You are on page 1of 176

Information Subject to Export Control Laws

Export Permitted Under NLR

COMPONENT MAINTENANCE MANUAL
WITH ILLUSTRATED PARTS LIST
© 1968, 1973, 1975, 1980, 1983, 1984, 1994, 1995, 1997, 2000, 2003, 2007 Hamilton Sundstrand
Corporation
PROPRIETARY
THIS DOCUMENT AND THE INFORMATION CONTAINED HEREIN ARE THE PROPERTY OF HAMILTON SUNDSTRAND CORPORATION
(HSC). RECIPIENT AGREES TO HOLD ALL SUCH INFORMATION IN CONFIDENCE AND AGREES IT SHALL BE USED ONLY FOR
RECIPIENT’S INTERNAL PURPOSES TO MAINTAIN RECIPIENT’S EQUIPMENT OR AS MAY OTHERWISE BE PERMITTED IN AN
APPLICABLE AGREEMENT BETWEEN RECIPIENT AND HSC. THIS DOCUMENT AND THE INFORMATION CONTAINED HEREIN SHALL
NOT BE USED FOR ANY OTHER PURPOSE, INCLUDING THE CREATION, MANUFACTURE, DEVELOPMENT, OR DERIVATION OF ANY
REPAIRS, MODIFICATIONS, SPARE PARTS, DESIGN, OR CONFIGURATION CHANGES, OR TO OBTAIN FAA OR ANY OTHER
GOVERNMENT OR REGULATORY APPROVAL FOR SAME. RECIPIENT AGREES NOT TO DISCLOSE SUCH INFORMATION TO ANY THIRD
PARTY, EXCEPT AS MAY OTHERWISE BE PROVIDED FOR IN AN APPLICABLE AGREEMENT BETWEEN RECIPIENT AND HSC. COPYING
OR DISCLOSURE OF THIS DOCUMENT AND THE INFORMATION CONTAINED HEREIN BY ANYONE WITHOUT HSC’S PRIOR WRITTEN
PERMISSION IS NOT AUTHORIZED AND MAY RESULT IN CRIMINAL AND/OR CIVIL LIABILITY.

AC GENERATOR
PART NUMBERS
976J497-1
976J597-1

NOTICE

THE DATA IN THIS DOCUMENT WERE DEVELOPED ONLY TO MAINTAIN SYSTEMS AND/OR PARTS MANUFACTURED
BY OR FOR HAMILTON SUNDSTRAND OR APPROVED BY HAMILTON SUNDSTRAND. THE DATA MAY NOT BE
APPLICABLE TO ANY OTHER SYSTEMS AND/OR PARTS, REGARDLESS OF THEIR APPARENT SIMILARITY TO
SYSTEMS AND/OR PARTS MANUFACTURED BY OR FOR HAMILTON SUNDSTRAND OR APPROVED BY HAMILTON
SUNDSTRAND. DO NOT RELY IN ANY WAY ON DATA IN THIS DOCUMENT TO MAINTAIN OR OTHERWISE SUPPORT
SYSTEMS AND/OR PARTS THAT WERE NOT MANUFACTURED BY OR FOR HAMILTON SUNDSTRAND OR APPROVED
BY HAMILTON SUNDSTRAND WITHOUT EVIDENCE THAT THE FEDERAL AVIATION ADMINISTRATION OR OTHER
REGULATORY AGENCY HAS DETERMINED THAT THE DATA IN THIS DOCUMENT IS VALID FOR SUCH USE.

HAMILTON SUNDSTRAND ASSUMES NO LIABILITY WHATSOEVER, WHETHER CONTRACTUAL, WARRANTY, TORT
OR OTHERWISE, FOR UNAUTHORIZED ALTERATIONS OR ALTERATIONS NOT PERFORMED IN ACCORDANCE
WITH HAMILTON SUNDSTRAND APPROVED PROCEDURES.

HAMILTON SUNDSTRAND
CAGE CODE 99167

24-20-76

TITLE PAGE, 1
ORIGINAL ISSUE MAR 15/68
REVISION 11
FEB 26/07

HAMILTON SUNDSTRAND
COMPONENT MAINTENANCE MANUAL
PART NUMBER 976J497 AND 976J597
TO ALL HOLDERS OF HAMILTON SUNDSTRAND’S
COMPONENT MAINTENANCE MANUAL 24-20-76
APPLICABILITY: Boeing 737
THIS SHEET TRANSMITS REVISION NO. 11 DATED FEB 26/07
HIGHLIGHTS
We recommend that you put this revision into your manual without delay. After you have put the
revised pages in your manual, mark the Record of Revisions sheet with the new revision number and
date, and write the date that you insert the revised pages into your manual and your initials on the
Record of Revisions sheet in the appropriate spaces.
The revised pages of this manual were reprinted. Please replace these pages of your manual with
the pages of this revision. General format and layout changes were made in addition to these
technical changes.
If you have questions about this manual, you can contact Technical Publications by email at
mailto:tech.pubs@hs.utc.com or fax at (860) 660-9014.
The changes made to the manual during this revision are described in the table that follows.
NOTE: We constantly monitor our parts cataloging system to standardize names and other data that
is common to a part wherever it is used. The changes made by this activity will have change
bars but will not be specifically identified in the Highlights descriptions.
PAGE NUMBER

DESCRIPTION OF CHANGE

All affected pages

Updated warnings. Added metric conversions.

Safety Advisory,
1, 2

Updated the Safety Advisory.

Introduction, 2

Added paragraph 4.

105

Revised the Test Record, Figure 103 (Sheet 2 of 2).

107, 108

Revised paragraphs 1.B.(9)(b) and 1.B.(9)(c).

501

Revised Figure 501 to show Impedance Bridge P/N TS460/u as being no
longer manufactured. Added Digibridge 1750 LCR Tester. Deleted and
added a note.

505, 507, 510, 512

Changed "Miami Repair Center" to "Shannon Repair Center" and added
corresponding address.

506

Revised paragraph 2.D.(2).

511

Revised paragraph 3.A.(4).
HIGHLIGHTS

24-20-76

Page 1
Feb 26/07

1001 Added paragraphs 1. Deleted items 70 and 70C and added items 70A and 70D in IPL Figure 3A. 604. SZA-0105241402. 601 Changed "Miami Repair Center" to "Shannon Repair Center". 605 Added a Military Spec for Commercial Tape and revised the Federal Specification for Isopropyl Alcohol. Revised Figure 901 (Sheet 1 of 4) to show Impedance Bridge P/N TS460/u as being no longer manufactured. 601 Added the NOTEs after paragraph 1. Revised the title of Figure 603.T. Deleted item 30 and added item 30A in IPL Figure 1A. Added the NOTE after paragraph 1.C. The following Hamilton Sundstrand internal documents were included in this revision: HCO-0010200914.A. Added CAGE Codes where applicable in Figure 602. 901.D. 904 Added the NOTE after paragraph 1. 603. 1045 through 1050 Moved IPL Figure 4 to IPL Figure 4A to accommodate top assembly item numbers. 1033 through 1035 Moved IPL Figure 2 to IPL Figure 2A to accommodate top assembly item numbers. 903. 604 Replaced the sealer in steps 2.C. 1003 Added paragraph 2. Deleted items 60 and 130 and added items 60A and 130A in IPL Figure 4A. Revised company name in note. 1016 through 1031 Moved IPL Figure 1 to IPL Figure 1A to accommodate top assembly item numbers. 1036 through 1042 Moved IPL Figure 3 to IPL Figure 3A to accommodate top assembly item numbers. Added a note. and 2.HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 PAGE NUMBER DESCRIPTION OF CHANGE Repair. 702. 701 Added NOTEs after paragraphs 1. 5.C. C6032-AI37847 (C6038-A35762). IH-041025-135044. Added Digibridge 1750 LCR Tester. Repair No. NPC C06-0004-R (IH-06727-14292). 602 Changed "Miami Repair Center" to "Shannon Repair Center" and added corresponding address. 703 Removed addresses and added CAGE Codes to Figure 701.J. Deleted item 430 and added item 430A in IPL Figure 1A. SZA-0107251212.G. Removed addresses in the Vendor Code section of Figure 901.B. NPC 93-0262 (IH-041026-93441).B and 1. HIGHLIGHTS 24-20-76 Page 2 Feb 26/07 . and 1.

THE USER MUST BECOME COMPLETELY FAMILIAR WITH THE MANUFACTURER OR SUPPLIER INFORMATION AND ADHERE TO THE PROCEDURES. Purpose A. paints. and (3) what to do if the dangers occur. B. or other materials that can affect a person’s health or safety. The information contained in the Warnings Registry is a summary of the manufacturer’s MSDS. The warnings do not replace the manufacturer's recommendations. contact the manufacturer and request that a MSDS be supplied before you use the material. solvents. When there is a reference to the Warnings Registry 341-006. WARNINGS. B. Refer to the materials list at the beginning of each section of this manual for materials used to repair and maintain the covered equipment. Warnings are placed just ahead of these procedures to bring attention to the existence of a procedure or material that can be dangerous. (2) what is needed to do to protect you from the dangers. 3. If you do not have a copy of the manufacturer’s MSDS for the materials covered in the materials list. The warnings bring your attention to the existence of a procedure that can affect a person’s health or safety. 2. BE AWARE OF ALL HANDLING. SAFETY ADVISORY 24-20-76 Page 1 Feb 26/07 . STORAGE. Scope A. Short warnings are provided in this maintenance publication to alert operating and maintenance personnel of potential hazards that could result in personal injury or health hazards. AND DISPOSAL OF THESE MATERIALS. A. The full-length warnings provide three principle parts of safety: (1) a listing of the known dangers. RECOMMENDATIONS. STORAGE. Significance of Material Safety Data Sheets (MSDS) and How to Obtain MSDS WARNING: BEFORE USING ANY OF THE MATERIALS SPECIFIED IN HAMILTON SUNDSTRAND MAINTENANCE PUBLICATIONS. THE USER OF THIS PUBLICATION SHOULD OBTAIN THE MATERIAL SAFETY DATA SHEETS (OCCUPATIONAL SAFETY AND HEALTH ACT (OSHA) FORM 20 OR EQUIVALENT) FROM THE MANUFACTURERS OR SUPPLIERS OF MATERIALS TO BE USED. AND CAUTIONS OF THE MANUFACTURER OR SUPPLIER FOR THE SAFE USE. AND DISPOSAL PRECAUTIONS RECOMMENDED BY THE MANUFACTURER OR SUPPLIER. that publication will provide more information about the dangers of the material. FAILURE TO COMPLY WITH MANUFACTURER'S OR SUPPLIER'S RECOMMENDATIONS MAY RESULT IN PERSONAL INJURY OR DISEASE. HANDLING. It may also cover high energy procedures that can affect a person’s health or safety.HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 SAFETY ADVISORY 1. This publication describes processes that may require the use of chemicals.

SAFETY ADVISORY 24-20-76 Page 2 Feb 26/07 .com or fax at (860) 660-9014 if you find a material in a Hamilton Sundstrand maintenance document that is known to be covered by a material safety data sheet (MSDS). Shock (Electrical): the result of any source of electricity more than 50 volts that causes current to flow through a person and can result in dangerous burns to human tissues or death. Exposure: contact with the material or physical process without protection. or pilot lights. D. sparks. but is not covered by a warning in the procedure. G. rash. skin absorption. E. soreness. D. or general discomfort. Cautions are provided in the maintenance publication or service bulletin to alert operating and maintenance personnel to conditions that could result in equipment damage. Flash Point: the lowest temperature at which a flammable liquid gives off fumes that can burn. breathing. C. (2) Sparks: materials such as lighted cigarettes.HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 4. Reporting Materials or Processes Not Covered A. Irritation: any sense of pain. propane torches.utc. Flammable: a material that can catch fire easily and can be explosive. electrical motors. burn. H. or heat. or can be explosive when mixed with certain other materials. Ignition Source: includes flames. Reactive: material that will make fumes. touch. or static electricity. Corrosive: acidic or alkaline material that will remove human tissue or create chemical reactions with other materials. You may contact Technical Publications personnel by email at mailto:tech. 5. C. or swallowing. B. The detailed warnings in Warnings Registry 341-006 are a summary of the manufacturer’s MSDS and are not intended to replace the material on the sheet. Definitions Applying to Warnings A. heated tools. F. (1) Flames: materials that are burning such as lit matches. Toxic: material that is poisonous. (3) Heat: any source of energy that will raise the temperature of a flammable material to its flash point and could include hot parts. or direct sunlight. These materials are labeled according to the flash point of the material. Contact may be by the eyes.pubs@hs. but are intended to supplement them. I.

1 Sep 1/73 Sep 1/73 S 2 Sep 15/75 Sep 15/75 S 3 Jun 1/80 Jun 1/80 DATE REV INSERTED BY NO.HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 RECORD OF REVISIONS REV NO. ISSUE DATE DATE REV INSERTED BY NO. ISSUE DATE DATE INSERTED BY S 4 Aug 15/83 Aug 15/83 S 5 May 1/84 May 1/84 S 6 Nov 1/94 Nov 15/94 S 7 Dec 15/95 Dec 30/95 S 8 May 1/97 May 15/97 S 9 Jun 1/00 10 ISSUE DATE Jun 23/00 HS Feb 25/03 Feb 26/03 HS 11 Feb 26/07 Feb 27/07 HS RECORD OF REVISIONS 24-20-76 Page 1 Jun 1/00 .

.

PAGE NUMBER ISSUE DATE BY DATE REMOVED BY RECORD OF TEMPORARY REVISIONS 24-20-76 Page 1 Jun 1/00 . NO.HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 RECORD OF TEMPORARY REVISIONS TEMPORARY REV.

.

and the date the service bulletin was incorporated in the manual (manual revision date).) BULLETIN DATE INCORPORATED 70-103 Oct 30/70 Sep 1/72 71-103 Rev. if applicable.HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 SERVICE BULLETIN LIST The Service Bulletin List identifies the service bulletin number and revision number. 1 Feb 1/80 Mar 1/80 79-103 Nov 1/79 Mar 1/80 45 Sep 26/72 Apr 15/75 48 Oct 30/73 Apr 15/75 Service News Letter SERVICE BULLETIN LIST 24-20-76 Page 1 Jun 1/00 . SB SERVICE BULLETIN SERVICE DATE REF NO. NUMBER (REVISION NO. the date of the service bulletin. 1 Oct 1/72 Apr 15/75 72-101 Mar 15/72 Apr 15/75 78-103 Rev.

.

5 601 602 603 604 605 Feb 26/07 Jun 1/00 Feb 26/07 Feb 26/07 Jun 1/00 Repair No. 2 601 602 603 604 605 Jun 1/00 Jun 1/00 Jun 1/00 Jun 1/00 Jun 1/00 Repair No. 3 601 602 603 Jun 1/00 Jun 1/00 Jun 1/00 Repair No.HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 LIST OF EFFECTIVE PAGES Subject Page Date Title Page 1 Feb 26/07 Highlights 1 2 Feb 26/07 Feb 26/07 Safety Advisory 1 2 Feb 26/07 Feb 26/07 Record of Revisions 1 Jun 1/00 Record of Temporary Revisions 1 Jun 1/00 Service Bulletin List 1 Jun 1/00 List of Effective Pages 1 2 Feb 26/07 Feb 26/07 Table of Contents 1 Jun 1/00 Introduction 1 2 Feb 26/07 Feb 26/07 Description and Operation 1 2 Jun 1/00 Jun 1/00 Testing and Fault Isolation 101 102 103 104 105 106 107 108 Jun 1/00 Jun 1/00 Jun 1/00 Jun 1/00 Feb 26/07 Jun 1/00 Feb 26/07 Feb 26/07 Automatic Test Requirements 201 Jun 1/00 Disassembly 301 302 303 304 Jun 1/00 Jun 1/00 Jun 1/00 Jun 1/00 Cleaning 401 Jun 1/00 Check 501 502 503 504 505 506 507 508 509 Feb 26/07 Feb 26/07 Feb 26/07 Jun 1/00 Feb 26/07 Feb 26/07 Feb 26/07 Jun 1/00 Jun 1/00 Subject Page Date 510 511 512 513 514 515 516 517 518 519 520 521 522 523 524 525 526 Feb 26/07 Feb 26/07 Feb 26/07 Feb 26/07 Jun 1/00 Jun 1/00 Jun 1/00 Jun 1/00 Jun 1/00 Jun 1/00 Jun 1/00 Jun 1/00 Jun 1/00 Jun 1/00 Jun 1/00 Jun 1/00 Jun 1/00 Repair 601 602 603 604 605 Feb 26/07 Feb 26/07 Feb 26/07 Feb 26/07 Feb 26/07 Repair No. 6 601 602 Jun 1/00 Jun 1/00 Check (Continued) LIST OF EFFECTIVE PAGES 24-20-76 Page 1 Feb 26/07 . 4 601 602 603 Jun 1/00 Jun 1/00 Jun 1/00 Repair No. 1 601 Jun 1/00 Repair No.

HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 Subject Repair No. and Equipment 901 902 903 904 905 906 907 908 909 Feb 26/07 Feb 26/07 Feb 26/07 Feb 26/07 Jun 1/00 Jun 1/00 Jun 1/00 Jun 1/00 Jun 1/00 Illustrated Parts List 1001 1002 1003 1004 1005 1006 1007 1008 1009 1010 1011 1012 1013 1014 1015 Feb 26/07 Feb 26/07 Feb 26/07 Feb 26/07 Feb 26/07 Feb 26/07 Feb 26/07 Feb 26/07 Feb 26/07 Feb 26/07 Feb 26/07 Feb 26/07 Feb 26/07 Feb 26/07 Feb 26/07 Subject Page Illustrated Parts List 1016 (Continued) 1017 1018 1019 1020 1021 1022 1023 1024 1025 1026 1027 1028 1029 1030 1031 1032 1033 1034 1035 1036 1037 1038 1039 1040 1041 1042 1043 1044 1045 1046 1047 1048 1049 1050 Date Feb 26/07 Feb 26/07 Feb 26/07 Feb 26/07 Feb 26/07 Feb 26/07 Feb 26/07 Feb 26/07 Feb 26/07 Feb 26/07 Feb 26/07 Feb 26/07 Feb 26/07 Feb 26/07 Feb 26/07 Feb 26/07 Feb 26/07 Feb 26/07 Feb 26/07 Feb 26/07 Feb 26/07 Feb 26/07 Feb 26/07 Feb 26/07 Feb 26/07 Feb 26/07 Feb 26/07 Feb 26/07 Feb 26/07 Feb 26/07 Feb 26/07 Feb 26/07 Feb 26/07 Feb 26/07 Feb 26/07 LIST OF EFFECTIVE PAGES 24-20-76 Page 2 Feb 26/07 . Fixtures. 8 601 602 Jun 1/00 Jun 1/00 Repair No. 9 601 Jun 1/00 Repair No. 7 Page 601 Date Jun 1/00 Repair No. 11 601 602 603 Jun 1/00 Jun 1/00 Jun 1/00 Assembly 701 702 703 704 705 706 707 708 Feb 26/07 Feb 26/07 Feb 26/07 Feb 26/07 Feb 26/07 Feb 26/07 Feb 26/07 Feb 26/07 Fits and Clearances 801 802 803 Jun 1/00 Jun 1/00 Jun 1/00 Special Tools. 10 601 602 Jun 1/00 Jun 1/00 Repair No.

..........................................HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 TABLE OF CONTENTS Subject Page Description and Operation ............... 101 Automatic Test Requirements ...................................................................................................................................................................................... 501 Repair ............ and Equipment ................................................................ 801 Special Tools............................................................................................................................................................................................................................................. 401 Check .................................................................................................................................................................................................. 1001 TABLE OF CONTENTS 24-20-76 Page 1 Jun 1/00 .................................................................................................................................................. 701 Fits and Clearances ..................................................................... 1 Testing and Fault Isolation ............................... 201 Disassembly ..................... 301 Cleaning ..................................................... 901 Illustrated Parts List ..................................... Fixtures........................................................................................................................ 601 Assembly (Including Storage) ......

.

Generator 976J597-1 has rotor and stator laminations made from CUBEX electrical sheet steel. 2. Box 7002.O. Rockford. This manual contains maintenance information for generators 976J497-1 and 976J597-1. 4747 Harrison Ave. P. IL 61125-7002.A. General A. a United Technologies Company. Reference Service News Letters 45 and 48 for discontinuance of this generator. The CUBEX steel parts are no longer available. Configuration Differences A. Generator 976J497-1 has rotor and stator laminations made from conventional silicon steel (AISI M-15). U.. Differences among the various generator part numbers are listed below: (1) 3.S.HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 INTRODUCTION 1. List of Abbreviations ABBREVIATION DEFINITION ABBREVIATION DEFINITION AC Alternating Current HP Horsepower Hz Hertz CCW Counterclockwise IPL Illustrated Parts List CFM Cubic Feet Per Minute kVA Kilovolt Ampere CT Current Transformer L-N Line-to-Neutral CW Clockwise mA Milliampere DC Direct Current MAX Maximum EFA Exciter Field Current MIN Minimum EFR Exciter Field Resistance Vdc Volts Direct Current EFV Exciter Field Voltage GCU Generator Control Unit INTRODUCTION 24-20-76 Page 1 Feb 26/07 . The AC Generator is manufactured by Hamilton Sundstrand.

Statement of Verification SECTION Testing and Troubleshooting Disassembly Assembly METHOD Review of source documentation Review of source documentation Review of source documentation DATE ------- INTRODUCTION 24-20-76 Page 2 Feb 26/07 .HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 4.

. The voltage regulator rectifies the voltage signal and returns a controlled signal to the generator through pins A. . . . . . . . . . . . . . . . . . . . . . . . . . . .and F. . . . . . . . . . . . . . . . . . 5700/6300 rpm Rotation (facing end opposite drive) . . . . . . . .5 lbs (30. 83. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Description A. . . . main rotating field. . . . . . . . . . . . . cutting conductors in the stationary armature produces three-phase alternating current output to the main terminals. . . . . . . . . . . . . . . . alternating current stationary armature. . . . . . . . . . . . . . . . (279. . . . . . . . . . . . . . . . . . . . . . . . a three-phase full-wave rectifier bridge and a capacitor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Amperes Phase . . . . . . . DESCRIPTION AND OPERATION 24-20-76 Page 1 Jun 1/00 . . . . . . . . . . . . . . . . . The magnetic field. . . . . .82 in. . exciter stationary field. . . . . . . . . . . . . .30 kVA Voltage . . . . . . . 380/420 Hertz Current . . (300. . . . . .HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 DESCRIPTION AND OPERATION 1. . . . . .00 in. . . . . . . . T2. . . Operation A. . . . . which is in turn driven by the aircraft engine. . . . This current excites the main rotating field where it sets up a magnetic flux in the field poles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B. . . . . . . . . air cooled. . . . . . . . . . . . . . . . This is then fed to the three-phase full-wave rotating rectifier where it is rectified to direct current. . . . . . . . . . . . . . . . . . . . . . . . . . . 915F316 Size: Maximum Length From Mounting Flange . . . . . . . . . . . 11.62 kg) Specifications Figure 1 2. . . . . . . . . . These permanent magnets provide a minimum residual voltage from the generator to the regulator to assure buildup under all conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications of the generator are shown in Figure 1 below. . . . . . . . . . . . . . . . . .75 kg) Maximum Weight for 976J597-1 . . . Turning the rotor produces a voltage buildup as a result of the residual magnetism or flux from the permanent magnets. . . . . . . . . . . . . . Rating . . . . . . . . . . . . . . . . . . . . . . . . . T3/T2. . . . . . . . . . This produced voltage is fed to the voltage regulator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . This voltage excites the exciter field and produces a threephase alternating current voltage in the rotating exciter armature. . . . The stationary exciter winding has permanent magnets between the coils. . . . . . . . . . . . . . . . . .22 mm) Maximum Height . . . . . . . . . . . . It consists of an exciter rotating armature. . . . . . . . . . . . . . . . . . 70 lbs (31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T1. . T3 Outline (Installation Drawing) . . . . . . CCW/CW Phase Rotation . . . 120/208 Volts AC Frequency . T1. . . . . . . . . . . 3 Power Factor . . . . . . brushless machine designed for use in aerospace applications to provide alternating current power for aircraft electrical systems. . . . . . . . . . . . . . . .75 Speed . . . . . 11. . . . . . . . . . . . .40 mm) Maximum Weight for 976J497-1 . . . . . . . . . . . 67. . . . . . . . It is driven and held within the speed range by a constant speed transmission. . . . . . . . . . . . . . . . . . . The generator is a self-excited. 0. . . .

The copper rings are reinforced by steel bands fitted over them. The leads from the three stator phases are brought directly to the upper surface of the terminal board. the amortisseur windings serve to reduce excessively high voltage transients caused by the line-to-line system faults. F. The alternating current armature is designed to have a high reactance so that its excitation requirements are dependent on exciter load current rather than on exciter load voltage. In isolated generator operation. The exciter. to damp out torsional vibration originating in the generator drive. The coils are mounted on eight poles which are each an integral portion of the main laminated or stacked core rotor. A thermistor (negative temperature coefficient resistor) is placed. Heavy. E. providing a three-phase alternating current output voltage of 208 volts line-to-line and 120 volts line-to-neutral at a frequency of 400 hertz with a nominal input speed of 6000 revolutions per minute. thus aircraft wiring can be clamped directly against them without current passing through the terminal studs. A capacitor is connected across the direct current output of the full-wave bridge to provide transient voltage suppression. D. wedge shaped amortisseur windings are mounted between the pole faces. The rotating rectifier consists of six silicon power diodes connected in a three-phase fullwave bridge. in series. which provides power for the rotating field. Each set of coils consists of two coils. connected in series with alternate polarities. These windings are wye connected. The output windings or stationary armature of the main generator consist of lap wound coil groups arranged in 120 degree phase belt windings on a slotted laminated stator.HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 B. C. with one of the windings in order to provide near constant exciter field resistance over the temperature range encountered by the generator. The diodes have a reverse voltage rating equal to 150 percent of the measured transient overvoltage under the most severe operating conditions. which are assembled concentrically on a single pole and connected in like polarity. Both ends of each of the three phase windings are brought out to a terminal board mounted externally on the generator frame. The stationary field has two windings in parallel. These amortisseur windings are interconnected by circular copper rings on both sides of the rotor. The main rotating field consists of eight sets of field coils. uses a stationary direct current field and a rotating alternating current armature. a larger and a smaller. and to decrease voltage unbalance during unbalanced loads. Direct current excitation current from the rotating rectifier produces a flux in the eight poles which in turn induces output voltage in the main stator windings. This is used to reduce the commutation voltage and to control other overvoltages caused by system transients which could subject the diodes to excessive peak reverse voltage. DESCRIPTION AND OPERATION 24-20-76 Page 2 Jun 1/00 . Amortisseur (damper) windings are provided in longitudinal slots in the pole faces. They also function as wedges to retain the field windings in place.

(6) Before connecting the generator to the test stand. Type XVI-C. (1) Mount the generator on the test stand and connect to load bank metering and control circuits (See Figures 101 and 102) for connections to the regulator or generator control unit being used for testing. T3 and T6. Preparation and Conditions for Test (See Figures 101 and 102) (1) The generator shall be mounted on a test stand having an intermittent four hour rating of not less than 65 horsepower at 6000 revolutions per minute and a maximum acceleration rate of 1500 revolutions per minute per second. (2) Cooling air shall be provided to the generator through adapter 938D844-3. The stand shall permit generator flange mounting in accordance with AND10266. The impedance shall be balanced to obtain equal short circuit currents in each phase. NOTE: During all tests.HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 TESTING AND FAULT ISOLATION 1. (4) The load bank should be located so as not to appreciably affect the ambient temperature or cooling air temperature. and F and A-. with rotor axis horizontal. perform a continuity check between generator terminals T1 and T4. T2 and T5. shall not be more than 10 degrees Celsius (18 degrees Fahrenheit) higher or lower than the ambient temperature. the three line-to-neutral load voltages shall be balanced within one volt. Test Procedure The following tests are to be run in the sequence shown. (5) Provisions shall be made for a three-phase short circuit impedance sufficiently low so that the voltage measured at the generator terminals does not exceed 15 volts line-to-neutral. B. It shall be 461 to 509 ohms for generators 976J497 and 446 to 494 for generator 976J597. CARE SHOULD BE TAKEN TO AVOID CONTACT WITH CONDUCTING PARTS OF THE CIRCUIT. (7) Check the resistance values between S and A-. (3) The ambient temperature in the test area shall be 10 to 40 degrees Celsius (50 to 104 degrees Fahrenheit). measured at the adapter. The cooling air supply. The line voltage shall remain stable under both load switching and steady state conditions. A. The air supply shall be capable of supplying up to 250 cubic feet per minute (118 liters per second) and be adjusted to provide a constant head pressure of two inches (498 pascals) of water measured at the adapter. TESTING AND FAULT ISOLATION 24-20-76 Page 101 Jun 1/00 . Test WARNING: THE TEST PROCEDURES OUTLINED IN THIS SECTION INVOLVE HIGH VOLTAGE CIRCUITS.

3 pole. 0 to 300. 1 pole. ± 2 percent or better.3 phase.Ammeter. M5 . 400 hertz. 10 kilohertz bandwidth or better. Load Metering . R1 . 30 kilowatts resistive. 400 hertz. SPST.5 ± 1 percent ohms.Circuit Breaker. * Leave oscilloscope ungrounded when testing with regulator 939D150.Ammeter. 3 phase.Voltmeter. S2 . 15 ampere at 125 volts. alternating current average or root-mean. . 1 percent balance. 220 volt. 115 volts line-to-neutral. 0 to 5 amperes direct current. 3 phase.Voltmeter. 3 position.Metering. 0. 0 to 50 volts direct current. 10 amperes at 250 volts. transformers and switches to read up to 50 kilowatts total load and individual phase currents up to 150 amperes.Circuit Breaker. M6 .Resistor. Generator Test Circuit Figure 101 TESTING AND FAULT ISOLATION 24-20-76 Page 102 Jun 1/00 . . 400 hertz average or root-mean-square. 600 Amperes.Switch. . Load Bank . 220 volt.* . 400 hertz ± 2 percent or better. 50 horsepower. 0 to 30.Phase sequence indicator.Oscilloscope. ± 3 percent or better. . 2 ampere. S1 . ON-OFF. 0 to 150. Nema size 4. selector.Switch. 3 pole.HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 A-67163 CB1 CB2 M1 M2 M3 M4 . ± 2 percent or better. 25 watt.square.

check the exciter field current on M6.3 line amperes. *** If CT package is used. unity power factor. (3) (4) Test 1 . 30 kilowatt. The total KW load shall be within ± 2. close the field switch and apply 30 kilowatt load. In either case. Connections to Test Circuit Figure 102 (2) The normal phase sequence for connecting the generator shall be T1. TESTING AND FAULT ISOLATION 24-20-76 Page 103 Jun 1/00 . as viewed from the end opposite the mounting flange. the rotational speed of the generator shall be maintained within ± 15 RPM of that specified. Test 2 . T2. phase sequence at the regulator or generator control unit terminals shall be T1. ** Make certain the GCR is closed in generator control unit before connecting into test circuit. T2.EFA. This record shall be retained in accordance with airworthiness authority requirements. For clockwise rotation change the generator connections to T1. short out all transformers that are not used. Make a copy of Figure 103 and use the copy to record test results.Warm-Up (a) Operate the generator at 6000 revolutions per minute. T2. The current shall not exceed 1. T3 for counterclockwise rotation. based on local requirements. EFV Resistance Limits and Diode Check (a) After the generator has stabilized at 6000 revolutions per minute. NOTE: During all tests. (b) Allow the generator to stabilize for 20 minutes. 83.0 ohm resistor across terminals X1 and X2 of Regulator 905D977-3 or terminals 15 and 16 of Regulator 939D150.HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 Test Circuit Regulator Regulator GCU Regulator Leads 905D977-3* 939D150* 915F212 ** T1 T1 1 A39 T2 T2 3 A41 T3 T3 5 A40 CT1 CT1 12 A42 CT2 CT2 13 A44 CT3 CT3 14 A43 F F 19 B9 AA28 B3 S S --GND G 7 -CURRENT 25B8904-2 OR 906D896-3 TRANSFORMER 950D968-3*** *** * Connect a 1. T3. (2A) Optional. T3.25 % and the average three phase load current shall be within ± 3% of that specified.7 amperes maximum.

NOTES A . CAUTION: FAILURE TO OBSERVE NOTE B MAY RESULT IN DAMAGE TO THE MAIN ARMATURE AND STATOR WINDINGS.7 MAX ---- ---- 6. B .0 volt.Residual voltage test is run with field switch open and no load. Test is to be performed with field switch open.3 0 30 0 1. E .The three phase short circuit is to be on for 5 seconds maximum.T5 T3 .Stabilize for 5 minutes and then read meters. Only the voltage and current for phase A is to be measured and recorded.T6 (F) . then record readings.HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 Continuity Check Resistance T1 . Observe oscilloscope trace and record condition of diode assembly by comparing trace to Figures 104 and 105.(A-) (OK) S/N (OK) (OK) ORDER _________ (OK) (461/509 OHMS) (P/N 976J497) (446/494 OHMS) (P/N 976J597) Rotation (CW) ONLY Phase Sequence (T1-T2-T3) TEST NO 1&2 PHASE VOLTS * φA φB φC LINE KILO- EFA EFV EFR AMPS WATTS AMPS VOLTS OHMS 120 83.Close field switch and allow 20 minutes warm-up under full load.2/8.0 ---- 0 ---- ---- ---- 3 15 max 4 0 250 MIN 0 5 120 6 83.(A-) (S) .Overspeed test is to be run only if armature rotor assembly has been replaced or repaired. D . Test Record Figure 103 (Sheet 1 of 2) TESTING AND FAULT ISOLATION 24-20-76 Page 104 Jun 1/00 . C .3 30 0 1.2/8.T4 T2 .7 MAX ---- 6.0 ---- ---- RECORD RPM 6000 NOTES A ACTUAL 6000 B Phase A Only C 9000 6000 D 6000 E 12/19 (16/20 ccw) * Output voltages should be balanced within 1.(A-) (S) .

C.HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 DIODE TEST OK Dielectric Test (Reference Paragraph B. *TESTER *Q. 60 Hz REJECT (OK) Phase to Phase .T2 T2 .60 Hz T1 .9 AC Windings to Ground .900 Vac.900 Vac .T3 T1 .T3 (OK) (OK) (OK) S/N ORDER This unit meets test criteria. Acceptance * Date & Sign Test Record Figure 103 (Sheet 2 of 2) TESTING AND FAULT ISOLATION 24-20-76 Page 105 Feb 26/07 .

Good Figure 104 A-67165 Oscilloscope View of Exciter Current (EFA). (b) The line voltages. TESTING AND FAULT ISOLATION 24-20-76 Page 106 Jun 1/00 . Bad Figure 105 (5) Test 3 . A-67164 Oscilloscope View of Exciter Current (EFA).2 and 8. (c) The exciter field current shall appear as shown in Figure 104. a defective diode or open exciter armature winding is indicated. shall not exceed 15 volts and the short circuit current on M5 shall not be less than 250 amperes per phase. measured at the generator terminals. may be used as an alternate method of checking the diodes. Diode test set 939D192-1. If it appears as shown in Figure 105.Short Circuit Capacity (a) Operate the generator at 6000 revolutions per minute and apply a short circuit on the generator by closing CB2 for 5 seconds.HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 (b) The exciter field resistance shall be between 6.0 ohms when calculated by dividing the exciter field voltage on M1 by the exciter field current.

700 revolutions per minute. WARNING: ELECTRIC SHOCK CAN OCCUR WHEN USING A HIGH POTENTIAL TESTER. There shall be no breakdown in insulation. with the field switch open. (b) Connect the AC terminals T4. CAUTION: DO NOT REMOVE OR APPLY THE PROBES OF THE INSULATION BREAKDOWN TEST SET EXCEPT AT ZERO VOLTAGE. PERSONNEL WORKING WITH ELECTRICITY SHALL HAVE ANOTHER PERSON SKILLED IN MODERN METHODS OF FIRST AID AND RESUSCITATION NEAR BY. NOTE: Clockwise rotational check is only required for older applications (707 or 720) where the generator operates clockwise. with the field circuit open and no load on the generator. TESTING AND FAULT ISOLATION 24-20-76 Page 107 Feb 26/07 . Apply a test potential of 900 volts root-mean-square. After 5 minutes reduce generator speed to 5.Recheck of Short Circuit Capacity (a) Stabilize at 6000 revolutions per minute for 5 minutes to recheck the generator following short circuit and overspeed tests. Test 6 . no load. DO NOT TOUCH EXPOSED UNINSULATED CONNECTIONS.required only if the armature-rotor assembly has been replaced or if major repairs have been made on the rotor windings. COMPONENETS BEING TESTED OR THE TESTING SURFACE.HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 (6) (7) (8) Test 4 . Slowly increase test potential from zero at a rate not to exceed 500 volts per second. Dielectric Test (a) Before preceding with this test. T5. 60B4-1or 2512 to ground check between the terminals and the frame. Test 5 . (b) Repeat Test 2.Overspeed (Optional . 60 hertz. and T6 together and use insulation breakdown test set 103MP-2.) (a) Operate the generator at 9000 revolutions per minute for 5 minutes. Make the following tests. (b) The generator shall show no signs of mechanical or electrical failure. (b) (9) The generator terminal voltage (residual) on M4 shall be 12 to 19 for clockwise rotation and 16 to 20 for counterclockwise rotation.Residual Voltage (a) Operate the generator at 6000 revolutions per minute. for one minute. remove the generator from the test stand and disconnect all wires.5DJU. 13700-1C. Reduce at same rate before removing connections.

General (1) Locate fault symptom. (10) Final Inspection (a) 2. 1. 2. Check for opens or shorts. 1. See CHECKS. Fault Isolation A. Faulty external connections. 1. for one minute between phases as follows: Terminals T1 and T2 Terminals T2 and T3 Terminals T1 and T3 There shall be no more than 5 milliamperes compensated current leakage breakdown in insulation. Exciter Armature. Faulty diodes. Troubleshooting Chart Figure 106 TESTING AND FAULT ISOLATION 24-20-76 Page 108 Feb 26/07 . Rotating Field. 5. and corrective action in Figure 106. Replace spindle. 3. 4. See CHECKS. 2. Low residual voltage Faulty permanent magnets Replace exciter stator. Check for opens or shorts. High exciter field current. Shorted diode in rectifier assembly. Carefully inspect the generator and determine that all screws (inside and out) are safety wired or otherwise securely locked. and T6. Exciter Winding. 5. Check for opens or shorts. Waveforms for field current not as shown. 1. Fault exciter armature. See CHECKS. 2. Check connections. 2. T5. Use insulation breakdown test set and the same rate of application to check for phase-to-phase shorts by applying a test potential of 900 volts root-mean-square. 60 hertz. No voltage buildup. NOTE: Proper compensation requires adjusting the Control Knob on the Slaughter test set for the lowest microampere indication possible with the windings connected to the test lead. FAULT SYMPTOM PROBABLE CAUSE CORRECTIVE ACTION Sheared generator spindle. probable cause. 4.HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 (c) Remove jumper from T4. 3.

AUTOMATIC TEST REQUIREMENTS (ATLAS) 24-20-76 Page 201 Jun 1/00 .HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 AUTOMATIC TEST REQUIREMENTS (ATLAS) 1. General There are no (ATLAS) requirements for AC Generators P/N 976J497-1 or 976J597-1.

.

NOTE: Reference to item numbers in text implies that alpha variant items listed in the IPL may be used as determined by the effect code for that item. Tool Number Description 908C714-1 910C176-1 Spline Wrench Mechanical Puller 916B366-11 Step Plate 916B366-17 Step Plate 918B448-1 Adapter 922B865-2 Spanner Wrench See Figure 901 Generator Support See Figure 902 Cradle Fixture See Figure 903 End Bell Removal Tool Special Tools and Equipment Figure 301 DISASSEMBLY 24-20-76 Page 301 Jun 1/00 . thoroughly cleaned. checked. -1B. Parts recommended for discard are listed in Figure 302.HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 DISASSEMBLY 1. and -1C). reference to item (1) means that procedures also apply to alpha variant items (-1A. An AC generator that is in for overhaul (approximately 6. A. Equivalent tools may be used. References to item numbers in the text and accompanying illustrations are identical to those in the ILLUSTRATED PARTS LIST. D. DISASSEMBLY.000 operational hours) should be disassembled to the complete extent of DISASSEMBLY. When necessary. The input shaft should turn freely and with no excess noise. If no fault is found the AC generator should be tested to verify that a fault exists before starting disassembly. 24-10-00. C. For example. An AC generator removed for fault prior to the overhaul interval should be visually examined for for obvious damage. and have the bearings replaced. Disassemble the AC generator only to the extent required to correct faults. for general disassembly procedures. General This section contains disassembly procedures. B. Refer to FITS AND CLEARANCES for summarized disassembly information. Refer to Standard Practices Manual. disassembly illustrations are also provided. Special tools used for disassembly are listed in Figure 301.

Place AC generator on its side in a horizontal position. Remove retaining ring (2. CAUTION: DO NOT REMOVE THE SIX SCREWS THAT HAVE EPOXY COMPOUND IN THEIR HEADS. NOTE: Do not use an allen wrench with ball head or chamfered head to remove screws (9A) as these types of wrench heads cause the wrenching surface of the screws to distort and make it difficult to obtain the correct torque and will make it difficult to remove these screws. Remove and discard packing (3). shouldered washer (5). C. THESE SCREWS HOLD THE END BELL TOGETHER AND SHOULD NEVER BE REMOVED. F. Remove six screws (9) and backing ring (8). Remove machine screw (6) using spline wrench 908C714-1 to hold spline adapter (4). Remove spindle cover (1) carefully using a pick or scribe to lift around the outside diameter of the spindle cover. DISASSEMBLY 24-20-76 Page 302 Jun 1/00 . Disassembly A. Place the AC generator drive end down on generator support (See Figure 901). E. Remove spline adapter (4). B.HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 IPL Figure 1 Nomenclature and Item Number 1 Preformed Packing (3) Machine Screw (6) 1 Preformed Packing (7) 1 Screw (9 or 9A) 1 Bearings (36) 1 Shields (37) 1 Screw (54 or -54A) 1 Key Washer (39) 3 Preformed Packing (6) 3 Preformed Packing (7) Parts Recommended for Discard Figure 302 2. and packing (7). D. G. IPL Figure 1) using retaining ring plier.

Remove retaining ring (38) using retaining ring plier. WARNING: WEAR GOGGLES WHEN REMOVING LOCKWIRE. R. Remove drive-end bearing (36) using step plate 916B366-11 and puller 910C176-1.HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 H. DISASSEMBLY 24-20-76 Page 303 Jun 1/00 . Remove end bell (52) using end bell removal tool (See Figure 903) to gently tap around inside of the end bell outside diameter. S. Remove screws (54). L. Bend tab of key washer (39) out of nut (40). Remove rotating parts (36 through 42) and set in cradle fixture (See Figure 902). NOTE: Do not use an allen wrench with ball head or chamfered head to remove screws (10) as these types of wrench heads cause the wrenching surface of the screws to distort and make it difficult to obtain the correct torque and will make it difficult to remove these screws. T. N. Remove one shield (37) and bearing cover (41). NOTE: Do not use an allen wrench with ball head or chamfered head to remove screws (54) as these types of wrench heads cause the wrenching surface of the screws to distort and make it difficult to obtain the correct torque and will make it difficult to remove these screws. I. CAUTION: DO NOT SET ROTATING COMPONENTS DIRECTLY ON THE WORK BENCH AS THEY MAY ROLL OFF THE BENCH AND THUS BE DAMAGED. Cut and remove lockwire from screws (54). J. M. P. Remove end bell (30) using puller 910C176-1 and adapter 918B448-1. Remove key washer (39) and one shield (37). Remove screws (11). Remove nut (40) using spanner wrench 922B865-2. washers (12). Remove one shield (37). U. Q. and washers (53). NOTE: The tool must be slightly curved in order to reach under the stator windings and out to the outside diameter of the end bell. CAUTION: DO NOT TAP END BELL TOO HARD AS IT MAY DISTORT THE END BELL WHICH CAN CAUSE SUBSEQUENT BEARING DAMAGE. O. Lift AC generator so that the armature-rotor spindle rests on the generator support (not in the hole) and press down on generator stator until the drive end bearing (36) is pressed out of end bell (52). K. and bearing cover (10).

Y. W.HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 V. For further disassembly. Remove antidrive-end bearing (36) using step plate 916B366-17 and puller 910C176-1. NOTE: No farther disassembly is required at overhaul unless checks indicate a defective part. refer to REPAIR. Remove screws (2. Remove retaining ring (5) using retaining ring plier. Remove one shield (37) and bearing cover (41). X. DISASSEMBLY 24-20-76 Page 304 Jun 1/00 . IPL Figure 3). Z. Remove spindle (3) and retainer seal (4) using a rawhide or soft-faced mallet to tap on the spindle. AA. Remove stub shaft (1) using a rawhide or soft-faced mallet to tap around the flange of the stub shaft.

for Ultrasonic Cleaning method. 2. IL 61125-7002 Indicator papers or pH meter Commercially Available Cleaning Materials Figure 401 WARNING: WHEN USING COMPRESSED AIR FOR CLEANING OR DRYING. CLEANING. REGULATE PRESSURE TO 29 POUNDS PER SQUARE INCH (200 KILOPASCALS) OR LESS. WEAR GOGGLES OR FACE SHIELD TO PROTECT EYES.Alternate Method Refer to Standard Practices Manual. CLEANING 24-20-76 Page 401 Jun 1/00 . NOTE: Remove particles from the permanent magnet poles with pressure-sensitive tape or with compressed air. P. Material Source Detergent Commercially Available Water. Soft Commercially Available Tape. Refer to Figure 201 for materials used to clean parts. Pressure Sensitive Commercially Available Ultrasonic Cleaning Equipment or equivalent Hamilton Sundstrand 4747 Harrison Ave. Ultrasonic Cleaning . Special instructions to clean parts are given in paragraph 2. 24-10-00. Box 7002 Rockford.HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 CLEANING 1. 24-10-00.O. General Refer to Standard Practices Manual. for the general procedures used to clean parts. CLEANING.

.

Special tools and equipment required for checks are listed in Figure 501.HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 CHECK 1. Refer to Standard Practices Manual 24-10-00. General A. for general check information.5DJU 60B4-1 13700-C1 2512 TS460/u Digibridge 1750 LCR Tester Air Snap Gage Master Setting Disks with Hose Assembly Checking Fixture Kelvin Bridge (Note 1) Surge Comparison Test Set Insulation Breakdown Test Set (Note 2) Insulation Breakdown Test Set Insulation Breakdown Test Set Insulation Breakdown Test Set Impedance Bridge. Refer to Standard Practices Manual. and equipment can be used provided they meet the requirements of ARINC Report 668. B. and equipment used in this section are listed in Figure 501. Plug-In Model (Note 1) Model 78 Multimeter NOTE 1: Use Electro Scientific Industries Low Ohm Meter. as preferred option to Kelvin Bridge 4286. See FITS AND CLEARANCES for applicable wear tolerances. reference to item (1) means that procedures also apply to alpha-variant items (-1A. CHECK. Check Special Tools and Equipment Figure 501 CHECK 24-20-76 Page 501 Feb 26/07 . NOTE: Reference to item numbers in text implies that alpha-variant items listed in the IPL may be used as determined by the effect code for that item. STANDARD TOOLS. NOTE: Equivalent tools. fixtures. continued use authorized by Hamilton Sundstrand. and Digital Converter 1700. fixtures. FIXTURES. Type 1650A H20B Dynamic Balancing Machine 5220A Direct Current Hypot 1700 Digital Converter (Note 1) 1701B Low Ohm Meter. 24-10-00. Special tools. For example. Plug-in Model 1701B. Type 1650A (Note 2) Quad Tech Digibridge 1750 LCR Tester * * Replaces Impedance Bridge. Visually check all parts for obvious wear or damage. and -1C). -1B. AND EQUIPMENT for general equipment information. NUMBER DESCRIPTION 60087019 60060562 903J801-1 4286 976J552-4 103MP-2. NOTE 2: No longer manufactured.

corrosion. (1) Preferred Method (a) (2) Place appropriate size pins between teeth 180 degrees apart. Overhaul Check A. and obstructed air passages. CHECK 24-20-76 Page 502 Feb 26/07 . Determine the percentage of wear on the original spline width outer diameter face as shown in "enlarged view of spline. and stub shaft (1. frayed wires. B. corrosion. worn parts. IPL Figure 1). bends. IPL Figure 3). Visually check all components for structural damage such as cracks.HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 2. measure diameter (Refer to FITS AND CLEARANCES). IPL Figure 3) for spline wear as follows: NOTE: Splined parts must be thoroughly cleaned to remove all traces of lubrication. it is not desirable to replace one spline without replacing the mating spline. Using standard micrometers. or other foreign matter prior to inspection. if available). Check adapter (4.” Figure 502. NOTE: Since mating splines tend to wear evenly. spindle (3. Alternate Method (a) Check splines visually using a 5 to 10 power magnifying glass (or precision magnifying-measuring equipment. Inspect the leads for damaged insulation or broken conductors. stripped threads. NOTE: See FITS AND CLEARANCES for complete listing of all mechanical fits and clearances called for in this section.

Visually check for pitting or rough finish in accordance with Hamilton Sundstrand Standard Practices Manual 24-10-00 General Check Procedures and Spline Inspection. CHECK 24-20-76 Page 503 Feb 26/07 . IPL Figure 1) as follows: (1) Use air snap gage 60087019. NOTE: As an alternate method. Check armature-rotor (42. and masting setting disks with the hose assembly 60060562. to check the anti-drive end bearing shaft journals for wear (see Figure 503). use a standard micrometer and check journals.HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 A-67166 Typical Example of Spline Wear Figure 502 (3) C. Replace if drive surface condition exceeds limits in FITS AND CLEARANCES.

HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 A-67167-1 Armature-Rotor Check Criteria Figure 503 (Sheet 1 of 2) CHECK 24-20-76 Page 504 Jun 1/00 .

Co. check holding wedges (See View A-A. CHECK 24-20-76 Page 505 Feb 26/07 . Clare Ireland (3) Optional. Top View of Holding Wedge. and check concentricity of rotor cores with respect to bearing journals (see Figure 503).HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 A-73038 Armature-Rotor Check Criteria Figure 503 (Sheet 2 of 2) (2) Place rotor in checking fixture 903J801-1. and View B-B) as follows: (a) Hairline cracks that extend completely through the thickness of the holding wedge or extend from the stamped area to the edge of the holding wedge are not allowed. NOTE: Armature-rotors requiring repair can be sent to the Hamilton Sundstrand Shannon Repair Center at the following address: Hamilton Sundstrand Shannon Repair Center World Aviation Park Shannon.

Check for phase-to-phase faults by applying 900 volts rms. NOTE: If is recommended that when a holding wedge is suspected to be faulty. CHECK 24-20-76 Page 506 Feb 26/07 . (5) Check for frayed. PERSONNEL WORKING WITH ELECTRICITY SHALL HAVE ANOTHER PERSON SKILLED IN MODERN METHODS OF FIRST AID AND RESUSCITATION NEAR BY. Check Generator Stator (55. NOTE: As an alternate method. COMPONENTS BEING TESTED OR THE TESTING SURFACE. T2 and T5. DO NOT TOUCH EXPOSED UNINSULATED CONNECTIONS. Connect the frame of the stator to the other terminal of the test set. starting from zero. and T6. T5.046 ohms (for 976J597-1) per phase at 25 degrees Celsius (77 degrees Fahrenheit). worn. These resistance values should be 0.5DJU. for one minute. 60B4-1 or 2512. Reduce voltage to zero at the same rate before disconnecting.047 ohms (for 976J497-1) and 0. (3) Remove jumper from T4. Holding wedges can not be removed without damaging the armature-rotor insulation to the extent of requiring a complete rewind.039 to 0. and T3 and T6 with Electro-Scientific meters 1700 and 1701B or optional Kelvin Bridge 4286. (2) Tie terminals T4. Apply a test potential of 900 volts rms. D. WARNING: ELECTRIC SHOCK CAN OCCUR WHEN USING A HIGH POTENTIAL TESTER. IPL Figure 1) as follows: (1) Check the resistance between terminals T1 and T4. and T6 together and connect to insulation breakdown test set 103MP-2. die. for one minute between the phases as follows: Terminals T1 and T2 Terminals T2 and T3 Terminals T1 and T3 (4) Check the terminal studs (51. There shall be no more than 5 milliamperes compensated current leakage breakdown in insulation. or missing insulation or ties. that the armature-rotor be returned to Hamilton Sundstrand for evaluation and possible repair.038 to 0. T5. 13700-1C. 60 hertz. 60 hertz. IPL Figure 1) for mounting looseness in the terminal board (48). at a rate not to exceed 500 volts per second. the generator stator can be checked by comparison to a new generator stator using surge comparison test set 976J552-4.HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 (b) Ridges. Attempts at braze repair will result in temperatures that take the holding wedges out of the required hardness range and result in eventual failure of the armature rotor. or draw marks are allowed on the stamped areas as long as they are not in the range defined in step (3)(a).

use a standard micrometer to check bearing insert. NOTE: As an alternate method. NOTE: Generator stators may be rewound or have the frames replaced at the Hamilton Sundstrand Shannon Repair Center at the following address: Hamilton Sundstrand Shannon Repair Center World Aviation Park Shannon. or 63). Clare Ireland E. check critical diameters (see Figure 504). CAUTION: NO WELD REPAIRS OF THE LUG HOLES IS ALLOWED. (2) Check for any cracks or breaks.2 N•m) torque. There shall be no more than three holes with cracks and no two may be in lug holes next to each other (see Figure 504). (3) Check exciter field coils for movement with respect to the field poles. F. IPL Figure 1) and exciter stator (27.4407 to 2. (61. Screws shall not move more than 1/4 turn. (2) Check exciter stator mounting screws (28) for 45 to 55 lb-in. 62. (5. If present. (10) Check stator leads for cracks or breaks near to braze joint. Check end bell (30. they must be corrected in accordance with REPAIR or replaced. (9) Check the mounting diameter dimension (see Figure 504) at several points around the outside diameter. disassemble and repair in accordance with REPAIR. (1) Push and pull exciter stator assembly to determine any axial or radial movement with respect to the end bell.1 to 6. THE HEAT FROM WELDING REDUCES THE REQUIRED STRENGTH OF THE FLANGE. (11) If the generator stator has any of the above faults. Rotate gage to check entire diameter. If cracks or breaks exist. IPL Figure 1) as follows: NOTE: If the end bell or exciter stator assembly fails to meet any of the following checks. making sure to check entire diameter. IPL Figure 1) as follows: (1) Visually check end bell diaphragm for bends or dents which would affect concentricity or axial run-out.HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 (6) Check for cracked.9938 to 62. Check end bell (52. (3) Check bearing insert for 2. cut. Co. (8) Check the inside diameter of the stator for evidence of rubs from the armature-rotor. (7) Check mounting lug holes for cracks.4412 in. the stator must be replaced or rewound. Check field poles for movement with respect to the exciter stator ring. CHECK 24-20-76 Page 507 Feb 26/07 . Measurements exceeding the maximum diameter indicate an out-of-round frame. or degraded insulation sleeves (61.0065 mm) using air gage set. No movement shall be detected. No movement shall be detected.

IN CASE OF EYE CONTACT. DO NOT BREATHE VAPORS. Rotate gage to check entire diameter. FLAME OR HOT SURFACES. (6) Check bearing insert bore for 2. use a standard micrometer to check bearing insert. refer to REPAIR. NOTE: As an alternate method. USE IN WELL VENTILATED AREA FREE FROM SPARKS. FLUSH WITH WATER FOR 15 MINUTES AND SEEK MEDICAL ATTENTION. SOLVENTRESISTANT GLOVES AND OTHER PROTECTIVE GEAR. IN CASE OF SKIN CONTACT.0065 mm) using an air gage set. If coating shows signs of severe wear.4407 to 2. WEAR SPLASH GOGGLES. CHECK 24-20-76 Page 508 Jun 1/00 .9938 to 62. (5) Check exciter terminal board (20) for cracks and stripped threads. (4) Check the condition of the epoxy coating on anti-drive end of the coils. (61.4412 in.HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 WARNING: EPOXY RESIN IS TOXIC AND FLAMMABLE. WASH WITH SOAP AND WATER. making sure to check entire diameter.

HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 A-67168 Generator Stator Check Criteria Figure 504 CHECK 24-20-76 Page 509 Jun 1/00 .

A-67169 Schematic Figure 505 CHECK 24-20-76 Page 510 Feb 26/07 . 10. and A. Check rotor windings resistance and dielectric as follows: (1) Disconnect rotor winding leads (two direct current field and three alternating current armature) from the semiconductor device set by removing the screws.0 ohms at 77 degrees Fahrenheit [25 degrees Celsius]). rms. Clare Ireland (8) 3. Co.(black) and F (yellow). Optional Checks The optional checks may facilitate troubleshooting and repair procedures. and bushings (9. See Figure 505 for a schematic. Make sure no terminal is touching the frame during this test. and 12.1 ohms (for 976J497-1) and 5. Check from any lead to the stator frame. as read on an impedance bridge TS460/u. The resistance of the stabilizing winding. washers.0 to 2.7 ohms (for 976J597-1).HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 (7) Check the resistance of the coils in exciter stator by placing a jumper around the thermistor to shunt it out. S (red).6 to 6. IPL Figure 3) before checking resistance or dielectric of the windings. shall be 5. NOTE: Exciter stators may be repaired at the Hamilton Sundstrand Shannon Repair Center at the following address: Hamilton Sundstrand Shannon Repair Center World Aviation Park Shannon.0 to 6. With jumper removed.(black). 60 hertz for one minute. Dielectric check excitor stator at 900 volts. the resistance shall increase slightly (1. 11. The resistance between A. shall be between 450 and 560 ohms (for 976J497-1) and 423 to 517 ohms (for 976J597-1). A.

3) of three alternating current armature leads. increase voltage to 900 volts. CHECK 24-20-76 Page 511 Feb 26/07 .3. B.HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 (2) Use Electro Scientific Industries meters 1700 and 1701B or optional Kelvin Bridge 4286.30 ounce-inch (216 gram-millimeter) square maximum.5DJU.2. at a rate not to exceed 500 volts per second. Starting from zero. 13700-1C. the semiconductor device set or rectifier assembly (8 or 8A) has been removed and reinstalled. (3) Using Electro Scientific Industries meters 1700 and 1701B or optional Kelvin Bridge 4286. IPL Figure 1) windings have been repaired. or exciter armature (13) has been replaced. The remaining unbalance limit is 0. 2 . check resistance across each pair (1 . (4) Using insulation breakdown test set 103MP-2. PERSONEL WORKING WITH ELECTRICITY SHALL HAVE ANOTHER PERSON SKILLED IN MODERN METHODS OF FIRST AID AND RESUSCITATION NEARBY. WARNING: DO NOT TOUCH THE EXPOSED UNINSULATED CONNECTIONS.057 to 0. or the main rotor (42. rms.176 to 0. (1) Use dynamic balancing machine. BE SURE WINDING LEADS ARE ALL DISCONNECTED FROM SEMICONDUCTOR DEVICE SET OR RECTIFIER ASSEMBLY AS HIGH CURRENT MAY BURN OUT THE DIODES. Balance in both planes (each end of main direct current field) using balance weights (14.165 to 0. 15. ELECTRIC SHOCK CAN OCCUR.052 to 0. Type H20B. Resistance shall be 0. Reduce voltage to zero at same rate before disconnecting leads. Phase-to-phase resistance (each pair) must be 0.070 ohms (for 976J497-1) and 0. IPL Figure 3) at a balancing speed of 1800 revolutions per minute. There shall be no more than 5 milliamperes compensated current leakage breakdown in insulation. 60 hertz. and check the resistance across two direct current field leads. Balance one plane at a time by treating each correction plane as a single plane problem using the nearest bearing journal for the vibration readings. 16. for one minute. THE COMPONENTS TO BE TESTED OR THE TESTING SURFACE WHEN YOU USE A DIELECTRIC TESTER. or equivalent. CAUTION: BEFORE DIELECTRIC CHECK. Repeat for alternating current windings.064 ohms (for 976J597-1).214 ohms (for 976J497-1) and 0. 1 . 60B4-1or 2512 dielectric check from direct current windings to rotor shaft. (2) Support the rotor assembly on its bearing journals. IPL Figure 3). Check armature-rotor dynamic balance as follows: NOTE: This check shall be performed if: stub shaft (1.201 ohms (for 976J597-1).

(3) Before inserting balance weights. Co. IPL Figure 3) from the armaturerotor (42. Stake balance weights across ends after insertion to prevent loosening and falling out. IPL Figure 1) in accordance with REPAIR. which use weights (16. which use weights (14. (3. (216 gram-millimeter) squared. IPL Figure 3) in each correction plane 180 degrees apart.429 mm) maximum for holes numbered 1 and 6.(terminal 4). which use weights (15.135 in. Clare Ireland (1) Remove the semiconductor device set (8 or -8A.30 oz-in. Add a balance weight (14. Weights shall not extend beyond face of wedge. IPL Figure 3). (4) To calibrate the balancing machine.188 inch (4. Check semiconductor device set or rectifier assembly (8 or 8A. IPL Figure 3). IPL Figure 3) as follows: NOTE: Semiconductor device set or rectifier assembly may be repaired at the Hamilton Sundstrand Shannon Repair Center at the following address: Hamilton Sundstrand Shannon Repair Center World Aviation Park Shannon.773 mm) maximum for holes numbered 2 and 5. (2) Disconnect one of the soldered connections to the capacitor. and 0. begin with a perfectly balanced rotor where no unbalance can be measured. IPL Figure 3). 0. (Refer to Figure 506. (a) Check the capacitance of the capacitor by connecting a Fluke 87 True RMS Multimeter between the disconnected capacitor lead and DC .) A-67170 Semiconductor Device Set or Rectifier Assembly Electrical Connection Terminals Figure 506 CHECK 24-20-76 Page 512 Feb 26/07 . The reading in each plane will indicate an unbalance of 0.HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 C.775 mm) maximum for holes numbered 3 and 4.147 inch (3. clean out holes in wedges to 0.

(e) Turn on the direct current supply and increase the current to 10. CHECK 24-20-76 Page 513 Feb 26/07 . Check forward voltage drop as follows: (a) Connect positive lead of the DC current supply to DC . (c) Connect the positive lead of DC voltmeter (Fluke 8026B) to DC .(terminal 4). replace the capacitor. (d) Connect negative lead to the AC (terminal 1). then check continuity between the other side of the unsoldered connection and the appropriate direct current terminal. (c) If the capacitance is out-of-limits.22 +20 percent to -10 percent microfarads. move the one meter probe from the DC connection to the DC + (terminal 2) connection.20 amperes.HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 (3) (b) The capacitor should measure 0. (b) Connect negative lead to the AC (terminal 1).(terminal 4). If the capacitor is still out limits. (d) If the capacitor checks good.0 ± 0. (Refer to Figure 507.) (e) Then leave the capacitor disconnected for the following checks.

HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 A-67171 A-67172 Diode Continuity Check Figure 507 CHECK 24-20-76 Page 514 Jun 1/00 .

CHECK 24-20-76 Page 515 Jun 1/00 . DO NOT TOUCH EXPOSED UNINSULATED CONNECTIONS. Connect the negative lead of DC voltmeter to the DC + (terminal 2) and connect positive lead to the AC (terminal 1). (e) With the kilovolts switch in the low position.HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 (f) Observe the voltage reading on the DC voltmeter then immediately decrease the current to zero. The forward voltage drop should be 1. CAUTION: DO NOT APPLY MORE THAN THE SPECIFIED DC VOLTAGE TO DIODES OR THEY MAY BE DAMAGED. PERSONNEL WORKING WITH ELECTRICITY SHALL HAVE ANOTHER PERSON SKILLED IN MODERN METHODS OF FIRST AID AND RESUSCITATION NEAR BY. (4) (j) Move the positive leads of the direct current supply and DC voltmeter to the AC (terminal 3). and connect positive lead to the AC (terminal 1). NOTE: Follow the manufacturers operating directions to turn on and warm up DC hypot. (g) Move the negative leads of the direct current supply and the DC voltmeter to the AC (terminal 3). NOTE: Leave the “Bypass Return” terminal and the “Ground” terminal unconnected. Repeat steps e and f. Repeat steps e and f. WARNING: ELECTRIC SHOCK CAN OCCUR WHEN USING A VOLTMETER. (k) Move the positive leads of the direct current supply and the DC voltmeter to the AC (terminal 5). (h) Move the negative leads of the direct current supply and the DC voltmeter to the AC (terminal 5). Repeat steps e and f. (d) Connect (safety ground) terminal to building ground. (b) Connect the positive lead of DC voltmeter to the DC + (terminal 2). Repeat steps e and f. Repeat steps e and f. and with the voltage control knob in the full counterclockwise position and the current range in the 2000μ A position. Check reverse voltage leakage current as follows: (a) Connect the DC Hypot high voltage lead (positive lead) to the DC + (terminal 2). (i) Connect the negative lead of the direct current supply to the DC + (terminal 2). and connect the “metered return” lead to the AC point (terminal 1). slowly turn the knob clockwise until the voltmeter reads 390 volts minimum to 400 volts maximum.0 volts direct current maximum. (c) Connect the negative lead to the AC (terminal 1). COMPONENTS TO BE TESTED OR THE TESTING SURFACE. DO NOT APPLY ALTERNATING CURRENT.

(5) (n) Repeat steps i and j. (q) Move the high voltage lead to the AC (terminal 5). Put the current range switch in the 2000μ A position. Check individual diodes before they are installed or if they are removed for suspected defect for forward voltage drop as follows: (a) Connect the positive lead of the direct current supply to the anode of the diode. and put the current range switch in the 2000μ A position. (l) Repeat steps i and j. but the voltmeter must not be connected while a leakage current reading is being taken. remove the voltmeter or the leakage current reading will be erroneously high. CHECK 24-20-76 Page 516 Jun 1/00 . and put the current range switch in the 2000μ A position. (k) Move the “metered return” lead to the AC (terminal 5). (p) Repeat steps i and j. and move the high voltage lead to the AC (terminal 1). and put the current range switch in the 2000μ A position. and connect the negative lead to the cathode of the diode (refer to Figures 508 and 509).HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 NOTE: After making the voltage setting. (m) Move the “metered return” lead to the DC . Do not touch the voltage control knob. (h) Move the “metered return” lead to the AC (terminal 3). (f) Change the current range as required to obtain a leakage current reading. The voltmeter must be reconnected for each diode to check on the voltage setting. (o) Move the high voltage lead to the AC (terminal 3).(terminal 4). Repeat steps i and j. The limit is 75 microamperes maximum. (j) Turn the high voltage switch off. (g) Remove the voltage by turning the high voltage switch off. The limit is 75 microamperes maximum. (i) Turn the high voltage switch on. and put the current range switch in the 2000μ A position. Change the current range as required to obtain a leakage current reading.

A-67174 Schematic for Checking Forward Voltage Drop Across Diode Figure 509 CHECK 24-20-76 Page 517 Jun 1/00 .HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 A-67173 Diode Polarity Figure 508 (b) Connect the positive lead of the DC voltmeter to the anode of the diode.00 ± 0. (d) Observe the voltage reading on the DC voltmeter. then immediately decrease the current to zero. (c) Turn on the DC current supply and increase the current to 10.20 amperes.0 volt direct current maximum. and connect the negative lead to the cathode of the diode. The forward voltage drop should be 1.

slowly turn the knob clockwise until the voltmeter reads 390 volts minimum to 400 volts maximum. the voltage control knob in the full counterclockwise position. PERSONNEL WORKING WITH ELECTRICITY SHALL HAVE ANOTHER PERSON SKILLED IN MODERN METHODS OF FIRST AID AND RESUSCITATION NEAR BY. (b) Connect the positive lead of the DC voltmeter to the cathode of the diode. NOTE: Follow the manufacturers operating instructions to turn on and warm up DC Hypot. CAUTION: DO NOT APPLY MORE THAN THE SPECIFIED DC VOLTAGE TO DIODES OR THEY MAY BE DAMAGED. CHECK 24-20-76 Page 518 Jun 1/00 . NOTE: Leave the “Bypass Return” terminal and the “Ground” terminal unconnected. (c) With the kilovolts switch in the low position.HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 (6) Check individual diodes before they are installed or if they are removed for suspected defect for reverse voltage leakage current as follows: (a) Connect the DC Hypot high voltage lead (positive lead) to the cathode of the diode. DO NOT TOUCH EXPOSED UNINSULATED CONNECTIONS. and connect the negative lead to the anode of the diode. WARNING: ELECTRIC SHOCK CAN OCCUR WHEN USING A VOLTMETER. and connect the “metered return” lead to the end of the diode (refer to Figure 508 and 510). remove the voltmeter or the leakage current reading will be erroneously high. COMPONENTS BEING TESTED OR THE TESTING SURFACE. DO NOT APPLY ALTERNATING CURRENT. NOTE: After making this voltage setting. and the current range in the 2000μ A position.

(a) Apply 9. the three-phase alternating current input voltages shall be balanced within one volt (line-to-neutral).44 liters per second) of air at room temperature across the cooling fins of the device.8 ± 1 volt line-to-neutral (17 ± 1 volts line-to-line) to the input terminals of the unit under test.6 amperes. (b) Close S2 and measure the direct current amperes on M2. CHECK 24-20-76 Page 519 Jun 1/00 . run steps (a) through (c) in sequence. (8) Using the test set-up of Figure 512. Measure input voltage on M1. Supply cooling air to the semiconductor device set/ rectifier assembly by blowing a minimum of 20 cubic feet per minute (9.HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 A-67175-1 Schematic for Checking Leakage Current Through Diode Figure 510 (d) Change the current range as required to obtain a leakage current reading. (7) Reconnect any leads that were disconnected. (e) Remove the voltage by turning the high voltage switch off. NOTE: During either of the alternate tests. The limit is 50 microamperes maximum. The current shall be between 17.9 and 22.

terminal and the other to the frame of the stator. repeat as required steps 1 through 7. CHECK 24-20-76 Page 520 Jun 1/00 . Check end bell (30. PERSONNEL WORKING WITH ELECTRICITY SHALL HAVE ANOTHER PERSON SKILLED IN MODERN METHODS OF FIRST AID AND RESUSCITATION NEAR BY.5DJU. Reduce voltage to zero at same rate before disconnecting. starting from zero. IPL Figure 1) as follows: (1) Remove exciter stator from end bell in accordance with REPAIR. If it appears as shown in Figure 514 or 515. Microfarads at 1000 Hz (25° C) Tolerance % WVDC at 85° C 0.22 -10. DO NOT TOUCH EXPOSED UNINSULATED CONNECTIONS BEING TESTED OR THE TESTING SURFACE. Refer to Figure 511 for values. for one minute. (4) Check the inside diameter of the exciter stator (ground surface of main poles) and mounting tab outside diameter (see Figure 516). Apply 600 volts rms. +20 400 Capacitor Values Figure 511 D. WARNING: ELECTRIC SHOCK CAN OCCUR WHEN USING A HIGH POTENTIAL TESTER. The output shall appear as shown in Figure 513. Capacitor rating is 400 working volts direct current at 85 degrees Celsius (185 degrees Fahrenheit). at a rate not to exceed 500 volts per second. -10 percent. For rejected units. (3) Connect one lead from insulation breakdown test set 103MP-2. one or more diodes may be defective and the unit under test shall be rejected. Discard if any cracks are visible. IPL Figure 1) and exciter stator (27.HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 (c) Measure the unit under test output on M3. 25 degrees Celsius (77 degrees Fahrenheit) for 0. PERSONNEL WORKING WITH ELECTRICITY SHALL HAVE ANOTHER PERSON SKILLED IN MODERN METHODS OF FIRST AID AND RESUSCITATION NEAR BY. DO NOT TOUCH EXPOSED UNINSULATED CONNECTIONS BEING TESTED OR THE TESTING SURFACE. WARNING: ELECTRIC SHOCK CAN OCCUR WHEN USING A HIGH POTENTIAL TESTER.22. (5) Use an indicator and check the runout of the mating surface of tabs on exciter stator in relation to bore (see Figure 516). (2) Disassemble the thermistor (see IPL Figure 2) and check element (1). (9) Check the capacitor at 1000 hertz. 13700-1C 60B4-1 or 2512 to the A. +20 percent microfarads.

IPL Figure 1) for minimum diameter (see Figure 503). (3) Check the inside diameter of the generator stator (55. (2) Check the outside diameter of the exciter armature (13. IPL Figure 1) for maximum diameter (see Figure 504).HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 E. IPL Figure 3) for minimum diameter (see Figure 503). Check from the end bell generator stator mating fit to the pads (see Figure 517). (7) Use an indicator to check the six mounting pads in the end bell for runout. (6) Check the inside diameter of the end bell at mounting pads (see Figure 517). CHECK 24-20-76 Page 521 Jun 1/00 . Check Dimensions as follows: (1) Check the outside diameter of the main rotating field of armature-rotor (42.

NOTE: The unit under test is to be cooled by blowing a minimum of 20 cubic feet per minute (9.Power Supply 1. 575 watt (minimum) NOTE: Switch ratings to be selected for proper operation.HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 A-67176-1 PS1 . SPST M1 . 1.Switch 2. ammeter.Resistor 1. voltmeter. 200/110 volt. 400 hertz ± 2 percent. on-off. 0 to 30 amperes direct current ± 2 percent M3 .Metering 1. S1 . M2 . 50 or 60 hertz stepped down with a variac to 20 volts at 20 amperes. 3-phase alternating current. 20 volts or 3-phase.0 ± 0.Metering 2. 1 pole. oscilloscope. selector. 400 hertz.44 liters per second) of air at room temperature across the device. 20 amperes. NOTE: The oscilloscope ground shall be isolated from the alternating current power supply ground.1 ohms. 0 to 30 alternating current root-mean-square.Switch 1. 10 kilohertz or better R1 . 3 position S2 .Metering 3. Semiconductor Device Set or Rectifier Assembly Figure 512 CHECK 24-20-76 Page 522 Jun 1/00 .

HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 A-66110 Waveform for Good Semiconductor Device Set or Rectifier Assembly Figure 513 A-66111 Waveform for Semiconductor Device Set or Rectifier Assembly with an Open Diode or Rectifier Figure 514 CHECK 24-20-76 Page 523 Jun 1/00 .

HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 A-66112 Waveform for Semiconductor Device Set or Rectifier Assembly with a Short Figure 515 CHECK 24-20-76 Page 524 Jun 1/00 .

HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 A-67177 Exciter Stator Check Criteria Figure 516 CHECK 24-20-76 Page 525 Jun 1/00 .

HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 A-67178 Stator Exciter End Bell Check Criteria Figure 517 CHECK 24-20-76 Page 526 Jun 1/00 .

and equipment required for repair are listed in Figure 603. For example. These consumable materials are known to align with all of the design and qualification requirements. -1B. and -1C). General A. C.gov/bincs/begin_search. fixtures. A list of repairs is provided in Figure 601. B. reference to item (1) means that procedures also apply to alpha variant items (-1A. for general repair information. Refer to Standard Practices Manual. 24-10-00. and equipment can be used if they align with the requirements of ARINC Report 668. REPAIR. REPAIR 24-20-76 Page 601 Feb 26/07 . NOTE: The full address and other information regarding vendors or suppliers listed in Figure 602 can be obtained by using the World Wide Web (www) at the following URL http://www. Materials required for repair are listed in Figure 602.bpn. Other CAGE Code sites are also available on the web. This section contains repair procedures required to return the generator assembly to serviceable condition. NOTE: Reference to item numbers in text implies that alpha variant items listed in the IPL may be used as determined by the effect code for that item. NOTE: Equivalent tools.HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 REPAIR 1. Only approved materials engineering can make equivalent consumable material decisions and these materials are used at the risk of the organization who makes the decision.asp. NOTE: Maintenance personnel must use the specified consumable material for the specified task. Replace all parts that do not meet requirements after repair. fixtures. Special tools. D.

paint. 915F469-2. Co. Clare Ireland For example. and polyurethane foam export pack for shipping. NOTE: Hamilton Sundstrand Shannon Repair Center has developed a series of proprietary repairs for armature-rotor part numbers 915F306-1 and 915F508-1. Refer to Hamilton Sundstrand Standard Practices Manual 24-10-00 for replacement of helical inserts. REPAIR 24-20-76 Page 602 Feb 26/07 . rewind. For an incoming inspection and written quote. semiconductor devise set 946F177-1. stator 915F469-1. varnish dip and bake. final inspection and certification.HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 E. Perform repair of components listed in Figure 601 that do not meet requirements in CHECK according to the specified repair number. pre-dip inspection. dynamic balance of complete rotor. pre-wind inspection. 2. Repair A. Be sure to carefully remove drive tang after helical insert is installed. IPL Figure 3) into the drive-end (smaller spline) of generator spindle (3) with the drive tang out. and 915F512-2. NOTE: Install helical insert (3M. send parts requiring repair or rewind to: Hamilton Sundstrand Shannon Repair Center World Aviation Park Shannon. the rotor repair typically includes stripping. exciter stator part number 915F262-1 and 915F511-1.

and insulation (1 through 11. IPL Figure 3) Wound Armature (13 or -13A. retainer. insulation. IPL Figure 2) 5 Armature-rotor (42. TITLE DESCRIPTION 1 End bell and exciter stator (13 through 35. -42A. or -42B. IPL Figure 1) 2 End bell and exciter stator (13 through 35. IPL Figure 1) 8 Stator Replacement of electrical terminals. terminals. Repair List Figure 601 REPAIR 24-20-76 Page 603 Feb 26/07 .HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 REPAIR NO. IPL Figure 1) Repair or replacement of semiconductor device set or rectifier assembly (8 or -8A. IPL Figure 1) 9 Stator Identification plate (-67A through 69) 10 Terminal Board (48. IPL Figure 1) 3 End bell (30 or -30A) and exciter stator (13 through 35. IPL Figure 3). IPL Figure 1) Repair of terminal block separators 11 Wound Armature (13 or -13A. screws. IPL Figure 1) Replacement of damaged or missing terminal parts (13 through 23. and screws (24 through 29A. IPL Figure 1) 4 Exciter stator Replacement of thermal resistance element. IPL Figure 3) 7 Stator terminal Replacement of damaged or missing stator terminal parts (43 through 51. IPL Figure 1) Replacement of exciter stator (24 through 29A. IPL Figure 1) Replacement of wound armature (9 through 13M. and helical inserts (56 through 66. IPL Figure 3) 6 Armature-rotor (42 or -42A. IPL Figure 1) Replacement of bearing insert (30F).

Type Sn96Ag04WRMAP3) Commercially Available Dry Ice Commercially Available Repair Materials Figure 602 (Sheet 1 of 2) REPAIR 24-20-76 Page 604 Feb 26/07 .HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 MATERIAL SOURCE Resin. Type ECC-A. Ohio 45202 Silicone Rubber Sealant (Military Specification MIL-L-46106.381 by 3. Inc. Form 5.254 by 1.175 mm) and 0. Sterling Division CAGE Code: 78580 Lockwire. Epoxy.048 inch (0. Subsidiary of Avnet Inc.75% Pure Tin) Commercially Available Sealer. Class 3) Commercially Available Adhesive A701 Resin Technology Group. Co.177 x 12. Scotchcast 253 3M 3M Center St. Lubricating (Military Specification MIL-L-46014. D-163B (replacement for Resin.219 mm) Arkins and Pearce Mfg. MN 55101 Resin. CAGE Code: 0D3L4 Silver Solder (Federal Specification QQ-S-571. 537 East Pearl Street Cincinnati. Glyptal 1201EW Brownell Electro. MS20995C32 Commercially Available Chemical Film (MIL-C-5541. Type A) (99.125 inch (0. Type I) Commercially Available Commercial Tape (Military Specification MIL-Y-1140.500 inch (0.007 x 0. Inc. Scotchcast 253) Nu-Brite Chemical Co.010 by 0.700 mm) Commercially Available Oil. Grade III) Commercially Available Pure Tin Solder and Flux. (Military Specification MIL-F-14256. Inc. CAGE Code: 0JVX9 Brazing Alloy (Federal Specification QQ-B-654.015 by 0. 450 Yarn) 0. Type II) British Petroleum Oil Co. CAGE Code: 2Y601 Lacing Tape 0. Paul.

187 inch minimum I. CL BCUP-5 Commercially Available Alcohol. and Equipment Figure 603 REPAIR 24-20-76 Page 605 Feb 26/07 .. CAGE Code: 1U766 Repair Materials Figure 602 (Sheet 2 of 2) TOOL NUMBER DESCRIPTION Type 12-062 or 12-064 Brazing Set 909C499-1 Curing Fixture 928A903-3 Adapter Set Special Tools. Versamid 125 Henkel Corp.D.HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 MATERIAL SOURCE Zinc Chromate Primer (Military Specification MIL-P-15328) Commercially Available Brazing Rod (Military Specification MIL-B-7883) Alloy QQ-B-654. available from the following: Shell Epon 828 or 8280 Commercially Available Shell Chemical Company A Division of Shell Oil Co. Isopropyl (Federal Specification ASTM-D770) Commercially Available Insulation Sleeving. Fixtures. CAGE Code: 5S850 DER 331 Dow Corning Corporation CAGE Code: 71984 Reactive Polyamide Resin. Black Commercially Available P/N M23053/6-105-0 Fluoropolymer-Insulated Electrical Wire (Military Specification MIL-W-22759) Black P/N M22759/7-12-0 Epoxide Resin. CAGE Code: 86961 Araldite 6010 or GY2600 Ciba-Geigy Corp. Polymers Div. (Military Specification MIL-I-23053.. Class 1) 0.

HAMILTON SUNDSTRAND
COMPONENT MAINTENANCE MANUAL
PART NUMBER 976J497 AND 976J597
PROCEDURE
1.

Disassembly
NOTE: Remove only those parts necessary to replace damaged part or to replace missing
parts.

2.

A.

Remove screws (14, IPL Figure 1), washers (15), and terminal board cover (13).

B.

Remove self-locking nuts (16), lock washers (17), washers (16), and lift terminal lugs
(29A) from stud terminals (23).

C.

Remove screws (21), washers (22), and terminal board (20).

D.

Remove nuts (19) to remove stud terminals (23).

Assembly
A.

Install stud terminals (23) through the bottom of terminal board (20).

B.

Lubricate threads with lubricating oil and install nuts (19). Torque nuts 5 to 10 lb-in. (0.6 to
1.1 N•m).

C.

Install terminal board (20), washers (22), and screws (21). Torque screws 16 to 20 lb-in.
(1.9 to 2.2 N•m).

D.

Install terminal lug (29A) with black lead to stud marked "A-", yellow lead to stud marked
"F", and red lead to stud marked "S".
NOTE: These connections are from left to right when the AC generator is viewed from
the anti-drive end with the terminal block at the twelve o'clock position. The
fourth stud is not used for these AC generators.

E.

Install washers (18), lock washers (17), and self-locking nuts (16). Do not torque the nuts,
aircraft or test stand connections will be made after assembly.

F.

Install terminal board cover (13), washers (15), and screws (14). Do not torque the
screws, aircraft or test stand connections will be made after assembly.

Replacement of Damaged or Missing Exciter
Stator Terminal Parts

24-20-76

REPAIR
Repair No. 1
Page 601
Jun 1/00

and 2 parts alcohol.0127 mm) thick when dry.0076 to 0. Disassembly A. (0. it is a necessary activator and must be used in exact proportions indicated above. Remove parts (13 through 18. WASH WITH SOAP AND WATER. D. (2) Mask areas that are not to be coated. If the zinc chromate primer on the inside diameter has been worn away or removed. Assembly WARNING: PRIMER IS TOXIC AND FLAMMABLE. (1) Clean the exciter stator in accordance with CLEANING. 1 part by volume of the acid component. (6) Then slowly add the alcohol while stirring. B. A. 2. If the temperature is under 32 degrees Celsius (90 degrees Fahrenheit) the primer must be used within 4 hours. WARNING: WEAR GOGGLES WHEN REMOVING LOCKWIRE. IPL Figure 1) in accordance with procedures in Repair Number 1 and lift terminal lugs (29A) from terminal studs (23). (4) Stir the resin component thoroughly. WARNING: WEAR THERMALLY INSULATED GLOVES AND OTHER SUITABLE PROTECTION TO WARNING: PREVENT BURNS WHEN HANDLING HEATED PARTS.0005 in.0003 to 0. apply a coating of primer as follows: NOTE: Quantity of primer to be mixed should be determined by how much will be used under the either of the following conditions. Push the three exciter stator leads through grommet (24) to the inside of end bell (30 or -30A). (7) Spray a thin film of primer on surfaces shown. C. USE IN WELL VENTILATED AREA FREE FROM SPARKS OR FLAME.HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 PROCEDURE 1. Heat unit to 93 to 121 degrees Celsius (200 to 250 degrees Fahrenheit) to help remove exciter stator (27 or -27A) from end bell (30 or -30A). NOTE: The acid component is not a thinner. Cut and remove lockwire from screws (28). FLUSH WITH WATER FOR 15 MINUTES AND SEEK MEDICAL ATTENTION. The film should be 0. IN CASE OF SKIN CONTACT. (5) Then slowly add the acid component while stirring. DO NOT BREATHE VAPORS. (3) Obtain 4 parts by volume of the resin component. IN CASE OF EYE CONTACT. 2 Page 601 Jun 1/00 . E. Remove screws (28) and washers (29). If the temperature is above 32 degrees Celsius the primer must be used within 2 hours. Repair or Replacement of End Bell Components (Sheet 1 of 5) 24-20-76 REPAIR Repair No.

HAMILTON SUNDSTRAND
COMPONENT MAINTENANCE MANUAL
PART NUMBER 976J497 AND 976J597
(8)

Air dry for 1 hour but not more than 4 hours if more coats of primer need to be
applied.

(9)

Remove masking materials.

(10) Check that the coating does not exceed the minimum inside clearance requirement
shown.
B.

Check the condition of the resin coating on the anti-drive end of three coils of the exciter
stator.
WARNING: EPOXY RESIN IS TOXIC AND FLAMMABLE. DO NOT BREATHE
VAPORS. USE IN WELL VENTILATED AREA FREE FROM SPARKS,
FLAME OR HOT SURFACES. WEAR SPLASH GOGGLES, SOLVENTRESISTANT GLOVES AND OTHER PROTECTIVE GEAR. IN CASE OF
EYE CONTACT, FLUSH WITH WATER FOR 15 MINUTES AND SEEK
MEDICAL ATTENTION. IN CASE OF SKIN CONTACT, WASH WITH
SOAP AND WATER.

C.

If resin shows signs of deterioration, apply a coat of Sterling D163B Epoxy Resin (Scotchcast 253 Resin can be used until supply is exhausted) to antidrive end of the coil with two
thermistor leads and the coils shown as follows:
CAUTION: DO NOT FLUSH PART WITH SOLVENT.
(1)

Clean any dirt of grease from the area to be coated in accordance with CLEANING.

WARNING: WEAR THERMALLY INSULATED GLOVES AND OTHER SUITABLE PROTECTION TO PREVENT BURNS WHEN HANDLING HEATED PARTS.
(2)

Preheat the exciter stator at 145 ± 8 degrees Celsius (293 ± 15 degrees Fahrenheit
for 1 hour minimum.

(3)

Cool the heated parts to 38 to 60 degrees Celsius (100 to 140 degrees Fahrenheit)
and hold them at that temperature until the Epoxy Resin is applied.
WARNING: EPOXY RESIN IS TOXIC AND FLAMMABLE. DO NOT BREATHE
VAPORS. USE IN WELL VENTILATED AREA FREE FROM
SPARKS, FLAME OR HOT SURFACES. WEAR SPLASH GOGGLES, SOLVENT-RESISTANT GLOVES AND OTHER PROTECTIVE
GEAR. IN CASE OF EYE CONTACT, FLUSH WITH WATER FOR 15
MINUTES AND SEEK MEDICAL ATTENTION. IN CASE OF SKIN
CONTACT, WASH WITH SOAP AND WATER.

(4)

Remove the Epoxy Resin from the freezer and allow it to come to room temperature.

(5)

Stir the Epoxy Resin thoroughly before applying it.
NOTE: Apply resin to anti-drive end of coils only. The other coils do not get coated.

D.

(6)

Using a spatula or brush cover the connection between the indicated coils.

(7)

Cure the Epoxy Resin by baking at 142 to 158 degrees Celsius (288 to 316 degrees
Fahrenheit) for 7 ± 1/2 hours.

Reassemble the exciter stator in the end bell in accordance with the following instructions:
Repair or Replacement of End Bell Components
(Sheet 2 of 5)

24-20-76

REPAIR
Repair No. 2
Page 602
Jun 1/00

HAMILTON SUNDSTRAND
COMPONENT MAINTENANCE MANUAL
PART NUMBER 976J497 AND 976J597
WARNING: WEAR INSULATED GLOVES AND OTHER SUITABLE PROTECTION
WHEN HANDLING HEATED PARTS.
CAUTION: MAKE CERTAIN THAT BURRS OR FOREIGN MATTER DO NOT PREVENT
SEATING OF THE SIX STATOR MOUNTING TABS ON THE MATING SURFACES OF THE END BELL. IF THE STATOR IS NOT PROPERLY SEATED
IT MAY RUB AGAINST THE ROTOR CAUSING ELECTRICAL FAILURE.
(1)

Heat the end bell (30, IPL Figure 1) to 93 to 121 degrees Celsius (200 to 250
degrees Fahrenheit).
CAUTION: DO NOT INTERCHANGE EXCITER STATOR OF GENERATOR
976J598-1 (CUBEX STEEL) WITH PARTS OF ANY OTHER GENERATORS COVERED IN THIS MANUAL (REFERENCE SERVICE NEWS
LETTER 45 THE CUBEX PARTS ARE SHORTER IN LENGTH THAN
THE OTHER PARTS AND THIS DIFFERENCE IN LENGTH CAUSES
CIRCULATING CURRENTS IN THE ROTOR BANDS THAT RESULT IN
OVERHEATING THAT CAN DAMAGE THE GENERATOR.

(2)

Install exciter stator (27 or 27A) with mounting tabs down and carefully align bolt
holes with end bell mounting holes.
WARNING: WEAR GOGGLES WHEN INSTALLING LOCKWIRE.

(3)

Install washers (29) and screws (28). Torque screws 45 to 55 lb-in. (5.1 to 6.2 N•m)
and install lockwire.

E.

Install grommet (24) in end bell (30 or -30A).

F.

Insert exciter stator leads through the grommet.

G.

Install parts (13 through 18, IPL Figure 1) in accordance with procedures in Repair Number 1 and place terminal lugs (29A) on terminal studs (23).

Repair or Replacement of End Bell Components
(Sheet 3 of 5)

24-20-76

REPAIR
Repair No. 2
Page 603
Jun 1/00

HAMILTON SUNDSTRAND
COMPONENT MAINTENANCE MANUAL
PART NUMBER 976J497 AND 976J597

A-67983-1

Repair or Replacement of End Bell Components
(Sheet 4 of 5)

24-20-76

REPAIR
Repair No. 2
Page 604
Jun 1/00

2 Page 605 Jun 1/00 .HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 A-67984-1 Repair or Replacement of End Bell Components (Sheet 5 of 5) 24-20-76 REPAIR Repair No.

.

IPL Figure 1) Sheet 1 of 3) 24-20-76 REPAIR Repair No. B. F.HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 PROCEDURE 1. D. Finish machine inside diameter of bearing insert in accordance with dimensions. Assembly A. 3 Page 601 Jun 1/00 . WARNING: WEAR INSULATED GLOVES AND OTHER SUITABLE PROTECTION WHEN HANDLING HEATED OR COOLED PARTS. C. Replacement of Bearing Insert (30F. Drill six holes in bearing insert in accordance with dimensions. touch up nicks and scratches on surface of end bell with chemical film (MIL-C-5541. (4) Hold insert in place under pressure a minimum of 30 seconds. 2. Disassembly A. (2) Press bearing insert (30F) into end bell (30 or -30A) until it is seated tight against the end bell rib areas. (5) Allow end bell to cool for a minimum of 1 hour at -50 ± 5 degrees Celsius (-60 ± 10 degrees Fahrenheit) before machining to stabilize steel contraction and expansion. Place end bell (30 or -30A) in an oven for one hour at 175 ± 5 degrees Celsius (350 ± 10 degrees Fahrenheit). Clean thoroughly.076 mm) feeler gage can not enter between bearing insert flange and end bell at any rib areas. (3) Check that a 0. Install new bearing insert (30F) in accordance with the following instructions: (1) Place end bell (30 or -30A) in an oven for 1 hour at 175 ± 5 degrees Celsius (350 ± 100 degrees Fahrenheit). Machining Procedure A. Check according to notes and dimensions.003 in. After machining. NOTE: The bearing insert can be cooled with dry ice or a deep freeze unit to help with assembly. B. (0. 3. Penetrant check. Remove end bell (30 or -30A) from oven and press out bearing insert (30F). Class 3). E.

IPL Figure 1) (Sheet 2 of 3) 24-20-76 REPAIR Repair No.HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 A-67181 Replacement of Bearing Insert (30F. 3 Page 602 Jun 1/00 .

3 Page 603 Jun 1/00 . IPL Figure 1) (Sheet 3 of 3) 24-20-76 REPAIR Repair No.HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 A-67182 Replacement of Bearing Insert (30F.

.

terminal lug (6). WARNING: WEAR INSULATED GLOVES AND OTHER SUITABLE PROTECTION WHEN HANDLING HEATED PARTS. (1. washer (4). flat washer (7). If damaged or missing replace insulation sleeves (10). Place terminal lugs (6) as shown. C. insulator washer (5).4 to 1. Replace if damaged or loose. B. insulator washer (5). B. Remove screw (2. spring tension washer (3). thermal resistance element (1).5 N•m). Repair of Replacement of Exciter Stator Components (Sheet 1 of 3) 24-20-76 REPAIR Repair No. IPL Figure 2). flat washer (7). Terminal lugs (6. insulator washer (5). and screw (2). Be sure necessary clearance between terminal lugs (6) and terminal lugs (9) exist and braze the lugs together. thermal resistance element (1). and 11) and insulation sleeves (10). 9. 2. Check the condition of terminal lugs (6. and 11) must be tightly crimped to retain them on the appropriate lead. flat washer (7). and insulator washer (5). NOTE: It may be desirable to install terminal lugs (11) after the exciter stator has been installed in the end bell. Disassembly A.HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 PROCEDURE 1. 4 Page 601 Jun 1/00 . washer (4). terminal lug (6). black lead terminal lug (6). Assembly A. Torque screw (2) 12 to 14 lb-in. terminal lug (6). Install insulation bushing (8). 9. spring tension washer (3).

4 Page 602 Jun 1/00 .HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 A-67985-1 Repair of Replacement of Exciter Stator Components (Sheet 2 of 3) 24-20-76 REPAIR Repair No.

HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 A-67986-1 Repair of Replacement of Exciter Stator Components (Sheet 3 of 3) 24-20-76 REPAIR Repair No. 4 Page 603 Jun 1/00 .

.

To remove the lead from a diode. Disassembly NOTE: Original 915F199-1 is a cemented assembly without a snap ring (1. C. Remove diodes (4 and 5) and holders (8) can be removed from bus ring tube (3). Remove screws (9. Remove lead connections to bus ring tube (3) using brazing set. NOTE: Due to the complexity and the special equipment and tooling required to repair Semiconductor Device Set 949F283-1. F. Lightly tap the semiconductor device set (8) out of the armature-rotor shaft with a 3/4 inch (19 millimeter) diameter phenolic rod and a soft-faced mallet. Remove nuts (6). B. 5 Page 601 Feb 26/07 . drill out rivet (13) with a Number 35 drill. A. Type 12-062 or 12-064. IPL Figure 4). washers (7). IPL Figure 4) from insulating tube (18) proceed as follows: (1) Cut the lacing tape holding capacitor leads to capacitor fixture (15) and unsolder the capacitor connections. If repair is required. H. to heat the brazed joint. NOTE: It may be necessary to use a sharp pointed instrument to cut holding material for spacer (2). washers (10). (3) Remove assembled items (4 through -15F) from insulating tube (18). and bushings (11 and 12). modify to 946F177-1 in accordance with Service Bulletin 71-103. and diodes (4 or 5). (2) Remove retaining ring (1) and spacer (2). IPL Figure 3). Disconnect rotor winding leads (two DC field and three AC armature leads) from the semiconductor device set. To remove assembled items (4 through -15F. D. it is recommended that repair of this item be accomplished by the Hamilton Sundstrand Shannon Repair Center. G.HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 PROCEDURE 1. NOTE: The diodes are numbered consecutively from 1 to 6 beginning at the capacitor end. Semiconductor Device Set (Sheet 1 of 5) 24-20-76 REPAIR Repair No. E.

Semiconductor Device Set (Sheet 2 of 5) 24-20-76 REPAIR Repair No. Install diodes (4 or 5) in holder (8) and attach with washer (7) and nut (6). Diodes in positions 1 and 4 have two leads. WARNING: WEAR INSULATED GLOVES AND OTHER SUITABLE PROTECTION WHEN HANDLING HEATED PARTS. Diodes in positions 4. Hold the assembly with diode position 6 at the end near you and with the split in bus ring tube (3 or -3A) at the twelve o'clock position (refer to illustrations) connect leads as follows: NOTE: Diodes in positions 1. A. (2. HOLD DIODE BY RIVET TERMINAL NOT BY THE CASE. (1) Braze larger lead from diode in position 4 to the terminal at twelve o'clock position on the near end of bus ring tube (3 or -3A). Type 12-062 or 12-064. Bend terminal of bus ring tube as shown in illustration. and 3 have black leads and connect to the bus tabs closest to the capacitor end. If missing or damaged. (2) Braze larger lead from diode in position 1 to the terminal at twelve o'clock position on the far end of bus ring tube (3 or -3A). and 6 have white leads and connect to the bus tabs farthest from the capacitor end. 5 Page 602 Jun 1/00 . This is to provide clearance between lead wires and insulating tube (3). D. C. also provide clearance with spacer (2).HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 2.9 to 3. (6) Braze lead from diode in position 3 to the terminal at eight o'clock position on the far end of bus ring tube (3 or -3A). Braze the diode leads to bus ring tube (3) using brazing set. Torque nut 25 to 30 lb-in. attach new leads (9 through 12) to diodes (4 and 5) using rivets (13) and spring washers (14) B. (5) Braze lead from diode in position 6 to the terminal at eight o'clock position on the near end of bus ring tube (3 or -3A). (7) Perform a continuity check for proper diode polarity and/or shorts. the smaller lead is for connection to the capacitor. 5. 2. Assembly CAUTION: TO PREVENT DAMAGE TO THE DIODE WHEN RIVETING. (3) Braze lead from diode in position 5 to the terminal at four o'clock position on the near end of bus ring tube (3 or -3A). (4) Braze lead from diode in position 2 to the terminal at four o'clock position on the far end of bus ring tube (3 or -3A). Braze in accordance with Military Standard MIL-B-7883.3 N•m).

[0. DO NOT BREATHE VAPORS. Semiconductor Device Set (Sheet 3 of 5) 24-20-76 REPAIR Repair No.125 in. and capacitor must be concentric within 0. or insulating tube (18).598 to 12. WASH WITH SOAP AND WATER. FLUSH WITH WATER FOR 15 MINUTES AND SEEK MEDICAL ATTENTION.175 mm]). (5) Cure adhesive at 150 degrees Celsius (300 degrees Fahrenheit) for 6 hours.12 in. (1) Apply adhesive A701 to ring (16) and capacitor fixture (15) to insulating tube (18).06 in. (3) At the capacitor end. OR HOT SURFACES. Install assembled parts (4 through -15F) into insulating tube (18).52 mm). F. I. G. J.954 mm) holes in insulating tube (18).381 by 3. IN CASE OF SKIN CONTACT. (2) Install parts in curing fixture 909C499-1. IS TOXIC. WARNING: ENAMEL IS TOXIC AND FLAMMABLE. USE IN WELL-VENTILATED AREA. (1. (0. Install insulation sleeve (-15F) over capacitor leads. (3. If necessary to replace ring (16).04 mm) diameter holes in the tube. WARNING: PUT ON THERMALLY INSULATED GLOVES AND OTHER SUITABLE PROTECTION TO PREVENT BURNS WHEN LOADING PARTS INTO A PREHEATED OVEN OR HANDLING HEATED OR CHILLED PARTS. IN CASE OF EYE CONTACT. FLUSH WITH WATER FOR 15 MINUTES AND SEEK MEDICAL ATTENTION. PREVENT EYE AND SKIN CONTACT AND DO NOT BREATHE VAPORS. PUT ON SPLASH GOGGLES. SOLVENT-RESISTANT GLOVES. IN CASE OF EYE CONTACT. WASH WITH SOAP AND WATER. tube. Slide sleeving (-15F) over connection and tie to leg of capacitor fixture (15) with lacing tape (0. The diameter of the ring. aligning five swage nuts of bus ring tube (3) and holders (8) with five 0. FLAME.508 mm) total indicated reading (See flag note 1 of illustration). AND OTHER PROTECTIVE GEAR. USE IN WELL-VENTILATED AREA FREE FROM SPARKS.496 to 0. 5 Page 603 Feb 26/07 . Leads must not protrude outside capacitor holder leg more than 0. IN CASE OF SKIN CONTACT. Apply a coating of Glyptal 1201EW Sealer over the taped connection. H.015 by 0. bond insulating tube (18) to capacitor fixture (15) at the 0. capacitor fixture (15). bond as follows: WARNING: ADHESIVE. STRUCTURAL. Solder capacitor leads in accordance with Military Standard MIL-S-6872 using pure tin solder. (4) No adhesive is to extend above the outside diameter of the tube.HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 E.020 in. (12.510 in.

P. IPL Figure 3) into armature-rotor shaft by pressing on metal end ring until the holes in the semiconductor device set or rectifier assembly line up with the holes in the shaft. R. Remove retaining ring (1) and spacer (3).500 in. 3.007 x 0. Q. (0. N.9 N•m). (1.001 in.7 to 1. (0. perform a dynamic balance in accordance with CHECK. Tie leads from AC Generator rotating field to shaft using commercial tape. Place a small amount of silicone rubber sealant to spacer (2) in three equally spaced places. and screws (9). Install spacer (2) and retaining ring (1).025 mm) feeler gauge. Assemble semiconductor device set (8. IN CASE OF EYE CONTACT. WASH WITH SOAP AND WATER. PUT ON SPLASH GOGGLES. Coat tape with Glyptal 1201EW Sealer. L. FLAME. Check repaired semiconductor device set in accordance with CHECK. Shape lead from the exciter armature to be under the end turns of the exciter armature before tightening screws (9). After complete assembly of the rotor-armature. IN CASE OF SKIN CONTACT. DO NOT BREATHE VAPORS. Temporarily insert spacer (2) and retaining ring (1). The spacer must be tight against holder (8) when retaining ring is in place. AND OTHER PROTECTIVE GEAR. K. USE IN WELL-VENTILATED AREA FREE FROM SPARKS. 5 Page 604 Feb 26/07 .700 mm). OR HOT SURFACES. Semiconductor Device Set (Sheet 4 of 5) 24-20-76 REPAIR Repair No. Be sure screws are fully seated. WARNING: ENAMEL IS TOXIC AND FLAMMABLE. T. 0. FLUSH WITH WATER FOR 15 MINUTES AND SEEK MEDICAL ATTENTION. Install bushings (11 and 12) washers (10). S. O.177 x 12. check for clearance with a 0.HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 CAUTION: DO NOT ROUTE ANY LEAD DIRECTLY UNDER A SWAGE NUT OR AGAINST THE HEX BASE OF A DIODE BECAUSE THE LEAD MAY FRAY AND SHORT IN SERVICE. Where capacitor leads must pass by a swage nut. Torque screws 15 to 17 lb-in. Bond holders (8) to insulating tube (18) in locations and lengths shown in illustration M. SOLVENT-RESISTANT GLOVES. bond the lead to the holder with a small amount of silicone rubber sealant.

5 Page 605 Jun 1/00 .HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 A-67186 Semiconductor Device Set (Sheet 5 of 5) 24-20-76 REPAIR Repair No.

.

disconnect the armature-rotor leads in accordance with CHECK.rotor shaft as follows: NOTE: The adapter set contains a base support and a press adapter to facilitate wound armature (13 or -13A) installation. Assembly CAUTION: DO NOT INTERCHANGE WOUND ARMATURE (EXCITER) OF GENERATOR 976J598-1 (CUBEX STEEL) WITH PARTS OF ANY OTHER GENERATORS COVERED IN THIS MANUAL (REFERENCE SERVICE NEWS LETTER 45). adapter plate. 6 Page 601 Jun 1/00 . to press off wound armature (13 or -13A)as follows: NOTE: The adapter set contains a base support. on an arbor press and place padding in the bottom to protect the armature-rotor. and press adapter to facilitate exciter removal. (2) Place armature-rotor (IPL Figure 3)into base support with drive end down.HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 PROCEDURE 1. A. To remove wound armature (13 or -13A). (4) Place press adapter 909C497-1. (3) Lift the armature-rotor out of the base support high enough to slide adapter 944B451-2 between the exciter winding and the main alternating current winding. with drive end towards support. (1) Place armature-rotor on base support 909C498-1. CAUTION: DO NOT INTERCHANGE WOUND ARMATURE (EXCITER) OF GENERATOR 976J598-1 (CUBEX STEEL) WITH PARTS OF ANY OTHER GENERATORS COVERED IN THIS MANUAL (REFERENCE SERVICE NEWS LETTER 45). The armature-rotor will now rest on the base support and the adapter. 2. (2) Heat wound armature (13 or -13A) to 160 ± 10 degrees Celsius (325 ± 25 degrees Fahrenheit). Use adapter set 928A903-3. Disassembly A. THE CUBEX PARTS ARE SHORTER IN LENGTH THAN THE OTHER PARTS AND THIS DIFFERENCE IN LENGTH CAUSES CIRCULATING CURRENTS IN THE ROTOR BANDS THAT RESULT IN OVERHEATING THAT CAN DAMAGE THE GENERATOR. on anti-drive end of armature-rotor and press off wound armature (13 or -13A). Wound Armature Replacement (Sheet 1 of 2) 24-20-76 REPAIR Repair No. Use adapter set 928A903-3. THE CUBEX PARTS ARE SHORTER IN LENGTH THAN THE OTHER PARTS AND THIS DIFFERENCE IN LENGTH CAUSES CIRCULATING CURRENTS IN THE ROTOR BANDS THAT RESULT IN OVERHEATING THAT CAN DAMAGE THE GENERATOR. (1) Place base support 944B450-2. to assemble wound armature (13 or -13A) on armature. B.

6 Page 602 Jun 1/00 . (97. CAUTION: BE SURE ADAPTER IS PRESSING ON THE STEEL CORE WHEN PRESSING ON THE WOUND ARMATURE. IN CASE OF EYE CONTACT. (0. FLUSH WITH WATER FOR 15 MINUTES AND SEEK MEDICAL ATTENTION.002 in. WEAR SPLASH GOGGLES. apply one coat of MIL-P-15328 (zinc chromate primer finish) to the outside diameter. (3) Set wound armature (13 or -13A) on shaft while it is still hot. (7) Check armature-rotor balance in accordance with CHECK. (6) Install items (9 through 12. (97.917 mm) diameter after application. The outside diameter shall not exceed 3. aligning the three leads with the three terminal connection points. Over spray is permissible on all areas except bearing journals. Press the wound armature onto the shaft with press adapter 962C206-1. (5) After grinding wound armature (13). WARNING: ZINC CHROMATE PRIMER IS TOXIC AND FLAMMABLE.790 to 97.855 in. USE IN WELL VENTILATED AREA FREE FROM SPARKS. until it bottoms against the shoulder of the armaturerotor shaft. IN CASE OF SKIN CONTACT. IPL Figure 3) in accordance with Repair 6. WASH WITH SOAP AND WATER. FLAME OR HOT SURFACES. (4) Grind outside diameter of wound armature to 3. DO NOT BREATHE VAPORS. Wound Armature Replacement (Sheet 2 of 2) 24-20-76 REPAIR Repair No.HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 WARNING: WEAR INSULATED GLOVES AND OTHER SUITABLE PROTECTION WHEN HANDLING HEATED PARTS. Maximum run out of cores must be within 0.854 in.850 to 3.050 mm) total indicated reading from the bearing journals. SOLVENT RESISTANT GLOVES AND OTHER PROTECTIVE GEAR.890 mm).

D. Remove screws (49) and washers (50). Repair of Stator Terminal 24-20-76 REPAIR Repair No. flat washers (46). B. completely covering the head. WARNING: WEAR INSULATED GLOVES AND OTHER SUITABLE PROTECTION WHEN HANDLING HEATED PARTS. Install terminal board (48) on generator stator (55) with washers (50) and screws (49). F. Install stud (51) through the bottom of terminal board (48 or -48A). NOTE: Parts may be preheated to 65 degrees Celsius (150 degrees Fahrenheit) to aid the flow of adhesive. D. Apply A701 adhesive around head of stud (51).0 N•m). and square shouldered washers (47) from any stud (51) that is to be removed. Remove self-locking nuts (44). check that studs (51) are securely bonded into terminal board (48). Torque screws 30 to 36 lb-in. WARNING: WEAR INSULATED GLOVES AND OTHER SUITABLE PROTECTION WHEN HANDLING HEATED PARTS. (3. flat washers (46). Cure by baking at 150 degrees Celsius (300 degrees Fahrenheit) for 6 hours. B. Remove terminal board cover (43. C. NOTE: Screws attaching terminal board have lockwire holes. To replace a stud (51). The threads must be free of any adhesive. C. WARNING: WEAR INSULATED GLOVES AND OTHER SUITABLE PROTECTION WHEN HANDLING HEATED PARTS. Disassembly A. 2. After the assembly has cooled. Install square shouldered washers (47). heat the terminal board at 150 degrees Celsius (300 degrees Fahrenheit) until the bonding material is soft and the stud can be pressed out of the terminal board. IPL Figure 1). 7 Page 601 Jun 1/00 .HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 PROCEDURE 1. lock washers (45).4 to 4. and selflocking nuts (44) on stud (51). Do not torque self-locking screws. E. NOTE: The studs are assembled from the underside of the terminal board and the stud heads are bonded in place (on underside only). but do not need to be wired since they go into self-locking helical inserts. lock washers (45). they are tightened after either test leads or aircraft leads are installed. Assembly A.

.

Touch up any bare or scratched metal by applying chemical conversion coating in accordance with MIL-C-5541. IPL Figure 1).076 mm) thick coating of primer. FLUSH WITH WATER FOR 15 MINUTES AND SEEK MEDICAL ATTENTION. Install the appropriate insulation sleeve (61 through 63) for the the terminal (56 through 60) that is being replaced. WASH WITH SOAP AND WATER. FLUSH WITH WATER FOR 15 MINUTES AND SEEK MEDICAL ATTENTION. replace helical inserts (64 and 65) in accordance with Hamilton Sundstrand Standard Practices Manual 24-10-00. (0.001 to 0. 8 Page 601 Jun 1/00 . bend the terminal as shown to provide later assembly clearance. E. (2) Lubricate screw threads with lubricating oil and install screw. SOLVENT-RESISTANT GLOVES. FLAME. WARNING: CHEMICAL CONVERSION COATING IS CORROSIVE TO HUMAN TISSUE. WARNING: PRIMER IS TOXIC AND FLAMMABLE. If damaged or missing. IN CASE OF EYE CONTACT.016 in. 2. AND OTHER PROTECTIVE GEAR. For terminal T4. WARNING: WEAR INSULATED GLOVES AND OTHER SUITABLE PROTECTION WHEN HANDLING HEATED PARTS. USE IN WELL-VENTILATED AREA FREE FROM SPARKS. Disassembly WARNING: WEAR INSULATED GLOVES AND OTHER SUITABLE PROTECTION WHEN HANDLING HEATED PARTS.025 to 0. THE COATING RESIDUE MAYBE EASILY IGNITED WHEN DRY. Braze lead to terminal lug in accordance with Military Standard MIL-B-7883. Torque screw to 140 lb-in. DO NOT BREATHE VAPORS. replace screw (66) as follows: (1) Using an 82 degree countersink remove any burrs from old staking of the screw. IN CASE OF EYE CONTACT. If the primer on the inside diameter has been worn away or removed.HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 PROCEDURE 1. If damaged or missing. SOLVENT-RESISTANT GLOVES. RINSE APPLICATOR WITH WATER BEFORE DISPOSAL. Using localized heat (refer to Hamilton Sundstrand Standard Practices Manual 24-10-00) disconnect brazed lead from any defective terminal (56 through 60. WASH WITH SOAP AND WATER. Repair of Stator (Sheet 1 of 2) 24-20-76 REPAIR Repair No. USE IN WELL-VENTILATED AREA. A. AND OTHER PROTECTIVE GEAR. (0. OR HOT SURFACES. IN CASE OF SKIN CONTACT. DO NOT BREATHE VAPORS. WEAR SPLASH GOGGLES. Do not exceed the minimum inside clearance requirement shown. apply a 0. B. Remove terminal and insulating sleeve (61 through 63) Assembly A. F. D.9 N•m).003 in. G. C. IN CASE OF SKIN CONTACT. (3) Stake the screw so that a minimum of 0. (15. WEAR SPLASH GOGGLES.406 mm) of stator housing material is displaced into the screw slot. B. Install terminal in stator (55) to the height and clearance shown. Class 3.

HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 A-67187 Repair of Stator (Sheet 2 of 2) 24-20-76 REPAIR Repair No. 8 Page 602 Jun 1/00 .

4 to 0. Torque screws 4 to 5 lbin. Assembly A.HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 PROCEDURE 1. 9 Page 601 Jun 1/00 . washers (69). B. Mark the new identification plate (-67A) with all information such as serial number using either steel stamps or vibro-etch method. B. Remove screws (68). and screws (68). (0. Lubricate threads of screws (68) with lubricating oil. Install identification plate (-67A). Disassembly A. 2.5 N•m). Replacement of Identification Plate 24-20-76 REPAIR Repair No. washers (69). and identification plate (67).

.

10 Page 601 Jun 1/00 .HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 A-69060 Repair of Terminal Block Separators (Sheet 1 of 2) 24-20-76 REPAIR Repair No.

B. use sandpaper to restore the contour of the repaired area. WARNING: REACTIVE POLYAMIDE RESIN AND EPOXIDE RESIN ARE TOXIC AND FLAMMABLE. SOLVENT-RESISTANT GLOVES. C. grease. WARNING: WEAR INSULATED GLOVES AND OTHER SUITABLE PROTECTION WHEN HANDLING HEATED PARTS.3 square inch (193. Stir the mixture gently until the color is uniform. AND OTHER PROTECTIVE GEAR. Check (refer to the view). Repair terminal block separators as follows: WARNING: ISOPROPYL ALCOHOL IS TOXIC AND FLAMMABLE. OR HOT SURFACES. IN CASE OF SKIN CONTACT. Cure the terminal block in an oven at 149 ± 15 degrees Fahrenheit (65 ± 8 degrees Celsius) for 2 hours minimum. USE IN WELL VENTILATED AREA FREE FROM SPARKS. F. WEAR SPLASH GOGGLES. SOLVENT-RESISTANT GLOVES. DO NOT BREATHE VAPORS. IN CASE OF SKIN CONTACT. remove any glossy or shiny finish from the terminal block separators with fine sandpaper. WASH WITH SOAP AND WATER. OR HOT SURFACES. Clean the terminal block with isopropyl alcohol to remove dirt. NOTE: The pot life of the mixture is approximately 30 minutes. The base of the rib must be intact. D. IN CASE OF EYE CONTACT. or build up the separator to the original contour. NOTE: The following procedure can only be used on the separators of the terminal block. AND OTHER PROTECTIVE GEAR. E. FLAME. and oil. WASH WITH SOAP AND WATER.5 mm) or less each can be built up to the original contour. WEAR SPLASH GOGGLES. bond broken pieces. FLAME. Apply the epoxy mixture with a brush or spatula as necessary to seal cracks. A. Mix 30 parts by weight of Reactive Polyamide Resin with 70 parts by weight of epoxide resin. USE IN WELL VENTILATED AREA FREE FROM SPARKS. Broken sections and chips can be bonded to the separator. or at 176 ± 15 degrees Fahrenheit (80 ± 8 degrees Celsius) for 30 minutes minimum. If necessary. DO NOT BREATHE VAPORS. FLUSH WITH WATER FOR 15 MINUTES AND SEEK MEDICAL ATTENTION. If necessary. Allow the part to dry. Repair of Terminal Block Separators (Sheet 2 of 2) 24-20-76 REPAIR Repair No. NOTE: Cure time begins after the part reaches oven temperature. 10 Page 602 Jun 1/00 . FLUSH WITH WATER FOR 15 MINUTES AND SEEK MEDICAL ATTENTION. IN CASE OF EYE CONTACT.HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 PROCEDURE 1. Missing pieces with an area of 0.

11 Page 601 Jun 1/00 .HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 A-71618 Wound Armature Lead Wire Repair (Sheet 1 of 3) 24-20-76 REPAIR Repair No.

Remove wound armature (13 or -13A) in accordance with Repair No. DO NOT TOUCH THE CLEANED WIRES WITH BARE SKIN AS OILS IN THE SKIN MAY WEAKEN THE BRAZED OR SILVER SOLDERED JOINT.HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 PROCEDURE 1. USE IN WELL VENTILATED AREA FREE FROM SPARKS. IN CASE OF EYE CONTACT. repair number SP R10. Install lug terminal (13M. Locate broken lead and cut it as close as possible to the break. 10. WARNING: ISOPROPYL ALCOHOL IS TOXIC AND FLAMMABLE. Also allow a minimum of 1 in. Prepare the replacement lead to achieve the total lead length shown. AND OTHER PROTECTIVE GEAR.4 mm) length of new lead. (25. 4. 7. Strip insulation from existing lead to dimension shown in accordance with Hamilton Sundstrand Standard Practice Manual. WASH WITH SOAP AND WATER. 3.4 mm) of lead extending from wound armature (13 or -13A). 24-10-00. 12. 9. FLUSH WITH WATER FOR 15 MINUTES AND SEEK MEDICAL ATTENTION. Strip insulation from both ends of the new lead to dimension shown in accordance with Hamilton Sundstrand Standard Practice Manual. Braze the wires together in accordance with Military Specification MIL-B-7883 or silver solder in accordance with Hamilton Sundstrand Standard Practices Manual. repair number SP R9. CAUTION: WEAR CLEAN GLOVES TO HANDLE THE CLEANED WIRE. Wound Armature Lead Wire Repair (Sheet 2 of 3) 24-20-76 REPAIR Repair No. DO NOT BREATHE VAPORS. Clean bare wires with cotton swabs soaked with isopropyl alcohol and allow to air-dry. IPL Figure 3) and crimp onto the lead wire using appropriate crimping tool. NOTE: There must be a minimum of 1 in. 6. WEAR SPLASH GOGGLES. FLAME OR HOT SURFACES. 11. repair number SP R9. apply new adhesive glass tape as shown. If the tape used to secure the lead where it exits the coil has been removed or damaged. 24-10-00. Clamp the bare wire of the new lead to the bare wire of the existing lead. IN CASE OF SKIN CONTACT. SOLVENT-RESISTANT GLOVES. 2. Verify the length of the combined leads will meet the dimension shown. 8. 11 Page 602 Jun 1/00 . 7. WARNING: WEAR INSULATED GLOVES AND OTHER SUITABLE PROTECTION WHEN HANDLING HEATED PARTS. 5. 24-10-00. Install an appropriate length of insulation sleeving (heat shrink tubing) over the solder joint and shrink tubing using a heat gun at 230 to 275 degrees Fahrenheit (110 to 135 degrees Celcius) for approximately 10 seconds until the sleeving is snug. (25.

Perform a dielectric check in accordance with CHECK section. If new tape was installed. 6.HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 WARNING: WEAR INSULATED GLOVES AND OTHER SUITABLE PROTECTION WHEN HANDLING HEATED PARTS. Check the tape. Remove wound armature (13 or -13A) from the oven and allow it to cool to room temperature. Install wound armature (13 or -13A) in accordance with Repair No. 13. 15. 17. it should be hard. 11 Page 603 Jun 1/00 . Wound Armature Lead Wire Repair (Sheet 3 of 3) 24-20-76 REPAIR Repair No. 16. place wound armature (13 or -13A) in a preheated electric oven at 477 to 487 degrees Fahrenheit (247 to 253 degrees Celsius) for 2 hours maximum. 14.

.

When necessary. Reference to item numbers in the text and accompanying illustrations are identical to those in the ILLUSTRATED PARTS LIST. 3. EXCITER STATOR. assembly illustrations are also provided.asp. reference to item (1) means that procedures also apply to alpha variant items (-1A. For example. B. Assembly of Semiconductor Device Set or Rectifier Assembly (IPL Figure 4) NOTE: Refer to REPAIR for assembly of Semiconductor Device Set or Rectifier Assembly. for general assembly procedures. Assembly of Armature-Rotor (IPL Figure 3) NOTE: For replacement of parts not covered in the following assembly procedures. These consumable materials are known to align with all of the design and qualification requirements. NOTE: Reference to item numbers in text implies that alpha variant items listed in the IPL may be used as determined by the effect code for that item.HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 ASSEMBLY 1. Storage instructions are also included in this section. Refer to FITS AND CLEARANCES for summarized assembly procedures and torque values. fixtures. ASSEMBLY 24-20-76 Page 701 Feb 26/07 . C. 2. refer to REPAIR. WOUND ARMATURE (EXCITER). NOTE: Equivalent tools. and equipment can be used if they align with the requirements of ARINC Report 668. NOTE: The full address and other information regarding vendors or suppliers listed in Figure 701 can be obtained by using the World Wide Web (www) at the following URL http://www. CAUTION: DO NOT INTERCHANGE ROTOR-ARMATURE (COMPLETE ASSEMBLY). Materials required for assembly are listed in Figure 701. Other CAGE Code sites are also available on the web. This section contains assembly procedures.bpn.gov/bincs/begin_search. General A. Special tools and equipment used for assembly are listed in Figure 702. THE CUBEX PARTS ARE SHORTER IN LENGTH THAN THE OTHER PARTS AND THIS DIFFERENCE IN LENGTH CAN CAUSE CIRCULATING CURRENTS IN THE ROTOR BANDS WITH RESULTANT HEATING IN THE BANDS THAT CAN DAMAGE THE GENERATOR. Only approved materials engineering can make equivalent consumable material decisions and these materials are used at the risk of the organization who makes the decision. and -1C). NOTE: Maintenance personnel must use the specified consumable material for the specified task. -1B. ASSEMBLY. Refer to Standard Practices Manual 24-10-00. OR GENERATOR STATOR OF GENERATOR 976J598-1 (CUBEX STEEL) WITH PARTS OF ANY OTHER GENERATORS COVERED IN THIS MANUAL (REFERENCE SERVICE NEWS LETTER 45).

Grease Aero Shell No. Install packing (6) on generator spindle (3) using “O” ring guide 919B555-1 until the packing is in the groove next to the large spline. Molybdenum Disulfide MIL-M-7866 Dow Corning Corp. CAGE Code: 71984 or Antifretting Compound.HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 A. C. Incorporated CAGE Code: 56385 or Preformed Packing Lubricant Royco HF825 Royal Lubricants Company. MS20995C32 Compound.032 inch diameter. NOTE: The “O” ring guide should be used to prevent cutting the packing while installing it over splines. Lubricant. 0. MATERIAL SOURCE Preformed Packing Lubricant NS6074R Syn-Tech Limited CAGE Code: 53592 or Preformed Packing Lubricant Assembly Fluid No. B. 1 Ultrachem. Lock. Part Number 730691 730691-1 = 5cc tubes 730691-2 = 16 oz container 730691-3 = 5 cc polyethylene bag 730691-4 = 24 oz cartridge 730691-5 = 25 cc tube 730691-6 = 30 cc plastic syringe Wire. Place armature-rotor components (8 through 16. Antiseize Compound(C-6380) MIL-T-22361 Hamilton Sundstrand CAGE Code: 99167 Commercially Available Federal-Mogul Corp. IPL Figure 3) in adapter 919B555-1. 14 MIL-G-25537 CAGE Code: ER096 Shell Oil Co. Lubricate packings (6 and 7) with preformed packing lubricant. Fel-Pro Gasket Division CAGE Code: 73165 Assembly Materials Figure 701 (Sheet 1 of 2) ASSEMBLY 24-20-76 Page 702 Feb 26/07 . Inc. CAGE Code: 3L586 and Lubricant.

Torque screws 40 to 50 lb-in. Install generator spindle (3). Scotchcast 253) CAGE Code: 76381 Nu-Brite Chemical Co. L. Install retaining ring (5) using retaining ring plier so that the sharp outside diameter of the ring faces away from the spindle. Inc. E. K. NUMBER DESCRIPTION 918B450-1 919B555-1 922B865-2 See Figure 901 See Figure 905 See Figure 906 Adapter (2 required) "O" Ring Guide Spanner Wrench Generator Support Alignment Pin Alignment Pin Assembly Special Tools and Equipment Figure 702 H.HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 MATERIAL SOURCE Resin. packing (7). Fill splines of stub shaft (1) and generator spindle (3) with antifretting compound. Install packing (7) on seal retainer (4). Sterling Division CAGE Code: 78580 Assembly Materials Figure 701 (Sheet 2 of 2) D. ASSEMBLY 24-20-76 Page 703 Feb 26/07 . Install lockwire on screws (2). NOTE: Some stub shafts may have a slight interference fit. Balance the armature in accordance with procedure in CHECK. Scotchcast 253 3M Resin. F. seal retainer (4) into stub shaft (1)..6 N•m).6 to 5. Be sure all voids are filled with antifretting compound. J. G. I. WARNING: WEAR GOGGLES WHEN INSTALLING LOCKWIRE. (4. Be sure that stub shaft (1) screw holes are aligned with screw holes in the armature-rotor and if necessary use a soft-faced mallet to tap stub shaft into armature-rotor. Lightly coat screws (2) with anti-seize compound and install. Prepare antifretting compound by thoroughly mixing equal parts by weight of molybdenum disulfide and lubricant (MIL-G-25537). Epoxy D-163B (replacement for Resin.

CAUTION: DO NOT INTERCHANGE ROTOR-ARMATURE (COMPLETE ASSEMBLY) OR WOUND ARMATURE (EXCITER) OF GENERATOR 976J598-1 (CUBEX STEEL) WITH PARTS OF ANY OTHER GENERATORS COVERED IN THIS MANUAL (REFERENCE SERVICE NEWS LETTER 45). Install one bearing shield (37) as shown in Figure 703. refer to REPAIR. B. A-73037 Installation of Bearing Shield Figure 703 ASSEMBLY 24-20-76 Page 704 Feb 26/07 . 5. NOTE: Armature-rotor (42) can only be used for generator 976J497-1. A. Assembly of AC Generator (IPL Figure 1) NOTE: For replacement of parts not covered in the following assembly procedures. THE CUBEX PARTS ARE SHORTER IN LENGTH THAN THE OTHER PARTS AND THIS DIFFERENCE IN LENGTH CAN CAUSE CIRCULATING CURRENTS IN THE ROTOR BANDS WITH RESULTANT HEATING IN THE BANDS THAT CAN DAMAGE THE GENERATOR. Assembly of Exciter Stator (IPL Figure 2) NOTE: Refer to REPAIR for assembly of Exciter Stator.HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 4. Install bearing cover (41) on drive-end shaft of armature-rotor (42 or -42A). Armature-rotor (-42A) can only be used on Cubex generator 976J597-1.

STOP AND REMOVE BEARING APPLYING REMOVAL FORCE ONLY TO THE INNER RACE. G. Install bearing cover (41) on shaft of armature-rotor (42 or -42A). E. N. M. NOTE: End bell (30) can only be used with generator stator (55). Install one bearing shield (37) as shown in Figure 703. Install a second bearing shield (37) as shown in Figure 703. Install bowed retaining ring (38) using retaining ring plier so that the tang of the bowed retaining ring contacts bearing shield (37). Place bearing (36) in the second adapter 918B450-1. ASSEMBLY 24-20-76 Page 705 Feb 26/07 .HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 C. CAUTION: BE SURE BEARING STARTS SQUARE ON THE SHAFT. Torque nut (40) 43 to 53 lb-ft. L. Install nut (40) with chamfered face toward bearing (36). K. J. P. IF THE BEARING IS NOT SQUARE TO THE SHAFT IT MAY BIND AND REQUIRE EXCESS FORCE THAT CAN DAMAGE THE BEARING. IF FORCE IS HIGH. IF THE BEARING IS NOT SQUARE TO THE SHAFT IT MAY BIND AND REQUIRE EXCESS FORCE THAT CAN DAMAGE THE BEARING. Position bearing (36) squarely on armature-rotor shaft and press until seated against shoulder of the shaft. F. Bend one tab of key washer (39) into a slot on the side of nut (40). Apply a thin coat of antifretting compound to both the inner and outer races of bearing (36). O. Apply a thin coat of antifretting compound to the chamfered face and threads of nut (40). CAUTION: BE SURE BEARING STARTS SQUARE ON THE SHAFT. Install a second bearing shield (37) as shown in Figure 703. Remove adapter 918B450-1. Position bearing (36) squarely on armature-rotor shaft and press until seated against shoulder of the shaft. Place bearing (36) in the second adapter 918B450-1. D. IF FORCE IS HIGH. Q. STOP AND REMOVE BEARING APPLYING REMOVAL FORCE ONLY TO THE INNER RACE. R. H. Apply a thin coat of a mixture of antifretting compound to both the inner and outer races of bearing (36). I. Install key washer (39) with inside tab aligned with slot in armature-rotor (42 or -42A) shaft and outside tabs away from bearing (36). (59 to 71 N•m) using spanner wrench 922B865-2 while aligning one outside tab of key washer (39) with slot on side of the nut. Install two alignment pins (see Figure 905) on bearing cover (41). Turn armature-rotor (42 or -42A) so that drive-end is in adapter 918B450-1.

Place generator stator (55. -55A. Carefully align and lower assembled components (-10A through -42A) into generator stator (55. Install washers (-26A) and screws (-25A).0 N•m). T.Generator 976J597-1 Cubex.Generator 976J497-1.HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 S. CAUTION: DO NOT ALLOW SURFACES OF THE ROTOR TO TOUCH SURFACES OF THE STATOR AS IT MAY DAMAGE PROTECTIVE COATINGS ON EITHER PART RESULTING IN ELECTRICAL DAMAGE DURING OPERATION. Torque screws 27 to 33 lb-in. or -55B) with terminal end up on generator support (see Figure 901). Generator stator (-55A) can only be used with armature-rotor (-42A) . and four screws (-11A). Turn the AC generator so the drive-end is up. NOTE: If cover (10) has not been modified to cover (-10A) refer to Service Bulletin 79-103. OR GENERATOR STATOR OF GENERATOR 976J598-1 (CUBEX STEEL) WITH PARTS OF ANY OTHER GENERATORS COVERED IN THIS MANUAL (REFERENCE SERVICE NEWS LETTER 45). Install lockwire on screws. V. Lightly coat threads of screws (25) with lubricating oil. (3.4 to 4. Align the screw holes in end bell (30 or -30A) over the alignment pins in bearing cover (41) and install it on armature-rotor (42 or -42A). W. WARNING: WEAR GOGGLES WHEN INSTALLING LOCKWIRE. ASSEMBLY 24-20-76 Page 706 Feb 26/07 . THE CUBEX PARTS ARE SHORTER IN LENGTH THAN THE OTHER PARTS AND THIS DIFFERENCE IN LENGTH CAN CAUSE CIRCULATING CURRENTS IN THE ROTOR BANDS WITH RESULTANT HEATING IN THE BANDS THAT CAN DAMAGE THE GENERATOR. Lightly coat threads of screws (-11A) with lubricating oil. (3. AA. CAUTION: DO NOT INTERCHANGE ROTOR-ARMATURE (COMPLETE ASSEMBLY). Remove the two alignment pins and install the remaining washers (12) and screws (-11A). Z. WOUND ARMATURE (EXCITER).1 to 3. NOTE: Generator stator (55) can only be used with end bell (30) . four washers (12). X. Y. EXCITER STATOR. NOTE: Do not use allen wrench with ball head or chamfered head to install screws (11A) as these types of wrench heads cause the wrenching surface of the screws to distort and make it difficult to obtain the correct torque and will make it difficult to remove these screws. Install lockwire on screws.7 N•m). U. Torque screws 30 to 36 lb-in. or -55B). WARNING: WEAR GOGGLES WHEN INSTALLING LOCKWIRE. -55A. Install cover (-10A).

CAUTION: FAILURE TO USE PROPER TOOL TO POSITION AND SEAT END BELL PROPERLY BEFORE TIGHTENING SCREWS CAN RESULT IN STRESSES IN THE END BELL WHICH COULD LEAD TO FAILURE OF THE END BELL OR THE BEARINGS. Install at least two washers (-53A) and screws (-54A). AK. -55A. If end bell (52A) is used install screws (9A). AJ. Install remaining washers (-53A) and screws (-54A).HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 AB.0 N•m). or -55B). ASSEMBLY 24-20-76 Page 707 Feb 26/07 . NOTE: Do not use allen wrench with ball head or chamfered head to install screws (-54A) as these types of wrench heads cause the wrenching surface of the screws to distort and make it difficult to obtain the correct torque and will make it difficult to remove these screws. Lightly coat threads of screws (-54A) with lubricating oil. AL. Torque screws (9A) 45 to 55 lb-in. AD. AI. AF. -55A or -55B) 180 degrees apart. Install two alignment pins (see Figure 906) on generator stator (55. Apply a thin coat of anitfretting compound to the splines of adapter (4).2 N•m). Install two alignment pins (see Figure 905) on bearing cover (41) 180 degrees apart. (3. AH. or -55B) and over bearing (36). AG. gently tap around the outside diameter until the end bell is fully seated in generator stator (55. -55A. NOTE: Do not use allen wrench with ball head or chamfered head to install screws (9A) as these types of wrench heads cause the wrenching surface of the screws to distort and make it difficult to obtain the correct torque and will make it difficult to remove these screws. Remove alignment pins from bearing cover (41) and generator stator (55. AE.0 N•m). Torque screws 30 to 36 lb-in. Lightly coat packing (7) with performed packing lubricant and install on the armature-rotor (42 or -42A) shaft using "O" ring guide 919B555-1.4 to 4. AC. Lightly coat threads of screws (9 or 9A) with lubricating oil. Install lockwire on screws (54 or -54A) and (9 or 9A).1 to 6. (5. Torque screws (9) 30 to 36 lb-in.4 to 4. NOTE: If end bell (52) is used install backing ring (8) and screws (9). (3. Align end bell (52 or 52A) over the four alignment pins and using end bell assembly tool (see Figure 904) installed over the end bell. WARNING: WEAR GOGGLES WHEN INSTALLING LOCKWIRE.

Install adapter (4).4 to 11.6 N•m). (9. Torque screw 83 to 103 lb-in. AN. and screw (6). Install cover (1) and retaining ring (2) using retaining ring plier. ASSEMBLY 24-20-76 Page 708 Feb 26/07 . washer (5). Lightly coat packing (3) with performed packing lubricant and install on cover (1).HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 AM. AO.

HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 FITS AND CLEARANCES 1. All other parts require pin diameter of 0.2853 (32.2989 mm) 0. (1.1242 (28.2810 (32.2810 (32.2853 (32.1160 (28. 2.7355 mm) 0.0449 mm) 0. (2.5 20 14 10 0 max inch (mm) 1. Reference CHECK.7598 (19.3080 (33.7680 (19.7639 (19.1074 (28.8815 (22.1946 mm).4582 mm) Spline Adapter % wear 25 22. Summarized disassembly and assembly views are also provided for the mechanic experienced in component maintenance procedures.0124 mm) Spindle % wear 25 22.2781 (32.4637 mm) 1.8842 (22.5844 mm) Wear Limit Chart .0864 in.0860 (27.5547 mm) 1. Item numbers used are identical to those shown in the referenced Illustrated Parts List Figure.4637 mm) 1.8773 mm) 0.5072 mm) 0.4031 mm) 0.9060 (23.2232 mm) Spindle % wear 25 22.1204 (28.0720 in.7812 mm) 1.5374 mm) 1.2232 mm) Stub Shaft % wear 25 22.9336 mm) 1.3080 33.2966 (32.5 20 14 10 0 (External) max inch (mm) 1.5 20 14 10 0 24 Teeth max inch (mm) 1.1013 (27.6466 mm) 1.9730 mm) 1.2906 (32.7432 (18. General This section contains dimensional requirements and wear tolerances.4582 mm) 1. Pin diameter for spline adapter (internal) is 0.4587 mm) 0.6466 mm) 1.7267 (18. The summarized views may also be used to check torque values and special maintenance procedures. (Refer to Figures 801 and 802).6238 mm) 0. Time to next overhaul 1000 hrs or less 1500 hrs 2000 hrs 3000 hrs 4000 hrs 6000 hrs Spline Adapter % wear 25 22.2781 (32.8951 (22.5 20 14 10 0 (Internal) max inch (mm) 0.8907 (22.8787 (22.1280 mm) 1.5374 mm) 1.7498 (19.Splined Parts Figure 801 FITS AND CLEARANCES 24-20-76 Page 801 Jun 1/00 .3190 mm) 0.3464 mm) 1.3901 mm) 0.2966 (32.9336 mm) 1. Numerical notes referenced in the summarized views refer to notes provided in the CHECK and REPAIR sections.5 20 14 10 0 16 Teeth max inch (mm) 0.8288 mm).2906 (32.7812 mm) 1.

1814 in.1809/1.139 mm) Wear Limit Chart .922 inches minimum (175.002 T. Exciter Armature O.D.9938/62. Dimensions 0.005 inch T.D.* (0.903 inches (99. Bearing Shaft Journals 1.HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 Item Checked Dimensions 1.I.127 mm) 7. Item Checked Armature .D.974 inches maximum (177.818 mm) 3. (29.R.I.319 mm) 0.Rotor Dynamic Balance Exciter Stator I. (61.D.613 inches (193.268 to 193. Bearing Inserts 2.R.609 to 7.854 inches (97. 4. AC Stator I. 5.085 to 99. (See CHECK and ASSEMBLY AND STORAGE. Other Diameters (Refer to Figure 803 and REPAIR) 3.611 inches (193.917 mm] over paint) 6.370 mm) 6. Exciter Stator Mounting Tab O.) 1.Repair Diameters Figure 803 FITS AND CLEARANCES 24-20-76 Page 802 Jun 1/00 . 7. Wear Limit Chart .611 to 7.0076 mm) 2. Exciter Stator Mounting Tab Runout Anti-Drive End Bell I.Critical Diameters Figure 802 2.D.901 to 3.891 mm) (3. 8.850 to 3.0065 mm) * See CHECK.9949/30.136 mm) 7. (0. 3.319 to 193. Torque Values Reference Figure 804 for the torque values required for assembly. 6.790 to 97. 2. for Exciter Stator Fit Main Rotating Field O.855 inches [97. Rotor Core Concentricity Within 0.4412 in.4407/2.D.050 mm) 3.30 ounce-inch square (216 gram-millimeter) 3.

54 1 . (3.36 lb-in.49 1 .5 lb-in.4 to 4.9 N•m) 30 .4 to 4.9 N•m) 25 . 1-6 1-9 1 .11A 1 .30 lb-in. (3.4 to 1.5 N•m) To 140 lb-in.14A 1 .6 N•m) 15 to 17 lb-in. (15.28 1 .55 lb-in.0 N•m) 45 . (1.5 N•m) 40 .0 N•m) 30 .40 1 .0 N•m) 30 .55 lb-in. (4. (4.21 1 .1 to 3. (1.36 lb-in.0 N•m) 36 .50 lb-in.36 lb-in.4 to 0. (3.36 lb-in.3 N•m) Torque Values Figure 804 FITS AND CLEARANCES 24-20-76 Page 803 Jun 1/00 .1 to 3. (1. (3. (4.HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 IPL Figure & Item No. (5.16 1 .2 N•m) 43 .6 to 5.4 to 4.5 N•m) 12 .11 1 .14 1 .9 to 2.2 N•m) 30 .7 N•m) 45 . (3.33 lb-in.7 to 1. (5.33 lb-in.1 to 6.9 N•m) 4 .0 N•m) No torque at this level of maintenance No torque at this level of maintenance No torque at this level of maintenance 16 .4 to 11.66 1 .4 to 4. (3.4 to 4.9 to 5.54A 1 .6 N•m) 30 .9 to 3.25 1 .25A 1 .53 lb-in.40 lb-in.20 lb-in.9A 1 . (3.1 to 4.7 N•m) 27 .103 lb-in.68 2-2 3-2 3-9 4-6 Item Screw Screw Screw Screw Screw Screw Screw Nut Screw Screw Screw Screw Nut Screw Screw Screw Screw Screw Screw Screw Screw Nut Torque 83 . (0.2 N•m) 27 .14 lb-in. (9.36 lb-in.1 to 6. (2.

.

Fork Attachment 30119 1227-6 3581-3 4286 60B4-1 Extraction Tool (REPAIR) Breakoff Tool (REPAIR) Kelvin Bridge (CHECK)* Insulation Test Set (CHECK & TESTING)* * No longer manufactured. and equipment used in this manual are listed in Figure 901. 04237 89536 8M267 8M267 12-062 or 12-064 L-2926 12-066 12-068 Brazing Set (REPAIR) . PART NUMBER NOMENCLATURE SUPPLIER Model 5220A Model 78 Model 1700 Model 1701B 933A819 H20B TS460/u Hypot Tester Multimeter Digital Converter Plug-In low Ohm Meter Ultrasonic Cleaner (CLEANING) Balancing Machine (CHECK) Impedance Bridge. Test Equipment A.HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 SPECIAL TOOLS. Continued use authorized by Hamilton Sundstrand. FIXTURES AND EQUIPMENT 24-20-76 Page 901 Feb 26/07 . fixtures. Lead Set . Replaced by Quad Tech Digibridge 1750 LCR Tester. Fixtures. Special tools. accuracy. and sources. FIXTURES. Continued use authorized by Hamilton Sundstrand. Refer to Standard Practices Manual. fixtures. 2. Requirements for test equipment are listed in TESTING AND TROUBLESHOOTING. This list includes information about equipment requirements. 3. NOTE: Equivalent tools. and Equipment Figure 901 (Sheet 1 of 4) SPECIAL TOOLS. Type 1650A* * No longer manufactured. Electrodes . Environmental Conditions A. 24-10-00. Insulation Test Set 26344 26344 31922 19315 Model 2512 30218 24655 05611 Special Tools. The environmental conditions present in any certified aircraft turbine engine overhaul shop are acceptable for reconditioning of the ac generator. STANDARD TOOLS. FIXTURES AND EQUIPMENT 1. and equipment can be used provided they meet the requirements of ARINC Report 668. AND EQUIPMENT for general equipment information. General A.

Fixtures. FIXTURES AND EQUIPMENT 24-20-76 Page 902 Feb 26/07 . 42838 948F859-1 976J552-4 6910 with opt. model TS-10 Figure 902 Figure 903 Figure 904 Figure 905 Figure 906 Figure 907 Figure 908 Surge Tester (with optional 3-phase switch) (CHECK) Support . and Equipment Figure 901 (Sheet 2 of 4) SPECIAL TOOLS. Adapter .HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 PART NUMBER NOMENCLATURE SUPPLIER 103MP-2.Gen. to Air Duct (TESTING) Diode Test Set (TESTING) * * No longer manufactured. Diode Test Set (TESTING) with Harness 4401B51-2 Surge Comparison Test Set (CHECK)* * No longer manufactured. Adapter . Continued use authorized by Hamilton Sundstrand. Continued use authorized by Hamilton Sundstrand. Adapter Plate .5DJU Insulation Test Set* * No longer manufactured. Base Support .Generator (DISASSEMBLY & ASSEMBLY) Cradle Fixture (DISASSEMBLY) End Bell Removal Tool (DISASSEMBLY) End Bell Assembly Tool (ASSEMBLY) Alignment Pin (2 required) Alignment Pins (2 required) Alignment Pins (6 required) Special Tools. 05611 7552-3 903J801-1 908C714-1 909C499-1 910C176-1 916B366-11 916B366-17 918B448-1 918B450-1 919B555-1 Installation Tool (REPAIR) Checking Fixture (CHECK) Wrench (DISASSEMBLY) Curing Fixture (REPAIR) Mechanical Puller (DISASSEMBLY) Step Plate (DISASSEMBLY) Step Plate (DISASSEMBLY) Adapter (DISASSEMBLY) Adapter (ASSEMBLY) (2 required) Sleeve Tool (ASSEMBLY) 91767 S-171 922B865-2 928A903-3 944B450-2 944B451-2 909C497-1 962C206-1 909C498-1 938D844-3 939D192-1 Riveting Tool (ASSEMBLY) Spanner Wrench (DISASSEMBLY & ASSEMBLY) Adapter Set (REPAIR) . Support Adapter . Continued use authorized by Hamilton Sundstrand.

62679 None None . and Equipment Figure 901 (Sheet 3 of 4) SPECIAL TOOLS.4411 has been determined on Column.4411 diameter)* * After the setting of 2.HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 PART NUMBER 60109148 601091052 60069565 60102149 60069562 60102175 60107601 60087019 None None None NOMENCLATURE SUPPLIER Air Gage Set (CHECK) . Fixtures. 60106869. Master Setting Disk (1.0003 in. Master Setting Ring (2. Connector . FIXTURES AND EQUIPMENT 24-20-76 Page 903 Feb 26/07 . High Speed Steel Gage Measuring Wire (0. Master Setting Disk (1. Hose Assembly Air Snap . Master Setting Ring (2. Air Snap Gage 54465 .1809 diameter) . Double Column .4407 diameter) .) . Hose Assembly .4407/2. dia. Single Column . Handle .1814 diameter) (Above no P/N's made from AGD Cylindrical Class XX Steel) Digibridge 1750 LCR Tester Quad Tech Digibridge 1750 LCR Tester * * Replaces Impedance Bridge. Type 1650A 0H4A4 Special Tools. Spindle (2. raise the scale marker on the column 0. (0.0076 mm) for upper limit.4411) .0864 in. and 0. dia.Spindle .0720 in.

g. 05611 Slaughter Company 0H4A4 Quad Technologies 24655 Genrad Inc. NOTE: To request a quotation for Ground Support Equipment. Box 7002. or better than. 89536 Fluke Corp. 62679 Van Keuren Co. Rockford. use the online order request website listed here: http://www. Corp. FIXTURES AND EQUIPMENT 24-20-76 Page 904 Feb 26/07 . 775.gov/bincs/begin_search. IL 61125-7002. 54465 Warner and Swasey Co. NOTE: Unless otherwise noted (CAGE Code Listed).O.asp. Co. Sheffield Measurement Div. and Equipment Figure 901 (Sheet 4 of 4) SPECIAL TOOLS.com/gse. Other CAGE Code sites are also available on the web.hamiltonsundstrand. you may get hardware with a build letter suffix added to the tool part number (e. Fixtures. the drawings for the tools listed above are available from Hamilton Sundstrand on request. Attention: Contract Data Management. 31922 Leeds and Northrup Co. 4747 Harrison Avenue. NOTE: The full address and other information regarding vendors or suppliers listed above can be obtained by using the World Wide Web (www) at the following URL http:// www. P. the part number in the list above. 26344 New Haven Mfg.HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 CAGE CODE SUPPLIER 04237 Associated Research Inc. AGEXXXXXA). 56477 P J Electronics Inc. 30119 Ideal Industries 30218 Schenk Corp. Forward requests for the drawings to the local Hamilton Sundstrand field service representative or request drawings from Hamilton Sundstrand. This hardware is the newest tool/equipment design and is equivalent to. Dept. When you order a special tool listed above. 8M267 Electro Scientific Industries Inc. Special Tools. 42838 National Rivet & Mfg.bpn.

HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 A-67188 Generator Support Figure 902 SPECIAL TOOLS. FIXTURES AND EQUIPMENT 24-20-76 Page 905 Jun 1/00 .

HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 A-67189 Cradle Fixture Figure 903 SPECIAL TOOLS. FIXTURES AND EQUIPMENT 24-20-76 Page 906 Jun 1/00 .

FIXTURES AND EQUIPMENT 24-20-76 Page 907 Jun 1/00 .HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 A-67190 End Bell Removal Tool Figure 904 SPECIAL TOOLS.

FIXTURES AND EQUIPMENT 24-20-76 Page 908 Jun 1/00 .HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 A-67191 End Bell Assembly Tool Figure 905 A-67192 Alignment Pin Figure 906 SPECIAL TOOLS.

FIXTURES AND EQUIPMENT 24-20-76 Page 909 Jun 1/00 .HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 A-67193 Alignment Pin Figure 907 A-67194 Alignment Pin Figure 908 SPECIAL TOOLS.

.

the NOMENCLATURE column employs the indenture system. D. They are preceded by the words ATTACHING PARTS and are followed by three asterisks (* * *).) are assigned and listed in the EFF CODE column. For identification of detail parts and assemblies. Effectivity codes (A. to the next higher assembly (NHA). B. Conversely. the next higher assembly of any detail part may be determined by its location in the indenture above and to the left. B. This IPC (or IPL) does not constitute a grant of direct-ship authority. showing relationships to higher and lower assemblies.. Introduction A. there is no relation between the codes of one figure and the codes of any other figure. or Parts Manufacture Approval (PMA) for use in the component listed. subassembly. when purchased from Hamilton Sundstrand. F. These codes show that a part of subassembly is used only on the assembly(ies) with the same effectivity code(s). Installation eligibility of all parts and assemblies purchased directly from a listed vendor must be supported by the vendor's Parts Manufacture Approval (PMA). C. when two or more similar assemblies are broken down in the same IPL figure. and are identified by corresponding index numbers on board-layout and exploded view illustrations. The part numbers identified in this Illustrated Parts List have been shown to comply with the applicable Federal Aviation Regulations and. All items are assigned an item number. and subsequently to the end-item figure and the end item(s).303 for parts and assemblies purchased directly from a listed vendor. or assembly is used when multiple end items are listed). ILLUSTRATED PARTS LIST 24-20-76 Page 1001 Feb 26/07 . To determine end-item effectivity (on which end item a part.. All parts are listed in order of disassembly. This lead to the assembly(ies) on which the item is used. are FAA-approved under a Hamilton Sundstrand FAA Production Certificate (PC). G.HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 ILLUSTRATED PARTS LIST 1. A part or subassembly with no effectivity code is used on all of the assemblies listed in that figure. find the effectivity code(s) of the item in question. C. or otherwise confer FAA-approval under FAR 21. Technical Standard Order (TSO). The Illustrated Parts List (IPL) provides a breakdown of the equipment covered by this manual. Attaching parts immediately follow the part or assembly which they attach and have the same indenture. Items listed but not illustrated are identified by a dash (-) preceding the item number. Each assembly is listed with its detailed parts list in the next indenture below and to the right. Although the same effectivity codes may be used in more than one IPL figure. E.

HAMILTON SUNDSTRAND
COMPONENT MAINTENANCE MANUAL
PART NUMBER 976J497 AND 976J597
H.

2.

Unless otherwise indicated by a vendor code number in parentheses following the part
name in the parts list, all parts are either commercial standard, military standard, or
Hamilton Sundstrand parts.

Definitions
The following is a list of terms, their abbreviations (if applicable), and interpretations of how they
are used in the IPL of this manual.
If the usage of any of the following terms is the result of a service bulletin, it is noted in the
NOMENCLATURE column preceding the term statement. Example: (PRE SB 4)(SUPSD BY
XX) or (POST SB 4) (SUPSDS XX).
A.

ALTERNATE (ALT). Indicates a part, subassembly, or assembly that fully meets required
functional and structural specifications but differs in overall dimensions, connections,
installation, or mounting provision, and requires modification to install in a specific
application. An alternate item is listed in the FIG-ITEM column as a variant and identified
in the NOMENCLATURE column as “(ALT TO XX).”

B.

OPTIONAL (OPT). Indicates a choice of interchangeable parts, subassemblies,
assemblies, or units that meet or exceed required functional and structural specifications
for a given application. Overall dimensions and connections may vary, provided that
installation or mounting does not require rework or modification.
An option item is listed in the FIG-ITEM column as a variant and identified in the
NOMENCLATURE column as “(OPT TO XX)” or “(VXXXXX) OPTIONAL.”

C.

REPLACES/REPLACED (REPLS/REPLD). A part, subassembly, assembly, or unit is
replaced when a new part is considered to have superior qualities. Old parts may be used
until stock is depleted. A replaced item is listed in the FIG-ITEM column as a variant and
identified in the NOMENCLATURE column as “(REPLD BY XX).” The replacing item is
listed in the FIG-ITEM column as a variant and identified in the NOMENCLATURE column
as “(REPLS XX).”

D.

SUPERSEDES/SUPERSEDED (SUPSDS/SUPSD). A part, subassembly, assembly, or
unit is superseded when it is not of an alternate or optional nature with the new one. It is
due to a design change and is no longer required at the specific application. Old item
stock may not be used for replacement. A superseded item is listed in the FIG-ITEM
column as a variant and identified in the NOMENCLATURE column as “(SUPSD BY XX).”
The superseding item is listed in the FIG-ITEM column as a variant and identified in the
NOMENCLATURE column as “(SUPSDS XX).”

E.

DELETED. A deleted part, subassembly, assembly, or unit is one which has been
removed from a specific application, and no replacement is required. The Figure-Item
number and part number of a deleted part are retained in their respective columns.
NOMENCLATURE and UNIT/ASSY column information is removed and the word
“DELETED” is added to the NOMENCLATURE column.
ILLUSTRATED PARTS LIST

24-20-76

Page 1002
Feb 26/07

HAMILTON SUNDSTRAND
COMPONENT MAINTENANCE MANUAL
PART NUMBER 976J497 AND 976J597
CAUTION: ELECTROSTATIC DISCHARGE SENSITIVE (ESDS) ITEMS ARE SUBJECT TO
DAMAGE BY EXCESSIVE LEVELS OF VOLTAGE. REFER TO DOD-HDBK-263
FOR PROPER HANDLING PROCEDURES.

3.

F.

ELECTROSTATIC DISCHARGE SENSITIVE (ESDS) DEVICES. Electronic parts,
assemblies, and equipment that are susceptible to damage from electrostatic discharge.
Electrostatic discharge sensitive devices are identified in the NOMENCLATURE column
as “(ESDS)”. Refer to REPAIR for information on ESDS.

G.

IDENT AS. When a part number is either too long (exceeds fifteen characters) or is not
compliant with ATA specifications (contains a slash or other symbols that are not
recognized); such as M83248/1-905, the part number would be modified to M83248-1-905
in the part number column and the following would appear in the nomenclature column
“IDENT. AS M83248/1-905”.

Equipment Designator Index
A.

4.

Numerical Index
A.

5.

This index contains the reference designators for components shown in the schematic
diagrams. The designators are arranged in alphanumerical order and the IPL Figure- Item
number(s) are provided.

The numerical index is a complete alphanumeric list of all part numbers in the IPL.
The Figure-Item number and quantity used at each location are included.

Manufacturers' Code, Name, and Address
A.

The following list contains the codes, names, and addresses of manufacturers as listed in
the Defense Logistics Agency Cataloging Handbook H4/H8, Commercial and Government
Entity (CAGE) (formerly FSCM). The CAGE code is a vendor (V) code listed in
parentheses in the NOMENCLATURE column of the parts list.

00779

AMP Inc.
2800 Fulling Mill Road
P.O. Box 3608
Harrisburg, PA 17105-3608

78189

Illinois Tool Works, Inc.
Shakeproof Division
St. Charles Road
Elgin, IL 60120

04866

N-D Industries, Inc.
1893 Barrett Rd.
Troy, MI 48084

79568

Whittet-Higgins Co.
33 Higginson Ave.
P.O. Box 8
Falls, RI 02863

16941

Long-Lok Fasteners Corp.
10630 Chester Rd.
Cincinnati, OH 45215-1206

80205

National Aerospace Standards
Committee
Aerospace Industries Association
1250 Eye St. NW
Washington, DC 20005
ILLUSTRATED PARTS LIST

24-20-76

Page 1003
Feb 26/07

HAMILTON SUNDSTRAND
COMPONENT MAINTENANCE MANUAL
PART NUMBER 976J497 AND 976J597
42838

National Rivet & Mfg Co.
1-21 East Jefferson St.
Waupun, WI 53963-2038

81349

Military Standards
Promulgated by Military
Departments/Agencies
under authority of Defense
Standardization Manual 4120
3-M

45681

Parker-Hannifin Corp.
17325 Euclid Ave.
Cleveland, OH 44112-1209

83186

Victory Engineering Corp.
Victory Rd.
Springfield, NJ 07081-1314

50157

Therm-O-Disk Inc.
Subsidiary of Emerson Electric
Co.
1981 Port City Blvd.
P.O. Box 787
Muskegon, MI 49443

21335

Torrington Co. Fafnir Bearings Div.
59 Field St.
Torrington, CT 06790-1008

70472

Barnes Group Inc.
123 Main St.
Bristol, CT 06010-6307

86579

Precision Rubber Products Corp.
Dayton, OH 45401

73682

Garrett George K. Co.
Div. MSL Industries Inc.
Philadelphia, PA 19092

88044

Aeronautical Standards Group
Dept. of Navy and Air Force

91265

Goshen Rubber Co., Inc.
1525 S. 10th St.
P.O. Box 517
Goshen, IN 46526-4505

96906

Military Standards
Promulgated by Military
Departments/Agencies
under authority of Defense
Standardization Manual 4120
3-M

99167

Hamilton Sundstrand
4747 Harrison Avenue
P.O. Box 7002
Rockford, IL 61125-7002

ILLUSTRATED PARTS LIST

24-20-76

Page 1004
Feb 26/07

1A 1 1A 1 1A 1 1 1A 1A 1 1A 1 1A 1 1A 1 1 1 1A 1A 1A 1 3 1A 3A 1 1 1A 1A 1 1A 4 4A 1 1A 1 1 1 3 1A 1A 1A 3A 3A 3 3A ITEM 30A 3 30 24G 240G 28 49 280 490 9 90 9A 90A 54 540 11A 21A 25A 110A 210A 250A 21 9 210 90 50 53 500 530 18 180 7 70 46 460 15 22 24K 10 150 220 240K 100 70A 7 70 TTL REQ 1 1 6 6 6 4 6 4 6 6 6 6 8 8 6 2 12 6 2 12 2 5 2 5 4 8 4 8 4 4 6 6 6 6 2 2 6 5 2 2 6 5 1 1 1 NUMERICAL INDEX 24-20-76 Page 1005 Feb 26/07 . FIG.HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 NUMERICAL INDEX PART NUMBER A116COMPSR277-20 A116COMP-SR277-70 AN500A8-7 AN502-10-10 AN502-10-12 AN502-10-14 AN502-10-6 AN503-8-10 AN503-8-12 AN960-10 AN960-10L AN960-416L AN960-616 AN960-8 GRC513-215COMP GRC513-215-COMP-PV1504 AIRLINE PART NO.

FIG. 1 3 1A 3A 1 1A 1 1A 1 1A 1 1A 1 1A 3 3A 4 4A 1 1A 4 4A 4A 1 1A 1 1A 1 1 1A 1A 1 1 1A 1A 1 1A 1A 1 2 1A 2A 3 3A 1 1A 1 1A ITEM 7 6 70 60 14A 140A 3C 30D 65 650 64 640 2 20 5 50 1 10 38 380 6 60 60A 32 320 31 310 11B 33 110B 330 11 25 110 250 54A 540A 110B 29A 11 290A 110 13M 130M 69 690 17 170 TTL REQ 1 1 1 1 2 2 1 1 12 12 8 8 1 1 1 1 1 1 1 1 6 6 6 6 6 4 4 6 6 6 6 6 12 6 12 8 8 6 3 3 3 3 3 3 4 4 4 4 NUMERICAL INDEX 24-20-76 Page 1006 Feb 26/07 .HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 PART NUMBER L591-19357 LP500-8-6 M83248-1-116 MS122159 MS124655 MS16625-1093 MS16625-1131 MS16625-1168 MS16628-4118 MS21042-L4 MS21042L4 MS21208F1-20 MS21209C0-815 MS21209F1-15 MS24677-16 MS24678-9 MS24678-15 MS25036-108 MS25036-56 MS35338-40 MS35338-43 AIRLINE PART NO.

ITEM 1 45 1A 450 1 6 1A 60 1 19 1A 190 1 16 1A 160 1 44A 1A 440A 1 44 1A 440 1 14 1A 140 1 36 1A 360 4 13 4A 130 4A 130A 1 39 1A 390 1 67A 1A 670A 1A 670B 1 3A 1A 30B 2 1B 2A 10B SEE W-06 SEE MS24677-16 SEE MS24678-9 SEE AN503-8-10 1 40 1A 400 SEE MS35458-30 SEE MS16625-1093 SEE MS16625-1131 SEE MS16625-1168 SEE TC1-6-ST 1 3B 1A 30C 3 7B 3A 70C 3A 70D 3 7A 3A 70B 1 68 1A 680 TTL REQ 6 6 1 1 4 4 4 4 6 6 2 2 6 6 6 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 4 4 NUMERICAL INDEX 24-20-76 Page 1007 Feb 26/07 . FIG.HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 PART NUMBER MS35338-46 MS35458-30 MS35650-305T NAS679A3W NAS679A6 NAS679A6W NK500-8-6CC PMW206PPC4FA-52695S8 TC1-6-ST TC1-6ST W-06 109P938 109P938-1 116COMP17107 11X1 14C4796-7 15C7989-2 15C7989-38 15C7989-45 15C8030-7 15C8095-55 18B1766-18 18B1766-23 18B1766-24 19C8355-33 2-116COMPV747 2-215-V747 2-215V747 215COMP19357 28B8800-3 AIRLINE PART NO.

HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 PART NUMBER 28B8802-33 28B8802-34 28B8802-6 28B8802-9 28B8803-45 28B8803-90 28B8803-91 28B8803-93 28B8803-99 28B9560-3 2W756 2WD1007501 3-243650-2-323 31398 3530-05-03 5908349 5908350 5911588 5911589 62276 769450 8C7714-34 908C828-1 908C832-1 908D049-1 908D049-2 910C331-10 910C331-11 910C331-16 910C331-8 910C331-9 AIRLINE PART NO. ITEM SEE AN503-8-12 SEE AN503-8-10 1 35 1A 350 2 2 2A 20 SEE MS24677-16 SEE AN502-10-12 SEE AN502-10-14 SEE AN502-10-10 SEE AN502-10-6 SEE NK500-8-6CC SEE LP500-8-6 2 1 2A 10 2 1A 2A 10A 2 3 2A 30 2 9 2A 90 4 14 4A 140 4 4A 4A 40A 4 5A 4A 50A 4 4B 4A 40B 4 5B 4A 50B 1 67 1A 670 3 1B 3A 10B 1 36A 1A 360A 1 13 1A 130 1 20 1A 200 1 43 1A 430 1A 430A SEE AN960-10 SEE AN960-416L SEE AN960-616 SEE AN960-8 SEE AN960-10L TTL REQ 2 2 1 1 1 1 1 1 1 1 2 2 6 6 3 3 3 3 3 3 3 3 1 1 1 1 2 2 1 1 1 1 1 1 1 NUMERICAL INDEX 24-20-76 Page 1008 Feb 26/07 . FIG.

HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 PART NUMBER 910C605-1 910C886-1 911C207-15 911C207-3 911C207-9 915F262-1 915F306-1 915F306-2 915F469-1 915F469-2 915F508-1 915F511-1 915F512-2 916B631-1 916B631-2 916B631-3 916B821-1 916B822-1 916B825-2 917B106-1 917B119-11 917B119-3 917B119-6 917B453-5 AIRLINE PART NO. ITEM 1 4 1A 40 SEE A116COMP-SR277SEE 116COMP17107 SEE M83248-1-116 SEE 2-116COMPV747 SEE MS35338-46 SEE MS35338-40 SEE MS35338-43 1 27 1A 270 2 2A 1 1 42 1A 420 3 3A 1 1 42B 1A 420B 3 3A 1B 1 55 1A 550 1 55A 1A 550A 1 42A 1A 420A 3 3A 1A 1 27A 1A 270A 2 2A 1A 1 55B 1A 550B SEE MS21209F1-15 SEE MS21209C0-815 3 3M 3A 30M 2 4 2A 40 2 7 2A 70 SEE 2W756 SEE 2WD1007501 SEE 11X1 SEE 31398 SEE MS122159 SEE MS124655 SEE MS21208F1-20 SEE MS16628-4118 TTL REQ 1 1 1 1 RF RF 1 1 RF RF 1 1 RF RF 1 1 1 1 1 1 RF RF 1 1 RF RF 1 1 1 1 1 1 2 2 NUMERICAL INDEX 24-20-76 Page 1009 Feb 26/07 . FIG.

FIG. ITEM 1 23 1A 230 2 6 2A 60 SEE 3-243650-2-323 1 24 1A 240 2 10 2 10A 2A 100 2A 100A SEE NAS679A3W SEE NAS679A6W 1 1 1A 10 1 37 1A 370 1 36B 1A 360B 1 5 1A 50 SEE MS25036-108 SEE MS25036-56 1 26 1 26A 1A 260 1A 260A 4 15E 4A 150E 4 15F 4A 150F 1 10 1A 100 4 4 4A 40 4 5 4A 50 3 2 3A 20 3 1 3A 10 3 13 3A 130 3 13A 3A 130A 1 30A 1A 300A 1 8 1A 80 1 47 1A 470 TTL REQ 4 4 2 2 1 1 3 2 3 2 1 1 4 4 2 2 1 1 6 12 6 12 2 2 2 2 1 1 3 3 3 3 8 8 1 1 1 1 1 1 1 1 1 1 6 6 NUMERICAL INDEX 24-20-76 Page 1010 Feb 26/07 .HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 PART NUMBER 917B579-1 917B596-1 917B597-1 917B599-1 917B621-1 918B105-2 918B105-4 919B113-1 920B836-1 9206WX7C0XG-29 922B314-1 927A402-19 927A402-25 929A939-1 931A052-1 931A052-2 936C235-1 938D679-11 938D679-12 939D982-1 940D366-1 941D586-2 942D262-2 943D450-1 944B718-1 944B791-1 AIRLINE PART NO.

FIG. ITEM 2 8 2A 80 2 5 2A 50 1 7A 1A 70A 3 6A 3A 60A SEE L591-19357 1 30F 1A 300F 3 3 3A 30 3 3A 3A 30A 3 4 3A 40 1 51 1A 510 3 8 3A 80 4 4A 1 3 8A 3A 80A 4 4A 1A 3 13R 3A 130R 3 12 3A 120 3 11 3A 110 4 3M 4A 30M 4 8 4A 80 1 12 1A 120 1 61 1A 610 1 63 1A 630 1 62 1A 620 4 14A 4A 140A SEE 947B872-2 SEE 3530-05-03 TTL REQ 1 1 2 2 1 1 1 1 1 1 1 1 1 1 1 1 6 6 1 1 RF RF 1 1 RF RF 16 16 5 5 5 5 2 2 3 3 6 6 2 2 1 1 3 3 NUMERICAL INDEX 24-20-76 Page 1011 Feb 26/07 .HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 PART NUMBER 944B851-1 944B852-1 945B161-1 945B477-1 945B527-1 945B527-2 945B550-1 945B985-1 946F177-1 946F177-3 947B438-1 947B449-1 947B450-1 947B451-1 947B473-1 947B495-1 947B529-1 947B529-6 947B529-7 947B872-2 AIRLINE PART NO.

ITEM 1 12A 1 29 1 53A 1A 120A 1A 290 1A 530A 4 12 4A 120 4 9 4A 90 4 10 4A 100 1 57 1A 570 1 60 1A 600 1 58 1A 580 1 59 1A 590 1 56 1A 560 3 14 3A 140 3 15 3A 150 3 16 3A 160 4 2 4A 20 4 11 4A 110 4 10B 4A 100B 3 1A 3A 10A 4 10A 4A 100A 1 66 1A 660 SEE MS35650-305T SEE GRC513-215-COMPSEE 215COMP19357 SEE 2-215-V747 SEE MS21042-L4 4 15 4A 150 1 52 1A 520 TTL REQ 6 6 8 6 6 8 2 AR 2 AR 1 1 1 1 1 1 2 2 1 1 1 1 AR AR AR AR AR AR 1 1 1 AR 1 AR 1 1 3 3 1 1 1 1 NUMERICAL INDEX 24-20-76 Page 1012 Feb 26/07 . FIG.HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 PART NUMBER 948B029-1 948B031-1 948B032-1 948B034-1 948B212-1 948B213-1 948B214-1 948B215-1 948B216-1 949B105-3 949B105-5 949B105-6 949B352-1 949B362-1 949B363-1 949F308-1 949F363-1 955C170-86 955C551-14 959C442-2 959C711-5 961C451-1 961C730-1 AIRLINE PART NO.

HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 PART NUMBER 962C235-3 962C261-1 962C265-1 962C279-1 963C047-1 963C054-1 963C055-1 964C157-2 964C592-1 966C576-1 976J497-1 976J597-1 AIRLINE PART NO. 1 1A 1 1A 4 4A 1 1A 1 1A 1 1A 1 1A 4 4A 4 4A 1 1A 1 1A 1 1A ITEM 10A 100A 41 410 3 30 24D 240D 30 300 48 480 34 340 16 160 18 180 52A 520A 1 1A TTL REQ 1 1 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 RF RF RF RF NUMERICAL INDEX 24-20-76 Page 1013 Feb 26/07 . FIG.

HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 A-68064 AC Generator Figure 1 (Sheet 1 of 2) ILLUSTRATED PARTS LIST 24-20-76 Page 1014 Feb 26/07 .

HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 A-67987 AC Generator Figure 1 (Sheet 2 of 2) ILLUSTRATED PARTS LIST 24-20-76 Page 1015 Feb 26/07 .

PREFORMED (MOVED TO ITEM 70 IPL FIGURE 1A) • PACKING. PREFORMED (MOVED TO ITEM 30D IPL FIGURE 1A) ADAPTER. ITEM PART NUMBER 1234567 NOMENCLATURE EFF CODE UNITS PER ASSY A RF B RF 1 976J497-1 976J597-1 GENERATOR. SPLINE (MOVED TO ITEM 40 IPL FIGURE 1A) ATTACHING PARTS WASHER. PREFORMED (MOVED TO ITEM 70A IPL FIGURE 1A) • RING. PREFORMED (MOVED TO ITEM 30 IPL FIGURE 1A) PACKING. SPINDLE (MOVED TO ITEM 10 IPL FIGURE 1A) 1 919B113-1 2 MS16625-1093 • 3 A116COMP-SR277-70 • -3A 116COMP17107 • -3B 2-116COMPV747 • -3C M83248-1-116 • 4 910C605-1 • 5 922B314-1 • 6 MS35458-30 7 L591-19357 -7A 945B161-1 8 944B718-1 9 AN502-10-12 9A AN502-10-14 .HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 FIG. AC (MOVED TO ITEM 1A IPL FIGURE 1A) • COVER. PREFORMED (MOVED TO ITEM 30C IPL FIGURE 1A) PACKING. SHOULDERED (MOVED TO ITEM 50 IPL FIGURE 1A) • SCREW. PREFORMED (MOVED TO ITEM 30B IPL FIGURE 1A) PACKING. RETAINING (MOVED TO ITEM 20 IPL FIGURE 1A) -----*----PACKING. AC (MOVED TO ITEM 1 IPL FIGURE 1A) GENERATOR.ITEM NOT ILLUSTRATED ATTACHING PARTS RING. MACHINE (MOVED TO ITEM 60 IPL FIGURE 1A) -----*----PACKING. BACKING (MOVED TO ITEM 80 IPL FIGURE 1A) • ATTACHING PARTS • SCREW (MOVED TO ITEM 90 IPL FIGURE 1A) -----*----• SCREW (MOVED TO ITEM 90A IPL FIGURE 1A) 1 1 1 1 1 1 1 1 1 1 1 1 6 6 ILLUSTRATED PARTS LIST 24-20-76 Page 1016 Feb 26/07 .

BEARING (MOVED TO ITEM 100A IPL FIGURE 1A) • ATTACHING PARTS SCREW (MOVED TO ITEM 110 IPL FIGURE 1A) SCREW (MOVED TO ITEM 110A IPL FIGURE 1A) SCREW (MOVED TO ITEM 110B IPL FIGURE 1A) WASHER. MACH. 8-32 UNC-2A X 0. ITEM PART NUMBER 1234567 1 10 936C235-1 -10A 962C235-3 11 MS24677-16 • -11A AN503-8-10 • -11B MS24678-15 • 12 947B495-1 • -12A 948B029-1 • 13 908C828-1 • 14 NK500-8-6CC • -14A LP500-8-6 15 AN960-8 16 NAS679A3W 17 MS35338-43 18 AN960-10L 19 MS35650-305T . TERMINAL BOARD (MOVED TO ITEM 130 IPL FIGURE 1A) ATTACHING PARTS SCREW.375 CD PL (MOVED TO ITEM 140A IPL FIGURE 1A) • WASHER. BEARING (MOVED TO ITEM 100 IPL FIGURE 1A) • COVER. MACH.. SELF LOCKING. 8-32 UNC-2A X 0. FLAT (MOVED TO ITEM 150 IPL FIGURE 1A) -----*----NUT.HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 FIG. SELF LOCKING. LOCK (MOVED TO ITEM 170 IPL FIGURE 1A) • WASHER. SELF LOCKING (MOVED TO ITEM 160 IPL FIGURE 1A) • WASHER.. FLAT (MOVED TO ITEM 120 IPL FIGURE 1A) WASHER.ITEM NOT ILLUSTRATED NOMENCLATURE COVER. FLAT (MOVED TO ITEM 120A IPL FIGURE 1A) -----*----COVER. PLAIN HEX (MOVED TO ITEM 190 IPL FIGURE 1A) • EFF CODE UNITS PER ASSY 1 1 6 6 6 6 6 1 2 2 2 4 4 4 4 ILLUSTRATED PARTS LIST 24-20-76 Page 1017 Feb 26/07 .375 CD PL (MOVED TO ITEM 140 IPL FIGURE 1A) • SCREW. FLAT (MOVED TO ITEM 180 IPL FIGURE 1A) • NUT.

MACHINE (MOVED TO ITEM 250A IPL FIGURE 1A) WASHER (MOVED TO ITEM 260 IPL FIGURE 1A) WASHER. FLAT (MOVED TO ITEM 220 IPL FIGURE 1A) -----*----TERMINAL.HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 FIG. FIL H (MOVED TO ITEM 240G IPL FIGURE 1A) • WASHER (MOVED TO ITEM 240K IPL FIGURE 1A) -----*----• SCREW. MACHINE (MOVED TO ITEM 210A IPL FIGURE 1A) • WASHER. FLAT (MOVED TO ITEM 260A IPL FIGURE 1A) STATOR. ITEM PART NUMBER 1234567 1 20 908C832-1 • 21 AN503-8-12 • 21A AN503-8-10 22 AN960-8 23 917B579-1 24 917B599-1 -24D 962C279-1 -24G AN500A8-7 -24K AN960-8 25 MS24677-16 • -25A AN503-8-10 • 26 929A939-1 • 26A 929A939-1 • 27 915F262-1 • -ITEM NOT ILLUSTRATED NOMENCLATURE EFF CODE TERMINAL BOARD (MOVED TO ITEM 200 IPL FIGURE 1A) ATTACHING PARTS SCREW. EXCITER (MOVED TO ITEM 270 IPL FIGURE 1A) UNITS PER ASSY 1 A 1 A 6 A 6 12 12 6 12 A 1 ILLUSTRATED PARTS LIST 24-20-76 Page 1018 Feb 26/07 . MACH (MOVED TO ITEM 250 IPL FIGURE 1A) SCREW. MACHINE (MOVED TO ITEM 210 IPL FIGURE 1A) • SCREW. MACH. STUD (MOVED TO ITEM 230 IPL FIGURE 1A) • GROMMET (MOVED TO ITEM 240 IPL FIGURE 1A) • FLANGE (NP) (MOVED TO ITEM 240D IPL FIGURE 1A) 1 A 2 B 2 2 4 • ATTACHING PARTS SCREW.

ITEM 1 -27A PART NUMBER 915F511-1 1234567 • STATOR.ITEM NOT ILLUSTRATED NOMENCLATURE EFF CODE TERMINAL LUG (MOVED TO ITEM 290A IPL FIGURE 1A) END BELL.HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 FIG. EXCITER (CUBEX) (MOVED TO ITEM 270A IPL FIGURE 1A) UNITS PER ASSY B 1 ATTACHING PARTS • SCREW. FLAT (MOVED TO ITEM 290 IPL FIGURE 1A) -----*----- 28 AN502-10-10 29 948B029-1 29A MS25036-108 • 30 963C047-1 • -30A 943D450-1 • 30F 945B477-1 • 31 MS21209C0-815 • 32 MS21208F1-20 • 33 MS21209F1-15 • 34 963C055-1 • 35 28B8802-6 36 -36A PMW206PPC4FA52695S8 8C7714-34 -36B 9206WX7C0XG-29 . SCREW THREAD (MOVED TO ITEM 330 IPL FIGURE 1A) • RETAINER (MOVED TO ITEM 340 IPL FIGURE 1A) ATTACHING PARTS • • SCREW. BEARING (MOVED TO ITEM 300F IPL FIGURE 1A) • INSERT. ROTATING (MOVED TO ITEM 300A IPL FIGURE 1A) • INSERT.44 CD PL (MOVED TO ITEM 350 IPL FIGURE 1A) -----*----DELETED (BEARING. ROTATING (MOVED TO ITEM 300 IPL FIGURE 1A) END BELL. SCREW THREAD (MOVED TO ITEM 310 IPL FIGURE 1A) • INSERT. BALL) (MOVED TO ITEM 360 IPL FIGURE 1A) • BEARING. MACHINE (MOVED TO ITEM 280 IPL FIGURE 1A) • WASHER. BALL (MOVED TO ITEM 360B IPL FIGURE 1A) 6 6 3 A 1 B 1 1 4 6 6 1 2 2 2 ILLUSTRATED PARTS LIST 24-20-76 Page 1019 Feb 26/07 . FIL H 8-32 UNC-2A X 0. BALL (MOVED TO ITEM 360A IPL FIGURE 1A) • BEARING. ELEC. ELEC. SCREW THREAD (MOVED TO ITEM 320 IPL FIGURE 1A) • INSERT.

SELF LOCK (MOVED TO ITEM 440A IPL FIGURE 1A) WASHER. LOCK (MOVED TO ITEM 450 IPL FIGURE 1A) WASHER. FLAT (MOVED TO ITEM 500 IPL FIGURE 1A) -----*----- UNITS PER ASSY 4 ATTACHING PARTS • RING. SQUARE (MOVED TO ITEM 470 IPL FIGURE 1A) TERMINAL BOARD (MOVED TO ITEM 480 IPL FIGURE 1A) ATTACHING PARTS SCREW. ROUND (MOVED TO ITEM 400 IPL FIGURE 1A) -----*----- 38 . RETAINING (MOVED TO ITEM 380 IPL FIGURE 1A) • WASHER. ITEM 1 37 PART NUMBER 920B836-1 1234567 • SHIELD. BEARING (MOVED TO ITEM 410 IPL FIGURE 1A) ARMATURE-ROTOR (MOVED TO ITEM 420 IPL FIGURE 1A) ARMATURE-ROTOR (CUBEX) (NP) (MOVED TO ITEM 420A IPL FIGURE 1A) ARMATURE-ROTOR (MOVED TO ITEM 420B IPL FIGURE 1A) COVER. MACHINE (MOVED TO ITEM 490 IPL FIGURE 1A) • WASHER. FLAT (MOVED TO ITEM 460 IPL FIGURE 1A) WASHER.ITEM NOT ILLUSTRATED NOMENCLATURE EFF CODE 1 1 1 2 A 1 B 1 A 1 1 6 6 6 6 1 4 4 ILLUSTRATED PARTS LIST 24-20-76 Page 1020 Feb 26/07 . PLAIN.HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 FIG. KEY (MOVED TO ITEM 390 IPL FIGURE 1A) • NUT. SHOULDERED. TERMINAL BOARD (MOVED TO ITEM 430 IPL FIGURE 1A) DELETED (NUT) (MOVED TO ITEM 440 IPL FIGURE 1A) NUT. BEARING (MOVED TO ITEM 370 IPL FIGURE 1A) MS16628-4118 39 W-06 40 15C8030-7 41 962C261-1 • 42 915F306-1 • -42A 915F508-1 • -42B 915F306-2 • 43 908D049-1 • 44 NAS679A6W • -44A NAS679A6 • 45 MS35338-46 • 46 AN960-616 • 47 944B791-1 • 48 963C054-1 • 49 AN502-10-10 • 50 AN960-10 COVER.

ELECTRICAL (MOVED TO ITEM 580 IPL FIGURE 1A) • TERMINAL. SLEEVING (MOVED TO ITEM 630 IPL FIGURE 1A) • INSERT (MOVED TO ITEM 640 IPL FIGURE 1A) • INSERT (MOVED TO ITEM 650 IPL FIGURE 1A) UNITS PER ASSY 8 8 8 A 1 A 1 B 1 1 1 2 1 1 2 3 1 8 12 ILLUSTRATED PARTS LIST 24-20-76 Page 1021 Feb 26/07 . FLAT (MOVED TO ITEM 530A IPL FIGURE 1A) • SCREW (MOVED TO ITEM 540 IPL FIGURE 1A) • SCREW (MOVED TO ITEM 540A IPL FIGURE 1A) -----*----- 8 • STATOR. SLEEVING (MOVED TO ITEM 610 IPL FIGURE 1A) • INSULATION. SLEEVING (MOVED TO ITEM 620 IPL FIGURE 1A) • INSULATION. ELECTRICAL (MOVED TO ITEM 560 IPL FIGURE 1A) • TERMINAL. GENERATOR (CUBEX) (NP) (MOVED TO ITEM 550B IPL FIGURE 1A) • TERMINAL. MACHINE. ITEM PART NUMBER 1234567 1 51 945B985-1 52 961C730-1 52A 966C576-1 53 AN960-10 -53A 948B029-1 54 AN502-10-6 -54A MS24678-9 55 915F469-1 • -55A 915F469-2 • -55B 915F512-2 • 56 948B216-1 • 57 948B212-1 • 58 948B214-1 • 59 948B215-1 • 60 948B213-1 • 61 947B529-1 • 62 947B529-7 • 63 947B529-6 • 64 MS124655 • 65 MS122159 • . GENERATOR (MOVED TO ITEM 550A IPL FIGURE 1A) STATOR. ELEC.HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 FIG. ELECTRICAL (MOVED TO ITEM 570 IPL FIGURE 1A) • TERMINAL. ROTATING (MOVED TO ITEM 520 IPL FIGURE 1A) • END BELL. ROTATING (MOVED TO ITEM 520A IPL FIGURE 1A) 6 • • 1 1 ATTACHING PARTS WASHER (MOVED TO ITEM 530 IPL FIGURE 1A) • WASHER. ELECTRICAL (MOVED TO ITEM 600 IPL FIGURE 1A) • INSULATION.ITEM NOT ILLUSTRATED NOMENCLATURE EFF CODE STUD. GENERATOR (MOVED TO ITEM 550 IPL FIGURE 1A) STATOR. ELEC. ELECTRICAL (MOVED TO ITEM 590 IPL FIGURE 1A) • TERMINAL. HEX HD (MOVED TO ITEM 510 IPL FIGURE 1A) • END BELL.

FIL HD STL.HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 FIG. ITEM PART NUMBER 1 66 955C170-86 67 62276 -67A 109P938 -67B 109P938-1 68 28B8800-3 69 MS35338-40 1234567 NOMENCLATURE SCREW (MOVED TO ITEM 660 IPL FIGURE 1A) • PLATE. MACHINE. IDENTIFICATION (NP) (MOVED TO ITEM 670 IPL FIGURE 1A) • PLATE. IDENTIFICATION (MOVED TO ITEM 670B IPL FIGURE 1A) • • ATTACHING PARTS • SCREW. IDENTIFICATION (MOVED TO ITEM 670A IPL FIGURE 1A) • PLATE. LOCK (MOVED TO ITEM 690 IPL FIGURE 1A) -----*----- EFF CODE UNITS PER ASSY 3 1 1 1 4 4 ILLUSTRATED PARTS LIST 24-20-76 Page 1022 Feb 26/07 . CD PL 4-40 X 1/4 INCH LG (MOVED TO ITEM 680 IPL FIGURE 1A) • WASHER.

HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 THIS PAGE INTENTIONALLY LEFT BLANK ILLUSTRATED PARTS LIST 24-20-76 Page 1023 Feb 26/07 .

HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 HE-242076-68064-A AC Generator Figure 1A (Sheet 1 of 2) ILLUSTRATED PARTS LIST 24-20-76 Page 1024 Feb 26/07 .

HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 HE-242076-67987-A AC Generator Figure 1A (Sheet 2 of 2) ILLUSTRATED PARTS LIST 24-20-76 Page 1025 Feb 26/07 .

MACHINE (15C8095-55) -----*----- 1 1 1 1 1 1 1 PACKING.HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 FIG. AC GENERATOR. PREFORMED (V95272) (910C886-1) IDENT AS A116COMP-SR277-70 • PACKING. PREFORMED (V45681) (910C886-1) • PACKING. PREFORMED (V25184) (910C886-1) • PACKING. ITEM PART NUMBER 1234567 NOMENCLATURE 1A -1 -1A 10 976J497-1 976J597-1 919B113-1 GENERATOR.ITEM NOT ILLUSTRATED EFF CODE A B ATTACHING PARTS RING. PREFORMED) • PACKING. PREFORMED (V45681) 1 • 1 ILLUSTRATED PARTS LIST 24-20-76 Page 1026 Feb 26/07 . SPINDLE 20 MS16625-1093 • 30 -30A A116COMP-SR277-70 A116COMPSR277-70 -30B 116COMP17107 -30C 2-116COMPV747 -30D M83248-1-116 40 910C605-1 DELETED (PACKING. RETAINING (18B1766-18) -----*----- UNITS PER ASSY RF RF 1 1 ATTACHING PARTS • WASHER. SHOULDERED • SCREW. PREFORMED (910C886-1) • ADAPTER. PREFORMED (V86579) (945B161-1) • PACKING. AC • COVER. SPLINE 50 60 922B314-1 MS35458-30 70 L591-19357 -70A 945B161-1 .

B.B. 79-103) MS24677-16 • -110A AN503-8-10 • -110B MS24678-15 • 120 947B495-1 • -120A 948B029-1 • UNITS PER ASSY 1 6 6 • 110 . 78-103) ATTACHING PARTS • SCREW (28B8803-90) (USED WITH ITEMS 520 AND 80. FLAT (REPLS ITEM 120) -----*----- 6 6 6 6 6 ILLUSTRATED PARTS LIST 24-20-76 Page 1027 Feb 26/07 .B. FLAT (REPLD BY ITEM -120A) (S.B. 84-103) SCREW (15C7989-45) (REPLS ITEM 110) (REPLD BY ITEM 110B) SCREW (15C7989) (REPLS ITEM 110A) WASHER. BEARING (REPLD BY ITEM -100A) (S. SCREWS REPLD BY ITEM 90A.ITEM NOT ILLUSTRATED NOMENCLATURE EFF CODE 1 1 ATTACHING PARTS SCREW (28B8803-45) (REPLD BY ITEM 110A) (S.B. 78-103) • COVER. END BELL AND RING REPLD BY 966C576-1.B.B. 79-103) • COVER. ITEM 1A 80 PART NUMBER 944B718-1 90 AN502-10-12 90A AN502-10-14 100 936C235-1 -100A 962C235-3 1234567 • RING. REPLD BY ITEM 520A.HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 FIG.) (S. ITEM 520A. BEARING (REPLS ITEM 100) (S. USE UP SPARES) (S. 78-103) -----*----SCREW (28B8803-91) (USED WITH ITEM 520A. BACKING (USED WITH END BELL 961C730-1. ITEM 520.) (S. 84-103) WASHER.

.HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 FIG. MACH (15C7989-2) • SCREW. LOCK (911C207-9) WASHER. SELF LOCKING (918B105-2) WASHER. MACH. MACHINE (28B8802-34) • WASHER. ITEM PART NUMBER 1234567 1A 130 908C828-1 • 140 NK500-8-6CC • -140A LP500-8-6 150 AN960-8 160 NAS679A3W • 170 MS35338-43 • 180 AN960-10L • 190 MS35650-305T • 200 908C832-1 • 210 AN503-8-12 • -210A AN503-8-10 220 AN960-8 230 240 -240D 917B579-1 917B599-1 962C279-1 • -240G -240K AN500A8-7 AN960-8 • -250 MS24677-16 250A AN503-8-10 .ITEM NOT ILLUSTRATED NOMENCLATURE EFF CODE COVER. SELF LOCKING. STUD GROMMET • FLANGE (NP) A 4 1 1 A A 6 6 • ATTACHING PARTS SCREW. SELF LOCKING. MACHINE (28B8802-34) 12 12 ILLUSTRATED PARTS LIST 24-20-76 Page 1028 Feb 26/07 .375 CD PL (V04866) (28B9560-3) • SCREW. 8-32 UNC-2A X 0. FIL H • WASHER -----*----• SCREW. TERMINAL BOARD UNITS PER ASSY 1 ATTACHING PARTS SCREW. MACH.375 CD PL (V16941) (28B9560-3) • WASHER. FLAT (910C331-8) -----*----- A 2 B 2 2 TERMINAL. PLAIN HEX (955C551-14) TERMINAL BOARD 4 4 4 4 1 ATTACHING PARTS SCREW. FLAT (910C331-9) NUT. 8-32 UNC-2A X 0.. MACHINE (28B8802-33) • SCREW. FLAT (910C331-8) -----*----- 2 2 2 NUT. MACH.

) EFF CODE UNITS PER ASSY A 6 12 1 B 1 • • ATTACHING PARTS SCREW. ROTATING END BELL. EXCITER (SEE IPL FIGURE 2A FOR DETAILS. BEARING 2 ILLUSTRATED PARTS LIST 24-20-76 Page 1029 Feb 26/07 . EXCITER (CUBEX) (SEE IPL FIGURE 2A FOR DETAILS. BALL BEARING. ROTATING • INSERT. BEARING • INSERT. SCREW THREAD (V96906) (916B631-2) • INSERT. FLAT • STATOR. BALL • SHIELD. ELEC. RETAINING (917B453-5) • WASHER. BALL) -360A -360B 370 PMW206PPC4FA52695S8 8C7714-34 9206WX7C0XG-29 920B836-1 380 390 MS16628-4118 W-06 • 400 15C8030-7 410 962C261-1 . ITEM PART NUMBER 1234567 NOMENCLATURE 1A -260 260A 270 929A939-1 929A939-1 915F262-1 -270A 915F511-1 280 290 AN502-10-10 948B029-1 • 290A 300 -300A 300F 310 MS25036-108 963C047-1 943D450-1 945B477-1 MS21209C0-815 • 320 MS21208F1-20 • 330 MS21209F1-15 • 340 963C055-1 • 350 28B8802-6 ATTACHING PARTS • • SCREW.HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 FIG. SCREW THREAD (V96906) (916B631-1) • RETAINER A B 6 6 1 BEARING. PLAIN. KEY (V79568) (14C4796-7) • NUT.) • STATOR. MACHINE (28B8803-93) • WASHER.ITEM NOT ILLUSTRATED WASHER WASHER. SCREW THREAD (V96906) (917B119-6) • INSERT. ELEC. ROUND -----*----• 3 1 1 1 4 1 1 1 COVER.44 CD PL -----*----- 360 DELETED (BEARING. FLAT -----*----- • • • • 6 6 TERMINAL LUG (927A402-19) END BELL. BEARING 2 2 2 4 • • ATTACHING PARTS RING. FIL H 8-32 UNC-2A X 0.

HAMILTON SUNDSTRAND
COMPONENT MAINTENANCE MANUAL
PART NUMBER 976J497 AND 976J597

FIG.
ITEM

PART
NUMBER

1234567

1A
420

915F306-1

-420A

915F508-1

-420B

915F306-2

430

908D049-1

-430A

908D049-2

440
-440A

NAS679A6W
NAS679A6

450

MS35338-46

460

AN960-616

470
480

944B791-1
963C054-1

490

AN502-10-10

500

AN960-10

510
520

945B985-1
961C730-1

520A

966C576-1

530

AN960-10

- ITEM NOT ILLUSTRATED

NOMENCLATURE

ARMATURE-ROTOR
(SEE IPL FIGURE 3A FOR DETAILS.)
(SEE SERVICE NEWS LETTER 48.)
ARMATURE-ROTOR (CUBEX)
(SEE IPL FIGURE 3A FOR DETAILS.)
(SEE SERVICE NEWS LETTER 48.) (NP)
ARMATURE-ROTOR
(SEE IPL FIGURE 3A FOR DETAILS)
COVER, TERMINAL BOARD
REPLD BY ITEM 430A
COVER, TERMINAL BOARD
REPLS ITEM 430
DELETED (NUT)
NUT, SELF LOCK
(918B105-4)
WASHER, LOCK
(911C207-15)
WASHER, FLAT
(910C331-16)
WASHER, SHOULDERED, SQUARE
TERMINAL BOARD

ATTACHING PARTS
SCREW, MACHINE
(28B8803-93)
• WASHER, FLAT
(910C331-10)
-----*-----

UNITS
PER
ASSY

A

1

B

1

A

1
1
1

6
6
6
6
1

4
4

STUD, MACHINE, HEX HD
END BELL, ELEC. ROTATING
(USED WITH ITEM 80)
(REPLD BY ITEM 520A. USE UP
SPARES.)
(S.B. 78-103)
• END BELL, ELEC. ROTATING
(REPLS ITEM 520 AND ITEM 80)
(S.B. 78-103)
• •

EFF
CODE

ATTACHING PARTS
WASHER (910C331-10)
(USED WITH ITEM 520)
(REPLD BY ITEM -530A)
(S.B. 78-103)

6
1

1

8

ILLUSTRATED PARTS LIST

24-20-76

Page 1030
Feb 26/07

HAMILTON SUNDSTRAND
COMPONENT MAINTENANCE MANUAL
PART NUMBER 976J497 AND 976J597
FIG.
ITEM

PART
NUMBER

1234567

1A
-530A

948B029-1

540

AN502-10-6

-540A

MS24678-9

550
-550A
-550B

915F469-1
915F469-2
915F512-2

560
570
580
590
600
610
620
630
640

948B216-1
948B212-1
948B214-1
948B215-1
948B213-1
947B529-1
947B529-7
947B529-6
MS124655

650

MS122159

660
670

955C170-86
62276

-670A

109P938

-670B

109P938-1

680

28B8800-3

690

MS35338-40

- ITEM NOT ILLUSTRATED

NOMENCLATURE

EFF
CODE

WASHER, FLAT
(REPLS ITEM 530)
(S.B. 78-103)
• SCREW
(28B8803-99)
(REPLD BY ITEM -540A)
• SCREW
(15C7989-38)
(REPLS ITEM 540)
-----*-----

8









UNITS
PER
ASSY

8

8

STATOR, GENERATOR
STATOR, GENERATOR
STATOR, GENERATOR (CUBEX) (NP)
(SEE SERVICE NEWS LETTER 48)
• TERMINAL, ELECTRICAL
• TERMINAL, ELECTRICAL
• TERMINAL, ELECTRICAL
• TERMINAL, ELECTRICAL
• TERMINAL, ELECTRICAL
• INSULATION, SLEEVING
• INSULATION, SLEEVING
• INSULATION, SLEEVING
• INSERT
(917B119-3)
• INSERT
(917B119-11)
• SCREW
PLATE, IDENTIFICATION (NP)
(REPLD BY ITEM 670A)
PLATE, IDENTIFICATION
(REPLS ITEM 670)
(REPLD BY ITEM 670B)
PLATE, IDENTIFICATION
(REPLS ITEM 670A)

ATTACHING PARTS
SCREW, MACHINE, FIL HD STL, CD PL 4-40
X 1/4 INCH LG
• WASHER, LOCK
(911C207-3)
-----*-----

A
A
B

1
1
1
1
1
2
1
1
2
3
1
8
12
3
1
1

1

4
4

ILLUSTRATED PARTS LIST

24-20-76

Page 1031
Feb 26/07

HAMILTON SUNDSTRAND
COMPONENT MAINTENANCE MANUAL
PART NUMBER 976J497 AND 976J597

A-67988
Exciter Stator
Figure 2

ILLUSTRATED PARTS LIST

24-20-76

Page 1032
Feb 26/07

LUG (MOVED TO ITEM 90 IPL FIGURE 2A) • INSULATION.ITEM NOT ILLUSTRATED 1 1 1 ATTACHING PARTS SCREW. EXCITER (MOVED TO ITEM 1 IPL FIGURE 2A) STATOR. THERMAL (MOVED TO ITEM 10A IPL FIGURE 2A) • RESISTANCE ELEMENT. SPRING TENSION (MOVED TO ITEM 30 IPL FIGURE 2A) WASHER. WASHER (MOVED TO ITEM 50 IPL FIGURE 2A) TERMINAL. THERMAL (MOVED TO ITEM 10 IPL FIGURE 2A) • RESISTANCE ELEMENT. ITEM PART NUMBER 1234567 NOMENCLATURE EFF CODE UNITS PER ASSY AC RF B RF 2 915F262-1 915F511-1 1 2W756 -1A 2WD1007501 -1B 11X1 STATOR. SLEEVING (MOVED TO ITEM 100A IPL FIGURE 2A) • TERMINAL. EXCITER (CUBEX) (MOVED TO ITEM 1A IPL FIGURE 2A) • RESISTANCE ELEMENT. LUG (MOVED TO ITEM 110 IPL FIGURE 2A) 1 1 1 2 2 2 1 2 AC 3 B 2 B 3 ILLUSTRATED PARTS LIST 24-20-76 Page 1033 Feb 26/07 . MACHINE. BUSHING (MOVED TO ITEM 80 IPL FIGURE 2A) -----*----- TERMINAL.HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 FIG. FIL HD STL. SLEEVING (MOVED TO ITEM 100 IPL FIGURE 2A) • INSULATION. 8-32 X 5/8 INCH LG (MOVED TO ITEM 20 IPL FIGURE 2A) WASHER. FLAT (MOVED TO ITEM 70 IPL FIGURE 2A) INSULATOR. LUG (MOVED TO ITEM 60 IPL FIGURE 2A) WASHER. THERMAL (MOVED TO ITEM 10B IPL FIGURE 2A) 2 28B8802-9 • 3 3-243650-2-323 • 4 916B821-1 • 5 944B852-1 • 6 917B596-1 • 7 916B822-1 • 8 944B851-1 • 9 31398 • 10 917B621-1 -10A 917B621-1 11 MS25036-108 . FLAT (MOVED TO ITEM 40 IPL FIGURE 2A) INSULATOR. CD PL.

HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 HE-242076-67988-A Exciter Stator Figure 2A ILLUSTRATED PARTS LIST 24-20-76 Page 1034 Feb 26/07 .

IPL FIGURE 1A FOR NHA) • RESISTANCE ELEMENT. FLAT INSULATOR. ITEM PART NUMBER 2A -1 915F262-1 -1A 915F511-1 10 2W756 -10A 2WD1007501 -10B 11X1 1234567 STATOR. THERMAL (V83186) (916B825-2) (ALTERNATE TO ITEM -10A) 20 28B8802-9 • 30 3-243650-2-323 • 40 50 60 70 80 916B821-1 944B852-1 917B596-1 916B822-1 944B851-1 • 90 31398 • 100 -100A 110 917B621-1 917B621-1 MS25036-108 . FIL HD STL. BUSHING -----*----- TERMINAL. THERMAL (V50157) (916B825-2) (REPLS ITEM 10) • RESISTANCE ELEMENT. IPL FIGURE 1A FOR NHA) STATOR. LUG WASHER. MACHINE. EXCITER (SEE ITEM 270. 8-32 X 5/8 INCH LG WASHER. EXCITER (CUBEX) (SEE ITEM 270A. LUG (V00779) (917B106-1) • INSULATION. SLEEVING • INSULATION. SPRING TENSION (V73682) (917B597-1) WASHER. SLEEVING • TERMINAL. WASHER TERMINAL. LUG (927A402-19) 1 1 1 2 2 2 1 2 A B B 3 2 3 ILLUSTRATED PARTS LIST 24-20-76 Page 1035 Feb 26/07 .HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 FIG. THERMAL (V50157) (916B825-2) (REPLD BY ITEM -10A) • RESISTANCE ELEMENT.ITEM NOT ILLUSTRATED NOMENCLATURE • • • • EFF CODE UNITS PER ASSY A RF B RF 1 1 1 ATTACHING PARTS SCREW. FLAT INSULATOR. CD PL.

STUB (MOVED TO ITEM 10B IPL FIGURE 3A) • ATTACHING PARTS SCREW.HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 A-67989 Armature-Rotor Figure 3 FIG.ITEM NOT ILLUSTRATED ARMATURE-ROTOR (MOVED TO ITEM 1 IPL FIGURE 3A) ARMATURE-ROTOR (CUBEX) (MOVED TO ITEM 1A IPL FIGURE 3A) ARMATURE-ROTOR (MOVED TO ITEM 1B IPL FIGURE 3A) • SHAFT. DRILLED (MOVED TO ITEM 20 IPL FIGURE 3A) -----*----- 1 1 1 8 ILLUSTRATED PARTS LIST 24-20-76 Page 1036 Feb 26/07 . ITEM PART NUMBER 1234567 NOMENCLATURE EFF CODE UNITS PER ASSY A RF B RF C RF 3 915F306-1 915F508-1 915F306-2 1 940D366-1 -1A 949F308-1 -1B 769450 2 939D982-1 . CAP. STUB (MOVED TO ITEM 10 IPL FIGURE 3A) • SHAFT. HEX HD. STUB (MOVED TO ITEM 10A IPL FIGURE 3A) • SHAFT.

LUG (927A402-25) (MOVED TO ITEM 130M IPL FIGURE 3A) • UNITS PER ASSY 5 5 5 5 A 1 B 1 3 ILLUSTRATED PARTS LIST 24-20-76 Page 1037 Feb 26/07 . WOUND (MOVED TO ITEM 130 IPL FIGURE 3A) • ARMATURE. ITEM PART NUMBER 1234567 3 3 945B527-1 3M 916B631-3 4 945B550-1 5 MS16625-1131 • 6 L591-19357 • -6A 945B161-1 • 7 • -7A GRC513-215-COMPPV1504 215COMP19357 -7B 2-215-V747 • 8 946F177-1 • -8A 946F177-3 • 9 AN503-8-12 • 10 AN960-8 11 947B450-1 12 947B449-1 13 941D586-2 -13A 942D262-2 13M MS25036-56 . PREFORMED (MOVED TO ITEM 60A IPL FIGURE 3A) PACKING. SEAL (MOVED TO ITEM 40 IPL FIGURE 3A) 1 • • 1 1 ATTACHING PARTS RING. WOUND (CUBEX) (NP) (MOVED TO ITEM 130A IPL FIGURE 3A) • • TERMINAL. SCREW THREAD (MOVED TO ITEM 30M IPL FIGURE 3A) • RETAINER. INSULATION (MOVED TO ITEM 110 IPL FIGURE 3A) • BUSHING (MOVED TO ITEM 120 IPL FIGURE 3A) -----*----ARMATURE. PREFORMED (MOVED TO ITEM 60 IPL FIGURE 3A) PACKING. FIL HD (MOVED TO ITEM 90 IPL FIGURE 3A) • WASHER. PREFORMED (MOVED TO ITEM 70C IPL FIGURE 3A) SEMICONDUCTOR DEVICE SET (MOVED TO ITEM 80 IPL FIGURE 3A) SEMICONDUCTOR DEVICE SET (MOVED TO ITEM 80A IPL FIGURE 3A) 1 1 1 1 1 1 1 1 ATTACHING PARTS SCREW.ITEM NOT ILLUSTRATED NOMENCLATURE EFF CODE SPINDLE. FLAT (MOVED TO ITEM 100 IPL FIGURE 3A) • BUSHING. RETAINING (MOVED TO ITEM 50 IPL FIGURE 3A) -----*----PACKING. GENERATOR (MOVED TO ITEM 30 IPL FIGURE 3A) • • INSERT. PREFORMED (MOVED TO ITEM 70B IPL FIGURE 3A) PACKING. PREFORMED (MOVED TO ITEM 70 IPL FIGURE 3A) PACKING.HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 FIG.

ITEM PART NUMBER 3 13R 947B438-1 14 949B105-3 15 949B105-5 16 949B105-6 . BALANCING (MOVED TO ITEM 160 IPL FIGURE 3A) • • EFF CODE UNITS PER ASSY 16 AR AR AR ILLUSTRATED PARTS LIST 24-20-76 Page 1038 Feb 26/07 .ITEM NOT ILLUSTRATED 1234567 NOMENCLATURE WEDGE (MOVED TO ITEM 130R IPL FIGURE 3A) • WEIGHT. BALANCING (MOVED TO ITEM 150 IPL FIGURE 3A) • WEIGHT.HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 FIG. BALANCING (MOVED TO ITEM 140 IPL FIGURE 3A) • WEIGHT.

HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 THIS PAGE INTENTIONALLY LEFT BLANK ILLUSTRATED PARTS LIST 24-20-76 Page 1039 Feb 26/07 .

HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 HE-242076-67989-A Armature-Rotor Figure 3A ILLUSTRATED PARTS LIST 24-20-76 Page 1040 Feb 26/07 .

PREFORMED) PV1504 GRC513-215COMP • PACKING. IPL FIGURE 1A FOR NHA) ARMATURE-ROTOR (CUBEX) (SEE ITEM -420A. STUB (REPLD BY ITEM -10A) • SHAFT. DRILLED -----*----- .ITEM NOT ILLUSTRATED UNITS PER ASSY A RF B RF C RF 1 1 1 8 SPINDLE. PREFORMED (V45681) (959C442-2) IDENT AS 2-215-V747 MS16625-1131 EFF CODE • 1 1 1 1 1 1 ILLUSTRATED PARTS LIST 24-20-76 Page 1041 Feb 26/07 . IPL FIGURE 1A FOR NHA) (SEE SERVICE NEWS LETTER 48. STUB (REPLD BY ITEM -10B) • SHAFT. PREFORMED) 2-215V747 • PACKING.) ARMATURE-ROTOR (SEE ITEM -420B. HEX HD. ITEM PART NUMBER 1234567 3A -1 915F306-1 -1A 915F508-1 -1B 915F306-2 10 940D366-1 -10A 949F308-1 -10B 769450 20 939D982-1 • 30 30M 40 945B527-1 916B631-3 945B550-1 • 50 60 -60A 70 -70A -70B -70C -70D NOMENCLATURE ARMATURE-ROTOR (SEE ITEM 420. CAP.DELETED (PACKING. PREFORMED (V86579) (945B161-1) 945B161-1 • PACKING. GENERATOR INSERT. PREFORMED (V91265) (959C442-2) IDENT AS GRC513-215-COMP-PV1504 • PACKING. IPL FIGURE 1A FOR NHA) • SHAFT. SEAL 1 1 1 • • ATTACHING PARTS RING. STUB (REPLS ITEM -10A) ATTACHING PARTS SCREW. SCREW THREAD • RETAINER. PREFORMED (V45681) GRC513-215-COMP. PREFORMED 215COMP19357 (V86579) (959C442-2) 2-215-V747 DELETED (PACKING.HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 FIG. RETAINING (18B1766-23) -----*----L591-19357 • PACKING.

) (S.ITEM NOT ILLUSTRATED NOMENCLATURE EFF CODE 1 ATTACHING PARTS SCREW.HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 FIG. FIL HD (28B8802-33) WASHER. BALANCING WEIGHT. 71-103) (FORMERLY 915F199-1. WOUND ARMATURE. ITEM PART NUMBER 3A 80 946F177-1 -80A 946F177-3 1234567 AN503-8-12 • 100 AN960-8 • 110 120 947B450-1 947B449-1 • 130 -130A 130M 941D586-2 942D262-2 MS25036-56 • 130R 140 150 160 947B438-1 949B105-3 949B105-5 949B105-6 • • • • • • • UNITS PER ASSY 1 SEMICONDUCTOR DEVICE SET (SEE IPL FIGURE 4A FOR DETAILS.B. WOUND (CUBEX) (NP) • TERMINAL. USE UP SPARES.) • SEMICONDUCTOR DEVICE SET (SEE IPL FIGURE 4A FOR DETAILS.) • 90 . LUG (927A402-25) • WEDGE WEIGHT. FLAT (910C331-8) BUSHING. INSULATION BUSHING -----*----- 5 5 5 5 ARMATURE. BALANCING WEIGHT. BALANCING A B 1 1 3 16 AR AR AR ILLUSTRATED PARTS LIST 24-20-76 Page 1042 Feb 26/07 .

HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 THIS PAGE INTENTIONALLY LEFT BLANK ILLUSTRATED PARTS LIST 24-20-76 Page 1043 Feb 26/07 .

HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 A-67199 Semiconductor Device Set Figure 4 ILLUSTRATED PARTS LIST 24-20-76 Page 1044 Feb 26/07 .

DIODE (MOVED TO ITEM 80 IPL FIGURE 4A) • LEAD. ELECTRICAL (MOVED TO ITEM 100B IPL FIGURE 4A) • LEAD. ITEM PART NUMBER 1234567 NOMENCLATURE EFF CODE UNITS PER ASSY 4 946F177-1 946F177-3 1 MS16625-1168 2 949B352-1 3 962C265-1 3M 947B451-1 4 938D679-11 -4A 5908349 -4B 5911588 5 938D679-12 -5A 5908350 -5B 5911589 6 MS21042-L4 7 AN960-416L 8 947B473-1 9 948B032-1 10 948B034-1 -10A 949F363-1 -10B 949B363-1 11 949B362-1 . DIODE (MOVED TO ITEM 40 IPL FIGURE 4A) • SEMICONDUCTOR DEVICE. DIODE (MOVED TO ITEM 50 IPL FIGURE 4A) • SEMICONDUCTOR DEVICE. RETAINING (MOVED TO ITEM 10 IPL FIGURE 4A) • SPACER (MOVED TO ITEM 20 IPL FIGURE 4A) • TUBE. ELECTRICAL (MOVED TO ITEM 90 IPL FIGURE 4A) • LEAD. BUS RING (MOVED TO ITEM 30 IPL FIGURE 4A) • • BUSHING (MOVED TO ITEM 30M IPL FIGURE 4A) • SEMICONDUCTOR DEVICE. ELECTRICAL (S.B. DIODE (MOVED TO ITEM 40B IPL FIGURE 4A) • SEMICONDUCTOR DEVICE. DIODE (MOVED TO ITEM 40A IPL FIGURE 4A) • SEMICONDUCTOR DEVICE. FLAT (MOVED TO ITEM 70 IPL FIGURE 4A) -----*----• HOLDER. ELECTRICAL (MOVED TO ITEM 100 IPL FIGURE 4A) DELETED (LEAD.HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 FIG. 71-103) (MOVED TO ITEM 110 IPL FIGURE 4A) • RF RF 1 1 1 2 3 3 3 3 3 3 6 6 3 AR 1 AR AR ILLUSTRATED PARTS LIST 24-20-76 Page 1045 Feb 26/07 . DIODE (MOVED TO ITEM 50A IPL FIGURE 4A) • SEMICONDUCTOR DEVICE.ITEM NOT ILLUSTRATED SEMICONDUCTOR DEVICE SET (MOVED TO ITEM 1 IPL FIGURE 4A) SEMICONDUCTOR DEVICE SET (MOVED TO ITEM 1A IPL FIGURE 4A) • RING. SELF LOCK (MOVED TO ITEM 60 IPL FIGURE 4A) • WASHER. DIODE (MOVED TO ITEM 50B IPL FIGURE 4A) ATTACHING PARTS FOR ITEMS 4 & 5 NUT. ELECTRICAL) (MOVED TO ITEM 100A IPL FIGURE 4A) • LEAD.

ITEM NOT ILLUSTRATED 1234567 • NOMENCLATURE LEAD. SPRING (MOVED TO ITEM 140 IPL FIGURE 4A) DELETED (SPRING. ELECTRICAL (MOVED TO ITEM 120 IPL FIGURE 4A) ATTACHING PARTS FOR ITEMS 9.HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 FIG. 11 & 12 • RIVET. INSULATING (MOVED TO ITEM 180 IPL FIGURE 4A) EFF CODE UNITS PER ASSY AR 6 6 1 2 2 1 1 ILLUSTRATED PARTS LIST 24-20-76 Page 1046 Feb 26/07 . WASHER) (MOVED TO ITEM 140A IPL FIGURE 4A) -----*----• CAPACITOR FIXTURE (MOVED TO ITEM 150 IPL FIGURE 4A) • INSULATION. SLEEVING (MOVED TO ITEM 150F IPL FIGURE 4A) • RING (MOVED TO ITEM 160 IPL FIGURE 4A) (MOVED TO ITEM 170 IPL FIGURE 4A) • TUBE. TUBULAR (MOVED TO ITEM 130 IPL FIGURE 4A) • WASHER. SLEEVING (MOVED TO ITEM 150E IPL FIGURE 4A) • INSULATION. ITEM 4 12 PART NUMBER 948B031-1 13 TC1-6-ST 14 3530-05-03 -14A 947B872-2 15 961C451-1 15E 931A052-1 -15F 931A052-2 16 964C157-2 17 18 DELETED 964C592-1 . 10.

HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 THIS PAGE INTENTIONALLY LEFT BLANK ILLUSTRATED PARTS LIST 24-20-76 Page 1047 Feb 26/07 .

HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 HE-242076-67199-A Semiconductor Device Set Figure 4A ILLUSTRATED PARTS LIST 24-20-76 Page 1048 Feb 26/07 .

IPL FIGURE 3A FOR NHA) (S.B. DIODE LEAD. DIODE (S. DIODE (REPLS ITEM 50) (REPLD BY ITEM 50B) • SEMICONDUCTOR DEVICE. IPL FIGURE 3A FOR NHA) • RING. DIODE (REPLS ITEM 50A) ATTACHING PARTS FOR ITEMS 40 & 50 DELETED (NUT.B. SELF LOCK (959C711-5) IDENT AS MS21042-L4 • WASHER.B.HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 FIG. DIODE (S. FLAT (910C331-11) -----*----HOLDER. BUS RING • • BUSHING • SEMICONDUCTOR DEVICE.ITEM NOT ILLUSTRATED 1234567 NOMENCLATURE SEMICONDUCTOR DEVICE SET (SEE ITEM 80. ELECTRICAL (REPLD BY MIL-SPEC WIRE) • LEAD. 71-103) SEMICONDUCTOR DEVICE SET (SEE ITEM -80A. 71-103) • SPACER (S. DIODE (REPLS ITEM 40A) • SEMICONDUCTOR DEVICE. SELF LOCK) • NUT.B. DIODE (REPLS ITEM 40) (REPLD BY ITEM 4B) • SEMICONDUCTOR DEVICE.B. 71-103) (REPLD BY ITEM -40A) • SEMICONDUCTOR DEVICE. 71-103) • TUBE. RETAINING (18B1766-24) (S. ITEM PART NUMBER 4A -1 946F177-1 -1A 946F177-3 10 MS16625-1168 20 949B352-1 30 30M 40 962C265-1 947B451-1 938D679-11 -40A 5908349 -40B 5911588 50 938D679-12 -50A 5908350 -50B 5911589 60 -60A MS21042-L4 MS21042L4 70 AN960-416L 80 90 947B473-1 948B032-1 100 948B034-1 . ELECTRICAL (REPLD BY ITEM -100A) EFF CODE UNITS PER ASSY A RF B RF 1 1 1 2 3 3 3 3 3 3 6 6 3 AR • • 1 ILLUSTRATED PARTS LIST 24-20-76 Page 1049 Feb 26/07 . 71-103) (REPLD BY ITEM -50A) • SEMICONDUCTOR DEVICE.

B. • INSULATION. ELECTRICAL (S. 71-103) (REPLD BY MIL-SPEC WIRE) • LEAD.ITEM NOT ILLUSTRATED 1234567 NOMENCLATURE DELETED (LEAD. ELECTRICAL) • LEAD. INSULATING (S.HAMILTON SUNDSTRAND COMPONENT MAINTENANCE MANUAL PART NUMBER 976J497 AND 976J597 FIG. 71-103) • EFF CODE TUBE. SPRING (V78189) DELETED (SPRING. SLEEVING (REPLS ITEM 150E) • RING (S.B. TUBULAR) • RIVET. ITEM PART NUMBER 4A -100A -100B 949F363-1 949B363-1 110 949B362-1 120 948B031-1 130 -130A TC1-6-ST TC1-6ST 140 3530-05-03 -140A 947B872-2 150 150E 961C451-1 931A052-1 -150F 931A052-2 160 964C157-2 -170 180 DELETED 964C592-1 . 110 & 120 DELETED (RIVET.B. ELECTRICAL (REPLS ITEM 100) (REPLD BY MIL-SPEC WIRE) • LEAD. TUBULAR (V42838) (19C8355-33) IDENT AS TC1-6-ST • WASHER. DISCARD ANY REMAINING STOCK AND USE ITEM -150F). 100. ELECTRICAL (REPLD BY MIL-SPEC WIRE) UNITS PER ASSY AR AR AR ATTACHING PARTS FOR ITEMS 90. SLEEVING (REPLD BY ITEM -150F. 71-103) 6 6 1 2 2 1 1 ILLUSTRATED PARTS LIST 24-20-76 Page 1050 Feb 26/07 . WASHER) -----*----• CAPACITOR FIXTURE • INSULATION.