Plane-Power ALV-9610, Maintenance Manual

Page 1: ...tzell Engine Technologies All rights reserved AIRCRAFT ALTERNATOR MAINTENANCE MANUAL P N 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...

Page 2: ...Aircraft Alternator Maintenance Manual 24 30 01 ES1031 Page ii Rev B 20 Apr 2022 2022 Hartzell Engine Technologies All rights reserved THIS PAGE INTENTIONALLY LEFT BLANK...

Page 3: ...re 1 3 1 6 Abbreviations 1 4 1 7 Definitions 1 4 1 8 Disposal 1 6 1 9 Model Identification 1 6 1 10 Serial number Identification 1 6 1 11 Warranties 1 6 CHAPTER 2 DESCRIPTION OF OPERATION 2 1 2 1 Desc...

Page 4: ...er Brushes and Springs 5 3 G Pulley Run Out Check 5 4 5 3 Alternator Bench Testing 5 4 A Alternator Output Test Conditions 5 4 B Ventilation 5 4 C Order of Tests 5 5 D Test Setup 5 5 5 4 Alternator Se...

Page 5: ...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 Sudden Engine St...

Page 6: ...Fax 1 334 386 5450 Web www Hartzell aero contact PlanePower is a trademark of Hartzell Engine Technologies LLC WARNING People who fly should recognize that there are various types of risks are involve...

Page 7: ...Aircraft Alternator Maintenance Manual ES1031 24 30 01 Rev B 20 Apr 2022 Page vii 2022 Hartzell Engine Technologies All rights reserved THIS PAGE INTENTIONALLY LEFT BLANK...

Page 8: ...ft 1 6 Para 1 9 change ES 10024B to ES 10024B 1 thru 5 and 5LS 2 2 Update Operational Data and Dimensions paragraphs 2 3 Update dimensions illustration Figure 2 3 2 4 thru 2 7 Add basic dimension illu...

Page 9: ...1 thru 5 1LS to para 1 2 B 1 6 Add ES 14024B 1 thru 5 to para 1 9 2 2 Add ES 14024B Operational Data 2 9 thru 2 14 Add ES 14024B 1 thru 14024B 5 illustrations 2 18 Add ES 14024B to Table 2 1 Operatio...

Page 10: ...rnator Maintenance Manual 24 30 01 ES1031 Page x Rev B 20 Apr 2022 2022 Hartzell Engine Technologies All rights reserved RECORD OF TEMPORARY REVISIONS Temporary Rev Letter Page Number Date Removed Iss...

Page 11: ...E MINIMUM REQUIRED TO MEET CONTINUED AIRWORTHINESS BUT MAY BE SUPERSEDED BY MORE STRINGENT REQUIREMENTS AS PUBLISHED BY THE FAA AIRCRAFT ROTORCRAFT OR OTHER MANUFACTURERS THAT USE THESE COMPONENTS IN...

Page 12: ...pter Such limits require replacement of the identified parts after a specified number of cycles or hours of use B Additions of or changes to any life limit for alternator components will be noted in t...

Page 13: ...amages directly or indirectly resulting from the unauthorized use of this manual for other than its stated purposes The liability for use of the authorized data herein for the maintenance or return to...

Page 14: ...nd at www PlanePower aero Revisions will be tracked and recorded in the Record of Revisions section of this document 1 3 How to use the manual A Make sure the manual contains information applicable to...

Page 15: ...Volt C Degree Celsius Ohm W Watt Hz Hertz m Meter cm Centimeter kg Kilogram B U S Units ft Foot in Inch lb Pound lbf Pound force lbf in Pound force inch lbf ft Pound force foot 0 F Degree Fahrenheit...

Page 16: ...rials procedures or limitations which must be followed without deviation to avoid injury to the technician or other persons CAUTIONS place immediate attention to use of tools and procedures which must...

Page 17: ...as 360 degrees of phase Phase can also be an expression of relative displacement between or among waves having the same frequency In our case the alternator is three phase or 120 degrees separation P...

Page 18: ...ng year 1 11 Warranties A Hartzell Engine Technologies LLC HET offers a Limited warranty with each new overhauled or rebuilt Alternator assembly or component parts it sells through it s distribution s...

Page 19: ...nd the vibration and extreme temperature changes encountered in aircraft applications Basic features are identified in Fig 2 1 thru 2 20 below 1 Through Bolts 4 ea 5 Aux Terminal 2 Field Terminal 6 Ou...

Page 20: ...ltitude 31 900 feet MSL 9 723 meters MSL Weight See Table 2 1 this chapter Belt Driven ES 14024B External Fan Cooling Operating Speed Minimum for Regulation 2 400 RPM Maximum Continuous Operating Spee...

Page 21: ...9610 Dimensions 8 63 4 122 4 118 50 81 2 44 669 1 42 2 00 5 25 25 0 90 0 4 00 5 25 4 122 Aircraft Alternator Maintenance Manual ES1031 24 30 01 Rev B 20 Apr 2022 Page 2 3 2022 Hartzell Engine Technolo...

Page 22: ...t Alternator Maintenance Manual 24 30 01 ES1031 Page 2 4 Rev B 20 Apr 2022 2022 Hartzell Engine Technologies All rights reserved 3 985 2 610 875 112 5 116 1 13 50 Figure 2 4 ES 10024B 1 10024B 5LS Dim...

Page 23: ...e Manual ES1031 24 30 01 Rev B 20 Apr 2022 Page 2 5 2022 Hartzell Engine Technologies All rights reserved Figure 2 5 ES 10024B 2 Dimensions 2 56 2 223 7 66 Figure 2 6 ES 10024B 3 Dimensions 7 50 2 40...

Page 24: ...l 24 30 01 ES1031 Page 2 6 Rev B 20 Apr 2022 2022 Hartzell Engine Technologies All rights reserved Figure 2 7 ES 10024B 4 Dimensions 7 61 1 978 2 52 3 00 K 6 290 STD Figure 2 8 ES 10024B 5 Dimensions...

Page 25: ...aft Alternator Maintenance Manual ES1031 24 30 01 Rev B 20 Apr 2022 Page 2 7 2022 Hartzell Engine Technologies All rights reserved Figure 2 9 ES 10024B 1 thru 4 5LS ES 10024B 5 Less blast tube cover R...

Page 26: ...Aircraft Alternator Maintenance Manual 24 30 01 ES1031 Page 2 8 Rev B 20 Apr 2022 2022 Hartzell Engine Technologies All rights reserved 5 725 4 122 Figure 2 10 6024D Dimensions 1 42 81...

Page 27: ...Aircraft Alternator Maintenance Manual ES1031 24 30 01 Rev B 20 Apr 2022 Page 2 9 2022 Hartzell Engine Technologies All rights reserved Figure 2 11 ES 14024B 1 R3 50 21 21...

Page 28: ...tenance Manual 24 30 01 ES1031 Page 2 10 Rev B 20 Apr 2022 2022 Hartzell Engine Technologies All rights reserved 2 225 015 3 968 022 1 13 2 59 7 69 875 112 5 118 2 74 50 49 Figure 2 12 ES 14024B 1 1LS...

Page 29: ...e Manual ES1031 24 30 01 Rev B 20 Apr 2022 Page 2 11 2022 Hartzell Engine Technologies All rights reserved 5 900 Figure 2 14 ES 14024B 2 Dimensions 7 190 1 758 1 713 3 00 600 130 3 17 4 106 3 980 Figu...

Page 30: ...ance Manual 24 30 01 ES1031 Page 2 12 Rev B 20 Apr 2022 2022 Hartzell Engine Technologies All rights reserved 4 106 3 980 Figure 2 15 ES 14024B 3 Dimensions 7 516 3 00 130 Shipping Spacer 600 Figure 2...

Page 31: ...tenance Manual ES1031 24 30 01 Rev B 20 Apr 2022 Page 2 13 2022 Hartzell Engine Technologies All rights reserved Figure 2 18 ES 14024B 4 Dimensions 4 106 3 980 Figure 2 17 ES 14024B 4 Dimensions 600 1...

Page 32: ...anual 24 30 01 ES1031 Page 2 14 Rev B 20 Apr 2022 2022 Hartzell Engine Technologies All rights reserved 485 Figure 2 19 ES 14024B 5 Dimensions R3 50 21 21 Figure 2 20 ES 14024B 5 Dimensions 8 0 3 955...

Page 33: ...tate of charge in the battery and supply current to the electrically powered equipment and accessories in the aircraft It performs this function by converting mechanical energy derived from its rotati...

Page 34: ...printed circuit board incorporating a capacitor and gas dischargetube Both types perform the same function and provide similar performance Aircraft Alternator Maintenance Manual 24 30 01 ES1031 Page 2...

Page 35: ...rnating current to direct current This rectified DC current is made available to external loads via the B terminal 2 6 Self Excitation Description A The HET alternator model ES 10024B 5 5LS when used...

Page 36: ...Rated 28 volt 28 volt 28 volt 28 volt 28 volt Current Rated 100 Amp 100 Amp 140 Amp 100 Amp 60 Amp Rated Altitude feet 31 900 feet MSL 31 900 feet MSL 35 000 feet MSL 31 900 feet MSL 31 900 feet MSL R...

Page 37: ...ided Upon determination of fault s refer to the TESTING section 6 for applicable test procedure s 3 2 Procedure WARNING WHEN SERVICING REPAIRING OR OVERHAULING THE ALTERNATOR GREAT CARE AND CAUTION MU...

Page 38: ...ke care not to scratch the surface If the slip rings are worn beyond limits replace or overhaul alternator see section 6 Short or leakage from field terminals to housing Unless it is determined the wi...

Page 39: ...epair as necessary Check condition of the slip rings and clean Check rotors as found in section 6 and if failed replace or overhaul alternator Voltage regulator malfunction Check the voltage regulator...

Page 40: ...ery on battery tester to verify the condition Replace failed battery Shorted voltage regulator output full field condition Before replacing the voltage regulator check wiring harness for shorts or ope...

Page 41: ...be overhauled or replaced Loose mounting bolts Inspect mount points for damage and if found overhaul the alternator If not re torque mounting bolts per the engine or aircraft service manual Loose coo...

Page 42: ...ain relief to the cables and tighten properly See engine or aircraft service manuals Resistive or arcing circuit breaker Make a resistance check of the circuit breaker essentially there should be no r...

Page 43: ...s found in section 6 Disassembly may be required to verify symptom Replace or overhaul alternator Insufficient output filtering Check the RFI filter by performing a capacitance check Replace RFI filte...

Page 44: ...engine manuals and also in service bulletins Refer to CMI SB11 3 and or SB95 3B for drive coupling service information 3 4 Alternator Belt Troubleshooting A Although the alternator belt is provided b...

Page 45: ...and pulley is the critical factor responsible for causing the chirp from a misalignment Misalignment angle can result from many different combinations of pulley positions An in or out positioning err...

Page 46: ...Aircraft Alternator Maintenance Manual 24 30 01 ES1031 Page 3 10 Rev B 20 Apr 2022 2022 Hartzell Engine Technologies All rights reserved THIS PAGE INTENTIONALLY LEFT BLANK...

Page 47: ...raft and or engine service instructions or maintenance manual Inspect area around the brush holder for soot If a large amount of soot appears remove each brush and check for wear or damaged brushes If...

Page 48: ...Aircraft Alternator Maintenance Manual 24 30 01 ES1031 Page 4 2 Rev B 20 Apr 2022 2022 Hartzell Engine Technologies All rights reserved THIS PAGE INTENTIONALLY LEFT BLANK...

Page 49: ...meter Safety gloves Protective goggles eye protection Ear Plugs hearing protection Safety shoes Protective cotton apron Air compressor shop air 2 Special tools The following are only requred if alter...

Page 50: ...e threads and each terminal stud should be inspected for signs of arcing 2 Arc marks are usually caused by a loose wire terminal connection resulting from failure to tighten the attaching nut 3 Arc ma...

Page 51: ...intenance for brushes 6 Item 3 4 failed rotor requires overhaul or replacement of the alternator D Mounting Hardware 1 Inspect and replace any removed metallic hardware i e screws flat washers nuts sh...

Page 52: ...ley must not exceed a runout of 0 006 inch on either axis c The ES 14024B 1LS ES 14024B 3 and ES 14024B 4 must not exceed pulley run out tolerance requirements of OEM 5 3 Alternator Bench Testing CAUT...

Page 53: ...Y AND OR COMPONENT DAMAGE FROM ARCING HOOK THE BATTERY TO THE SYSTEM ONLY AFTER ALL OTHER CONNECTIONS ARE MADE NOTE It is recommended to use a switched jumper from the F1 terminal to the DC output ter...

Page 54: ...ltage Min Output Amps Max Alternator RPM Test 1 28 0 5 100 8000 Test 2 28 0 5 65 4000 Test 3 28 0 5 10 2500 Order of Tests Output Voltage Min Output Amps Max Alternator RPM Test 1 28 0 5 65 8000 Test...

Page 55: ...with the current limit set to 3 5 amp can be used to polarize the rotor by briefly applying 28VDC nominal 2 Connect the positive lead of the power supply to the F1 terminal 3 Connect the negative lea...

Page 56: ...Figure 5 1 Test Pulley Fabrication Dimensions Aircraft Alternator Maintenance Manual 24 30 01 ES1031 Page 5 8 Rev B 20 Apr 2022 2022 Hartzell Engine Technologies All rights reserved...

Page 57: ...Alternator DC Load Bank V A Drive Motor Mounted below alternator Fig 5 3 Gear Driven Alternator Mounting Fixture Drive Belt Test Bench Surface 3 03 385 x4 4 14 90 Aircraft Alternator Maintenance Manua...

Page 58: ...und Terminal DC Output DC Load Bank 24v Battery Field Terminal 1 to DC Output Jumper switched V A Aircraft Alternator Maintenance Manual 24 30 01 ES1031 Page 5 10 Rev B 20 Apr 2022 2022 Hartzell Engin...

Page 59: ...own Ground Terminal DC Output DC Load Bank 24v Battery Field 2 Terminal to Ground Jumper Field 1 Terminal to DC Output Jumper switched V A Aircraft Alternator Maintenance Manual ES1031 24 30 01 Rev B...

Page 60: ...THIS PAGE INTENTIONALLY LEFT BLANK Aircraft Alternator Maintenance Manual 24 30 01 ES1031 Page 5 12 Rev B 20 Apr 2022 2022 Hartzell Engine Technologies All rights reserved...

Page 61: ...the proper level with approved water Perform a battery capacitance check using an aircraft battery capacitance tester to determine battery condition Check for dirt and corrosion and clean If other typ...

Page 62: ...ngine airframe and the drive coupling manufacturer concerning the installation inspection and replacement of the drive coupling 2 Check the general condition of the drive coupling requires removal of...

Page 63: ...rminal 2 Disconnect the cable from the positive battery post and isolate the terminal 3 Disconnect the Field wires AUX wire output and ground cables from the alternator 4 Remove the retaining hardware...

Page 64: ...s maintenance C Whenever maintenance is required on a belt driven alternator the external cooling fan must be visually inspected The following may be used with engine or airframe guidance in the most...

Page 65: ...Remove belt from the pulley Disconnect the retaining hardware and bracketry as required 5 Remove the alternator from the engine Some OEM applications may require the pulley to be removed before the a...

Page 66: ...ce mismatched belts Increase tension Check P N and or replace pulley Pulley size on components correct Belt Separated Foreign materials in drive belt Belt slippage over time Heavy start up loads Belts...

Page 67: ...MAY HAVE A HARMFUL EFFECT ON BRUSHES AND SLIP RINGS OPENINGS SHOULD BE TEMPORARILY PLUGGED WITH SHOP TOWELS A If mounted on an aircraft to engine initial cleaning may be done using mineral spirits or...

Page 68: ...nstallation Prepare to install brush holder into the alternator 1 Install a new set of brushes HET P N ALE 13A into the brush holder Place each new brush into the brush holder Brushes must be oriented...

Page 69: ...end of the alternator and discard Using a calibrated torque wrench apply 40 45 in lbs 5 08 5 65 Nm torque to the loose through bolt After application of torque check and apply the proper torque to the...

Page 70: ...ove and discard lockwasher Field nuts are HET P N 8X 0140 Lockwashers are HET P N 12X 0194 B Installation 1 AUX Terminal Check bottom nut for a torque of 25 to 30 in lbs 2 82 3 39 Nm Place a new lockw...

Page 71: ...Terminal Aux Terminal Nut Flat Washer AUX Terminal Stud Lock washer Insulator Fiber Washer Rectifier Mounting Plate Rectifier Mounting Plate Output Terminal Stud Nut Lock washer Flat Washer Fiber Wash...

Page 72: ...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...

Page 73: ...AR AR AR AR AR AR AR 40482 Pulley V Belt 1 40483 Pulley 6 Groove 1 40485 Pulley 6 Groove 1 40840 Pulley 10 Groove 1 41045 Pulley V Belt 1 41003 Pulley V Belt 1 41154 16 Pulley V Belt 1 41185 Pulley In...

Page 74: ...case gasket on the clean crankcase surface per the applicable Continental Motors Inc engine manual Obtain applicable part number gasket from CMI 4 Position the alternator and install the retaining ha...

Page 75: ...ned by the engine manufacturer the alternator may be impacted critically by this event Although the alternator drive system is designed with an OEM supplied elastomer drive coupling which protects the...

Page 76: ...ed in accordance with the appropriate engine or airframe manuals Assure all steps are taken to properly return the aircraft to service C Lightning Strike NOTE For engine OEM s Special Condition Lightn...

Page 77: ...r there are several categories to consider Short term storage or long term storage on or off the aircraft Short term storage will be considered as storage up to but not exceeding twenty four 24 calend...

Page 78: ...Aircraft Alternator Maintenance Manual 24 30 01 ES1031 Page 6 18 Rev B 20 Apr 2022 2022 Hartzell Engine Technologies All rights reserved THIS PAGE INTENTIONALLY LEFT BLANK...