RG
ALZ-8423
ALZ-8423G
ALZ-8423R
ALZ-8423RG
ISSUED: 3-5-79(REv~) SHEET 3
ALZ SERIES ALTERNATDR PARTS LIST
Nut 6 Rotor Vent. Drive
Eyelet
Washer Sha~L Fan Pulley Regul ator
Assembly Package
Pac (;ZRc´•
O la It
FVR-(IO11A
ALZ-8401RG
VSF-7203S
ALZ-8423
FVR-4011A
ALZ-8423G
YSF-7203S
ALZ-8423R
FVR-4011A
ALZ-8423RG
Rotor ALE-2173S-1
ALTERNATOR DESCRIPTION
SERVICE INFORMATION
ALTERNATOR SERVICE
SERIES PUBLICATION
SERVICE BULLETINS
Refer to the Service Bulletin Section of this manual for bulletins pertaining
to the ALZ series alternators.
SERVICE SPECIFICATIONS
DRIVE PULLEY
AIRCRAFT ALTERNATORS
Page 2 of 3 INFORMATION
4. Alternator not to be run more than 2 minutes for each test point.
VENTILATION
The 8400 series alternators use a slip ring end cover that has a
hose type connection for air pressure ventilation. Remove this
cover when bench testing the alternator.
ALZ
AIRCRAFT AI~TFRNATORS
SERVICE Issued: 4/1/83
INFORMATION Page 3 of 3
I(\(I)
FIELD FI
DIODES C
II I
ST~TO(1 It
I
II
ROtOl WIWDINO 1-11IJI
INFORMATION Page 1 of 1
terminal to ground.
VSF-7201u´•it-~
VSF-7202
VSFc7203,S II
zn~
VSF-7204
I
aLGiiL1TPa
5r rC*
Rdl-FL 1
Typical Schematic Circuit of Regulator
INFORMATION Page 1 of 1
VOLTS 24 Negati ve
OPERATING VOLTAGE The regulator should be adjusted to 28.4 volts when con-
trolling a.load of 10 to 15 amps after 1 minute operation.
These units are not affected by ambient temperatures.
The voltmeter must be connected from the "I" or ignition
terminal to ground.
’I
al´•r "~n´• u
Unit ;ti:
VSF-7401
c~
VSF-7402 i~Z
PI 12 91
I
VSF-7403,S ~Fs
VSF-7404 i
u
5*"~Y
’C
3Y
Tech.
File in the REGULATORS R RELC\YS
Data
Princ´•d in US.* OE-AI AIRCRAFf MANUAL