Planet ES-10024B-1 User manual

Aircraft Alternator

Maintenance Manual

ES1031 24-30-01

Rev. A: 11 Aug. 2021 Page: i

AIRCRAFT ALTERNATOR

MAINTENANCE MANUAL

P/N ES1031

ALTERNATOR

MODELS

ES-10024B-1 ES-10024B-5LS

ES-10024B-2 ES-10024

ES-10024B-3 ALV-9610

ES-10024B-4 ES-6024D

ES-10024B-5

Aircraft Alternator

Maintenance Manual

24-30-01 ES1031

Page: ii Rev. A: 11 Aug. 2021

stored in a retrieval system, or transmitted, in any form or by any

means, electronic, mechanical, photocopying, recording, or otherwise,

without the prior written permission of Hartzell Engine Technologies

LLC.

Aircraft Alternator

Maintenance Manual

ES1031 24-30-01

Rev. A: 11 Aug. 2021 Page: iii

Airworthiness Limitations ....................................................................................................................... A-1

A.1 General Information........................................................................................................................... A-1

A.2 Airworthiness Limitations Statement ................................................................................................. A-1

A.3 Life Limits .......................................................................................................................................... A-2

CHAPTER 1 - INTRODUCTION................................................................................................................1-1

1.1 General Information............................................................................................................................1-1

1.2 General Specification (manual) ..........................................................................................................1-2

1.3 How to use the manual ......................................................................................................................1-2

1.4 Measurements....................................................................................................................................1-3

1.5 Units of Measure ................................................................................................................................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 Description..........................................................................................................................................2-1

A. General.........................................................................................................................................2-1

B. Operational Data ..........................................................................................................................2-2

C. Dimensions...................................................................................................................................2-2

2.2 Basic Component Description ............................................................................................................2-9

2.3 Technical Purpose..............................................................................................................................2-9

2.4 Physical Detail...................................................................................................................................2-10

2.5 Theory of Operation ..........................................................................................................................2-11

2.6 Self Excitation Description.................................................................................................................2-11

2.7 Operational Data ...............................................................................................................................2-12

CHAPTER 3 - TROUBLESHOOTING ......................................................................................................3-1

3.1 General...............................................................................................................................................3-1

3.2 Procedure ...........................................................................................................................................3-1

3.3 Alternator Drive Coupling Troubleshooting ........................................................................................3-8

3.4 Alternator Belt Troubleshooting..........................................................................................................3-8

TABLE OF CONTENTS

Aircraft Alternator

Maintenance Manual

24-30-01 ES1031

Page: iv Rev. A: 11 Aug. 2021

CHAPTER 4 - CHECK .................................................................................................................................4-1

4.1 General...............................................................................................................................................4-1

4.2 Inspection Checks ..............................................................................................................................4-1

CHAPTER 5 - INSPECTION & TESTING..............................................................................................5-1

5.1 General...............................................................................................................................................5-1

A. Equipment ....................................................................................................................................5-1

B. Precautions ..................................................................................................................................5-2

5.2 Inspection ...........................................................................................................................................5-2

A. Arc Marks on Terminals (Visual Inspection): ...............................................................................5-2

B. Bearing Inspection (For Troubleshooting Purposes): ..................................................................5-2

C. Field Circuit Open or Ground Test Procedure: ............................................................................5-3

D. Mounting Hardware: .....................................................................................................................5-3

E. Insulators (Washers and Spacers):..............................................................................................5-3

F. Brush holder, 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 ..............................................................................................................................5-4

D. Test Setup ....................................................................................................................................5-5

5.4 Alternator Self Excitation Test (-5 & -5LS only) .................................................................................5-7

CHAPTER 6 - MAINTENANCE ..................................................................................................................6-1

6.1 General...............................................................................................................................................6-1

6.2 Bi-Annual Maintenance ......................................................................................................................6-1

6.3 Torque Information .............................................................................................................................6-2

6.4 Alternator Drive Coupling Inspection & Maintenance .......................................................................6-2

6.5 Alternator Belt & Pulley Inspection & Maintenance............................................................................6-4

6.6 Removal from the Aircraft (Belt Drive) ...............................................................................................6-5

6.7 Exterior Cleaning (direct drive or belt drive).......................................................................................6-7

6.8 Brush Removal

and Installation..........................................................................................................6-7

A. Removal: ......................................................................................................................................6-8

B. Installation: .................................................................................................................................6-8

6.9 Through Bolts .........................................................................................................................................6-8

6.10 Terminal Hardware Removal and Installation ...................................................................................6-10

A. Removal ......................................................................................................................................6-10

B. Installation ...................................................................................................................................6-10

Aircraft Alternator

Maintenance Manual

ES1031 24-30-01

Rev. A: 11 Aug. 2021 Page: v

6.11 Materials ............................................................................................................................................6-12

A. Hardware.....................................................................................................................................6-12

B. Specific Items ..............................................................................................................................6-12

C. Special Items...............................................................................................................................6-12

6.12 Applying Safety Wire .........................................................................................................................6-13

6.13 Applying Safety Cable .......................................................................................................................6-13

6.14 Installation on the Aircraft (Gear Drive).............................................................................................6-13

6.15 Installation on the Aircraft (Belt Drive)...............................................................................................6-13

6.16 Special Conditions:............................................................................................................................6-14

A. Sudden Engine Stoppage

(gear drive):.......................................................................................6-14

B. Sudden Engine Stoppage

(belt drive) .........................................................................................6-14

C. Lightning Strike............................................................................................................................6-15

6.17 Storage and Shelf Life

:......................................................................................................................6-16

A. Storage........................................................................................................................................6-16

B. Shelf Life .....................................................................................................................................6-16

REFERENCES

A. PP2002 - AIRCRAFT ALTERNATOR OVERHAUL MANUAL, ALTERNATOR MODELS: ES-10024 &

ALV-9610

Aircraft Alternator

Maintenance Manual

24-30-01 ES1031

Page: vi Rev. A: 11 Aug. 2021

Thank you for purchasing a PlanePower* alternator. We encourage you to read this manual

thoroughly. It contains a wealth of information about how to properly install and maintain your

alternator so that it may give you many years of safe and reliable service.

Should you have a question regarding your alternator that is not covered in the manual,

Hartzell Engine Technologies Product Support is ready to assist you. We may be reached at

the following contact information:

Phone: +1.334.386.5400, option 2

E-mail: [email protected]

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 involved

in this activity; and they should take all precautions to minimize them, since they

cannot be eliminated entirely. The alternator is an important component of the

aircraft. An alternator failure could result in an unplanned landing or even more

severe consequences creating an unsafe condition that may result in death, serious

bodily injury, and/or substantial property damage. It is, therefore, essential that the

alternator is properly maintained according to the recommended service procedures

and monitored to detect impending problems before they become serious. Any

unusual operation should be investigated and corrected, as it may be a warning of

impending failure.

Aircraft Alternator

Maintenance Manual

ES1031 24-30-01

Rev. A: 11 Aug. 2021 Page: vii

INTENTIONALLY LEFT BLANK

Aircraft Alternator

Maintenance Manual

24-30-01 ES1031

Page: viii Rev. A: 11 Aug. 2021

RECORD OF REVISIONS

Revision

Level

Issue

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Page(s)

Revised Description Date

New 5/05/16 N/A New Release 5/05/16

A 8/11/21 All Approved via PCO-110543; 8/11/21

Formated to comply with FAA Order 8100.54, Appdx A;

Replace Hartzell Engine Technologies logo with PlanePower

logo;

i Change “Owner’s” to “Maintenance”;

󰀨

ii Update copyright date;

iii Update Table of Contents;

v Add References section;

vi Add “*PlanePower is a trademark of Hartzell Engine

Technologies LLC”;

1-2 Add para.1.2 H. Changes and Updates;

Change ES-10024B-( ) to ES-10024B-1 thru -5 and 5LS;

1-3 



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 illustrations for ES10024B-1, -2, -3, -4, -5,

-5LS model alternators;

2-8 Add basic dimension illustration for 6024D alternator;

2-11 Update Figure 2.12 to show alternator exploded view, typical;

2-12 Table 2.1, change temerature ranges to N/A;

Change Minimum regulation speed from 2,200 RPM to 1,800

RPM;

Filter Type: Change 50 µF to .50 µF;

Field Resistance: Change 6.3-6.7 ohm to 14.9-15.4 ohm;

Change * 50 µF to .47 µF;

3-8 Para. 3.3 B.(3), add “and correct the issue”;

5-4 & 5-5 Update para. 5.4, Alternator Bench Testing;

5-8 thru 5-11 Add test illustrations 5-1 thru 5-5;

6-2 Update torque value, Table 6-1, Figure 6.1 (gear), “Output Shaft

Nut”, from 37-42 ft-lbs to 25.0-37.5 ft-lbs;

6-5 Table 6.2, remove alternator ES10024B-7 not covered under

scope of manual;

6-12 Para. 6.11, Materials, update various part numbers;

6.13 Para. 6.15, add sub-paragraph A.

Aircraft Alternator

Maintenance Manual

ES1031 24-30-01

Rev. A: 11 Aug. 2021 Page: ix

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Date

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Aircraft Alternator

Maintenance Manual

24-30-01 ES1031

Page: x Rev. A: 11 Aug. 2021

RECORD OF TEMPORARY REVISIONS

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