OE-A2 - Maintenance and Overhaul Manual With IPL

Hartzell Engine Technologies LLC
2900 Selma Highway

Montgomery, AL 36108
USA
Tel: +1.334.386.5400
Fax: +1.334.386.5410
AIRCRAFT ALTERNATOR
AND STARTER
MAINTENANCE AND
OVERHAUL MANUAL
with
Illustrated Parts
Lists (IPL)
P/N OE-A2
Overhaul Manual - Aircraft Alternators & Starters

Part Number OE-A2 - Rev. 12 i
THIS PAGE INTENTIONALLY LEFT BLANK

ii Part Number OE-A2 - Rev. 12
General Information
........................................................................................
WARNING: IMPROPER OR UNAUTHORIZED APPLICATIONS OF INFORMATION

CONTAINED IN THIS MANUAL MAY RESULT IN PERSONAL INJURY,
EQUIPMENT DAMAGE, AND LOSSES OR OTHER DAMAGES TO THE
USER.
The accuracy and applicability of this manual has not been verified for any assembly,
component or part not manufactured by Hartzell Engine Technologies LLC (HET). Any
use of this manual for other than its intended purpose or for performing any installation,
maintenance, replacement, adjustment, inspection or overhaul of any assembly, component
or part not manufactured by HET is not approved, endorsed, or sanctioned by HET.
No liability will be assumed by Hartzell Engine Technologies LLC for actual, consequential
or any other types of damages directly or indirectly resulting from the unauthorized use of this
manual for other than its stated purposes.
Because of the numerous modifications, Supplemental Type Certificates (STC), Parts
Manufacturing Approvals (PMA), Technical Standard Orders (TSO), Form 337 Field
Approvals, and other documents, the information used in the Aircraft Application Data is for
reference use only. For proper Engine/Airframe application, please refer to the appropriate
Type Certificate (TC), POH/AFM, and/or the applicable Log Book. Chapter 1 Application
Data is presented as reference only. As such, it remains the responsibility of the
installer to assure that the selected equipment applies to the specific aircraft,
rotorcraft, or engine the component is being installed upon.
When performing installation, maintenance, replacement, adjustment, inspection or
overhaul of any HET assembly, component or part, it is imperative that the latest revision
of the appropriate HET manual or product support document be referenced. Consult
Skytec.aero website for starter service information, and PlanePower.aero for alternator
service information prior to performing any work.
The OE-A2 manual does not cover every alternator or starter manufactured by HET,
however, all alternators, starters, and their component parts in this manual are FAA/PMA
approved. For non FAA/PMA approved components which are built by HET, overhaul
manuals or instructions must be obtained from the TC or STC design holder (OEM) to affect
any repair or overhaul.
All reasonable attempts were made to make this manual as complete and accurate
as possible. The data herein is limited to those components listed. If you do not find the
component you are seeking, it may be listed in other HET publications or manuals. If you
have any questions, comments, corrections or require clarification of any information
contained herein, please write or Fax, Hartzell Engine Technologies at 2900 Selma
Highway, Montgomery, AL 36108, USA or if by Fax +1 334-386-5410 or if by e-mail,
techsupport@hartzell.aero.

Part Number OE-A2 - Rev. 10 iii
ALTERNATORS:
I
If Units Begins With: Then Unit Is:
ALE- 12V/40A

ALT- 24V/50A
ALU- 24V/70A
ALV- 24V/100A
ALX- 12V/70A
ALY- 12V/60A
ALZ- 12V/50A
-
If First Digit After (1) Is: Then Unit Is:
6 Belt Driven - No Blast Tube
8 Belt Driven - Blast Tube
9 Gear Driven
If Units Ends With: Then Unit Is:
LS New Unit - No Pulley
RS Rebuilt / Ovh Unit - No Pulley
G With Ground Strap
R Rebuilt / Overhauled Unit
None New Unit
No information is available for FORD or CHRYSLER alternators. HET does not own these product
lines and has no PMA. Service or overhaul information must be obtained from engine or airframe
manufacturer’s instructions or service manuals.
STARTERS:
If Units Begins With: Then Unit Is:
MCL- 12V
-
MHB- 24V
MHJ- 24V
-
MMU- 24V
MZ- 12V
If Units Ends With: Then Unit Is:

R Rebuilt / Overhauled Unit
None New Unit
BD Belt Driven
GD Gear Driven
No information is available for E, X, or M-Drive starters as these may be found in other HET manuals
or publications. Consult http://www.SkyTec.aero for information on the latest publications.

iv Part Number OE-A2 - Rev. 011
RECORD OF TEMPORARY REVISIONS
Temporary Page Issue Date
By By
Rev. Letter Number Date Removed
TR-001 2-700-01 & 2-710-01 8-05-15 HET 4-28-16 HET

Part Number OE-A2 - Rev. 07 iv-a
RECORD OF TEMPORARY REVISIONS
Temporary Page Issue Date
By By
Rev. Letter Number Date Removed

Part Number OE-A2 - Rev. 05 iv-b
LIST OF EFFECTIVE PAGES
CONTENT OF PAGES PAGES REV & DATE

Title Page i Rev. 12 - 02/21/22
Copyright statement ii Rev. 12 - 02-22-22
General Information iii Rev. 10 - 02/10/21
iv Rev. 08 - 10-03-18
Record of Temporary Revisions iv-a Rev. 07 - 04-28-16
Record of Temporary Revisions iv-b Rev. 06 - 07-06-15
List of Effective Pages iv-c Rev. 12 - 02-22-22
Record of Revisions iv-d Rev. 12 - 02-22-22
iv-e Rev. 11 - 12-15-21
iv-f & iv-g Rev. 11 - 12-15-21
v Rev. 03 - 02-09-07
vi & vi-a Rev. 04 - 10-01-10
vi-b thru vi-h Rev. 05 - 06-18-13
vi-b thru vi-h Rev. 05 - 06-18-13
vi-i thru vi-j Rev. 07 - 04-28-16
vi-k thru vi-l Rev. 07 - 04-28-16
Table of Contents vi-m Rev. 10 - 02/10/21
vi-n Rev. 12 - 02-22-22
vii Rev. 07 - 04-28-16
Purpose of Manual viii & ix Rev. 07 - 04-28-16
Aircraft & Engine Application Data x Rev. 08 - 10-03-18
Alternator Service Parts List xi thru xiv Rev. 05 - 06-18-13
1-10-01 & 1-20-01 Rev. 07 - 04-28-16
2-10-01 Rev. 05 - 06-18-13
2-20-01, 2-60-01, 2-100-01 Original - 05-01-03
2-30-01 Rev. 05 - 06-18-13
2-40-01 & 2-50-01 Rev. 07 - 04-28-16
2-70-01 thru 2-90-01 Rev. 05 - 06-18-13
2-110-01 thru 2-130-01 Rev. 05 - 06-18-13
2-140-01 & 2-260-01 Original - 05-01-03
2-150-01 Rev. 05 - 06-18-13
2-160-01 thru 2-180-01 Rev. 07 - 04-28-16
2-190-01 Rev. 05 - 06-18-13
2-200-01 & 2-210-01 Rev. 07 - 04-28-16
2-220-01 & 2-230-01 Rev. 05 - 06-18-13
2-240-01 & 2-250-01 Rev. 07 - 04-28-16
2-270-01thru 2-300-01 Rev. 07 - 04-28-16
2-310-01 Rev. 05 - 06-18-13
2-320-01 thru 2-340-01 Rev. 07 - 04-28-16
2-350-01 Rev. 05 - 06-18-13
2-360-01 thru 3-380-01 Rev. 07 - 04-28-16
2-390-01 Rev. 05 - 06-18-13
2-400-01 & 2-410-01 Rev. 07 - 04-28-16
2-420-01 Original - 05-01-03
2-430-01 thru 2-450-01 Rev. 05 - 06-18-13
2-460-01, 2-500-01, 2-520-01 Original - 05-01-03
2-470-01 Rev. 05 - 06-18-13
2-480-01 & 2-490-01 Rev. 07 - 12-07-15
2-510-01 Rev. 07 - 04-28-16
2-520-01 & 2-530-01 Rev. 12 - 02-22-22
2-540-01 & 2-550-01 Rev. 11 - 12-15-21
2-560-01 Rev. 11 - 12-15-21
2-570-01. 2-590-01 2-600-01, Rev. 12 - 02-22-22
2-600-02
2-580-01, 2-610-01, 2-620-01 Rev. 07 - 04-28-16

Part Number OE-A2 - Rev. 12 iv-c
Alternator Service Parts List (cont’d) 2-630-01 Rev. 07 - 04-28-16
2-640-01 thru 2-660-01 Rev. 11 - 12-15-21
2-670-01 Rev. 05 - 06-18-13
2-680-01 & 2-720-01 Original - 05-01-03
2-690-01 Rev. 05 - 06-18-13
2-700-01 & 2-710-01 Rev. 07 - 04-28-16
2-730-01 thru 2-750-01 Rev. 05 - 06-18-13
2-770-01 thru 2-790-01 2-730- Rev. 05 - 06-18-13
01 thru 2-750-01 Rev. 05 - 06-18-13
2-770-01 thru 2-790-01 Rev. 05 - 06-18-13
2-760-01 & 2-800-01 Original - 05-01-03
Alternator Maintenance and Overhaul Information 3-10-01 Rev. 07 - 04-28-16
3-20-01 Rev. 05 - 06-18-13
3-30-01 Rev. 04 - 10-01-10
3-40-01 Rev. 06 - 07-06-15
3-50-01, 3-60-01, 3-100-01 Original - 05-01-03
3-70-01 thru 3-90-01 Rev. 05 - 06-18-13
3-110-01 thru 3-130-01 Rev. 05 - 06-18-13
3-140-01, 3-180-01, 3-220-01 Original - 05-01-03
3-150-01 & 3-190-01 Rev. 04 - 10-01-10
3-160-01 & 3-170-01 Rev. 06 - 07-06-15
3-200-01 & 3-210-01 Rev. 06 - 07-06-15
3-230-01 & 3-270-01 Rev. 04 - 10-01-10
3-240-01 & 3-250-01 Rev. 06 - 07-06-15
3-260-01, 3-300-01, 3-340-01 Original - 05-01-03
3-280-01 & 3-290-01 Rev. 06 - 07-06-15
3-310-01 & 3-350-01 Rev. 04 - 10-01-10
3-320-01 & 3-360-01 Rev. 04 - 10-01-10
3-330-01 Rev. 05 - 06-18-13
3-370-01, 3-380-01, 3-420-01 Original - 05-01-03
3-390-01 thru 3-410-01 Rev. 05 - 06-18-13
3-430-01 Rev. 04 - 10-01-10
3-440-01 Rev. 12 - 02-22-22
3-450-01 Rev. 06 - 07-06-15
3-460-0 1thru 3-490-01 Rev. 07 - 04-28-16
3-500-01 thru 3-540-01 Rev. 04 - 10-01-10
3-550-01 thru 3-600-01 Rev. 05 - 06-18-13
Alternator Service Information 4-10-01 Rev. 07 - 04-28-16
4-20-01 Rev. 05 - 06-18-13
4-30-01 Rev. 08 - 10-03-18
4-40-01 & 4-60-01 Original - 05-01-03
4-50-01 & 4-70-01 Rev. 05 - 06-18-13
4-80-01 & 4-90-01 Original - 05-01-03
4-100-01 Rev. 07 - 04-28-16
4-110-01 Rev. 08 - 10-03-18
4-120-01 & 4-130-01 Rev. 08 - 10-03-18
4-140-01 Original - 05-01-03
4-150-01 thru 4-230-01 Rev. 05 - 06-18-13
4-240-01, 4-280-01, 4-380-01 Original - 05-01-03
4-250-01 & 4-260-01 Rev. 05 - 06-18-13
4-270-01, 4-290-01, 4-300-01 Rev. 07 - 04-28-16
4-310-01 Rev. 04 - 10-01-10
4-320-01 & 4-370-01 Rev. 07 - 04-28-16
4-330-01 thru 4-360-01 Rev. 05 - 06-18-13
4-390-01 & 4-400-01 Rev. 07 - 04-28-16

Part Number OE-A2 - Rev. 12 iv-d
Alternator Service Information (cont’d) 4-410-01 Rev. 04 - 10-01-10
4-420-01, 4-440-01, 4-460-01 Original - 05-01-03
4-430-01, 4-450-01, 4-470-01 Rev. 05 - 06-18-13
4-490-01 thru 4-510-01 Rev. 07 - 04-28-16
4-520-01 Rev. 04 - 10-01-10
4-480-01 & 4-540-01 Original - 05-01-03
4-580-01 Rev. 11 - 12-15-21
4-530-01, 4-550-01, 4-590-0 Rev. 05 - 06-18-13
4-600-01, 4-620-01, 4-630-01 Original - 05-01-03
4-610-01 & 4-640-01 Rev. 07 - 04-28-16
4-650-01 & 4-660-01 Rev. 11 - 12-15-21
4-670-01 & 4-690-01 Rev. 07 - 04-28-16
4-680-01 Rev. 04 - 10-01-10
4-700-01 & 4-720-01 Original - 05-01-03
4-710-01 & 4-730-01 Rev. 05 - 06-18-13
4-740-01 & 4-750-01 Original - 05-01-03
4-760-01 Rev. 11 - 12-15-21
4-770-01 Rev. 05 - 06-18-13
4-780-01 Original - 05-01-03
4-790-01 & 4-820-01 Rev. 07 - 04-28-16
4-800-01 & 4-810-01 Original - 05-01-03
4-830-01 Rev. 06 - 07-06-15
4-840-01 Rev. 11 - 12-15-21
4-860-01 Rev. 04 - 10-01-10
4-850-01 thru 4-870-01 Rev. 07 - 04-28-16
4-880-01, 4-900-01 Original - 05-01-03
4-890-01 & 4-910-01 Rev. 05 - 06-18-13
4-920-01 thru 4-940-01 Original - 05-01-03
4-950-01 Rev. 05 - 06-18-13
4-960-01, 4-980-01, 4-990-01 Original - 05-01-03
4-970-01 & 4-1000-01 Rev. 07 - 04-28-16
4-1010-01 Rev. 06 - 07-06-15
4-1020-01 & 4-1050-01 Original - 05-01-03
4-1030-01 & 4-1040-01 Rev. 07 - 04-28-16
4-1060-01 & 4-1080-01 Original - 05-01-03
4-1070-01 & 4-1090-01 Rev. 05 - 06-18-13
4-1100-01 & 4-1110-01 Original - 05-01-03
4-1120-01 Rev. 05 - 06-18-13
4-1130-01, 1150-01, 4-1190-01 Rev. 07 - 04-28-16
4-1140-01 & 4-1160-01 Original - 05-01-03
4-1170-01 Original - 05-01-03
4-1180-01 Rev. 04 - 10-01-10
4-1200-01 Rev. 05 - 06-18-13
Alternator Specifications & Tolerances 5-10-01, 5-30-01, 5-40-01 Rev. 05 - 06-18-13
5-20-01 Original - 05-01-03
5-50-01 & 5-80-01 Rev. 06 - 07-06-15
5-60-01 & 5-70-01 Rev. 05 - 06-18-13
Starter Service Parts List 6-10-01 & 6-20-01 Original - 05-01-03
6-30-01 Rev. 05 - 06-18-13
6-40-01 Rev. 11 - 12-15-21
6-50-01 Rev. 11 - 12-15-21
6-60-01, 6-100-01, 6-140-01 Original - 05-01-03
6-70-01 Rev. 05 - 06-18-13
6-80-01 & 6-90-01 Rev. 07 - 04-28-16
6-110-01 thru 6-130-01 Rev. 05 - 06-18-13
6-150-01 & 6-190-01 Rev. 05 - 06-18-13
6-160-01 Rev. 07 - 04-28-16
6-170-01 & 6-180-01 Rev. 09 - 05-05-20

Part Number OE-A2 - Rev. 11 iv-e

Starter Service Parts List (cont’d) 6-200-01, 6-210-01, 6-240-01 Rev. 07 - 04-28-16
6-220-01, 6-260-01, 6-300-01 Original - 05-01-03
6-230-01 Rev. 05 - 06-18-13
6-240-01 Rev. 07 - 04-28-16
6-270-01 thru 6-290-01 Rev. 05 - 06-18-13
6-310-01, 6-320-01, 6-330-01 Rev. 07 - 04-28-16
6-340-01, 6-380-01, 6-460-01 Original - 05-01-03
6-350-01, 6-360-01, 6-390-01 Rev. 05 - 06-18-13
6-350-01 Rev. 05 - 06-18-13
6-360-01 & 6-370-01 Rev. 07 - 04-28-16
6-400-01, 6-410-01, 6-420-01 Rev. 07 - 04-28-16
6-430-01 Rev. 05 - 06-18-13
6-440-01 & 6-450-01 Rev. 07 - 04-28-16
6-460-01 Original - 05-01-03
Starter Service Information 7-10-01 & 7-40-03 Rev. 07 - 04-28-16
7-20-01 Original - 05-01-03
7-30-01 Rev. 11 - 12-15-21
7-40-01 & 7-40-02 Rev. 06 - 07-06-15
7-50-01 Rev. 06 - 07-06-15
7-60-01 Rev. 11 - 12-15-21
7-60-02 thru 7-60-05 Rev. 06 - 07-06-15
7-70-01 thru 7-90-01 Rev. 05 - 06-18-13
7-100-01, 7-190-01, 7-220-01 Rev. 07 - 04-28-16
7-110-01 thru 7-130-01 Rev. 05 - 06-18-13
7-140-01, 7-200-01, 7-240-01 Original - 05-01-03
7-150-01 thru 7-180-01 Rev. 05 - 06-18-13
7-210-01 Rev. 05 - 06-18-13
7-230-01 Rev. 03 - 02-09-07
7-250-01, 7-260-01, 7-270-01 Rev. 05 - 06-18-13
7-280-01, 7-330-01, 7-430-01 Rev. 07 - 04-28-16
7-290-01 & 7-300-01 Rev. 05 - 06-18-13
7-310-01, 7-340-01, 7-380-01 Original - 05-01-03
7-320-01, 7-350-01, 7-360-01 Rev. 05 - 06-18-13
7-370-01 Rev. 03 - 02-09-07
7-400-01 & 7-420-01 Rev. 05 - 06-18-13
7-390-01, 7-410-01, 7-440-01 Original - 05-01-03
7-450-01 & 7-460-01 Rev. 05 - 06-18-13
7-470-01 Rev. 03 - 02-09-07
7-480-01 & 7-500-01 Original - 05-01-03
7-490-01 & 7-510-01 Rev. 07 - 04-28-16
7-520-01 thru 7-540-01 Rev. 07 - 04-28-16
Starter Maintenance and Overhaul Information 8-10-01, 8-30-01, 8-70-01 Rev. 06 - 07-06-15
8-20-01 Rev. 05 - 06-18-13
8-40-01 Original - 05-01-03
8-50-01 & 8-60-01 Rev. 05 - 06-18-13
8-80-01 thru 8-140-01 Original - 05-01-03
8-150-01 & 8-170-01 Rev. 05 - 06-18-13
8-160-01, 8-180-01, 8-190-01 Original - 05-01-03
8-200-01 Rev. 05 - 06-18-13
8-210-01 thru 8-280-01 Original - 05-01-03
8-290-01, 8-310-01, 8-320-01 Rev. 05 - 06-18-13
8-300-01 & 8-380-01 Original - 05-01-03
8-330-01 thru 8-360-01 Original - 05-01-03
8-370-01 Rev. 03 - 02-09-07
Starter Specifications & Tolerances 8-390-01 Rev. 09 - 05-05-20
8-400-01 Rev. 06 - 07-06-15

Part Number OE-A2 - Rev. 11 iv-f

Starter Specifications & Tolerances(cont’d) 8-410-01 Rev. 10 - 02/10/21
8-420-01 Rev. 10 - 02/10/21
8-430-01 Rev. 11 - 12-15-21
8-440-01 Rev. 11 - 12-15-21
8-450-01 Rev. 11 - 12-15-21
8-460-01 thru 8-500-01 Rev. 06 - 07-06-15
9-10-01 Original - 05-01-03
8-20-01 Rev. 07 - 04-28-16
9-30-01 & 9-70-01 Rev. 05 - 06-18-13
9-40-01 & 9-60-01 Rev. 06 - 07-06-15
9-50-01 Rev. 05 - 06-18-13
9-60-01 & 9-80-01 Rev. 07 - 04-28-16
9-70-01 thru 9-100-01 Rev. 06 - 07-06-15
9-110-01 & 9-120-01 Rev. 11 - 12-15-21
Service Bulletins & Other Publications 10-10-01 Original - 05-01-03
10-20-01 Rev. 06 - 07-06-15
10-30-01 thru 10-120-01 10- Rev. 03 - 02-09-07
130-01 & 10-140-01 Rev. 03 - 02-09-07
10-150-01 thru 10-400-01 Rev. 06 - 07-06-15
10-410-01 thru 10-700-01 Rev. 04 - 10-01-10
10-710-01 thru 10-740-01 Rev. 06 - 07-06-15
10-750-01 & 10-760-01 Rev. 04 - 10-01-10
10-770-01 thru 10-820-01 Rev. 05 - 06-18-13
10-830-01 thru 10-980-01 Rev. 06 - 07-06-15

Part Number OE-A2 - Rev. 11 iv-g
REVISION PAGE
REVISION PAGES AFFECTED DATE DESCRIPTION FAA ACCEPT
Release
All 5/1/03 Original Printing of Manual
-02 iii 5/23/03 Copyright Disclaimer Added
-03 i 2/09/07 Registration Info. Modified
ii & iii Copyright updated, contact
info. changed.
vii Added titles to TOC
viii Added alternator model number
ix Moved Chpt.-10 Title to pg x
x Added SB TOC-10 to pg x
1-10-01 Added aircraft model numbers
1-240-01 Added aircraft model info.
1-250-01 Added chart, page 1-250-01
through page 1-280-01
2-210-01 Correct part numbers, add model
2-240-01 Circled item 11 & 13
2-250-01 Circled item 11 & 13,
modified note
2-290-01 Corrected part numbers,
modified notes
2-300-01 Corrected part numbers,
modified notes
2-570-01 Added alternator model number
2-580-01 Circled item 26 & 27,
changed (c) to (d)
2-590-01 Circled item 26, 27, & 28
2-600-01 Circled item 26, 27, & 28
2-600-02 Added page 2-600-02
2-600-03 Added page 2-600-03
2-630-01 Circled item 25
2-640-01 Circled item 25
2-740-01 Change (d) to 30
2-750-01 Change 30, add 31, add note (a)
3-460-01 Added reference
6-50-01 Removed part number
6-170-01 Corrected part numbers
6-400-01 Add (p)
6-410-01 Corrected model numbers &
part numbers, add note (p)
6-420-01 Corrected part numbers, add note (p)
7-220-01 Changed sentence, added note
7-230-01 Removed Figure.
8-370-01 Removed Figure, modified procedure
9-40-01 Corrected dimension
-03 (Continued) 2/09/07
10-10-01 Modified service pub TOC info
10-30-01 Added SB #016 Rev. A page no.

Part Number OE-A2 - Rev. 03 v
REVISION PAGE
10-130-01 Added SB #021
10-150-01 Added SB A-112 Rev. A
10-230-01 Added SB A-115
10-250-01 Added SB A-116
10-270-01 Added SB A-118
-04 (all revised pages) 10/1/10 (Logo change KAPS to HET)
i Registration Info. Modified.
ii & iii Copyright updated, contact
& info. changed, para. added.
iv Notations added.
v Relocated Rev -03 info.
vi Added Rev -04 info.
vi-a & vi-b Added Revision pages.
vii Added models.& relocated data.
viii Added models.& relocated data.
ix Relocated data, added note.
x Relocated data, added service pubs.
1-10-01 thru Revised all pages by relocating,
1-400-01 changing, & adding pages with data.
2-90-01 Added (e), (**) notes.
2-170-01 Update (c), added (h), (i), (x), (*) notes.
2-180-01 Update (c), added (h), (i), (x), (*) notes.
2-210-01 Update (c), added (h), (i), (x), (**) notes.
2-220-01 Update (c), added (h), (i), (x), (**) notes.
2-250-01 Update (d), added (e), (x), (**) notes.
2-290-01 Update (c), added (g), (h), (x), (**) notes.
2-300-01 Correct P/N error, Update (c), added (g),
(h), (x), (**) notes.
2-330-01 Update (c), added (d), (e), (x), (**) notes.
2-370-01 Update (c), added (e), (f), (x), (**) notes.
2-380-01 Update (c), added (e), (f), (x), (**) notes.
2-530-01 Added (c), note.
2-650-01 Added comment in headline.
2-710-01 Added (a), note.
2-750-01 Added (b), note.
3-10-01 Added sections to chapter TOC.
3-20-01 Added precautions section.
(all revised pages) (Logo change KAPS to HET)
3-30-01 Added notation to S.I. para.
3-40-01 Added lube comment.

Part Number OE-A2 - Rev. 04 vi
REVISION PAGE
04 (Continued) 10/1/10
3-460-01 Corrected chart error.
3-470-01 thru Added new pages, added ICA
3-530-01 section and associated data.
3-540-01 Added intentionally left blank page.
3-550-01 & Added pages, added Special Conditions
3-560-01 section.
4-10-01 Added section to chapter TOC.
4-50-01 Add 7 to 1st note, comment on 2nd note.
4-110-01 Added notation under item 6.
4-120-01 Added notation under title line
4-170-01 Added notation to second note.
4-220-01 Added notation under title line.
4-450-01 Added notation to second Note.
4-550-01 Added 9 to !st note.
4-730-01 Added 9 to !st note.
4-860-01 Add to 9, add notation under title line.
section.
4-1200-01 Added note under Table 2.
5-50-01 Correct dim. error for ALV series.
6-30-01 Added alternate starters.
7-460-01 Corrected Test Spec.
7-490-01 Added starter duty cycle section
10-10-01 Added Pubs to chapter TOC.
10-290-01 thru 10-320-01 Added SB 033, (4 pages)

Part Number OE-A2 - Rev. 04 vi-a
REVISION PAGE
04 (Continued) 10/1/10
10-330-01 thru Added SB 038 Rev A, (3 pages)
10-370-01 thru Added SIL A-125 Rev A, (4 pages)
10-400-01
10-410-01 thru Added SIL A-126, (30 pages)
10-700-01
10-710-01 thru Added SIL A-132, (2 pages)
10-720-01
10-730-01 Added SL 24 Rev A, (1 pages)
10-750-01 Added SL 25, (1 page.)
-05 i 6/18/13 Updated registration page.
ii Copyright updated
iii Copyright updated, changed &
modified Warning. Add OEM statement
to para. second from bottom of page.
iv Removed ALH, ALM, & ANG in Alt.
table & MDB & MHP from starter.table.
Modified disclaimer under Alt table.
iv-a & iv-b Added pgs iv-a & iv-b for Temp Rev’s.
vi-c thru vi-h. Added LOR pages.
vi-b thru vi-h. Added Rev -05 info.
viii Removed TOC info, chg TCM to CMI,
removed Chrysler & Ford alternators.
ix Mod note at Alt Service, mod Alt Maint
& Ovh TOC, mod Alt Spec & Tol TOC.
x Added SB, SIL’s & deleted SL from TOC.
xi thru xiv Added pages & sections; Manual Purpose,
Org, Other Pubs, Qualified Personnel,
Warnings, Cautions & Notes, & Revising
Manual.
1-20-01 Chg name to HET, chg name to CMI
1-30-01 Modify Caution Note to add OBS & ^.
1-40-01 Notate non-PMA & obsolete alternators.
1-50-01 thru 1-70-01 Notate non-PMA alt’s, fix typos, add note,
add current alternator models.
1-80-01 & 1-90-01 Delete CMI, obsolete alt’s, correct typos,
& add Great Lakes models.
1-100-01 & 1-110-01 Chg. TCM to CMI, & correct typos,
correct Palm Beach Roamer alt. no.
1-120-01 & 1-130-01 Notate non-PMA alt’s & correct typos.
1-140-01 Chg. TCM to CMI, delete Delco P/N’s.

Part Number OE-A2 - Rev. 05 vi-b
REVISION PAGE
-05 (Continued) 6/18/13

1-150-01 Chg. to HET in header, chg. TCM to
CMI, notate obsolete alternators.
1-160-01 Chg. to HET in header, chg. TCM to
CMI, chg Textron Lycoming to
Lycoming Engines.
1-170-01 & 1-180-01 Chg. Textron Lycoming to Lycoming
Engines, notate non-PMA alternators.
1-210-01 Chg. Textron Lycoming to Lycoming
Engines.
1-220-01 Chg. Textron Lycoming to Lycoming
Engines, notate non-PMA alternator.
Engines.
Engines.
1-290-01 Notate obsolete alternators.
1-310-01 Chg. to HET in header, add note at top
update * notes at bottom of page.
1-320-01 & 1-330-01 Chg. to HET in header, add note at top
update * notes at bottom of page.
1-340-01 & 1-350-01 Chg. to HET in header.
1-360-01 & 1-370-01 Chg. to HET in header, 2 places,
TIGO/TIO-541 starters changed to NA.
1-380-01 & 1-390-01 Chg. to HET in header.
1-400-01 Chg. to HET & CMI in (3) places each.
Correct all LM model to PM model.
2-10-01 Removed Chysler & 2 lines Ford, TOC.
2-30-01 Added FAA/PMA comment in header;
Removed non-PMA model ALE-8521.
2-40-01 Changed mandatory to required in note.
2-50-01 Removed ALE-8521 parts, changed
mandatory to required in note.
2-70-01 thru 2-90-01 ALH obsolete, removed data from pages.
2-110-01 thru 2-130-01 ALM obsolete, removed data from pages.
Removed obsolete ALT-5101A &
ALT-5102S; chg. TCM to CMI
2-160-01 Changed mandatory to required in note.
2-170-01 & 2-180-01 Changed mandatory to required in note,
added HET to * note, rep’l P/N X-4087.
Removed non-PMA ALU model parts,
removed OEM note.
2-200-01 Changed mandatory to required in note,
added HET to ** note. Removed
non-PMA ALU model parts.
removed non-PMAALV-6403LS,
ALV-8512; ALV-9405, & ALV-9406,
chg. TCM to CMI.

Part Number OE-A2 - Rev. 05 vi-c
REVISION PAGE
-05 (Continued) 6/18/13

removed non-PMAALV model parts,
added HET to note, rep’l P/N X-4087.
removed non-PMAALX-6408,
ALV-6423; & ALX-6523, chg. TCM
to CMI.
2-290-01 Changed mandatory to required in * note,
removed non-PMAALX model parts,
added HET to note, rep’l P/N X-4087.
2-300-01 Changed mandatory to required in * note,
add *** note, added HET to note,
replaced P/N X-4087.
removed non-PMAALY-6408, ALY-6412
ALY-6421 & ALY-6425.
2-330-01 & 2-340-01 Removed non-PMAALY model parts,
added HET to note.
removed non-PMAALY-8410 &
ALY-8410R; chg. TCM to CMI.
2-370-01 Removed obsolete model parts,
chg mandatory to required in note,
added HET to ** note.
2-380-01 Updated #16 & #18 part no, chg
mandatory to required in note,
2-410-01 chg mandatory to required in note,
2-430-01 thru 2-450-01 ANG obsolete, removed data from pages.
2-490-01 Changed mandatory to required in note
& chg name to HET.
removed non-PMA ES4005, ES4005-2,
ES4007; ES4013, ES4013 LS, ES4017
ES4018, ES4018LS, ES4021, ES4023
ES4024L, ES4030, ES4031, & ES4040,
chg. TCM to CMI, removed * note,
added ES4024LP-2 & ES4024LP-3.
2-530-01 & 2-540-01 Removed non-PMA ES model parts,
Changed mandatory to required in note,
chg to HET on note, added ES4024LP-2
& ES4024LP-3 parts.
relocated date, made 2-550-01 blank.

Part Number OE-A2 - Rev. 05 vi-d
REVISION PAGE
-05
(Continued) 6/18/13
2-570-01 Added FAA/PMA comment in
header; removed non-PMA ES4014,
ES4016, ES4019-2/LS, & ES4022.
chg to HET on note.
2-600-02 Removed non-PMA ES model parts &
made page blank.
removed non-PMA ES4028, chg. TCM
to CMI,
2-630-01 Removed non-PMA ES model parts,
chg to HET on note.
2-640-01 Chg to HET on note.
2-650-01 thru 2-670-01 Removed non-PMA data, made into
Intentionally Left Blank page.
2-690-01 Delete non-PMA parts, chg title para.
2-710-01 Delete non-PMA, chg to required in note.
Intentionally Left Blank pages.
Intentionally Left Blank pages.
3-10-01 Add Identification to TOC.
3-20-01 Modify warning, add 1 & 2, made caps.
3-70-01 thru 3-90-01 Obsolete, removed all data from pages
for ALH alternators.
for ALM alternators.
3-330-01 Removed ALY-6525 from table.
for ANG alternators.
3-440-01 Corrected 130 amp pulley torque.
3-460-01 Corrected ref table by removing non-
PMA alt’s, modified para at bottom of
page, added ES4024LP-2 & -3 to table.
3-470-01 Removed unnecessary data from ICA.
3-480-01 & 3-490-01 Modify General para. & last sentence
of 500 hour. Modify * note.
3-550-01 Modify Sudden Eng Stop (belt) para 1,
2(2), (gear) 1 & 2.
3-560-01 thru 3-600-01 Added pages.
3-560-01 Added item 3.MPI & FPI instruction,
corrected Lightning Strike errors.
3-570-01 thru 3-590-01 Added identification section data, added
Figs. 3.1, 3.2, & 3.3.
3-600-01 Page intentionally left blank.
4-10-01 Deleted OBS & non-PMA items on TOC.
4-30-01 Deleted OBS items add note, name chg,
modify General & modify Fig. 2.
4-50-01 Mod Caution to caps, chg Notes to 1 & 2,
modify Note 1 & 2 content.

Part Number OE-A2 - Rev. 05 vi-e
REVISION PAGE
-05
(Continued) 6/18/13
4-70-01 Name change to HET, Modify Caution.
4-120-01 Removed obsolete ALH & ANG ref.
for ALM alternators.
4-230-01 Add note, name chg to HET, modify
General & modify Fig. 2.
4-250-01 & 4-260-01 Mod Caution to caps, chg Notes to 1 & 2,
modify Note 1 & 2 content, name chg
to HET, delete error in 1, add mark in 2.
4-340-01 Caution modified to all caps & HET,
to HET, add ref. mark in 1.
4-360-01 Name change to HET, two places.
to HET, add 1 ref. mark.
4-470-01 Name change to HET, one place.
4-530-01 Delete non-PMA’s, add note, name chg
to HET, modify General & modify Fig. 2.
4-550-01 Caution mod. to HET & caps, note mod.
4-1070-01 Modified Title at top of page, add note,
name chg to HET, modify General &
modify Fig. 2
name change & General para modified.
4-1200-01 Corrected page error in note.
5-10-01 Name change to HET top of page Title,
add millimeter section to TOC.
5-30-01 Name change to HET top of page Title.
5-40-01 Corrected P/N error in SRE end housing.
5-50-01 Removed ALH & ANG ref. from Table,
Caution modified to all caps.
5-60-01 thru 5-80-01 Added pages for millimeter section and
added millimeter data.
6-30-01 Added parts statement at top of page,
chg TCM to CMI, add alternate starters.
chg Notes to Note 1 & 2 at bottom of pg.
6-40-01 Chg Notes to Note 1 & 2, chg mandatory
to required.
6-50-01 In notes, chg mandatory to required,
add mount O-ring note.

Part Number OE-A2 - Rev. 05 vi-f
REVISION PAGE
-05
(Continued) 6/18/13
removed non-PMA MCL-6502 & 6503,
added orig. equip. 634592, changed
TCM to CMI.
6-80-01 In Note, chg mandatory to required.
6-90-01 Removed parts data for non-PMA MCL.
In notes, chg mandatory to required.
6-110-01 thru 6-130-01 MDB obsolete, removed data from pgs.
emoved non-PMA MHB-4002, -4004,
-4005, -4006, -4008, -4011, -4017,
* note removed.
6-170-01 & 6-180-01 Removed parts data for non-PMA MHB,
in notes, chg mandatory to required.
added no longer available, added
alternate use starters, added ** note.
6-200-01 & 6-210-01 In Note, chg mandatory to required.
changed TCM to CMI, removed
non-PMA MHJ-4005 starter.
6-250-01 Removed non-PMA MHJ-4005 starter
parts data, in Note, changed mandatory
to required.
6-270-01 thru 6-290-01 MHP obsolete, removed data from pgs.
added alternate use starters.
6-320-01 & 6-330-01 In notes, chg mandatory to required.
added alternate use starters.
6-360-01 & 6-370-01 In notes, chg mandatory to required.
removed non-PMA MZ-4203, -4207,
-4208, -4219, -4223, -4225, changed
TCM to CMI.
6-410-01 & 6-420-01 Removed non-PMA MZ starter parts
data, in note, chg mandatory to required.
added no longer available, added
alternate use starters, added ** note.
6-440-01 & 6-450-01 In Note, chg mandatory to required.
7-10-01 Add NLA to lightweight starters, add note.
7-30-01 Remove SB ref., add Go to ref.
7-50-01 Added brush replacement procedure.
7-70-01 Added non-PMA references, removed
non-PMA starter data.
7-80-01 Removed non-PMA starter data, remove
SB ref., add Go to ref.
7-90-01 Removed non-PMA starter data,
removed Figure 2 & Figure 2 ref.


Part Number OE-A2 - Rev. 05 vi-g
REVISION PAGE
-05 (Continued) 6/18/13

7-110-01 thru 7-130-01 MDB obsolete, removed data from pages.
7-150-01 Removed non-PMA starter note & data.
7-160-01 Removed non-PMA starter note & data,
removed SB ref., add Go to ref.
7-170-01 Removed non-PMA starter note & data.
7-180-01 Removed non-PMA starters from table.
7-190-01 Removed Fig. 1 Continental, removed
Fig. 2 Franklin, added brush replacement
procedure.
7-210-01 Added NLA & parts ref., top of page.
7-250-01 Removed non-PMA starter data.
removed SB ref., add Go to ref.
added brush replacement procedure.
7-290-01 & 7-300-01 MHP not PMA, removed data from pages.
7-320-01 Removed SB ref., add Go to ref.
7-360-01 Change Notes to Note 1 & 2.
7-400-01 Removed SB ref., add Go to ref.
7-420-01 Removed non-PMA starter data on Table.
7-430-01 Removed Fig. 1 Franklin, added
brush replacement procedure.
7-460-01 Change Notes to Note 1 & 2.
7-490-01 Added HET three places.
8-10-01 Added note.
8-20-01 Modify warning, add 1 & 2, made caps,
name change to HET.
8-30-01 Added note, modify Fig. 2.
8-50-01 Modify caution, made all caps, change
notes to note 1 & 2, modify note 1.
8-60-01 & 8-70-01 Name change to HET.
8-200-01 Name change to HET.
8-320-01 Modify caution, made all caps,
9-10-01 thru 9-40-01 Change TCM to CMI, add inches.
9-50-01 & 9-60-01 Chg. TCM to CMI in header, add inches.
9-70-01 thru 9-100-01 Added pages for millimeter section and
added millimeter data.
10-10-01 Modify TOC to add & delete pubs.
10-200-01 Correct page reference.
10-770-01 thru 10-820-01 Add pages, add SB 044.
10-830-01 thru 10-900-01 Add pages, add SIL A-140.
10-910-01 thru 10-980-01 Add pages, add SIL A-141.


Part Number OE-A2 - Rev. 05 vi-h
REVISION PAGE

-06 i 7/06/15 Updated registration page.
- ii Update copyright.
- iii Removed S/N block, update copyright,
updated website & e-mail address.
iv-a & iv-b. Added ROTR pages.
iv-c thru iv-f Added LOEP pages & LOEP info.
vi-i & vi-j Added LOR pages.
vi-i thru vi-j Added Rev -06 info.
2-50-01 Modified ** note.
2-170-01 & 2-180-01 Add * note & modified ** note.
2-210 Modified ** note.
2-290-01 Added code (d 2) with seal P/N,
modified ** note.
2-300-01 Removed *** note & P/N, revise note (b)
added code (d 2) with correct seal P/N,
modified ** note.
2-330 & 3-340-01 Modified ** note.
2-370 & 3-380-01 Modified ** note.
2-410-01 Modified ** note.
2-540-01 Correct header & P/N error item 2.
3-10-01 Added note at bottom of page.
3-40-01 Added temperature in C° & updated
rotor resistance values.
3-170-01 Added temperature in C°.
4-650-01 Add new epoxy, remove RTV from note.
Modify Caution to caps.
4-830-01 Add new epoxy, remove RTV from note.
4-1010-01 Add new epoxy, remove RTV to item 5.
5-50-01 Corrected & expanded tables.
5-80-01 Corrected & expanded tables, add Note
and Caution.
6-40-01 Update illustration, add Æ to note 1.
6-50-01 Update P/N of items, add Æ, add items
24 thru 27, update (a), add (b & c) note,
add Qty, AR, & ∆ note at bottom of page.
6-170-01 & 6-180-01 Update note (a thru d), add ** to item 6.
6-250-01 Corrected item 19 P/N.

Part Number OE-A2 - Rev. 06 vi-i
REVISION PAGE

-06 (Continued) 7/06/15
6-410-01 & 6-420-01 Update note (a thru c), add ** to item 6.
7-10-01 Add Periodic Insp.-Starter to TOC.
7-30-01 Modify para. Bearing & Oil seal repl,
correct brush length requirement.
7-40-01 Add item no. End Play para, add Fig. 1.
7-40-02 & 7-40-03 Add pages to relocate into.
7-40-02 Relocate Test Spec’s, Installation Note,
& change Fig. 1 to Fig. 2.
7-40-03 Relocate Brush Replacement Procedure,
change all of brush replacement section.
7-50-01 Add Repairs at Overhaul section, add
Fig. 3, 4, & 5, add oil seal repl.
7-60-02 thru 7-40-05 Add pages to locate new into.
7-60-01 Add bushing repl, add Fig. 6, & 7.
7-60-02 Add Fig. 8, add Bench Testing, add
Fig. 9, add torque & drive shaft tol.
7-60-03 Add Fig. 10 & 11, add drive shaft position
check.
7-60-04 Add Fig. 12 & 13, add drive shaft max
length check, add end play determination.
7-510-01 thru 7-540-01 Add pages for periodic inspection
section.
7-510-01 Added periodic insp. section, general &
bi-annual requirements.
7-520-01 Add Chart 1 inspection.
7-530-01 Add Chart 2 inspection.
7-540-01 Intentionally left blank page.
8-10-01 Add ES646 starter to TOC, modify note.
8-30-01 Modify heading.
8-70-01 Modify note.
8-390-01 thru 8-500-01 Added pages for ES646 Starter M & O
section.
8-390-01 thru 8-500-01 Add ES646 Starter M & O information,
add Figures 1 thru 14.
9-10-01 Add ES646 inches & millimeters to TOC.
9-30-01 Update PS1432C Max. Dim.
9-50-01 & 9-70-01 Modify header.
9-110-01 & 9-120-01 Add pages for ES646 tolerances section.
9-110-01 & 9-120-01 Add inches & millimeters information.
10-10-01 Modify TOC for deleted publications.
10-30-01 & 10-40-01 Delete SB 016 A, obsolete & incorp’d.
10-50-01 thru 10-80-01 Delete SB 017 A, obsolete & incorp’d.
10-90-01 thru 10-120-01 Delete SB 018 A, obsolete & incorp’d.
10-150-01 thru 10-220-01 Delete SB A-112, obsolete & expired.
10-230-01 & 10-240-01 Delete SIL A-115, obsolete & expired.
10-250-01 & 10-260-01 Delete SIL A-116, obsolete & incorp’d.
10-270-01 & 10-280-01 Delete SIL A-118, obsolete & incorp’d.
10-290-01 thru 10-320-01 Delete SB 033, does not apply.
10-330-01 thru 10-360-01 Delete SB 038, does not apply.
10-370-01 thru 10-400-01 Delete SIL A-125, does not apply.
10-710-01 thru 10-720-01 Delete SIL A-132, does not apply.
10-730-01 thru 10-740-01 Delete SL 024, does not apply.
10-830-01 thru 10-900-01 Update SIL A-140 to Rev 1.
10-910-01 thru 10-900-01 Delete SIL A-141, obsolete & incorp’d.


Part Number OE-A2 - Rev. 06 vi-j
REVISION PAGE
-07
i & ii 4/28/16 Remove registration info, add title.
iii Update copyright, update website.
iv-a Update ROTR to remove TR-001.
iv-c thru iv-f Added LOEP pages & LOEP info. &
correct typo on page iv-c.
vi-k & vi-l Added LOR pages.
vi-k thru vi-l Added Rev -07 info.
vii thru x Remove app. data TOC, add note, relocate
TOC from viii, ix & x to vii, viii & ix.
1-10-01 & 1-20-01 Remove app. data, add note below title.
1-20-01 Remove app. data, make blank page.
1-30-01 thru 1-400-01 Remove app. data, remove pages.
2-40-01 & 2-50-01 Add item 21 to illust & BOM, modify notes
(b) & add note ∆, qty req, & new to repl pt.
2-160-01 Update illust, add item 21 & modify note.
2-170-01 & 2-180-01 Add item 21 to BOM, modify notes (b),
(d) & (e) & add qty req, new repl & note ∆
2-200-01 Update illust, add item 21, & modify note.
2-210-01 Correct 19, add 21 to BOM, & mod note.
Modify notes (b), (d) & (e) & add notes
qty req’d, note ∆, & new to repl part.
2-240-01 Update illust, add item 21 & modify note.
2-250-01 Update P/N item 18, modify notes (a)
(d) & (e,), add item 21 to BOM, add
∆ to 19, note ∆, qty req’d & new to repl pt.
2-280-01 Add item 22 to illustration & modify note.
2-290-01 Add ALX-8523 alternator & BOM.
2-290-01 & 2-300-01 Add code (d2) seal P/N & rep’l with new,
add note ∆, qty req’d, & new to repl part,
Add item 22, add (i) to notes & item 7.
2-330-01 & 2-340-01 Modify note (b) & (e,), add item 21 to
BOM, add note ∆, qty req’d, new to repl pt.
2-370-01 & 2-380-01 Modify note (b) & (f,), add item 21 to
2-410-01 Modify note (b) & (e,), add item 21 to
2-480-01 Modify note by adding new to repl part.
2-490-01 Update P/N item 1, 19, 20, 28, 35, 36, 37,
add note ∆, qty req’d, & new to repl part.
2-510-01 Delete ES4024 non PMA alternator.
2-520-01 Update illust, add new P/N’s, & mod note.
2-530-01 Update P/N’s 6, 9, 10, 13, 15, 18, 20, 24, 27
30, 31, 33 & 34, mod notes (c), (d), (e), (f),
2-540-01 Update P/N’s 6, 9, 10, 13, 15, 18, 20, 24, 27
30, 31, 33 & 34, mod notes (c), (d), (e), (f),
Delete ES4024 non PMA alt. parts.
2-590-01 & 2-600-01 Mod note (b), add ∆, qty req, & new to pt.

Part Number OE-A2 - Rev. 07 vi-k
REVISION PAGE
-07
(cont’d) 4/28/16
2-630 & 2-640-01 Update P/N’s 1, 3, 4, 7, 9, 12, 17, 19, 23,26
29, 32, & 33, mod notes (c), (d), (e), (f).
Add note ∆, qty req’d, & new to repl part.
2-710-01 Update P/N’s 4, 7, 9, 13, 14, 15, 18, 24, 27
30, 31, 33, & 34, mod notes (a), (b), (c), (d).
Add note ∆, qty req’d, & new to repl part.
3-10-01 4/28/16 Modify note at bottom of page.
3-440-01 Update drive pulley torque chart.
3-460-01 Update volt/amp rating, delete ES4024.
3-470-01 Update ALS page, add life limits LOR
info. and log table, add signature block.
3-480-01 & 3-490-01 Update info. for alternator overhaul.
4-10-01 Modify note at bottom of page.
4-100-01 & 4-130-01 Modify Caution statement.
4-270-01 & 4-300-01 Modify Caution to all caps.
4-290-01 Modify Caution to caps, add item 1 ref.
4-510-01 Modify Caution to all caps.
4-670-01 Modify Caution to all caps, add thru
bolt instruction, modify item 9 torque.
4-690-01 & 4-790-01 Modify Caution statement
4-850-01 Modify Caution to all caps, add thru bolt
assembly instruction.
4-1000-01 Modify Caution, modify item 3 torque.
4-1190-01 Modify Caution statement.
6-40-01 & 6-50-01 Modify note by adding new to repl part.
6-80-01, 6-160-01, 6-200-01 Modify note by adding new to repl part.
6-90-01 Add note ∆, & 4 & 14, add new to repl pt.
6-170-01 & 6-180-01 Add note ∆ & to 1, 10, & 19, add 23 & 24.
Add qty req’d & new to repl part. Correct
typo note (j).
6-210-01 Add note ∆ & to 7 & 11, add new to repl pt.
6-250-01 Add note ∆ & to 1,8,10,&17 add new to RP.
6-310-01 Delete alternate model ref.
6-320-01 Update illust, add new parts, add new to RP.
6-330-01 Add note ∆& to 1, 5, 11, add new to
6-360-01 & 6-440-01 Modify note by adding new to repl part.
6-370-01 Add note ∆ & to 7 & 11, add new to repl pt.
6-400-01 Update illust, add new parts, add new to RP.
6-410-01 & 6-420-01 Add note ∆ & to 1, 8, 10, & 19, add new to
repl pt, add items 23, 24, & 25, add (q) kit.
6-450-01 Add note ∆ & to 7 & 11, add new to repl pt
7-10-01 Deleted Duty Cycle title.
7-40-03 & 7-100-01 Correct solder instruction (2 plcs).

Part Number OE-A2 - Rev. 07 vi-l
REVISION PAGE
-07 (cont’d) 4/28/16

7-190-01 Correct solder instruction (2 plcs).
7-220-01 Change to note 1 & 2.
7-280-01 & 7-330-01 Correct solder instruction (2 plcs).
7-430-01 Correct solder instruction (2 plcs).
7-490-01 Deleted Duty Cycle information.
7-510-01 Update ALS information, add LOR table.
7-520-01 Update item 3 info.
7-530-01 & 7-540-01 Update periodic insp. 1 & 2.
9-30-01 & 9-70-01 Update drive end specs (2 plcs).
9-80-01 thru 9-120-01 Correct various spec errors.
- 08
ii 10/30/18 Updated Copyright information to 2018.
iii Added product web-links for starters and
alternators. Updated FAX number.
iv Added product web-link to starter.
vi-m Information from pg. vi-l pushed to pg.
vi-m.
x Existing information pushed from pg. ix.
4-30-01 Added Fan and Fan Backplate labels to
Figure 2.
4-110-01 Added fan backplate to assembly
procedure, step 5.
Added CAUTION for proper installation
of the fan backplate while installing the
fan.
Added Figures 14 & 15 in support of
fan backplate CAUTION.
4-120-01 Re-labeled Figure 15 to Figure 16
(2 plcs).
4-130-01 Existing information pushed from page
4-120-01.
- 09 2-530-01 & 2-540-01 05/05/20 Change stator terminal lead P/N from
N/A to ES4135 pg. 2-530-01 & 2-540-01
alternator series ES4009 & ES4009LS;
6-040-01 Update illustration pg.6-040-01: rotate
ITM #17 180° to show correct alignment
with housing ITM# 8;
6-170-01 & 6-180-01 Change P/N MHB-2399S to MHB-2399,
all instances;
8-390-01 Update illustration pg. 8-390-01: rotate
ITM #5 180° to show correct alignment
with housting ITM #3;
8-450-01 Udate starter assembly step #13, pg.
8-450-01 with installation of brush plate
assembly ITM#17.
-10
vi-n 02/10/21 Page insert;
6-40-01 Remove required replacement indicator
from ITM #22;
Change assembly ITM #22 to ITMs #22A
& 22B;
6-50-01 Add Notes D and E to the Notes section
of the IPL;
Add ITM #20 to support Note D;
Replace ITM #23 QTY to support Note E;

Part Number OE-A2 - Rev. 10 vi-m
REVISION PAGE
-10 (cont’d)
8-410-01 02/10/21 Remove item 4 under Note 1;
8-420-01 Remove “discard” comment, para 4;
8-430-01 Reword para. 4 - Commutator End Head
for component reuse clarification;
8-450-01 Reword para. 6, remove overhaul
replacement part instruction.
-11
iv 12/15/21 Change “S” to “LS” in Alternator Table;
2-250-01 Add ITM# 18a (washer) to illustration;
2-530-01 & 2-540-01 Change ITM# 18 P/N ES4117 to
HDW10004-1;
Add ITM# 18a, P/N HDW10005-1;
Update Notes to include ITM#s 18 & 18a;
Add (i) to ITM# 24;
2-560-01 Change ITM# 20 P/N ES4117 to
HDW10004-1;
Add note (a) to ITM# 26;
2-650-01 & 2-660-01 Change ITM# 17 P/N ES4117 to
HDW10004-1;
Add note (g) to ITM# 23;
4-580-01 Update Figure 10 to include washers;
Update step 4 to include washers;
Update para. 2 to include washers
during brush holder installation;
Update step 4 to include washers;
Update para. 6 to include washers
during brush holder installation;
6-40-01 Mark ITM# 22B as a replacement item at
overhaul;
6-50-01 Add (AR) to ITM# 21;
Mark ITM# 22B as a replacement item at
overhaul;
Change ITM# 22A P/N 50033 to 50796;
Update notes (b), (d), & (e) to include
P/N 50796:
7-30-01 Update Service Information para. 2,
Bearing and Oil Seal Replacement to
include P/N 50796;
7-60-01 Add P/N 50796 to para. 3;
Para. 5, change 0.700” to .06 in.;
Update Figure 6 & 7 with P/N 50796;
8-430-01 Add P/N 50796 to para. 4;
Update NOTE:, para. 4;
8-440-01 Add Figure 5a, P/N 50796;
8-450-01 Update para. 6 and NOTE;
9 -110-01 Update Housing Seat O.D. dimensions,
reversed;
Change Comm. End Bushing Bore max
dimension from 0.7520 to 0.6255;

Part Number OE-A2 - Rev. 11 vi-n
REVISION PAGE
-11 (cont.) 9 -110-01 12/15/21 Armature Assy., change 1.27 Micrometer

to 50 µin;
9 -120-01 Update Housing Seat O.D. dimensions,
reversed;
Change Comm. End Bushing Bore max
dimension from 19.100 to 15.888;
Change micrometer to µm.
-12
i 02/22/22 Update Title-Page footer to Rev. 12;
ii Remove copyright boilerplate;
2-520-01 Update illustration to current drawing
revision;
2-530-01 & 2-540-01 Update parts list IAW current drawing
revision.
2-570-01 Update replacement list table, add
ES-4019-5 & ES-4019-5R;
2-590-01 and 2-600-01 Update parts list IAW current drawing
revision;
2-600-02 Add ES4019-5 to IPL;
3-440-01 Remove drive pulley P/N ES4014 from
table.

Part Number OE-A2 - Rev. 12 vi-m
OE-A2
Table of Contents
AIRCRAFT APPLICATION DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
NOTE: Application Information has been deleted and pages 1-30-01 through 1-400-01 have been removed.. 1-10-01
ALTERNATOR SERVICE PARTS LIST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

ALE Series (12 Volt Alternator). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30-01
ALH Series (12 Volt Alternator) (Obsolete). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-70-01
ALM Series (24 Volt Alternator) (Obsolete) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-110-01
ALT Series (24 Volt Alternator). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-150-01
ALU Series (24 Volt Alternator). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-190-01
ALV Series (24 Volt Alternator). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-230-01
ALX Series (12 Volt Alternator). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-270-01
ALY-6520 to ALY-6527 Series (12 Volt Alternator). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-310-01
ALY-8520 to ALY-8526 Series (12 Volt Alternator). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-350-01
ALZ Series (12 Volt Alternator). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-390-01
ANG Series (24 Volt Alternator) (Obsolete) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-430-01
ES Series (Chrysler Style) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-470-01
ES4000 Series (Small Frame Belt Driven). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-510-01
ES4000 Series (Large Frame Belt Driven). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-570-01
ES4000 Series (Small Frame Gear Driven). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-610-01
Intentionally Left Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-650-01
Ford Series (Small Frame Belt Driven) (For Reference Only To Show Replacement Parts). . . . . . . . . . . . . . . . 2-690-01
ALTERNATOR SERVICE INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

ALE Series (12 Volt Alternator). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30-01
ALH Series (12 Volt Alternator) (Obsolete). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-70-01
ALM Series (24 Volt Alternator) (Obsolete) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-110-01
ALT Series (24 Volt Alternator). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-150-01
ALU Series (24 Volt Alternator). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-190-01
ALV Series (24 Volt Alternator). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-230-01
ALX Series (12 Volt Alternator). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-270-01
ALY Series (12 Volt Alternator). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-310-01
ALZ Series (12 Volt Alternator). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-350-01

vii Part Number OE-A2 - Rev. 06
Table of Contents (cont’d)

ES4000 Series (12/24 Volt Alternator) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-430-01
Continued Airworthiness Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-470-01
Special Conditions (Sudden Stoppage, Lightning Strike). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-550-01
NOTE: There is NO original FORD or CHRYSLER series service information in this manual.
ALTERNATOR MAINTENANCE AND OVERHAUL INFORMATION . . . . . . . . . . . . 4

ES1001 – Belt Driven Alternators (ALE, ALT, ALU, ALX, ALY, ALZ Series ALH & ANG obsolete). . . . . . . . . . . . 4-30-01
ES1002 – Gear Driven Alternator (ALM Series Obsolete). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-150-01
ES1003 – Gear Driven Alternators (ALT, ALU, and ALX Series). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-230-01
ES1004 – Belt Driven 100 Amp Alternator (ALV-6000 and ALV-8000 Series) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-330-01
ES1005 – Gear Driven 100 Amp Alternators (ALV-9400 & ALV-9500 Series). . . . . . . . . . . . . . . . . . . . . . . . . . . 4-430-01
ES1006 – Small Frame Belt Drive (ES4000, ES4000-LS, ES4009, ES4009-LS, ES4024, ES4024-LP) . . . . . . . 4-530-01
ES1007 – Small Frame Gear Driven (ES4001, 4002, 4004, 4006, 4008, and 4029) . . . . . . . . . . . . . . . . . . . . . . 4-710-01
ES1008 – Large Frame Belt Drive (ES4003, ES4003-LS, ES4011, ES4011-1LS, ES4011-1, ES4019, ES4019-LS,
and ES4019-3, ES4019-3-LS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-890-01
ES1009 – ES4020 Belt Driven Alternator (Chrysler Style). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1070-01
NOTE: There is NO original FORD or CHRYSLER series maintenance or overhaul information in this manual.
ALTERNATOR SPECIFICATIONS AND TOLERANCES . . . . . . . . . . . . . . . . . . . . . 5
Pulley (inches). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30-01
Rotor Shaft Spacer; Vent Fan Limits (inches). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40-01
Drive End Head; Slip Ring End Head (inches). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40-01
Rotor Assembly; Stator Assembly (inches). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-50-01
Bushing for SRE Head Assembly - Belt Drive (all). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-50-01
Bushing for Drive End Head Assembly - Belt Drive (all). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-50-01
Pulley (millimeter). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-60-01
Rotor Shaft Spacer; Vent Fan Limits (millimeter). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-70-01
Drive End Head; Slip Ring End Head (millimeter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-70-01
Rotor Assembly; Stator Assembly (millimeter). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-80-01
STARTER SERVICE PARTS LISTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
ES646 Series (12/24 Volt Starter). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30-01
MCL Series (12 Volt Starter). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-70-01
MDB Series (24 Volt Starter) (Obsolete). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-110-01
MHB Series (24 Volt Starter). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-150-01

Part Number OE-A2 - Rev. 07 viii
Lightweight MHB Series (24 Volt Starter). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-190-01

MHJ Series (24 Volt Starter). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-230-01
MHP Series (24 Volt Starter) (CMI only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-270-01
MMU Series (24 Volt Starter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-310-01
Lightweight MMU Series (24 Volt Starter). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-350-01
MZ Series (12 Volt Starter). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-390-01
Lightweight MZ Series (12 Volt Starter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-430-01
STARTER SERVICE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
ES646 Series (12/24 Volt Starter). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30-01
MCL Series (12 Volt Starter). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-70-01
MDB Series (24 Volt Starter) (Obsolete). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-110-01
MHB Series (24 Volt Starter). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-150-01
Lightweight MHB Series (24 Volt Starter). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-210-01
MHJ Series (24 Volt Starter). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-250-01
MHP Series (24 Volt Starter). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-290-01
MMU Series (24 Volt Starter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-310-01
Lightweight MMU Series (24 Volt Starter). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-350-01
MZ Series (12 Volt Starter). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-390-01
Lightweight MZ Series (12 Volt Starter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-450-01
Continued Airworthiness Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-510-01
STARTER MAINTENANCE AND OVERHAUL INFORMATION. . . . . . . . . . . . . . . . 8
ES2001 – Direct Drive Starting Motor (All Except MagnaFlite Lightweight & ES646 Starters). . . . . . . . . . . . . . . 8-30-01
ES2002 – Gear Reduction Starting Motor (All Models Except Lycoming Style MagnaFlite). . . . . . . . . . . . . . . . 8-150-01
ES2003 – Gear Reduction Starting Motor (Lycoming Style MagnaFlite). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-290-01
ES6462 – Direct Drive Starting Motor (All Except MagnaFlite Lightweight & ES646 Starters). . . . . . . . . . . . . . 8-390-01
STARTER SPECIFICATION AND TOLERANCES. . . . . . . . . . . . . . . . . . . . . . . . . . 9
Lycoming Style Starters (Except MagnaFlite Lightweight Starters) Inches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-30-01
CMI Style Starters (Except MagnaFlite Lightweight & ES646 Starters) Inches. . . . . . . . . . . . . . . . . . . . . . . . . . . 9-50-01
MagnaFlite Lightweight Starters (Inches). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-60-01
Lycoming Style Starters (Except MagnaFlite Lightweight Starters) Millimeter. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-70-01
CMI Style Starters (Except MagnaFlite Lightweight & ES646 Starters) Millimeter. . . . . . . . . . . . . . . . . . . . . . . . . 9-90-01
MagnaFlite Lightweight Starters (Millimeter). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-100-01
ES646 (CMI Style) Starters (Inches). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-110-01
ES646 (CMI Style) Starters (Millimeter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-120-01

ix Part Number OE-A2 - Rev. 08
SERVICE BULLETINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Service Bulletin #016 Rev. A (Obsolete). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-01
Service Bulletin #021 (OE-A1 Superseded). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-01
Service Bulletin #033 (Deleted - Does Not Apply). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-290-01
Service Bulletin #038 Rev. A (Deleted - Does Not Apply). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-330-01
Service Bulletin #044 (Alternator Wave Clip). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-770-01
Service Bulletin A-112 Rev. A (Expired & Obsolete). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150-01
Service Information Letter A-115 (Expired & Obsolete). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-230-01
Service Information Letter A-116 (Obsolete). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-250-01
Service Information Letter A-118 (Obsolete). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-270-01
Service Information Letter A-125 Rev. A (Deleted - Does Not Apply). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-370-01
Service Information Letter A-126 Rev. B (Starter Eligibility). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-410-01
Service Information Letter A-132 (Deleted - Does Not Apply). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-710-01
Service Information Letter A-140 (Shipping Spacer on Gear Driven Alternators). . . . . . . . . . . . . . . . . . . . . . . 10-840-01
Service Information Letter A-141 (Direct Drive Starter Checks) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-910-01
Service Letter 024 Rev. A (Obsolete) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-730-01
Service Letter #25 (Starter Supersedure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-750-01

Part Number OE-A2 - Rev. 08 x
PURPOSE OF MANUAL:
This publication contains descriptions and instructions for operating, maintaining, and over-
hauling aircraft alternators and starters manufactured by Hartzell Engine Technologies LLC,
2900 Selma Highway, Montgomery, AL 36108, USA (334) 386-5400, Fax (334) 386-5410.
ORGANIZATION OF MANUAL:
This OE-A2 Alternator and Starter Manual is divided into 10 Chapters with the preambles
explaining the purpose of the manual, organization, and other publications that are sources of
information. Chapter 1 is an application guide to be used for reference only. Chapter 2 & 6
offer IPL information. Chapter 3 & 7 offer service information including troubleshooting
issues. Chapter 4 & 8 provide overhaul information. Chapter 5 & 9 provide tolerances and
specifications. Chapter 10 lists Service publications not incorporated into the manual.
OTHER PUBLICATIONS:
Service Bulletins and Letters (to date of print) have been incorporated herein if applicable,
however new publications may have been issued after the date of the latest revision of this
manual.
QUALIFIED PERSONNEL:
The components covered by this manual include alternator and starter assemblies, which are
close tolerance devices operating with rotating parts spinning at high speeds, high torque, and
high electrical current. It is required that persons attempting overhaul work be competent,
appropriately qualified to service these components, and observe the tolerances and high
standards of workmanship that are involved.
WARNING: EXTREME CARE SHOULD BE USED AT ALL TIMES TO AVOID

INJURY WHILE SERVICING OPERATING ALTERNATORS AND STARTERS.
KEEP FINGERS AND FOREIGN OBJECTS AWAY FROM BELTS OR GEARS. USE
OF OSHA STANDARD SAFETY GLASSES, SHIELDS AND PROTECTIVE
CLOTHING IS REQUIRED.
Agencies other than Hartzell Engine Technologies (HET) performing repair must
not remove original nameplate. Unless field overhauled, the original
manufacturer must remain on the nameplate.
Proper service and repair is important to the safe, reliable operation of all machinery. The
service procedures recommended by HET as described in this Maintenance Manual are
effective methods of performing service operations. Some of these service operations require
the use of tools specially designed for the purpose. The special tools should be used when and
as recommended. Should specific information regarding the use of a special tool not be found
in this manual, use of the original manufacturers operating instructions shall be used. Assure
that the function and use of any special tool is understood prior to using that tool.

Part Number OE-A2 - Rev. 05 xi
WARNINGS, CAUTIONS, AND NOTES
This Technical Manual contains various WARNINGS, CAUTIONS, and NOTES, which
should be read and followed:
WARNING: WARNINGS ARE USED IN SITUATIONS WHERE PERSONAL INJURY TO THE

TECHNICIAN COULD RESULT FROM IMPROPER SERVICE PROCEDURES.
CAUTION: CAUTIONS ARE USED IN SITUATIONS WHERE DAMAGE RESULTING FROM

IMPROPER SERVICE PROCEDURES COULD RENDER THE AIRCRAFT UN-AIRWORTHY
Notes are used to supply helpful information to the technician performing the service
operation.
It is important to understand that WARNINGS and CAUTIONS are not exhaustive. Hartzell
Engine Technologies LLC (HET) can not anticipate, evaluate, or advise technicians of all
conceivable circumstance in which service might be done and/or the possible hazardous
consequences which may be encountered. As a result, anyone who uses a service procedure
or tool not specifically recommended in this manual by HET must first ensure that safety of
personal and machinery is observed prior to and during the use of that selected service
procedure or tool.

xii Part Number OE-A2 - Rev. 07
OBTAINING & REVISING THE MANUAL
GENERAL: Hartzell Engine Technologies LLC has an exclusive arrangement with Aviation
Technical Publishers (ATP) to provide all of HET’s maintenance publications and regulatory
documents through the ATP Knowledge™ information services platform including the ATP
Aviation Hub™ cloud application and NavigatorV™ desktop application.
PROCEDURE: Follow the steps below when revising this manual.
1. In order to obtain Hartzell Engine Technologies’ maintenance publications, subscribe to
any maintenance libraries, by going to: http://www.atp.com. This site has information on
ATP products and instructions for becoming a subscriber.
2. Manual revisions are handled through the appropriate platform obtained from desired
ATP subscription.
3. The following applies, whether a paper copy or digital copy is being used:
A. If a Temporary Revision has been made, the manual pages will be “pink”. When the
permanent revision is released and received, the pink pages must be removed and
discarded.
B. Black bars on the edge of the revised page indicate the area of revision. Black bars
adjacent to the page number indicate new page or a majority change to that page.
C. Revision status may be checked at any time by going to the HET website and
finding the latest revision issued for this manual. (http://www.hartzell.aero)
(TM) ATP Knowledge, and ATP Aviation Hub and NavigatorV are trademarks of ATP.

Part Number OE-A2 - Rev. 07 xiii
This Page Intentionally Left Blank

xiv Part Number OE-A2 - Rev. 05
Aircraft & Engine
Application Data 1
...............................................................
NOTE:
The application data and guide has been deleted. Pages 1-30-01 through
1-400-01 have been removed. For the most current application information,
refer to the Hartzell Engine Technologies LLC website. http://www.hartzell.aero

Part Number OE-A2 - Rev. 07 1-10-01

1-20-01 Part Number OE-A2 - Rev. 07
Alternator
.Service
. . . . . . . . . . . . . .Parts
. . . . . . . . . .List
...................................... 2
ALE Series (12 Volt Alternator) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30-01
ALH Series (12 Volt Alternator) (Obsolete) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-70-01
ALM Series (24 Volt Alternator) (Obsolete) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-110-01
ALT Series (24 Volt Alternator) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-150-01
ALU Series (24 Volt Alternator) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-190-01
ALV Series (24 Volt Alternator) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-230-01
ALX Series (12 Volt Alternator) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-270-01
ALY-6520 to ALY-6527 Series (12 Volt Alternator) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-310-01
ALY-8520 to ALY-8526 Series (12 Volt Alternator) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-350-01
ALZ Series (12 Volt Alternator) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-390-01
ANG Series (24 Volt Alternator) (Obsolete) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-430-01
ES Series (Chrysler Style) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-470-01
ES4000 Series (Small Frame Belt Driven) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-510-01
ES4000 Series (Large Frame Belt Driven) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-570-01
ES4000 Series (Small Frame Gear Driven) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-630-01
Intentionally Left Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-650-01
Ford Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-690-01


2-20-01 Part Number OE-A2
ALE Series
Service
.. . . . . . . . .. . . . .Parts
. . . . . . . . . .List
................
Alternators and their corresponding parts shown

in this section are FAA/PMA approved. 12 Volt Alternator
REPLACEMENT LIST:
Original Equip. Current Factory Overhaul
Alternator Replaced Alternator Alternator Engine/Airframe
Part Number By Part Number Part Number Application
ALE-6406 Use ALE-6520 ALE-6520R Lycoming
ALE-6406G Use ALE-6520 ALE-6520R Lycoming
ALE-6406R Use ALE-6520 ALE-6520R Lycoming
ALE-8105A NA NA NA Lycoming

ALE-8406RG Use ALE-8520 ALE-8520R Lycoming
ALE-8408 NA NA NA Lycoming
ALE-8408R NA NA NA Lycoming
ALE-8421 NA NA NA Lycoming
ALE-8421R NA NA NA Lycoming
NOTE:
The “R” at the end of an “Original Equipment Alternator Part Number” now signifies Factory Overhauled.
See parts list for alternator being serviced when component parts are required.

ALE Series (Exploded Parts View of Typical ALE Series Alternator)
1
2
21
9
4
11 6
12
13 8
15
16
10
17
14
18
NOTE: replacement parts required at

13 Circled items represent new
14 each overhaul.
19

No. Part ALE-6406, G ALE-6420, G ALE-6520 ALE-8105A ALE-8406, G ALE-8408
1 Nut & Washer Package 90-33 90-33 90-33 90-33 90-33 90-33
2 Drive Pulley PU-672A PU-672A PU-672A PU-672A PU-672A PU-672A
3 Vent Fan (2 Piece) 90-2241 90-2241 90-2241 90-2241 90-2241 90-2241
4 Rotor Shaft ALD-21 ALD-21 ALD-21 ALD-21 ALD-21 ALD-21
5 Drive End Head Assembly ALE-1003K ALE-1003K ALE-1003K ALE-1003K ALE-1003K ALE-1003K
6 Drive End Bearing X-4612 X-4612 X-4612 X-4612 X-4612 X-4612
7 Thru-bolt Package ALA-20JS ALA-20JS ALA-20JS ALA-20JS ALA-20JS ALA-20JS
8 Drive End Retainer GR-32 GR-32 GR-32 GR-32 GR-32 GR-32
9 Rotor Assembly 90-2503 (c) 90-2503 (c) ALE-2273S-1 90-2513 (c) 90-2503 (c) 90-2513 (c)
10 Stator Assembly ALE-2008AD ALE-2008AD ALE-2008AD ALE-2008AD ALE-2008AD ALE-2008AD
11 Eyelet Package 90-818 90-818 90-818 90-818 90-818 90-818
12 Negative Rectifier XA-944JS XA-944JS XA-944JS XA-944JS XA-944JS XA-944JS
13 Slip Ring End Head Assembly 90-2503 (c) 90-2503 (c) ALK-1232BS-2 90-2513 (c) 90-2503 (c) 90-2513 (c)
14 Terminal Stud Package 90-2030 90-2030 90-2030 90-2030 90-2030 90-2030
15 Positive Rectifier & Plate Ass’y. ALE-1054A* ALE-1054A* ALE-1054A* ALE-1054A* ALE-1054A* ALE-1054A*
16 Brush Set ALE-2013AS (d) ALE-2013AS (d) ALE-1013AS (NA) ALE-2013AS (d) ALE-2013AS (d)
17 Brush Holder & Spring Ass’y** ALU-2045BS (b) ALU-2045BS (b) ALU-3045BS (NA) ALU-2045BS (b) ALE-2045BS (b)
18 Slip Ring End Bearing X-4130 (a) X-4130 (a) X-4130 X-4130 (a) X-4130 (a) X-4130 (a)
19 Slip Ring End Cover (NA) (NA) (NA) ALU-1062A ALU-1062A ALU-1062A
20 Repair Kit 90-3032 90-3032 90-3032 90-3032 90-3032
21 Woodruff Key ∆ X-0261 X-0261 X-0261 X-0261 X-0261 X-0261
X Caution Placard (Red) (e) QA-235 QA-235 QA-235 QA-235 QA-235 QA-235
No. Part ALE-8420, G ALE-8520

1 Nut & Washer Package 90-33 90-33
2 Drive Pulley PU-672A PU-672A
3 Vent Fan (2 Piece) 90-2241 90-2241
4 Rotor Shaft Spacer ALD-21 ALD-21
5 Drive End Head Assembly ALE-1003K ALE-1003K
6 Drive End Bearing X-4612 X-4612
7 Thru-bolt Package ALA-20JS ALA-20JS
8 Drive End Retainer GR-32 GR-32
9 Rotor Assembly 90-2503 (c) ALE-2273S-1
10 Stator Assembly ALE-2008AD ALE-2008AD
11 Eyelet Package 90-818 90-818
12 Negative Rectifier XA-944JS XA-944JS
13 Slip Ring End Head Assembly 90-2503 (c) ALK-1232BS-2
14 Terminal Stud Package 90-2030 90-2030
15 Positive Rectifier & Plate Ass’y. ALE-1054A* ALE-1054A*
16 Brush Set ALE-2013AS (d) ALE-1013AS
17 Brush Holder & Spring Ass’y** ALU-2045BS (b) ALU-3045BS
18 Slip Ring End Bearing X-4130 (a) X-4130
19 Slip Ring End Cover ALU-1062A ALU-1062A
20 Repair Kit 90-3032 90-3032
21 Woodruff Key ∆ X-0261 X-0261
X Caution Placard (Red) (e) QA-235 QA-235
Notes:
(a) S.R.E. Bearing is included with S.R.E. Head and Rotor Package.
(b) The superseded ALU-1045BS or ALE-1045BS and the ALU-2045BS or ALE-2045BS Brush Holder designs must be replaced at overhaul
with the latest configuration.
(c) S.R.E. Head & Rotor Kit must be used at time of first repair/overhaul. Individual components may be used thereafter.
Contents of 90-2503 S.R.E. Head & Rotor Kit:
S.R.E. Head Assembly With Bearing - ALK-1232BS-2; Brush Holder Assembly - ALU-3045BS; Rotor Assembly - ALE-2273S-1.
S.R.E. Head Assembly With Bearing - ALK-1232BS-2; Brush Holder Assembly - ALE-3045BS; Rotor Assembly - ALE-2273S-1.
(d) When converted to ALU-3045BS or ALE-3045BS Brush Holder Assembly, use ALE-1013AS only Captive Brush & Spring Sets.
(e) Red caution placard (through bolt torquing) is required on all installations.
(NA) Not Applicable ∆ Replace with new whenever parts are removed.
Circled items represent new replacement parts required at each overhaul, and are available in repair kits from HET.
* Rectifier diode package available separately - Part Number XA-943FS.
** ALU-2045BS or ALE-2045BS is no longer available, use ALU-3045BS or ALE-3045BS brush holder assembly.
X Not shown in parts view. All quantities one (1) unless noted.


ALH Series
.Service
.. . . . . . . .. . . . .Parts
. . . . . . . . . .List
................
OBSOLETE 12 Volt Alternator




ALM Series
.Service
.. . . . . . . . . . . . .Parts
. . . . . . . . . .List
................
OBSOLETE 24 Volt Alternator




ALT Series
.Service
.. . . . . . . . . . . . .Parts
. . . . . . . . . ..List
...............

REPLACEMENT LIST:
ALT-8403 Use ALT-8520 ALT-8520R Continental (CMI)

ALT-8404 Use ALT-8521 ALT-8521R Lycoming
ALT8404LS Use ALT-8521LS ALT-8521RS Lycoming
ALT8404RS Use ALT-8521LS ALT-8521RS Lycoming
ALT-8421R Use ALT-8521 ALT-8521R Lycoming
ALT-8421RS Use ALT-8521LS ALT-8521RS Lycoming
ALT-8421LS ALT-8521LS ALT-8521RS Lycoming

NOTE:

ALT Series (Exploded Parts View of Typical ALT Series Alternator)
6 4
5
3
21
9 1
10
11
12
14 13 6
8
15
14 5
16
17 7
18
13
14
19
18
17
16
13
NOTE:
replacement parts required at
each overhaul.

No. Part ALT-8403 ALT-8404 ALT-8404LS ALT-8407 ALT-8420 ALT-8421
2 Drive Pulley (g) PU-672A (g) (g) (g) PU-672A
3 Vent Fan (2 Piece) 90-2259 90-2241 90-2241 90-2259 90-2259 90-2241
4 Rotor Shaft Spacer ALC-21F ALD-21 ALD-21 ALC-21F ALC-21F ALD-21
7 Thru-bolt Package ALA-20GS ALA-20GS ALA-20GS ALA-20GS ALA-20GS ALA-20GS
9 Rotor Assembly 90-2500 (c) 90-2501 (c) 90-2501 (c) 90-2500 (c) 90-2500 (c) 90-2501 (c)
10 Stator Assembly ALE-2008AA ALE-2008AA ALE-2008AA ALE-2008AA ALE-2008AA ALE-2008AA
11 Eyelet Package 90-818 90-818 90-818 90-818 90-818 90-818
12 Negative Rectifier Package XA-944JS XA-944JS XA-944JS XA-944JS XA-944JS XA-944JS
13 Slip Ring End Head Assembly 90-2500 (c) 90-2501 (c) 90-2501 (c) 90-2500 (c) 90-2500 (c) 90-2501 (c)
16 Slip Ring End Bearing X-4130 (a) X-4130 (a) X-4130 (a) X-4130 (a) X-4130 (a) X-4130 (a)
17 Brush Holder & Spring Ass’y* ALU-2045BS (b) ALU-2045BS (b) ALU-2045BS (b) ALU-2045BS (b) ALU-2045BS (b) ALU-2045BS (b)
18 Brush Set ALE-2013AS (h) ALE-2013AS (h) ALE-2013AS (h) ALE-2013AS (h) ALE-2013AS (h) ALE-2013AS (h)
19 Slip Ring End Cover ALU-1062 ALU-1062A ALU-1062A ALU-1062 ALU-1062 ALU-1062A
20 Repair Kit 90-3035 90-3035 90-3035 90-3035 90-3035 90-3035
X Caution Placard (Red) (i) QA-235 QA-235 QA-235 QA-235 QA-235 QA-235
ALT-8421LS ALT-8520 ALT-8521 ALT-8521LS ALT-9405 ALT-9422

1 Nut & Washer Package 90-33 90-33 90-33 90-33 8X-4075 (f) 8X-4075 (f)
2 Drive Pulley (g) (g) PU-672A (g) (NA) (NA)
3 Vent Fan (2 Piece) 90-2241 90-2259 90-2241 90-2241 (NA) (NA)
4 Rotor Shaft Spacer ALD-21 ALC-21F ALD-21 ALD-21 ALU-23 (e) ALU-23 (e)
6 Drive End Head Assembly ALE-1003K ALE-1003K ALE-1003K ALE-1003K ALU-1043 (d) ALU-1043 (d)
9 Rotor Assembly 90-2501 (c) ALU-2228S-1 ALU-2228S-1 ALU-2228S-1 90-2511 (c) 90-2511 (c)
10 Stator Assembly ALE-2008AA ALE-2008AA ALE-2008AA ALE-2008AA ALE-2008AA ALE-2008AA
11 Eyelet Package 90-818 90-818 90-818 90-818 90-818 90-818
13 Slip Ring End Head Assembly 90-2501 (c) ALK-1232LS-2 ALK-1232CS-2 ALK-1232CS-2 90-2511 (c) 90-2511 (c)
16 Slip Ring End Bearing X-4130 (a) X-4130 X-4130 X-4130 X-4130 (a) X-4130 (a)
17 Brush Holder & Spring Ass’y** ALU-2045BS (b) ALU-3045BS ALU-3045BS ALU-3045BS ALU-2045BS ALU-2045BS
18 Brush Set ALE-2013AS (h) ALE-1013AS ALE-1013AS ALE-1013AS ALE-2013AS (h) ALE-2013AS (h)
19 Slip Ring End Cover ALU-1062A ALU-1062 ALU-1062A ALU-1062A (NA) (NA)
20 Repair Kit 90-3035 90-3035 90-3035 90-3035 90-3036 90-3036
Notes:
S.R.E. Head Assembly With Bearing - ALK-1232LS-2; Brush Holder Assembly - ALU-3045BS; Rotor Assembly - ALU-2228S-1.
S.R.E. Head Assembly With Bearing - ALK-1232CS-2; Brush Holder Assembly - ALU-3045BS; Rotor Assembly - ALU-2228S-1.
S.R.E. Head Assembly With Bearing - ALE-1242AAS-2; Brush Holder Assembly - ALU-3045BS; Rotor Assembly - ALU-2238S-1.
(d) XA-1026 Drive End Oil Seal also available. (Replace with new whenever seal is removed.)
(e) XA-744AZ Shaft Spacer O-ring Seal available. (Replace with new whenever seal is removed.)
(f) Nut Only; Washer not required. ∆ Replace with new whenever parts are removed.
(g) Available through engine or airframe OEM.
(h) When converted to ALU-3045BS or ALE-3045BS Brush Holder Assembly, use ALE-1013AS only Captive Brush & Spring Sets.
(i) Red caution placard (through bolt torquing) is required on all installations.
(NA) Not Applicable. X Not shown in parts view. * Rectifier diode package available separately - Part Number XA-943FS.
** ALU-2045BS no longer available, use ALU-3045BS brush holder assembly. All quantities one (1) unless noted.

No. Part ALT-9522
1 Nut & Washer Package 8X-4075 (f)
2 Drive Pulley (NA)
3 Vent Fan (2 Piece) (NA)
4 Rotor Shaft Spacer ALU-23 (e)
5 Drive End Bearing X-4612
6 Drive End Head Assembly ALU-1043 (d)
7 Thru-bolt Package ALA-20GS
8 Drive End Retainer GR-32
9 Rotor Assembly ALU-2238S-1
10 Stator Assembly ALE-2008AA
11 Eyelet Package 90-818
12 Negative Rectifier Package XA-944JS
13 Slip Ring End Head Assembly ALE-1242AAS-2
14 Terminal Stud Package 90-2043
15 Positive Rectifier & Plate Ass’y. ALE-1054A*
16 Slip Ring End Bearing X-4130 (a)
17 Brush Holder & Spring Ass’y** ALU-3045BS
18 Brush Set ALE-1013AS
19 Slip Ring End Cover (NA)
20 Repair Kit 90-3036
21 Woodruff Key ∆ X-0260
X Caution Placard (Red) (i) QA-235
Notes:
S.R.E. Head Assembly With Bearing - ALK-1232LS-2; Brush Holder Assembly - ALU-3045BS; Rotor Assembly - ALU-2228S-1.
(NA) Not Applicable. X Not shown in parts view. * Rectifier diode package available separately - Part Number XA-943FS.

ALU Series
Service
.. . . . . . . . .. . . . .Parts
. . . . . . . . . .List
................

REPLACEMENT LIST:
ALU-6421LS Use ALU-6521LS ALU-6521RS Lycoming
ALU-6539-3 Use ALU-6539-3 ALU-6539-3R Lycoming
ALU-6539-4 Use ALU-6539-4 ALU-6539-4R Lycoming
ALU-8403 Use ALU-8521 ALU-8521R Lycoming

ALU-8421 Use ALU-8521 ALU-8521R Lycoming
ALU-8421RS Use ALU-8521LS ALU-8521RS Lycoming
ES4032LS Use ALU-8532LS ALU-8532LS Lycoming
ES4039LS Use ALU-8539LS ALU-8539LS Lycoming
NOTE:

ALU Series (Exploded Parts View of Typical ALU Series Alternator)
1
2
21
8 3
10 7
11
12
14 9
16
17 13
12
15
15
19
18
NOTE:
Circled items represent new
each overhaul.

No. Part ALU-6421LS ALU-6521LS ALU-8403 ALU-8403LS ALU-8421 ALU-8421LS
2 Drive Pulley (g) (g) PU-672A (g) PU-672A (g)
3 Vent Fan (2 Pieces) 90-2241 90-2241 90-2241 90-2241 90-2241 90-2241
4 Rotor Shaft Spacer ALD-21 ALD-21 ALD-21 ALD-21 ALD-21 ALD-21
8 Rotor Assembly 90-2501 (c) ALU-2228S-1 90-2501 (c) 90-2501 (c) 90-2501 (c) 90-2501 (c)
9 Stator Assembly ALE-2008ABS ALE-2008ABS ALE-2008ABS ALE-2008ABS ALE-2008ABS ALE-2008ABS
10 Eyelet Package 90-818 90-818 90-818 90-818 90-818 90-818
12 Slip Ring End Head Assembly 90-2501 (c) ALK-1232CS-2 90-2501 (c) 90-2501 (c) 90-2501 (c) 90-2501 (c)
14 Pos. Rectifier & Plate Assembly ALE-1054A* ALE-1054A* ALE-1054A* ALE-1054A* ALE-1054A* ALE-1054A*
16 Brush Holder & Spring Ass’y** ALU-2045BS (b) ALU-3045BS ALU-2045BS (b) ALU-2045BS (b) ALU-2045BS (b) ALU-3045BS (b)
17 Brush Set ALE-2013AS (h) ALE-1013AS ALE-2013AS (h) ALE-2013AS (h) ALE-2013AS (h) ALE-2013AS (b)
19 Slip Ring End Cover (NA) (NA) (NA) (NA) (NA) (NA)
20 Repair Kit 90-3037 90-3037 90-3037 90-3037 90-3037 90-3037
No. Part ALU-8521 ALU-8521LS ALU-8532LS ALU-8539LS ALU-6539-3 ALU-6539-4

2 Drive Pulley PU-672A (g) (NA) (NA) 41004 41005
3 Vent Fan (2 Pieces) 90-2241 90-2241 90-2241 90-2241 90-2241 (NA)
4 Rotor Shaft Spacer ALD-21 ALD-21 ALD-21A ALD-21 ALD-21 ALD-21
8 Rotor Assembly ALU-2228S-1 ALU-2228S-1 ALU-2227S-1 ALU-2228 ALU-2228 ALU-2228
9 Stator Assembly ALE-2008ABS ALE-2008ABS ALE-2008AMS ALE-2008AP ALE-2008AP ALE-2008AP
10 Eyelet Package 90-818 90-818 90-818 90-818 90-818 90-818
12 Slip Ring End Head Assembly ALK-1232CS-2 ALK-1232CS-2 ALK-1232ES-2 ALK-1232CS-2 ALK-1232CS-2 ALK-1232CS-2
13 Thru-bolt Package ALA-20GS ALA-20GS ALA-20JS ALA-20GS ALA-20GS ALA-20GS
16 Brush Holder & Spring Ass’y ALU-3045BS (b) ALU-3045BS (b) ALU-3045BS (b) ALU-3045BS (b) ALU-3045BS ALU-3045BS
17 Brush Set ALE-1013AS (h) ALE-1013AS (h) ALE-1013AS (h) ALE-1013AS (h) ALE-1013AS ALE-1013AS
19 Slip Ring End Cover ALU-1062A ALU-1062A 40078 ALU-1062AE (NA) (NA)
20 Repair Kit 90-3037 90-3037 90-3037 90-3037 90-3037 90-3037
X Washer, spacer (NA) (NA) (NA) (NA) (NA) ALK-50
Notes:
(NA) Not Applicable. X Not shown in parts view.


ALV Series
Service
.. . . . . . . .. . . . . .Parts
. . . . . . . . . ..List
...............

REPLACEMENT LIST:
ALV-8402 Use ALV-8511 ALV-8511R Continental (CMI)

ALV-8402L Use ALV-8511 ALV-8511R Lycoming
ALV-8511 Use ALV-8511 ALV-8511R Lycoming


ALV-9407S Use ALV-9510 ALV-9510R Continental (CMI)

NOTE:

ALV Series (Exploded Parts View of Typical ALV Series Alternator)
1
2
3
21
9 1
3
11 4
13
5
16
18
20 7
10
12
22
12
14
15
17
19
20
NOTE:
23
each overhaul.

No. Part ALV-8402, L ALV-8511 ALV-9401, L ALV-9405L
1 Nut & Washer Package 90-33 90-33 8X-4075 (c) 8X-4075 (c)
2 Vent Fan (2 Pieces) PU-1609A PU-1609A (NA) (NA)
3 Rotor Shaft Spacer ALB-21 (f) ALB-21 (f) ALV-21 (d) (f) ALV-21 (d) (f)
4 Drive End Head Assembly ALB-2003A ALB-2003B ALV-1003A (a) ALV-1003A (a)
5 Drive End Bearing X-4086 X-4086 X-4086 X-4086
6 Rotor Assembly ALV-2026AS ALV-2026AS ALV-2006AS ALV-2006AS
7 Thru-bolt Package ALB-20AS ALB-20AS ALB-20AS-1 ALB-20AS-1
8 Stator Assembly ALV-2008AS ALV-2008AS ALV-2008AS ALV-2008AS
9 Eyelet Package 90-818 90-818 90-818 90-818
10 Lock Tab Package MES-98S MES-98S MES-98S MES-98S
11 Pos. Rectifier & Plate Assembly ALV-1004 ALV-1004 ALV-1004 ALV-1004
12 Terminal Stud Package 90-2040 90-2040 90-2046 90-2046
13 Negative Rectifier Package ALV-1004A ALV-1004A ALV-1004A ALV-1004A
14 Brush Spring Set AMA-19S AMA-19S AMA-19S AMA-19S
15 Brush Set ALV-1012S ALV-1012S ALV-1012S ALV-1012S
16 Slip Ring End Retainer GR-32 (b) (NA) GR-32 (b) GR-32 (b)
17 Brush Holder & Spring Assembly ALV-1015 ALV-1015 ALV-1015 ALV-1015
18 Slip Ring End Bearing X-4612 X-4612 X-4612 X-4612
19 Bearing O-ring Seal ∆ XA-744AB XA-1540S XA-744AB XA-744AB
20 Slip Ring End Head Assembly ALV-1022S ALV-1022BS ALV-1002S ALV-1002S
21 Woodruff Key ∆ X-0261 X-3832 X-0260 X-0260
X Capacitor Assembly (NA) (NA) (NA) (NA)
22 Vent Cover Assembly ALV-1031 ALV-1031 (NA) (NA)
23 Slip Ring End Bearing Cover GJT-0047 GJT-0047 GJT-0047 GJT-0047
24 Repair Kit 90-3039 90-3039 90-3040 90-3040
No. Part ALV-9407, S ALV-9510

1 Nut & Washer Package 8X-4075 (c) 8X-4075 (c)
2 Vent Fan (2 Pieces) (NA) (NA)
3 Rotor Shaft Spacer ALV-21 (d) (f) 90-2822 (e)
4 Drive End Head Assembly ALV-1003 (a) ALV-1003 (a)
5 Drive End Bearing X-4086 X-4086
6 Rotor Assembly ALV-2006AS ALV-2006AS
7 Thru-bolt Package ALB-20AS-1 ALB-20AS-1
8 Stator Assembly ALV-2008AS ALV-2008AS
9 Eyelet Package 90-818 90-818
10 Lock Tab Package MES-98S 90-2639
11 Pos. Rectifier & Plate Assembly ALV-1004 ALV-1004
13 Negative Rectifier Package ALV-1004A ALV-1004A
14 Brush Spring Set AMA-19S AMA-19S
15 Brush Set ALV-1012S ALV-1012S
16 Slip Ring End Retainer GR-32 (b) (NA)
17 Brush Holder & Spring Assembly ALV-1015 ALV-1015
18 Slip Ring End Bearing X-4612 X-4612
19 Bearing O-ring Seal ∆ XA-744AB XA-1540S
20 Slip Ring End Head Assembly ALV-1002AS ALV-1102AS
21 Woodruff Key ∆ X-0260 X-0260
X Capacitor Assembly (NA) (NA)
22 Vent Cover Assembly (NA) (NA)
23 Slip Ring End Bearing Cover GJT-0047 GJT-0047
24 Repair Kit 90-3040 90-3042
Notes:
(a) XA-1441 Drive End Oil Seal also available. (Replace with new whenever seal is removed.)
(b) Used only on early production units having Snap Ring at Slip Ring End of Rotor Shaft.
(c) Nut only; Washer not required.
(d) XA-744AZ Shaft Spacer O-ring is also available. (Replace with new whenever seal is removed.)
(e) Includes XA-744AZ Shaft Spacer O-ring Seal. (Replace with new whenever seal is removed.)
(f) Spacer only.
(NA) Not Applicable.
∆ Replace with new whenever parts are removed.
All quantities one (1) unless noted.
X Part not shown on drawing - part no longer used.


ALX Series
.Service
.. . . . . . . .. . . . .Parts
. . . . . . . . . ..List
...............
in this section are FAA/PMA approved.
REPLACEMENT LIST: 12 Volt Alternator

ALX-8403 Use ALX-8521 ALX-8521R Lycoming

ALX-8403G Use ALX-8521 ALX-8521R Lycoming
ALX-8403LS Use ALX-8521LS ALX-8521RS Lycoming
ALX-8403LSG Use ALX-8521LS ALX-8521RS Lycoming
ALX-8403R Use ALX-8521 ALX-8521R Lycoming
ALX-8403RG Use ALX-8521 ALX-8521R Lycoming
ALX-8403RS Use ALX-8521LS ALX-8521RS Lycoming
ALX-8403RSG Use ALX-8521LS ALX-8521RS Lycoming
ALX-8421 Use ALX-8521 ALX-8521R Lycoming
ALX-8421G Use ALX-8521 ALX-8521R Lycoming
ALX-8421LS Use ALX-8521LS ALX-8521RS Lycoming
ALX-8421LSG Use ALX-8521LS ALX-8521RS Lycoming
ALX-8421RS Use ALX-8521LS ALX-8521RS Lycoming
ALX-8421RSG Use ALX-8521LS ALX-8521RS Lycoming
ALX-8423 Use ALX-8523 ALX-8523R Continental (CMI)
ALX-9402 Use ALX-9525B ALX-9525BR Continental (CMI)
ALX-9404L Use ALX-9522 ALX-9522R Lycoming
ALX-9404LG Use ALX-9522 ALX-9522R Lycoming
ALX-9422L Use ALX-9522 ALX-9522R Lycoming
ALX-9422LG Use ALX-9522 ALX-9522R Lycoming
ALX-9425 Use ALX-9525B ALX-9525R Continental (CMI)
ALX-9425A Use ALX-9525B ALX-9525BR Continental (CMI)
ALX-9425B Use ALX-9525B ALX-9525BR Continental (CMI)
NOTE: The “R” at the end of an “Original Equipment Alternator Part Number” now signifies Factory Overhauled.

ALX Series (Exploded Parts View of Typical ALX Series Alternator)
1
2
4
5
22 6
8
9 (d)
10
12
1
13 5
14
6
15 7
8
17
18 9
14
16
20
11
16
19
NOTE:
16 each overhaul.

No. Part ALX-8523 ALX-8403, ALX-8403LS, ALX-8421, G,
G, R, RG RS, LSG, RSG R, RG
1 Nut & Washer Package 90-33 90-33 90-33 90-33
2 Drive Pulley NA (d) PU-672A NA (d) PU-672A
3 Vent Fan (2 Pieces) 90-2241 90-2241 90-2241 90-2241
4 Rotor Shaft Spacer ALC-0021F ALD-21 ALD-21 ALD-21
5 Drive End Head Assembly ALE-1003K ALE-1003K ALE-1003K ALE-1003K
7 O-ring Seal (NA) (NA) (NA) (NA)
8 Drive End Retainer GR-32 GR-32 GR-32 GR-32
9 Rotor Assembly ALH-2228 90-2508 (c) 90-2508 (c) 90-2508 (c)
10 Stator Assembly ALE-2008ABS ALE-2008ABS ALE-2008ABS ALE-2008ABS
11 Thru-bolt Package ALA-20GS ALA-20GS ALA-20GS ALA-20GS
12 Eyelet Package 90-818 90-818 90-818 90-818
13 Negative Rectifier Package XA-944JS XA-944JS XA-944JS XA-944JS
14 Slip Ring End Head Assembly ALK-1232L 90-2508 (c) 90-2508 (c) 90-2508 (c)
15 Pos. Rectifier & Plate Assembly ALE-1054A* ALE-1054A* ALE-1054A* ALE-1054A*
17 Brush Holder & Spring Ass’y** ALU-2045BS (b) ALU-2045BS (b) ALU-2045BS (b) ALU-2045BS (b)
18 Brush Set ALE-2013AS (g) ALE-2013AS (g) ALE-2013AS (g) ALE-2013AS (g)
19 Slip Ring End Bearing X-4130 X-4130 (a) X-4130 (a) X-4130 (a)
20 Slip Ring End Cover ALU-1062A ALU-1062A ALU-1062A ALU-1062A
21 Repair Kit 90-3044 90-3044 90-3044 90-3044
X Caution Placard (Red) (h) QA-235 QA-235 QA-235 QA-235
No. Part ALX-8421LS, ALX-8521 ALX-8521LS ALX-9402 ALX-9404L, ALX-9405
RS, LSG, RSG LG, R, RG
1 Nut & Washer Package 90-33 90-33 90-33 (NA) 8X-4075 (e) ALU-23 (f)
2 Drive Pulley (d) PU-672A (d) (NA) (NA)
3 Vent Fan (2 Pieces) 90-2241 90-2241 90-2241 ALP-1034 (g) (NA) (NA)
4 Rotor Shaft Spacer ALD-21 ALD-21 ALD-21 (NA) ALU-23 (f) (NA)
5 Drive End Head Assembly ALE-1003K ALE-1003K ALE-1003K ALU-1003 (d2) ALU-1043 (d) ALU-1043 (d)
7 O-ring Seal (NA) (NA) (NA) (N/A) (i) (i)
9 Rotor Assembly 90-2508 (c) ALH-2228S-1 ALH-2228S-1 90-2505 (c) 90-2509 (c) 90-2504 (c)
12 Eyelet Package 90-818 90-818 90-818 90-818 90-818 8X-4075 (f)
14 Slip Ring End Head Assembly 90-2508 (c) ALK-1232CS-2 ALK-1232CS-2 90-2505 (c) 90-2509 (c) 90-2504 (c)
17 Brush Holder & Spring Ass’y** ALU-2045BS (b) ALU-3045BS ALU-3045BS (b) ALU-2045BS (b) ALU-2045BS (b) ALU-2045BS (b)
18 Brush Set ALE-2013AS (g) ALE-1013AS ALE-1013AS (g) ALE-2013AS (g) ALE-2013AS (g) ALE-2013AS (g)
19 Slip Ring End Bearing X-4130 (a) X-4130 X-4130 (a) X-4130 (a) X-4130 (a) X-4130 (a)
20 Slip Ring End Cover ALU-1062A ALU-1062A ALU-1062A ALX-1062S (NA) (NA)
21 Repair Kit 90-3044 90-3044 90-3044 90-3045 90-3046 90-3047
X Caution Placard (Red) (h) QA-235 QA-235 QA-235 QA-235 QA-235 QA-235
Notes:
Contents of 90-2505 Kit: S.R.E. Head Ass’y with Bearing - ALK-1242AAS-2; Brush Holder Ass’y - ALU-3045BS; Rotor Assembly - ALH-2306S-1.
Contents of 90-2508 Kit: S.R.E. Head Ass’y With Bearing - ALK-1232CS-2; Brush Holder Ass’. - ALU-3045BS; Rotor Assembly - ALH-2228S-1.
Contents of 90-2516 Kit: S.R.E. Head Ass’y With Bearing - ALK-1232CS-2/A; Brush Holder Ass’y - ALU-3045BS; Rotor Assembly - ALH-2228S-1.
(d) XA-1026 Drive End Oil Seal also available. (d2) 1281 Drive End Oil Seal also available. (Replace with new whenever seal is removed.)
(e) Also included with rotor. (i) XA-0744AZ Shaft Spacer O-ring Seal available.
(g) When converted to ALU-3045BS or ALE-3045BS Brush Holder Assembly, use ALE-1013AS only Captive Brush & Spring Sets.
(h) Red caution placard (through bolt torquing) is required on all installations.

No. Part ALX-9422L, LG, R, RG ALX-9424 ALX-9425, A, B ALX-9522 ALX-9524 ALX-9525B
1 Nut & Washer Package 8X-4075 (e) 8X-4075 (e) (NA) 8X-4075 (e) 8X-4075 (e) (NA)
2 Drive Pulley (NA) (NA) (NA) (NA) (NA) (NA)
3 Vent Fan (2 Pieces) (NA) (NA) ALP-1034 (g) (NA) (NA) ALP-1034 (g)
4 Rotor Shaft Spacer ALU-23 (f) ALU-23 (f) (NA) ALU-23 (f) ALU-23 (f) (NA)
5 Drive End Head Assembly ALU-1043 (d) ALU-1043 (d) ALU-1003 (d2) ALU-1043 (d) ALU-1043 (d) ALU-1003 (d2)
7 O-ring Seal (i) (i) (NA) (i) (i) (NA)
9 Rotor Assembly 90-2509 (c) 90-2504 (c) 90-2505 (c) ALH-2238S-1 ALX-2238AS-1 ALH-2306S-1
12 Eyelet Package 90-818 90-818 90-818 90-818 90-818 90-818
14 Slip Ring End Head Assembly 90-2509 (c) 90-2504 (c) 90-2505 (c) ALE-1242AAS-2 ALE-1242AAS-2 ALE-1242AAS-2
17 Brush Holder & Spring Ass’y** ALU-2045BS (b) ALU-2045BS (b) ALU-2045BS (b) ALU-3045BS ALU-3045BS ALU-3045BS
18 Brush Set ALE-2013AS (g) ALE-2013AS (g) ALE-2013AS (g) ALE-1013AS ALE-1013AS ALE-1013AS
19 Slip Ring End Bearing X-4130 (a) X-4130 (a) X-4130 (a) X-4130 X-4130 X-4130
20 Slip Ring End Cover (NA) (NA) ALX-1062S (NA) (NA) ALX-1062S
21 Repair Kit 90-3046 90-3046 90-3045 90-3046 90-3046 90-3045
22 Woodruff Key ∆ X-0260 X-0260 X-0260 X-0260 X-0260 4136
X Caution Placard (Red) (h) QA-235 QA-235 QA-235 QA-235 QA-235 QA-235
Notes:
Contents of 90-2504 Kit: S.R.E. Head Ass’y with Bearing - ALE-1242AAS-2; Brush Holder Ass’y - ALU-3045BS; Rotor Assembly - ALX-2238A.
Contents of 90-2505 Kit: S.R.E. Head Ass’y with Bearing - ALK-1242AAS-2; Brush Holder Ass’y - ALU-3045BS; Rotor Assembly - ALH-2306S-1.
Contents of 90-2509 Kit: S.R.E. Head Ass’y with Bearing - ALE-1242AAS-2; Brush Holder Ass’y - ALU-3045BS; Rotor Assembly - ALH-2238A.
(d) XA-1026 Drive End Oil Seal also available. (d2) 1281 Drive End Oil Seal also available. (Replace with new whenever seal is removed.)
(e) Also included with rotor. (i) XA-0744AZ Shaft Spacer O-ring Seal available.
(f) Nut only; washer not included. ∆ Replace with new whenever parts are removed.
(g) When converted to ALU-3045BS or ALE-3045BS Brush Holder Assembly, use ALE-1013AS only Captive Brush & Spring Sets.
(h) Red caution placard (through bolt torquing) is required on all installations.

ALY-6520 to 6527 Series
.Service
.. . . . . . . . . . . . .Parts
. . . . . . . . . ..List
.................
12 Volt Alternators
REPLACEMENT LIST:
ALY-6403 Use ALY-6520 ALY-6520R Lycoming
ALY-6403G Use ALY-6520 ALY-6520R Lycoming
ALY-6403R Use ALY-6520 ALY-6520R Lycoming
ALY-6403RG Use ALY-6520 ALY-6520R Lycoming
ALY-6408 Use ALY-6521 ALY-6521R Piper



NOTE:

(Exploded Parts View of Typical
ALY-6520 to 6527 Series Alternator)
5
21
1
7
3
10
11
15
8
16
9
18
14
12
13
14
17
13
NOTE:
19 each overhaul.

No. Part ALY-6403, G ALY-6406, G ALY-6409 ALY-6420, G
2 Drive Pulley PU-672A PU-676A PU-692A PU-672A
3 Vent Fan (2 Pieces) 90-2241 90-2241 90-2241 90-2241
4 Rotor Shaft Spacer ALD-21 ALD-21 ALD-21A ALD-21
8 Rotor Assembly 90-2517 (c) 90-2503 (c) 90-2507 (c) 90-2517 (c)
9 Thru-bolt Package ALA-20JS ALA-20JS ALA-20JS ALA-20JS
10 Stator Assembly ALE-2008AE ALE-2008AE ALE-2008AE ALE-2008AE
11 Eyelet Package 90-818 90-818 90-818 90-818
12 Negative Rectifier XA-944JS XA-944JS XA-944JS XA-944JS
13 Slip Ring End Head Assembly 90-2517 (c) 90-2503 (c) 90-2507 (c) 90-2503 (c)
16 Brush Holder & Spring Ass’y** ALU-2045BS (b) ALU-2045BS (b) ALE-2045BS (b) ALU-2045BS (b)
17 Slip Ring End Bearing X-4130 (a) X-4130 (a) X-4130(a) X-4130(a)
18 Brush Set ALE-2013AS (d) ALE-2013AS (d) ALE-2013S (d) ALE-2013AS (d)
19 Slip Ring End Cover (NA) (NA) (NA) (NA)
20 Repair Kit 90-3048 90-3048 90-3049 90-3048
X Caution Placard (Red) (e) QA-235 QA-235 QA-235 QA-235
No. Part ALY-6422 ALY-6425 ALY-6427, G ALY-6520, G ALY-6520LS

1 Nut & Washer Package 90-33 90-33 90-33 90-33 90-33
2 Drive Pulley PU-692A (NA) PU-676A PU-672A (NA)
3 Vent Fan (2 Pieces) 90-2241 90-2259 90-2241 90-2241 90-2241
4 Rotor Shaft Spacer ALD-21A ALC-21F ALD-21 ALD-21 ALD-21
5 Drive End Head Assembly ALE-1003K ALE-1003R ALE-1003K ALE-1003K ALE-1003K
6 Drive End Bearing X-4612 X-4612 X-4612 X-4612 X-4612
7 Drive End Retainer GR-32 GR-32 GR-32 GR-32 GR-32
8 Rotor Assembly 90-2507 (c) 90-2517 (c) 90-2503 (c) ALE-2273S-1 ALE-2273S-1
9 Thru-bolt Package ALA-20JS ALA-20JS ALA-20JS ALA-20JS ALA-20JS
10 Stator Assembly ALE-2008AE ALE-2008AE ALE-2008AE ALE-2008AE ALE-2008AE
11 Eyelet Package 90-818 90-818 90-818 90-818 90-818
12 Negative Rectifier XA-944JS XA-944JS XA-944JS XA-944JS XA-944JS
13 Slip Ring End Head Assembly 90-2507 (c) 90-2503 (c) 90-2503 (c) ALK-1232BS-2 ALK-1232BS-2
14 Terminal Stud Package 90-2043 90-2043 90-2030 90-2030 90-2030
15 Pos. Rectifier & Plate Assembly ALE-1054A* ALE-1054A* ALE-1054A* ALE-1054A* ALE-1054A*
16 Brush Holder & Spring Ass’y** ALE-2045BS (b) ALU-2045BS (b) ALU-2045BS (b) ALU-3045BS ALU-3045BS
17 Slip Ring End Bearing X-4130 (a) X-4130 (a) X-4130 (a) X-4130 X-4130
18 Brush Set ALE-2013AS (d) ALE-2013AS (d) ALE-2013AS (d) ALE-1013AS ALE-1013AS
19 Slip Ring End Cover (NA) (NA) (NA) (NA) (NA)
20 Repair Kit 90-3049 90-3049 90-3048 90-3048 90-3048
21 Woodruff Key ∆ X-0258 X-3832 X-3832 X-3832 X-3832
X Caution Placard (Red) (e) QA-235 QA-235 QA-235 QA-235 QA-235
Notes:
S.R.E. Head Assembly with Bearing - ALK-1232BS-2; Brush Holder Assembly - ALU-3045BS; Rotor Assembly - ALE-2273S-1.
S.R.E. Head Assembly with Bearing - ALK-1232ES-2; Brush Holder Assembly - ALE-3045BS; Rotor Assembly - ALE-2277S-1.
(e) Red caution placard (through bolt torquing) is required on all installations. ∆ Replace with new whenever parts are removed.
(NA) Not Applicable. X Not shown in parts view. All quantities one (1) unless noted.
** ALU-2045BS or ALE-2045BS no longer available, use ALU-3045BS or ALE-3045BS brush holder assembly.

No. Part ALY-6521 ALY-6522 ALY-6525 ALY-6527, G
2 Drive Pulley PU-692A PU-692A (NA) PU-676A
3 Vent Fan (2 Pieces) 90-2241 90-2241 90-2259 90-2241
4 Rotor Shaft Spacer ALD-21 ALD-21A ALC-21F ALD-21
5 Drive End Head Assembly ALE-1003K ALE-1003K ALE-1003R ALE-1003K
8 Rotor Assembly ALE-2273S-1 ALE-2277S-1 ALE-2273S-1 ALE-2273S-1
11 Eyelet Package 90-818 90-818 90-818 90-818
13 Slip Ring End Head Assembly ALK-1232BS-2 ALK-1232BS-2 ALK-1232BS-2 ALK-1232BS-2
16 Brush Holder & Spring Ass’y** ALU-3045BS ALU-3045BS ALU-3045BS ALU-3045BS
18 Brush Set ALE-1013AS (d ALE-1013AS ALE-1013AS ALE-1013AS
19 Slip Ring End Cover (NA) (NA) (NA) (NA)
20 Repair Kit 90-3049 90-3049 90-3049 90-3048
X Caution Placard (Red) (e) QA-235 QA-235 QA-235 QA-235
Notes:
** ALU-2045BS no longer available, use ALU-3045BS brush holder assembly.

.Service
.. . . . . . . . . . . . .Parts
. . . . . . . . . .List
..................
12 Volt Alternators
REPLACEMENT LIST:
ALY-8402 Use ALY-8524 ALY-8524R Continental (CMI)
ALY-8403LS Use ALY-8520LS ALY-8520RS Lycoming
ALY-8403LSG Use ALY-8520LS ALY-8520RS Lycoming
ALY-8403RS Use ALY-8520LS ALY-8520RS Lycoming
ALY-8403RSG Use ALY-8520LS ALY-8520RS Lycoming

ALY-8420LS Use ALY-8520LS ALY-8520RS Lycoming
ALY-8420LSG Use ALY-8520LS ALY-8520RS Lycoming
ALY-8420RS Use ALY-8520LS ALY-8520RS Lycoming
ALY-8420RSG Use ALY-8520LS ALY-8520RS Lycoming
NOTE:

ALY-8520 to 8526 Series Alternator)
5
21
1
7
3
10
11
15
8
16
9
18
14
12
13
14
17
13
NOTE:
each overhaul.
19

No. Part ALY-8402 ALY-8403, G ALY-8403LS, G ALY-8405, G ALY-8411
1 Nut & Washer Package 90-33 90-33 90-33 90-33 90-33
2 Drive Pulley (NA) PU-672A (NA) PU-672A (NA)
3 Vent Fan (2 Pieces) 90-2259 90-2241 90-2241 90-2241 90-2259
4 Rotor Shaft Spacer ALC-21F ALD-21 ALD-21 ALD-21 ALC-21F
5 Drive End Head Assembly ALE-1003K ALE-1003K ALE-1003K ALE-1003K ALE-1003K
6 Drive End Bearing X-4612 X-4612 X-4612 X-4612 X-4612
7 Drive End Retainer GR-32 GR-32 GR-32 GR-32 GR-32
8 Rotor Assembly 90-2517 (c) 90-2503 (c) 90-2503 (c) 90-2517 (c) 90-2517 (c)
9 Thru-bolt Package ALA-20JS ALA-20JS ALA-20JS ALA-20JS ALA-20JS
10 Stator Assembly ALE-2008AE ALE-2008AE ALE-2008AE ALE-2008AE ALE-2008AE
11 Eyelet Package 90-818 90-818 90-818 90-818 90-818
12 Negative Rectifier XA-944JS XA-944JS XA-944JS XA-944JS XA-944JS
13 Slip Ring End Head Assembly 90-2503 (c) 90-2503 (c) 90-2503 (c) 90-2503 (c) 90-2503 (c)
15 Pos. Rectifier & Plate Assembly ALE-1054A* ALE-1054A* ALE-1054A* ALE-1054A* ALE-1054A*
16 Brush Holder & Spring Ass’y** ALU-2045BS (b) ALU-2045BS (b) ALU-2045BS (b) ALU-2045BS (b) ALU-2045BS (b)
17 Slip Ring End Bearing X-4130 (a) X-4130(a) X-4130(a) X-4130 (a) X-4130(a)
18 Brush Set ALE-2013AS (e) ALE-2013AS (e) ALE-2013AS (e) ALE-2013AS (e) ALE-2013AS (e)
19 Slip Ring End Cover ALU-1062 ALU-1062A ALU-1062A ALU-1062D ALU-1062
20 Repair Kit 90-3049 90-3048 90-3048 90-3049 90-3049
21 Woodruff Key ∆ X-0258 X-0261 X-0261 X-0261 X-0261
X Caution Placard (Red) (f) QA-235 QA-235 QA-235 QA-235 QA-235
No. Part ALY-8420, G ALY-8420LS, G ALY-8423 ALY-8424 ALY-8426, G ALY-8520

2 Drive Pulley PU-672A (NA) PU-672A (NA) PU-672A PU-672A
3 Vent Fan (2 Pieces) 90-2241 90-2241 90-2241 90-2259 90-2241 90-2241
4 Rotor Shaft Spacer ALD-21 ALD-21 ALD-21 ALC-21F ALD-21 ALD-21
8 Rotor Assembly 90-2503 (c) 90-2503 (c) 90-2513 (c) 90-2517 (c) 90-2517 (c) ALE-2273S-1
9 Thru-bolt Package ALA-20JS ALA-20JS ALA-20JS ALA-20JS ALA-20JS ALA-20JS
10 Stator Assembly ALE-2008AE ALE-2008AE ALE-2008AE ALE-2008AE ALE-2008AE ALE-2008AE
11 Eyelet Package 90-818 90-818 90-818 90-818 90-818 90-818
12 Negative Rectifier XA-944JS XA-944JS XA-944JS XA-944JS XA-944JS XA-944JS
13 Slip Ring End Head Assembly 90-2503 (c) 90-2503 (c) 90-2513 (c) 90-2503 (c) 90-2503 (c) ALK-1232BS-2
16 Brush Holder & Spring Ass’y** ALU-2045BS (b) ALU-2045BS (b) ALE-2045BS (b) ALU-2045BS (b) ALU-2045BS (b) ALU-3045BS
17 Slip Ring End Bearing X-4130 (a) X-4130 (a) X-4130(a) X-4130(a) X-4130 (a) X-4130
18 Brush Set ALE-2013AS (e) ALE-2013AS (e) ALE-2013AS (e) ALE-2013AS (e) ALE-2013AS (e) ALE-1013AS
19 Slip Ring End Cover ALU-1062A ALU-1062A ALU-1062A ALU-1062 ALU-1062D ALU-1062A
20 Repair Kit 90-3048 90-3048 90-3048 90-3049 90-3049 90-3048
X Caution Placard (Red) (f) QA-235 QA-235 QA-235 QA-235 QA-235 QA-235
Notes:
S.R.E. Head Assembly with Bearing - ALK-1232BS-2; Brush Holder Assembly - ALE-3045BS; Rotor Assembly - ALE-2273S-1.
(d) Available through engine or airframe OEM.
(e) When converted to ALU-3045BS or ALE-3045BS Brush Holder Assembly, use ALE-1013AS only Captive Brush & Spring Sets.
(f) Red caution placard (through bolt torquing) is required on all installations. ∆ Replace with new whenever parts are removed.
** ALU-2045BS or ALE-2045BS no longer available, use ALU-3045BS or ALE-3045BS brush holder assembly.

No. Part ALY-8520LS ALY-8523 ALY-8524 ALY-8526
2 Drive Pulley (NA) PU-672A (NA) PU-672A
3 Vent Fan (2 Pieces) 90-2241 90-2241 90-2259 90-2241
4 Rotor Shaft Spacer ALD-21 ALD-21 ALC-21F ALD-21
8 Rotor Assembly ALE-2273S-1 ALE-2273S-1 ALE-2273S-1 ALE-2273S-1
11 Eyelet Package 90-818 90-818 90-818 90-818
13 Slip Ring End Head Assembly ALK-1232BS-2 ALK-1232BS-2 ALK-1232BS-2 ALK-1232BS-2
16 Brush Holder & Spring Ass’y** ALU-3045BS ALE-3045BS ALU-3045BS ALU-3045BS
18 Brush Set ALE-1013AS ALE-1013AS ALE-1013AS ALE-1013AS
19 Slip Ring End Cover ALU-1062A ALU-1062A ALU-1062 ALU-1062D
20 Repair Kit 90-3048 90-3049 90-3049 90-3049
X Caution Placard (Red) (f) QA-235 QA-235 QA-235 QA-235
Notes:
S.R.E. Head Assembly with Bearing - ALK-1232BS-2; Brush Holder Assembly - ALE-3045BS; Rotor Assembly - ALE-2273S-1.
(d) Available through engine or airframe OEM.
(e) When converted to ALU-3045BS or ALE-3045BS Brush Holder Assembly, use ALE-1013AS only Captive Brush & Spring Sets.
(f) Red caution placard (through bolt torquing) is required on all installations. ∆ Replace with new whenever parts are removed.
** ALU-2045BS no longer available, use ALU-3045BS brush holder assembly.

ALZ Series
Service
.. . . . . . . . . . . . . .Parts
. . . . . . . . . .List
................
REPLACEMENT LIST: 12 Volt Alternator

ALZ-8401 Use ALZ-8523 ALZ-8523R Lycoming
ALZ-8401G Use ALZ-8523 ALZ-8523R Lycoming
ALZ-8401R Use ALZ-8523 ALZ-8523R Lycoming
ALZ-8401RG Use ALZ-8523 ALZ-8523R Lycoming
ALZ-8423 Use ALZ-8523 ALZ-8523R Lycoming

ALZ-8423G Use ALZ-8523 ALZ-8523R Lycoming
ALZ-8423R Use ALZ-8523 ALZ-8523R Lycoming
ALZ-8423RG Use ALZ-8523 ALZ-8523R Lycoming
NOTE:

ALZ-8000 Series (Exploded Parts View of Typical ALZ Series Alternator)
5
21
1
7
3
10
11
15
8
16
9
18
14
12
13
14
17
NOTE:
each overhaul.
19

No. Part ALZ-8401, G ALZ-8423, G ALZ-8523
1 Nut & Washer Package 90-33 90-33 90-33
2 Drive Pulley PU-672A PU-672A PU-672A
3 Vent Fan (2 Pieces) 90-2241 90-2241 90-2241
4 Rotor Shaft Spacer ALD-21 ALD-21 ALD-21
5 Drive End Head Assembly ALE-1003K ALE-1003K ALE-1003K
6 Drive End Bearing X-4612 X-4612 X-4612
7 Drive End Retainer GR-32 GR-32 GR-32
8 Rotor Assembly 90-2517 (c) 90-2517 (c) ALE-2273S-1
9 Thru-bolt Package ALA-20JS ALA-20JS ALA-20JS
10 Stator Assembly ALE-2008AG ALE-2008AG ALE-2008AG
11 Eyelet Package 90-818 90-818 90-818
12 Negative Rectifier XA-944JS XA-944JS XA-944JS
13 Slip Ring End Head Assembly 90-2503 (c) 90-2503 (c) ALK-1232BS-2
14 Terminal Stud Package 90-2030 90-2030 90-2030
15 Pos. Rectifier & Plate Assembly ALE-1054A* ALE-1054A* ALE-1054A*
16 Brush Holder & Spring Ass’y** ALU-2045BS (b) ALU-2045BS (b) ALU-3045BS
17 Slip Ring End Bearing X-4130 (a) X-4130 (a) X-4130
18 Brush Set ALE-2013AS (d) ALE-2013AS (d) ALE-1013AS
19 Slip Ring End Cover ALU-1062A ALU-1062A ALU-1062A
20 Repair Kit 90-3050 90-3050 90-3050
21 Woodruff Key ∆ X-0261 X-0261 X-0261
X Caution Placard (Red) (e) QA-235 QA-235 QA-235
Notes:
S.R.E. Head Assembly With Bearing - ALK-1232BS-2; Brush Holder Assembly - ALU-3045BS; Rotor Assembly - ALE-2273S-1.


ANG Series
.Service
.. . . . . . . .. . . . .Parts
. . . . . . . . . .List
. . . . . . .24
. . .Volt
. . . .Alternator
. . . . . . . . .(Obsolete)
. . . . . . . ........
OBSOLETE




ES Series
Service
.. . . . . . . . .. . . . .Parts
. . . . . . . . . .List
................

in this section are FAA/PMA approved. Chrysler Style
REPLACEMENT LIST:
ES4020 Use ES4020 ES4020R Piper
NOTE:

ES4000 Series (Exploded Parts View of Typical Chrysler Style Alternator)
27 28
23
22 25
21
26
6 19
5 20 19
4
3 18
11 24
2
1
10 12 17
9 38
8 36
15
7 16
13 37
1 14
35
33
34
32
30 31
29
NOTE:
each overhaul.

No. Part ES4020
1 Brush Holder Screw (2 ea.) ES4313
2 Negative Brush Flat Washer ES4306
3 Negative Brush Assembly ES4314
4 Negative Brush Holder ES4308
5 Nut & Washer Assembly-Battery ES4125
6 Battery Terminal Outer Insulator ES4301
7 Slip Ring End Bearing X-4130
8 Positive Brush Insulator ES4303
9 Terminal Plate ES4305
10 Grounding Screw ES4315
11 Coned Washer ES4316-4
12 Slip Ring End Shield Stud ES4330
13 Terminal Plate Screw ES4317
14 Positive Brush Assembly ES4312
15 Positive Brush Holder ES4311
16 Slip Ring End Housing ES4327
17 Mounting Insert ES4318
18 Positive Rectifier Insulator ES4335
19 Terminal Block Screw (3 ea.) ES4333
20 Terminal Block Nut (3 ea.) ES4334
21 Terminal Block ES4331
22 Battery Term. Internal Insulator ES4332
23 Positive Rectifier ES4337
24 Capacitor Assembly ∆ ES4336
25 Capacitor Insulator ES4302
26 Nut & Washer Assembly ES4129
27 Negative Rectifier ES4338
28 Negative Rectifier Screw (4 ea.) ES4339
29 Stator Assembly ES4320
30 Grease Slinger ES4340
31 Rotor Assembly ES4307
32 Drive End Bearing Retainer ES40002
33 Drive End Bearing X-4612
34 Drive End Housing ES4326
35 Lock Tab - Thru Bolt (3 ea.) ∆ ES4309
36 Bearing Retainer Screw (3 ea.) ES40003
37 Thru-bolt (3 ea.) ES4310
38 Pulley Assembly ES4304
X Lockwasher-Battery Terminal ES4208
X Nut-Battery Terminal ES4210
Notes:
X Part not shown on drawing.


ES4000 Series
Service
.. . . . . . . . . . . . . .Parts
. . . . . . . . . ..List
...............

in this section are FAA/PMA approved. Small Frame Belt Driven
REPLACEMENT LIST:
ES4000 Use ES4000 ES4000R Cessna
ES4000LS Use ES4000LS ES4000RS
ES4009 Use ES4009 ES4009R Continental (CMI)

ES4009LS Use ES4009LS ES4009RS Mooney
ES4024LP Use ES4024LP ES4024LPR Continental (CMI)

ES4024LP-2 Use ES4024LP-2 ES4024LP-2R Continental (CMI)
ES4024LP-3 Use ES4024LP-3 ES4024LP-3R Continental (CMI)
NOTE:

ES4000 Series (Exploded Parts View of Typical
Small Frame Belt Driven Alt.)
27a
27a 30 27
34
27 33
34
29
33
30 31
28
20
27 19
34 18
33 18a
27a 17
26
17a 14
25
30a
24
23
22 13
13a
21
16
(b)
15
12
11 10 2a
(a)
9
8 1a
7 1
6
2
each overhaul.

No. Part ES4000 ES4000LS ES4009
1 Nut ES4101 ES4101 ES4101
1a Lockwasher, Steel (NA) (NA) (NA)
2 Fan & Pulley Assembly ES4102 (NA) ES4102
2a Spacer, Fan (NA) (NA) (NA)
X Pulley (NA) (NA) (NA)
X Fan (NA) (NA) (NA)
X Backplate Fan (NA) (NA) (NA)
6 Front Housing ES4103 (d) ES4103 (d) ES4103 (d)
Front Housing 41052 (f) 41052 (f) 41052 (f)
7 Front Bearing X-4612 X-4612 X-4612
8 Front Bearing Retainer ES4105 ES4105 ES4105
9 Bearing Retainer Screw (3 ea) ES4106-1 ES4106-1 ES4106-1
10 Woodruff Key ∆ ES4219 ES4219 ES4219
11 Rotor Assembly ES4145 (a) ES4145 (a) ES4109 (a)
12 Stator Assembly ES4147 ES4147 ES4110
13 Rectifier Bolt (2 ea) ES4111 (b) ES4111 (b) ES4111 (b)
13a Rectifier Bolt (NA) (NA) (NA)
14 Rectifier Assembly ES4113 ES4113 ES4113
15 Capacitor ∆ ES4114 ES4114 ES4114
16 Battery Insulator-Inner ES4115 ES4115 ES4115
17 Stator Insulator-Inner ES4116 ES4116 ES4116
17a Washer, Flat (NA) (NA) (NA)
18 Screw, Brush Holder (2 ea) HDW10004-1 HDW10004-1 HDW10004-1
18a Washer, Brush Holder (2 ea) HDW10005-1 HDW10005-1 HDW10005-1
19 Brush Kit ES4118 ES4118 ES4118
20 Brush Spring (2 ea) ES4119 ES4119 ES4119
21 Brush Holder ES4120 ES4120 ES4120
22 Field Terminal Stud ES4121 ES4121 ES4121
23 Field Insulator ES4122 ES4122 ES4122
24 Rear Housing ES4123 (e) ES4123 (e) ES4123 (e)
Rear Housing 41053 (f) (i) 41053 (f) (i) 41053 (f) (i)
25 Battery Insulator-Outer ES4124 ES4124 ES4124
26 Nut & Washer Ass’y-Battery ES4125 ES4125 ES4125
27 Thru-bolt (3 ea) ES4126 (f) ES4126 (f) ES4126 (f)
27a Thru-bolt (3 ea) HDW10020-3 (d) HDW10020-3 (d) HDW10020-3 (d)
28 Field Insulator-Outer ES4127 ES4127 ES4127
29 Stator Insulator-Outer ES4128 ES4128 ES4128
30 Nut & Washer-Grd/Field (2 ea) ES4129 ES4129 ES4129
30a Nut & Washer Assembly (NA) (NA) (NA)
31 Rear Bearing X-4130 X-4130 X-4130
X Nut Grd/Field (2 ea) ∆ ES4209 ES4209 ES4209
X Lockwasher-Grd/Field (2 ea) ∆ ES4207 ES4207 ES4207
X Lockwasher-Battery ∆ ES4208 ES4208 ES4208
X Nut-Battery ES4210 ES4210 ES4210
X Spacer-Outer (NA) (NA) (NA)
X Spacer-Inner (NA) (NA) (NA)
X Stator Terminal Lead (NA) (NA) ES4135
X Lockwasher-Shaft (NA) (NA) (NA)
32 Repair Kit 90-3053 90-3053 90-3053
X Caution Placard (Red) (c) QA-234 QA-234 QA-234
33 Washer, flat (3 ea) ∆ AN-960-10 AN-960-10 AN-960-10
34 Lockwasher (3 ea) ∆ MS35338-43 MS35338-43 MS35338-43
Notes:
(a) ES4107 Rotor Stop also available.
(b) ES4112 Insulator also available.
(c) Red caution placard is required on all installations except when using 27a thru bolt (HWD10020-3), red placard is not required.
(d) ES4103 no longer available, when replacing housing with 41052 for first time, replace items 18, 24 & 27, add items 27a, 33, 34, & 18a.
(e) ES4123 no longer available, when replacing housing with 41053 for first time, replace items 6, 18, & 27 with 27a, & add items 33 34, & 18a.
(f) ES4126 not used with 41052 or 41053 housings. For first time only, replace item 6, 18, 18a, 24, & 27 with 27a, & add items 33 & 34.
(i) Previous versions of rear housing 24, P/N 41053, do not contain tapped 6-32 threads. Return non-tapped housings for replacement.
(NA) Not Applicable

No. Part ES-4009LS ES-4024LP ES-4024LP-2 ES-4024LP-3
1 Nut ES4101 2A41435A04 2A41435A04 2A41435A04
1a Lockwasher, Steel (NA) 12X-0864 12X-0864 12X-0864
2 Fan & Pulley Assembly (NA) (NA) (NA) (NA)
2a Spacer, Fan (NA) 40407-1 40407-1 40407-1
X Pulley (NA) ES40088-1 ES40408 ES40408-1
X Fan (NA) ES40406-1 ES40406-1 ES40406-1
X Backplate Fan (NA) (NA) (NA) (NA)
6 Front Housing ES4103 (d) ES4103-1 (g) ES4103-1 (g) ES4103-1 (g)
Front Housing 41052 (f) 41052-1 (f) 41052-1 (f) 41052-1 (f)
7 Front Bearing X-4612 X-4612 X-4612 X-4612
8 Front Bearing Retainer ES4105 ES4105 ES4105 ES4105
9 Bearing Retainer Screw (3 ea) ES4106-1 ES4106-1 ES4106-1 ES4106-1
10 Woodruff Key ∆ ES4219 ES4224 ES4224 ES4224
11 Rotor Assembly ES4109 (a) ES40009-1 (a) ES40009-1 (a) ES40009-1 (a)
12 Stator Assembly ES4110 ES40010 ES40010 ES40010
13 Rectifier Bolt ES4111 (b) (2 ea) ES4111 (b) (2 ea) ES4111 (b) (2 ea) ES4111 (b) (1 ea)
13a Rectifier Bolt (NA) (NA) (NA) 41138 (1 ea)
14 Rectifier Assembly ES4113 ES4113 ES4113 ES4113
15 Capacitor ES4114 ES4114 ES4114 ES4114
16 Battery Insulator-Inner ES4115 ES4115 ES4115 ES4115
17 Stator Insulator-Inner ES4116 ES4116 ES4116 ES4116
17a Washer, Flat (NA) GBW-0034 GBW-0034 GBW-0034
18 Screw Brush Holder (2 ea) HDW10004-1 HDW10004-1 HDW10004-1 HDW10004-1
18a Washer, Brush Holder (2 ea) HDW10005-1 HDW10005-1 HDW10005-1 HDW10005-1
19 Brush Kit ES4118 ES4118 ES4118 ES4118
20 Brush Spring (2 ea) ES4119 ES4119 ES4119 ES4119
21 Brush Holder ES4120 ES4120 ES4120 ES4120
22 Field Terminal Stud ES4121 ES4121 ES4121 ES4121
23 Field Insulator ES4122 ES4122 ES4122 ES4122
24 Rear Housing ES4123 (e) ES4123 (e) ES4123 (e) ES4123 (e)
Rear Housing 41053 (f) (i) 41053 (f) (i) 41053 (f) (i) 41053 (f) (i)
25 Battery Insulator-Outer ES4124 ES4124 ES4124 ES4124
26 Nut & Washer Assembly-Battery ES4125 ES4125 ES4125 ES4125
27 Thru-bolt (3 ea) ES4126 (f) ES4126 (h) ES4126 (h) ES4126 (h)
27a Thru-bolt (3 ea) HDW10020-3 (d&g) HDW10020-3 (d&g) HDW10020-3 (d&g) HDW10020-3 (d&g)
28 Field Insulator-Outer ES4127 ES4127 ES4127 ES4127
29 Stator Insulator-Outer ES4128 ES4128 ES4128 ES4128
30 Nut & Washer-Ground/Field (3 ea) ES4129 ES4129 ES4129 ES4129
30a Nut & Washer Assembly ES4129 ES4129 ES4129 ES4129
31 Rear Bearing X-4130 X-4130 X-4130 X-4130
X Nut-Grd/Field (3 ea) ∆ ES4209 ES4209 ES4209 ES4209
X Lockwasher-Grd/Field (2 ea) ∆ ES4207 ES4207 ES4207 ES4207
X Lockwasher-Battery ∆ ES4208 ES4208 ES4208 ES4208
X Nut-Battery ES4210 ES4210 ES4210 ES4210
X Spacer-Outer (NA) ES4186-1 (NA) ES40194-1
X Spacer-Inner (NA) (NA) (NA) ES40407-1
X Stator Terminal Lead ES4135 ES4135 ES4135 ES4135
X Lockwasher-Shaft ∆ (NA) 12X-0864 12X-0864 12X-0864
32 Repair Kit 90-3053 90-3054 90-3054 (NA)
X Caution Placard (Red) (c) QA-234 QA-234 QA-234 QA-234
33 Washer, flat (3 ea) ∆ AN-960-10 AN-960-10 AN-960-10 AN-960-10
34 Lockwasher (3 ea) ∆ MS35338-43 MS35338-43 MS35338-43 MS35338-43
Notes:
(d) ES4103 no longer available, when replacing housing with 41052 for first time, replace items 18, 24 & 27 with 27a & add items 33, 34 & 18a.
(e) ES4123 no longer available, when replacing housing with 41053 for first time, replace items 6, 18, & 27 with 27a & add items 33 34 & 18a.
(f) ES4126 not used with 41052 or 41053 housings. For first time only, replace item 6, 18, 24, & 27 with 27a & add items 34, 34 & 18a.
(g) ES4103-1 no longer available, when replacing housing with 41052-1 for first time, replace items 18, 24 & 27a, add items 33, 34, & 18a.
(h) ES4126 not used with 41052-1 or 41053 housings. For first time only, replace item 6, 18, 24, & 27 with 27a & add items 33, 34 & 18a.
(i) Previous versions of rear housing 24, P/N 41053, do not contain tapped 6-32 threads. Return non-tapped housings for replacement.
(NA) Not Applicable

Large Frame Belt Driven Alt.)
32
31
29
30
29
28
37 27
38 33
36 22
35
21
19
34 15
14
12 25
26 24 20a
23 20
18
8
17
6 16
11 13
10
9
3
5 1
2
4

each overhaul.

No. Part ES4018-1
1 Nut-Shaft 2A41435A04
2 Lockwasher-Shaft ∆ 12X-0864
3 Pulley, V-Belt 41154-6
4 Backplate, Fan 4240
5 Fan PU-605A-2
6 Spacer 4226
7 Housing, Front 41052
8 Bearing, Ball X-4612
9 Retainer 4105
10 Screw (3 ea.) 4106-1
11 Rotor Assembly 4223
12 Woodruff Key 4224
13 Stator and Coil Assembly 4110
14 Bolt, Rectifier (2 ea.) 4111
15 Washer, Insulating 4112
16 Rectifier Assembly 4113
17 Capacitor 4114
18 Insulator 4115
19 Insulator, Stator 4116
20 Screw Brush Holder (2 ea.) HDW10004-1
20a Washer, Brush Holder (2 ea) HDW10005-1
21 Kit, Brush 4118
22 Spring, Brush 4119
23 Holder, Brush 4120
24 Stud, Field Terminal 4121
25 Insulator, Field 4122
26 Housing, Rear 41053 (a)
27 Insulator, Field 4127
28 Nut & Washer Assembly (4 ea.) 4129
29 Washer, Lock (6 ea.) MS35338-43
30 Nut, Field and Ground (3 ea.) 4209
31 Washer, Flat (3 ea.) AN960-10
32 Bolt, Thru (3 ea.) HDW10020-3
33 Bearing, Rear X-4130
34 Insulator, Battery 4128
35 Insulator, Battery 4124
36 Nut & Washer Assembly 4125
37 Washer, Lock MS35338-44
38 Nut, Hex 4210
Notes:
(a) Previous versions of rear housing 26, P/N 41053, do not contain tapped 6-32 threads. Return non-tapped housings for replacement.

ES4000 Series
Service Parts List
. . . . . . . . . . . . . . . . . . . . . . . ..............
Alternators and their corresponding

parts shown in this section are FAA/PMA Large Frame, Belt Driven
approved.
REPLACEMENT LIST:

Replaced Engine/Airframe
Alternator Alternator Alternator
By Application
Part Number Part Number Part Number
ES4003 Use ES4003 ES4003R Piper

ES4003/LS Use ES4003/LS ES4003RS
ES4011 Use ES4011 ES4011R Lycoming
ES4011/LS Use ES4011/LS ES4011RS Lycoming & Mooney
ES4011-1 Use ES4011-1 ES4011-1R Piper

ES4019 Use ES4019 ES4019R
ES4019/LS Use ES4019LS ES4019RS
ES4019-3 LS Use ES4019-3LS ES4019-3RS Lycoming

ES4019-5 Use ES4019-5 ES4019-5R Lycoming
.
NOTE:

ES4000 Series (Exploded Parts View of Typical Large Frame Belt Driven Alt.)
28
26
27 25
24
27 32 29
30 23
28
31 22 21
22
28 27 19 17
18
16
(b) 15
20
(d)
(d)
14
13
(a)
11
10
9
12 8
4
3
2
1
6
5
3
NOTE:
each overhaul.

No. Part ES4003 ES4003LS ES4011 ES4011LS ES4011-1 ES4011-2
1 Nut-Shaft 2A41435A04 2A41435A04 2A41435A04 2A41435A04 2A41435A04 2A41435A04
2 Lockwasher-Shaft ∆ 12X-0864 12X-0864 12X-0864 12X-0864 12X-0864 12X-0864
3 Spacer-Outer ES4186 (NA) ES4186 (NA) ES4186-1 ES4186-1
4 Fan & Pulley Assembly ES4249 (NA) ES4249 (NA) (NA) (NA)
5 Pulley (NA) (NA) (NA) (NA) ES40082 41154-3
6 Backplate Fan (NA) (NA) (NA) (NA) PU-604B PU-604B
7 Fan (NA) (NA) (NA) (NA) PU-605A PU-605A
8 Spacer-Fan ES4185 (NA) ES4185 (NA) ES4220 ES4220
9 Front Housing ES4204 ES4204 ES4204 ES4204 ES4204 ES4204
10 Front Bearing X-4612 X-4612 X-4612 X-4612 X-4612 X-4612
11 Bearing Retainer Screw (3 ea.) ES4192 ES4192 ES4192 ES4192 ES4192 ES4192
12 Woodruff Key ∆ ES4224 ES4224 ES4224 ES4224 ES4224 ES4224
13 Rotor Assembly ES4199 (a) ES4199 (a) ES4200 (a) ES4200 (a) ES4200 (a) ES4200 (a)
14 Stator Assembly ES4194 ES4194 ES4194 ES4194 ES4194 ES4194
15 Screw & Washer-Rectifier (4 ea.) ES4191 ES4191 ES4191 ES4191 ES4191 ES4191
16 Rectifier Assembly ES4203 (b) ES4203 (b) ES4203 (b) ES4203 (b) ES4203 (b) ES4203 (b)
17 Battery Insulator-Inner ES4115 ES4115 ES4115 ES4115 ES4115 ES4115
18 Screw-Brush Holder (2 ea.) ES4190 ES4190 ES4190 ES4190 ES4190 ES4190
19 Brush Holder ES4201 (c) ES4201 (c) ES4201 (c) ES4201 (c) ES4201 (c) ES4201 (c)
20 Capacitor ∆ ES4202 (d) ES4202 (d) ES4202 (d) ES4202 (d) ES4202 (d) ES4202 (d)
21 Adapter Harness ES40024 ES40024 ES40024 ES40024 ES40024 ES40024
22 Rear Housing ES4193 ES4193 ES4193 ES4193 ES4193 ES4193
23 Battery Insulator-Outer ES4124 ES4124 ES4124 ES4124 ES4124 ES4124
24 Nut & Washer Assembly-Battery ES4125 ES4125 ES4125 ES4125 ES4125 ES4125
25 Lockwasher-Battery ∆ ES4208 ES4208 ES4208 ES4208 ES4208 ES4208
26 Nut-Battery ES4210 ES4210 ES4210 ES4210 ES4210 ES4210
27 Lockwasher (5 ea.) ∆ 12X-3074 12X-3074 12X-3074 12X-3074 12X-3074 12X-3074
28 Thru-bolt (4 ea.) ES4188 ES4188 ES4188 ES4188 ES4188 ES4188
29 Nut-Field & Ground ES4209 ES4209 ES4209 ES4209 ES4209 ES4209
30 Lockwasher-Field & Ground ∆ ES4207 ES4207 ES4207 ES4207 ES4207 ES4207
31 Nut & Washer Ass’y-Field & Gnd ES4129 ES4129 ES4129 ES4129 ES4129 ES4129
32 Rear Bearing X-4130 X-4130 X-4130 X-4130 X-4130 X-4130
X Screw-Cooling Shroud Attach (NA) (NA) (NA) (NA) (NA) (NA)
X Cooling Shroud (NA) (NA) (NA) (NA) (NA) (NA)
33 Repair Kit 90-3055 90-3055 90-3055 90-3055 90-3055 90-3055
Notes:
(b) ES4184 Rectangle Rectifier Insulator also available (2 ea. required).
(c) Springs & Brushes included.
(d) ES4187 Capacitor Terminal Screw & ES4189 Capacitor Attaching Screw also available.

No. Part ES4011-3 ES4011-4 ES4011-5 ES4019 ES4019LS
1 Nut-Shaft 2A41435A04 2A41435A04 2A41435A04 2A41435A04 2A41435A04
2 Lockwasher-Shaft ∆ 12X-0864 12X-0864 12X-0864 12X-0864 12X-0864
3 Spacer-Outer ES4186-1 ES4186-1 ES4186-1 ES4186 (NA)
4 Fan & Pulley Assembly (NA) (NA) (NA) ES4249 (NA)
5 Pulley 41154-1 41154-8 41154-2 (NA) (NA)
6 Backplate Fan PU-604B PU-604B PU-604B (NA) (NA)
7 Fan PU-605A PU-605A PU-605A (NA) (NA)
8 Spacer-Fan ES4220 ES4220 ES4220 ES4185 ES4185
9 Front Housing ES4204 ES4204 ES4204 ES4204 ES4204
10 Front Bearing X-4612 X-4612 X-4612 X-4104 X-4104
11 Bearing Retainer Screw (3 ea.) ES4192 ES4192 ES4192 ES4192 ES4192
12 Woodruff Key ∆ ES4224 ES4224 ES4224 ES4224 ES4224
13 Rotor Assembly ES4200 (a) ES4200 (a) ES4200 (a) ES40048 (a) ES40048 (a)
14 Stator Assembly ES4194 ES4194 ES4194 ES4235 ES4235
15 Screw & Washer-Rectifier (4 ea.) ES4191 ES4191 ES4191 ES4191 ES4191
16 Rectifier Assembly ES4203 (b) ES4203 (b) ES4203 (b) ES4203 (b) ES4203 (b)
17 Battery Insulator-Inner ES4115 ES4115 ES4115 ES4115 ES4115
18 Screw-Brush Holder (2 ea.) ES4190 ES4190 ES4190 ES4190 ES4190
19 Brush Holder ES4201 (c) ES4201 (c) ES4201 (c) ES4201 (c) ES4201 (c)
20 Capacitor ∆ ES4202 (d) ES4202 (d) ES4202 (d) ES4202-1 (d) ES4202 (d)
21 Adapter Harness ES40024 ES40024 ES40024 ES40024 ES40024
22 Rear Housing ES4193 ES4193 ES4193 ES4193 ES4193
23 Battery Insulator-Outer ES4124 ES4124 ES4124 ES4124 ES4124
24 Nut & Washer Assembly-Battery ES4125 ES4125 ES4125 ES4125 ES4125
25 Lockwasher-Battery ∆ ES4208 ES4208 ES4208 ES4208 ES4208
26 Nut-Battery ES4210 ES4210 ES4210 ES4210 ES4210
27 Lockwasher (4 ea.) ∆ 12X-3074 12X-3074 12X-3074 12X-3074 12X-3074
28 Thru-bolt (4 ea.) ES4188 ES4188 ES4188 ES4188 ES4188
29 Nut-Field & Ground ES4209 ES4209 ES4209 ES4209 ES4209
30 Lockwasher-Field & Ground ∆ ES4207 ES4207 ES4207 ES4207 ES4207
31 Nut & Washer Ass’y-Field & Gnd ES4129 ES4129 ES4129 ES4129 ES4129
32 Rear Bearing X-4130 X-4130 X-4130 X-4130 X-4130
X Screw-Cooling Shroud Attach (NA) (NA) (NA) (NA) (NA)
X Cooling Shroud (NA) (NA) (NA) (NA) (NA)
33 Repair Kit 90-3055 90-3055 90-3055 (NA) (NA)
Notes:

No. Part ES4019-3LS ES4019-5
1 Nut-Shaft 2A41435A04 2A41435A04
2 Lockwasher-Shaft ∆ 12X-0864 12X-0864
3 Spacer-Outer (NA) (NA)
4 Fan & Pulley Assembly (NA) (N/A)
5 Pulley (NA) 41154-3
6 Backplate Fan PU-604B PU-604B
7 Fan PU-605A PU-605A
8 Spacer-Fan ES4220 ES4220
9 Front Housing ES4204 ES4204
10 Front Bearing X-4104 X-4104
11 Bearing Retainer Screw (3 ea.) ES4192 ES4192
12 Woodruff Key ∆ ES4224 ES4224
13 Rotor Assembly ES40048 (a) ES40048 (a)
14 Stator Assembly ES4235 ES4235
15 Screw & Washer-Rectifier (4 ea.) ES4191 ES4191
16 Rectifier Assembly ES4203 (b) ES4203 (b)
17 Battery Insulator-Inner ES4115 ES4115
18 Screw-Brush Holder (2 ea.) ES4190 ES4190
19 Brush Holder ES4201 (c) ES4201 (c)
20 Capacitor ∆ ES4202-1 (d) ES4202-1 (d)
21 Adapter Harness ES40024 ES40024
22 Rear Housing ES4193 ES4193
23 Battery Insulator-Outer ES4124 ES4124
24 Nut & Washer Assembly-Battery ES4125 ES4125
25 Lockwasher-Battery ∆ 12X-0199 MS35338-43
26 Nut-Battery ES4210 ES4210
27 Lockwasher (4 ea.) ∆ 12X-0199 MS35338-44
28 Thru-bolt (4 ea.) ES4126 ES4188
29 Nut-Field & Ground ES4209 ES4209
30 Lockwasher-Field & Ground ∆ 12X-0196 MS35338-44
31 Nut & Washer Ass’y-Field & Gnd ES4129 ES4129
32 Rear Bearing X-4130 X-4130
X Screw-Cooling Shroud Attach ES4106-1 (NA)
X Cooling Shroud (NA) (NA)
33 Repair Kit (NA) (NA)
Notes:


ES4000 Series
Service
. .. . . . . . .. . . . . .Parts
. . . . . . . . . .List
................

in this section are FAA/PMA approved. Small Frame Gear Driven
REPLACEMENT LIST:
ORIGINAL EQUIP. CURRENT FACTORY OVERHAUL
ALTERNATOR REPLACED ALTERNATOR ALTERNATOR ENGINE/AIRFRAME
PART NUMBER BY PART NUMBER PART NUMBER APPLICATION
ES4001 Use ES4001 ES4001R Continental (CMI) & Cessna

ES4004 Use ES4004 ES4004R Continental (CMI) & Cessna
NOTE:

ES4000 Series (Exploded Parts View of Typical Small Frame Gear Driven Alt.)
26a
26a 29 26
33
26 32
33
28
29 32
30
27
26 19
18
26a 33
32 17 16
11
25
24 13
29
10 23
22
21 12
9
20
15
(a) 8
(b)
14
7
6
3
2
1
NOTE:
each overhaul.

No. Part ES4001 ES4002 ES4004 ES4006 ES4008
1 Drive Seal ∆ ES4142 ES4142 ES4142 ES4142 ES4142
2 Spacer-Outer ES4141 ES4141 ES4141 ES4141 ES4141
3 O-ring Seal ∆ ES4140 ES4140 ES4140 ES4140 ES4140
4 Front Housing ES4139 (d ES4139 (d ES4139 (d ES4139 (d ES4139 (d
Front Housing 41051 (f) 41051 (f) 41051 (f) 41051 (f) 41051 (f)
6 Front Bearing Retainer ES4138 ES4138 ES4138 ES4138 ES4138
7 Bearing Retainer Screw (3 ea) ES4106-2 ES4106-2 ES4106-2 ES4106-2 ES4106-2
8 Fan Assembly ES4137 ES4137 ES4137 ES4137 ES4137
9 Woodruff Key (2 ea) ∆ ES4136 ES4136 ES4136 ES4136 ES4136
12 Rectifier Bolt (2 ea) ES4111 (b) ES4111 (b) ES4111 (b) ES4111 (b) ES4111 (b)
13 Rectifier Assembly ES4113 ES4113 ES4113 ES4113 ES4113
14 Capacitor ES4114 ES4114 ES4114 ES4114 ES4114
16 Stator Insulator-Inner ES4116 ES4116 ES4116 ES4116 ES4116
17 Screw-Brush Holder (2 ea) ES4117 ES4117 ES4117 ES4117 ES4117
18 Brush Kit ES4118 ES4118 ES4118 ES4118 ES4118
19 Brush Spring (2 ea) ES4119 ES4119 ES4119 ES4119 ES4119
20 Brush Holder ES4120 ES4120 ES4120 ES4120 ES4120
21 Field Terminal Stud ES4121 ES4121 ES4121 ES4121 ES4121
22 Field Insulator ES4122 ES4122 ES4122 ES4122 ES4122
23 Rear Housing ES4123 (e) ES4123 (e) ES4123 (e) ES4123 (e) ES4123 (e)
Rear Housing 41053 (f) 41053 (f) 41053 (f) 41053 (f) 41053 (f)
25 Nut & Washer Ass’y-Battery ES4125 ES4125 ES4125 ES4125 ES4125
26 Thru-bolt (3 ea) ES4126 (f) ES4126 (f) ES4126 (f) ES4126 (f) ES4126 (f)
26a Thru-bolt (3 ea) HDW10020-3 (d) HDW10020-3 (d) HDW10020-3 (d) HDW10020-3 (d) HDW10020-3 (d)
27 Field Insulator-Outer ES4127 ES4127 ES4127 ES4127 ES4127
28 Stator Insulator-Outer ES4128 ES4128 ES4128 ES4128 ES4128
29 Nut & Washer-Grd/Field (2 ea) ES4129 ES4129 ES4129 ES4129 ES4129
X Nut Grd/Field (2 ea) ES4209 ES4209 ES4209 ES4209 ES4209
X Lockwasher-Grd/Field (2 ea) ∆ ES4207 ES4207 ES4207 ES4207 ES4207
X Lockwasher-Battery ∆ ES4208 ES4208 ES4208 ES4208 ES4208
X Nut-Battery ES4210 ES4210 ES4210 ES4210 ES4210
X Stator Terminal Lead (NA) 4135 (NA) (NA) ES4135
31 Repair Kit 90-3056 90-3056 90-3056 90-3056 90-3056
X Caution Placard (Red) (c) QA-234 QA-234 QA-234 QA-234 QA-234
32 Washer, flat (3 ea) ∆ AN-960-10 AN-960-10 AN-960-10 AN-960-10 AN-960-10
33 Lockwasher (3 ea) ∆ MS35338-43 MS35338-43 MS35338-43 MS35338-43 MS35338-43
Notes:
(d) ES4139 no longer available, when replacing housing with 41051 for first time, replace items 23 & 26, add items 26a, 32 & 33.
(e) ES4123 no longer available, when replacing housing with 41053 for first time, replace items 4 & 26, add items 32 & 33.
(f) ES4126 not used with 41051 or 41053 housings. For first time only, replace item 4 & 23, 26 with 26a & add items 32 & 33.
(NA) Not Applicable

Small Frame Gear Driven Alt.)
26a
26a 29 26
33
26 32
33
28
29 32
30
27
26 19
18
26a 33 17
32 17a
16
11
25
24 13
29
10 23
22
21 12
9
20
15
(a) 8
(b)
14
7
6
3
2
1

each overhaul.

No. Part ES4001 ES4002 ES4004 ES4006 ES4008
1 Drive Seal ∆ ES4142 ES4142 ES4142 ES4142 ES4142
2 Spacer-Outer ES4141 ES4141 ES4141 ES4141 ES4141
3 O-ring Seal ∆ ES4140 ES4140 ES4140 ES4140 ES4140
4 Front Housing ES4139 (d) ES4139 (d ES4139 (d ES4139 (d ES4139 (d
Front Housing 41051 (f) 41051 (f) 41051 (f) 41051 (f) 41051 (f)
6 Front Bearing Retainer ES4138 ES4138 ES4138 ES4138 ES4138
7 Bearing Retainer Screw (3 ea) ES4106-2 ES4106-2 ES4106-2 ES4106-2 ES4106-2
8 Fan Assembly ES4137 ES4137 ES4137 ES4137 ES4137
9 Woodruff Key (2 ea) ∆ ES4136 ES4136 ES4136 ES4136 ES4136
12 Rectifier Bolt (2 ea) ES4111 (b) ES4111 (b) ES4111 (b) ES4111 (b) ES4111 (b)
13 Rectifier Assembly ES4113 ES4113 ES4113 ES4113 ES4113
14 Capacitor ES4114 ES4114 ES4114 ES4114 ES4114
16 Stator Insulator-Inner ES4116 ES4116 ES4116 ES4116 ES4116
17 Screw-Brush Holder (2 ea) HDW10004-1 HDW10004-1 HDW10004-1 HDW10004-1 HDW10004-1
17a Washer, Brush Holder (2ea) HDW10005-1 HDW10005-1 HDW10005-1 HDW10005-1 HDW10005-1
18 Brush Kit ES4118 ES4118 ES4118 ES4118 ES4118
19 Brush Spring (2 ea) ES4119 ES4119 ES4119 ES4119 ES4119
20 Brush Holder ES4120 ES4120 ES4120 ES4120 ES4120
21 Field Terminal Stud ES4121 ES4121 ES4121 ES4121 ES4121
22 Field Insulator ES4122 ES4122 ES4122 ES4122 ES4122
23 Rear Housing ES4123 (e) ES4123 (e) ES4123 (e) ES4123 (e) ES4123 (e)
Rear Housing 41053 (f) (g) 41053 (f) (g) 41053 (f) (g) 41053 (f) (g) 41053 (f) (g)
25 Nut & Washer Ass’y-Battery ES4125 ES4125 ES4125 ES4125 ES4125
26 Thru-bolt (3 ea) ES4126 (f) ES4126 (f) ES4126 (f) ES4126 (f) ES4126 (f)
26a Thru-bolt (3 ea) HDW10020-3 (d) HDW10020-3 (d) HDW10020-3 (d) HDW10020-3 (d) HDW10020-3 (d)
27 Field Insulator-Outer ES4127 ES4127 ES4127 ES4127 ES4127
28 Stator Insulator-Outer ES4128 ES4128 ES4128 ES4128 ES4128
29 Nut & Washer-Grd/Field (2 ea) ES4129 ES4129 ES4129 ES4129 ES4129
X Nut Grd/Field (2 ea) ES4209 ES4209 ES4209 ES4209 ES4209
X Lockwasher-Grd/Field (2 ea) ∆ ES4207 ES4207 ES4207 ES4207 ES4207
X Lockwasher-Battery ∆ ES4208 ES4208 ES4208 ES4208 ES4208
X Nut-Battery ES4210 ES4210 ES4210 ES4210 ES4210
X Stator Terminal Lead (NA) 4135 (NA) (NA) ES4135
31 Repair Kit 90-3056 90-3056 90-3056 90-3056 90-3056
X Caution Placard (Red) (c) QA-234 QA-234 QA-234 QA-234 QA-234
32 Washer, flat (3 ea) ∆ AN-960-10 AN-960-10 AN-960-10 AN-960-10 AN-960-10
33 Lockwasher (3 ea) ∆ MS35338-43 MS35338-43 MS35338-43 MS35338-43 MS35338-43
Notes:
(d) ES4139 no longer available, when replacing housing with 41051 for first time, replace items 17, 23 26, add items 26a, 32, 33 & 17a.
(e) ES4123 no longer available, when replacing housing with 41053 for first time, replace items 4, 17, 26, add items 32, 33 & 17a.
(f) ES4126 not used with 41051 or 41053 housings. For first time only, replace item 4,17, 23, 26 with 26a & add items 32, 33 & 17a.
(g) Previous versions of rear housing 23, P/N 41053, do not contain tapped 6-32 threads. Return non-tapped housings for replacement.
(NA) Not Applicable
*

No. Part ES4029
1 Drive Seal ∆ ES4142
2 Spacer-Outer ES4141
3 O-ring Seal ∆ ES4140
4 Front Housing ES4139 (d)
Front Housing 41051 (f)
5 Front Bearing X-4612
6 Front Bearing Retainer ES4138
7 Bearing Retainer Screw (3 ea) ES4106-2
8 Fan Assembly ES4137
9 Woodruff Key (2 ea) ∆ ES4136
10 Rotor Assembly ES40005 (a)
12 Rectifier Bolt ES4111 (b)
13 Rectifier Assembly ES4113
14 Capacitor ES4114
15 Battery Insulator-Inner ES4115
16 Stator Insulator-Inner ES4116
17 Screw-Brush Holder (2 ea) HDW10004-1
17a Washer, Brush Holder (2ea) HDW10005-1
18 Brush Kit ES4118
19 Brush Spring (2 ea) ES4119
20 Brush Holder ES4120
21 Field Terminal Stud ES4121
22 Field Insulator ES4122
23 Rear Housing ES4123 (e)
Rear Housing 41053 (f) (g)
24 Battery Insulator-Outer ES4124
25 Nut & Washer Ass’y-Battery ES4125
26 Thru-bolt (3 ea) ES4126
26a Thru-bolt (3 ea) HDW10020-3 (d)
27 Field Insulator-Outer ES4127
28 Stator Insulator-Outer ES4128
29 Nut & Washer Ass’y-Grd/Field ES4129
30 Rear Bearing X-4130
X Nut Ground/Field (2 ea) ES4209
X Lockwasher-Grd/Field (2 ea) ES4207
X Lockwasher-Battery ∆ ES4208
X Nut-Battery ES4210
X Stator Terminal Lead ES4135
X Caution Placard (Red) (c) QA-234
32 Washer, flat (3 ea) ∆ AN-960-10
33 Lockwasher (3 ea) ∆ MS35338-43
Notes:
(d) ES4139 no longer available, when replacing housing with 41051 for first time, replace items 17, 23 & 26, add items 26a, 32, 33, & 17a.
(e) ES4123 no longer available, when replacing housing with 41053 for first time, replace items 4, 17 & 26, add items 32, 33, & 17a.
(f) ES4126 not used with 41051 or 41053 housings. For first time only, replace item 4, 17, 23, 26 with 26a & add items 32, 33, & 17a.
(g) Previous versions of rear housing 24, P/N 41053, do not contain tapped 6-32 threads. Return non-tapped housings for replacement.
(NA) Not Applicable



Ford Series
Service
.. . . . . . . .. . . . . .Parts
. . . . . . . . . ..List
...............
For Reference Only to Show Replacement Parts.
(No Overhaul instruction for ORIGINAL FORD units may be
found in the OE-A2 manual.)
Small Frame Belt Driven
REPLACEMENT LIST:
DOFF10300B Use DOFF10300B DOFF10300BR
NOTE:

FORD Series (Exploded Parts View of Typical Ford Series Small Frame Belt Driven Alt.)
For Reference Only to Show PMA Replacement Parts.
27a
27a 27
30 34
27 33
34
29
33
29 31
28
27 20 19
34
27a 33 18 17
26
25 12
29
24
23
22 13
21
16
15
14
11
10 9
8
7
6
5 1
NOTE:
Circled items represent new 4
replacement parts required at 3
each overhaul.

No. Part DOFF10300B
1 Nut-Shaft ES4101
X Lockwasher-Shaft (NA)
3 Fan & Pulley Assembly ES4102
4 Front Housing 41052 (b)
5 Front Bearing X-4612
6 Front Bearing Retainer ES4105
7 Bearing Retainer Screw (3 ea) ES4106-1
8 Rotor Stop ES4107
9 Woodruff Key ∆ ES4219
10 Rotor Assembly ES4109
12 Rectifier Assembly ES4113
13 Rectifier Bolt (2 ea) ES4111
14 Capacitor ∆ ES4114
15 Insulator-Rectifier (2 ea) ES4112
16 Battery Insulator-Inner ES4115
17 Stator Insulator-Inner ES4116
18 Screw-Brush Holder (2 ea) ES4117
19 Brush Kit ES4118
20 Brush Spring ES4119
21 Brush Holder ES4120
22 Field Terminal Stud ES4121
23 Field Insulator-Inner ES4122
24 Rear Housing 41053 (c)
25 Battery Insulator-Outer ES4124
26 Nut & Washer Ass’y-Battery ES4125
27 Thru-bolt Package ES4126 (d)
27a Thru-bolt (3 ea) HDW10020-3
28 Field Insulator-Outer ES4127
29 Stator Insulator-Outer ES4128
30 Nut & Washer Ass’y-Gnd/Fld (2) ES4129
31 Rear Bearing X-4130
X Spacer-Outer (NA)
X Adapter Harness (NA)
X Nut-Field & Ground ES4209
X Lockwasher-Field & Grd ∆ ES4207
X Lockwasher-Battery ∆ ES4206
X Nut-Battery ES4210
X Stator Terminal Lead (NA)
32 Repair Kit 90-3058 (d)
X Caution Placard (Red) QA-234 (a)
33 Lockwasher, thru bolt (3 ea) ∆ MS35338-43
34 Washer, flat (3 ea) AN960-10
Notes:
(NA) Not Applicable
Circled items represent recommended replacement items and are available for repair kits from Hartzell Engine Technologies.
(a) Red caution placard is required on all installations except when using 27a thru bolt (HWD10020-3), red placard is not required.
(b) ES4103 no longer available, when replacing housing with 41052 for first time, replace items 24 & 27, add items 27a, 33 & 34.
(c) ES4123 no longer available, when replacing housing with 41053 for first time, replace items 4 & 27, add items 27a, 33 & 34.
(d) ES4126 not used with 41052 or 41053 housings. For first time only, replace item 4 & 24, 27 with 27a & add items 33 & 34.










Alternator
Service Information
………………………………………………………… 3
Before You Start Work, Observe Warnings and Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20-01
ALE Series (12 Volt Alternator) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30-01
ALH Series (12 Volt Alternator) (Obsolete) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-70-01
ALM Series (24 Volt Alternator) (Obsolete) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-110-01
ALT Series (24 Volt Alternator) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-150-01
ALU Series (24 Volt Alternator) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-190-01
ALV Series (24 Volt Alternator) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-230-01
ALX Series (12 Volt Alternator) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-270-01
ALY Series (12 Volt Alternator) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-310-01
ALZ Series (12 Volt Alternator) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-350-01
ANG Series (24 Volt Alternator) (Obsolete) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-390-01
ES4000 Series (12/24 Volt Alternator) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-430-01
Continued Airworthiness Information (component only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-470-01
Chart 1: Periodic Inspection BELT Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-480-01
Chart 2: Periodic Inspection GEAR Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-490-01
Chart 3: Troubleshooting System BELT Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-500-01
Chart 4: Troubleshooting System GEAR Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-510-01
Discussion for Troubleshooting BELTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-520-01
Chart 5: Troubleshooting BELT only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-530-01
Special Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-550-01
Sudden Stoppage BELT Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-550-01
Sudden Stoppage GEAR Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-550-01
Lightning Strike . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-560-01
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-570-01
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-570-01
Parts Identification & Serialization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-570-01
NOTE:
Service information for ES-6000, ES-7000, ES-10024, ES-10024B, ES-6024D series
alternators or for HET Jasco, ASG, and Plane Power style alternators are not included
in this manual. Instruction for these alternators may be found in other HET manuals
or publications.

Before You Start Work, Observe Warnings and Precautions
(Applies to all alternators included in this Chapter.)
WARNING 1: WHEN DISCONNECTING THE AIRCRAFT BATTERY OR
!
EXTERNAL POWER, NOTE THAT THE ENGINE MAGNETO MAY STILL BE
LIVE. TAG THE PROPELLER “DO NOT MOVE” BEFORE ANY SERVICE OR
TESTING IS PERFORMED. FAILURE TO DO SO MAY RESULT IN INJURY OR
DEATH SHOULD THE ENGINE “KICK OVER” OR START.
WARNING 2: MAKE SURE THAT ALL ELECTRICAL EQUIPMENT IS IN
!
THE OFF OR IN AN INACTIVE POSITION PRIOR TO RE-CONNECTING THE
AIRCRAFT BATTERY OR EXTERNAL POWER. ITEMS SUCH AS STARTER,
LANDING GEAR, AND FLAPS TO NAME A FEW MAY SUDDENLY ACTIVATE
WHEN POWER IS APPLIED. FAILURE TO DO SO MAY RESULT IN
EQUIPMENT DAMAGE, AND INJURY OR DEATH SHOULD SHOULD
COMPONENTS ACTIVATE.
PRECAUTIONS TO BE OBSERVED WHEN TESTING OR SERVICING THE ELECTRICAL SYSTEM:

1. MAKE FIRE EXTINGUISHER AVAILABLE (for fuel or electrical fires) in a
convenient location whenever working on the electrical system.
2. DISCONNECT THE BATTERY (and/or external power) before connecting or
disconnecting test instruments (except voltmeter), or before removing or replacing any
unit or wiring. Accidental grounding or shorting at the regulator, alternator, ammeter
or accessories, will cause severe damage to the units and/or wiring.
3. The output lead must not be removed from the alternator while the rotor winding is
energized and the alternator is operating.
4. DO NOT ATTEMPT TO POLARIZE THE ALTERNATOR. No polarization is
required. Any attempt to do so may result in damage to the alternator, regulator or
aircraft electrical circuits.
5. Grounding of the alternator output terminal may damage the alternator and/or aircraft
electrical circuit.
6. Reversed battery connections may damage the rectifiers, aircraft wiring or other
components of the charging system. Battery polarity should be checked with a
voltmeter before connecting the battery.
7. If a booster-battery or fast-charger is used, its polarity must be connected correctly to
prevent damage to the electrical system components.
8. When using external power (with or without battery power) be certain that the external
power is of the correct voltage and capacity prior to engaging or applying the power.
Should the incorrect voltage or capacity be used severe damage will occur to electrical
system and it’s components.

ALE Series
Service Information
…………………………………….
12 Volt Alternator
ALTERNATOR DESCRIPTION:
Rated Voltage: 12
Rated Output: 40 Amperes
Rotation: Bi-Directional
Grounded Polarity: Negative
Approximate Weight: See Tabulation
SERVICE INFORMATION:
Detailed service procedures covering disassembly, component testing, component
replacement, assembly and bench testing, are contained in the Maintenance and Overhaul
Information located in section 4 of this manual. Refer to the following service publications
when detailed service information is required. (See page 3-20-01 prior to starting work.)
Alternator Series: Overhaul Information:

ALE-6500 to ALE-8500 ES1001
SERVICE BULLETINS:
Refer to the Service Bulletin Section of this manual for bulletins pertaining to the ALE Series
alternators.
SERVICE SPECIFICATIONS:
Bearing Test Prior to Disassembly (Inspection or Repairs):
Before disassembling the alternator, a simple bearing test should be performed regardless of
the reason for alternator removal from the engine. The purpose of the test is to determine if
either of the bearings are a potential for noise or failure.

To perform a test for faulty bearings, hold the alternator in one hand and snap-spin the
pulley/shaft with the other. A defective bearing will be heard or felt. In noisy locations, press
the alternator adjusting ear to your ear lobe and snap-spin the pulley/shaft a few times.
To determine which bearing is defective, separate the alternator into its two major assemblies.
Snap-spin the rotor with only the front bearings supporting the shaft, as a method for
determining the condition of the front bearing. The rotor shaft must be held in a vertical plane
in order to avoid misleading results caused by unbalanced bearing loading.
Inspect rear bearing surface of rotor shaft for nicks, chatter marks, and other surface
irregularities. Inspect rear bearing for damage to rollers, or bearing case. Also look for
missing rollers. If grease is hard and dry when smeared or excessively dirty, the bearing
should be replaced. A good bearing may be lubricated with Chevron SRI #2 or exact
equivalent, however do not repack a dry bearing, replace it. At any overhaul, bearings must
be discarded and replaced with new.
Drive Pulley:
Torque the drive pulley retaining nut to 35 ft.-lbs. minimum to 40 ft.-lbs. maximum.
Rotor Ohmmeter Test Conditions:

1. The rotor is to be at room temperature 70˚-80˚ F (21˚to 26˚C).
2. The ohmmeter must be accurate and the batteries must be fresh. Frequently check the
ohmmeter accuracy by measuring a known resistance such as a 10.0 ohm resistor.
3. The ohmmeter must be checked to zero before and after the rotor test.
4. The slip rings and ohmmeter test probes must be clean, and in good condition.
Rotor Ohmmeter Test Specifications:

The rotor winding resistance is 3.3 to 3.8 ohms @ 25˚C.
Rotor Current Draw Test Conditions:

1. The rotor is to be at room temperature.
2. Voltmeter and ammeter must be accurate.
3. Refer to overhaul manual for the test wiring diagram.
Rotor Current Draw Test Specification:

Current Draw at 12.0 volts is 2.4 to 4.0 amperes.
Slip Ring Refinishing:

Minimum Diameter: 1.350”
Total Indicator Runout: .002” maximum measure from bearing journals
Surface Finish: 50 microinches maximum
Alternator Output Test Conditions:

1. Alternator to be at room temperature 70˚-80˚ F (21˚to 26˚C) before beginning the test.
2. The alternator is to be connected so it is supplying its own field current. Refer to the
overhaul manual referenced above for bench test wiring diagram.

3. The output voltage is to be controlled by an adjustable load.
4. The alternator is not to be run for more than 2 minutes for each test point.
Ventilation:
All units, except the 6500 series, use a slip ring end cover that has a hose type connection for
air pressure ventilation. Remove this cover when bench testing the alternator.
ALTERNATOR OUTPUT TEST SPECIFICATIONS (WITHOUT REGULATOR):

Alternator Series: ALE-6500 and ALE-8500:
Output Voltage: Output Amperage: Minimum Alternator RPM:
14.0 19 2000
14.0 32 4000
Alternator: Approximate Weight: Internal Wiring:

ALE-6520 10 lb. 6 oz. Figure 1
Figure 1 -
Internal
Wiring
Diagram
Overhaul Manual
Overhaul Manual -- Aircraft
Aircraft Alternators
Alternators &
& Starters
Starters
Part Number
Part Number OE-A2
OE-A2 3-50-01

ALH Series
Service Information
…………………………………….
Obsolete - No Longer Supported.
12 Volt Alternator
OBSOLETE




ALM Series
Service Information
…………………………………….
Obsolete - For Reference Only.
24 Volt Alternator
OBSOLETE




ALT Series
Service Information
…………………………………….
24 Volt Alternator
Rated Voltage: 24

ALT-8500 ES1001
ALT-9500 ES1003
SERVICE BULLETINS:
Refer to the Service Bulletin Section of this manual for bulletins pertaining to the ALT Series
alternators.

Drive Pulley:
Coupling Gear:
See Engine Manufacturers Service Information for appropriate torque specifications.

2. The ohmmeter must be accurate, and its batteries must be fresh. Frequently check the


1. The rotor is to be at room temperature.
2. The voltmeter and ammeter must be accurate.
3. Refer to the overhaul manual for the test wiring diagram.



1. The alternator is to be at room temperature 70˚-80˚ F (21˚to 26˚C) before beginning the
test.
2. The alternator is to be connected so that it is supplying its own field current. Refer to the
overhaul manual for the bench test wiring diagram.
4. The alternator is not to be run for longer than 2 minutes for each test point.
Ventilation:
The 8500 Series alternators use a slip ring end cover that has a hose type connection for air
pressure ventilation. Remove this cover when bench testing the alternators.
The 9500 Series alternators are cooled entirely by air pressure through a hose type connection
on the drive end head. When bench testing this type of alternator, make output tests as short
as possible unless adequate air pressure for cooling is supplied.

Alternator Series - ALT-8500:
Output Voltage: Minimum Output Amperage: Minimum Alternator RPM:
28.0 20 3000
28.0 43 6000
Alternator Series - ALT-9500:

28.0 17 3000
28.0 43 6000

ALT-8520 12 lb. 2 oz. Figure 1
ALT-8521, LS 12 lb. 2 oz. Figure 1
ALT-9505, 9522 11 lb. 6 oz. Figure 1
Figure 1 -
Internal
Wiring
Diagram


ALU Series
Service Information
…………………………………….
24 Volt Alternator
Rated Voltage: 24

ALU-6500, ALU-8500 ES1001
ALU-9500 ES1003
SERVICE BULLETINS:
Refer to the Service Bulletin Section of this manual for bulletins pertaining to the ALU Series
alternators.

Drive Pulley:
Coupling Gear:


Rotor winding resistance: 10.1 to 11.7 ohms on all rotors except ALU-2227S (@ 25˚C),
8.4 to 9.2 ohms on ALU-2227S (@ 25˚C).


1. Current Draw at 24.0 volts is 1.9 to 2.3 amperes for all rotors except ALU-2227S.
2. Current Draw at 24.0 volts is 2.5 to 3.0 amperes for ALU-2227S.


test.
Ventilation:
1. The 8500 Series alternators use a slip ring end cover that has a hose type connection for
air pressure ventilation. Remove this cover when bench testing the alternators.
2. The 9500 Series alternators are cooled entirely by air pressure through a hose type
connection on the drive end head. When bench testing this type of alternator, make output
tests as short as possible unless adequate air pressure for cooling is supplied.

Alternator Series - ALU-6500, ALU-8500:
28.0 23 4000
28.0 61 8000
Alternator Series - ALU-9500:

28.0 21 4000
28.0 60 8000

ALU-6521LS 11 lb. 12 oz. Figure 1
ALU-8521, LS 12 lb. 2 oz. Figure 1
ALU-9522 11 lb. 6 oz. Figure 1
Figure 1 -
Internal
Wiring
Diagram


ALV Series
Service Information
…………………………………….
24 Volt Alternator
Rated Voltage: 24
Grounded Polarity: Insulated System

ALV-6000 ES1004
ALV-8000 ES1004
ALV-9000 ES1005
SERVICE BULLETINS:
Refer to the Service Bulletin Section of this manual for bulletins pertaining to the ALV Series
alternators.

Drive Pulley:
Coupling Gear:





Surface Finish : 50 microinches maximum

test.
Ventilation:

Alternator Series - ALV-6000, 8000:
28.0 53 3000
28.0 88 6000
Alternator Series - ALV-9000:

28.0 48 3000
28.0 83 6000

ALV-6403 21 lb. 0 oz. Figure 1

Figure 1 -
Internal
Wiring
Diagram

ALX Series
Service Information
…………………………………….
12 Volt Alternator
Rated Voltage: 12

ALX-6500, ALX-8500 ES1001
ALX-9500 ES1003
SERVICE BULLETINS:
Refer to the Service Bulletin Section of this manual for bulletins pertaining to the ALX Series
alternators.

Drive Pulley:
Coupling Gear:






test.
Ventilation:

Alternator Series - ALX-6500, ALX-8500, ALX-9500:
14.0 33 3000
14.0 57 6000

ALX-6523 11 lb. 12 oz. Figure 1
ALX-8521, LS 12 lb. 2 oz. Figure 1
ALX-9525, B 11 lb. 6 oz. Figure 1
Figure 1 -
Internal
Wiring
Diagram


ALY Series
Service Information
………………………………………
Rated Voltage: 12
12 Volt Alternators

ALY-6500 to ALY-8500 ES1001
SERVICE BULLETINS:
Refer to the Service Bulletin Section of this manual for bulletins pertaining to the ALY Series
alternators.

Drive Pulley:


Rotor winding resistance is 3.3 to 3.8 ohms @ 25˚C.




test.

Ventilation:

Alternator Series - ALY-6500, ALY-8500:
14.0 13.0 2000
14.0 47.0 4000

ALY-6520 10 lb. 6 oz. Figure 1
ALY-6527, R 10 lb. 6 oz. Figure 1

ALY-8520, LS 10 lb. 12 oz. Figure 1
Figure 1 -
Internal
Wiring
Diagram
Figure 2 -
Internal
Wiring
Diagram


ALZ Series
Service Information
…………………………………….
12 Volt Alternator
Rated Voltage: 12
Approximate Weight: 10 lb. 12 oz.

ALZ-8500 ES1001
SERVICE BULLETINS:
Refer to the Service Bulletin Section of this manual for bulletins pertaining to the ALZ Series
alternators.

Drive Pulley:


Rotor winding resistance is 3.3 to 3.8 ohms @ 25˚C.




test.

Ventilation:

Alternator Series - ALZ-8400:
14.0 17.0 2000
14.0 41.0 4000

ALZ-8523 10 lb. 12 oz. Figure 1
Figure 1 -
Internal
Wiring
Diagram

Part Number OE-A2 3-370-01

ANG Series
Service Information 24 Volt Alternator (Obsolete)
…………………………………….….….….….….….
OBSOLETE




ES4000 Series Service
Information
…………………………
Rated Voltage: 12 / 24
Rated Output: 38-130 Amperes
12/24 Volt Alternators


All ES Series Belt Driven Small Frame Alternators ES1006
All ES Series Gear Driven Small Frame Alternators ES1007
All ES Series Belt Driven Large Frame Alternators ES1008
ES4020 Belt Driven Alternators ES1009
SERVICE BULLETINS:
Refer to the Service Bulletin Section of this manual for bulletins pertaining to the ES Series
alternators.

pulley/shaft with the other. A defective bearing will be heard or felt. In noisy locations,
press the alternator adjusting ear to your ear lobe and snap-spin the pulley/shaft a few
times.
To determine which bearing is defective, separate the alternator into its two major
assemblies. Snap-spin the rotor with only the front bearings supporting the shaft, as a
method for determining the condition of the front bearing. The rotor shaft must be held in
a vertical plane in order to avoid misleading results caused by unbalanced bearing loading.
Drive Pulley:
Torque the drive pulley retaining nut: Minimal Ft.-Lbs. Maximum Ft.-Lbs.
ES4000, ES4005, ES4007, ES4009, ES4009LS,
60 100
ES4012, ES4013, ES4013LS, ES4017, ES4024
ES4003 & LS, ES4011 & LS, ES4016, ES4018LS,
ES4019 (all), ES4021, ES4022, ES4023, ES4024L, 67 77
ES4024LP, ES4024LP-3
Torque the drive pulley retaining nut: Minimal Ft.-Lbs. Maximum Ft.-Lbs.
For all Gear Driven Models refer to the Engine Manufacturer for proper torque
NOTE: specifications.

4. The slip rings and ohmmeter test probes must be clean, and in good condition.Rotor
Ohmmeter Test Specifications (Rotor winding resistance @ 25˚C):
Part Number: Minimum: Maximum:

ES4109 11.5 12.5
ES4143 11.5 12.5
ES4144 3.5 5.0
ES4145 3.5 5.0
ES4199 3.0 3.5
ES4200 13.5 13.8
ES4223 11.5 12.5
ES4307 3.4 4.3
ES40005 5.8 6.2
ES40009 5.8 6.2
ES40009-1 5.8 6.2
ES40048 7.0 7.2

Rotor Current Draw Test Specification (Current Draw Amperes):

Part Number: At Volts: Minimum: Maximum:
ES4109 & ES4143 24 1.9 2.1
ES4144 & ES4145 12 2.4 3.4
ES4199 12 3.4 4.0
ES4200 24 1.7 1.8
ES4223 24 1.9 2.1
ES4307 12 3.0 3.3
ES40005 24 3.8 4.1
ES40009 & ES40009-1 24 3.8 4.1
ES40048 24 3.3 3.5
Slip Ring Refinishing (Minimum Diameter):

All Rotors Except ES4307: 1.22”
ES4307: 1.10”

test.

Alternator Series - ES4000 Series:
Alternator Alternator Shaft Output Minimum Approximate
Voltage Current Speed Voltage Output Amp. Weight
15* 60 5400 15 58 10 lbs. 5 oz.
15 80 5000 15 61 10 lbs. 5 oz.
15 90 5000 15 88 17 lbs.
15 130 4000 15 120 17 lbs.
28 38 3000 28 29 10 lbs. 5 oz.
28 60 4900 28 43 10 lbs. 5 oz.

Alternator Series - ES4000 Series (Con’t):
Alternator Alternator Shaft Output Minimum Approximate
Voltage Current Speed Voltage Output Amp. Weight
28 70 5000 28 45 10 lbs. 5 oz.

28 85 5000 28 65 10 lbs. 5 oz.
28 90 4500 28 86 15 lbs.
28 130 5000 28 80 17 lbs.
* Except ES4020 - Specification as follows:

15 60 2500 15 49 13 lbs.
Reference by Part Number

P/N Volt/Amp Drive
ES4000 15V/60A Belt Driven

ES4000LS 15V/60A Belt Driven
ES4001 15V/60A Gear Driven


ES4024LP 28V/85A Belt Driven

ES4024LP-2 & -3 28V/85A Belt Driven
The alternators listed above are FAA/PMA approved. HET products that are not FAA/PMA approved are the
responsibility of the engine or airframe manufacturer. Parts and overhaul instructions for these alternators are
available only through the Type Certificate (TC) or Supplemental Type Certificate (STC) Holder.

Continued Airworthiness
Information
………………………………………………………
(component level only)
General Information
CAUTION:
THE INSTRUCTIONS HEREIN ARE THOSE MANDATED BY HARTZELL ENGINE
TECHNOLOGIES (HET). THESE LIMITATIONS ARE THE MINIMUM REQUIRED TO
MEET CONTINUED AIRWORTHINESS BUT MAY BE SUPERSEDED BY MORE
STRINGENT REQUIREMENTS AS PUBLISHED BY THE ENGINE, AIRCRAFT,
ROTORCRAFT OR OTHER MANUFACTURER USING THIS COMPONENT IN THEIR
APPLICATION. FAILURE TO OBSERVE THESE INSTRUCTIONS MAY COMPROMISE
THE COMPONENT OR THE APPLICATION IT IS USED IN.
A.1 Airworthiness Limitation Statement

A. The Airworthiness Limitations section is FAA approved and specifies maintenance required under Secs.
43.16 and 91.403 of the Federal Aviation Regulations unless an alternative program has been FAA approved.
A.2 Life Limits
A. The FAA establishes specific life limits for certain component parts as well as the complete alternator. Such
limits require replacement of the identified parts after a specified number of cycles or hours of use.
B. Additions of, or changes to, any life limit for the alternator or alternator components, will be noted in the
Airworthiness Limitation Revision Log.
C. Life Limits
(1) Alternator models and their component parts affected by this manual currently do not have any
life limited parts.
(2) There are no new (or additional) Airworthiness Limitations associated with this equipment.
Airworthiness Limitation Revisions Log
Revision Number Description of Revision
FAA APPROVED

CHART 1
PERIODIC INSPECTION
BELT DRIVEN STYLE ALTERNATOR
General
This chart calls out the various checks and inspections needed to assure reliable and safe operation of the
alternator while in service (instruction for continued airworthiness). They are listed in hours time in service
(TIS) or in calendar time whichever is applicable. Some checks and inspections are one time initial and others
are recurring. This periodic inspection applies to all new, rebuilt, or overhauled belt driven style alternators
produced by Hartzell Engine Technologies LLC (HET). They include but are not limited to all series ALE, ALT,
ALU, ALV, ALX, ALY, ALZ, ES-4000 alternators. ALH, ALM, and ANG are obsolete, however if still in service,
observe this periodic inspection. Specific details for each series may vary and all work must be done utilizing
the latest revision of the HET OE-A2 overhaul and maintenance manual.
Inspection Checks
10 Hours (TIS). (one time)

Perform an initial check of the alternator assembly. Note through bolt security and proper safety wire
application. Re-torque if bolts are found loose*. Check drive belt tension per the aircraft or engine
maintenance instructions or manual. Note drive belt for unusual wear and check pulley for security.
Check for signs of overheating or electrical arcing. Check the cooling duct connection and associated
air inlet for security and cleanliness (if installed). Make sure the alternator assembly is clear of
interference with any engine or airframe structure. Check the alternator to engine mounting bolts for
proper torque per aircraft, rotorcraft and/or engine service instructions or maintenance manual. Check
all terminal hardware for tightness and insulators for condition.

Perform a check of the alternator assembly. Note through bolt security and proper safety wire application.
Re-torque if bolts are found loose*. Check the alternator to engine mounting bolts for proper torque and
check drive belt tension per aircraft and/or engine service instructions or maintenance manual. Note
drive belt for unusual wear and check pulley for security. Check for signs of overheating or electrical
arcing. Check all terminal hardware for tightness and insulators for condition.
100 Hours (TIS) and each 100 hours thereafter. (or each annual inspection, not to exceed 100 hours.)
Perform a check of the alternator assembly. Note through bolt security and proper safety wire application.
Re-torque if bolts are found loose*. Check the alternator to engine mounting bolts for proper torque and
check drive belt tension per aircraft and/or engine service instructions or maintenance manual. Note
drive belt for unusual wear and check pulley for security. Inspect area around the brush holder for soot.
If a large amount of soot appears, remove each brush and check for wear or damaged brushes. If severe
wear has occurred, check slip rings for gouges or scratches. Check for oil leaks at cooling air outlet
spout. Check all terminal hardware for tightness and insulators for condition.
500 Hours (TIS) and each 500 hours thereafter. (or each two years, not to exceed 500 hours.)
Remove each brush and check for wear or damaged brushes. If brush(es) show more than 50% wear,
has chips or damage, or broken brush lead strands, replace brushes (brushes must be replaced as a set
with the brush holder). If brushes are to be reused, return them in the position and orientation as
removed, as a set. Check the alternator to engine mounting bolts for proper torque and check drive belt
tension per aircraft and/or engine service instructions or maintenance manual. Note drive belt for
unusual wear and check pulley for security. Replace if required. Examine insulators for cracks or burns.
Inspect the aluminum housings for condition and for surface corrosion, clean and treat if required. The
recurring 100 hour inspection is not inclusive and must be done in conjunction with this inspection.
Unlimited Hour TBO.

Recommended overhaul or replacement based on condition of alternator assembly. The actual
overhaul time may vary based on cooling, electrical load, and conditions of use. The airframe or engine
manufacturer recommended overhaul or replacement shall supersede this HET recommendation.
* Observe instructions on the red placard installed on many Prestolite & Ford style alternators manufactured or
overhauled by HET.

CHART 2
PERIODIC INSPECTION
GEAR DRIVEN STYLE ALTERNATOR
General
This form calls out the various checks and inspections needed to assure reliable and safe operation of
the alternator while in service (instruction for continued airworthiness). They are listed in hours time in
service (TIS) or in calendar time whichever is applicable. Some checks and inspections are one time
initial and others are recurring. This periodic inspection applies to all new, rebuilt, or overhauled gear
driven style alternators produced by Hartzell Engine Technologies LLC (HET). They include but are
not limited to all series ALT, ALU, ALV, ALX, ES-4000 alternators. ALM is obsolete, however if still in
service, observe this periodic inspection. Specific details for each series may vary and all work must
be done utilizing the latest revision of the HET OE-A2 overhaul and maintenance manual.
Inspection Checks

Perform an initial check of the alternator assembly. Note through bolt security and proper safety
wire application. Re-torque if bolts are found loose*. Check alternator for general security. Check
for signs of overheating or electrical arcing. Check the cooling duct connection and associated
air inlet for security and cleanliness (if installed). Make sure the alternator assembly is clear of
interference with any engine or airframe structure. Check the alternator to engine mounting bolts
for proper torque per aircraft, rotorcraft and/or engine service instructions or maintenance
manual. Check all terminal hardware for tightness and insulators for condition.

Perform a check of the alternator assembly. Note through bolt security and proper safety wire
application. Re-torque if bolts are found loose*. Check the alternator to engine mounting bolts for
proper torque per aircraft, rotorcraft and/or engine service instructions or maintenance manual.
Check for signs of overheating or electrical arcing. Check all terminal hardware for tightness and
insulators for condition.
100 Hours (TIS) and each 100 hours thereafter. (or each annual inspection, not to exceed 100 hours.)
Perform a check of the alternator assembly. Note through bolt security and proper safety wire
application. Re-torque if bolts are found loose*. Check the alternator to engine mounting bolts for
proper torque per aircraft, rotorcraft and/or engine service instructions or maintenance manual.
Inspect area around the brush holder for soot. If a large amount of soot appears, remove each
brush and check for wear or damaged brushes. If severe wear has occurred, check slip rings
for gouges or scratches. Check for oil leaks at cooling air outlet spout. Check all terminal hardware
for tightness and insulators for condition.
500 Hours (TIS) and each 500 hours thereafter. (or each two years, not to exceed 500 hours.)
Remove each brush and check for wear or damaged brushes. If brush(es) show more than 50%
wear, has chips or damage, or broken brush lead strands, replace brushes (brushes must be
replaced as a set with the brush holder). If brushes are to be reused, return them in the position
and orientation as removed, as a set. Remove alternator and check the engine to alternator
gear clutch assembly (If installed) for slippage and condition of gear teeth per TCM’s or other
engine manufacturers service instructions or maintenance manual. Replace if required.
Examine insulators for cracks or burns. Inspect the aluminum housings for condition and for
surface corrosion, clean and treat if required. The recurring 100 hour inspection is not inclusive and
must be done in conjunction with this inspection. Remove the alternator and perform a drive gear
coupling inspection IAW appropriate engine manufacturer publications..
Unlimited Hour TBO.
Recommended overhaul or replacement based on condition of alternator assembly. The actual
overhaul time may vary based on cooling, electrical load, and conditions of use. The airframe or
engine manufacturer recommended overhaul or replacement shall supersede this HET
recommendation.
* Observe instructions on the red placard installed on many Prestolite & Ford style alternators manufactured
or overhauled by HET.

CHART 3
GENERAL TROUBLESHOOTING FOR BELT DRIVEN STYLE ALTERNATOR
General troubleshooting consists of five areas of trouble in an alternator. Choose the applicable symptom you are experiencing and
follow the trouble shooting advice as applicable. If corrective action on the alternator is beyond tightening hardware or replacing
the brush holder assembly, the alternator must be sent for overhaul.
1. Symptom: Low or no output

Loose terminal connections: Inspect the terminals, if they will tighten, do so, if not the alternator may need to be disassembled
to replace studs or receptacles. Also observe the wire terminal ends to assure they are crimped properly on the wire and no
corrosion or burns are present.
Worn or broken brushes: Remove and examine brush material, spring, and leads. If spring in broken or the lead is coming out of
brush, or if brush is chipped or worn past 50% replace brush holder assembly.
Loose drive belt: Inspect the condition of the drive belt. If frayed or has age cracks, replace the belt. If the belt is in good condition,
check that the belt seats properly in the pulley. V belt must not bottom out in pulley groove. Apply proper tension per the engine or
aircraft service manual.
2. Symptom: Battery is discharged
Corroded or loose battery cable connectors: If connections to the battery are corroded, disconnect and clean. Clean battery
posts or terminals. If aluminum cable is installed, make sure that corrosion has not spread under the insulation. If severe, replace
cables and connectors. Tighten battery connections.
Defective battery or needs maintenance: Perform normal battery maintenance. Check water level and electrolyte condition,
service per the aircraft service manual. Check for expected battery life, if near or beyond normal life, replace battery.
Accessory load too high for alternator rating: Refer to the AFM or POH (and aircraft service manual) for the maximum allowable
load specification. Equipment installed beyond aircraft load capability, reduce electrical load to meet these limitations.
Voltage regulator malfunction: Check the voltage regulator per the aircraft service manual and adjust if necessary. If adjustment
is not possible, check wiring and replace voltage regulator.
Loose drive belt: Inspect the condition of the drive belt. If frayed or has age cracks, replace the belt. If the belt is in good
condition, check the belt seats properly in the pulley. Apply proper tension per the engine or aircraft service manual.
3. Symptom: Battery is overcharged
Voltage regulator set too high for aircraft operating conditions: Check the voltage regulator setting per the aircraft service
manual. Adjust if necessary. If adjustment is not possible, check the wiring harness before replacing the voltage regulator.
Ground wire loose or broken between regulator and alternator: If wire is broken, make sure there is adequate strain relief and
clear chaffing areas. Repair or replace wire. If loose, tighten connection.
Shorted voltage regulator output - full field condition: Before replacing the voltage regulator, check wiring harness for shorts or
open conditions. If harness is burnt or shows signs of overheating, replace harness. If, wiring is good replace voltage regulator.
4. Symptom: Noisy in operation (mechanical)
Foreign object in cooling duct: Check the duct and inlet to see if debris have entered the alternator and are rubbing or vibrating.
Loose mounting bolts: Inspect mount points for damage and if found overhaul the alternator. If not, re-torque mounting bolts per
the engine or aircraft service manual.
Interference from airframe components or structure: Examine the alternator and large electrical cables for contact or chaffing on
airframe structure. Check and clear any interference areas.
Defective bearing: To perform a test for faulty bearings, hold the alternator in one hand and snap-spin the /shaft with the other. A
defective bearing will be heard or felt. Replace the bearing or overhaul the alternator.
Loose drive belt: Inspect the condition of the drive belt. If frayed or has age cracks, replace the belt. If the belt is in good
condition, check the belt seats properly in the pulley. Apply proper tension per the engine or aircraft service manual.
5. Symptom: Noisy in operation (electrical)
Shorted rectifier (magnetic noise): Place oscilloscope on main electrical bus. If excessive AC is on DC bus, overhaul the alternator.
Insufficient output filtering: Check the RFI filter by performing a capacitance check. Replace RFI filter if defective. In some
cases, additional RFI filters may be installed, be sure that a check is performed on each.
Brush arcing: Remove and examine brush material, spring, and leads. If spring is broken or the lead is coming out of brush, or if
brush is chipped or worn past 50% replace brush holder assembly.
Rough or damaged slip ring surface: If the slip rings show minor surface roughness they may be polished. If the slip rings are
worn or damaged beyond limits, replace the rotor (requires overhaul of alternator).
Loose field or aux terminal connections: Check terminal connections for damage. Provide adequate strain relief to the wiring
and tighten terminals properly.
Loose ground or battery connections: Check ground and battery connections for damage. Provide adequate strain relief to the
cables and tighten properly. (See engine or aircraft service manuals.)
Resistive or arcing circuit breaker: Make a resistance check of the circuit breaker, essentially, there should be no resistance.
Check breaker function. Old circuit breakers should be replaced.
Defective voltage regulator or connector: Check to see if the regulator connector is attached properly. Remove and examine
connector. Look for arcing or overheating. Check wiring harness and replace the voltage regulator if defective.

CHART 4
GENERAL TROUBLESHOOTING FOR GEAR DRIVEN STYLE ALTERNATOR
General troubleshooting consists of five areas of trouble in an alternator. Choose the applicable symptom you are experiencing and
follow the trouble shooting advice as applicable. If corrective action on the alternator is beyond tightening hardware or replacing
the brush holder assembly, the alternator must be sent for overhaul.
1. Symptom: Low or no output

Loose terminal connections: Inspect the terminals, if they will tighten, do so, if not the alternator may need to be disassembled
to replace studs or receptacles. Also observe the wire terminal ends to assure they are crimped properly on the wire and no
corrosion or burns are present.
Worn or broken brushes: Remove and examine brush material, spring, and leads. If spring in broken or the lead is coming out of
brush, or if brush is chipped or worn past 50% replace brush holder assembly.
2. Symptom: Battery is discharged
Corroded or loose battery cable connectors: If connections to the battery are corroded, disconnect and clean. Clean battery
posts or terminals. If aluminum cable is installed, make sure that corrosion has not spread under the insulation. If severe, replace
cables and connectors. Tighten battery connections.
Defective battery or needs maintenance: Perform normal battery maintenance. Check water level and electrolyte condition,
service per the aircraft service manual. Check for expected battery life, if near or beyond normal life, replace battery.
Accessory load too high for alternator rating: Refer to the AFM or POH (and aircraft service manual) for the maximum allowable
load specification. Equipment installed beyond aircraft load capability, reduce electrical load to meet these limitations.
Drive clutch slipping: Inspect the condition of the drive gear clutch. (As installed) This part may be supplied by OE engine
manufacturer or by after market suppliers. Improper tension supplied by this clutch will allow slippage during high alternator output.
Voltage regulator malfunction: Check the voltage regulator per the aircraft service manual and adjust if necessary. If adjustment
is not possible, check wiring and replace voltage regulator.
3. Symptom: Battery is overcharged
Voltage regulator set too high for aircraft operating conditions: Check the voltage regulator setting per the aircraft service
manual. Adjust if necessary. If adjustment is not possible, check the wiring harness before replacing the voltage regulator.
Ground wire loose or broken between regulator and alternator: If wire is broken, make sure there is adequate strain relief and
clear chaffing areas. Repair or replace wire. If loose, tighten connection.
Shorted voltage regulator output - full field condition: Before replacing the voltage regulator, check wiring harness for shorts or
open conditions. If harness is burnt or shows signs of overheating, replace harness. If, wiring is good replace voltage regulator.
4. Symptom: Noisy in operation (mechanical)
Foreign object in cooling duct: Check the duct and inlet to see if debris have entered the alternator and are rubbing or vibrating.
Loose mounting bolts: Inspect mount points for damage and if found overhaul the alternator. If not, re-torque mounting bolts per
the engine or aircraft service manual.
Interference from airframe components or structure: Examine the alternator and large electrical cables for contact or chaffing
on airframe structure. Check and clear any interference areas.
Defective bearing: To perform a test for faulty bearings, hold the alternator in one hand and snap-spin the /shaft with the other. A
defective bearing will be heard or felt. Replace the bearing or overhaul the alternator.
Drive clutch slipping: Inspect the condition of the drive gear clutch. (As installed) This part is supplied by the engine manufacturer.
Improper tension supplied by this clutch will allow slippage during high alternator output. Consult engine service instructions.
5. Symptom: Noisy in operation (electrical)
Shorted rectifier (magnetic noise): Place oscilloscope on main electrical bus. If excessive AC is on DC bus, overhaul the alternator.
Insufficient output filtering: Check the RFI filter by performing a capacitance check. Replace RFI filter if defective. In some
cases, additional RFI filters may be installed, be sure that a check is performed on each.
Brush arcing: Remove and examine brush material, spring, and leads. If spring is broken or the lead is coming out of brush, or if
brush is chipped or worn past 50% replace brush holder assembly.
Rough or damaged slip ring surface: If the slip rings show minor surface roughness they may be polished. If the slip rings are
worn or damaged beyond limits, replace the rotor (requires overhaul of alternator).
Loose field or aux terminal connections: Check terminal connections for damage. Provide adequate strain relief to the wiring
and tighten terminals properly.
Loose ground or battery connections: Check ground and battery connections for damage. Provide adequate strain relief to the
cables and tighten properly. (See engine or aircraft service manuals.)
Resistive or arcing circuit breaker: Make a resistance check of the circuit breaker, essentially, there should be no resistance.
Check breaker function. Old circuit breakers should be replaced.
Defective voltage regulator or connector: Check to see if the regulator connector is attached properly. Remove and examine
connector. Look for arcing or overheating. Check wiring harness and replace the voltage regulator if defective.

DISCUSSION FOR THE
GENERAL TROUBLESHOOTING OF ALTERNATOR BELTS
Although the alternator belt is provided by the airframe or engine manufacturer and those manufacturers normally issue manuals
or instructions regarding their maintenance, the belt is fundamental to the operation of Hartzell Engine Technologies, LLC (HET)
alternator products. As such, some general troubleshooting regarding the belt is offered here to prevent mis-diagnosis of what may seem
to be an alternator fault.
Hartzell Engine Technologies new, rebuilt, or overhauled alternators using belts are provisioned for two basic types of belts via custom
pulley installations. The most common type is the single smooth V belt (large and small width) and the Ribbed V belt type which has
multi V groves but is nearly flat. The basic function of these belts (either type) is to transform rotational energy produced in the engine to
rotational energy required by various accessories that are needed for the aircraft or rotorcraft. The belt system or “drive” may be
simple running from the bell housing to an alternator and nothing else, or it might be complex picking up alternator, A/C compressor,
hydraulic pump, idler pulley’s to name a few. Belt drives are efficient and very safe. However, the more complex, the more difficult
it is to align the “drive”. The troubleshooting coming up will give you some insight into both sound and visual inspection to identify
a belt condition before moving on to the alternator or other component.
If you do determine an alternator is at fault, you should note that Hartzell Engine Technologies sells alternators both with a pulley or
without a pulley due to the desire of engine and airframe manufacturers to use their own custom pulley and belt arrangements. All
HET alternators with a designation of LS are delivered without a pulley. (i.g. ALU-8521LS) HET receives many overhauls and core
alternators which still have an OEM manufacturers pulley attached. This can be very costly as we cannot return used parts, so please
check before returning your alternator!
General Troubleshooting of the belt breaks down to sound detection and visual inspection.
Abnormal belt condition, low belt tension, belt contamination, and belt vibration are other common sources of belt noise. A screeching or
squealing noise that occurs when starting or increasing engine RPM rapidly normally indicates a lack of tension; check belt tension. A
tapping or grinding noise caused by debris imbedded in the under side of the belt can be the cause (it is an unusual occurrence but is
worth checking). Grinding sound also can result from worn or damaged bearings, these must be replaced, to eliminate the noise and
further damage to the alternator. Mechanical noise from vibration can develop over time as drive components such as pulleys and spring
tensioners (if used) wear beyond tolerance, as bearings wear, or as belts wear and stretch allowing brackets and attachments to loosen.
Specific belt noises give clues to misalignment conditions. These noises can occur in both single V type and Ribbed V type belts. Belts
are less likely to generate misalignment noise when they are in new condition. As belts wear, they develop a smooth, glossy surface which
will increase the possibility of noise. This wear condition will be accelerated if misalignment exists between any of the pulleys in the drive
system.
A drive misalignment will make a “Chirp” noise in both the common V belt and the Ribbed V belt. This is caused by entry of the belt
contact surface into the pulley as the V(s) seat into the pulley groove there sill be a chirp that is not repeated as the belt exits. The angle
between belt surface and pulley is the critical factor responsible for causing the "chirp" from a misalignment. Misalignment angle can result
from many different combinations of pulley positions. An in or out “positioning” error and/or an angular “tilt” error are two typical examples.
Misalignment noise is most likely to occur on the shortest span in a drive system, such as between two adjacent accessory pulleys. Proper
pulley alignment is particularly critical in these locations. The common V belt pulley has a generally large groove while the nearly flat
multi-groove pulley has very small grooves guiding the belt both can have considerable misalignment and create the same noises.
Misalignment noise is generally loudest at idle speed and diminishes with increasing engine rpm, often vanishing higher RPM’s. The
presence of high humidity (or a damp belt) often increases the likelihood for misalignment noise to occur. Whenever the pilot complains
of belt noise, it is important to determine the type of noise and under what circumstances it occurs. Repairing a drive misalignment (chirp)
is not likely to resolve a slip noise (squeal) that may be caused by insufficient tension. Find out if the problem is more noticeable when
starting and while the engine is cool (cool damp belt). Is the noise loudest at idle speed, or when accelerating the engine RPM (rapid
changes in RPM speed can cause a belt to slip). Try to recreate the problem in the maintenance run area. If the noise is heard, use a
spray bottle or other source of misting water, mist the belt lightly. If the noise level recedes or goes away for several seconds, then returns,
a misalignment problem is likely. If the noise immediately increases after the belt is sprayed, slipping is likely. If the water spray test is
inconclusive and the noise remains unchanged, the problem is not likely related to drive alignment.
In most applications, the highest occurrence of belt noise due to misalignment will come from short belt spans entering large diameter
pulleys (bell housing groove). Service technicians are encouraged to look for the source of noise wherever these conditions exist. Also,
look at any replaced drive components, such as alternator or the A/C compressor, which may have have a pulley misalignment or pulley
runout condition. Remember, replacing a belt with new will most often cure noise, however, failure to correct conditions responsible for
belt noise will result in the problem returning.
Once it is determined that misalignment exists or a simple belt tensioning is required, the corrective action will be contained in either the
airframe or the engine manufacturers service instructions or maintenance manual. Never attempt to align or tension a drive system
without using the proper tools and manuals!
For additional troubleshooting steps, see chart on page 3-500-01.

CHART 5
Problem Possible Cause Corrective Action
Belt Slippage Lack of tension increase tension

Overloaded drive Reduce load or check pulley size.
Worn pulley or V grooves Replace pulley
Oily drive conditions Clean drive, resolve oil leak
Belt turn over Misaligned drive Realign shafts and pulleys

Worn pulley or V grooves Replace pulley
Heavy Impulse loads Check idler pulley (spring or not).
Check tension.
Excessive vibration Tension v-belt. If tension good,
inspect belt condition or replace.
Broken cords caused by prying Replace belts.
belt over pulley Do not pry belt over pulley
Wrong pulley or belt Check to see if belt rides high or if
belt bottoms out in groove.
Rapid belt wear Worn pulley grooves Replace pulley.

Pulleys misaligned Align the pulleys & brackets.
Mismatched belts (Multi belts only) Replace with matched belts
Belt slippage Increase tension
Pulley diameter too small Check P/N and/or replace pulley.
Overloaded drive Pulley size on components correct?
Belt separated Foreign materials in drive belt Check that pulley are protected.
Belt slippage (over much time) Increase tension or replace belt.
Heavy start up loads Reduce load before starting.
Belts damaged during installation Install new belts properly.
Belt stretch Excessive drive tension Use proper tension

Broken cords using multiple belts Replace belts with matched set
Large misalignment. Realign brackets and pulleys
Belt squeal Belt slippage Increase tension.

Insufficient arc of contact Increase center distance.
Overloaded drive Pulley size on components correct?
Belt chirp Misaligned drive. Align the pulleys & brackets.

Belt tilted in pulley groove. Correct angle of belt.
Belt riding on side of pulley groove. Adjust bracket in or out to seat belt.
Belt bottom cracks High surrounding temperature Provide ventilation

Pulley diameter too small Redesign drive
Belt slippage Increase tension
Overheated Continuous belt slippage Increase tension.

bearings Excessive drive tension Tension drive properly.
Bearings not lubed or damaged. Replace bearings


Special Conditions:
Sudden Engine Stoppage (belt drive):

1. If the aircraft engine has experienced a “sudden stoppage” as defined by the engine
manufacturer, the alternator may be impacted critically by this event. A belt driven
alternator is protected somewhat by the ability of the belt to slip if a sudden stoppage
occurs. Should a seizure of the rotating components inside the alternator occur, the belt
will slip or come off. However the sudden stop may bend the pulley, damage the bearings,
or shift close tolerance parts inside the alternator allowing contact when rotating.
2. If “sudden stoppage” as defined by the engine manufacturer has occurred or the sudden
stoppage caused the belt to twist or come off, the alternator must be inspected. Refer to
the appropriate engine or airframe manuals to remove the alternator. Refer to this chapter
for bearing check and chapter 5 for other tolerance data. Check the following:
1. Belt - Remove belt - check for flat spots, cuts, or broken fabric.
2. Pulley - check for damage such as bending or scarring. Perform a run out check on
the face of the pulley to check for significant mis-shape of the pulley due to bending.
Check the depth and width of the pulley grove where applicable. Check appropriate
engine or airframe manuals for run out spec’s as many pulleys are OE supplied items.
3. Alternator - snap spin the pulley to check for interference between the rotor and stator
and to check for bearing noise. See bearing check section in chapter 3 for the
applicable alternator.
4. Brushes - remove brush holder and remove brushes to check for chipping and other
damage.
5. Pulley Nut - check for fractures and assure proper torque at the completion of these
procedures.
6. If you find damage in steps 2 thru 5, repair or overhaul the alternator. In addition, all
supporting bracketry or mounts associated with the alternator should be inspected per
the appropriate engine or airframe manuals. Assure all steps are taken to properly
return the aircraft to service.
Sudden Engine Stoppage (gear drive):

1. If the engine has experienced “sudden stoppage” as defined by the engine manufacturer,
the alternator may be impacted critically by this event. Although the alternator drive
system is designed with an OEM supplied elastomer drive coupling which protects the
engine from seizure of the rotating components inside the alternator, the coupling may
place unknown strain on the alternator shaft from the sudden stoppage of the engine drive
train. The shaft may be weakened, cracked, or have unseen damage from this event,
setting up for a future failure under normal operating conditions if not thoroughly
inspected.
2. If “sudden stoppage” as defined by the engine manufacturer has occurred, the gear driven
alternator must be removed and overhauled. Refer to the appropriate engine or airframe
manuals to remove the alternator. Item 3 must be performed on any sudden stoppage.

3. If the alternator has been involved in an accident or sudden stoppage, perform magnetic
particle inspection (ASTM E1444) to check the condition of the drive shaft threaded end
and rotor shaft. Fluorescent penetrant inspection (FPI) is required for the remainder of the
components. Use of FPI should be done per ASTM E1417 latest revision (supersedes
MIL-STD-6866). To assure proper FPI inspection, classroom and on the job training is
recommended. Popular manufacturers of FPI include Magnaflux using the MAGNAGLO
kit, Zyglo, using the ZA-70 kit, and Spotcheck using the SK-5 kit. These manufacturers
include complete instruction for use of their product. Magnetic particle or fluorescent
penetrant inspection criteria are not required for units that have experienced normal
operating conditions.
Lightning Strike:
1. Lightning strike is an unpredictable event both in occurrence and in resultant damage. A
lightning bolt entry point may have one or more exit points. On a well bonded aluminum
aircraft, the lightning bolt will stay on the outer surface throughout the aircraft with little
damage to components. The path of the electrical current cannot easily be determined in
most cases because while the current may surge through well bonded areas without
damage, a gap in any metal contact point will result in an arc or flash burn. This is
especially true of rotating parts such as gears or splines.
2. If a report of a potential or actual lightning strike is made, inspect the aircraft for entry
and exit points for the lightning bolt to verify the strike. The purpose is to assure that
there was indeed a strike. The points of entry or exit are generally on the aircraft
extremities such as the wing tip, propeller tips, spinner tip or the tips of tail surfaces.
Commonly, the entry point is a single burn mark and the exit several burn marks or burnt
static wicks. This is important because if there was a strike it may have coursed through
the engine. Cowlings, especially fiberglass or other non-metallic types may not have as
good a bond. Many cowlings will not be well bonded due to frequent removal. This
many times will force the electric charge to take a route through the engine components.
Lightning will arc at any gap.
3. If a strike has occurred, (especially if arc burns appear on the propeller) remove the
alternator and inspect for arc marks. Observe the drive coupling as an arc here may leave
raised metal which will also cause further damage when running (gear driven alternators).
Also observe the mounting areas. Should any damage be noted, overhaul the alternator.
Use the appropriate airframe and engine manufacturers maintenance or service
instructions to accomplish this task.
4 If no indication of arc marks or damage exists, reinstall the alternator and performance
check per the appropriate airframe and engine manufacturers maintenance or service
instructions to accomplish this task.
5. Upon completion, test run the engine per the POH or AFM prior to returning the airplane
or rotorcraft to service. Make an appropriate logbook entry concerning the lightning strike.

Identification:
General:
Use of any part or component not certified or manufactured by HET constitutes altering or
modifying the alternator thus voiding any and all warranties. Furthermore, HET will be relieved
of responsibility for any expressed, implied, or product liability for the alternator that has
non-HET authorized parts installed or any other “unapproved part” as deemed by the FAA. The
owner or overhauling entity will assume full and complete liability for the alternator if
unauthorized parts are used. HET is not responsible for damage (actual or economic) or harm to
the aircraft or it’s occupants from such an altered or modified alternator.
Part Identification and Serialization:
!
WARNING 1: THE USE OF ANY PARTS OTHER THAN THOSE APPROVED BY THE
FAA IS PROHIBITED. PARTS SHOWN IN THE IPL OF THIS MANUAL ARE
FAA/PMA APPROVED AND ARE SUITABLE FOR USE.
WARNING 2: IF YOU SUSPECT THAT YOU HAVE RECEIVED OR USED AN
!
“UNAPPROVED PART” REMOVE THIS PART FROM SERVICE IMMEDIATELY.
CONSULT WITH THE FAA’S SUSPECTED UNAPPROVED PARTS PROGRAM
(SUP). FILE FAA FORM 8120-11 AND SUBMIT IT TO: FEDERAL AVIATION
ADMINISTRATION, OFFICE OF AUDIT AND EVALUATION, AVIATION SAFETY
HOTLINE, ROOM 911, 800 INDEPENDENCE AVENUE, SW, WASHINGTON, DC
20591. (OR) YOU MAY CONTACT THE AVIATION SAFETY HOTLINE AT TEL.
1-800-255-1111 OR 1-866-835-5322. SUBMIT THE FORM AT THE AVIATION
SAFETY HOTLINE EMAIL: 9-AWA-AVS-AAI-SafetyHotline@faa.gov.
This information explains the HET parts numbering system for aircraft alternators, thereby
enabling proper identification of the part in question and facilitating spare parts ordering.
1. Newly manufactured HET alternator assemblies supplied to an original equipment

manufacturer (OEM) are identified with a RED nameplate bearing the OEM part number
and may contain the OEM name or other OEM details. Nameplate style may vary with
age and original manufacturer logo. (See Fig. 3-1.)
NOTE:
THE ORIGINAL NAMEPLATE MUST BE RETAINED IN THE AIRCRAFT
RECORDS WHENEVER THE NAMEPLATE IS REMOVED FOR A FIELD
OVERHAUL.
Fig. 3.1
New OEM
Nameplate

2. Newly manufactured HET alternator supplied as an FAA-PMA assembly is identified with
a RED nameplate bearing the part number as found on the FAA-PMA supplement.
Nameplate style may vary with age and original manufacturer logo. (See Fig. 3.2)
Fig. 3.2
New PMA
Nameplate
3. Overhauled Hartzell Engine Technologies alternator assemblies are identified with a

BLACK nameplate bearing the HET name. The nameplate has fields containing the
original part number and indicating the overhauled part number if applicable. It also will
show OEM and any conditions (mods) that apply to the overhauled unit. (See Fig. 3.3)
Fig. 3.3 - HET Overhaul Nameplate
Each nameplate will indicate overhauled FAA-PMA or overhauled OEM unit. Only
FAA-PMA units may use this manual for overhaul. If repair or overhaul is required on a
unit with an OEM nameplate, the unit must be returned to the OEM.
Conditions typically found on the factory nameplate:
R - suffix after the model no. indicates overhaul on current Kelly or HET units.
R - suffix after the model no. indicates rebuilt on Kelly units. (legacy)
R - suffix after the model no. indicates a PMA on Prestolite units. (legacy)
LP - suffix after the model no. indicates original unit has no pulley installed.
LS - suffix after the model no. indicates original unit has no pulley installed.
RS - suffix after the model no. indicates overhauled unit with no pulley installed.
G - suffix after the model no. indicates ground strap included. (legacy)
RG - suffix after the model no. indicates overhauled with ground strap. (legacy)
L - suffix after the model no. is no longer used.
The conditions above are stamped or etched in the appropriate field and are related to factory
units. Since overhauled units may be OEM, the conditions may relate to the OEM drawing
or other documents and are not defined here. If repair or overhaul is required on a unit with
an overhauled OEM nameplate, the unit must be returned to the OEM. Nameplate style may
vary with age and original manufacturer logo. The Chrysler style alternator overhaul
nameplate is similar but smaller with the data fields rearranged for fit.

5. Field Overhauls:
Agencies other than HET performing field overhaul must permanently affix their own
identification (nameplate) to the unit. The performing facility must include the legend
“Field Overhauled.” with a yellow (golden rod) or equivalent background color, original
nameplate data, plus the performing Repair Station Number and/or Facility Code (or
equivalent identification numbers). All original nameplates must be permanently retained
with the aircraft logbook or maintenance records. The nameplate design should be similar
to the nameplate in Figure 3.3.
The instructions below should be followed:
1. Enter HET's complete part number in top field marked P/N.
2. Enter the serial number, in field marked S/N as taken from unit being overhauled.
3. Enter the original manufacturer's part number type or model designation on this line.
4. Enter the original manufacturer's name and serial number on this line.
Data for lines 3 & 4 should be transferred from the original manufacturer's nameplate.
(See example Fig. 3.4.)
Fig. 3.4 - Example Field Overhaul Nameplate
Serial Number Breakdown:

Hartzell unit H- M 05 0001
Year Code
Month Code
5-Digit Serial No.
Example above: HET unit, 2012, May, first unit of the month (batch)


4
Alternator Maintenance
and
. . . . . . . . Overhaul
. . . . . . . . . . . . . . . . . .Information
................................
Before You Start Work, Observe Warnings and Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20-01

ES1001 – Belt Driven Alternators (ALE, ALT, ALU, ALX, ALY, and ALZ Series) . . . . . . . . . . . . . . . 4-30-01
ES1002 – Gear Driven Alternator (ALM Series Obsolete). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-150-01
ES1003 – Gear Driven Alternators (ALT, ALU, and ALX Series). . . . . . . . . . . . . . . . . . . . . . . . . . . 4-230-01
ES1004 – Belt Driven 100 Amp Alternator (ALV-6000 and ALV-8000 Series) . . . . . . . . . . . . . . . . 4-330-01
ES1005 – Gear Driven 100 Amp Alternators (ALV-9400 & ALV-9500 Series). . . . . . . . . . . . . . . . 4-430-01
ES1006 – Small Frame Belt Drive (ES4000, ES4000-LS, ES4009, ES4009-LS, ES4024/L/LP). . . 4-530-01
ES1007 – Small Frame Gear Driven (ES4001, 4002, 4004, 4006, 4008, and 4029) . . . . . . . . . . . 4-710-01
ES1008 – Large Frame Belt Drive (ES4003, ES4011, ES4011-LS, 4011-1/LS, 4019/LS,
ES4019-3, ES4019-3LS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-890-01
ES1009 – ES4020 Belt Driven Alternator (Chrysler Style). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1070-01
Maintenance and overhaul information for HET ES-6000, ES-7000,

ES-10024, ES-10024B, ES-6024D series alternators or for HET Jasco, ASG,
NOTE: and Plane Power style alternators are not included in this manual. Instruction
for these alternators may be found in other HET manuals or publications.

(Applies to all alternators included in this Chapter.)
WARNING 1: When disconnecting the aircraft battery or

external power, note that the engine magneto may still be
! live. Tag the propeller “DO NOT MOVE” before any service
or testing is performed. Failure to do so may result in
injury or death should the engine “kick over” or start.
WARNING 2: Make sure that all electrical equipment is in

the OFF or in an inactive position prior to re-connecting
! the aircraft battery or external power. Items such
as starter, landing gear, and flaps to name a few may
suddenly activate when power is applied. Failure to do
so may result in equipment damage, and injury or death
should should components activate.
PRECAUTIONS TO BE OBSERVED WHEN TESTING OR SERVICING THE

ELECTRICAL SYSTEM:
1. MAKE FIRE EXTINGUISHER AVAILABLE (for fuel or electrical fires) in a convenient
location whenever working on the electrical system.
disconnecting test instruments (except voltmeter), or before removing or replacing
any unit or wiring. Accidental grounding or shorting at the regulator, alternator,
ammeter or accessories, will cause severe damage to the units and/or wiring.
4. DO NOT ATTEMPT TO POLARIZE THE ALTERNATOR. No polarization is required.
Any attempt to do so may result in damage to the alternator, regulator or aircraft
electrical circuits.
electrical circuit.
components of the charging system. Battery polarity should be checked with a
voltmeter before connecting the battery.
8. When using external power (with or without battery power) be certain that the external
power is of the correct voltage and capacity prior to engaging or applying the power.
Should the incorrect voltage or capacity be used severe damage will occur to electrical
system and it’s components.

Belt Driven Alternators
Maintenance and Overhaul
…………………………………………………………
Covers Alternator Series: ALE, ALT, ALU, ALX, ALY, and ALZ ES1001
Circled items in this chapter
NOTE: represent replacement parts
required at each overhaul.
GENERAL:
HET Belt Driven Aircraft Alternators (Figure
1) are designed and constructed to provide
extended periods of trouble-free operation with
a minimum amount of maintenance. They will
withstand the vibration and extreme temperature
changes encountered in aircraft applications.
This information is provided for use on HET
PMA alternators only. The ALH and ANG Series
alternators are considered obsolete and are no
longer supported by HET.
Figure 1 - Belt Driven Alternator.
DESCRIPTION And principles of operation:
The principle components (Figure 2) of the aircraft alternator are (1) the brush rack assembly,
(2) the slip ring end (SRE) head, (3) the rectifiers, (4) the stator, (5) the rotor (6) the drive
end head and (7) the bearings.
Figure 2 -
Principle
Components
of Belt Driven 4
Alternator.
3
1
7 Fan
2 Backplate
Fan
6
7

1. The brush rack assembly consists of a brush rack housing assembly and two brush
assemblies. Each brush is connected to a separate terminal stud and is insulated
from ground. The brush rack assembly can be easily removed for inspection or brush
replacement without removal or disassembly of the alternator.
2. The slip ring end head provides the mounting for the rectifier mounting plate, output and
auxiliary terminal studs, and the brush rack assembly. The slip ring end head accepts a
needle bearing with integral grease seal.
3. The rectifiers used in these units are rated at 150% Peak Inverse Voltage minimum for
transient voltage protection. Three positive rectifiers are mounted in the rectifier mounting
plate, and three negative rectifiers are mounted in the slip ring end head. Each pair of
rectifiers is connected to a stator lead with high temperature solder. The stator leads are
anchored to the rectifier mounting plate with epoxy cement for vibration protection.
4. The stator consists of a laminated iron core on which three phase windings are wound in
slots around the inside circumference. Leads are connected to each of the three points
of the phase windings, and each lead is connected to a pair of rectifiers, one negative and
one positive. The stator also contains a special lead that is connected to the center of
the three phase windings, and is used to activate low voltage warning systems or relays.
The stator has been treated with a special epoxy varnish for high temperature resistance.
5. The rotor consists of a single field coil encased between two four-pole, interleaved iron
sections assembled on a shaft. The ends of the field coil are connected to a pair of
slip rings, which are insulated from each other and the shaft. The rotor winding has
been specially treated with a high temperature epoxy varnish to provide vibration and
temperature resistance characteristics. High temperature solder is used to secure the
winding leads to the slip rings.
6. The drive end head accepts a sealed, pre-lubricated ball bearing in which the drive end
of the rotor shaft rotates.
7. The bearings support the rotor shaft and carry the radial and thrust loads of the assembly.
ALTERNATOR OVERHAUL INSTRUCTIONS:
When repairing the alternator, complete disassembly may not be required. In some cases
it will only be necessary to perform those operations that are required to affect the repair.
However, in this section, compete overhaul is covered step by step to provide detailed
information on each operation. In actual service practice, these operations may be used as
required. If a return to service tag is to be marked “overhauled”, then each step must be
performed as outlined in this overhaul manual.

CAUTION: When servicing the alternator, all replacement
parts must be original equipment parts manufactured by
! Hartzell Engine Technologies (HET) or an approved HET source.
Failure to use genuine HET replacement parts may result
in serious damage to the alternator or other electrical
system components.
During overhaul the following components must be replaced

NOTE: 1 with new:
1. Brushes and terminal stud
2. Drive end bearing
3. Slip ring end bearing
4. Thru-bolts
5. Rectifiers
6. Lockwashers, terminal stud nuts, and fiber washers
7. Red caution placard (thru bolt torquing label).
NOTE: 2 Before disassembling the alternator, the threads on each terminal stud should be
inspected for signs of arcing. Diode damage is frequently the side effect of arcing.
Arc marks are usually caused by a loose wire terminal connection resulting from
failure to tighten the attaching nut. Arc marks can also be caused by improper
service techniques that permit wires to be connected and disconnected while
current is flowing. A loose connection at the alternator output (battery) terminal
can cause the terminal stud to burn through over time.
Diode damage can occur because of the inductive voltage spikes (similar to
ignition coil sparking action) generated by the make and break of a loose terminal
connection. EACH DIODE must be replaced before the alternator is returned to
service.
(See page 4-20-01 prior to starting work.)
ALTERNATOR DISASSEMBLY:
CAUTION: In order to prevent damage to the blast tube

! assembly, it should be removed before any servicing is
attempted.
1. Remove the two screws that hold the brush holder assembly in the slip ring end head.
Remove the brush rack assembly from the end head and discard the brushes. If the
brush holder assembly has not yet been replaced with the new black injection molded
brush holder assembly, replacement is required at overhaul. Discard the old-style brush
holder assembly and replace it with the new-style brush holder assembly.
2. While holding the pulley with a strap wrench, remove the pulley nut. Remove the pulley
using a puller. Do not attempt to remove the pulley by clamping it in a vise. This will
result in severe damage to the pulley. Remove the fan, woodruff key and spacer from
the shaft. Discard the woodruff key.

3.
Using a marker, scribe across the stator and front and rear housings to determine
alignment during reassembly. Remove the safety wire from the four thru-bolts. Remove
the thru-bolts and discard. Lightly tap the drive end head to separate the drive end head
and rotor, as a unit, from the stator and slip ring end head.
4. Note the correct assembly of the insulators and washers prior to disassembly. Remove
the nuts, lockwashers, flat washers and insulators from the output and auxiliary terminal
studs and discard.
5. Clip the positive and negative rectifier leads as close to the rectifier case as possible. The
slip ring end head can now be separated from the stator assembly. Using appropriate
tools, support the positive rectifier plate and press out the three positive rectifiers and
discard. Using the same tools (Figure 3), support the slip ring end head and press out
the three negative rectifiers and discard.
6. Remove the slip ring end bearing as shown in (Figure

4), making sure to properly support the slip ring end
housing. Discard the slip ring end bearing. If the slip
ring end and rotor have not yet been replaced with
those that utilize the new needle bearing and slip ring
end configuration, then it will be necessary to discard
Figure 3 - Diode Removal. the slip ring end housing and rotor and replace it with
the appropriate kit as outlined in the Service Parts List
Section.
Figure 4 - Slip Ring End

Bearing Removal.
7. To remove the rotor shaft from the drive end

head, use a puller that grips on the bearing
retainer plate as shown in (Figure 5). Do
not attempt to remove it by supporting the
end head and pressing on the shaft, as
this may result in distortion of the end head
or stripping of the retainer plate screws.
Remove the three retainer plate screws,
and press the bearing out of the end head,
(Figure 6). Discard the bearing.
Figure 5 - Rotor Figure 6 - End
Shaft Removal. Head Bearing
Removal.

COMPONENT INSPECTION AND TESTING:
Upon completion of the disassembly, all parts should be cleaned and visually inspected
for cracks, wear, distortion and any signs of overheating or mechanical interference. Any
cracked, worn or distorted parts should be discarded and replaced with new HET parts. All
wear limitations and tolerances are outlined in Section 5 of this manual.
Rotor Assembly: Using a

1.
VOM measure rotor resistance Size: 1/16 Diameter
between slip ring terminals. DO
NOT SCRATCH THE SLIP RING Contents: 60% Tin
SURFACE. Coil resistance for 40% Lead
each Series may be found in the
Service Information section of this Plastic Temperature: Kester “44”
manual. If resistance is higher
than specified, inspect soldered Liquid Temperature: 190o C Approximate
connections at slip ring terminals.
Repair is necessary using a Vendor Source: MSC Industrial Supply
high temperature solder per the Birmingham, Alabama
specification shown in (Figure Or Equivalent
7) with rosin and alcohol flux.
Replace rotor if coil fails resistance Figure 7 - High Temperature Solder
test. Specification.
Using a VOM on RX1000 range, measure resistance between slip ring terminal and
pole piece. No meter movement should occur (infinite resistance). Inspect slip ring and
solder connections to make sure they are not touching shaft. Repair and repeat test as
required. Replace rotor if any meter movement is detected.
CAUTION: Exercise extreme care, so as not to nick or

! scratch the machined copper surface of the slip ring. A
nick or scratch can result in increased brush wear.
To test for shorted turns in the rotor winding, connect a

voltmeter, ammeter, rheostat and battery as shown in
(Figure 8), or use an ohmmeter. The acceptable ranges Ammeter
for rotor current draw and resistance are listed on the
Rheostat
individual service specification pages in the Service Voltmeter
Information section of this manual. Excessive current
draw or a low ohmmeter reading indicates shorted
windings. No current draw or an infinite ohmmeter
reading indicates an open winding. If either case exists, Rotor Battery
discard the rotor and replace with new. No rewound
rotors are approved without factory and FAA approval. Figure 8 - Rotor
Winding Test.

An alternate method for testing the rotor for grounded or shorted windings is to utilize an
appropriate surge/hipot tester, such as the Baker instrument, model ST106A.

The rotor body is to be checked for balance. Unbalance is the single largest source of
vibration. Too much vibration can cause premature failure to the bearings, excessive
wear to the end housings and uneven wear and/or arcing of the brushes. All rotors to be
balanced to .10 ounce inch maximum. Utilize an appropriate balance machine, such as
the American Hofmann Balancing Machine, Model HM-11.1. Refer to the manufacturer
for suitable instructions and settings.

Inspect rotor for any of the following faults and replace if any are detected (with exception
of the slip ring repair noted in step “g”):
a. Stripped shaft threads.
b. Worn key slots/holes (woodruff and cotter).
c. Worn and/or corroded bearing journal surfaces of the drive end and slip ring end.
d. Loose slip ring assembly or pole pieces on shaft.
e. Gouged, bent, cracked or excessive corrosion of pole pieces.
f. Bent, gouged, or excessive corrosion of shaft.
g. Slip rings which are rough or out of round may be trued in a lathe (do not chuck shaft
on bearing journals). Concentricity of slip rings, with respect to bearing journal, must
not exceed 0.002 inch total indicator reading. Remove only enough material to make
slip rings smooth and round. Final surface finish shall be 50 microinches maximum.
The finished slip ring diameter must not be less than 1.350 inches, otherwise rotor
must be replaced. Insure there are no burrs or metal particles on or between slip
rings. Clean dirty slip ring using a non-corrosive chemical degreaser and wipe
residue away with a clean, lint free cloth.
h. Burned/discolored coil (insulation will flake off burned coil). Damaged varnish coating
is not repairable.
Rotor is not serviceable in parts and must be replaced as a whole.
Stator: The stator can be tested for grounded, open or shorted windings using an
2.
ohmmeter, in the following manner.
To test for grounded windings (use VOM on RX1000 range), touch one ohmmeter probe
to any stator lead, and the other ohmmeter probe to the stator frame. If the ohmmeter
indicates continuity, then the stator is grounded and must be discarded. An alternate
method for testing the stator for grounded windings is to utilize an appropriate surge/
hipot tester, such as the Baker instrument, model ST106A. Refer to the manufacturer
To test for open windings, connect one test probe to the stator winding center connection
and touch the other test probe to each of the three stator leads. The ohmmeter should
indicate continuity. If not, then the stator is defective and must be discarded. While this
test will indicate an open-winding condition, it will not detect an imbalance in the winding
resistance between the three winding phases. To test for winding imbalance, use an
appropriate surge/hipot tester such as the Baker instrument model ST106A. Refer to the
manufacturer for suitable instructions and settings.

Due to the low resistance in the stator windings, shorted windings are almost impossible to
locate without an appropriate surge tester. However, shorted stator windings will usually
cause the alternator to “growl” or be noisy during operation and will show some signs of
overheating. If either of these conditions exists, then the stator must be discarded.
If all other electrical checks are normal and the alternator fails to supply its rated output,
the stator should be replaced to determine whether or not it is the faulty component. No
rewound stators are approved without factory and FAA approval.
Pulley, Rotor Shaft, Spacer, Vent Fans, Drive End Head, Slip Ring End
3.
Head, and Bushings: Must be inspected to the tolerance and limitations outlined in
Section 5. Any component not meeting the tolerance requirements of Section 5 must be
replaced with a new or serviceable component.
4. Front and Rear Housing: Clean both housings using a noncorrosive chemical
degreaser to remove grease and dirt. Air dry with filtered low pressure compressed
dry air or wipe dry with clean cloth. Inspect both housings for stripped threads, cracks
on exterior and interior surfaces, and wear and corrosion in the bearing mounting area.
Replace housing at reassembly if any of the above faults are noted.
Mounting Hardware: Inspect any removed metallic hardware, i.e., screws, flat
5.
washers, nuts, bearing retainer plates, bearing ring retainer, shaft spacer, bearing
cover, shaft key, etc., for any damage, wear, corrosion or distortion. Replace any faulty
parts at reassembly. Hardware that will be reused shall be cleaned as required using
noncorrosive chemical degreaser. Air-dry parts using filtered low pressure compressed
dry air or wipe dry with clean, lint free cloth.
6. Insulators (Washers and Spacers): Inspect parts for cracks, deformation, and burn
marks. Parts that are suitable for reuse shall be cleaned as required using isopropyl
alcohol. Any other cleaner may damage insulators. Air-dry parts with filtered low
pressure compressed dry air or wipe dry with clean, lint free cloth.
Brush Holder, Brushes and Springs: Inspect brush holder for cracks and breaks.
7.
If damaged, discard the brush assemblies and replace with new. Inspect two stainless
steel brush springs for any deformation, change in length or spring force. Replace
springs if they are damaged.

ALTERNATOR ASSEMBLY:
CAUTION: In the following steps, do not use a hammer to

seat the bearings or rectifiers, as this may cause damage
! to the components. Use an arbor press or equivalent for
proper installation.
1. Press the drive end bearing into the drive

end head using a flat block of approximately
2” square so that the pressure is exerted
evenly on the outer race of the bearing
(Figure 9). Install the retainer plate and
screws. With the rotor snap ring and
retainer cup in place on the rotor shaft, use
a tool that fits over the shaft and against
the inner bearing race. Press the drive end
head assembly onto the rotor shaft until the Figure 10 -
inner bearing race contacts the snap ring Figure 9 - Drive Drive End
retainer cup (Figure10). End Bearing and Rotor
Installation. Assembly.
2. Making sure to properly support the slip ring end (SRE) housing,
press the slip ring end bearing into the SRE Housing, as shown
in (Figure 11), until the open end of the SRE bearing is flush with
the inner SRE casting surface. Note: Be certain the bearing is
recessed .040” from the outside edge of the housing.
3. Carefully install the negative rectifiers in the slip ring end head
and the positive rectifiers
in the mounting plate by
supporting the unit and
using appropriate tools Figure 11 - Slip
like those illustrated in Ring End Bearing
(Figure 12). Connect Installation.
the stator leads to the
rectifiers using eyelet
terminals and 60/40 Figure 12 - Positive
rosin core solder. and Negative Rectifier
Installation.
CAUTION: When soldering these connections, use solder

! heat sink clamps or pliers on the lead between the solder
joint and the rectifier. Too much heat will damage the
rectifiers.

4. Reassemble the rectifier mounting plate
studs and insulators, making sure they are Nut Lockwasher
in the correct order on the terminal studs,
as shown in (Figure 13). Make sure the Flat Washer
Fiberwasher
stator leads are positioned so that they do
not interfere with the rotor. After the slip End Head
ring end head is completely assembled,
secure the stator leads and rectifier leads Insulator
Rectifier
to the rectifier mounting plate with epoxy. Mounting
Terminal Stud Plate
Install blast tube assembly.
AUXILIARY TERMINAL
Use shop air to dislodge any
NOTE: contaminant’s or debris from
assembled unit. Nut Lockwasher
Flat Washer
Fiberwasher
5. Assemble the slip ring head on to the drive
end head and rotor assembly, and install End Head
the thru-bolts. Spin the rotor to make sure
Insulator
there is no mechanical interference. Torque Rectifier
Mounting Plate
the thru-bolts to 30 to 35 in-lbs. Safety wire Terminal Stud
should be installed in the thru-bolts only OUTPUT (+) TERMINAL
after the unit has been bench tested for
output. Install the shaft spacer, woodruff Figure 13 - Terminal and
key, fan and fan backplate (see Figure 2), Aux Stud Assembly.
pulley, lockwasher, and nut. Using a strap
wrench to hold the pulley, torque the pulley
nut to 35 ft-lbs.
CAUTION: The fan is comprised of two COMPONENTS; the fan,

and the FAN backplate (refer to figure 2). TO ENSURE THE FAN IS
! PROPERY SUPPORTED, The FAN backplate must be installed with
the concave surface facing the fan. REFER TO FIGUREs 14 & 15.
Gap
Zero Gap
Figure 14 - Fan & Backplate: Figure 15 - Fan & Backplate:

CORRECT inCORRECT

6. Install the brush rack assembly and retaining screws. Remove insulated brush retaining
wire from the brush rack assembly. Spin the rotor and check for interference between
the brush holder and rotor. Measure the resistance across the field terminals with an
ohmmeter. The ohmmeter must indicate the amount of rotor resistance listed in the
Alternator Service Information section of this manual. Be sure to install a Red caution
placard P/N QA-234 or QA-235 (as applicable) with the thru bolt torque instructions.
ALTERNATOR BENCH TESTING:

Carbon Pile Jumper Wire
Wiring connections for bench testing the
alternator are shown in (Figure 16). Refer
to the Alternator Service Information Section
for the output test figures. Adjust the carbon
pile, if necessary, to obtain the specified
voltage. After bench testing the alternator, Test
install the safety wire in the thru-bolts. Install Ammeter
the blast tube. The alternator is now ready
for installation on the engine. Always refer
to the airframe manufacturers wiring diagram
Test
when installing the alternator or testing the Voltmeter
alternator on the aircraft.
Figure 16 - Wiring Connections.
PRECAUTIONS TO BE OBSERVED WHEN TESTING OR SERVICING THE ELECTRICAL

SYSTEM:
(See page 4-20-01 for additional precautions prior to starting work.)
1. DISCONNECT THE BATTERY (and/or external power) before connecting or disconnecting

test instruments (except voltmeter), or before removing or replacing any unit or wiring.
Accidental grounding or shorting at the regulator, alternator, ammeter or accessories, will
cause severe damage to the units and/or wiring.

Any attempt to do so may result in damage to the alternator, regulator or aircraft electrical
circuits.
electrical circuit.
components of the charging system. Battery polarity should be checked with a voltmeter
before connecting the battery.


Bushing for Slip Ring End Head Assembly - Belt Drive:
BBushing Part Number Alternator Type

ALE-20 ALE Series
ALE-24 ALT Series

ALE-24 ALU Series
ALE-24 ALX Series
ALE-20 ALY Series
ALE-20 ALZ Series
Bushing for Drive End Head Assembly - Belt Drive:
Bushing Part Number Alternator Type

All Head Assembly ALE-20
All measurements are in inches. A component MUST be discarded and replaced

NOTE:
with a new or serviceable component if any serviceable limit or tolerance not met.
! CAUTION: No weld repairs are PERMITTED.


Gear Driven Alternators
…………………………………………………………
Covers Alternator Series: ALM (obsolete and no longer supported) ES1002
OBSOLETE
Figure 1 - Gear Driven Alternator.








Gear Driven Alternators
…………………………………………………………
Covers Alternator Series: ALT, ALU, and ALX ES1003
NOTE:
represent replacement parts
GENERAL:
The HET Gear Driven Alternators (Figure 1) have

been designed and constructed to provide extended
periods of trouble-free operation with a minimum
amount of maintenance. They will withstand the
vibration and extreme temperature changes
encountered in aircraft applications. This
information is provided for use on HET PMA
alternators only.
DESCRIPTION AND PRINCIPLES OF OPERATION:

(2) the slip ring end head, (3) the rectifiers, (4) the stator, (5) the rotor (6) the drive end head
and (7) the bearings.
Figure 2 -
Principle
Components 4
of ALT, ALU,
and ALX
3
1
Alternator. 2
6
7

1. The brush rack assembly consists of a brush rack housing assembly and two brush
assemblies. Each brush is connected to a separate terminal stud and is insulated from
ground. The brush rack assembly can be easily removed for inspection or brush
replacement without removal or disassembly of the alternator.
2. The slip ring end head provides the mounting for the rectifier mounting plate, output and
auxiliary terminal studs, and the brush rack assembly. The slip ring end head accepts a
needle bearing with integral grease seal.
transient voltage protection. Three positive rectifiers are mounted in the positive rectifier
mounting plate, and three negative rectifiers are mounted in the negative rectifier plate.
Each pair of rectifiers is connected to a stator lead with high temperature solder. The
stator leads are anchored to the rectifier mounting plate with epoxy cement for vibration
protection.
slots around the inside circumference. Leads are connected to each of the three points of
the phase windings, and each lead is connected to a pair of rectifiers, one negative and one
positive. The stator also contains a special lead that is connected to the center of the three
phase windings, and is used to activate low voltage warning systems or relays. The stator
has been treated with a special epoxy varnish for high temperature resistance.
sections assembled on a shaft. The ends of the field coil are connected to a pair of slip
rings, which are insulated from each other and the shaft. The rotor winding has been
specially treated with a high temperature epoxy varnish to provide vibration and
6. The drive end head accepts a sealed, pre-lubricated ball bearing in which the drive end of
the rotor shaft rotates.

When repairing the alternator, complete disassembly may not be required. In some cases it
will only be necessary to perform those operations that are required to affect the repair.

CAUTION: WHEN SERVICING THE ALTERNATOR, ALL REPLACEMENT PARTS
!
MUST BE ORIGINAL EQUIPMENT PARTS MANUFACTURED BY HET OR AN
APPROVED HET SOURCE. FAILURE TO USE GENUINE HET REPLACEMENT
PARTS MAY RESULT IN SERIOUS DAMAGE TO THE ALTERNATOR OR OTHER
ELECTRICAL SYSTEM COMPONENTS.
During overhaul the following components must be replaced with new:

NOTE: 1
1. Brushes and terminal stud
4. Thru-bolts
5. Shaft seal o-ring
6. Rectifiers
NOTE: 2
Before disassembling the alternator, the threads an each terminal stud should be
inspected for signs of arcing. Diode damage is frequently the side effect of
arcing. Arc marks are usually caused by a loose wire terminal connection
resulting from failure to tighten the attaching nut. Arc marks can also be caused
by improper service techniques that permit wires to be connected and
disconnected while current is flowing. A loose connection at the alternator output
(battery) terminal can cause the terminal stud to burn through over time.
service.
1. Remove the cotter pin, nut, drive gear assembly and woodruff key. Note: The drive gear
assembly is not a Hartzell Engine Technologies part. It is serviced by the engine
manufacturer.
2. Using a marker, scribe across the stator, front and rear housings to determine alignment
during reassembly. Remove the two screws that hold the brush holder assembly in the slip
ring end head. Remove the brush rack assembly from the end head and discard the
brushes. If the brush holder assembly has not yet been replaced with the new black
injection molded brush holder assembly, replacement is required at overhaul. Discard the
old-style brush holder assembly and replace it with the new-style brush holder assembly.
3. Remove the safety wire from the four thru-bolts. Remove the thru-bolts and discard.
Lightly tap the drive end head to separate the drive end head and rotor, as a unit, from the
stator and slip ring end head.

4. Note the correct assembly of the insulators and washers prior to disassembly. Remove the
nuts, lockwashers, flat washers and insulators from the output and auxiliary terminal studs
and discard.
5. Clip the positive and negative rectifier leads as close to

the rectifier case as possible. The slip ring end head can
now be separated from the stator assembly. Using
appropriate tools, support the positive rectifier plate and
press out the three positive rectifiers and discard. Using
the same special tools (Figure 3), support the slip ring
Fig. 3 - Diode Removal Press

end head and press out the three negative rectifiers and
discard.
6. Remove the slip ring end bearing as shown in

(Figure 4), making sure to properly support the slip
ring end housing. Discard the slip ring end bearing.
If the slip ring end and rotor have not yet been
replaced with those that utilize the new needle
bearing and slip ring end configuration, then it will
be necessary to discard the slip ring end housing and
rotor and replace it with the appropriate kit as Figure 4 - Slip Ring End
Head Bearing Removal.
outlined in the Service Parts List Section.
To remove the rotor shaft from the drive end head, support the end head and carefully
press out the rotor assembly. Remove the three retainer plate screws, and press the bearing
out of the end head. Discard the bearing. Note: For alternator part number ALX-9525, a
snap ring is used instead of the retainer plate. Remove the snap ring before attempting to
remove the bearing. Once the bearing is removed, the oil seal may be removed from the
inside of the housing.

Upon completion of the disassembly, all parts should be cleaned and visually inspected for
cracks, wear, distortion and any signs of overheating or mechanical interference. Any
1. Rotor Assembly: Using a VOM measure rotor resistance between slip ring terminals. DO
NOT SCRATCH THE SLIP RING SURFACE. Coil resistance for each Series may be
found in the Service Information Section of this manual. If resistance is higher than
specified, inspect soldered connections at slip ring terminals. Repair is necessary using a

high temperature solder per the Size: 1/16 Diameter
specification shown in (Figure 5)
with rosin and alcohol flux. Contents: 60% Tin
Replace rotor if coil fails 40% Lead
resistance test.
Plastic Temperature: Kester “44”
Using a VOM on RX1000 range,
measure resistance between slip Liquid Temperature: 190o C Approximate
ring terminal and pole piece. No
meter movement should occur Vendor Source: MSC Industrial Supply
(infinite resistance). Inspect slip Birmingham, Alabama
ring and solder connections to or Equivalent
Figure 5 - High Temperature Solder Specification.

make sure they are not touching
shaft. Repair and repeat test as
required. Replace rotor if any
meter movement is detected.
!
CAUTION: EXERCISE EXTREME CARE, SO AS NOT TO NICK OR
SCRATCH THE MACHINED COPPER SURFACE OF THE SLIP RING. A
NICK OR SCRATCH CAN RESULT IN INCREASED BRUSH WEAR.

Ammeter
(Figure 6), or use an ohmmeter. The acceptable ranges
for rotor current draw and resistance are listed in the Rheostat
Voltmeter
Service Information Section of this manual. Excessive
current draw or a low ohmmeter reading indicates
shorted windings. No current draw or an infinite
ohmmeter reading indicates an open winding. If either Rotor Battery
Figure 6 - Test Rotor

case exists, discard the rotor and replace with new. No
Field Current Draw.

rewound rotors are approved without factory and FAA
approval.
appropriate surge/hipot tester, such as the Baker instrument, model ST106A.
vibration. Too much vibration can cause premature failure to the bearings, excessive wear
to the end housings and uneven wear and/or arcing of the brushes. All rotors are to be

Inspect rotor for any of the following faults and replace if any are detected (with exception
of the slip ring repair noted in step “g”):
must be replaced. Insure there are no burrs or metal particles on or between slip rings.
Clean dirty slip ring using a noncorrosive chemical degreaser and wipe residue away
with a clean, lint free cloth.
h. Burned/discolored coil (insulation will flake off burned coil). Damaged varnish
coating is not repairable.
2. Stator: The stator can be tested for grounded, open or shorted windings using an
method for testing the stator for grounded windings is to utilize an appropriate surge/hipot
tester, such as the Baker instrument, model ST106A. Refer to the manufacturer for
suitable instructions and settings.
Due to the low resistance in the stator windings, shorted windings are almost impossible
to locate without an appropriate surge tester. However, shorted stator windings will
usually cause the alternator to “growl” or be noisy during operation and will show some
signs of overheating. If either of these conditions exists, then the stator must be discarded.

3. Rotor Shaft, Spacer, Drive End Head, and Slip Ring End Head: Must be inspected to the
tolerance and limitations outlined in Section 5. Any component not meeting the tolerance
requirements of Section 5 must be replaced with new or serviceable component.
4. Front and Rear Housing: Clean both housings using a non-corrosive chemical degreaser
to remove grease and dirt. Air dry with filtered low pressure compressed dry air or wipe
dry with clean cloth. Inspect both housings for stripped threads, cracks on exterior and
interior surfaces, and wear and corrosion in the bearing mounting area. Replace housing
at reassembly if any of the above faults are noted.
5. Mounting Hardware: Inspect any removed metallic hardware, i.e., screws, flat washers,
nuts bearing retainer plate, bearing snap ring retainer, shaft spacer, bearing cover, shaft
key, etc., for any damage, wear, corrosion, or distortion. Replace any faulty parts at
reassembly. Hardware that will be reused shall be cleaned as required, using a non-
corrosive chemical degreaser. Air-dry parts using filtered low pressure compressed dry air
or wipe dry with clean, lint free, cloth.
6. Insulators (Washers and Spacers): Inspect parts for cracks, deformation, and burn marks.
Parts that are suitable for reuse shall be cleaned as required using isopropyl alcohol. Any
other cleaner may damage insulators. Air-dry parts with filtered low pressure compressed
7. Brush Holder, Brushes and Springs: Inspect brush holder for cracks and breaks. If
damaged, discard the brush assemblies and replace with new. Inspect two stainless steel
brush springs for any deformation, change in length or spring force. Replace springs if
they are damaged.
CAUTION: IN THE FOLLOWING STEPS, DO NOT USE A HAMMER TO SEAT
!
THE BEARINGS OR RECTIFIERS, AS THIS MAY CAUSE DAMAGE TO THE
COMPONENTS. USE AN ARBOR PRESS OR EQUIVALENT FOR PROPER
INSTALLATION.
1. Install the oil seal with the lip toward the outside of the drive end head. Press the oil seal
in approximately 1/16” below the edge of the casting. The correct assembly of the drive
end oil seals is shown in (Figure 7, page 4-300-01).

2. Press the drive end bearing into the
drive end head using a flat block of 1/16” Bellow Casting
approximately 2" square so that the

pressure is exerted evenly on the
outer race of the bearing. Install the Oil Seal D.E. Head
retainer plate and screws. Note: For
alternator part number ALX-9525B, a Sealed Side Collar
snap ring is used instead of the of Bearing
retainer plate (install with concave Rotor

Shaft
curve of snap ring facing slip-ring
end). Once the bearing has been
installed, insert the snap ring into the Bearing O-Ring Seal
snap ring groove. With the rotor snap

ring and retainer cup in place on the
Bearing
rotor shaft, use a tool that fits over the Retainer
shaft and against the inner bearing
Figure 7 - Drive End

race, and press the drive end
Oil Seals Assembly.

assembly on to the rotor shaft until
the inner bearing race contacts the
snap ring retainer cup. Install the
collar and o-ring onto the rotor shaft
(refer to Figure 7).
3. Making sure to properly support the slip ring end (SRE) housing, press the SRE bearing
into the SRE housing, as shown in (Figure 8), until the open end of the SRE bearing is
flush with the inner SRE casting surface. Note: Be certain the
bearing is recessed .040” from the outside edge of the housing.
4. Carefully install the negative rectifiers in the slip ring end head and
the positive rectifiers in the mounting plate by supporting the unit
and using tools like those illustrated in (Figure 9). Connect the
stator leads to the rectifiers, and solder using 60/40 rosin core
solder. Install blast tube assembly.
Figure 8 - Slip
Ring End Bearing
Installation.
Use shop air to dislodge any contaminant's
Figure 9 - Rectifier NOTE:

or debris from assembled unit.
Installation.
!
CAUTION:WHEN SOLDERING THESE CONNECTIONS, USE SOLDER
HEAT SINK CLAMPS OR PLIERS ON THE LEAD BETWEEN THE
SOLDER JOINT AND THE RECTIFIER. TOO MUCH HEAT WILL
DAMAGE THE RECTIFIERS.

5. Reassemble the rectifier mounting plate
Nut Lockwasher
studs and insulators, making sure they
are in the correct order on the terminal
Flat Washer
Fiberwasher
studs, as shown in (Figure 10). Make
sure the stator leads are positioned so
End Head
that they do not interfere with the rotor.
Insulator After the slip ring end head is completely
Rectifier
Mounting assembled, secure the stator leads and
AUXILIARY TERMINAL
Plate
Terminal Stud rectifier leads to the rectifier mounting
plate with epoxy.
6. Assemble the slip ring head on to the

Nut Lockwasher drive end head and rotor assembly, and
Flat Washer
Fiberwasher install the thru-bolts. Spin the rotor to
make sure there is no mechanical
End Head interference. Torque the thru-bolts to 30
Rectifier
Insulator to 35 in-lbs. Safety wire should be
Mounting Plate installed in the thru-bolts only after the
OUTPUT (+) TERMINAL
Terminal Stud
unit has been bench tested for output.
Figure 10 - Terminal and
Aux Stud Assembly.
7. Install the brush rack assembly and retaining screws. Spin the rotor and check for
interference between the brush holder and rotor. Remove insulated brush retaining wire
from brush rack assembly. Measure the resistance across the field terminals with an
ohmmeter. The ohmmeter must indicate the amount of rotor resistance listed in the
Service Information Section of this manual.
8. Install the woodruff key, drive gear assembly, nut and cotter pin. Torque the coupling gear
nut. Refer to the engine manufacturer specifications for proper torque. Be sure to install
a Red caution placard P/N QA-234 or QA-235 (as applicable) with the thru bolt torque
instructions.

Jumper Wire
Wiring connections for bench testing the Carbon Pile
alternator are shown in (Figure 11). Refer
to the Alternator Service Information
Section for the output test figures. Adjust
the carbon pile, if necessary, to obtain the
specified voltage. After bench testing the Test
Ammeter
alternator, install the safety wire in the thru-
bolts. The alternator is now ready for
installation on the engine. Always refer to
Test Voltmeter
the airframe manufacturers wiring diagram
when installing the alternator or testing the
alternator on the aircraft.

!
CAUTION: ALL GEAR DRIVEN ALTERNATORS REQUIRE A SOURCE OF
VENTILATION. DO NOT TEST THESE ALTERNATORS AT FULL RATED
OUTPUT FOR MORE THAN 30 SECONDS.

ELECTRICAL SYSTEM:

unit or wiring. Accidental grounding or shorting at the regulator, alternator, ammeter or
accessories, will cause severe damage to the units and/or wiring.

circuits.
electrical circuit.

prevent damage to the electrical system components. Any attempt to do so may result in
damage to the alternator, regulator or circuits.

Belt Driven, 100 Ampere
…………………………………………………………
Covers Alternator Series: ALV-6400 and ALV-8500 Series ES1004
NOTE:
GENERAL:
The HET Belt Driven, 100 ampere Alternators are designed and constructed to provide heavy-
duty service for extended periods of trouble-free operation with a minimum amount of
maintenance. They will withstand the vibration and extreme temperature changes
encountered in aircraft applications. The ALV-6400 and ALV-8500 Series alternators are no
longer in production; therefore, parts availability may be limited. This information is
provided for use on HET PMA alternators only.

(2) the slip ring end head, (3) the rectifiers, (4) the stator, (5) the rotor, (6) the drive end head,
(7) the bearings, (8) blast tube.
Figure 1 -
Principle
Components
of ALV-8500
Series
5
7
Alternator. 6
8
2
7
1
3
1. The brush set consists of two brushes, one of which is connected to the positive field
terminal stud, and the other is connected to the negative field terminal stud.

2. The slip ring end head provides the mounting for the rectifier mounting plate, output,
auxiliary and ground terminal studs, the brush rack assembly and the slip ring end bearing.
protection.

!
PARTS MAY RESULT IN SERIOUS DAMAGE TO THE ALTERNATOR OR
OTHER ELECTRICAL SYSTEM COMPONENTS AND MAY RESULT IN INJURY.

NOTE: 1 1. Brushes and terminal studs
4. Thru-bolts
5. Lock tab washers
6. Rectifiers
8. O-rings
NOTE: 2
Diode damage can occur because of the inductive voltage spikes (similar to ignition
coil sparking action) generated by the make and break of a loose terminal connection.
EACH DIODE must be replaced before the alternator is returned to service.
!
CAUTION: IN ORDER TO PREVENT DAMAGE TO THE BLAST TUBE ASSEMBLY,
IT SHOULD BE REMOVED BEFORE ANY SERVICING IS ATTEMPTED.
1. Using a marker, mark across the stator, front

and rear housings to determine alignment during
reassembly. Straighten the ears on the lock tab
washers and remove the three thru-bolts and
blast tube assembly if applicable.
2. Remove the slip ring end bearing cover.

This can be accomplished by wedging a
small, sharp object, such as a chisel, between
the cover and the slip ring end head as Fig. 2 - Bearing Fig. 3 - SRE/ Rotor
Cover Removal. Shaft Removal.
shown in (Figure 2).
3. Use a puller, as shown in (Figure 3), to press the rotor shaft out of the slip ring end
bearing. Separate the drive end head and rotor, as a unit, from the stator and slip ring end
head, being careful not to lose the brush springs while separating the units.

4. Remove the nuts, lockwashers, flat washers and insulators from the output, ground, and
auxiliary terminal studs and discard. The slip ring end head can now be separated from
the stator and heat sink assemblies. After removing the snap ring, the slip ring end bearing
can be pushed out from the inside of the end head. Remove the o-rings from the end
housing and discard.
NOTE:
Early series ALV alternators used only one o-ring in the slip ring end head.
It is required that any single-groove slip ring end housing be replaced with
the newer, double-groove end head. Refer to the Service Parts List section
for the correct housing part number.
slip ring end head can now be separated from the stator assembly. Support the rectifier
plates and press out the rectifiers and discard. Note: If the rectifiers are soldered into
the rectifier plates, then discard the rectifier plate assemblies, and replace with newer
style press in rectifier plate assemblies.
6. Each brush is connected to a terminal stud that is insulated and mounted through the slip
ring end head. Remove the negative and positive brush and terminal stud assembly from
the slip ring end housing and discard. Service brushes come complete with the terminal
studs attached. Remove the two screws securing the brush holder to the slip ring end head.
This is easily accomplished once the alternator is disassembled.
7. Remove the drive components from the rotor shaft. Note: The
pulley is not manufactured by HET.
8. To remove the rotor shaft from the drive end head, use a puller that
grips on the bearing retainer plate as shown in (Figure 4). Do not
attempt to remove it by supporting the end head and pressing on
the shaft, as this may result in distortion of the end head or
stripping of the retainer plate screws. Remove the three retainer
plate screws, and press the bearing out of the drive end head.
Figure 4 - Rotor
Discard the bearing.
Shaft Removal.

1. Rotor Assembly: Using a VOM measure rotor resistance between slip ring terminals. DO
NOT SCRATCH THE SLIP RING SURFACE. Coil resistance for each Series may be
found in the Service Information Section of this manual. If resistance is higher than

specified, inspect soldered
Size: 1/16 Diameter
connections at slip ring terminals.
Repair is necessary using a high
Contents: 60% Tin
temperature solder per the
40% Lead
with rosin and alcohol flux. Replace
rotor if coil fails resistance test.
Liquid Temperature: 190o C Approximate
Using a VOM on RX1000 range,
measure resistance between slip
Vendor Source: MSC Industrial Supply
ring terminal and pole piece. No
Birmingham, Alabama
meter movement should occur
Or Equivalent
(infinite resistance). Inspect slip
Figure 5 - High Temperature Solder Specification.

ring and solder connections to
make sure they are not touching
shaft. Repair and repeat test as
required. Replace rotor if any
meter movement is detected.
! SCRATCH THE MACHINED COPPER SURFACE OF THE SLIP RING. A


Ammeter
Rheostat for rotor current draw and resistance are listed on the
Voltmeter
individual service specification pages in the Service
Information Section of this manual. Excessive current
draw or a low ohmmeter reading indicates shorted
Rotor Battery windings. No current draw or an infinite ohmmeter
Figure 6 - Test Rotor Field

reading indicates an open winding. If either case exists,
Current Draw.
discard the rotor and replace with new. No rewound
rotors are approved without factory and FAA approval.
An alternate method for testing the rotor for grounded

or shorted windings is to utilize an appropriate
surge/hipot tester, such as the Baker instrument, model
ST106A.
vibration. Too much vibration can cause premature failure to the bearings, excessive wear
to the end housings and uneven wear and/or arcing of the brushes. All rotors to be

Inspect rotor for any of the following faults and replace rotor if any are detected (with the
exception of the slip ring repair noted in step “g”):
Clean dirty slip ring using a non-corrosive chemical degreaser and wipe residue away
2. Stator: The stator can be tested for grounded, open or shorted windings using an
method for testing the stator for grounded windings is to utilize an appropriate surge/hipot
tester, such as the Baker instrument, model ST106A. Refer to the manufacturer for

3. Rotor Shaft, Spacer, Drive End Head, Slip Ring End Head, and Bushings: Must be inspected
to the tolerance and limitations outlined in Section 5. Any component not meeting the
tolerance requirements of Section 5 must be replaced with new or serviceable component.
4. Front and Rear Housing: Clean both housings using a non-corrosive chemical degreaser to
remove grease and dirt. Air dry with filtered low pressure compressed dry air or wipe dry
with clean cloth. Inspect both housings for stripped threads, cracks on exterior and interior
surfaces, and wear and corrosion in the bearing mounting area. Replace housing at
reassembly if any of the above faults are noted.
5. Mounting Hardware: Inspect any removed metallic hardware, i.e., screws, lockwashers,
flat washers, nuts, bearing retainer plate, bearing snap ring retainer, shaft spacer, bearing
cover, shaft key, etc., for any damage, wear, corrosion, or distortion. Replace any faulty
parts at reassembly. Hardware that will be reused shall be cleaned as required, using a non-
corrosive chemical degreaser. Air-dry parts using filtered low pressure compressed dry air
or wipe dry with clean, lint free, cloth.
Parts that are suitable for reuse, shall be cleaned as required using isopropyl alcohol. Any
7. Brush Holder, Brushes and Springs: Inspect brush holder for cracks and breaks. If
damaged, discard the brush assemblies and replace with new. Inspect two stainless steel
brush springs for any deformation, change in length or spring force. Replace springs if
they are damaged.
!
INSTALLATION.
After thoroughly cleaning, inspecting, testing, and replacing any faulty components,
reassemble and test the unit. The following procedures must be observed to obtain a properly
assembled unit.

1. Drive End Head: Install the bearing with the sealed side toward the
rotor by pressing on the outer race only. Install the bearing
retainer and screws. Support the rotor shaft and press the end
head onto the shaft using the tool shown in (Figure 7). Do not
attempt to press the rotor into the end head without supporting the
bearing inner race or the end head and bearing may be damaged.
Install the spacer, fan, woodruff key, pulley, lockwasher, and nut.
Torque the pulley retaining nut to 35 to 45 ft.-lbs.
Figure 7 -
2. Carefully install the rectifiers in the mounting plate by supporting Rotor Installation.
the unit. Connect the stator leads to the rectifiers, and solder.
!
CAUTION: WHEN SOLDERING THESE CONNECTIONS, USE SOLDER HEAT
SINK CLAMPS OR PLIERS ON THE LEAD BETWEEN THE SOLDER JOINT
AND THE RECTIFIER. TOO MUCH HEAT WILL DAMAGE THE
RECTIFIERS.
3. Slip Ring End Assembly: Assemble the brush and terminal stud assemblies in the end head.
Install brush holder, insuring that retaining screws are tight.
4. Reassemble the rectifier mounting

plate studs and insulators, making sure
they are in the correct order on the
terminal studs, as shown in (Figure 8).
Make sure the stator leads are
positioned so that they do not interfere
with the rotor. After the slip ring end
head is completely assembled, secure
the stator leads and rectifier leads to
Figure 8 - Terminal and Aux Stud Assembly.

the rectifier mounting plate with
epoxy.
5. Position the snap ring (install with convex curve of snap ring facing slip ring housing) in
the slip ring end head so that one of the holes is directly in line with the brushes. Install
the brush springs and brushes in the brush holder. Insert a small coated or insulated metal
pin through the snap ring hole to hold the brushes in place.
!
CAUTION: USE OF A NONCOATED/INSULATED METAL DRILL OR PIN
MAY CAUSE BRUSH AND/OR ROTOR SLIP RING DAMAGE.
6. When assembling the drive end head assembly to the slip ring end head assembly, take
care to remove the brush pin as the two assemblies are coming together so as not to scratch
the slip ring itself, and install the through bolts to hold the unit together. Make sure the
brushes are contacting the slip rings.

7. Visually check to make sure that the brush leads are free and do not bind against anything.
Make sure the shaft snap ring retainer is in place.
8. Install the slip ring end bearing into the slip ring end housing, with the sealed side toward
the rotor. While supporting the drive end of the shaft, use a tool that fits against both inner
and outer races and press the bearing onto the rotor shaft. Install slip ring end bearing
cover.
9. Torque the through bolts as specified below. Do not secure the lock tab washers until after
the unit has been bench tested for output.
Torque Specifications – After the alternator is fully assembled, the following components
should be torqued as specified below:
Thru-bolts: 30 to 35 in.-lbs.
1/4” Terminal Stud Nuts: 70 to 85 in.-lbs.
#10-32 Terminal Stud Nuts: 30 to 35 in.-lbs.
Pulley Retaining Nut: 35 to 45 ft.-lbs.

Wiring connections for bench testing the alternator are
shown in (Figure 9). Refer to the Alternator Service
Information Section for the output test figures. Adjust Test Voltage Test Ammeter
the carbon pile, if necessary, to obtain the specified

voltage. After bench testing the alternator, bend up Carbon Pile
lock-tabs on the through bolts. The alternator is now
ready for installation on the engine. Always refer to the
airframe manufacturers wiring diagram when installing Battery
Jumper Wire
the alternator or testing the alternator on the aircraft.
PRECAUTIONS TO BE OBSERVED WHEN TESTING

OR SERVICING THE ELECTRICAL SYSTEM:


circuits.
electrical circuit.


Gear Driven, 100 Ampere
…………………………………………………………
Covers Alternator Series: ALV-9400 Series and ALV-9500 Series ES1005
NOTE:
GENERAL:
The HET Gear Driven, 100 ampere Alternators

(Figure 1) are designed and constructed to provide
heavy-duty service for extended periods of trouble-
free operation with a minimum amount of
maintenance. They will withstand the vibration
and extreme temperature changes encountered in
aircraft applications. The ALV-9400 and ALV-9500
Series alternators are no longer in production;

therefore, parts may be limited. This information
is provided for use on HET PMA alternators only.

(2) the slip ring end head, (3) the rectifiers, (4) the stator, (5) the rotor (6) the drive end head
and (7) the bearings.
Figure 2 -
Principle
Components
of ALV-9400 1
Series and 7
ALV-9500
2
Series
Alternator. 6
7
5
4

1. The brush set consists of two brushes, one of which is connected to the positive field
terminal stud, and the other is connected to the negative field terminal stud.
2. The slip ring end head provides the mounting for the rectifier mounting plate, output,
auxiliary and ground terminal studs, the brush rack assembly and the slip ring end bearing.
protection.


!
MUST BE ORIGINAL EQUIPMENT PARTS MANUFACTURED BY HARTZELL
ENGINE TECHNOLOGIES (HET) OR AN APPROVED HET SOURCE. FAILURE
TO USE GENUINE HET REPLACEMENT PARTS MAY RESULT IN SERIOUS
DAMAGE TO THE ALTERNATOR OR OTHER ELECTRICAL SYSTEM
COMPONENTS.
NOTE: 1 1. Brushes and terminal studs
4. Thru-bolts
5. Lock tab washers
6. Rectifiers
8. O-rings and oil seal
NOTE: 2
service.
1. Using a marker, mark across the stator, front and rear housings to
determine alignment during reassembly. Straighten the lock tabs
on each of the six thru-bolts (use new lock tabs when
reassembling). Using a socket wrench, remove the six thru-bolts
and lock tabs. Discard thru-bolts and replace with new. Then,
remove the slip ring end head bearing cover (Figure 3).
2. Place alternator on wood holding block having a clearance hole for

the shaft diameter (including shaft spacer) and shaft length so that
end housings. Scribe a mark across housings and stator to indicate Fig. 3 - Bearing
it rests on the front surface of the machined circular part of drive
alignment for ease of reassembly. Cover Removal.

3. Using a puller (Stanley Proto Co. #4212SJB recommended,
another may cause spine damage) installed on the slip ring end
head housing to prevent damage to housing, separate the slip ring
end housing and stator rectifier assembly (Figure 4). Retrieve
brush springs if they fall out during this operation. Place the
removed slip ring end head and stator assembly on a pad to
protect exposed stator winding pending further disassembly.
Fig. 4 - Slip Ring

4. To remove stator and rectifier heat sinks assembly from slip ring
End and Rotor

end head, position the assembly on holding block. Using a
Shaft Removal.
socket wrench, remove nuts, washers and insulators from the (+)
output terminal, (-) ground terminal, AUX terminal and the other
auxiliary terminal. Note location to facilitate reassembly.
Separate the rectifier-stator assembly from the slip ring end
housing, pushing terminals through the housing and remove housing. Remove remaining
insulators and washers from terminals and housing. Note location to facilitate reassembly.
5. To remove brush holder, brushes and capacitor from slip ring end housing, begin by using
a socket wrench to remove nuts, washers, and insulators from field terminals. Note
location to facilitate reassembly. Then, remove terminals with integral brushes and
discard. Also, remove internal insulators from brush terminals, capacitor clamp screw,
clamp and capacitor. The capacitor may be discarded as it is no longer applicable.
Remove brush holder fastening hardware, including brush springs if not removed.
6. Remove bearing snap ring retainer using required removal pliers. Position end housing in
a press with rear of housing towards press table. Using a 1-1/2” diameter x 8” long bar
on inner race of bearing and with the end housing bearing boss area supported by a tube
2-1/8” O.D. X 1-7/8” I.D. X 2” long, press bearing from housing (DO NOT HAMMER).
Discard bearing. Remove bearing O-ring seal from housing and discard seal.
7. To separate rotor and drive end housing, remove shaft cotter key and nut. Discard cotter
key. Remove shaft shipping sleeve and shipping washer or drive gear assembly if
installed. Remove woodruff key and discard. Remove rotor shaft spacer and O-ring seal
and discard seal. Position assembly vertically in a press with slip ring end towards press
table and housing supported above press table by two/three vertical support plates
between housing and press table. Apply press ram to shaft end and press rotor out of
housing (DO NOT HAMMER), being careful not to allow housing or rotor to drop and be
damaged.

8. Remove three screws that secure drive end bearing
retainer and remove retainer. Place housing in press Press Ram
and using bearing removal tools, as shown in (Figure Bearing
1 3/16” DIA Bar Stock
5), press bearing from housing. Discard bearing.
9. Position drive end housing in press with front of

housing towards press table and supported on a 2- 2 1/2” ID Pipe
1/2” I.D. pipe at housing oil seal pocket. Using a 1-
Figure 5 - Bearing Removal.

7/8” diameter bar between press ram and rear of oil Bed of Press
seal, press oil seal from housing (DO NOT

HAMMER). Discard oil seal.
slip ring end head can now be separated from the stator assembly. Support the rectifier
plates and press out the rectifiers and discard. Note: If the rectifiers are soldered on to
the rectifier plates, then discard the rectifier plate assemblies, and replace with newer style
press in rectifier plate assemblies.

2. Mounting Hardware: Inspect any removed metallic hardware, i.e., screws, lockwashers,
flat washers, nuts, bearing retainer plate, bearing snap ring retainer, shaft spacer, bearing
cover, shaft key, etc., for any damage, wear, corrosion, or distortion. Replace any faulty
parts at reassembly. Hardware that will be reused shall be cleaned as required, using a
non-corrosive chemical degreaser. Air-dry parts using filtered low pressure compressed
dry air or wipe dry with clean, lint free, cloth.
Parts that are suitable for reuse shall be cleaned as required using isopropyl alcohol. Any

4. Brush Holder, Brushes and Springs: Inspect brush holder for cracks and breaks in plastic.
If damaged, discard the brush holder assembly and replace with new. Inspect two
stainless steel brush springs for any deformation, change in length or spring force. Service
springs have a free length of about 1.2 inches, 0.29 inch maximum diameter and a spring
force of 0.54 pounds at compressed length of 0.87 inches. Replace springs if they are
damaged.
5. Rotor Assembly: Inspect rotor for any of the following faults and replace rotor if any are
detected (with the exception of the slip ring repair noted in step “g”):
Using a VOM measure rotor resistance between slip ring terminals. DO NOT SCRATCH
TO SLIP RING SURFACE. See (Figure 6). Coil resistance should be 9.9 to 11.8 ohms
at 20-27 degrees C (70-80 degrees F). If resistance is higher, inspect soldered connections
at slip ring terminals. Repair as necessary using a high temperature solder per the
with rosin and alcohol flux. Replace Size: 1/16 Diameter
rotor if coil fails resistance test.
Contents: 60% Tin
40% Lead
Liquid Temperature: 190o C Approximate
Vendor Source: MSC Industrial Supply

Birmingham, Alabama
Or Equivalent
Figure 6 - Rotor Ground Test. Figure 7 - High Temperature Solder Specification.

Using a VOM on RX1000 range, measure resistance between slip ring terminal and pole
piece. No meter movement should occur (infinite resistance). Inspect slip ring and solder
connections to make sure they are not touching shaft. Repair and repeat test as required.
Replace rotor if any meter movement is detected.
!
INSTALLATION.
After thoroughly cleaning, inspecting, testing, and replacing any faulty components,
reassemble and test the unit. The following procedures must be observed to obtain a properly
assembled unit.
1. Drive End Head: Position drive end housing on press with front of housing on press table.
Position new oil seal squarely in housing with lip towards outside of end head. Using a
length of 1-7/8 inch diameter bar stock, press oil seal squarely into end head to a distance
of approximately 1/16 inch from outside of casting. DO NOT HAMMER. Position new
bearing squarely into bearing pocket of housing with sealed side of bearing towards inside
of housing. Care must be taken to prevent contamination of bearing. Using a 2-7/16 inch
O.D. pipe with 5/32 inch wall, press bearing into housing up to the housing bearing stop.
Apply pressure to outer race only. Pressure on inner race will damage bearing. DO NOT
HAMMER. Install bearing retainer and screws. Torque 25-30 in.-lbs.
To install drive end housing to rotor assembly, lubricate oil seal lip with Chevron SRI #2
grease. Position rotor assembly in press with flat surface at slip ring end of shaft against
a flat and true surface of press. Position drive end housing and bearing assembly on rotor
shaft. The bearing must be square with rotor shaft. Take care not to damage oil seal as
shaft passes through oil seal. Install the shaft oil seal spacer (collar) on shaft, being careful
not to fold the oil seal lip under, up to contact with the bearing inner race. The collar
O-ring groove should be on the outside. SURFACE 1/16” Below
DAMAGE NOT TOLERABLE, SURFACE HAS Casting
10-20 MICROINCHES FINISH. Position bearing D.E. Head

installation tool (1-3/16 inch O.D. pipe X 1/4 inch
wall X 2-1/2 inch long) on shaft in contact with end Sealed
Side of Oil Seal
of shaft collar and press bearing onto the shaft up to Bearing
Collar
shaft stop. Install a new O-ring seal onto shaft and
Rotor Shaft
position into groove of shaft collar. Use a small
O-Ring Seal
blunt instrument to push O-ring into groove. A
small amount of Dow Corning DC4 grease on the Bearing
O-ring seal will make installation easier. Make Bearing
certain the seal is fully installed before assembling Retainer
Figure 8 - Oil Seal and

the remainder of the drive assembly. (Figure 8)
shows correct assembly of oil seal and drive end
head components. Drive End Head Assembly.

2. Carefully install the rectifiers in the mounting plate by supporting the unit. Connect the
stator leads to the rectifiers, and solder using 60/40 rosin core solder.
CAUTION: WHEN SOLDERING THESE CONNECTIONS, USE SOLDER
!
HEAT SINK CLAMPS OR PLIERS ON THE LEAD BETWEEN THE
SOLDER JOINT AND THE RECTIFIER. TOO MUCH HEAT WILL
3. Slip Ring End Head, Brush Holder and Brushes:

Install brush holder in end head using screws and
lockwashers. Tighten screws to 15-20 in.-lbs.
Install bearing snap ring retainer (install with
Bearing
convex curve of snap ring facing slip ring end Retainer
housing), positioning gap in retainer relative to Hole
brush holder. Install two brush springs and brushes Drill

into holder. Depress brushes (with leads in holder or
Rod
slots) and insert a small coated or insulated metal
Slip Ring
pin through the snap ring hole to hold the brushes in End
place (Figure 9). Assemble brush terminal Housing
Brush Holder
Figure 9 - Brush Holder Ass’y.

insulators and install to housing. Torque field
(brush) terminal stud nuts to 25-30 in.-lbs.
4. Stator and Rectifier-Heat Sink Assemblies to Slip Ring End Housing: Assemble the stator
and rectifier heat sink assemblies into the end head assembly, making certain terminals,
insulators and hardware are correctly assembled as shown in (Figure 10). Align housing
and stator with previous scribe marks to insure alignment of thru-bolt holes. Final torque
of terminal nuts will be done at complete assembly of alternator. Insure that the mating
surfaces of housing and
stator are clean and free of
any dirt, burrs or foreign
material. Position the
stator leads so that they will
not interfere with the rotor
and secure leads at six
places to heat sinks with
3M Co. Scotchcast®
#10 resin (or equivalent),
Figure 10 - Terminal and Aux Stud Assembly.
following manufacturers
instructions.
5. Rear Housing-Stator Assembly to Drive End Housing and Rotor Assembly: Assemble the
rear housing-stator assembly to the drive end housing and rotor assembly, aligning the
sections with previous scribe marks on sections.

NOTE:
Insure that the mating surfaces of housing and stator are clean and free of any
dirt, burrs or foreign material.
Temporarily install two thru-bolts to hold unit together. Remove the brush retraction tool
and verify brushes seat against slip rings. Visually check that brush leads are free and
cannot bind against anything. Lubricate O-rings with Dow Corning DC-4 grease (or
equivalent). Install bearing O-ring seals into the rear housing bearing sleeve grooves.
6. Slip Ring End Bearing: Position assembly of paragraph 5 in arbor press with flat surface
of drive end shaft against a flat and true surface of press. Position new bearing squarely
into bearing pocket of housing. Use a length of bar stock to press bearing into housing
onto shaft and up to shaft stop. Apply equal pressure to inner and outer bearing race. DO
NOT HAMMER. Install slip ring end bearing cover.
7. Thru-Bolts and Lock Tabs: Install the six thru-bolts and new lock tabs. The longest thru-
bolt is installed in the hole between F1 and F2 and passes through the blast tube of the
drive end housing. Tighten bolts evenly, while maintaining lock tab orientation, each a
little bit at a time in sequence until all are tight and torqued to 30-35 in.-lbs.
8. Terminal Torque: Tighten the terminal mounting nuts to the following torque values.
Terminal Screw Size Torque (in.-lbs.)

F1 #10-32 25-30
F2 #10-32 25-30
AUX #10-32 25-30
(-) 1/4”-28 70-85
(+) 1/4”-28 70-85
AUX(-) 1/4”-28 70-85

CAUTION: THE 24 VOLT, 100 AMPERE
!
GEAR DRIVEN ALTERNATOR REQUIRES
A SOURCE OF VENTILATION. DO NOT Test Voltage Test Ammeter
TEST THESE UNITS AT FULL-RATED

OUTPUT FOR MORE THAN 20 SECONDS. Carbon Pile
Wiring connections for bench testing the alternator are

shown in (Figure 11). Refer to the Alternator Service Battery
Information section for the output test figures. Adjust the Jumper Wire

carbon pile, if necessary, to obtain the specified voltage.
After bench testing the alternator, Bend six lock tabs on
the `-bolts. The alternator is now ready for installation on

the engine. Always refer to the airframe manufacturers wiring diagram when installing the
alternator or testing the alternator on the aircraft.

ELECTRICAL SYSTEM:


circuits.
electrical circuit.

Table 1 - Trouble Probable Cause
Trouble
Shooting Low/No Alternator Output 1. Loose terminal connections.
Chart
2. Worn/broken brush.
3. Dirty/worn rotor slip rings
4. Short/leakage from field terminals to housing.
5. Shorted/open rotor field.
6. Shorted/open stator windings.
7. Shorted/open rectifiers on positive and/or negative
rectifier-heat sinks.
8. Shorted/leaking RFI capacitor
Noisy Alternator 1. Defective bearings at drive end or slip ring end.
2. Loose frame thru bolts.
3. Shorted rectifiers (magnetic noise).
Intermittent Output 1. Worn brushes/dirty slip rings.
2. Loose connections/corroded terminals.

Small Frame Belt Driven
…………………………………………………………
Covers Alternator Series: ES4000, ES4000LS, ES4009, ES4009LS, ES4024/L/LP.
ES1006
NOTE:
GENERAL:
HET Belt Driven Aircraft Alternators (Figure 1) are

designed and constructed to provide extended
amount of maintenance. They will withstand the
vibration and extreme temperature changes
alternators only.
Figure 1 - ES4000 Series Alternator.

(2) the slip ring end head, (3) the rectifier assembly, (4) the stator, (5) the rotor (6) the drive
Figure 2 -
Principle
Components 3
of
ES4000/LS,
2
4009/LS,
7
6
7
5
4
Alternator. 1

The alternator in this manual is a 12-pole, three-phase, internal rectified electrical unit
designed to provide an adequate quantity of power for all accessory requirements, even at low
engine speeds, and maintain the battery in fully charged condition.
The rotor shaft is supported at each end by bearings. The front bearing (ball-type) is a slip-
fit on the rotor shaft and is retained in the front housing with a retainer. The rear bearing
(needle-type) is pressed into the rear housing. The slip rings and the core and coil assembly
are press-fitted to the shaft with a rotor half enveloping each end of the coil. The rotor core
and coil assembly turns inside the stator core and coil assembly with a very narrow air gap
between the two assemblies. This narrow clearance permits maximum magnetic induction.
1. The brush rack assembly consists of a brush rack housing assembly, two brush assemblies,
and two springs. The brushes in the alternator ride the surfaces of the slip rings on the
rotor shaft under spring pressure and transmit field current through their circuit to ground.
One brush or field terminal is, therefore, insulated from the housing. In the standard
alternators, the brush and holder assembly is installed in a cavity inside the rear housing.
2. The slip ring end head provides the mounting for the rectifier assembly plate, output, field,
and stator terminal studs. The slip ring end head accepts a needle bearing with integral
grease seal.
3. The rectifiers used in these units are rated at Ground Terminal Negative Diode Plate
400 volts (Figure 3). Three positive and
three negative rectifiers are mounted in the
rectifier assembly plate which is then
mounted in the slip ring end head. Each pair
of rectifiers is connected to a stator lead with
high temperature solder.
The rectifier assembly is located between the

Battery
stator and the inside surface of the rear Terminal Positive
Figure 3 - Rectifiers.
housing. It is attached to the housing by Diode Plate
means of mounting studs that protrude from
the positive and negative diode plates or heat
sinks as they are sometimes called. The
positive plate is insulated from the housing,
To
the negative plate is grounded to the housing Diodes
through the studs.
4. The stator consists of a laminated iron core on which three

phase windings are wound in slots around the inside
circumference. Leads are connected to each of the three
points of the phase windings (Figure 4), and each lead is
connected to a pair of rectifiers, one negative and one
positive. The stator has been treated with a special epoxy
varnish for high temperature resistance. Figure 4 - Stator.

A number of steel stampings are riveted together to form
the stator core. The inner surface of this core contains 36
equally spaced vertical slots which accommodate the stator
coil windings. The Delta winding receives its name from
its schematic symbol which resembles the Greek Letter
Delta (Figure 5). Each coil-winding end is connected to
another to form a closed series circuit.
5. The rotor consists of a single field coil encased between Figure 5 - Delta Winding.
two six-pole, interleaved iron sections assembled on a
shaft. The ends of the field coil are connected to a pair of slip rings, which are insulated
from each other and the shaft. The rotor winding has been specially treated with a high
temperature epoxy varnish to provide vibration and temperature resistance characteristics.
High temperature solder is used to secure the winding leads to the slip rings.

When repairing the alternator, complete disassembly will be required. In this section,
compete overhaul is covered step by step to provide detailed information on each operation.
In actual service practice, these operations may be used as required. If a return to service tag
is to be marked “overhauled”, then each step must be performed as outlined in this overhaul
manual.
!
COMPONENTS.
NOTE: 1. Brushes
2. Drive End Bearing
3. Slip Ring End Bearing
4. Thru-bolts
5. Woodruff Key
6. Lockwashers, Terminal Stud Nuts, Battery, Field & Ground Nuts & Washers
7. Capacitor
8. Field Terminal Stud and Insulator

PRIOR TO DISASSEMBLY:
1. Arc Marks on Terminals (Visual Inspection): Before disassembling the alternator, the
threads on each terminal stud should be inspected for signs of arcing. Diode damage is
frequently the side effect of arcing. Arc marks are usually caused by a loose wire terminal
connection resulting from failure to tighten the attaching nut. Arc marks can also be
caused by improper service techniques that permit wires to be connected and disconnected
while current is flowing. A loose connection at the alternator output (battery) terminal can
cause the terminal stud to burn through over time.
Diode damage can occur because of the inductive voltage spikes (similar to ignition coil
sparking action) generated by the make and break of a loose terminal connection. EACH
DIODE must be tested, before the alternator is returned to service.
Voltage regulator and field relay damage can also be expected due to chattering contacts
each time the loose connection makes or breaks. Chattering contacts cause the contacts to
arc excessively with consequent rapid contact erosion.
2. Bearing Inspection (For Troubleshooting Purposes): Before disassembling the alternator

a simple bearing inspection should be performed regardless of the reason for the alternator
removal from the engine. The purpose of the inspection is to determine whether either of
the bearings is a potential noise or failure item.
To inspect for faulty bearings, hold the alternator in one hand and snap-spin the pulley
with the other hand. A defective bearing can be heard or felt. In noisy conditions, press the
alternator housing to your ear lobe and snap-spin the pulley a few times.
To determine which bearing is defective, separate the alternator housing. Snap-spin the
rotor with only the front bearing supporting the shaft to determine the condition of the
front bearing. The rotor shaft must be held in the vertical plane in order to avoid
misleading results caused by unbalanced bearing loading.
Inspect the rear bearing surface of rotor shaft for nicks, chatter marks, grooves, and other
surface irregularities. Inspect rear bearing for damage to rollers, felt seal, or bearing case.
Also look for missing rollers. If grease is hard and dry when smeared or excessively dirty,
the bearing should be replaced.
NOTE:
Bearings are to be discarded and replaced
with new at overhaul.
3. Field Circuit Open or Ground Test: Set ohmmeter

selector switch to resistance scale 1. Connect one
lead to the “FLD” terminal and the other lead to the
“GRD” terminal (Figure 6). Spin the pulley and
note ohmmeter reading. Meter should read between
4 and 25 ohms and will fluctuate while rotor is
turning. Figure 6 - Field Circuit Open
or Ground Test.

4. Test Conclusions: A reading lower than 4 ohms indicates either a grounded field terminal
or a defective rotor. A reading higher than 25 ohms indicates one of the following: either
worn out or hung brushes, an open brush lead, or a defective rotor.
1. Remove pulley nut with an impact wrench 5/16 Inch Hex Drive
(Be certain impact wrench is set to rotate in
15/16 Inch Wrench
the counterclockwise direction) OR position
alternator on bench next to a vise using the
tooling as shown in (Figure 7). The tooling
consists of a standard 15/16 inch box-end
wrench, ratchet, and a 5/16 inch hex drive.
Set ratchet to rotate the shaft in a clockwise Note: Use impact wrench to remove nut if rotor slot is
direction (right-handed thread). Support not machined to accept hex drive.
alternator with nut in box-end wrench. Be Figure 7 - Pulley Removal.

sure that hex drive is fully seated in hex hole
of shaft. Turn shaft to loosen nut.
Remove the nut, fan and pulley assembly, and woodruff key from the shaft. Discard the
woodruff key.
NOTE:
Do not attempt to remove the pulley by clamping it in a vise. This will result
in severe damage to the pulley.
2. Using a marker, scribe across the stator and front and rear housings to determine
alignment during reassembly. Remove the safety wire from the thru-bolts. Separate the
front housing and rotor from rear housing by removing the three thru-bolts and remove
rear housing and stator. Discard the thru-bolts and the old style tab washers.
Lightly tap the drive end head to

separate the drive end head and STA - Stator Terminal
Black Insulator
rotor, as a unit, from the stator and
slip ring end head. Separate rear
housing from front housing by
Thru-
sliding stator over rotor with one Bolts
continuous motion to reduce
possibility of breaking the BAT - Battery Terminal Red Insulator
FLD - Field Terminal White Insulator
grounded brush against the slip- GND - Ground Terminal
Figure 8 - Front and Rear Housing Assembly.

ring. Retrieve brush springs from No Insulator Note: Discard Old Style Tab Washers.
rear housing. See (Figure 8).

3. Remove nuts, washers, and
insulators from the four studs on
the rectifier. Push the rectifier
studs, the rectifier, and stator
through and out of the rear housing
as shown in (Figure 9). Remove
the two insulating spacers from
the rectifier studs and remove the
radio noise suppression capacitor
and disard capacitor.
4. Remove the two screws and two

washers that attach the brush holder
and grounded brush wire terminal to
rear housing (Figure 10). Remove
brush holder from rear housing.
Remove square headed terminal
screw, brush, and insulator from
rear housing and discard. During
repairs, brushes worn down to .25 or
less must be replaced with new.
5. Remove the two screws and two washers

that attach the brush holder and grounded
brush wire terminal to rear housing
(Figure 10). Remove brush holder from
rear housing. Remove square headed
terminal screw, brush, and insulator from
rear housing and discard. During repairs,
brushes worn down to .25 or less must be
replaced with new.
6. To remove rectifier assembly from stator

assembly, unsolder three stator lead
wires from rectifier assembly (Figure 12).
Use a small soldering iron or gun rated at
100 watts or less. Melt solder and open
wire loop, then remove wire from terminal
pin. Excessive heat can damage the
circuit board. Remove the stator terminal
screw and insulating washer, and the
mounting screw and insulating washer.

7. The rotor shaft
is slip fit into
Press Ram
the front bearing.
1 Inch DIA
To remove the Bar Stock
Front
rotor shaft from Housing
the drive end

head, use a puller 2” LD Pipe
3” Long
that grips on the
Press
bearing retainer Bed
plate. Do not
Figure 13 - Bearing Figure 14 - Bearing Removal.
attempt to remove
Retaining Plate Removal.

it by supporting
the end head
and pressing on the shaft, as this may result in distortion of the end head or stripping of
the retainer plate screws. Remove the three retainer plate screws, and press the bearing
out of the end head, as shown in (Figures 13 & 14).
Discard the bearing. An application of penetrating oil will permit ease of removal when
rust or corrosion has caused shaft to adhere to the bearing. Remove rotor stop spacer from
the shaft for cleaning and inspection. Do not remove the rotor stop-ring from the rotor
shaft unless it has been damaged and must be replaced.

A diode tester, a voltmeter, ammeter and carbon pile are recommended for bench testing the
alternator. The voltmeter, ammeter and carbon pile are often combined in one unit. Testers of
this type are readily available from Automotive
Equipment Suppliers.
An alternate recommended method of bench testing the

alternator and its components requires the use of a Volt-
Ohm-Meter (VOM). Equipment of this type is generally
available from electronic equipment suppliers. Typical
VOM’s which would be adequate are the Simpson 260
(Figure 15), Triplett 630 and other equivalent models.
1. Testing Diodes: (Figure 15) A digital multimeter with

diode testing function may be used for this test. An
Figure 15 - Testing Diodes.
analog meter, as shown, may also be used. With the

stator and rectifier assembly removed from rear housing (prior to removing stator leads
from the rectifier assembly), connect test clip/prod from diode tester to negative stud as
shown. Gently push, pull, and wiggle the connections while testing diodes to locate
intermittent conditions.
Touch the test prod to each of the three stator wires which connect the positive and
negative diodes together. In general, the meter reading should be the same for all three
diodes. A low reading will usually indicate a faulty soldered connection at one of the diode
terminations. Shorted and open diodes will cause specific meter indications depending
upon the tester type. Refer to the instruction manual. Move the test clip/probe to the
positive stud and repeat test as outlined in preceding steps.
2. Testing Diodes - Alternative Method (VOM): Disassemble the stator leads from the rectifier
assembly. Set the VOM on the Rx1 multiplier range scale.
3. Positive Diode Test: Connect one test probe to the large positive terminal stud and touch
the other test probe to each of the three stator terminals. Note the three ohmmeter
readings, they must be within 1%.
Reverse the test probes and repeat the test. Note the three ohm meter readings, again they
should be identical to each other but not the same as in step “3” above.
Three of the ohm meter readings should show a low resistance reading of approximately
6 to 20 ohms in one of the above steps and an infinite reading (no meter movement) in the
other step. If these readings are not obtained, the rectifier is detective and must be
replaced.
4. Negative Diode Test: Repeat above steps but connect one test probe to the small negative
terminal stud and the other probe to the stator terminals.
Examine the rectifier assembly for cracked or burnt areas and overall general appearance,
free of damage.
NOTE:
It is of little importance as to the sequence that is followed in taking the
resistance readings across each diode, but what is important is that in one
direction, a reading of 6 to 20 ohms is obtained while an infinite reading is
obtained in the other direction (probes reversed).
Some VOM’s due to their electrical circuitry and characteristics may

indicate a slightly different reading in one direction, example 35 ohms. If all
the diodes indicate this same reading in one direction and Infinity in the
other direction, the rectifier assembly should be considered functionally OK
and acceptable for further service.

5. Rotor Continuity Test: (Figure 16) Set the
ohmmeter selector switch on resistance scale 1.
Touch one lead of ohmmeter to each segment of
the slip ring. Refer to the applicable Service
Information data for appropriate meter readings.
An infinite reading on the ohmmeter is usually

indicative of either a damaged solder connection
Figure 16 - Rotor Continuity Test.
at the slip ring or a broken coil wire. Readings
lower than specified ohms indicate a shorted wire
or slip ring. Replace the Rotor if it is defective.
6. Rotor Ground Test: (Figure 17) Set the Ammeter

selector switch on 1000 scale. Touch one lead to
the rotor shaft and the other lead to first slip ring
then to the other. The ohmmeter should read
infinity in both checks.
If the meter shows a reading, a short to ground

exists. Check the soldered connections at the
Figure 17 - Rotor Ground Test.

slip rings to make sure they are secure and not
grounding against the rotor shaft, or that excess
solder is not grounding the rotor coil. Replace
the rotor if it is defective.
!
NOTE:
If both the “Rotor Continuity Test” and the “Rotor Ground Test” (above)
prove satisfactory, and the “Field Circuit Open or Ground Test” (Figure 6)
showed trouble, the brushes are potentially at fault.

Ammeter
for rotor current draw and resistance are listed on the Rheostat
Voltmeter
individual service specification pages in the Service
Information section of this manual. Excessive draw or
a low ohmmeter reading indicates shorted windings.
No current draw or an infinite ohmmeter reading Rotor Battery
Figure 18 - Rotor
indicates an open winding. If either case exists, discard
Winding Test.
the rotor and replace with a new one. No rewound rotor
are approved without factory and FAA approval.

appropriate surge/hipot tester, such as the Baker instrument, model ST106A. Refer to the
The finished slip ring diameter is found in the Specifications and Tolerances Section
of this manual. Insure there are no burrs or metal particles on or between slip rings.
7. Testing the Stator: (Figures 19 & 20) The stator

can be tested for grounded, open or shorted
windings using an ohmmeter, in the following
manner:
8. Test for Grounded Windings: (Figure 19) Set

Ohmmeter selector switch on resistance scale
1000 and zero the meter. Connect one meter lead
to bare metal portion of stator core and other lead
alternately to each of the stator leads. The Figure 19 - Stator Ground Test.
ohmmeter should read infinity (no needle
movement). Be sure lead is making good contact
with stator core surface.
Test Conclusion: If the ohmmeter indicates any

continuity reading, the stator is grounded and
must be discarded and replaced.
An alternate method for testing the stator for
Figure 20 - Stator Continuity Test.

grounded windings is to utilize an appropriate

surge/hipot tester, such as the Baker instrument, model ST106A. Refer to the manufacturer
9. Test for Open Windings: (Figure 20) Set the ohmmeter selector switch on resistance scale
1. Connect ohmmeter leads alternately between all three sets of leads. Meter reading
should be equal between any pair of stator leads. If not, then the stator is defective and
must be discarded.
Test Conclusions: If unequal readings are obtained, the stator winding is open. Check
wiring junction, if breaks are found replace and recheck.
While this test will indicate an open-winding condition, it will not detect an imbalance in
the winding resistance between the three winding phases. To test for winding imbalance,
use an appropriate surge/hipot tester such as the Baker instrument model ST106A. Refer
to the manufacturer for suitable instructions and settings.
a. Pulley, Rotor Shaft, Spacer, Fans, Drive End Head, and Slip Ring End Head: Must be
inspected to the tolerance and limitations outlined in Section 5. Any component not
meeting the tolerance requirements of Section 5 must be replaced with new or
serviceable component.
b. Front and Rear Housing: Clean both housings using a non-corrosive chemical
c. Mounting Hardware: Inspect any removed metallic hardware, i.e., screws, flat
washers, bearing retainer plate, bearing snap ring retainer, shaft spacer, etc., for any
damage, wear, corrosion, or distortion. Replace any faulty parts at reassembly.
Hardware that will be reused shall be cleaned as required, using a non-corrosive
chemical degreaser. Air-dry parts using filtered low pressure compressed dry air or
wipe dry with clean, lint free, cloth.

d. Insulators (Washers and Spacers): Inspect parts for cracks, deformation, and burn
marks. Parts that are suitable for reuse shall be cleaned as required using isopropyl
alcohol. Any other cleaner may damage insulators. Air-dry parts with filtered low
e. Brush Holder, Brushes and Springs: Inspect brush holder for cracks and breaks in
plastic. If damaged, discard the brush holder assembly and replace with new. Inspect
two stainless steel brush springs for any deformation, change in length or spring force.
Replace springs if they are damaged.
CAUTION: IN THE FOLLOWING STEPS, DO NOT USE A HAMMER TO
!
SEAT THE BEARINGS AS THIS MAY CAUSE DAMAGE TO THE
COMPONENTS. USE AN ARBOR PRESS OR EQUIVALENT FOR
PROPER INSTALLATION.
1. Prior to installing the drive end (front) bearing

(Figure 21), thoroughly clean the bearing bore Press Ram
and the O.D. of the bearing itself. Apply thin film
of Loctite® #609 to both surfaces. This bearing 1 1/4 Inch
I.D. Pipe
is a line to line press-fit in the housing. Under Apply
New Bearing
Pressure
normal circumstances, bearing can be installed to Outer Front
Race Only Housing
with only finger pressure. However, in some
instances, application of light pressure in a press
Press
will be expedient, using extreme care not to Bed
damage the bearing.

Bearing Installation.
Position front housing in press as shown. Position
bearing squarely into bearing pocket in housing.
Use a 1-1/4 inch diameter pipe to press bearing
into housing. Apply pressure evenly on the outer race only. Pressure on inner race will
damage bearing.
2. Position bearing retainer to front housing with flanged edge positioned outward. Install
three hex head bearing retainer screws. Do not over-tighten. Torque 25-40 in.-lbs.
3. Install front housing to rotor assembly. Slide bearing stop, counter bore towards stop ring,
onto shaft and against stop ring. Insert rotor shaft into front housing.
CAUTION: DO NOT CLAMP ROTOR POLE FINGERS IN A VISE.
!
DAMAGE TO THE ROTOR FINGERS WILL PRODUCE NOISY
OPERATION OR BROKEN FINGERS. A HEX HOLE, PROVIDED IN
THE DRIVE END OF THE ROTOR SHAFT FOR USE DURING PULLEY
NUT TIGHTENING OR LOOSENING, SHOULD BE UTILIZED. USE
IMPACT WRENCH IN THE EVENT THAT THE SHAFT DOES NOT
INCORPORATE A HEX HOLE.

4. Install the slip ring end bearing in the rear bearing
housing (Figure 22) making certain to properly support
the slip ring housing. Position rear housing in press and
support with 1 inch I.D. pipe as shown. Position bearing
squarely into bearing pocket of housing. Using a 7/8 inch
DIA punch or bar stock, press bearing into housing. Note
that the bearing is flush with the edge of the housing.
5. Install rectifier assembly to stator assembly (Figure 23).

Install stator terminal screw and an insulating washer as
shown.
Solder three stator lead wires to

rectifier terminals. Polarity is not
important but solder each wire to the
nearest terminal with the center wire
on the center terminal. Maintain a
spacing of approximately one inch
between circuit board and stator
core. Bend surplus length of stator
wire sideways to prevent them from
contacting the rear housing. Note:
Loctite® Durabond E-20NS epoxy or
equivalent, may be used to stabilize
stator wires and capacitor. Do Not
use RTV.

! SINK CLAMPS OR PLIERS ON THE LEAD BETWEEN THE SOLDER JOINT AND THE
RECTIFIER. TOO MUCH HEAT WILL DAMAGE THE RECTIFIERS.
6. Install brush holder and brushes

(Figure 24). Install brush springs to
brush holder. Identify the insulated
brush by the eyelet terminal having
straight sides and pig-tail wire
connected at a right angle. Insert
insulated brush into holder with pig-
tail wire extending from slot in holder.
Flat end of brush must be in contact
with spring as illustrated.
Depress brush using a two inch long

“brush retracting wire” (insulated wire
or plastic stick) until wire enters the
hole in the partition between brush
Insert grounded brush into holder with pig-tail
cavities. Identify the grounded brush
wire extending from slot in holder. Flat end
by the eyelet terminal having round
of brush must be in contact with spring as
sides and a locating tab extending
illustrated.
from the side.

Depress brush with a small wire or small
screwdriver. Push retracting wire over end of
brush and against opposite side of holder. Insert
square headed screw into eyelet terminal on
insulated brush pig-tail wire as illustrated (Figure
25). Work pig-tail wire into slot and square
headed screw into channel as illustrated. Pig-tail
wire must be positioned against holder to prevent
interference with rotor slip-rings.
Position flat insulator against brush holder with

retracting wire and screw thread protruding.
Position brush holder to rear housing (Figure 26).
Press holder firmly against housing to produce
maximum sealing effect. Locate eyelet terminal
to holder with locating tab positioned between
the holder and housing. Install two retaining
screws and two washers to the brush holder. Be
sure pig-tail wires are positioned against brush
holder to prevent interference with rotor slip-
CAUTION: DO NOT OVER TIGHTEN
!
SCREWS, DAMAGE TO THE BRUSH
HOLDER MAY RESULT (TORQUE 17-25
IN.-LBS.).
Position the orange terminal insulator to field terminal stud and install retaining nut and
washer assembly.
7. Install Stator and Rectifier Assembly

to Rear Housing (Figure 27). Install
small stepped insulator to stator
terminal screw. Position the radio
noise suppression capacitor to the
ectifier terminals. Install the large
stepped insulator on the battery
terminal stud.

Position stator and rectifier assembly in rear housing with the large stud (1/4 – 20 thread)
inserted into the largest terminal hole (BAT). Be sure that both insulating spacers have
been inserted into the BAT and STA terminal holes. Insert stator core into machined step
in rear housing.
While holding the insulating spacers firmly in place, install the red terminal insulator to
the BAT terminals using a 1/4-20 nut with integral dished washer, torque to 45 to 60 in.-
lbs.; and the black terminal insulator to the STA terminal using a 10-24 nut with integral
dished washer, torque to 25-35 in.-lbs.
Install two 10-24 nut and washer assemblies to the two remaining studs.
8. Install rear housing, rectifier, and stator assembly. Before assembling the alternator front
and rear sections, wipe the rear bearing surface of the rotor shaft to insure a clean, dry
surface.
Position rear housing to front housing in accordance with reference line scribed across the
housings at teardown. Be sure that stator is properly seated to both housings. Align thru-
bolt ears on rear housing with threaded holes on front housing. Install the three thru-bolts
(and washers if using #10-24 bolts) finger tight.
Tighten the thru-bolts evenly by tightening each a little at a time in sequence until all are tight.
Spin the rotor to make sure there is no mechanical interference. For 1/4 20 bolts (ES4126),
torque to 75-85 in.-lbs. For #10-24 bolts (HDW10020-3), torque to 50-60 in.-lbs.
Remove insulated brush retaining wire from the brush rack assembly. Spin the rotor and
check for interference between the brush holder and rotor. Measure the resistance across
the field terminals with an ohmmeter. The ohmmeter must indicate the amount of rotor
resistance listed in the Alternator Service Information section of this manual.
!
CAUTION: DAMAGE TO THE WIRING AND REGULATOR CAN OCCUR
IF THE RETRACTING WIRE IS NOT REMOVED FROM THE
ALTERNATOR.
9. Install Fan and Pulley Assembly. Install the woodruff key, fan and pulley assembly.
Using a strap wrench to hold the pulley, torque the pulley nut to 60-100 ft.-lbs (for
ES4024L, ES4024LP, and ES4024LP-3, torque to 67-77 ft.-lbs). Be sure to install a Red
caution placard P/N QA-234 or QA-235 (as applicable) with the thru bolt torque
instructions.
Safety wire should be installed in the thru-bolts only after the unit has been bench tested
for output.

ALTERNATOR BENCH TESTING: Stator
Wiring connections for bench testing the alternator

are shown in (Figure 28). Refer to the Alternator
Service Information Section for the output test
figures. Adjust the carbon pile, if necessary, to
obtain the specified voltage. After bench testing the
alternator, install the safety wire in the thru-bolts.
The alternator is now ready for installation on the
engine. Always refer to the airframe manufacturers Ground
wiring diagram when installing the alternator or
Field

Battery
testing the alternator on the aircraft.

ELECTRICAL SYSTEM:


circuits.
electrical circuit.

7. Never operate the alternator on the open circuit with the rotor (field) coil energized. Very
high voltage will develop which can burn the rotor coil or possibly damage the diodes.
8. Never use acid core solder for electrical connections. Use rosin core solder.

9. Do not use a 115 volt test lamp to check diodes.
NOTE:
All measurements are in inches. Any serviceable limit or tolerance not met
by a component MUST be discarded and replaced with new or serviceable
component.
! CAUTION: NO WELD REPAIRS ARE PERMITTED.
TROUBLESHOOTING:
Table 1: Trouble Indication Probable Cause

Trouble- Battery Discharged 1. Loose drive belt.
shooting 2. Field circuit resistance too high.
Chart
3. Voltage regulator malfunction.
4. Accessory load too high for alternator rating.
5. Corroded or loose battery cable connector clamps.
6. Low field voltage.
7. Defective battery.
Battery Overcharged 1. Voltage regulator set too high for aircraft operating conditions.
2. Ground wire loose or broken between regulator and alternator.
3. Shorted cell in battery causing other cells to use water
excessively.
4. Shorted voltage regulator output - full field condition.
5. Voltage drop in voltage regulator feedback circuit.
Noisy Alternator 1. Defective bearing.

2. Shorted rectifier (magnetic noise).
3. Loose, worn, or frayed drive belts.
4. Bent fan.
5. Loose rear housing or improperly installed stator.
6. Loose pulley or pulley not seated against bearing.
7. Loose mounting bolts.
8. Insufficient output filtering.
Ammeter Pointer 1. Dirty or oxidized regulator contacts.

or Lights Flicker 2. Loose connections in charging system or damaged wiring
harness.
3. Dirty slip ring.
4. Partially shorted rectifier.


Small Frame Gear Driven
…………………………………………………………
Covers Alternator Series: ES4001, 4002, 4004, 4006, 4008, and 4029. ES1007
NOTE:
GENERAL:
HET Belt Driven Aircraft Alternators (Figure 1) are designed and

constructed to provide extended periods of trouble-free operation
with a minimum amount of maintenance. They will withstand the
vibration and extreme temperature changes encountered in aircraft
applications. This information is provided for use on HET PMA
alternators only.
Figure 1 - ES4000

Series Alternator.
end head, (7) the bearings and (8) the fan.
Figure 2 -
Principle
Components
of ES4001,
4002, 4004,
4006, 4008, 3
4029. 1 6
Alternator. 2 7
7
8
5
4

The rotor shaft is supported at each end by bearings. The front bearing (ball-type) is a slip-fit
on the rotor shaft and is retained in the front housing with a retainer. The rear bearing (needle-
type) is pressed into the rear housing. The slip rings and the core and coil assembly are press-
fitted to the shaft with a rotor half enveloping each end of the coil. The rotor core and coil
assembly turn inside the stator core and coil assembly with a very narrow air gap between the
two assemblies. This narrow clearance permits maximum magnetic induction.
grease seal.
3. The rectifiers used in these units are rated at

Ground Terminal Negative Diode Plate
400 volts. Three positive and three negative
rectifiers are mounted in the rectifier
assembly plate which is then mounted in the
slip ring end head. Each pair of rectifiers is
connected to a stator lead with high
temperature solder.
The rectifier assembly is located between the Battery

stator and the inside surface of the rear Terminal Positive
Diode Plate
housing. It is attached to the housing by
the positive and negative diode plates or heat sinks as they are sometimes called. The
positive plate is insulated from the housing, the negative plate is grounded to the housing
through the studs (Figure 3).
To
Diodes
4. The stator consists of a laminated iron core on which
three phase windings are wound in slots around the
inside circumference. Leads are connected to each of
the three points of the phase windings (Figure 4), and
each lead is connected to a pair of rectifiers, one
negative and one positive. The stator has been treated
with a special epoxy varnish for high temperature
Figure 4 - Stator.
resistance.

its schematic symbol which resembles the Greek Letter

manual.
!
COMPONENTS.
NOTE:
1. Brushes
4. Thru-bolts
5. Woodruff Key
6. Lockwashers, Terminal Stud Nuts, Battery, Field & Ground, Nut & Washers
7. Capacitor
8. Field Terminal Stud & Insulator

1. Arc Marks on Terminals - Visual Inspection: Before disassembling the alternator, the

surface irregularities. Inspect rear bearing for damage to rollers, felt seal, or bearing case.
Also look for missing rollers. If grease is hard and dry when smeared or excessively dirty,
the bearing should be replaced.
NOTE:
Bearings are to be discarded and
replaced with new at overhaul.
Figure 6 - Field Circuit Open

or Ground Test.
“GRD” terminal (Figure 6). Spin the pulley and

note ohmmeter reading. Meter should read between 4 and 25 ohms and will fluctuate
while rotor is turning.
4. TEST CONCLUSIONS: A reading lower than 4 ohms indicates either a grounded field
terminal or a defective rotor. A reading higher than 25 ohms indicates one of the
following: worn out or hung brushes, an open brush lead, or a defective rotor.
1. To remove drive gear and coupling assembly, remove cotter key. Set ratchet to rotate
the shaft in a clockwise direction (right-handed thread). Remove nut, drive gear, and
coupling assembly.
alignment during reassembly. Remove safety wire. Remove the three thru-bolts that
attach the rear housing to front housing.
Separate stator core from front housing. (Use a screwdriver in one of the three core
slots for stubborn cases.) Lightly tap the drive end head to separate the drive end head
and rotor, as a unit, from the stator and slip ring end head.
Separate rear housing from front housing by sliding stator over rotor with one
continuous motion to reduce possibility of breaking the grounded brush against the
slip-ring. Discard the thru bolts.
Retrieve brush springs from rear housing. Wipe away any bearing grease that brushes
may have acquired during removal.
3. Remove nut and

Capacitor washer assemblies
Terminal Insulators
from studs protruding
through rear housing.
Remove three
terminal insulators.
Separate stator core
from rear housing.
Insulating
Spacers (Use a screwdriver in
Figure 7 - Stator and Rectifier Removal.

one of the three core
slots for stubborn
cases.)
Push rectifier studs through holes in rear housing and remove housing. Remove two
insulating spacers from rectifier studs. Remove radio noise suppression capacitor.
(Figure 7).

4. To remove brush holder from rear
housing, remove two screws and
two washers that attach the brush
holder and grounded brush wire
terminal to rear housing (Figure
8). Remove brush holder from rear
housing. Remove square headed
terminal screw, brush, and insulator
from rear housing. Separate brushes
from attaching hardware. At overhaul
brushes must be replaced with new.
During repairs, brushes worn down
to .25 or less must be replaced with
new.
5. To remove slip ring end bearing, position rear

housing in arbor press. Use the appropriate tools
shown in (Figure 9), or fabricate tools to the
dimensions indicated.
Support the rear housing at the area directly below

the bearing boss, as shown, to prevent damage or
distortion to the housing. Remove and discard the
slip ring end bearing.
6. Remove rectifier assembly from stator

assembly. Unsolder three stator lead
wires from rectifier assembly (Figure
10). Use a small soldering iron or gun
rated at 100 watts or less. Melt solder
and open wire loop, then remove wire
from terminal pin. Excessive heat can
damage the circuit board. Remove the
stator terminal screw and insulating
washer, and the mounting screw and
insulating washer.
7. Remove drive gear spacer and O-ring from end housing and discard O-ring. The rotor shaft is
slip fit into the front bearing. To remove the rotor, lightly tap on the end of the rotor shaft with
a rubber mallet to release shaft from the front bearing. An application of penetrating oil will
permit ease of removal when rust or corrosion has caused shaft to adhere to the bearing. Do
not attempt to remove it by supporting the end head and pressing on the shaft, as this may
result in distortion of the end head or stripping of the retainer plate screws.

adhere to the bearing. Do not attempt to
remove it by supporting the end head and
pressing on the shaft, as this may result in
distortion of the end head or stripping of the
retainer plate screws.
Remove the three retainer plate screws, and

press the bearing out of the end head, as
shown in (Figures 11 & 12). Discard the
bearing. Remove rotor stop spacer from the
Figure 11 - Bearing Plate

shaft for cleaning and inspection. Do not
Retainer Removal.
remove the rotor stop-ring from the rotor
shaft unless it has been damaged and must be
replaced.
8. Using a slide hammer

remove drive end seal
from end housing
(Figure 13). Exercise
care not to distort or
deform the pilot
diameter of the end
housing.
Figure 12 - Drive End Figure 13 - Drive End

Bearing Removal. Seal Removal.

this type are readily available from Automotive Equipment Suppliers.
An alternate recommended method of bench testing the alternator and its components requires
the use of a Volt-Ohm-Meter (VOM). Equipment of this type is generally available from
electronic equipment suppliers. Typical VOM’s which would be adequate are the Simpson
260, Triplett 630 and other equivalent models.

1. Testing Diodes: (Figure 14) A digital multimeter with diode
testing function may be used for this test. An analog meter,
as shown, may also be used. With the stator and rectifier
assembly removed from rear housing (prior to removing
stator leads from the rectifier assembly), connect test
clip/probe from diode tester to negative stud as shown.
Gently push, pull, and wiggle the connections while testing
diodes to locate intermittent conditions.
Touch the test prod to each of the three stator wires which
connect the positive and negative diodes together. In Figure 14-Testing Diodes.
general, the meter reading should be the same for all three
diodes. A low reading will usually indicate a faulty soldered connection at one of the diode
terminations. Shorted and open diodes will cause specific meter indications depending
upon the tester type. Refer to the instruction manual.
Move the test clip/prod to the positive stud and repeat test as outlined in preceding steps.
2. Testing Diodes – Alternative Method (VOM): Disassemble the stator leads from the rectifier
assembly. Set the VOM on the Rx1 multiplier range scale.
3. Positive Diode Test: Connect one test probe to the large positive terminal stud and touch
the other test probe to each of the three stator terminals. Note the three ohmmeter
readings, they must be within 1%.
Reverse the test probes and repeat the test. Note the three ohm meter readings, again they
should be identical to each other but not the same as in step “3” above.
Three of the ohm meter readings should show a low resistance reading of approximately
6 to 20 ohms in one of the above steps and an infinite reading (no meter movement) in the
other step. If these readings are not obtained, the rectifier is detective and must be
replaced.
4. Negative Diode Test: Repeat above steps but connect one test probe to the small negative
terminal stud and the other probe to the stator terminals.
Examine the rectifier assembly for cracked or burnt areas and overall general appearance,
free of damage.
NOTE:

NOTE:
Some VOM’s due to their electrical circuitry and characteristics may indicate
a slightly different reading in one direction, example 35 ohms. If all the
diodes indicate this same reading in one direction and Infinity in the other
direction, the rectifier assembly should be considered functionally OK and
acceptable for further service.
5. Rotor Continuity Test: (Figure 15) Set the ohmmeter

selector switch on resistance scale 1. Touch one
lead of ohmmeter to each segment of the slip ring.
Refer to the applicable Service Information data for
appropriate meter readings.

indicative of either a damaged solder connection at

the slip ring or a broken coil wire. Readings lower
than specified ohms indicate a shorted wire or slip
ring. Replace the rotor if it is defective.
6. Rotor Ground Test: (Figure 16) Set the Ammeter

selector switch on 1000 scale. Touch one lead to
the rotor shaft and the other lead to first slip ring
then to the other. The ohmmeter should read
infinity in both checks.


!
NOTE:
If both the “Rotor Continuity Test” and
the “Rotor Ground Test” (above) prove
Ammeter
satisfactory, and the “Field Circuit Open
or Ground Test” (Figure 5 on page 4-730- Rheostat
Voltmeter
01) showed trouble, the brushes are
potentially at fault.
7. Shorts in Rotor Winding: To test for shorted turns in the Rotor Battery
Figure 17 - Rotor
rotor winding, connect a voltmeter, ammeter, rheostat
Winding Test.
and battery as shown in (Figure 17), or use an
ohmmeter. The acceptable ranges for rotor current

draw and resistance are listed on the individual service specification pages in the Service
Information section of this manual. Excessive current draw or a low ohmmeter reading
indicates shorted windings. No current draw or an infinite ohmmeter reading indicates an
open winding. If either case exists, discard the rotor and replace with a new one. No
rewound rotors are approved without factory and FAA approval.
exception of the slip ring repair noted in step G):
NOTE: Rotor is not serviceable in parts. It must be replaced as a whole.
8. Testing The Stator: The stator can be tested for grounded, open or shorted windings using
an ohmmeter, in the following manner.
9. Testing Stator for Grounded Windings: (Figure 18) Set Ohmmeter selector switch on
resistance scale 1000 and zero the meter. Connect
one meter lead to bare metal portion of stator core
and other lead alternately to each of the stator leads.
The ohmmeter should read infinity (no needle
movement). Be sure lead is making good contact
with stator core surface.
Test Conclusion: If the ohmmeter indicates any
Figure 18 - Stator Ground Test.

continuity reading, the stator is grounded and must
be discarded and replaced.

surge/hipot tester, such as the Baker instrument,
model ST106A. Refer to the manufacturer for
10. Test Stator for Open Windings: (Figure 19) Set the
ohmmeter selector switch on resistance scale 1.
Connect ohmmeter leads alternately between all
three sets of leads. Meter reading should be equal
between any pair of stator leads. If not, then the
stator is defective and must be discarded.
11. Rotor Shaft, Spacer, Vent Fans, Drive End Head, and Slip Ring End Head: Must be inspected
tolerance requirements of Section 5 must be replaced with a new or serviceable
component.
bearing retainer plate, bearing snap ring retainer, shaft spacer, etc., for any damage, wear,
corrosion, or distortion. Replace any faulty parts at reassembly. Hardware that will be

reused shall be cleaned as required, using a non-corrosive chemical degreaser. Air-dry
parts using filtered low pressure compressed dry air or wipe dry with clean, lint free, cloth.
stainless steel brush springs for any deformation, change in length or spring force.
Replace springs if they are damaged.
!
THE BEARINGS AS THIS MAY CAUSE DAMAGE TO THE COMPONENTS.
USE AN ARBOR PRESS OR EQUIVALENT FOR PROPER INSTALLATION.
1. Prior to installing the drive end (front) bearing

(Figure 20), thoroughly clean the bearing bore and Arbor
Press
the O.D. of the bearing itself. Apply thin film of Ram
Locktite #609 to both surfaces. This bearing is a

line to line press-fit in the housing. Under normal Press
circumstances, bearing can be installed with only Table
finger pressure. However, in some instances,

application of light pressure in a press will be
expedient, using extreme care not to damage the
bearing. Figure 20 - Drive End
Position front housing in press as shown. Position Bearing Installation.
bearing squarely into bearing pocket in housing.
Use a 1-1/4 inch diameter pipe to press bearing into
housing. Apply pressure evenly on the outer race
only. Pressure on inner race will damage bearing.
2. Position bearing retainer to front housing with

flanged edge positioned outward as shown in
(Figure 21). Install three hex head bearing retainer
Figure 21 - Bearing Plate
screws. Do not over-tighten. Torque 25-40 in.-lbs.
3. Install front housing to rotor assembly. Slide rotor Retainer Installation.

stop, counter bore facing rotor stop ring onto rotor shaft until it contacts stop ring. Install
the woodruff key that secures the fan assembly to the rotor shaft. Index slot in fan

assembly with woodruff key in the rotor shaft and install fan. Insert rotor shaft through
front bearing.
!
CAUTION: DO NOT CLAMP ROTOR POLE FINGERS IN A VISE. DAMAGE TO
THE ROTOR FINGERS WILL PRODUCE NOISY OPERATION OR BROKEN
FINGERS.
Press Ram
4. Install the slip ring end bearing in the rear bearing
7/8 Inch
DIA Press housing (Figure 22) making certain to properly
support the slip ring housing. Position rear
Rear 1 Inch
Housing I.D. housing in press and support with 1 inch I.D. pipe
Pipe
or as shown. Position bearing squarely into bearing
pocket of housing. Using a 7/8 inch DIA punch or
Bearing Tool bar stock, press bearing into housing.
With 1/8 Inch
Wall Thickness
Press Bed
5. Install rectifier assembly to stator assembly

Note: The bearing is flush with the edge of the (Figure 23). Install stator terminal screw and an
Figure 22 - Rear
housing.
insulating washer as shown.
Bearing Installation.
Solder three stator lead wires to

rectifier terminals using 60/40 Stator
rosin core solder. Polarity is not Terminal
Screw
important but solder each wire Negative
Diode
to the nearest terminal with the Plate
center wire on the center terminal.

Maintain a spacing of approximately
Insulating
one inch between circuit board Washers
and stator core. Bend surplus length Positive Diode Plate
Soldering Gun or
of stator wire sideways to prevent Iron Rated at 100
Figure 23 - Rectifier to Stator Assembly.

Stator Wires Watts or Less
them from contacting the rear
housing.
NOTE:
Loctite® Durabond E-20NS epoxy or equivalent, may be used to stabilize
stator wires and capacitor. Do Not use RTV.
!
SINK CLAMPS OR PLIERS ON THE LEAD BETWEEN THE SOLDER JOINT
AND THE RECTIFIER. TOO MUCH HEAT WILL DAMAGE THE RECTIFIERS.

6. Install brush holder and brushes
(Figure 24). Install brush springs to
brush holder. Identify the insulated
brush by the eyelet terminal having
straight sides and pig-tail wire
connected at a right angle. Insert
insulated brush into holder with pig-
tail wire extending from slot in holder.
Flat end of brush must be in contact
with spring as illustrated.
Depress brush using a two inch long “brush

retracting wire” (insulated wire or plastic stick)
until wire enters the hole in the partition between
brush cavities. Identify the grounded brush by the
eyelet terminal having round sides and a locating
tab extending from the side. Insert grounded brush
into holder with pig-tail wire extending from slot in
holder. Flat end of brush must be in contact with
spring as illustrated.
Depress brush with a small wire or small

screwdriver. Push retracting wire over end of brush
and against opposite side of holder. Insert square
headed screw into eyelet terminal on insulated
brush pig-tail wire as illustrated (Figure 25). Work
pig-tail wire into slot and square headed screw
into channel as illustrated. Pig-tail wire must be
positioned against holder to prevent interference
with rotor slip-rings.
Position flat insulator against brush holder with

retracting wire and screw thread protruding. Position
brush holder to rear housing (Figure 26). Press
holder firmly against housing to produce maximum
sealing effect. Locate eyelet terminal to holder
with locating tab positioned between the holder
and housing. Install two retaining screws and two
washers to brush holder. Be sure pig-tail wires
are positioned against brush holder to prevent
interference with rotor slip-rings.

!
CAUTION: DO NOT OVER TIGHTEN SCREWS OR CRACKED BRUSH
HOLDER MAY RESULT (TORQUE 17-25 IN.-LBS.).
Position the orange terminal insulator to field terminal stud and Install retaining nut and
washer assembly.
Capacitor
7. Install stator and rectifier
Terminal Insulators assembly to rear housing
(Figure 27). Install small
stepped insulator to stator
terminal screw. Position
the radio noise suppression
capacitor to the rectifier
Insulating
terminals. Install the large
Figure 27 - Rectifier Assembly.

Spacers stepped insulator on the
battery terminal stud.
Position stator and rectifier assembly in rear housing with the large stud (1/4 – 20 thread)
inserted into the largest terminal hole (BAT). Be sure that both insulating spacers have
been inserted into the BAT and STA terminal holes. Insert stator core into machined step
in rear housing.
While holding the insulating spacers firmly in place, install the red terminal insulator to
the BAT terminals using a 1/4-20 nut with integral dished washer, torque to 45 to 60 in.-
lbs.; and the black terminal insulator to the STA terminal using a 10-24 nut with integral
dished washer, torque to 25-35 in.-lbs.
Install two 10-24 nut and washer assemblies to the two remaining studs.
8. Install rear housing, rectifier, and stator assembly. Before assembling the alternator front
and rear sections, wipe the rear bearing surface of the rotor shaft to insure a clean, dry
surface.
Position rear housing to front housing in accordance with reference line scribed across the
housings at teardown. Be sure that stator is properly seated to both housings. Align
through-bolt ears on rear housing with threaded holes on front housing. Install the three
through-bolts (and washers if using #10-24 bolts) finger tight.
Tighten the through-bolts evenly by tightening each a little at a time in sequence until
all are tight. Spin the rotor to make sure there is no mechanical interference. For 1/4 20
bolts (ES4126), torque to 75-85 in.-lbs. For #10-24 bolts (HDW10020-3), torque to
50-60 in.-lbs.

!
ALTERNATOR.
9. Press the drive seal into the front housing until it seats against the internal stop. Apply
thin coating of Dow Corning DC-4 or equivalent lubricant to the O-ring and install the
O-ring and drive gear spacer on the rotor shaft between the shaft and the drive seal. Install
woodruff key in rotor shaft and slip drive coupling assembly and drive gear on rotor shaft.
Be sure to install a Red caution placard P/N QA-234 or QA-235 (as applicable) with the
thru bolt torque instructions.
See Engine Manufacturers instructions for proper installation of drive coupling.
Safety wire should be installed in the thru-bolts only after the unit has been bench tested
for output.

Wiring connections for bench testing
the alternator are shown in (Figure Field (FLD)
Battery (BAT) Ground (GRD)
28). Refer to the Alternator Service
Stator (STA)
Information Section for the output test
figures. Adjust the carbon pile, if
necessary, to obtain the specified
voltage. After bench testing the
alternator, install the safety wire in the
thru-bolts. The alternator is now ready
for installation on the engine. Always
refer to the airframe manufacturers
wiring diagram when installing the
alternator or testing the alternator on
the aircraft. Figure 28-Wiring Connections for Bench Testing.

ELECTRICAL SYSTEM:


circuits.
electrical circuit.
NOTE:
All measurements are in inches. Any serviceable limit or tolerance not met by a
component MUST be discarded and replaced with new or serviceable
!
component.
CAUTION: NO WELD REPAIRS ARE PERMITTED.
TROUBLESHOOTING:
Trouble- Battery Discharged 1. Defective drive coupling.
Chart
excessively.

Trouble- Noisy Alternator 1. Defective bearing.
shooting
Chart Cont.
4. Bent fan.

or Lights Flicker 2. Loose connections in charging system or damaged wiring harness.
3. Dirty slip ring.

Large Frame Belt Driven
…………………………………………………………
Covers Alternator Series: ES4003/LS, 4011/LS, 4019/LS, and 4019-3/LS.
ES1008
NOTE:
GENERAL:

designed and constructed to provide extended
amount of maintenance. They will withstand
the vibration and extreme temperature changes
alternators only.
Figure 1 - ES4019 Series Alternator.

Figure 2 -
Principle
Components of
4
ES4003/LS, 5
4011/LS,
4011-1/LS
7
4019/LS, 6 7
2
4019-3/LS,
1
Alternator. 3

The rotor shaft is supported at each end by bearings. The front bearing (ball-type) is a slip-fit
on the rotor shaft and is retained in the front housing with a retainer. The rear bearing (needle-
type) is pressed into the rear housing. The slip rings and the core and coil assembly are press-
fitted to the shaft with a rotor half enveloping each end of the coil. The rotor core and coil
assembly turns inside the stator core and coil assembly with a very narrow air gap between
the two assemblies. This narrow clearance permits maximum magnetic induction.
grease seal.
3. The rectifiers used in these units are rated at Ground Terminal Negative Diode Plate
400 volts. Three positive and three negative
rectifiers are mounted in the rectifier
assembly plate which is then mounted in the
slip ring end head. Each pair of rectifiers is
connected to a stator lead with high
temperature solder (Figure 3).
The rectifier assembly is located between the Battery

Terminal Positive
stator and the inside surface of the rear
Diode Plate
housing. It is attached to the housing by
the positive and negative diode plates or heat
sinks as they are sometimes called. The
positive plate is insulated from the housing,
To
the negative plate is grounded to the housing Diodes
through the studs.
4. The stator consists of a laminated iron core on which three

phase windings are wound in slots around the inside
circumference. Leads are connected to each of the three
points of the phase windings (Figure 4), and each lead is
connected to a pair of rectifiers, one negative and one
positive. The stator has been treated with a special epoxy
varnish for high temperature resistance. Figure 4 - Stator.

its schematic symbol which resembles the Greek letter

manual.
!
ELECTRICAL SYSTEM COMPONENTS AND MAY RESULT IN INJURY.

NOTE: 1. Brush and Brush Holder Assembly
4. Thru-bolts
5. Woodruff Key
6. Lockwashers, Terminal Stud Nuts
7. Capacitor
8. Battery, Ground, and Field Nut Washer Assembly

1. Arc Marks on Terminals - Visual Inspection: Before disassembling the alternator, the

surface irregularities. Inspect rear bearing for
damage to rollers, felt seal, or bearing case. Also look
for missing rollers. If grease is hard and dry when
smeared or excessively dirty, the bearing should be
replaced. NOTE: Bearings are to be discarded and
replaced with new at overhaul.

Figure 6 - Field Circuit Open
“GRD” terminal (Figure 6). Spin the pulley and note
or Ground Test.
ohmmeter reading. Meter should read between 4 and
25 ohms and will fluctuate while rotor is turning.

1. Remove pulley nut with an impact wrench (Be certain impact wrench is set to rotate in the
counterclockwise direction) OR position alternator on bench next to a vise using the
tooling as shown in (Figure 7). The tooling consists of a standard 15/16 inch box-end
wrench, ratchet, and a 5/16 inch hex drive.
5/16 Inch Hex Drive
2. Set ratchet to rotate the shaft in a clockwise 15/16 Inch Wrench

direction (right-handed thread).Support
alternator with nut in box-end wrench, be
sure that hex drive is fully seated in hex hole
of shaft. Turn shaft to loosen nut.
3. Remove the nut, washer, pulley spacer, fan

and pulley assembly, fan spacer, and Note: Use impact wrench to remove nut if rotor slot is
not machined to accept hex drive.
Figure 7 - Pulley Removal.

woodruff key from the shaft. Discard the
woodruff key.
NOTE:
Do not attempt to remove the pulley by clamping it in a vise. This will result
in severe damage to the pulley.
alignment during reassembly (Figure 8). Separate the front housing and rotor from rear
housing by removing the four thru-bolts and
lockwashers, and remove rear housing and stator.
Discard the thru-bolts and lockwashers.
5. Lightly tap the drive end head to separate the drive

end head and rotor, as a unit, from the stator and slip
ring end head. Separate rear housing from front
housing by sliding stator over rotor with one
continuous motion to reduce possibility of breaking
the grounded brush against the slip-ring. Retrieve
Figure 8 - Front and Rear

brush springs from rear housing.
6. Remove battery and ground terminal stud hardware Housing Assembly.

and battery terminal insulator. Discard lockwasher
and nut assemblies. Remove the four screw and
washer assemblies from the rectifier. Slide the

rectifier terminals,
Battery External Insulator
the rectifier, and
stator through and
out of the rear
housing as shown
in (Figure 9) and
Brush Block Assembly
remove the two
“Bat” Internal Insulator
insulating spacers
from the rectifier
Rectifier Assembly
studs. Remove the
two screws that Capacitor
attach the radio
noise capacitor and
remove capacitor
from rear housing
and discard.
Stator Assembly
7. Remove the two Figure 9 - Stator and Rectifier Removal.

screws that attach the
brush holder
and grounded Press Ram 7/8 Inch
brush wire DIA Press
terminal to 1 Inch ID Pipe or

Bearing Tool with
Rear
rear housing Housing 1/8 Inch Wall
Thickness
(Figure 10).
R e m o v e
brush holder
assembly
from the rear Press Bed
housing.
Figure 10 - Brush Holder Removal.
Replace
b r u s h Figure 11 - Rear Bearing Removal.
h o l d e r
assembly
with new at overhaul (if rectangular style brushes).
8. Remove slip ring end bearing. Position rear housing in arbor press. Use the special tools
shown in (Figure 11) or fabricate tools to the dimensions indicated.
NOTE:
Support the rear housing at the area directly below the bearing boss, as shown,
to prevent damage or distortion to the housing. Remove and discard the slip
ring end bearing.

9. Remove rectifier assembly from stator Soldering Gun
or Iron Rated
assembly. Unsolder three stator lead at 100 Watts
or Less
wires from rectifier assembly (Figure 12).
Use a small soldering iron or gun rated at
100 watts or less. Melt solder and open
wire loop, then remove wire from Rectifier Stator
terminal pin. Excessive heat can damage
Terminals
the circuit board. Remove the stator
terminal screw and insulating washer, and
the mounting screw and insulating
Figure 12 - Stator and Rectifier Assembly.

washer.
Screw & Washer Assembly

Front Bearing
10.Remove rotor. The rotor shaft is slip fit
into the front bearing. To remove the
rotor shaft from the drive end head, use a
puller that grips on the outside race of
the bearing assembly. An application of
penetrating oil will permit ease of
removal when rust or corrosion has
caused shaft to adhere to the bearing. Do
Front Housing not attempt to remove it by supporting
Figure 13 - Removal of Retaining Screws.

the end head and pressing on the shaft, as
this may result in distortion of the end
head or stripping of the retainer plate
screws. Remove the three retainer
Press Ram washers and screws, and press the
1 Inch DIA bearing out of the end head, as shown in
Bar Stock
Front
Housing
(Figures 13 and 14). Discard the
bearing. Remove rotor stop spacer from
2” ID Pipe the shaft for cleaning and inspection. Do
3” Long
not remove the rotor stop-ring from the
Press
Bed
rotor shaft unless it has been damaged
and must be replaced.
Figure 14 - Removal of
Drive End Bearing.


this type are readily available from Automotive Equipment Suppliers.
An alternate recommended method of bench testing the alternator and its components
requires the use of a Volt-Ohm-Meter (VOM). Equipment of this type is generally available
from electronic equipment suppliers. Typical VOM’s which would be adequate are the
Simpson 260, Triplett 630 and other equivalent models.
1. Testing Diodes: (Figure 15) A digital multimeter with

diode testing function may be used for this test. An analog
meter, as shown, may also be used. The stator must be
disconnected from the rectifier assembly to perform this
test (Rectifier shown removed for clarity).
Set the ohmmeter selector switch on a resistance scale 1.

Test the negative diodes by connecting one ohmmeter lead
to “GRD” post terminal on rectifier and connect other lead
to each stator lead connection of rectifier momentarily.
Reverse ohmmeter leads and check in opposite direction.
Meter must show continuity in one direction, and infinity
(no needle movement) in other direction. Figure 15-Testing Diodes.
Test the positive diodes by connecting one ohmmeter lead to the “BAT” terminal on
rectifier and other lead to each stator lead connection at rectifier momentarily. Reverse
ohmmeter leads and check in the opposite direction. Meter must show continuity in one
direction and infinity in other direction. Gently push, pull, and wiggle the connections
while testing diodes to locate intermittent conditions.
Test Conclusion: If continuity is observed in both directions, the diode(s) is/are shorted.
If no continuity is observed in both directions, the diode(s) is/are open. Replace the
rectifier assembly if open or shorted diodes are found.
NOTE:
Some VOM’s due to their electrical circuitry and characteristics may

indicate a slightly different reading in one direction, example 35 ohms. If all
the diodes indicate this same reading in one direction and infinity in the
other direction, the rectifier assembly should be considered functionally OK
and acceptable for further service.

2. Rotor Continuity Test: (Figure 16) - Set the ohmmeter
selector switch on resistance scale 1. Touch one lead
of ohmmeter to each segment of the slip ring. Refer
to the applicable Service Information data for

indicative of either a damaged solder connection at
the slip ring or a broken coil wire. Readings lower
Figure 16 - Rotor
than specified ohms indicate a shorted wire or slip
Continuity Test.
ring. Replace the rotor if it is defective.
3. Rotor Ground Test: (Figure 17) - Set the

Ammeter selector switch on 1000 scale. Touch
one lead to the rotor shaft and the other lead to
first slip ring then to the other. The ohmmeter
should read infinity in both checks.


!
NOTE:
prove satisfactory, and the “Field Circuit Open or Ground Test” (Figure 6 on
page 04-920-01) showed trouble, the brushes are potentially at fault.
(Figure 18), or use an ohmmeter. The acceptable Ammeter
ranges for rotor current draw and resistance are listed Rheostat
on the individual service specification pages in the Voltmeter
Service Information section of this manual. Excessive
current draw or a low ohmmeter reading indicates
shorted windings. No current draw or an infinite Battery
Rotor
ohmmeter reading indicates an open winding. If either
case exists, discard the rotor and replace with a new Figure 18 - Rotor
Winding Test.
one. No rewound rotors are approved without factory
and FAA approval.

4. Stator Ground Test / Continuity Test: (Figures 19 and

20) - The stator can be tested for grounded, open or
shorted windings using an ohmmeter, in the
following manner.
5. Test for Grounded Windings: (Figure 19) – Set

Ohmmeter selector switch on resistance scale 1000
and zero the meter. Connect one meter lead to bare
metal portion of stator core and other lead alternately
Figure 19 - Stator Ground Test.

to each of the stator leads. The ohmmeter should read
infinity (no needle movement). Be sure lead is
making good contact with stator core surface.
Test Conclusion: If the ohmmeter indicates

any continuity reading, the stator is grounded
and must be discarded and replaced.

surge/hipot tester, such as the Baker
instrument, model ST106A. Refer to the
manufacturer for suitable instructions and
settings.

6. Test for Open Windings: (Figure 20) - Set the ohmmeter selector switch on resistance scale
1. Connect ohmmeter leads alternately between all three sets of leads. Meter reading
should be equal between any pair of stator leads. If not, then the stator is defective and
must be discarded.
7. Pulley, Rotor Shaft, Spacer, Fan, Drive End Head, and Slip Ring End Head: Must be
inspected to the tolerance and limitations outlined in Section 5. Any component not
meeting the tolerance requirements of Section 5 must be replaced with new or serviceable
component. Replace any fan or pulley that is loose, bent , or out of shape.
8. Front and Rear Housing: Clean both housings using a non-corrosive chemical degreaser to
remove grease and dirt. Air dry with filtered low pressure compressed dry air or wipe dry
with clean cloth. Inspect both housings for stripped threads, cracks on exterior and interior
surfaces, and wear and corrosion in the bearing mounting area. Replace housing at
reassembly if any of the above faults are noted.
bearing retainer plate, bearing snap ring retainer, shaft spacer, etc., for any damage, wear,
corrosion, or distortion. Replace any faulty parts at reassembly. Hardware that will be
reused shall be cleaned as required, using a non-corrosive chemical degreaser. Air-dry
parts using filtered low pressure compressed dry air or wipe dry with clean, lint free, cloth.

stainless steel brush springs for any deformation. Replace Brush Holder Assembly if they
are damaged (rectangular style brushes). Replace brushes if damaged (round style).
!
1. Prior to installing, the drive end (front) bearing

(Figure 21), thoroughly clean the bearing bore
and the O.D. of the bearing itself. Apply thin film Press Ram
of Locktite #609 to both surfaces. This bearing is 1 1/4 Inch

a line to line press-fit in the housing. Under I.D. Pipe
New Bearing
Apply
normal circumstances, bearing can be installed Pressure Drive
to Outer End
with only finger pressure. However, in some Race Only Housing
instances, application of light pressure in a press
will be expedient, using extreme care not to Press
Table
damage the bearing.
Position front housing in press as shown. Figure 21 - Drive End

Position bearing squarely into bearing pocket in Bearing Installation.
housing. Use a 1-1/4 inch diameter pipe to press
bearing into housing. Apply pressure
evenly on the outer race only. Pressure on Front Bearing
Screw & Washer Assembly
inner race will damage bearing.
2. Install three bearing retaining screws to

front housing as shown in (Figure 22).
Incrementally tighten screws assemblies
to a torque value of 25-40 in.-lbs. Do not
over-tighten.
3. Install front housing to rotor assembly. Front Housing
Figure 22 - Bearing Retainer Installation.

Slide rotor stop, counter bore facing the
stop ring onto shaft and against stop ring.
Slide rotor shaft, counter bore facing the
stop ring, through housing and bearing.
Install fan spacer, woodruff key, fan and pulley assembly, pulley spacer, lockwasher and
nut. Tighten the nut to 67-77 ft.-lbs.

!
CAUTION: DO NOT CLAMP ROTOR POLE Press Ram 7/8 Inch
FINGERS IN A VISE. DAMAGE TO THE DIA Press
ROTOR FINGERS WILL PRODUCE NOISY 1 Inch ID Pipe or

Rear Bearing Tool with
OPERATION OR BROKEN FINGERS. A Housing 1/8 Inch Wall
Thickness
HEX HOLE, PROVIDED IN THE DRIVE
END OF THE ROTOR SHAFT FOR USE
DURING PULLEY NUT TIGHTENING OR
LOOSENING, SHOULD BE UTILIZED.
USE IMPACT WRENCH IN THE EVENT Press Bed
THAT THE SHAFT DOES NOT
INCORPORATE A HEX HOLE.
Figure 23-Rear Bearing Installation.
4. Install the slip ring end bearing in the rear
bearing housing (Figure 23) making certain to
properly support the slip ring housing. Position rear housing in press and support with 1
inch I.D. pipe as shown. Position bearing squarely into bearing pocket of housing. Using
a 7/8 inch DIA punch or bar stock, press bearing into housing.
5. Install rectifier assembly to stator assembly

(Figure 24). Solder three stator lead wires to
rectifier terminals with 60/40 rosin core solder.
Polarity is not important but solder each wire to
the nearest terminal with the center wire on the
center terminal. Maintain a spacing of
approximately one inch between circuit board
and stator core. Bend surplus length of stator
wire sideways to prevent them from contacting
Figure 24 - Rectifier
the rear housing. Add Loctite® Durabond
E-20NS epoxy or equivalent, to stator leads at
to Stator Assembly.
connection for stability. Do Not use RTV.
!
CAUTION: WHEN SOLDERING THESE
CONNECTIONS, USE SOLDER HEAT SINK
CLAMPS OR PLIERS ON THE LEAD
BETWEEN THE SOLDER JOINT AND THE
RECTIFIER. TOO MUCH HEAT WILL
Rear Housing
6. Install brush holder and brush Assembly
(Figure 25). Install springs and brushes into
Brush Holder
brush holder. Install short length of .040 Assembly
plastic or insulated wire through brush holder

to temporarily secure brushes in place. Wire Stationary
Brush
should be long enough to extend through hole Assembly
in housing for removal after housings are MTG Screw

assembled (bare wire might scratch slip ring Spring
when removed).
Figure 25 - Brush Holder Installation.

Removable Brush Assembly

Position the brush holder assembly in the rear
housing as shown in (Figure 26). The Rear Housing Brush Holder Assembly
Retracting
retracting wire will fit through the housing as Wire Hole in
Housing
the brush holder assembly sets in place above
the cavity where the slip ring will fit and as
the brush holder mounting slots line up with
the mounting screw holes in the housing.
Install the mounting screws and torque to

17-25 in.-lbs. Do not over tighten screws.
Figure 26 - Brush Installation.
NOTE:
Improper installation of the
brushes in the brush holder will result in damage the brushes, brush holder
assembly, rectifier, stator or rotor.
7. Install stator and rectifier

assembly to rear housing Battery External Insulator
(Figure 27 and 28). Install

insulator on “BAT” post of
rectifier assembly and install
insulators (2) in place in the Brush Block Assembly
rear housing for mounting “Bat” Internal

Insulator
bolts in positive “BAT” side
of rectifier. Carefully install Rectifier
Assembly
rectifier and stator into rear
Capacitor
housing, assure insulators
are in place. Install “BAT”
post insulator and nut and
“GRD” post retainer nut,
finger tight.
Stator Assembly
Figure 27 - Stator and Rectifier Installation.

Install the four rectifier
retainer bolts (check
insulators on positive side) finger tight, and install
suppression capacitor lead to rectifier and tighten
screw. Tighten “BAT” and “GRD” retainer nuts then
4 rectifier retainer bolts.
8. Install rear housing, rectifier, and stator assembly.

Before assembling the alternator front and rear
sections, wipe the rear bearing surface of the rotor
shaft to insure a clean, dry surface.
Position rear housing to front housing in accordance

with reference line scribed across the housings at Figure 28 - Stator and
Rectifier Installation.
teardown. Be sure that stator is properly seated to

both housings. Align through-bolt ears on rear housing with threaded holes on front
housing. Install three through-bolts finger tight.
Tighten the through-bolts evenly by tightening each a little at a time in sequence until all
are tight. Spin the rotor to make sure there is no mechanical interference. Torque to
75-85 in.-lbs.
!
ALTERNATOR.

Wiring connections for bench testing the alternator
Battery Field
are shown in (Figure 29). Refer to the Alternator
Service Information Section for the output test Ground
figures. Adjust the carbon pile, if necessary, to
obtain the specified voltage. The alternator is now
ready for installation on the engine. Always refer to
the airframe manufacturers wiring diagram when
installing the alternator or testing the alternator on
the aircraft.
Stator
Figure 29 - Wiring Connections for

Bench Testing Alternator.

ELECTRICAL SYSTEM:


circuits.
electrical circuit.

NOTE:
component MUST be discarded and replaced with new or serviceable component.

TROUBLESHOOTING:
Chart.
excessively.

4. Bent fan.

harness.
3. Dirty slip ring.


ES4020 Belt Driven (Chrysler Style)
…………………………………………………………
Covers Alternator Series: ES4020. ES1009
NOTE:
GENERAL:

designed and constructed to provide extended periods of
trouble-free operation with a minimum amount of
maintenance. They will withstand the vibration and
extreme temperature changes encountered in aircraft
applications. This information is provided for use on
HET PMA alternators only.
Figure 1 - ES4020
Series Alternator.

The principle components (Figure 2) of the aircraft alternator are (1) the brush rack
assemblies, (2) the slip ring end head, (3) the rectifier assembly, (4) the stator, (5) the rotor,
(6) the drive end head, (7) the bearings, and (8) pulley.
Figure 2 -
Principle
Components of
ES4020 Series
3
Alternator. 2
8
1 6
7
5
4
7 1

The rotor shaft is supported at each end by bearings. The front bearing (ball type) is a press-
fit on the rotor shaft and is retained in the front housing with a retainer. The rear bearing
(needle-type) is pressed into the rear housing. The slip rings and the core and coil assembly
are press-fitted to the shaft with a rotor half enveloping each end of the coil. The rotor core
and coil assembly turns inside the stator core and coil assembly with a very narrow air gap
between the two assemblies. This narrow clearance permits maximum magnetic induction.
1. The brushes (2) are in separate assemblies. The brushes in the alternator ride the surfaces
of the slip rings on the rotor shaft under spring pressure and transmit field current through
their circuit to ground.
2. The slip ring end head provides the mounting for the rectifier assembly, output terminal
bolt and field terminal studs. The slip ring end head accepts a needle bearing with integral
grease seal.
3. The rectifiers used in these

units are rated at 400 volts.
Three positive and three
negative rectifiers are
mounted in the rectifier
assembly which is then
mounted in the slip ring end
head. Each pair of rectifiers is connected to
a stator lead with ring terminal fastened to
a stud with a nut.
Figure 3 - Rectifier Assembly.

The rectifier assembly is located between the stator
and the inside surface of the rear housing. It is
attached to the housing by means of the B+ terminal
and a stud mounted in the housing, and four mounting bolts on the outside of the housing
above the rectifier assembly. The positive plate is insulated from the housing, the negative
plate is grounded to the housing through the four mounting bolts. See (Figure 3).
4. The stator consists of a laminated iron core on

which three phase windings are wound in slots around
the inside circumference. Ring terminals are soldered to
the ends of each of the three phase windings (Figure 4),
and each terminal is connected to a pair of rectifiers,
one negative and one positive on a stud on the rectifier
Figure 4 - Stator Assembly.

assembly. The stator has been treated with a special epoxy varnish for high temperature
resistance.
A number of steel stampings are riveted together to form the stator core. The inner surface
of this core contains 36 equally spaced vertical slots which accommodate the stator coil
windings.
5. The rotor consists of a single field coil encased between two six-pole, interleaved iron

complete overhaul is covered step-by-step to provide detailed information on each operation.
manual.
!
ELECTRICAL SYSTEM COMPONENT AND MAY RESULT IN INJURY.
NOTE:
1. Brush Assemblies
4. Thru-bolts and Lock Tabs.
5. Lock Washers, Terminal Stud Nuts
6. Positive and Negative Rectifier Assemblies
7. Capacitor
8. Ground, Field and Battery Nut and Washer Hardware

1. Arc Marks on Terminals (Visual Inspection): Before disassembling the alternator, the
DIODE must be tested before the alternator is returned to service.
each time the loose connection makes or breaks. Chattering contacts cause the contacts
to arc excessively with consequent rapid contact erosion.

removal for the engine. The purpose of the inspection is to determine whether either of
the bearings are a potential noise or failure item.
with the other hand. A defective bearing can be heard or felt. In noisy conditions, press
the alternator housing to your ear lobe and snap-spin the pulley a few times.
To determine which bearing is defective, separate the alternator housings. Snap-spin the
surface irregularities. Inspect rear bearing for damage to rollers, rubber seal, or bearing
case. Also look for missing rollers. If grease is hard and dry when smeared or excessively
dirty, the bearing should be replaced. NOTE:
Bearings are to be discarded and replaced with new
at overhaul. Do not attempt to add new grease to a
dry bearing.

lead to the “FLD” terminal and the other lead to
“FLD” terminal closest to the B+ terminal (Figure
5). Spin the pulley and note ohmmeter reading. Figure 5 - Field Circuit
Open or Ground Test.
Meter should read between 4 and 25 ohms while
rotor is turning.

1. Using a marker, scribe a line across both housings and stator for proper alignment when
re-assembling. Bend lock tabs from the thru-bolts. Separate the front housing and rotor
from the rear housing assembly by removing the thru-bolts. Discard the thru-bolts and
lock tabs.
2. Lightly tap the drive end head to separate the

drive end head and rotor, as a unit, from the
stator and slip ring end head. Separate rear
housing from front housing by sliding stator
over rotor with one continuous motion to
reduce possibility of breaking one of the
brushes against the slip ring.
3. Remove the three nuts from the rectifier.

Slide the rectifier terminals and stator out of
Figure 6 - Rectifier Terminal Removal.
the rear housing as shown in (Figure 6).
4. Remove the two screws that attach the

brush holder assemblies to rear housing
(Figure 7). Remove brush holder
assemblies from rear housing. Replace
brushes with new at overhaul.
5. Remove slip ring end bearing. Position

rear housing in arbor press. Use the
special tools shown in (Figure 8) or
fabricate tools to the dimensions
Fig. 7-Brush Holder Assembly Removal.

indicated.
Support the rear housing at the area directly

below the bearing boss, as shown, to prevent
damage or distortion to the housing. Remove
and discard the slip ring bearing.
6. Remove rectifier assembly. Remove battery

bolt nut washer and insulator, and internal nut,
washer and insulator from capacitor side.
Remove four bolts from outside of housing.
Rectifier is now loose. Note position of
insulators and washers inside and out. Fig 8-Slip Ring End Bearing Removal.

7. Remove pulley (Figure 9). A puller, Snap-On part
#CJ117C, must be used to remove pulley. DO NOT try to
press it off any other way.
8. Remove rotor. The rotor shaft is press fit into the front
bearing. To remove the rotor shaft and bearing from the
drive end head, push back the three black clips you see on
the front of the housing. Units have three bolts that also
must be removed. Support the housing over an opening
large enough to surround the rotor. Push on end of rotor
shaft to remove rotor and bearing. Remove bearing from
shaft with bearing puller.
Figure 9 - Pulley Removal.

A voltmeter, ammeter and carbon pile are recommended for bench testing the alternator. The
voltmeter, ammeter and carbon pile are often combined in one unit. Testers of this type are
readily available from Automotive Equipment Suppliers.
An alternate recommended method of bench testing the alternator and its components requires
the use of a Volt-Ohm-Meter (VOM). Equipment of this type is generally available from
electronic equipment suppliers. Typical VOM’s which would be adequate are the Simpson
260, Triplett 630 and other equivalent models.
1. Rotor Continuity Test: (Figure 10) Set the

ohmmeter selector switch on resistance
scale 1. Touch one lead of ohmmeter to
each segment of the slip ring. Refer to the
applicable Service Information data for
An infinite reading on the ohmmeter is

usually indicative of either a damaged
solder connection at the slip ring or a

broken coil wire. Readings lower than
specified ohms indicate a shorted wire or
slip ring. Replace the rotor if it is defective.

2. Rotor Ground Test: (Figure 11) Set the
ammeter selector switch on 1000 scale.
Touch one lead to the rotor shaft and the
other lead to first slip ring then to the other.
The ohmmeter should read infinity in both
checks.
If the meter shows a reading, a

s h o r t t o g r o u n d exists. Check the
soldered connections at the slip rings to
make sure they are secure and not Figure 11 - Rotor Ground Test.
grounding against the rotor shaft, or that
excess solder is not grounding the rotor coil.
Replace the rotor if it is defective.
!
SCRATCH THE MACHINED COPPER SURFACE OF THE SLIP RING.
A NICK OR SCRATCH CAN RESULT IN INCREASED BRUSH WEAR.
NOTE:
prove satisfactory, and the “Field Circuit Open or Ground Test” (Figure 4)
showed trouble, the brushes are potentially at fault.
To test for shorted turns in the rotor winding, connect a voltmeter, ammeter, rheostat and
battery, or use an ohmmeter. The acceptable ranges for rotor current draw and resistance
are listed on the individual service specification pages in the Service Information section
of this manual. Excessive current draw or a low ohmmeter reading indicates shorted
windings. No current draw or an infinite ohmmeter reading indicates an open winding.
If either case exists, discard the rotor and replace with a new one. No rewound rotors are
approved without factory and FAA approval.
exception of the slip ring repair noted in step “e”):
a. Worn and/or corroded bearing journal surfaces of the drive end and slip ring end.
b. Loose slip ring assembly or pole pieces on shaft.
c. Gouged, bent cracked or excessive corrosion of pole pieces.
d. Bent, gouged, or excessive corrosion of shaft.
e. Slip rings which are rough or out of round may be trued in a lathe (do not chuck shaft

The finished slip ring diameter is found in the Specifications and Tolerances section
f. Burned/discolored coil (insulation will flake off burned coil). Damaged varnish is not
repairable.
3. Stator Ground Test/Continuity Test: The stator can be tested for grounded, open or shorted
windings using an ohmmeter, in the following manner.
4. Test for grounded windings: (Figure 12) Set

ohmmeter selector switch on resistance
scale 1000 and zero the meter. Connect one
meter lead to bare metal portion of stator
core and other lead alternately to each of the
stator leads. The ohmmeter should read
infinity (no needle movement). Be sure
lead is making good contact with stator core
surface.
Test Conclusion: If the ohmmeter indicates Figure 12 - Grounded Windings Test.

any continuity reading, the stator is grounded
and must be discarded and replaced.
An alternate method for testing the stator for grounded windings is to utilize an
5. Test for open windings: (Figure 13) Set

the ohmmeter selector switch on
resistance scale 1. Connect ohmmeter
leads alternately between all three sets of
leads. Meter reading should be equal
between any pair of stator leads. If not,
then the stator is defective and must be
replaced.
Test Conclusions: If unequal readings
Figure 13 - Open Windings Test.

are obtained, the stator winding is open.
Check wiring junction, if breaks are
found replace and recheck.

rewound stators are approved without factory or FAA approval.
a. Pulley, Rotor Shaft, Drive End Head, Slip Ring End Head, and Bushing: Must be inspected
tolerance requirements of Section 5 must be replaced with new or serviceable
component. Replace any pulley that is bent or out of shape.
b. Front and Rear Housing: Clean both housings using a non-corrosive chemical
c. Mounting Hardware: Inspect any removed metallic hardware, i.e., screws, flatwashers,
bearing retainer plate, etc., for any damage, wear, corrosion, or distortion. Replace
any faulty parts at reassembly. Hardware that will be reused shall be cleaned as
required, using a non-corrosive chemical degreaser. Air-dry parts using filtered low
d. Insulators (Washers and Spacers): Inspect parts for cracks, deformation, and burn
marks. Parts suitable for reuse, shall be cleaned as required using isopropyl alcohol.
Any other cleaner may damage insulators. Air-dry parts with filtered low pressure
compressed dry air or wipe dry with clean, lint free cloth.
e. Brush Assemblies, Brushes and Springs: Inspect assemblies for cracks and breaks in
plastic and bent metal bracket. Replace if damaged, at reassembly. Discard the brush
assemblies and replace with new.
!

Figure 14-Drive End Bearing Installation. Figure 15-Drive End Bearing Installation.
1. Install the drive end (front) bearing.

Apply thin coat of Locktite #609 to the
front housing bearing bore ID and press
bearing into bore with an Arbor press as
pictured in (Figures 14 and 15). Install
bearing retainer (Figure 16).
2. Install front housing to rotor assembly.

Thoroughly clean the rotor shaft and the
I.D. of the bearing itself. Position bearing
Figure 16-Bearing Retainer Installation.
squarely onto shaft. This bearing is a line
to line press-fit on the shaft. Use extreme
care not to damage the bearing. Position
rotor in press as shown in (Figure 17). Use a 3/4 inch
diameter pipe (or equivalent tool) under bearing to press
bearing onto shaft. Apply pressure evenly on the inner race
only. Pressure on outer race will damage bearing.
3. Install pulley assembly. Install the pulley. Place pulley

flange side down, and insert rotor shaft into pulley. Press
rotor into pulley
from slip ring
end of shaft, Figure 17 - Press
Rotor Into Housing.
being careful not
to damage
surface of shaft
that rides in the needle bearing.
4. Install the slip ring end bearing in the

rear bearing housing (Figure 18) making
certain to properly support the slip ring
Fig 18-Slip Ring End Bearing Installation. housing. Position rear housing in press

and support with 1 inch I.D. pipe as shown.
Position bearing squarely into bearing pocket
of housing. Using the special tool shown in 2.78
(Figure 19), press bearing into housing. Note:
that the use of the special tool will recess the
slip ring end bearing .150 inches from the 0.925 1.06
outer edge of the housing (Figure 20).
0.150
5. Install rectifier assembly to slip ring end
housing. See (Figure 21).
Figure 19-Slip Ring End Installation Tool.
a. Install terminal
block and
attaching
screws. Torque
to 17-25 in.-lbs.
b. Install positive
Figure 20 - Slip Ring
rectifier and
End Bearing
insulators.
Installation.
Torque to 25-35
in.-lbs.
c. Install inner nut and capacitor. Torque Figure 21-Rectifier Assembly Installation.
to 25-35 in-lbs. Secure capacitor with
screw. Torque to 25-35 in.-lbs.
d. Install negative rectifier. Torque to 25-35 in.-lbs.
6. Install stator (Figure 22). Install stator

terminals over rectifier bolts and tighten nuts.
Torque to 17-25 in.-lbs.
7. Install rear housing, rectifier, and stator

assembly. Before assembling the alternator
front and rear sections, wipe the rear bearing
surface of the rotor shaft to insure a clean dry
surface.
Figure 22 - Stator Installation.

Position rear housing to front housing in
accordance with reference line scribed across
the housings at teardown. Be sure that stator
is properly seated to both housings. Align thru-bolts ears on front housing with threaded
holes on rear housing. Install three thru-bolts and lock tabs finger tight.

Tighten the thru-bolts evenly by tightening each a little at a time in sequence until all are
tight. Spin the rotor to make sure there is no mechanical interference. Torque to
40-60 in.-lbs.
Install brush assemblies, torque to 17-25

in.-lbs. (Figure 23). Spin the rotor and
check for interference between the brush
holders and rotor. Measure the
resistance across the field terminals with
an ohmmeter. The ohmmeter must
indicate the amount of rotor resistance
listed in the Alternator Service
Information section of this manual.
Figure 23 - Install Brush Assemblies.

Lock tabs should be bent on the thru-
bolts only after the unit has been bench
tested for output.

Wiring connections for bench testing the Field (FLD)
alternator are shown in (Figure 24). Refer to the
Alternator Service Information section for the
Field
output test figures. Adjust the carbon pile, if (FLD)
necessary, to obtain the specified voltage. The

alternator is now ready for installation on the
Battery
engine. Always refer to the airframe (BAT)
manufacturers wiring diagram when installing the
alternator or testing the alternator on the aircraft.
Figure 24 - Wiring Connections for

Bench Testing Alternator.

ELECTRICAL SYSTEM:


circuits.
electrical circuit.

NOTE:
component MUST be discarded and replaced with new or serviceable component.
SPECIFICATIONS:
Table 1:
Specifications APPLICATION:
TYPE: Type I; 60-amp, 14 Volt, Belt Drive, Bracket Mount.
Chart.
Aircraft
PULLEY: Press fit to shaft, single groove.
FAN: Internal
RPM: Up to 15,000 RPM maximum.
BEARINGS: Front: Single-row, double-sealed ball bearing.
Rear: Roller bearing, rides on shaft O.D., neoprene seal.
BRUSHES: Original length: 1/2 inch, spring tension: 6 to 8 oz.
ROTATION: Directional – counter clockwise.
ROTOR: 12-pole with 3.7 ohm (nominal) coil
STATOR: 3-Phase wye configuration
RECTIFICATION: Full wave utilizing 6 diodes: 3 positive, 3 negative
DIODES: Silicon, button, hermetically sealed
SLIP RINGS: Seamless copper. Concentricity with shaft .0005 inch.
WEIGHT: 13 pounds.

TROUBLESHOOTING:
Chart.
excessively.


harness.
3. Dirty slip ring.
NOTE:
Additional information regarding continued airworthiness including
the periodic inspection chart and additional troubleshooting
information may be found on pages 3-470-01 thru 3-530-01.

Alternator Specifications
And Tolerances All HET Alternator Styles
………………………………………………………… 5
INCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30-01
Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30-01
Rotor Shaft Spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40-01
Vent Fan Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40-01
Drive End Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40-01
Slip Ring End Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40-01
Rotor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-50-01
Stator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-50-01
Bushing for SRE Head Assembly - Belt Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-50-01
Bushing for Drive End Head Assembly - Belt Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-50-01
MILLIMETERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-60-01
Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-60-01
Rotor Shaft Spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-70-01
Vent Fan Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-70-01
Drive End Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-70-01
Slip Ring End Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-70-01
Rotor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-80-01
Stator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-80-01
Bushing for SRE Head Assembly - Belt Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-80-01
Bushing for Drive End Head Assembly - Belt Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-80-01


Alternator Specifications
And Tolerances All HET Alternator Styles
………………………………………………………… 5
All Specifications and Tolerances in Inches
Part Measurement Part Dimension
Description Area Number Maximum Minimum
Pulley Groove - Diameter PU-672A - Check with .3125 (5/16) pin or ball 3.20
PU-672B - Check with .3125 (5/16) pin or ball 3.20
PU-676A - Check with .3125 (5/16) pin or ball 2.85
4102 - Check with .3125 (5/16) pin or ball 3.03
Key Seat - Width PU-672A .162

PU-672B .162
PU-676A .161
PU-692A .130
4102 .128
4212 .160
4249 .160
40082 .162
40088 .162
40092 .162
Key Seat - Height* PU-672A .750

PU-672B .750
PU-676A .750
PU-692A .739
4102 .745
4212 .740
4249 .760
40082 .750
40088 .750
40092 .750
Bore I.D. PU-672A .673

PU-672B .673
PU-676A .671
PU-692A .672
4102 .671
4212 .675
4249 .671
40082 .673
40088 .673
40092 .673
* Height measured from bottom of Bore I.D. to top of Key Seat

Rotor Shaft Spacer Height - Thickness ALD-21 / ALD-21A .350
ALC-21F .402
ALU-23 .613
ALB-21 .463
ALV-21 .743
ALV-210 .643
4141 .364
4185 .149
4186 .459
4186-1 .256
4220 .344
4220-1 .284
Vent Fan Limits** Bore I.D. 90-2241 .674

90-2259 .674
40089 .671
Key Seat Width 90-2241 .210

90-2259 .210
40089 .160
Drive End Head Bearing Bore I.D. All except ALV series 1.575
ALV series 2.441
Bearing Bore Height All except ALV series .455

ALV series .665
Oil Seal Seat I.D. ALU-1043 1.251

ALU-1003 1.500
ALV-1003 2.063
4139 1.376
Oil Seal Seat Height ALU-1043 .290

ALU-1003 .375
ALV-1003 .420
4139 .660
Stator Seat I.D.*** All except ALV series, 4123 and 4193 5.010
ALV series 6.452
4103 and 4139 5.257
4204 6.361
Bearing Retainers Visual Inspection of three screw holes for

elongation and wear from the bearing.
Slip Ring End Head Bearing Bore I.D. All p/n except ALV series 0.937
ALV Series 1.576
ALV series 6.452
4123 5.257
4193 6.361
Diode Holes I.D. All P/N series .501
** Fan Back Plate - Each fan assembly has a dish shaped back plate to provide vibration dampening, at any time the plate loses
its dish shape or is damaged it is to be replaced with a new fan and spacer assembly.

Rotor Assembly Outside Body All early P/N’s 3.472 3.466
P/N’s 4109, 4109-2, 4143, 4144, 4145, 4223 3.580 3.577
and 40009 and 40009-1
P/N’s 4199, 4200, and 40048 4.465 4.460
ALV Series P/N’s except ALV-9510 4.721 4.718
ALV-9510 3.988 3.990
40005 3.570 3.566
4307 4.766 4.760
Bearing Journal Wear All early P/N’s .6693 .6688
on Rotor Shaft at SRE P/N’s 4109, 4109-2, 4143, 4144, 4145, 4223 .6693 .6688
P/N’s 4199, 4200, and 40048 .6696 .6690
ALV Series, all except ALV-9510 .6696 .6693
ALV-9510 with ALV-3006A rotor .6693 .6688
40005, 40009 and 40009-1 .6696 .6692
4307 .6699 .6694
Bearing Journal Wear All early P/N’s .6696 .6693
on Rotor Shaft at DE P/N’s 4109, 4109-2, 4143, 4144, 4145, 4223 .6690 .6684
P/N’s 4199, 4200, and 40048 .6696 .6692
ALV Series, all except ALV-9510 .9846 .9842
ALV-9510 with ALV-3006A rotor .6696 .6693
40005, 40009 and 40009-1 .6690 .6684
4307 .6699 .6694
Stator Assembly Stator Lead Length All p/n except ALV series 2.00
(Stator to end of lead) ALV series 2.50
Stator Core I.D All p/n except ALV series, 4146, 4147, 4149,
4194, 423 3.490 3.475
ALV Series 4.745 4.730
4146, 4147, 4149, 40010 3.605 3.599
4194, 4235 4.502 4.499
Stator Core Thickness ALE2008AA & AB 1.344 1.335
ALE2008AD,G,AE, AG .969 .960
ALV Series 1.5175 1.5120
4146, 4147, 4149, 40010 .855 .845
4235, 4194 1.025 .990
Bushing Insert for SRE Head Assembly - Belt Drive:

Alternator Type: Bushing Part Number:
ALE Series ALE-20
ALT Series ALE-24
ALU Series ALE-24
ALX Series ALE-24
ALY Series ALE-20
ALZ Series ALE-20
ALV Series Bushing molded in place, replace

SRE Head Assembly.
Bushing Insert for Drive End Head Assembly - Belt Drive:

Alternator Type: Bushing Part Number:
All Head Assembly (ALE-1003K,R) ALE-20
NOTE:
!
Any serviceable limit or tolerance not
CAUTION: WELD REPAIRS ARE
met by a component MUST be discarded
and replaced with a new or serviceable
component. NOT APPROVED.

All Specifications and Tolerances in Millimeters
Pulley Groove - Diameter PU-672A - Check with .3125 (5/16) pin or ball 81.28
PU-672B - Check with .3125 (5/16) pin or ball 81.28
Key Seat - Width PU-672A 4.12

PU-672B 4.12
PU-676A 4.09
PU-692A 3.30
4102 3.25
4212 4.06
4249 4.06
40082 4.12
40088 4.12
40092 4.12
Key Seat - Height* PU-672A 19.05

PU-672B 19.05
PU-676A 19.05
PU-692A 18.77
4102 18.92
4212 18.80
4249 19.30
40082 19.05
40088 19.05
40092 19.05
Bore I.D. PU-672A 17.09

PU-672B 17.09
PU-676A 17.04
PU-692A 17.07
4102 17.04
4212 17.15
4249 17.04
40082 17.09
40088 17.09
40092 17.09
* Height measured from bottom of Bore I.D. to top of Key Seat

Rotor Shaft Spacer Height - Thickness ALD-21 / ALD-21A 88.90
ALC-21F 10.21
ALU-23 15.57
ALB-21 11.76
ALV-21 18.87
ALV-210 16.33
4141 9.25
4185 3.79
4186 11.66
4186-1 6.50
4220 8.74
4220-1 7.21
Vent Fan Limits** Bore I.D. 90-2241 17.12

90-2259 17.12
40089 17.04
Key Seat Width 90-2241 5.33

90-2259 5.33
40089 4.06
Drive End Head Bearing Bore I.D. All except ALV series 40.01
ALV series 62.00
Bearing Bore Height All except ALV series 11.30

ALV series 16.89
Oil Seal Seat I.D. ALU-1043 31.78

ALU-1003 38.10
ALV-1003 52.40
4139 34.95
Oil Seal Seat Height ALU-1043 7.37

ALU-1003 9.53
ALV-1003 10.67
4139 16.76
ALV series 163.88
4103 and 4139 133.53
4204 161.57
Bearing Retainers Visual Inspection of three screw holes for

elongation and wear from the bearing.
Slip Ring End Head Bearing Bore I.D. All p/n except ALV series 23.80
ALV Series 40.03
ALV series 163.88
4123 133.53
4193 161.57
Diode Holes I.D. All P/N series 12.73
** Fan Back Plate - Each fan assembly has a dish shaped back plate to provide vibration dampening, at any time the plate loses
its dish shape or is damaged it is to be replaced with a new fan and spacer assembly.

Rotor Assembly Outside Body All early P/N’s 88.19 88.04
P/N’s 4109, 4109-2, 4143, 4144, 4145, 4223 90.93 90.86
and 40009 and 40009-1
P/N’s 4199, 4200, and 40048 113.41 113.28
ALV Series P/N’s except ALV-9510 119.91 119.84
ALV-9510 101.35 101.30
40005 90.68 90.58
4307 121.06 120.90
Bearing Journal Wear All early P/N’s 17.000 16.987
on Rotor Shaft at SRE P/N’s 4109, 4109-2, 4143, 4144, 4145, 4223 17.000 16.987
P/N’s 4199, 4200, and 40048 17.008 16.987
ALV Series, all except ALV-9510 17.008 17.000
ALV-9510 with ALV-3006A rotor 17.000 16.987
40005, 40009 and 40009-1 17.008 16.997
4307 17.015 17.003
Bearing Journal Wear All early P/N’s 17.008 17.000
on Rotor Shaft at DE P/N’s 4109, 4109-2, 4143, 4144, 4145, 4223 16.993 16.977
P/N’s 4199, 4200, and 40048 17.008 16.997
ALV Series, all except ALV-9510 25.009 24.998
ALV-9510 with ALV-3006A rotor 17.008 17.000
40005, 40009 and 40009-1 16.993 16.977
4307 17.015 17.003
Stator Assembly Stator Lead Length All p/n except ALV series 50.80
(Stator to end of lead) ALV series 63.50
Stator Core I.D All p/n except ALV series, 4146, 4147, 4149,
4194, 423 88.65 88.27
ALV Series 120.52 120.14
4146, 4147, 4149, 40010 91.57 91.41
4194, 4235 114.35 114.28
Stator Core Thickness ALE2008AA & AB 34.14 33.91
ALE2008AD,G,AE, AG 24.61 24.38
ALV Series 38.545 38.405
4146, 4147, 4149, 40010 21.72 21.46
4235, 4194 26.04 25.15
NOTE:
!
Any serviceable limit or tolerance not
CAUTION: WELD REPAIRS ARE
met by a component MUST be discarded
and replaced with a new or serviceable
component. NOT APPROVED.

Starter Service
Parts List
………………………………………………………… 6
ES646 Series (12/24 Volt Starter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30-01
MCL Series (12 Volt Starter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-70-01
MDB Series (24 Volt Starter) (Obsolete) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-110-01
MHB Series (24 Volt Starter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-150-01
Lightweight MHB Series (24 Volt Starter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-190-01
MHJ Series (24 Volt Starter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-230-01
MHP Series (24 Volt Starter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-270-01
MMU Series (24 Volt Starter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-310-01
Lightweight MMU Series (24 Volt Starter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-350-01
MZ Series (12 Volt Starter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-390-01
Lightweight MZ Series (12 Volt Starter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-430-01


ES646 Series
Service Parts List
……………………………………
Starters and their corresponding parts shown in

this section are FAA/PMA approved. 12/24 Volt Starter
REPLACEMENT LIST:
Starter Current Factory Overhaul
Part Replaced Starter Starter Engine/Airframe
Number By Part Number Part Number Application
646238 USE ES646238-2 ES646238-2R Continental (CMI)
646238-1 USE ES646238-3 ES646238-3R Continental (CMI)
646275 USE ES646275-1 ES646275-1R Continental (CMI)
ES646238-2 For Alternate use MRZ-7000 Continental (CMI)

ES646275-1 For Alternate use MRB-7000 Continental (CMI)
NOTE: 1 The “R” at the end of a “Starter Part Number” now signifies Overhauled. See
Parts List for starter being serviced when component parts are required.
Chapter 1 Application Data is presented as reference only. It remains the

NOTE: 2 responsibility of the installer to assure that the selected equipment applies to the
specific aircraft, rotorcraft, or engine the component is being installed upon.

ES646 Series
(Exploded Parts View of Typical ES646 Series Starter)
66 6
22A
22B
18
NOTE 1: Circled items represent new replacement

parts required at each overhaul. If marked
with ∆, replace with new whenever parts are
removed.
NOTE 2: Recessed thru-bolt requires two (2)

lockwashers. (ES646502 only)

No. Part ES646238, -2 ES646238-1, -3 ES646275, -1
1 Oil Seal ∆ ES646328 ES646328 ES646328

2 Drive End Head Assembly ES646326 ES646326 ES646326
3 Roll Pin-Drive End MS16562-21 MS16562-21 MS16562-21
4 Field Coil Package ES646351 (a) ES646351 (a) ES646376 (a)
5 Drive End Bushing ∆ ML-18A ML-18A ML-18A
6 Fiber Washer-Drive End (AR) ∆ ES646368 ES646368 ES646368
X Pole Shoe Blocks (4 ea.) ES652928 ES652928 ES652928
8 Housing Assembly ES646377-2 ES646377-3 ES646378-1
9 Pole Shoe Screw (4 ea.) ES652927 ES652927 ES652927
10 Washer (2 ea.) 50024 50024 50024
11 Washer Insulator 50026 50026 50026
12 Flat Washer 50027 50027 50027
13 Nut-Hex (2 ea.) 50029 50029 50029
14 Lockwasher (2 ea.) MS35338-45 MS35338-45 MS35338-45
15 Square Insulator 50025 50025 50025
16 Terminal Stud 50023 50023 50023
17 Brush Plate Assembly MDL-1064E (a) MDL-1064E (a) MDL-1064E (a)
18 Insulator-Field to Housing 50031 50031 50031
19 Armature ES646333 ES646333 ES646374
20 Thru-bolt (4 ea.) 50037 (d) 50037 (d) 50037 (d)
Thru-bolt (4 ea.) 50037-1 (d) 50037-1 (d) 50037-1 (d)
21 Fiber Washer-Comm. End ∆ (AR) ES646367 ES646367 ES646367
22A Commutator End Head Ass’y 50796 (b) 50796 (b) 50796 (b)
22B Bushing, Commutator End 50044 50044 50044
23 Lockwashers (e) 12X-0199 12X-0199 12X-0199
24 Screw (4 ea.) 8X-5435 8X-5435 8X-5435
25 Solenoid (NR) ES649107 (NR)
26 Connector (NR) ES649108 (NR)
27 Screw (2 ea.) (NR) ES649083-25-5 (NR)
X Brush Spring Set MZ-19S MZ-19S MZ-19S
X Repair Kit 90-3025 (c) 90-3025 (c) 90-3025 (c)
X Brush (a) ∆ ES646348 ES646348 ES646348
Notes:
(NR) Not required.
(a) 90-2526 Brush Set Kit also available (contains all four brushes).
(b) Commutator End Head Ass’y ES646502, ES646330, and 50033 no longer available, new 50796 Comm Head includes bushing.
(c) Includes items, 1, 5, 6, 16, 17, 21, 22, 23, & P/N’s 90-2526 brush set, and MZ-19S brush spring set.
(d) If starter being repaired is equipped with P/N 50033 (stamped steel type) commutator end head, use P/N 50037-1 thru-bolts. If P/N
ES646502 (cast aluminum type) or P/N 50796 (billet aluminum type) is used, use P/N 50037 thru-bolts.
(e) If starter being repaired is equipped with P/N 50033 (stamped steel type) or P/N 50796 (billet aluminum type) commutator end head, use
lockwashers (4 ea.). If P/N ES646502 (cast aluminum type) is used, use lockwashers (6 ea.)
Circled items represent new replacement parts required at each overhaul. Available in repair kits from HET.
O-ring - Starter mounting flange to engine: MS9021-038 not an HET part, procure locally.
Quantities one (1) unless noted.
(AR) As required.

No. Part ES646238, -2 ES646238-1, -3 ES646275, -1
1 Oil Seal ∆ ES646328 ES646328 ES646328

2 Drive End Head Assembly ES646326 ES646326 ES646326
3 Roll Pin-Drive End MS16562-21 MS16562-21 MS16562-21
4 Field Coil Package ES646351 (a) ES646351 (a) ES646376 (a)
5 Drive End Bushing ∆ ML-18A ML-18A ML-18A
6 Fiber Washer-Drive End (AR) ∆ ES646368 ES646368 ES646368
X Pole Shoe Blocks (4 ea.) ES652928 ES652928 ES652928
8 Housing Assembly ES646377-2 ES646377-3 ES646378-1
9 Pole Shoe Screw (4 ea.) ES652927 ES652927 ES652927
10 Washer (2 ea.) 50024 50024 50024
11 Washer Insulator 50026 50026 50026
12 Flat Washer 50027 50027 50027
13 Nut-Hex (2 ea.) 50029 50029 50029
14 Lockwasher (2 ea.) MS35338-45 MS35338-45 MS35338-45
15 Square Insulator 50025 50025 50025
16 Terminal Stud 50023 50023 50023
17 Brush Plate Assembly MDL-1064E (a) MDL-1064E (a) MDL-1064E (a)
18 Insulator-Field to Housing 50031 50031 50031
19 Armature ES646333 ES646333 ES646374
20 Thru-bolt (4 ea.) 50037 (d) 50037 (d) 50037 (d)
Thru-bolt (4 ea.) 50037-1 (d) 50037-1 (d) 50037-1 (d)
21 Fiber Washer-Commutator End ∆ ES646367 ES646367 ES646367
22A Commutator End Head Ass’y 50033 (b) 50033 (b) 50033 (b)
22B Bushing, Commutator End 50044 50044 50044
23 Lockwashers (e) 12X-0199 12X-0199 12X-0199
24 Screw (4 ea.) 8X-5435 8X-5435 8X-5435
25 Solenoid (NR) ES649107 (NR)
26 Connector (NR) ES649108 (NR)
27 Screw (2 ea.) (NR) ES649083-25-5 (NR)
X Brush Spring Set MZ-19S MZ-19S MZ-19S
X Repair Kit 90-3025 (c) 90-3025 (c) 90-3025 (c)
X Brush (a) ∆ ES646348 ES646348 ES646348
Notes:
(NR) Not required.
(a) 90-2526 Brush Set Kit also available (contains all four brushes).
(b) Commutator End Head Ass’y ES646502 no longer available, new ES646330 Comm Head includes bushing.
(c) Includes items, 1, 5, 6, 16, 17, 21, 22, 23, & P/N’s 90-2526 brush set, and MZ-19S brush spring set.
(d) If starter being repaired is equipped with P/N 50033 (stamped steel type) commutator end head, use P/N 50037-1 thru-bolts. If P/N
ES646502 (cast aluminum type) is used, use P/N 50037 thru-bolts.
(e) If starter being repaired is equipped with P/N 50033 (stamped steel type) commutator end head, use lockwashers (4 ea.). If P/N ES646502
(cast aluminum type) is used, use lockwashers (6 ea.)
O-ring - Starter mounting flange to engine: MS9021-038 not an HET part, procure locally.
Quantities one (1) unless noted.
(AR) As required.


MCL Series
Service Parts List
……………………………………..

this section are FAA/PMA approved. 12 Volt Starter
REPLACEMENT LIST:
Starter Replaced Starter Starter Engine/Airframe
MCL-6501 USE MCL-6501 MCL-6501R Continental (CMI)
634592 USE MCL-6501 MCL-6501R Continental (CMI)
NOTE:
The “R” at the end of an “Original Equipment Starter Part Number” now signifies Factory Overhauled.
See Parts List for motor being serviced when component parts are required.

MCL Series (Exploded Parts View of Typical MCL Series Starter)
3
(C)
5
7
8
4
10
14 11
15

12
13 each overhaul.
5

No. Part MCL-6501
1 Bendix Drive (NR)
2 Drive End Bearing ML-18A
3 Drive End Head Assembly MCL-2136
4 Oil Seal ∆ XA-1024
5 Thrust Washer Package 90-2677
6 Armature MCH-2147S
7 Switch (NR)
8 Connector (NR)
9 Thru-bolt Package GJ-20DS
11 Field Coil Package MCL-1005PS-1
12 Brush Plate Assembly MFX-1064S
13 Brush Spring Set MZ-19S
14 Brush Set ∆ MHD-2012S
15 Commutator End Head Assembly MDL-1002*
Notes:
(a) Bearing & Seal Package.
(b) 90-2191 Drive End Head Mounting Screw Package (25 pieces) also available.
(c) 90-2139 Bendix Pin Package (25 pieces) also available.
(d) No longer available.
(NA) Not Available.
(NR) Not Required.
* Bearing Part Number MDC-0034 available separately.


MDB Series
Service Parts List 24 Volt Starter (Obsolete)
…………………………………….……………………
OBSOLETE




MHB Series
Service Parts List
……………………………………..

REPLACEMENT LIST:
MHB-4001 USE MHB-4016 MHB-4016R Lycoming


MHB-4015 USE MMU-4001 MMU-4001R Lycoming

MHB-4019,A USE MHB-4020 MHB-4020R Lycoming
NOTE:

MHB Series (Exploded Parts View of Typical MHB Series Starter)
5
24
4
23
1
2 1
9 2
3
3
12 23 4
24
13 6
7
14 3
15 8
10
16
11
10
3 12
24 18
23
21
17
18
19
20
NOTE:
24
23 replacement parts required at
each overhaul.

Part MHB-4001 MHB-4003
1 Drive End Bearing ∆ (a) (c)
2 Drive End Head Assembly (a) (c)
3 Thrust Washer Package 90-601 90-601
4 Bendix Drive EBB-75A (g) ** EBB-75A (g) **
5 Intermediate Bearing Assembly (NR) (NR)
6 Bendix Drive Shaft (a) ** (c) **
7 Retainer Plate MZ-393 MZ-393
8 Gear MZ-396 MZ-396
9 Oil Seal (NR) (NR)
10 Needle Bearing ∆ (k) (k)
11 Gear Housing Assembly MZ-1390 MZ-1390
12 Armature MHB-2399 MHB-2399
14 Switch Connector (NR) (NR)
15 Switch (NR) (NR)
16 Field Coil Package MHB-3005S MHB-3005S
17 Brush Spring Set MZ-19S MZ-19S
18 Commutator End Head Assembly MHB-2400 MHB-2400
19 Brush Set ∆ MHB-2012S MHB-2012S
20 Commutator End Bearing X-3991 X-3991
21 Cover Band MZ-24A MZ-24A
22 Repair Kits 90-3004 90-3004
Part MHB-4007 MHB-4008 MHB-4009 MHB-4010 MHB-4011 MHB-4012
1 Drive End Bearing ∆ (d) (d) MZ-298 MZ-298

2 Drive End Head Assembly (d) (d) PS-1432C PS-2432B
3 Thrust Washer Package 90-601 90-601 90-601 90-601
4 Bendix Drive EBB-75A (g) EBB-142A (g) EBB-75A (g) EBB-75A (g)
5 Intermediate Bearing Assembly (NR) (NR) (NR) (NR)
6 Bendix Drive Shaft (d) ** (d) ** MZ-326A ** MZ-326A **
7 Retainer Plate MZ-393 MZ-393 MZ-393 MZ-393
8 Gear MZ-396 MZ-396 MZ-396 MZ-396
9 Oil Seal (NR) (NR) (NR) (NR)
10 Needle Bearing ∆ (k) (k) (k) (k)
11 Gear Housing Assembly MZ-1390 MZ-1390 MZ-1390 MZ-1390
12 Armature MHB-2399 MHB-2399 MHB-2399 MHB-2399
14 Switch Connector (NR) (NR) (NR) (NR)
15 Switch (NR) (NR) (NR) (NR)
16 Field Coil Package MHB-3005S MHB-3005BS MHB-3005S MHB-3005S
17 Brush Spring Set MZ-19S MZ-19S MZ-19S MZ-19S
18 Commutator End Head Assembly MHB-2400 MHB-2400 MHB-2400 MHB-2400
19 Brush Set ∆ MHB-2012S MHB-2012AS MHB-2012S MHB-2012S
20 Commutator End Bearing X-3991 X-3991 X-3991 X-3991
21 Cover Band MZ-24A MZ-24A MZ-24A MZ-24A
22 Repair Kits 90-3004 90-3009 90-3010 90-3010
Notes:
(a) PS-1432CS Housing & Shaft Pkg. must be used at time of first repair. Individual components (PS-1432C Pinion Hsg., MZ-298 Bearing, MZ-326A Bendix Drive Shaft) may be replaced after.
(b) PS-1437BS Housing & Shaft Pkg. must be used at time of first repair. Individual components (PS-1437B Pinion Hsg., MZ-298 Bearing, MZ-326A Bendix Drive Shaft) may be replaced after.
(c) PS-2432BS Housing & Shaft Pkg. must be used at time of first repair. Individual components (PS-2432B Pinion Hsg., MZ-298 Bearing, MZ-326A Bendix Drive Shaft) may be replaced after.
(d) PS-1432ES Housing & Shaft Pkg. must be used at time of first repair. Individual components (PS-1432E Pinion Hsg., MZ-298 Bearing, MZ-326A Bendix Drive Shaft) may be replaced after.
(e) MZ-414S Drive End Mounting Screw Gasket Package (10 pieces) and 90-2191 Mounting Screw Package (20 pieces) also available.
(f) Bearing & Seal Package.
(g) 90-2140 Bendix Pin Package (25 pieces) also available.
(h) 90-2139 Bendix Pin Package (25 pieces) also available.
(j) MZ-339 Bushing also available.
(k) Two used: XA-0997 (1/2” I.D.) and XA-0998 (13/16” I.D.).
(m) No longer available.
* Available thru Lycoming only.
** 90-2860 Bendix Drive Shaft Key Package (25 pieces) also available.
*** Bearing part number MZ-0040A available separately.
(NR) Not required. ∆ Replace with new whenever parts are removed.

Part MHB-4013 MHB-4014 MHB-4016 MHB-4016A MHB-4018 MHB-4019, A
1 Drive End Bearing ∆ MZ-298 MZ-298 MZ-298 MZ-298 MZ-298 MZ-298
2 Drive End Head Assembly PS-1432E PS-1432E PS-1432C PS-1432C PS-1432E PS-2432B
3 Thrust Washer Package 90-601 90-601 90-601 90-601 90-601 90-601
4 Bendix Drive EBB-75A (g) EBB-142A (g) EBB-131A (h) EBB-124A EBB-131A (h) EBB-131A (h)
5 Intermediate Bearing Assembly (NR) (NR) (NR) (NR) (NR) (NR)
6 Bendix Drive Shaft MZ-326A ** MZ-326A ** MZ-326A ** MHJ-0044A MZ-326A ** MZ-326A **
7 Retainer Plate MZ-393 MZ-393 MZ-393 MZ-393 MZ-393 MZ-393
8 Gear MZ-396 MZ-396 MZ-396 MZ-396 MZ-396 MZ-396
9 Oil Seal (NR) (NR) (NR) (NR) (NR) (NR)
10 Needle Bearing ∆ (k) (k) (k) (k) (k)
11 Gear Housing Assembly MZ-1390 MZ-1390 MZ-1390 MZ-1390 MZ-1390 MZ-1390
12 Armature MHB-2399 MHB-2399 MHB-2399 MHB-2399 MHB-2399 MHB-2399
14 Switch Connector (NR) (NR) (NR) (NR) (NR)
15 Switch (NR) (NR) (NR) (NR) (NR)
16 Field Coil Package MHB-3005S MHB-3005BS MHB-3005S MHB-3005S MHB-3005S
17 Brush Spring Set MZ-19S MZ-19S MZ-19S MZ-19S MZ-19S
18 Commutator End Head Assembly MHB-2400 MHB-2400 MHB-2400 MHB-2400 MHB-2400
19 Brush Set ∆ MHB-2012S MHB-2012AS MHB-2012S MHB-2012S MHB-2012S
20 Commutator End Bearing X-3991 X-3991 X-3991 X-3991 X-3991
21 Cover Band MZ-24A MZ-24A MZ-24A MZ-24A MZ-24A
22 Repair Kits 90-3010 90-3009 90-3011 90-3011 90-3011
23 Screw, plated (8 ea.) 19X-4634 (n) 19X-4634 (n) 19X-4634 (n) 19X-4634 (n) 19X-4634 (n)
24 Lockwasher, plated (8 ea.) 12X-0196 (n) 12X-0196 (n) 12X-0196 (n) 12X-0196 (n) 12X-0196 (n)
Part MHB-4020
1 Drive End Bearing ∆ MZ-298

2 Drive End Head Assembly PS-2432B
4 Bendix Drive EBB-131A (h)
5 Intermediate Bearing Assembly (NR)
6 Bendix Drive Shaft MZ-326A **
7 Retainer Plate MZ-393
8 Gear MZ-396
9 Oil Seal (NR)
10 Needle Bearing ∆ (k)
11 Gear Housing Assembly MZ-1390
12 Armature MHB-2399
14 Switch Connector (NR)
15 Switch (NR)
16 Field Coil Package MHB-3005S
18 Commutator End Head Assembly MHB-2400
19 Brush Set ∆ MHB-2012S
20 Commutator End Bearing X-3991
21 Cover Band MZ-24A
22 Repair Kits 90-3011
23 Screw, plated (8 ea.) 19X-4634 (n)
24 Lockwasher, plated (8 ea.) 12X-0196 (n)
Notes:
(a) PS-1432CS Housing & Shaft Pkg. must be used at time of first repair. Individual components (PS-1432C Pinion Hsg., MZ-298 Bearing, MZ-326A Bendix Drive Shaft) may be replaced after.
(b) PS-1437BS Housing & Shaft Pkg. must be used at time of first repair. Individual components (PS-1437B Pinion Hsg., MZ-298 Bearing, MZ-326A Bendix Drive Shaft) may be replaced after.
(d) PS-1432ES Housing & Shaft Pkg. Must be used at time of first repair. Individual components (PS-1432E Pinion Hsg., MZ-298 Bearing, MZ-326A Bendix Drive Shaft) may be replaced after.
(e) MZ-414S Drive End Mounting Screw Gasket Package (10 pieces) and 90-2191 Mounting Screw Package (20 pieces) also available.
(f) Bearing & Seal Package.
(h) 90-2139 Bendix Pin Package (25 pieces) also available.
(j) MZ-339 Bushing also available.
(k) Two used: XA-0997 (1/2” I.D.) and XA-0998 (13/16” I.D.).
(m) No longer available. (n) Also available, 90-3064 hardware kit complete.
* Available thru Lycoming only.
** 90-2860 Bendix Drive Shaft Key Package (25 pieces) also available.
(NR) Not required. ∆ Replace with new whenever parts are removed.

Lightweight MHB Series
Service Parts List
……………………………………..

REPLACEMENT LIST:
MHB-6014 USE No Longer Available* No Longer Available** Lycoming
MHB-6014 *Alternate, use ELB-8011 NA Lycoming

MHB-6016 *Alternate, use SRB-9021 or SRB-9031 NA Lycoming
ERB-8011
MHB-6018 *Alternate, use ERB-8011 or SRB-9021 NA Lycoming
** PMA approved parts for Lightweight MHB series available for service.
NOTE:

Lightweight MHB Series Starter)
1
2
2
4
(a)
5
4
6
9
12
13
14
8
10
8
11
15
14
16
(b)
17
NOTE:
each overhaul.
19

No. Part MHB-6014 MHB-6016 MHB-6018
1 Retaining Track Plate 40112 40112 40112
2 Gear Assembly 90-2520 90-2520 90-2520
3 Bendix Drive Shaft 40095 40095 40095
4 Thrust Washer Package 90-2525 90-2525 90-2525
5 Bendix Drive EBB-142A (a) EBB-75A (a) EBB-75A (a)
6 Drive End Head Assembly 40106-2 40106 40106-2
7 Drive End Bearing ∆ MZ-298 MZ-298 MZ-298
8 Hardware & Insulator Package 90-2522 90-2522 90-2522
9 Thru-bolt Package 90-2524 90-2524 90-2524
10 Commutator End Head Assembly 50102 40102 40102
11 Commutator End Bearing ∆ 40104 40104 40104
12 Insulator-Armature Housing 50075 50075 50075
13 Brush Retainer Insulator 40107 40107 40107
14 Brush Spring Package 90-2523 90-2523 90-2523
15 Brush & Terminal Stud Package 90-2521 90-2521 90-2521
16 Brush Holder 40110 40110 40110
17 Armature Housing 50101 (b) 50064 (b) 50064 (b)
18 Armature 50070 50070 50070
19 Thrust Ball 50074 50074 50074
20 Repair Kit 90-3026 90-3027 90-3027
Notes:
(a) 90-2140 Bendix Pin Package (25 pieces) also available.
(b) 50073 Rubber Insert also available. This part was used in earlier manufactured armature housing.


MHJ Series
Service Parts List
……………………………………

REPLACEMENT LIST:
MHP-4105 USE MHJ-4003 MHJ-4003R Continental (CMI)
MHJ-4002 USE MHJ-4003 MHJ-4003R Continental (CMI)
MHJ-4003 USE MHJ-4003 MHJ-4003R Continental (CMI)
MHJ-4004 USE MHJ-4004 MHJ-4004R Lycoming
NOTE:

MHJ Series (Exploded Parts View of Typical MHJ Series Starter)
3
4
5
6
7
9
12
8
15
2
1
18 10
11 11
12
13
14
NOTE:
17 each overhaul.
19

No. Part MHJ-4002 MHJ-4003, S MHJ-4004
1 Drive End Bearing ∆ ML-18A ML-18A MHJ-36
2 Drive End Head Assembly MCL-2136 MCL-2136A PS-1455
3 Bendix Drive (NR) (NR) EBB-124A
4 Retainer Plate (NR) (NR) MZ-393
5 Bendix Pin Package (NR) (NR) 90-2139
6 Bendix Drive Shaft (NR) (NR) MHJ-44 (b)
7 Gear (NR) (NR) MZ-396
8 Oil Seal ∆ XA-1024 XA-1024 (NR)
9 Gear Housing Assembly (NR) (NR) MHJ-1045
10 Needle Bearing ∆ (NR) (NR) (a)
12 Armature MHJ-2147S MHJ-2147S MHJ-3151S
13 Thru-bolt Package GJ-20DS GJ-20DS GJ-20S
14 Field Coil Package MDL-1005FS MDL-1005FS MDL-2005CS-1
16 Brush Spring Set MZ-19S MZ-19S MZ-19S
17 Brush Set ∆ MDL-2012ES MDL-2012ES MDZ-2012CS
18 Brush Plate Assembly MDL-1064ES MDL-1064ES MDL-1064GS
19 Commutator End Head Assembly MDL-1002B* MDL-1002B* MDL-1002B*
20 Repair Kit 90-3012 90-3012 90-3013
Notes:
(a) Two used: XA-0997 (1/2" I.D.) and XA-0998 (13/16" I.D.)
(b) 90-2860 Bendix Drive Shaft Key Package (25 pieces) also available.
(NR) Not required.
* Bearing part number MDC-0034 available separately.


MHP Series
Service Parts List 24 Volt Starter
…………………………………….……………………
MHP Series Starters and their corresponding parts must be obtained

from Continental Motors Inc. using OEM part numbers.




MMU Series
Service Parts List
……………………………………
24 Volt Starter
this section are FAA/PMA approved.
REPLACEMENT LIST:
MMU-4001 USE MMU-4001* MMU-4001R Lycoming
NOTE:

MMU Series (Exploded Parts View of Typical MMU Series Starter)
2
17
18
10
13
9
10
11
NOTE:
15 each overhaul.

No. Part MMU-4001
1 Drive End Bearing ∆ MG-77A
2 Drive End Head Assembly PS-1435
3 Bendix Drive EBB-124A (a)
4 Intermediate Bearing Assembly MZ-1236
5 Intermediate Bearing ∆ MZ-339
6 Armature MMU-2386S
8 Field Coil Package MHB-3005AS
10 Commutator End Head Assembly MBP-2002D*
11 Brush Set ∆ MHB-2012AS
13 Cover Band MZ-24A
15 Screw, plated (4 ea.) 19X-4654 (b)
16 Lockwasher, plated (4 ea.) 12X-0196 (b)
17 Screw, plated (4 ea.) 19X-4634 (b)
18 Lockwasher, plated (4 ea.) 12X-0196 (b)
Notes:
(a) 90-2139 Bendix Pin Package (25 Pieces) also available.
(b) Also available, 90-3064 hardware kit complete.
* Bearing part number MZ-0040A available separately.


Lightweight MMU Series
Service Parts List
……………………………………….
Starters and their corresponding parts shown in 24 Volt Starters

REPLACEMENT LIST:
MMU-6001 USE MMU-6001* MMU-6001R Lycoming
MMU-6001 *Alternate, use SRB-9032 or NA Lycoming

ERB-8012
NOTE:

Lightweight MMU Series Starter)
1
2
2
4
(a)
5
4
6
8
7
9
12
14
15 8
9
10
8
11
13
14
16
(b)
17
NOTE:
each overhaul.
19

No. Part MMU-6001
1 Retaining Track Plate 40112
2 Gear Assembly 90-2520
3 Bendix Drive Shaft 50110
5 Bendix Drive EBB-224A (a)
6 Drive End Head Assembly 50106
7 Drive End Bearing ∆ MZ-298
8 Hardware & Insulator Package 90-2522
9 Thru-bolt Package 90-2524
10 Commutator End Head Assembly 40102
11 Commutator End Bearing ∆ 40104
12 Insulator-Armature Housing 50075
13 Brush Retainer Insulator 40107
14 Brush Spring Package 90-2523
15 Brush & Terminal Stud Package 90-2521
16 Brush Holder 40110
17 Armature Housing 50064 (b)
18 Armature 50070
19 Thrust Ball 50074
Notes:


MZ Series
Service Parts List
……………………………………..
12 Volt Starter
REPLACEMENT LIST:
MZ-4204 USE MZ-4204 MZ-4204R Lycoming

MZ-4214 USE MZ-4214 MZ-4214R Continental (CMI)


NOTE:
See Parts List for starter being serviced when component parts are required.

MZ Series (Exploded Parts View of Typical MZ Series Starter)
1
23
24
4
1
2
9 25 2
3
24 3
4
12
13 5 6
7
14 3
8
15 10
11
10
16
12
3
18
24
(p)
23
25
21
17
18
19
20
18
NOTE:
24
each overhaul.
25

No. Part MZ-4204 MZ-4205 MZ-4206
1 Drive End Bearing ∆ MG-77A (a) (b)
2 Drive End Head Assembly PS-1435 (a) (b)
4 Bendix Drive EBB-124A (f) EBB-75A (g) EBB-75A (g)
5 Intermediate Bearing Assembly MZ-1236 (NR) (NR)
6 Bendix Drive Shaft (NR) (a) (**) (b) (**)
7 Retainer Plate (NR) MZ-393 MZ-393
8 Gear (NR) MZ-396 MZ-396
9 Oil Seal (NR) (NR) (NR)
10 Needle Bearing ∆ (NR) (m) (m)
11 Gear Housing Assembly (NR) MZ-1390 MZ-1390
12 Armature MZ-2386S MZ-2399S MZ-2399S
14 Switch Connector (NR) (NR) (NR)
15 Switch (NR) (NR) (NR)
16 Field Coil Package MZ-1005QSS MZ-3005GS MZ-3005GS
17 Brush Spring Set MZ-19S MZ-19S MZ-19S
18 Commutator End Head Assembly MZ-2002U* MZ-2400 MZ-2400
19 Brush Set ∆ MBG-2012S MBG-2012S MBG-2012S
20 Commutator End Bearing (NR) X-3991 X-3991
21 Cover Band MZ-24A MZ-24A MZ-24A
22 Repair Kit 90-3018 (p) 90-3019 (p) 90-3019 (p)
23 Screw, plated (4 ea.) 19X-4634
24 Lockwasher, plated (8 ea.) 12X-0196
No. Part MZ-4214 MZ-4216 MZ-4217 MZ-4218 MZ-4220

1 Drive End Bearing ∆ 90-2018 (e) (b) MZ-298 MZ-298 MZ-298

2 Drive End Head Assembly MZ-2413 (d) (b) PS-2432B PS-1432C PS-1432C
3 Thrust Washer Package 90-2006 90-601 90-601 90-601 90-601
4 Bendix Drive (h) EBB-142A (g) EBB-75A (g) EBB-75A (g) EBB-142A (g)
5 Intermediate Bearing Assembly (NR) (NR) (NR) (NR) (NR)
6 Bendix Drive Shaft (h) (b) (**) MZ-326A (**) MZ-326A (**) MZ-326A (**)
7 Retainer Plate (NR) MZ-393 MZ-393 MZ-393 MZ-393
8 Gear (h) MZ-396 MZ-396 MZ-396 MZ-396
9 Oil Seal ∆ XA-1024 (NR) (NR) (NR) (NR)
10 Needle Bearing ∆ (NR) (m) (m) (m) (m)
11 Gear Housing Assembly (NR) MZ-1390 MZ-1390 MZ-1390 MZ-1390
12 Armature MZ-2412S MZ-2399S MZ-2399S MZ-2399S MZ-2399S
14 Switch Connector (NR) (NR) (NR) (NR) (NR)
15 Switch (NR) (NR) (NR) (NR) (NR)
16 Field Coil Package MZ-1005RSS MZ-3005GS MZ-3005GS MZ-3005GS MZ-3005GS
17 Brush Spring Set MZ-19S MZ-19S MZ-19S MZ-19S MZ-19S
18 Commutator End Head Assembly MZ-2002VS* MZ-2400 MZ-2400 MZ-2400 MZ-2400
19 Brush Set ∆ MBG-2012CS MBG-2012S MBG-2012S MBG-2012S MBG-2012S
20 Commutator End Bearing (NR) X-3991 X-3991 X-3991 X-3991
21 Cover Band MZ-24A MZ-24A MZ-24A MZ-24A MZ-24A
22 Repair Kit 90-3021 (p) 90-3022 (p) 90-3023 (p) 90-3023 (p) 90-3022 (p)
23 Screw, plated (8 ea.) 20X-902 (4 ea.) 19X-4634 (q)
24 Lockwasher, plated (8 ea.) 12X-0196 12X-0196 (q)
25 Screw, plated (4 ea.) 19X-3644 (4 ea.)
Notes:
(a) PS-2432BS Housing & Shaft Pkg. must be used at time of first repair. Individual components (PS-2432B Pinion Hsg, MZ-298 Bearing, MZ-326A Bendix Drive Shaft) may be replaced after.
(b) PS-1432CS Housing & Shaft Pkg. must be used at time of first repair. Individual components (PS-1432C Pinion Hsg, MZ-298 Bearing, MZ-326A Bendix Drive Shaft) may be replaced after.
(c) PS-1437BS Housing & Shaft Pkg. must be used at time of first repair. Individual components (PS-1437B Pinion Hsg, MZ-298 Bearing, MZ-326A Bendix Drive Shaft) may be replaced after.
(d) MZ-414S Drive End Mounting Screw Gasket Package (10 pieces) also available.
(e) Bearing & Seal Package.
(f) 90-2139 Bendix Pin Package (25 pieces) also available.
(h) Not part of this Motor; available thru Continental #641500.
(m) Two used: XA-0997 (1/2" I.D.) and XA-0998 (13/16" I.D.).
(n) No longer available.
(p) Screw, found in starter repair kit. (q) Also available, 90-3064 hardware kit complete.
(**) 90-2860 Bendix Drive Shaft Key Package (25 pieces) also available.
(NR) Not required.
* Bearing part number MZ-0040A available separately.

No. Part MZ-4221 MZ-4222 MZ-4224 MZ-4226
1 Drive End Bearing ∆ MZ-298 MZ-298 MZ-298 MZ-298
2 Drive End Head Assembly PS-2432B PS-1432C PS-1432C PS-2432B
3 Thrust Washer Package 90-601 90-601 90-601 90-601
4 Bendix Drive EBB-131A (f) EBB-131A (f) EBB-131A (f) EBB-131A (f)
5 Intermediate Bearing Assembly (NR) (NR) (NR) (NR)
6 Bendix Drive Shaft MZ-326A (**) MZ-326A (**) MZ-326A (**) MZ-326A (**)
7 Retainer Plate MZ-393 MZ-393 MZ-393 MZ-393
8 Gear MZ-396 MZ-396 MZ-396 MZ-396
9 Oil Seal (NR) (NR) (NR) (NR)
10 Needle Bearing (m) (m) (m) (m)
11 Gear Housing Assembly MZ-1390 MZ-1390 MZ-1390 MZ-1390
12 Armature MZ-2399S MZ-2399S MZ-2399S MZ-2399S
14 Switch Connector (NR) (NR) (NR) (NR)
15 Switch (NR) (NR) (NR) (NR)
16 Field Coil Package MZ-3005GS MZ-3005GS MZ-3005GS MZ-3005GS
17 Brush Spring Set MZ-19S MZ-19S MZ-19S MZ-19S
18 Commutator End Head Assembly MZ-2400 MZ-2400 MZ-2400 MZ-2400
19 Brush Set MBG-2012S MBG-2012S MBG-2012S MBG-2012S
20 Commutator End Bearing X-3991 X-3991 X-3991 X-3991
21 Cover Band MZ-24A MZ-24A MZ-24A MZ-24A
22 Repair Kits 90-3024 (p) 90-3024 (p) 90-3024 (p) 90-3024 (p)
23 Screw, plated (8 ea.) 19X-4634 (q) 19X-4634 (q) 8X-120
24 Lockwasher, plated (8 ea.) 12X-0196 (q) 12X-0196 (q) 12X-0196
Notes:
(a) PS-2432BS Housing & Shaft Pkg. must be used at time of first repair. Individual components (PS-2432B Pinion Hsg., MZ-298 Bearing, MZ-326A Bendix Drive Shaft) may be replaced after.
(b) PS-1432CS Housing & Shaft Pkg. must be used at time of first repair. Individual components (PS-1432C Pinion Hsg., MZ-298 Bearing, MZ-326A Bendix Drive Shaft) may be replaced after.
(d) MZ-414S Drive End Mounting Screw Gasket Package (10 pieces) also available.
(e) Bearing & Seal Package.
(f) 90-2139 Bendix Pin Package (25 pieces) also available.
(h) Not part of this Motor; available thru Continental #641500.
(m) Two used: XA-0997 (1/2" I.D.) and XA-0998 (13/16" I.D.).
(n) No longer available.
(p) Screw, found in starter repair kit. (q) Also available, 90-3064 hardware kit complete.
(**) 90-2860 Bendix Drive Shaft Key Package (25 pieces) also available.
(NR) Not required.

Lightweight MZ Series
Service Parts List
………………………………….…
Parts shown in this section are FAA/PMA approved.
for starter models shown. Starters are NLA.
REPLACEMENT LIST: 12 Volt Starter

MZ-6204* USE No Longer Available* No Longer Available** Lycoming
MZ-6004 *Alternate, use SRZ-9022 or SRZ-9032 NA Lycoming

ELZ-8012
MZ-6220 *Alternate, use ELZ-8021 NA Lycoming
MZ-6222 *Alternate, use SRZ-9021 or SRZ-9031 NA Lycoming
ERZ-8011
MZ-6224 *Alternate, use SRZ-9021 or ERZ-8011 NA Lycoming
MZ-6226 *Alternate, use SRZ-9021 NA Lycoming
** PMA approved parts for Lightweight MZ series are available for service.
NOTE:

Lightweight MZ Series Starter)
1
2
4
(a)
5 8
4
6 9
8
12
7
13 9
14
10
8
11
15
18
NOTE:
19 each overhaul.
(b)
17

No. Part MZ-6204 MZ-6220 MZ-6222 MZ-6224 MZ-6226
1 Retaining Track Plate 40112 40112 40112 40112 40112
2 Gear Assembly 90-2520 90-2520 90-2520 90-2520 90-2520
3 Bendix Drive Shaft 50110 40095 40095 40095 40095
4 Thrust Washer Package 90-2525 90-2525 90-2525 90-2525 90-2525
5 Bendix Drive EBB-224A (a) EBB-142A (a) EBB-75A (a) EBB-75A (a) EBB-75A (a)
6 Drive End Head Assembly 50106 40106 40106 40106 40106-1
7 Drive End Bearing ∆ MZ-298 MZ-298 MZ-298 MZ-298 MZ-298
8 Hardware & Insulator Package 90-2522 90-2522 90-2522 90-2522 90-2522
9 Thru-bolt Package 90-2524 90-2524 90-2524 90-2524 90-2524
10 Commutator End Head Assembly 40102 50102 40102 40102 40102
11 Commutator End Bearing ∆ 40104 40104 40104 40104 40104
12 Insulator-Armature Housing 50075 50075 50075 50075 50075
13 Brush Retainer Insulator 40107 40107 40107 40107 40107
14 Brush Spring Package 90-2523 90-2523 90-2523 90-2523 90-2523
15 Brush & Terminal Stud Package 90-2521 90-2521 90-2521 90-2521 90-2521
16 Brush Holder 40110 40110 40110 40110 40110
17 Armature Housing 50064 (b) 50101 (b) 50064 (b) 50064 (b) 50064 (b)
18 Armature 50063 50063 50063 50063 50063
19 Thrust Ball 50074 50074 50074 50074 50074
20 Repair Kit 90-3029 90-3030 90-3031 90-3031 90-3031
Notes:


Starter
Service Information
………………………………………………………… 7
ES646 Series (12/24 Volt Starter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30-01
MCL Series (12 Volt Starter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-70-01
MDB Series (24 Volt Starter) (Obsolete) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-110-01
MHB Series (24 Volt Starter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-150-01
Lightweight MHB Series (24 Volt Starter)(NLA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-210-01
MHJ Series (24 Volt Starter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-250-01
MHP Series (24 Volt Starter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-290-01
MMU Series (24 Volt Starter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-310-01
Lightweight MMU Series (24 Volt Starter)(NLA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-350-01
MZ Series (12 Volt Starter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-390-01
Lightweight MZ Series (12 Volt Starter)(NLA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-450-01
Continued Airworthiness Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-510-01

Bi-Annual Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-520-01
Chart 1: Periodic Inspection with Bendix Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-530-01
Chart 2: Periodic Inspection without Bendix Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-540-01
NOTE:
No information is available for E, X, or M-Drive starters as these may be found in
other HET manuals or publications.

(Applies to all starters included in this Chapter.)
!
!
WARNING 2: MAKE SURE THAT ALL ELECTRICAL EQUIPMENT IS IN THE
OFF OR IN AN INACTIVE POSITION PRIOR TO RE-CONNECTING THE
LANDING GEAR, AND FLAPS TO NAME A FEW MAY SUDDENLY
ACTIVATE WHEN POWER IS APPLIED. FAILURE TO DO SO MAY RESULT
IN EQUIPMENT DAMAGE, INJURY OR DEATH SHOULD SHOULD

disconnecting test instruments (except voltmeter), or before removing or replacing
any unit or wiring. Accidental grounding or shorting of starter wiring, will cause
severe damage to the surrounding structure and/or wiring.
3. NEVER “free run” starter unless performing a specific test per instructions contained
in this manual. In many cases, severe damage to the starter will result.
4. CHECK voltage loss from insulated battery post to starter terminal – 0.3 volt maximum.
5. CHECK voltage loss from battery ground post to starter frame – 0.1 volt maximum.
6. ALWAYS observe starter duty cycle requirements for your model starter. Duty cycle
is originally provided with each new or rebuilt starter delivered from Hartzell Engine
Technologies LLC (HET).
7. WHEN USING EXTERNAL POWER (with or without battery power) be certain that
the external power supply is of the correct voltage and capacity prior to engaging or
applying the power. Should the incorrect voltage or capacity be used severe damage
will occur to electrical system and it’s components.

ES646 Series
Service Information
…………………………………….….
12/24 Volt Starter

GENERAL INFORMATION:
Voltage: 12 (ES646238, ES646238-1, ES646238-2, ES646238-3)
24 (ES646275, ES646275-1)
Brushes: 4
Rotation: CWDE (All Units)
Poles: 4
Switch: Separate
Drive: None Used
Gear Reduction: None
Lubrication:
Soak new absorbent bronze bearing (bushing) in SAE30 oil before installation.
Allow excess oil to drain out before installing end head on motor. Put a light film
of Lubriplate® #777 on the drive end and commutator end of armature shaft before
installing.
Bearing and Oil Seal Replacement:

Press bushing (5) into the drive end housing so that it is .06 in. below flush with the
edge of the oil seal bore. Press bushing into the commutator end head ass’y (cast
type ES646502 and billet type 50796 only) so that it is flush to .06 in. below the top
of the inside of the head assembly. Stamped type commutator end head ass’y comes
with the bushing installed, replace entire assembly if bushing is worn or damaged.
Press the oil seal (1) in until flat side bottoms in the bore.
Brush Replacement:
Brushes must be replaced when they have worn to a length of .39 in. or less or at
overhaul. Go to brush replacement procedure on page 7-50-01.
Brush Spring Tension:

Brush spring tension shall be 32 to 40 ounces with new brushes. Measure with spring
scale hooked under the spring at the brush. Pull on a line opposite the line of force
exerted by the spring and take the reading just as the spring leaves the brush.

End Play (Armature Shaft Only):
End play shall be adjusted to .005” to .050” using fiber washers (21) on the commutator end
of the shaft as required. Refer to Service Parts List section for fiber washer part number.
Pole Shoe Installation:

The pole shoes shall be installed so that the longer edge is pointing in the same direction as
armature rotation.
Figure 1 - Pole Shoe.
Commutator Refinishing:
• Minimum Diameter 1.50”
• Undercut .003”
• Total Indicator Runout .002” maximum measured from bearing journals.
• Surface Finish 50 microinch maximum

TEST SPECIFICATIONS (75° F):
ES646238, ES646238-1, ES646238-2, ES646238-3:
• No Load Test 5.7 volts, 91 maximum amperes, 3650 minimum r.p.m.
• Torque Test 10 volts, 220 maximum amperes, 10 ft.-lbs.
ES646275, ES646275-1:
• No Load Test 20 volts, 50 maximum amperes, 4300 minimum r.p.m.
• Torque Test 20 volts, 200 maximum amperes, 10 ft.-lbs.
Unit Internal Wiring Application

ES646238 Figure 2 Continental
ES646238-1 Figure 2 Continental
ES646275 Figure 2 Continental
INSTALLATION NOTE:
Prior to starting motor installation, clean any rust, corrosion or dirt from the mounting
surfaces of the starting motor and engine. Also check all ground strap connections to make
sure they are clean and tight.
Figure 2 - Repairs not at Overhaul

Internal
Grounded
Terminal
Brush The ES646 series starters are an accessory
Wiring
Stud Insulated
Brush
designed as a replacement component. HET
Diagram.
recommends a replacement starter as the most
View From
economic means of repair. However, the
Commutator
manual contains service information should
repair or overhaul be desired.
End.
Repair and inspection not at overhaul is
limited to brush, bushing, oil seal and
hardware replacement. These actions require
disassembly of the starter. Refer to Chapter 8
Insulated Grounded for disassembly, reassembly, and testing
Brush Brush instructions.
Figure 2 - For 646 Series Only.

Brush replacement procedure (repair)
(If brushes are less than 0.39 or 25/64 of an inch long they should be replaced.)
Remove the four (4) through bolts (20) and lockwashers (23) from the commutator end cover (22) and
remove the cover. Removal may require heat as thru-bolts are secured with Loctite® adhesive.
Insulated Brushes
1. Remove the three (3) brush holder plate retaining screws (24) and pull plate from housing.
2. Disassemble the two (2) field coil brushes from brush holder plate (17).
3. On the field coil assembly, cut the brush lead as close as possible to the field coil terminal.
Clean the side of the terminal post for soldering of new brushes.
4. Position the new brush lead so that it is directly above or below the remaining sections of
the original brush lead. (Replace both brushes with new only.)
5. Place insulation on new brush lead, holding brush lead to field coil terminal. Install the
brush (ES646348) and solder using 60/40 rosin core solder. Do not allow solder to wick up
the flexible brush lead during the soldering process. If solder wicking makes the lead rigid
it must be replaced with a new lead (See Figure 3).
6. Position the soldered connections so that they do not ground against the frame.
Ground Brushes
1. With brush holder plate out of the housing, remove the ground brush springs.
2. Use a pair of pliers to roll the brush lead out of the connector. On the brush holder assembly,
heat the brush lead connector and pry crimp from the wire. (See Figure 2)
4. Reshape the connector, install the new brush lead with brush. (Replace both brushes with
new only.)
5. Clinch and solder the connection using 60/40 rosin core solder. Make sure the soldered
connection does not interfere with the ground brush spring.
Brush Holder Plate Assembly
1. Install brushes into the brush holder plate and connect springs.
2. Install brush holder plate assembly in the housing and secure with the three retaining screws
(24).
Upon completion of the brush replacement, install the commutator end cap (22). Install the four (4)
through bolts (20) with new lockwashers (23) securing the thru-bolts finger tight. Remove the
through bolts (20) one at a time and apply Loctite® 271 adhesive, then insert each through bolt and
torque to 35-45 in-lbs.

Figure 3 - Field Coil Brush
Oil Seal Replacement Procedure (Repair)

(Replace Oil Seal if leaking or any time removed.)
1. For Oil Seal removal, carefully bend approximately one-half (1/2) the diameter of the steel oil
seal retainer down using a small, sharp chisel and mallet. Grasp the retainer and lift the seal out.
Refer to Figure 4.
2. For Oil Seal installation, press seal into the bore until the flat surface bottoms out as shown in
Figure 4.
Figure 4 - Oil Seal Removal from Drive End Flange Figure 5 - Bushing & Oil Seal Install in Drive End

Bushing Replacement Procedure (Repair)
1. For DE Bushing (bearing) removal and installation, place the drive end head assembly in a fixture and use a
press ram with a 0.8437” Dia. drift pin as shown in Figure 5. Be sure dimensions are observed.
2. Press out the bushing and discard, install a new bushing press flush to 0.06” below the surface.
3. If the starter is being repaired and has a P/N ES646502 (cast type) or P/N 50796 (billet type) comm. end head
(CE) with no cracks or damage, it may be reused if the proper dimensions for the bushing bore exist. (Refer to
Chapter 9)
4. For CE Bushing removal, use a blind hole bearing puller and extract the bushing as shown in
Figure 6. (ES646502 & 50796 only)
5. For CE Bushing installation, use a press ram with a 0.593” Dia. drift pin and press in a new
P/N 50044 bushing flush to .06 in. below surface, refer to Fig. 7.
Figure 6 - CE Bushing Removal (ES646502 & 50796 Only)
Press bearing
flush to .06 in.
below surface
Figure 7 - CE Bushing Install (ES646502 & 50796 Only)

Bench Testing
After the starter is reassembled, it
should be checked to see that the
no-load current at a certain voltage
is within the test specifications
given on page 7-40-01 . To make
this test, connect the assembled
unit as shown in (Figure 8). If
Ground
current is too high, check the
bushing alignment and end-play as
described below to make sure there Ground
is no binding or interference. If no
difficulty is indicated in the test. Figure 8 - No Load Current Test Connection.
If the torque and current are not within specifications, check the seating of the brushes and
internal connections for high resistance. If these checks are made and found to be in good order,
replace the armature assembly and retest the starter.
T o r q u e & D r i v e S h a f t T o l e r a n c e:
The torque and drive shaft tolerance checks may be done anytime the starter is removed or
when symptoms of noise or poor starter performance occur.
Specifications
1. See Figure 9 for the starter drive shaft specifications and torque.
Drive shaft “at rest” torque check
1. Check the drive shaft “at

rest” torque first, as any
discrepancy found will
require repair or overhaul of
the starter.
2. Rotate the starter drive shaft

by hand several turns
Figure 9 - Starter Shaft Specifications

clockwise (CW) as viewed
from the drive end.
3. Use a suitable tool with a

properly calibrated in-lbs torque wrench to check torque. A tool can be made using an
appropriately sized clevis bolt with a nut tightened securely on the thread end.
4. Slowly rotate the inch-pound torque wrench clockwise (CW) through 360˚ or more. The
torque indication must be 5 inch pounds or less. The starter must be repaired or
overhauled if rotational torque is higher.

Drive Shaft Position Check
1. Check the position of the drive shaft with
respect to the housing for min. and max.
tolerance using a dial indicator. Any style of
dial indicator set up is permissible provided
that the indicator reads to a minimum of 0.001
inch resolution.
2. The set up requires the starter be held
vertically with the drive end up and then
vertically with the drive end down.
(a) Placing the starter vertical with drive end
up allows a check of the length of the drive
shaft from the starter mounting flange.
(b) Placing the starter vertical with the drive
end down allows a check of the drive shaft
end play by measurement and calculation.
3. Check the starter drive shaft minimum length by Figure 10 - Set Dial at Zero
setting the starter on blocks vertically with the
drive shaft up.
(a) Size the blocks of equal measure and
width so the starter is stable.
(b) Place the back side of the mounting flange
on the blocks.
(c) Tap gently on the drive shaft with a plastic
mallet.
4. Place the dial indicator on the flange surface
which will mate to the engine starter drive
adapter, zero the indicator. Refer to Figure 10.
5. Place the dial indicator on the apex of the
drive shaft and record measurement. Refer to
Figure 11.
(a) The measurement recorded must fall
between 0.580 inch and 0.630 inch
inclusive of the starter end play allowance
shown in specifications.
Figure 11 - Record No. at Apex

Drive Shaft Maximum Length Check
1. Check the starter drive shaft maximum
length by setting the starter vertically with
the drive shaft down.
(a) Rotate the drive shaft by hand through one
revolution.
(b) Size the blocks of equal measure and
(c) Place the mounting flange (flange mating
to starter drive) on the blocks.
(d) Tap gently on the drive shaft rear cover
with a plastic mallet.
which will mate to the engine starter drive Figure 12 - Set Dial at Zero
adapter, zero the indicator. See Figure 12.
drive shaft and record measurement. See
Figure 13.
in between 0.580 inch and 0.630 inch
which is inclusive of the starter end
play allowance.
Figure 13 - Record No. at Top

Drive End Play Determination
1. Determine if the starter falls into the allowable end play measurement by making a
calculation. This is done by taking the maximum measurement found in “Drive Shaft
Maximum Length Check” step 3 and subtracting the minimum measurement found in
“Drive Shaft Position Check” step 5.
(a) For example, if the shaft maximum measurement was 0.610 inch and the minimum
measurement was 0.585 inch then subtracting 0.585 inch from the 0.610 inch will
result in 0.025 inch end play. This is acceptable as the allowable end play range
is 0.005 to 0.050 inch.
2. If the starter drive shaft end play is out of allowable range of 0.005 to 0.050 inch or
the drive shaft length is beyond the min 0.580 or max 0.630 inch, repair or overhaul
of the starter is recommended. Do not install starters outside of these limits on any
starter drive or application.


MCL Series
Service Information
…………………………………….….
12 Volt Starter
Voltage: 12
Brushes: 4
Rotation: See Tabulation
Poles: 4
Switch: MCL-6501 and 6503 - Switch Mounted Separately. (6503 not-PMA’d)
MCL-6502 - Switch Mounted on Motor Frame. (6502 not-PMA’d)
Drive: MCL-6501 - None Used.
MCL-6502 - Rubber Flow-Thru Type. (Ref. only 6502 not-PMA’d)
MCL-6503 - Gear Reduction and Drive Used With, But Not Part of,
This Motor. (Ref. only 6503 not-PMA’d)
(Above not-PMA’d reference used for identification purpose only.)
Lubrication:
• MCL-6501 - Soak new absorbent bronze bearings in SAE30 oil before installation.
Saturate the felt oiling pad in the commutator end head with SAE30 oil. Allow excess oil
to drain out before installing end head on motor. Put a light film of Lubriplate® #777 on
the drive end of the armature shaft before installing the drive end head. (Also see Drive
Assembly servicing).

• MCL-6501 - Press the Drive End bearing into the housing so that it is flush with the edge
of the oil seal counter bore. Press the oil seal in until it bottoms in the counter bore.
Brush Replacement:
Brushes must be replaced when they have worn to a length of .25” or less. Go to brush
replacement procedure on page 7-100-01.

Brush spring tension shall be 32 to 40 ounces with new brushes. Measure with a spring scale
hooked under the spring at the brush. Pull on a line opposite the line of force exerted by the
spring and take the reading just as the spring leaves the brush.
End Play:
End play shall be adjusted to .005” to .050” with thrust washers on the commutator end of the
shaft. Refer to Parts List for thrust washer package number.

The pole shoes shall be installed so that the longer tip is pointing in the same direction as
armature rotation.
• Total Indicator Runout .002” maximum measure from bearing journals

Motor: (With Drive Assembly Installed):
• No Load Test* 5.0 volts, 65 maximum amperes, 4900 minimum r.p.m.
• Stall Torque Test* 2.0 volts, 410 maximum amperes, 8 minimum ft.-lbs.
* These units are tested at 6 volts to avoid excessive free running R.P.M. which could
damage the motor.
Unit: Rotation: Internal Wiring: Application:

MCL-6501 CWDE Figure 1 Continental
INSTALLATION NOTE:
Figure 1 -
Internal
Terminal Post
Wiring
Diagram.
Insulated Brush
Grounded Brush
View from
Commutator
End.
Insulated
Brush Grounded
Brush
Figure 1 - For Continental (MCL-6501).

Brush replacement procedure:
Insulated Brushes
1. Remove brush holder plate assembly.
2. Cut original brush leads off approximately 1/2 inch from the field coil connector.
3. Position the new brush lead so that it is directly above or below the remaining sections of the
original brush lead.
4. Install the connectors contained in the brush package.
5. Clinch and solder using 60/40 rosin core solder.
Ground Brushes
1. Remove brush holder assembly.
2. Remove the ground brush springs.
3. Use a pair of pliers to roll the brush lead out of the connector.
4. Reshape the connector and install the new brush lead.

MDB Series
Service Information 24 Volt Starter (Obsolete)
…………………………………….….………………
OBSOLETE
Internal Wiring: Application:




MHB Series
Service Information
…………………………………….….
24 Volt Starter
Voltage: 24
Brushes: 4
Poles: 4
Switch: Gear Reduction Units - Separate
Direct Driven Units - Switch Mounted on Motor
Drive: Rubber Flow-Thru Type.
Gear Reduction: 3.38 to 1 Gear Ratio (See Following Note).
Lubrication:
• Gear Reduction Units - Thoroughly clean and repack needle bearings with Chevron
SRI#2 or an equivalent bearing lubricant. Pack gear box with 1-1/4 to 2 ounces of
Chevron SRI#2 or equivalent. (Also see Drive Assembly servicing.)
Direct Drive Units:

Soak new absorbent bronze bearings in SAE30 oil before installation. Saturate the felt oiling
pad in the commutator end head with SAE30 oil. Allow excess oil to drain out before
installing end head on motor. Put a light film of Lubriplate® #777 on the drive end of the
armature shaft before installing the drive end head. (Also see Drive Assembly servicing).

Drive Assemblies:
infield service, do Not use carburetor cleaner or any cleaning solution that could damage the
The Drive Assembly should be replaced with new when the motor is overhauled. During
rubber block inside the Drive Assembly. Use only clean petroleum base cleaners such as
all dirt, grease, and contamination from the screw shaft threads and control nut. Do Not
kerosene or mineral spirits, or equivalent. Thoroughly clean the Drive Assembly to remove
attempt to remove the control nut.
After the Drive Assembly has been cleaned and blown dry with compressed air, lubricate the
drive with a spray on type silicone lubricant. Lubricate the motor shaft with the same silicone
lubricant before installing the Drive Assembly. When reassembling the early style drive on
the shaft, make sure the spiral pin does not project beyond the outside diameter of the pinion
sleeve. When reassembling the late style drive, make sure the head washer covers both ends
of the retaining pin.
Bearing Replacement:
• Gear Reduction Units - When replacing needle bearings they must be pressed in flush
with the edge of the casting. The armature bearing must be flush on the side toward the
armature and the Drive Assembly shaft bearing flush on the side toward the Drive
Assembly. Press the pinion housing bearing in flush with the outside edge of the casting.
Direct Drive Units:

Press the drive end bearing in flush with the outside edge of the casting. Press the oil seal into
the casting so that it bottoms against the oil seal counter bore.
Intermediate Bearing Plate (MHB-4015, R):

Use “Loctite® Grade A” on threads of bearing plate retaining screws. Torque screws to
25-35 in.-lbs.
Brush Replacement:


End Play:
• Gear Reduction Units - No dimensions specification necessary. Make sure the fiber
thrust washer is on the drive end of the Drive Assembly shaft. Refer to Service Parts List
for thrust washer package number.
Direct Drive Units:

Shall be adjusted to .005” minimum with thrust washers. Maintain a clearance of .015” to
.109” between the inside edge of the drive pinion and the outside edge of the drive end casting
with the drive extended and the armature pushed toward the commutator end head. Refer to
Service Parts List for thrust washer package number.
Commutator End Head:

• Gear Reduction Units (Except MHB 4009, R; MHB-4014) - Assemble the end head on
the motor so that the letter “R” is directly in line with the motor terminal.
• MHB-4009; MHB-4014 and Direct Drive Units - Assemble the end head on the motor
so that the letter “L” is directly in line with the motor terminal.

See (Figures 1 and 2) for no load and stall torque test connections.
Figure 1 - No
Load
Connection.
Knife Ammeter Voltmeter
Switch
Carbon
Pile
Ground
Battery
Tachometer
Ground Starting Motor

Figure 2 - Stall
Torque Test
Connection. Knife Ammeter Voltmeter
Switch
Carbon
Pile Spring
Scale
Ground
Battery
Ground Starting
Motor
Gear Reduction Units:

• No Load Test (Motor Only) 20.0 volts, 35 maximum amperes, 4600 minimum r.p.m.
• No Load Test (Complete Unit) 20.0 volts, 35 maximum amperes, 1300 minimum r.p.m.
• Stall Torque Test 14.0 volts, 260 maximum amperes, 27.0 minimum ft.-lbs.
Direct Drive Units:

Shunt Field Current Draw:

• 8.7 to 10.4 amperes at 24.0 volts.
Unit: Drive Type: Internal Wiring: Application:

MHB-4001 Gear Reduction Figure 3 Lycoming


MHB-4015 Direct Figure 4 Lycoming


Figure 3 & 4 -
Internal
Terminal Post
Terminal Post
Wiring
Diagram.
Insulated Grounded Grounded
Brush Brush Brush Insulated
View from
Brush
Commutator
Shunt
Shunt Winding
Winding
End. Insulated
Brush
Grounded
Brush
Grounded
Insulated Brush
Brush
Figure 3 - For Lycoming Figure 4 - For Lycoming.
Brush replacement procedure.

Insulated Brushes
Ground Brushes


Service Information
…………………………………….…..….….….….…
These Starters are FAA/PMA approved but are no longer
available. Parts for service are shown in chapter 6 (IPL).
(Refer to latest revision of HET SL 025.) 24 Volt Starter
Voltage: 24
Brushes: 4
Poles: 4 Magnetic
Switch: None Used
Drive: Rubber Flow-Thru Type.
Gear Reduction: 3.38 to 1 Gear Ratio (See Following Note).
Lubrication:
Soak new absorbent bronze bearing (bushing) in SAE30 oil before installation. Allow excess
oil to drain out before installing end hand on motor. Thoroughly clean and apply a light coat
of Chevron SRI#2 or an equivalent grease to the inside of gear track. (Also see Drive
Drive Assembly:
service, do Not use carburetor cleaner or any cleaning solution that could damage the rubber
The Drive Assembly should be replaced with new when the motor is overhauled. During field
block inside the Drive Assembly. Use only clean petroleum base cleaners such as “mineral
from the screw shaft threads and control nut. Do Not attempt to remove this control unit.
sprits.” Thoroughly clean the Drive Assembly to remove all dirt, grease, and contamination
drive with a spray on type silicone lubricant. Lubricate the sub-shaft with the same silicone
lubricate before installing the Drive Assembly. When reassembling drive on the shaft make
sure the spiral pin does not project beyond the outside diameter of the pinion sleeve.

Press needle bearing flush with top of inside of commutator end head assembly. Apply a light
coat of Chevron SRI #2 or equivalent grease to needle bearing. Press drive end bearing
(bushing) in flush with the outside edge of the casting.
Brush Replacement:
Brushes must be replaced when they have worn to a length of .25” or less.

With spring compressed to a length of .5” load force must be 2 lbs., 3 ounces +/- 4 ounces.
End Play:
No dimensions specification necessary. Make sure thrust ball is in position.
• Total Indicator Runout .002 maximum measure from bearing journals

Start from rest and running torque measured. Do not fully stall motor.
Motor:
• Load Test 22 volts, 85 maximum amperes, 3 ft.-lbs.
22 volts, 105 maximum amperes, 15 ft.-lbs.
NOTE: 1 Do Not run this starter in a no load condition.
NOTE: 2
To determine the proper test specifications above, use of a starter tester
(or alternator/starter tester) must be employed. Tester must be able to
measure voltage, amperage, rpm, and torque. The tester must have the
capability of applying a dynamic load to the starter at the pinion.
Example of testers of this type can be found on www.crumbliss.com.
The Crumbliss testers come in several models.
Crumbliss Test Equipment
PO Box 3201
Collegedale, TN 37315
Tel. (239) 693-8588
Fax: (239) 693-1999
E-mail crumbliss@aol.com

Figure 1 - Internal
Wiring Diagram.
View From Battery Post
Commutator End. Brushes (4)
Commutator
Ground Connection
Figure 1 - For Lycoming Only.
Unit: Rotation: Drive Type: Internal Wiring: Application:

MHB-6014 CCWDE Gear Reduction Figure 1 Lycoming
MHB-6016 CWDE Gear Reduction Figure 1 Lycoming
MHB-6018 CWDE Gear Reduction Figure 1 Lycoming


MHJ Series
Service Information
…………………………………….….
24 Volt Starter
Voltage: 24
Brushes: 4
Rotation: MHJ-4002, MHJ-4003 - CWDE,
MHJ-4004; - Motor CCWDE, Drive CWDE
Poles: 4
Switch: Separate
Drive: MHJ-4004; - Rubber Flow-Thru Type.
Gear Reduction: MHJ-4004; - 3.38 to 1 Gear Ratio
Lubrication:
• MHJ-4002, MHJ-4003 - Soak new absorbent bronze bearings in SAE30 oil before
installation. Saturate the felt oiling pad in the commutator end head with SAE30 oil.
Allow excess oil to drain out before installing end head on motor. Put a light film of
Lubriplate® #777 on the drive end of the armature shaft before installing the drive end
head. (Also see Drive Assembly servicing).
• MHJ-4004, MHJ-4004 R - Thoroughly clean and repack needle bearings with Chevron
SRI#2 or an equivalent bearing lubricant with 1-1/4 to 2 ounces or Chevron SRI#2 or an
equivalent. (Also see Drive Assembly servicing).
Drive Assembly:
block inside the Drive Assembly. Use only clean petroleum base cleaners such as kerosene
grease, and contamination from the screw shaft threads and control nut. Do Not attempt to
or mineral spirits or equivalent. Thoroughly clean the Drive Assembly to remove all dirt,
remove the control nut. After the Drive Assembly has been cleaned and blown dry with
compressed air, lubricate the drive with a spray on type silicone lubricant. Lubricate the
motor shaft with the same silicone lubricant before installing the Drive Assembly. When
reassembling the drive on the shaft, make sure the spiral pin does not project beyond the
outside diameter of the pinion sleeve.

• MHJ-4002, MHJ-4003 - Press the bearing into the housing so that it is flush with the
edge of the oil seal counter bore. Press the oil seal in until it bottoms in the counter bore.
• MHJ-4004 - Press the armature shaft bearing into the housing until it is flush with the
bearing bore. Press the oil seal in until it is flush with the edge of the casting. Press the
gear reduction shaft bearing in so that the open end is flush with the edge of the casting.
Brush Replacement:

End Play (Armature Shaft Only):

End play shall be adjusted to .005” to .050” with thrust washers on the commutator end of the
shaft. Refer to Service Parts List section for thrust washer package number.

The pole shoes shall be installed so that the longer tip is pointing in the same direction as
armature rotation.


Figure 1 - No
Load Test
Switch
Carbon
Pile
Ground
Battery
Ground Tachometer
Starting Motor
Figure 2 -
Stall Torque
Test
Connection.
Switch
Carbon
Pile Spring
Scale
Ground
Battery
Ground Starting
Motor
MHJ-4002, MHJ-4003:
MHJ-4004; MHJ-4004 R:

• 4.8 to 6.0 amperes at 24.0 volts

Unit: Internal Wiring: Application:
MHJ-4002 Figure 3 Continental
MHJ-4003, S Figure 3 Continental
MHJ-4004 Figure 4 Lycoming
INSTALLATION NOTE:
Figure 3 & 4 -
Internal
Terminal Post Terminal Post
Wiring
Insulated
Insulated Brush
Diagram.
Grounded Brush Grounded
Brush Brush
Shunt
View From
Winding Shunt
Winding
Commutator
End. Insulated Insulated
Brush
Brush
Grounded Grounded
Brush Brush
Figure 3 - For Continental Only. Figure 4 - For Lycoming Only.
Brush replacement procedure.

Insulated Brushes
3. Position the new brush lead so that it is directly above or below the remaining sections of the original
brush lead.
Ground Brushes

MHP Series
Service Information 24 Volt Starter
…………………………………….….………………..
MHP Series Starter service and parts information must be obtained
from Continental Motors Inc.


MMU Series
Service Information
………………………………………
24 Volt Starter
Voltage: 24
Brushes: 4
Rotation: CWDE
Poles: 4
Drive: Rubber Flow-Thru Type
Lubrication:
Soak new absorbent bronze bearings in SAE30 oil before installation. Saturate the felt oiling
pad in the commutator end head with SAE30 oil. Allow excess oil to drain out before
installing end head on motor. Put a light film of Lubriplate® #777 on the drive end of the
armature shaft before installing the drive end head. (Also see Drive Assembly servicing).
Drive Assembly:
repair, do Not use carburetor cleaner or any cleaning solution that could damage the rubber
remove the control nut. After the Drive Assembly has been cleaned and blown dry with
compressed air, lubricate the drive with a spray on type silicone lubricant. Lubricate the
motor shaft with the same silicone lubricant before installing the Drive Assembly. When
reassembling the drive on the shaft, make sure the head washer covers both ends of the
retaining pin.
Press the drive end bearing in flush with the outside edge of the casting. Press the
intermediate bearing in flush to the side toward the armature.

Intermediate Bearing Plate:
Use “Loctite Grade A” on threads of bearing plate retaining screws. Torque screws to
25-35 in.-lbs.
Brush Replacement:

End Play:
End play shall be adjusted to .005” minimum with thrust washers on the commutator end of
the armature shaft. Refer to Service Parts List section for thrust washer package number.
Commutator End Head:

Assemble the end head on the motor so that the letter “L” is directly in line with the motor
terminal.
• Total Indicator Runout .002” max. measure from bearing journals
• Surface Finish 50 microinch max.

Motor:

• 8.8 to 10.4 amperes at 24.0 volts.
Unit: Rotation: Internal Wiring: Application:

MMU-4001, R CWDE Figure 1 Lycoming

Figure 1 -
Internal Terminal Post
Wiring
Diagram.
Insulated
Shunt
Brush
Winding
View From
Commutator
Grounded
Brush
End. Insulated
Brush
Grounded
Brush
Figure 1 - For Lycoming Only.

Insulated Brushes
Ground Brushes


Service Information
…………………………………….…
available. Parts for service are shown in chapter 6 (IPL). 24 Volt Starter
(Refer to latest revision of HET SL 025.)
Voltage: 24
Brushes: 4
Poles: 4 Magnetic
Switch: None Used
Drive: Rubber Flow-Thru Type Drives
Gear Reduction: 4 to 1 Gear Ratio
Lubrication:
oil to drain out before installing end head on motor. Thoroughly clean and apply a light coat
of Chevron SRI #2 or an equivalent grease to the inside of gear track. (Also see Drive
Drive Assembly:
from the screw shaft threads and control nut. Do Not attempt to remove the control nut.
spirits.” Thoroughly clean the Drive Assembly to remove all dirt, grease, and contamination

Press needle bearing flush with top of inside of commutator end head assembly. Press drive
end bearing (bushing) in flush with the outside edge of the casting.
Brush Replacement:

With spring compressed to a length of .5”, load force must be 2 lbs. 3 ounces +/- 4 ounces.
End Play:
• Total Indicator Runout .002” max. measure from bearing journals
• Surface Finish 50 microinch max.

Start from rest and running torque measured. Do not fully stall motor.
Motor:
• Load Test 22 volts, 85 maximum amperes, 3 ft.-lbs.
22 volts, 105 maximum amperes, 15 ft.-lbs.
NOTE 1: Do Not run this starter in a no load condition.
NOTE 2:
PO Box 3201
Tel. (239) 693-8588
Fax: (239) 693-1999

Unit Rotation Drive Type Internal Wiring Application
MMU-6001 CWDE Gear Reduction --- Lycoming


MZ Series
Service Information
…………………………………….….
12 Volt Starter
Voltage: 12
Brushes: 4
Poles: 4
Switch: Gear Reduction Units - Switch Mounted Separately.
Direct Drive Units - Switch Mounted on Motor Frame.
Drive: MZ-4214 Uses a Formsprag, Torque Limiting Drive
All Others Use Rubber Flow-Thru Type Drives
Gear Reduction: MZ-4214 - 7 to 1 Gear Ratio
All Others 3.38 to 1 Gear Ratio
Lubrication:
• Gear Reduction Units (Except MZ-4214) - Thoroughly clean and repack needle bearings
with Chevron SRI#2 or an equivalent bearing lubricant. Pack gear box with 1-1/4 to 2
ounces of Chevron SRI#2 or equivalent. (Also see Drive Assembly servicing.)
• Direct Drive Units and MZ-4214 - Soak new absorbent bronze bearings in SAE30 oil
before installation. Saturate the felt oiling pad in the commutator end head with SAE30
oil. Allow excess oil to drain out before installing end head on motor. Put a light film of
Lubriplate® #777 on the drive end of the armature shaft before installing the intermediate
bearing or drive end head. (Also see Drive Assembly servicing).
Formsprag Drive:
These units are not serviceable. If the drive feels rough when rotated in its free direction, or
if the gear rotates in both directions, the drive should be replaced. Never submerge the drive
assembly in a cleaning solution. To do so will destroy or contaminate the internal lubrication
which cannot be replaced.

Drive Assembly:
remove the control nut.
drive with a spray on type silicone lubricant. Lubricate the motor shaft with the same silicone
lubricant before installing the Drive Assembly. When reassembling the early style drive on
the shaft, make sure the spiral pin does not project beyond the outside diameter of the pinion
sleeve. When reassembling the late style drive, make sure the head washer covers both ends
of the retaining pin.
Gear Reduction Units - When replacing needle bearings they must be pressed in flush with
the edge of the casting. The armature bearing must be flush on the side toward the armature
and the Drive Assembly shaft bearing flush on the side toward the Drive Assembly. Press the
pinion housing bearing in flush with the outside edge of the casting.
• Direct Drive Units - Press the drive end bearing in flush with the outside edge of the
casting. Press the oil seal into the casting so that it bottoms against the oil seal counter
bore.
• Intermediate Bearing Plate (MZ-4204, R) - Use “Loctite® Grade A” on threads of
bearing plate retaining screws. Torque screws to 25-35 in/lbs.
Brush Replacement:

End Play:
• Gear Reduction Units (Except MZ-4216 and MZ4220) - Assemble the end head on the
motor so that the letter “R” is directly in line with the motor terminal.
• Direct Drive Units and MZ-4216; MZ-4220 - Assemble the end head on the motor so that
the letter “L” is directly in line with the motor terminal.

Surface Finish 50 microinch maximum

Figure 1 - No
Load Test
Switch
Carbon
Pile
Ground
Battery
Tachometer
Ground
Starting Motor
Figure 2 -
Stall Torque
Test
Connection.
Switch
Carbon
Pile Spring
Scale
Ground
Battery
Ground Starting
Motor
Gear Reduction Units:


Direct Drive Units:
MZ-4214 - Motor Only:

Unit Drive Type Internal Wiring Application
MZ-4204 Direct Figure 3 Lycoming

MZ-4205 Gear Reduction Figure 4 Lycoming
MZ-4214 * Figure 4 Continental



* Formsprag Torque Limiting Drive used with, but not a part of, this motor.
INSTALLATION NOTE:

Figure 3 & 4 -
Internal Terminal Post Terminal Post
Wiring
Grounded
Insulated Brush
Diagram.
Grounded Brush Insulated
Brush Brush
View From
Commutator
End. Insulated
Brush
Grounded
Brush
Insulated
Brush
Grounded
Brush
Figure 3 - For Lycoming. Figure 4 - For Lycoming & Continental.

Insulated Brushes
Ground Brushes


Service Information
…………………………………….….
available. Parts for service are shown in chapter 6 (IPL).
(Refer to latest revision of HET SL 025.) 12 Volt Starter
Voltage: 12
Brushes: 4
Poles: 4 Magnetic
Switch: None Used
Drive: Rubber Flow-Thru Type Drives
Gear Reduction: 4 to 1 Gear Ratio
Lubrication:
oil to drain out before installing end head on motor. Thoroughly clean and apply a light coat
of Chevron SRI #2 or an equivalent grease to the inside of gear track. (Also see Drive
Assembly servicing.)
Drive Assembly:
from the screw shaft threads and control nut. Do Not attempt to remove the control nut.
spirits”. Thoroughly clean the Drive Assembly to remove all dirt, grease, and contamination

Press needle bearing flush with top of inside of commutator end head assembly. Press drive
end bearing (bushing) in flush with the outside edge of the casting. Apply light film of
Chevron SRI #2 grease to needle bearing.
Brush Replacement:

With spring compressed to a length of .5”, load force must be 2 lbs. 3 ounces +/- 4 ounces.
End Play:

Start from rest and running torque measured. Six second cycles. Do not fully stall motor.
Motor:
• Load Test 10.5 volts, 200 maximum amperes, 3 ft.-lbs.
10.5 volts, 400 maximum amperes, 10 ft.-lbs.
NOTE 1: Do Not run this starter in a no load condition.
NOTE 2:
PO Box 3201
Tel. (239) 693-8588
Fax: (239) 693-1999

Unit Rotation Drive Type Internal Wiring Application
MZ-6204 CWDE Gear Reduction --- Lycoming
MZ-6220 CCWDE Gear Reduction --- Lycoming




Continued Airworthiness
Information (component level only)
…………………………………….….….….….….…
General Information
C A U T I O N:
THE INSTRUCTIONS HEREIN ARE THOSE MANDATED BY HARTZELL ENGINE
TECHNOLOGIES (HET). THESE LIMITATIONS ARE THE MINIMUM REQUIRED TO
MEET CONTINUED AIRWORTHINESS BUT MAY BE SUPERSEDED BY MORE
STRINGENT REQUIREMENTS AS PUBLISHED BY THE ENGINE, AIRCRAFT,
ROTORCRAFT OR OTHER MANUFACTURER USING THIS COMPONENT IN THEIR
APPLICATION. FAILURE TO OBSERVE THESE INSTRUCTIONS MAY COMPROMISE
THE COMPONENT OR THE APPLICATION IT IS USED IN.
A.1 Airworthiness Limitation Statement

A. The Airworthiness Limitations section is FAA approved and specifies maintenance required under Secs.
43.16 and 91.403 of the Federal Aviation Regulations unless an alternative program has been FAA approved.
A.2 Life Limits
A. The FAA establishes specific life limits for certain component parts as well as the complete starter. Such
limits require replacement of the identified parts after a specified number of cycles or hours of use.
B. Additions of, or changes to, any life limit for the starter or starter components, will be noted in the
Airworthiness Limitation Revision Log.
C. Life Limits
(1) Starter models and their component parts affected by this manual currently do not have any life
limited parts.
(2) There are no new (or additional) Airworthiness Limitations associated with this equipment.
Airworthiness Limitation Revisions Log
Revision Number Description of Revision
FAA APPROVED

Periodic Inspection - Starter
Information
This section has information regarding the recommended periodic inspection and maintenance. These
recommendations are instructions for continued airworthiness (ICA) and are needed to assure reliable and
safe operation of the starter while in service. Inspection and maintenance are listed in hours time in
service or calendar time, whichever is applicable. Some inspection and maintenance are one time initial and
others are recurring. The periodic inspection is for direct drive or gear reduction starters and is divided
BI-ANNUAL MAINTENANCE:
into two charts. Chart 1 is for “Bendix” type starters and Chart 2 is for starters without a “Bendix” drive.
(Applies to all starters.)

The starting circuit should be inspected at regular intervals, the frequency of which should be
determined by the type of service and the conditions under which the aircraft or rotorcraft is
operated. It is recommended that such inspection/maintenance be made at least twice a year and
should include the following:
1. Battery - The battery should be checked with a hydrometer (if applicable) to insure that it is
fully charged, and filled to the proper level with approved water. Perform a battery
capacitance check using an aircraft battery capacitance tester to determine battery condition.
Check for dirt and corrosion and clean.
2. Wiring - The starting circuit should be inspected to insure that all connections are clean and
tight and that the insulation is sound. A voltage loss test should be performed to locate any
high resistance connections, which would affect starting motor efficiency. This test is
performed with a low reading voltmeter while cranking the engine or at approximately 100
amperes. The following limits should be observed:
a. Voltage loss from insulated battery post to starting motor terminal 0.5 volt max.
b. Voltage loss from battery ground post to starter frame 0.1 volt max.
c. An ohmmeter check can also be made. The maximum resistance measuring from the
battery ground post to the starter frame is 0.2 ohms. If higher, check for resistance points
at connections in the ground circuit.
If the voltage loss is greater than the above limits, then additional test should be made
over each part of the circuit to locate the high resistance connections.
3. Lubrication & cleaning - At each annual not to exceed 50 hours TIS, clean with mineral
spirits then lubricate the Bendix drive with spray on silicone. Service Drive End Assembly &
Shaft at each annual or event inspection but no later than 500 Hours TIS. Clean with mineral
spirits and lubricate with Chevron SRI-2 or equivalent. Put a light film of Lubriplate® #777
on the drive end of the armature shaft before installing the drive end head. For gear reduction
starters, it may be required to pack the gear box with Chevron SRI-2 or equivalent if the
“Bendix” is removed or replaced. (Refer to Chapter 7 “Service Information”) Perform more
frequently if the aircraft is operated in abusive environments, such as dirt, dust, snow, and
high moisture areas. Recurring lubrication is not required and only exterior cleaning is
recommended for starter motors NOT using a Bendix drive. Consult the engine OEM for
required starter adapter maintenance.

PERIODIC INSPECTION CHART 1:
(Bendix Drive Starter)
10 Hours time in service. (one time)

Perform an initial check of the starter assembly. If safety wire or torque seal is broken, remove
from through bolts. Check bolt or housing screw torque per Assembly Chapter 8 for the
applicable starter. Apply safety wire or torque seal as applicable. Check starter drive gear
teeth for damage and condition. Check starter assembly mounted on the engine for security.
Re-torque the attach bolts per the engine/aircraft maintenance or service manual. Check for
signs of overheating or electrical arcing, if noted, determine cause. Refer to Chapter 7 “Service
Information”. Make sure starter assembly is clear of interference with any airframe structure.
Check terminal nut for tightness and insulator for condition. Check torque of terminal nut per
the engine or aircraft maintenance or service manual. Hold bottom nut when applying torque
to top nut.
50 Hours time in service. (or at oil change, the first to occur)

Clean with mineral spirits then lubricate the Bendix drive using a spray on silicone. Check
starter drive gear teeth for damage and condition. Check for signs of overheating or electrical
arcing. Check terminal nut for tightness and insulator for condition. Check torque of terminal
nut per the engine or aircraft maintenance or service manual. Hold bottom nut when applying
torque to top nut.
100 Hours time in service and each 100 hours thereafter. (or each annual inspection, the first to occur)
Check for corrosion at battery terminal and clean. Check starter drive gear teeth for damage
and condition. Check torque of terminal nut per the engine or aircraft maintenance or service
manual. Hold bottom nut when applying torque to top nut.
500 Hours time in service and each 500 hours thereafter*. (or each four years, the first to occur)
Remove starter from aircraft. Examine general condition of the starter. Inspect insulator and
replace if cracked or burnt. Inspect the housings for surface corrosion, clean and treat. Remove
com end to gain access to the brushes (see Disassembly Chapter 5). Remove each brush and
check for wear or damaged brushes. If severe wear has occurred, check commutator on the
armature for gouges or scratches. If brush shows more than 50% wear (approx. .25 inch), has
chips or damage, replace brush or brush block assembly. Clean commutator with crocus cloth
as required. Lubricate CE & DE bearing/bushing, Drive Assembly & Shaft with Chevron
SRI-2 or equivalent. Perform a check of the starter assembly per Chapter 7 “Service
Information”.
Unlimited Hour TBO

Recommended overhaul or replacement based on condition of starter assembly. The actual
overhaul time may vary based on operating environment and conditions of use. The airframe
or engine manufacturer recommended overhaul or replacement shall supersede this HET
recommendation.

PERIODIC INSPECTION CHART 2:
(Starter without “Bendix” drive)
10 Hours time in service. (one time)

Perform an initial check of the starter assembly. If safety wire or torque seal is broken, remove
from through bolts. Check bolt or housing screw torque per Assembly Chapter 8 for the
applicable starter. Apply safety wire or torque seal as applicable. Check starter assembly
mounted on the starter adapter for security. Torque the mounting bolts per the engine/aircraft
maintenance or service manual. Check for signs of overheating or electrical arcing, if noted,
determine cause. Refer to Chapter 7 “Service Information”. Make sure starter assembly is clear
of interference with any airframe structure. Check terminal nut for tightness and insulator for
condition. Check torque of terminal nut per the engine or aircraft maintenance or service
manual. Hold bottom nut when applying torque to top nut.
50 Hours time in service. (or at oil change, the first to occur)

Check starter assembly mounted on the starter adapter for security. Check starter for signs of
overheating or electrical arcing. Check terminal nut for tightness and insulator for condition.
Check torque of terminal nut per the engine or aircraft maintenance or service manual. Hold
bottom nut when applying torque to top nut.
100 Hours time in service and each 100 hours thereafter. (or each annual inspection, the first to occur)
Check for corrosion at battery terminal and clean. Using the applicable engine or aircraft
maintenance or service manual, check starter mount and drive adapter for damage/condition
and check torque of power terminal nut. Hold bottom nut when applying torque to top nut.
Check starter operation, there should not be excessive noise or slipping when engaged.
500 Hours time in service and each 500 hours thereafter. (or each four years, the first to occur)
Remove starter from aircraft. Examine general condition of the starter. Inspect insulator and
replace if cracked or burnt. Inspect the housings for surface corrosion, clean and treat. Remove
com end to gain access to the brushes (see Disassembly Chapter 5). Remove each brush and
check for wear or damaged brushes. If severe wear has occurred, check commutator on the
armature for gouges or scratches. If brush shows more than 50% wear (approx. .25 inch), has
chips or damage, replace brush or brush block assembly. Clean commutator with crocus cloth
as required. Lubricate CE & DE bearing/bushing, Drive Assembly & Shaft with Chevron
SRI-2 or equivalent. Check drive end shaft torque not to exceed 5 inch lbs (0.56 Nm) for a full
360˚ rotation. Perform a check of the starter assembly per Chapter 7 “Service Information”.
Unlimited Hour TBO

Recommended overhaul or replacement based on condition of starter assembly. The actual
overhaul time may vary based on operating environment and conditions of use. The airframe
or engine manufacturer recommended overhaul or replacement shall supersede this HET
recommendation.

Starter Maintenance
and Overhaul Information
………………………………………………………… 8
ES2001 – Direct Drive Starting Motor (All Except MagnaFlite Lightweight Starters) . . . . . . . . . . . . . . . . . . . 8-30-01
ES2002 – Gear Reduction Starting Motor (All Models Except Lycoming Style MagnaFlite) . . . . . . . . . . . . 8-150-01
ES2003 – Gear Reduction Starting Motor (Lycoming Style MagnaFlite) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-290-01
ES6462 – ES646 Series Direct Drive Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-390-01
NOTE:
HET E, X, M-Drive and Lamar style starters are not included in this manual.
Instruction for these HET starters may be found in other HET manuals or publications.

(Applies to all starters included in this Chapter.)
!
!
WARNING 2: MAKE SURE THAT ALL ELECTRICAL EQUIPMENT IS IN
THE OFF OR IN AN INACTIVE POSITION PRIOR TO RE-CONNECTING THE
LANDING GEAR, AND FLAPS TO NAME A FEW MAY SUDDENLY ACTIVATE
WHEN POWER IS APPLIED. FAILURE TO DO SO MAY RESULT IN
EQUIPMENT DAMAGE, INJURY OR DEATH SHOULD SHOULD

unit or wiring. Accidental grounding or shorting of starter wiring, will cause severe
damage to the surrounding structure and/or wiring.
3. NEVER “free run” starter unless performing a specific test per instructions contained
in this manual. In many cases, severe damage to the starter will result.
4. CHECK voltage loss from insulated battery post to starter terminal – 0.3 volt maximum.
5. CHECK voltage loss from battery ground post to starter frame – 0.1 volt maximum.
6. ALWAYS observe starter duty cycle requirements for your model starter. Duty cycle
is originally provided with each new or rebuilt starter delivered from Hartzell Engine
Technologies LLC.
7. WHEN USING EXTERNAL POWER (with or without battery power) be certain that
the external power supply is of the correct voltage and capacity prior to engaging or
applying the power. Should the incorrect voltage or capacity be used severe damage
will occur to electrical system and it’s components.

Direct Drive Starting Motor
…………………………………………………………
Covers Starter Series: All Except ES646 & MagnaFlite Lightweight Starter ES2001
NOTE:
GENERAL:
The starting circuit is designed to carry high current
with a minimum loss of voltage. The starting circuit
includes the battery, solenoid switch, manual
starting switch, starter motor, wiring and frame.
The starter motor cranks the engine for starting
while the battery supplies the power and the
manual key-switch and solenoid starting switch
control the operation.
Figure 1 - Direct Drive Starters,

The starter motor must develop a high cranking
Except Lycoming Style MagnaFlite.

torque during the period of time when the starting
switch is closed. The starter motor is designed to
engage its pinion in the flywheel ring gear on the
engine at the beginning of the starting cycle, and then disengage the pinion as soon as the
engine starts. This is accomplished through the use of a starter drive clutch assembly,
commonly referred to as a “Starter” drive. See (Figure 1).

Figure 2:
Principle
Components
of Typical
Direct Drive
Starting Motor,
3
Except
1
MagnaFlite 1
Lightweight
Starter.
2
4
6
5

The starter motor consists of six main components: (1) The Frame and Field Assembly, (2)
The Armature, (3) The Commutator End Head, (4) The Intermediate Bearing Assembly
(where applicable), (5) The Pinion Housing, and (6) The Starter Drive Assembly (where
applicable). See (Figure 2).
When the starting circuit is energized, battery current is applied to the starting motor terminal.
Current flows through the starter field coils creating a strong magnetic field. At the same
time, current flows through the brushes to the commutator, through the armature windings to
ground. The magnetic forces created in the armature and in the field windings, combine and
begin to turn the armature.
When the armature turns, the Bendix drive pinion meshes with the flywheel ring gear by
inertia and action of the screw threads within the Bendix sleeve. A detent pin engages in a
notch in the screw threads which prevents disengaging if the engine fails to start when the
starting circuit is de-energized.
When the engine reaches a predetermined speed, centrifugal action forces the detent pin out
of the notch in the screw shaft and allows the pinion gear to de-mesh from the flywheel ring
gear.
1. The Frame and Field Assembly includes the frame - which physically supports the other
components of the motor, the field coils, the brush holders (on certain models) and
brushes, and the pole shoes. The field coils supply the strong magnetic field required for
producing torque while the pole shoes and frame provide the path for the magnetic field.
2. The Armature consists of a laminated soft iron core assembled on the armature shaft, a
commutator and the windings, which are wound in slots in the core and connected to the
commutator. The commutator is made up of a number of copper segments insulated from
each other and from the armature shaft. The armature shaft extends through the pinion
housing and supports the starter drive (on certain models).
3. The Commutator End Head contains a bearing and in certain models the brush holder and
brushes in which the armature shaft rotates.
4. The Intermediate Bearing Assembly supports the armature shaft at a point between the
frame and field assembly, and the pinion housing.
5. The Pinion Housing partially encloses the drive mechanism and contains the other bearing
in which the armature shaft rotates.
6. The Starter Drive operates using a combination of screw action and inertia. The pinion is
mounted on a threaded sleeve, which is driven by the armature.

STARTER OVERHAUL INSTRUCTIONS:
!
CAUTION: WHEN SERVICING THE STARTER, ALL REPLACEMENT PARTS
PARTS MAY RESULT IN SERIOUS DAMAGE TO THE STARTER OR OTHER
NOTE 1: During overhaul the following components must be replaced with new:
2. Starter (Bendix) Drive
3. Thrust Washer Package
4. Needle Bearing
5. Brush Set
6. Commutator End Bearing
7. Field Coil
8. Terminal Stud Package
9. Hardware
NOTE 2:
Before removing the starting motor from the engine, disconnect the ground cable
from the battery post to prevent short circuiting. Disconnect the lead from the
starter motor terminal, then remove the mounting bolts and nuts. The starter
motor can then be removed and taken to the bench for overhaul.
STARTER DISASSEMBLY:
Direct Drive Starter Motor With Starter (Bendix) Drive:
NOTE:
As the motor is disassembled, each part should be cleaned and inspected for
excessive wear or damage. Bushings must be replaced during overhaul. Oil and
dirt should be removed from insulation and the condition of insulation should be
checked. The armature should be checked for shorts, grounds or open circuits.
1. Remove the cover band from the field case (where applicable).
2. Remove the battery terminal stud nuts, lockwashers, and insulators from the battery
terminal stud. Discard nuts, washers and insulator.
3. Using a flat blade screwdriver or other suitable tool,

unload the brush spring tension from the four brushes
as shown in (Figure 3). Remove the screws that hold
the commutator end head assembly to the field case,
and separate the commutator end head assembly
from the field case.
4. Carefully bend the negative brush shunt clamps out Figure 3 - Unload Brush
and remove the brush shunts. Discard the brushes. Spring Tension.

5. Remove the four screws that secure the drive end head assembly
to the field case, and remove the drive end head assembly,
intermediate bearing assembly, and armature.
6. Remove the two screws that secure the intermediate bearing

assembly to the drive end head assembly.
7. Remove the armature and the bendix drive from the drive end
head assembly and push the drive end bearing from the drive end
head assembly (Figure 4).
Bearing Removal.
8. Remove the four screws that hold the field pole shoes to the field case.
NOTE:
Strike the pole shoe screws once or twice firmly with hammer and drift pin
punch to loosen the screws for ease of removal. De-solder Battery terminal
from field coil assembly.
9. Remove the field coils and discard them.
10. Remove the battery terminal stud from the field case and discard.
11. Place the bendix assembly in a vise or other holding fixture, and press together until roll
pin is visible.
12. Use a drift pin punch to carefully drive out the

retaining roll pin as demonstrated in (Figure 5).
Remove the armature shaft and intermediate
bearing assembly from the bendix drive.
Discard the bendix drive.
Figure 5 - Roll Pin Removal.

13. Remove the intermediate bearing assembly from the armature shaft and remove the
bushing. Discard the bushing.
14. Using an internal bearing removal tool, remove the commutator end bearing from the
commutator end head assembly, and discard it.
Upon completion of disassembly, all parts should be cleaned and visually inspected for
cracked, worn, or distorted parts must be discarded and replaced with new HET parts. Refer
to the Specifications and Limitation Table for tolerances on the parts removed and inspected
for wear.

Direct Drive Starter Motor Without Starter (Bendix) Drive:
NOTE:
excessive wear or damage. Bushings and bearings must be replaced during
overhaul. Oil and dirt should be removed from insulation and the condition of
insulation should be checked. The armature should be checked for shorts,
grounds or open circuits. For ES646 series, refer to page 8-410-01.
1. Remove safety wire from commutator end head assembly (where used).
2. Remove the battery terminal stud nuts, lockwashers, and insulators from the battery
terminal stud. Discard nuts, washers and insulator.
3. Remove the two screws that secure the drive end head assembly to the field case (MHJ
Series, MCL Series).
4. Remove the thru-bolts from the field case.
5. Remove the commutator end head assembly from the field case.
6. Remove the three screws that secure the brush plate assembly to the field case, and
remove the brush plate assembly. On 28-volt direct drive starting motors there is a field
shunt screw that must be removed before the brush plate assembly can be removed from
the field case.
7. Unload the brush spring tension from the positive field brushes, and remove the brushes
from the brush plate assembly.
8. Carefully bend the negative brush shunt clamps out, and remove the brushes.
9. Remove the armature from the field case.
10. Press out the drive end bushing and the oil seal from the drive end head.
11. Remove the four screws that hold the field pole shoes to the field case. Remove the field
coils and discard them.
NOTE:
Strike the pole shoe screws once or twice firmly with hammer and drift pin punch
to loosen the screws for ease of removal. De-solder Battery terminal from field
coil assembly.
12. Remove the battery terminal stud from the field case, and discard it.
Upon completion of disassembly, all parts should be cleaned and visually inspected for
cracked, worn, or distorted parts must be discarded and replaced with new HET parts. Refer
to the Specifications and Limitation Table for tolerances on the parts removed and inspected
for wear.

NOTE:
Before removing the starting motor from the engine, disconnect the ground
cable from the battery post to prevent short-circuiting. Disconnect the lead
from the starter motor terminal, then remove the mounting bolts and nuts.
The starter motor can then be removed for overhaul or testing. Exercise
extreme caution when using 110 volt test light or any other high voltage test
equipment.
1. Armature - To test the armature for grounds, use a set

of test probes connected in series with a 110 volt light.
Touch one probe to a commutator segment and the
other to the armature core. If the test lamp lights, then
the armature is grounded and MUST be replaced. To
test for shorted armature coils, use a growler (Figure
6). Place the armature in the growler and slowly rotate Figure 6 - Armature
by hand while a holding steel strip over the core so on Growler.
that it passes over each armature core slot. If a coil is
shorted, the steel strip will vibrate. A quick check for opens can be made by inspecting
the trailing edge (in direction of rotation) of the commutator segments for excessive
discoloration. This condition indicates an open circuit.
An alternate method for testing the armature for grounded or shorted windings is to use
an appropriate surge/hipot tester, such as the Baker Instrument, Model ST106A. Refer
Check the commutator for uneven wear, excessive

glazing or evidence of excessive arcing. If it is only
slightly dirty, glazed or discolored, then the
commutator can be cleaned with 00 or 000 sandpaper.
If the commutator is rough or worn, then it should be
turned on a lathe (refer to Tolerances and
Figure 7 - Commutator
Specifications). (Figure 7) The armature shaft should
in Lathe.
be inspected for rough bearing surfaces and rough or
damaged splines.
2. Brush Holders - To test brush holders use a set of test probes connected in series with a
110 volt light. Touch one test probe to the frame or brush plate and the other to each
brush holder. The test lamp should light when the grounded brush holders are touched
and should not light when the insulated brush holders are touched.
3. Pinion Housing - Inspect housings for cracks. Replace the bushing and ream to proper
dimension found in Section 9. Remove corrosion, paint or grease from mounting
surfaces.
4. Drive Mechanism - The bendix drive must be replaced during overhaul.

STARTER ASSEMBLY:
NOTE:
When installing the absorbent bronze bushings, always use the proper bearing
arbor to obtain the proper fit.
Direct Drive Starter Motor With Starter (Bendix) Drive:

1. Install a new battery terminal stud package into the field
case, as shown in (Figure 8), being sure to assemble
washers, spacers, and nuts in their proper order.
Figure 8 - Battery Terminal

2. Install new field coils
Stud Installation.
into the pole shoes, and
assemble to the field
case, using the screws
Figure 9 - Tighten Pole

previously removed at disassembly. Tighten the four pole
shoe screws evenly using a pneumatic air hammer and finish
torque dry to 25 to 40 ft.-lbs. (Figure 9). Shoe Screws.
3. Install a new commutator end bearing into the

commutator end head and new intermediate bushings
into the intermediate housing (Figure 10). Ream
commutator end and
intermediate housing
bushings to the
dimension specified
Figure 10 - New
in the Tolerances and
Commutator End Bearing

Specifications section
Installation.
(Figure 11). Insert
felt and apply several
drops of SAE 30
weight oil for Figure 11 - Ream Bushings.
lubrication.
4. Install new negative brush shunts into the clamps of the

commutator end head assembly, and bend the clamps
back around the brush shunt (Figure 12). While holding
the brush shunt close to the clamp with pliers, carefully
solder the negative brush shunts to the clamps (Figure
13). Make certain that the solder does not wick up the
Figure 12 - Bend Clamps
brush shunt. Use 60/40 rosin core solder.
Around Brush Shunts.

5. Install the negative brushes into the brush rack.
6. Lubricate the armature shaft in the area where the

intermediate bushing
will be located with
Lubriplate® #777
grease. Install the
Figure 13 - Solder Brush
intermediate bushing
Shunts to Clamps.
assembly onto the
drive end of the
Figure 14 - Bushing
armature shaft
Assembly Installation.
(Figure 14).
7. Install the armature shaft into the bendix drive, and

align the retaining pin holes. (Slide the starter drive
onto the armature shaft.) Compress as necessary to
expose the retaining pin hole. Insert the retaining pin
into the bendix drive and armature shaft. Using an
appropriate punch, tap spiral pin in place making sure
the spiral pin does not project beyond the outside
Figure 15 - Spiral Pin
diameter of the pinion sleeve (Figure 15).
Installation.
8. Press the drive end bearing into the drive end head
assembly until the bearing is flush with the outside of the drive end head assembly.
Ream to the dimension specified in the Tolerances and Specifications section. Apply a
thin coat of Lubriplate #777 (or equivalent) to the armature shaft at the end located in the
drive end assembly.
9. Install the armature-and-bendix-drive assembly into the

drive end head assembly. Install intermediate bearing
assembly screws to the drive end head assembly (Figure
16). Torque screws to 25-35 in.-lbs.
10. Install the commutator end head assembly to the field

case, carefully positioning the positive brushes through
Figure 16 - Bearing Assembly
the brush windows in the field case. Secure the
Screws Installation.
commutator end head assembly with four new screws.
Torque screws to 25-35 in.-lbs.
11. Install the thrust washer onto the armature shaft at the commutator end. Apply a slight
amount of Lubriplate #777 to armature shaft at commutator end.
12. Install the armature-and-drive-end-head assembly into the field case assembly, and
secure with four new screws. Torque screws to 25-35 in.-lbs. Add thrust washer as

necessary to obtain the proper armature end-play, while maintaining proper armature
spacing.
To check for proper bearing alignment rotate the armature shaft in either direction. The
shaft should rotate freely with no binding and/or interference using 5 in.-lbs. of torque
or less.
13. Load the springs onto the four brushes and install the cover band.
Direct Drive Starter Motor Without Starter (Bendix) Drive:

1. Install a new battery terminal stud package into the
field case, being sure to assemble washers, spacers,
and nuts in the proper order (Figure 17).
2. Install new field

coils into the pole
shoes (Figure 18).
Figure 17 - Battery Terminal

Install the pole
Stud Package Installation.

shoes into the field
case, using the
screws removed
Figure 18 - Field Coil

previously. Tighten
Installation.
the four pole shoe screws evenly using a pneumatic air
hammer and finish torque dry to 25-40 ft.-lbs. Note:
The pole shoes must be installed so that the longer tip is
pointed in the same direction as armature rotation.
3. Install new negative

brush shunts into the
clamps, and bend the
clamps back around the
brush shunt (Figure 19).
While holding the brush
shunt close to the clamp
Figure 19 - Negative Brush Figure 20 - Negative Brush

with pliers, carefully
Shunt Installation. Shunt Solder.

solder the negative
brush shunts to the
clamps (Figure 20).
Make sure that the solder does not wick up the brush shunt. Use 60/40 rosin core solder.
4. Install the negative brushes into the brush plate assembly.
5. Install the brush plate assembly into the field case, and secure with the three screws.
6. 28-volt direct drive starting motors, secure the field shunt to the field case with the
screw.

7. Press a new bearing into the commutator end head assembly. Apply a thin coat of
“Lubriplate” #777 grease, or equivalent to the inside of the bearing.
8. Install a new bearing and seal into the drive end head assembly. Apply a thin coat of thin
coat of “lubriplate” #777 grease, or equivalent to the inside of the bearing.
9. Install a thrust washer onto the drive end of the armature shaft.
10. Place the drive end head assembly on a stable support, and install the armature into the
drive end bearing.
11. Assemble the field case onto the drive end head assembly, and secure with the 2 screws.
(MHJ Series only). Torque screws to 25-35 in.-lbs.
12. Install the positive brushes into the brush plate assembly. Load the springs onto the 4
brushes.
13. Install the thrust washer onto the armature shaft. Install the thru-bolts through the
commutator end head assembly. Install insulation tubes onto thru-bolts (provided in kits
for certain models only).
14. Assemble the commutator end head assembly to the field case, and secure with the thru-
bolts. Torque bolts to 35-45 in.-lbs.
15. Add thrust washer as necessary to obtain the proper armature end play, while
maintaining proper armature spacing. To check for proper end play pull the armature
forward. Take a dimension from the top of the armature shaft slot to the bottom side of
the drive end housing. Now push the armature shaft backward. Take the dimension using
the same criteria as above. Refer to the models part number service information section
for proper dimensions. Adjust as needed with thrust washers for proper position and end
play.
16. Torque the thru-bolts and safety-wire (where applicable). Test the starter for proper
operation.
BENCH TESTING OF STARTER:

After the starter motor is reassembled, it should be checked to see that the no-load current at
a certain voltage is within specifications. To make this test, connect the assembled unit as
shown in (Figure 21). If current is too high, check the bearing alignment and end-play as
described in the assembly process to make sure there is no binding or interference. If no
difficulty is indicated in the above test, a stall torque test may be made to see if the starter
motor is producing its rated cranking power. Make test connections as shown in (Figure 22).

If the torque and current are not
within specifications, check the
Knife
seating of the brushes and Switch
Carbon
Pile Ammeter Voltmeter
internal connections for high
resistance. If these checks are
made and found to be in good
order, replace the armature
assembly and retest the starter.
Operation - The starting motor

Ground
Tachometer
Battery
should be operated for a few Ground

seconds (not to exceed 10 Starting Motor
seconds) with the ignition
Figure 21 - No Load Current Test Connection.

disconnected to make sure that
the pinion engages properly and
that it turns freely without
binding or excessive noise. To
do this, connect a jumper lead to Knife Carbon
the “P” (primary) lead of both Switch Pile Ammeter Voltmeter
magnetos while connecting the
other end to a convenient clean
Spring Scale
engine grounding point. The
engine will now be inoperative
until the jumper lead is removed.
After making the above test,
remove the jumper lead. Engines Battery
incorporating the Starter Drive Ground
clutch assembly should be started

two or three times to see that the Starting Motor
Ground
Figure 22 - Stall Torque Test Connection.

pinion disengages properly when
the engine is turned off.


Gear Reduction Starting Motor
…………………………………………………………
Covers Starter Series: All Models Except Lycoming Style MagnaFlite ES2002
NOTE:
GENERAL:

with a minimum loss of voltage. The starting circuit
includes the battery, solenoid switch, manual
starting switch, starter motor, wiring and frame.
The starter motor cranks the engine for starting
while the battery supplies the power and the manual
key-switch and solenoid starting switch control the
operation.
Figure 1 - Gear Reduction Starters,

Except Lycoming Style MagnaFlite.
The starter motor must develop a high cranking
torque during the period of time when the starting
switch is closed. The starter motor is designed to engage its pinion in the flywheel ring gear
on the engine at the beginning of the starting cycle, and then disengage the pinion as soon as
the engine starts. This is accomplished through the use of a starter drive clutch assembly,
commonly referred to as a “Starter” drive. See (Figure 1).

Figure 2 -
Principle
1
Components
of Gear 2
Reduction 4
Starting
Motors, 1
Except
6
Lycoming
5 3
Style
MagnaFlite.
2
6 4

The gear reduction starter motor consists of six major components: (1) The Commutator End
Head Assembly, (2) The Armature, (3) The Frame and Field Assembly, (4) The Gear Housing,
(5) The Pinion Housing, and (6) The Starter Drive Assembly. See (Figure 2).
ground. The magnetic forces created in the armature and in the field windings, combine and
begin to turn the armature.
The gear cut on the drive end of the armature shaft extends through the gear housing where it
is supported by a roller bearing. The gear mates with the teeth of the reduction gear that drives
the Bendix shaft. The shaft is keyed to the reduction gear. The Bendix drive is held in
position on the shaft by a retaining pin. The shaft is supported in the gear housing by a closed
end roller bearing and in the pinion housing by a graphitized bronze bearing.
When the armature turns the reduction gear, the Bendix drive pinion meshes with the flywheel
ring gear by inertia and action of the screw threads within the Bendix sleeve. A detent pin
engages in a notch in the screw threads which prevents disengaging if the engine fails to start
when the starting circuit is de-energized.
When the engine reaches a predetermined speed, centrifugal action forces the detent pin out
of the notch in the screw shaft and allows the pinion gear to de-mesh from the flywheel ring
gear.
1. The Frame and Field Assembly includes the frame - which physically supports the other
components of the motor, the field coils, the brush holders and brushes, and the pole
shoes. The field coils supply the strong magnetic field required for producing torque
while the pole shoes and frame provide the path for the magnetic field.
each other and from the armature shaft. The armature shaft extends through the pinion
housing and supports the bendix drive.
3. The Commutator End Head contains a bearing and the brush holder in which the armature
shaft rotates.
4. The Gear Housing Assembly supports the armature shaft at a point between the frame and
field assembly, and the pinion housing. It also contains the bearing which supports the
Bendix drive shaft.
5. The Pinion Housing partially encloses the drive mechanism and contains the other bearing
in which the Bendix drive shaft rotates.
6. The Starter Drive operates using a combination of screw action and inertia. The pinion is
mounted on a threaded sleeve, which is driven by the armature.

!
PARTS MAY RESULT IN SERIOUS DAMAGE TO THE STARTER OR OTHER

NOTE 1: 1. Drive End Bearing
2. Starter Drive
4. Needle Bearings
5. Brushes
6. Commutator End (“CE”) Bearing
7. Field Coil
8. Terminal Stud Package
9. Hardware, self-locking nuts and woodruff key
NOTE 2:
from the battery post to prevent short-circuiting. Disconnect the lead from the
starter motor terminal, and remove the mounting bolts. The starter motor can
then be removed and taken to the bench for service.
NOTE:
excessive wear or damage. Bushings and bearings must be replaced during
overhaul. Oil and dirt should be removed from insulation and the condition of
insulation should be checked. The armature should be checked for shorts,
grounds or open circuits.
1. Remove the brush cover band from the field case.
2. Remove the battery terminal stud nuts, lockwashers, and

insulators from the battery terminal stud and discard.
3. Working through the

brush windows located in
the field case with a flat
bladed screwdriver or
other suitable tool, unload
the brush spring tension Figure 4 - Unload
Figure 3 - Unload Brush Brush Spring
from the four brushes as
Spring Tension. Tension.

shown in (Figure 3 &

Figure 4). Remove the positive brushes from the positive brush rack and position the
brushes outside the field case windows.
4. Remove the four screws that hold the commutator

end head (“CE”) assembly to the field case and
discard. Separate the CE assembly from the field
case. NOTE: The armature is a press fit into the CE
bearing and should normally remain fixed to the CE
assembly during removal. Remove the CE assembly
Figure 5 - C.E. Assembly

and armature from the field case (Figure 5).
5. Remove the grease plug from the gear housing. and Armature Removal.
6. Remove the four bolts that hold the drive end assembly to the gear housing assembly and
discard the self-locking nuts.
7. Remove the starter

drive shaft assembly
from the gear housing
and press out the
drive end bearing and
discard (Figure 6).
8. Remove all grease

from the gear housing
Figure 6 - Press Figure 7 - Drive Figure 8 - Drive

and discard.
9. Using a drift or Out Drive End Out Needle Out Needle

Bearing. Bearing. Bearing.
equivalent tool sized
to contact the outer
housings of the needle bearings, as shown in (Figures 7 and Figure 8), drive the needle
bearing out of the gear housing and discard.
10. Remove the four screws that secure the gear housing to the field case and discard.
11. Remove the gear housing from the field case and
remove the bearings.
12. Place the field case in a v-block and strike the

head of the pole shoe screw firmly with a staking
tool and hammer. Remove the four screws that
hold the field pole shoes to the field case using a
Figure 9 - Field Screw
pneumatic impact wrench (Figure 9). Remove
Removal.
the field coils and terminal stud and discard
(Figure 10).

13. Remove the
armature
from the CE
assembly by
placing the
assembly in
a holding
Figure 10 - Field Coil and
fixture
Terminal Stud Removal.

suitable to
Figure 11 - Figure 12 - Press
support the
Armature on Armature
CE housing
Removal. Shaft.
(an old damaged field case works very well) in
an Arbor press or equivalent (Figure 11). Press
on the end of the armature shaft using an
appropriately sized drift or equivalent tool (Figure 12). The CE bearing and armature
will remain together due to the press fit between the armature shaft and the inner race of
the CE bearing.
14. Using a bearing puller as shown in (Figure 13),

remove the CE bearing from the armature shaft
and discard.
15. Remove the four brush tension springs from the

Figure 13 - CE Bearing
CE assembly brush racks and discard.
Removal from
Armature Shaft.
16. Place the starter drive and shaft assembly in a vise or

other holding fixture as shown in (Figure 14), and press
Figure 14 - Starter Drive &

together until the roll pin is visible. In some models the
Shaft Assembly in Vise.

roll pin is located in the center of the starter drive and
only requires the alignment of the center hole with the
roll pin for removal.
17. As shown in (Figure 15), use a drift pin punch to

carefully drive out the roll pin. Remove the shaft,
gear track, and washer from the starter drive.
Discard the Starter drive and Roll Pin. Remove the
reduction gear, woodruff key, and thrust washer
from the starter drive shaft. Discard the woodruff
Figure 15 - Roll Pin

key and thrust washer.
Removal.

18. Carefully bend the negative brush shunt clamps out,
and remove the brush shunts. It may be necessary to
unsolder the brush shunt from the clamp to facilitate
removal of the brush and shunt assembly from the
negative brush holder clamps (Figure 16).
Upon completion of disassembly, all parts should be

cleaned and visually inspected for cracks, wear, Figure 16 - Brush Shunt
Removal.
distortion and any signs of overheating or mechanical
interference. Any cracked, worn, or distorted parts
must be discarded and replaced with new Hartzell Engine Technologies parts. Refer to
the Specifications and Limitation Table for tolerances on the parts removed and
inspected for wear.
NOTE:
from the battery post to prevent short circuiting. Disconnect the lead from the
starter motor terminal, then remove the mounting bolts and nuts. The starter
motor can then be removed for overhaul or testing. Exercise extreme care when
using 110 volt light or any other high voltage test equipment.
1. Armature - To test the armature for grounds, use a set

of test probes connected in series with a 110 volt light.
Touch one probe to a commutator segment and the
other to the armature core. If the test lamp lights, then
the armature is grounded and MUST be replaced. To
test for shorted armature coils, use a growler (Figure
Figure 17 - Armature
17). Place the armature in the growler and slowly
on Growler.
rotate by hand while a holding steel strip over the core
so that it passes over each armature core slot. If a coil
is shorted, the steel strip will vibrate. A quick check for opens can be made by inspecting
the trailing edge (in direction of rotation) of the commutator segments for excessive
discoloration. This condition indicates an open circuit.
An alternate method for testing the armature for grounded or shorted windings is to use
an appropriate surge/hipot tester, such as the Baker Instrument, Model ST106A. Refer to
the manufacturer for suitable instructions and settings.
Check the commutator for uneven wear, excessive

glazing or evidence of excessive arcing. If it is only
slightly dirty, glazed or discolored, then the commutator
can be cleaned with 00 or 000 sandpaper. If the
commutator is rough or worn, then it should be turned on
a lathe (refer to Tolerances and Specifications). (Figure
18). The armature shaft should be inspected for rough Figure 18 - Commutator
bearing surfaces and rough or damaged splines. in Lathe.

2. Commutator End Head and Brush Holder Assembly – To test the brush holders, touch one
test probe to the brush plate and the other to each brush holder. The test lamp should light
when the grounded brush holders are touched and should not light when the insulated
brush holder are touched. Should a failure occur, replace the entire assembly with new or
serviceable.
Check the CE bearing bore per the Starter Tolerance and Limitations section of this
manual. If the bearing bore does not meet the required specifications discard and replace
with a new or serviceable assembly.
3. Gear and Pinion Housing - Remove rust, paint, or grease from mounting surfaces. Inspect
the casting for cracks. Cast all dimensional requirements for the bearing bores and mating
surfaces as outlined in the Starter Tolerance and Limitation section of this manual.
4. Field Case – Remove rust, paint or grease from mounting surfaces. Inspect for overall
housing distortion and cracking around the brush windows. Check for elongated or
stripped threaded holes on both top and bottom mounting surfaces. If any distortion,
cracking, hole elongation or stripping has occurred, discard the field case and replace with
a new or serviceable component.
STARTER ASSEMBLY:
NOTE:
When assembling the starter motor, always use an arbor press and the proper
bearing arbor for installing graphitized bronze and roller bearings.
1. Install a new battery terminal stud package into the

field case, as shown in (Figure 19), being sure to
assemble washers, spacers and nuts in the proper
order.
2. Install new field coils into the pole shoes, and

assemble to the field case, using new pole shoe
screws. Tighten the four pole shoe screws evenly Figure 19 - Battery
Terminal Stud Installation.
using a pneumatic air hammer and finish torque dry to
25-40 ft.-lbs (Figure 20).
3. Insert the ends of the

field and shunt coil
(wire wound shunt coils
are used on all 24 volt
starter applications) into
Figure 20 - Tighten Pole Figure 21 - Field and

the terminal stud slot
Shoe Screws. Shunt Coil Installation.

and crimp (Figure 21).

4. Using a 120 volt 150 watt soldering machine
and 60/40 rosin core solder, solder the field coils
and terminal studs together, as shown in (Figure
22), making sure not to damage the field coil
insulation through excessive heat.
Figure 22 - Field Coil and

Terminal Stud Solder.
5. Install new negative

brush and shunt
assemblies into the
negative brush rack
clamps, and bend the
clamps back around
Figure 23 - Brush Figure 24 - Brush

the brush shunt
(Figure 23). Holding
the brush and shunt Shunt Installation. Shunt Solder.
assembly close to the
clamp with pliers, or some other form of heat sink, carefully solder the negative brush
and shunts to the clamps, making sure the solder does not wick up the brush shunt
(Figure 24). Use 60/40 rosin core solder.
6. Install a new CE bearing into the CE head

assembly. Apply a small amount of “Loctite®”
#271 to the outer edge of the CE bearing bore,
then using an arbor press and drift or equivalent
tool sized appropriately to contact the CE
bearing outer race only, press the bearing into the
Figure 25 - C.E. Bearing

CE bearing bore until the bearing bottoms out in
the bore seat (Figure 25).
Installation.
7. Press the armature into the CE bearing as shown in (Figure 26).
8. Insert the negative brushes into the brush rack, and load the brush
springs onto the negative brushes.
Figure 26 -
Armature
9. Install new needle bearings into the gear housing. The bearings must
Installation.
be pressed flush with the edge of the casting. The armature bearing
must be flush on the side towards the armature. The drive assembly

shaft bearing must be
flush on the side
towards the drive
assembly (Figures 27
and Figure 28).
10. Using an arbor press Figure 27 - Correct Drive Figure 28 - Correct Drive
Assembly Shaft Installation. Assembly Shaft Installation.
and an appropriately
sized drift or equivalent
tool, press the drive end
bushing into the drive
end housing flush with
the drive end casting.
11. Starter drive and shaft assembly – Install thrust
Figure 29 - Retaining
washer and woodruff key. Slide reduction gear into
Plate Installation.
drive shaft engaging the woodruff key and install
retaining plate as shown in (Figure 29).
12. Apply a light coat of spray-on type silicone

lubricant to the starter drive shaft and slide the
drive shaft through the center hole in the new
starter drive. Align the retaining pin holes in the
center of the starter drive and drive shaft and
install the spiral pin with appropriate punch by
Figure 30 - spiral Pin

tapping the spiral pin in place making sure the
pin does not project beyond the outside diameter
Installation. of the pinion sleeve (Figure 30). When
assembling starter drives with the retainer pin
located at the base of the component it will be
necessary to compress the starter drive, as
shown in (Figure 31), to expose the drive pin
hole in the starter drive. With the shaft inserted
through the center of the starter drive and the
starter drive compressed in the fixture, align the
retaining pin holes and insert the pin. Release
Figure 31 - Compress
the compression on the starter drive making sure
Starter Drive.
the head washer covers both ends of the
retaining pin.
13. Install the field case assembly over the CE and armature assembly. Do not at this step
secure the CE assembly to the field case.
14. Install the gear housing to the field case using the four new screws and lockwashers.
Torque screws to 25-35 in.-lbs.

15. Flip the field case and gear housing assembly over so that the motor assembly is resting
on the gear housing. Align the CE head assembly on the field case in accordance with
directives given in the Service Information Section of this manuals. Secure the CE
assembly to the field case using four new screws and lockwashers. Torque screws to
25-35 in.-lbs.
16. Insert the positive brushes into the brush rack and load
the springs onto the positive brushes (Figure 32).
17. Pack the gear housing with 1.3 to 2.0 ounces of

Chevron SRI Grease or equivalent. Do not over pack
the gear housing.
Figure 32 - Brush and

Spring Installation.
18. Install the starter drive and
shaft assembly into the gear
housing as shown in (Figure
33).
19. Install the thrust washer onto the armature shaft at the
commutator end and apply a slight amount of “Lubriplate”
#777 to the end of the shaft.
Figure 33 - Starter
20. Install the drive end head assembly over the starter and shaft
Drive and Shaft

assembly and secure with the four new screws and self-locking
Assembly
nuts. Torque screws to 35-45 in.-lbs.
Installation.

After the starter motor is
reassembled, it should be tested Knife
Carbon
Switch
to see that the no-load current at Pile Ammeter Voltmeter
a certain voltage is within
specifications. To make this
test, connect as shown in
(Figure 34). If the current is too
high, check the bearing
alignment and end-play to make Ground
Tachometer
sure there is no binding or Battery
interference. Two or three sharp Ground

raps on the frame with a rawhide Starting Motor
hammer will often help to

align the bearings and free

the armature. If no difficulty is
indicated in the above test, a Knife Carbon
Switch
stall torque test may be made to Pile Ammeter Voltmeter
see if the starter motor is

producing its rated cranking
Spring Scale
power. Make test connections
as shown in (Figure 35).
If the torque and current are not

within specifications, check the Battery
Ground
seating of the brushes and
internal connections for high
Ground
resistance. If these checks are Starting Motor
Figure 35 - Stall Torque Test Connection.

made and found to be in good
order, replace the field coils or
the frame and field assembly
and retest the starter.
STARTER MOTOR CONTROL CIRCUIT:

Inspect the control circuit between the battery, solenoid and manual starting switches for
breaks, poor connections and faulty insulation. Tighten all connections and make sure the
solenoid is firmly mounted and makes a good ground connection. Check the voltage loss
across the switch contacts during normal starting. If the loss is in excess of 0.2 volts per 100
amperes, then the solenoid should be replaced.
If solenoid fails to operate when the manual switch is turned on or if it fails to release when
the manual switch is released, it should be removed and tested to specifications. If either
opening or closing voltages are not as specified, replace the solenoid.
STARTER MAINTENANCE - DIRECT DRIVE:

determined by the type of service and the conditions under which the aircraft is operated. It
is recommended that such an inspection be made at least twice a year and should include the
following:
1. Battery - The battery should be checked with a hydrometer to insure that it is fully charged,
and filled to the proper level with approved water. A load test should be performed to
determine battery condition. If dirt and corrosion have accumulated on the battery, it
should be cleaned with a solution of baking soda and water. Be sure none of the solution
enters the battery cells.
2. Wiring - The starting circuit should be inspected to insure that all connections are clean
and tight and that the insulation is sound. A voltage loss test should be performed to locate

any high resistance connections, which would affect starting motor efficiency. This test is
performed with a low reading voltmeter while cranking the engine or at approximately 100
amperes. The following limits should be observed:
a. Voltage loss from insulated battery post to starting motor terminal -.3 volt maximum.
b. Voltage loss from battery ground post to starter frame - .1 volt maximum.
If the voltage loss is greater than the above limits, then additional test should be made
over each part of the circuit to locate the high resistance connections.
3. Lubrication - No lubrication is required on the starting motor except at the time of overhaul.
Service Drive Assembly & Shaft each 50 Hours. Wash clean with mineral spirits and
lubricate with spray silicone. (Do Not use oil or graphite)
4. Operation - The starting motor should be operated for a few seconds (not to exceed 10
seconds) with the ignition disconnected to make sure that the pinion engages properly and
that it turns freely without binding or excessive noise.
STARTER MAINTENANCE - GEAR REDUCTION:

determined by the amount of service and the conditions under which the aircraft is operated. It
is recommended that such an inspection be made at least twice a year and should include the
following:
1. Battery - The battery should be checked with a hydrometer to insure that it is fully charged,
and filled to the proper level with approved water. A load test should be performed to
determine battery condition. If dirt and corrosion have accumulated on the battery, it should
be cleaned with a solution of baking soda and water. Be sure none of the solution enters
the battery cells.
2. Wiring - The starting circuit wiring should be inspected to insure that all connections are
clean and tight and that the insulation is sound. A voltage loss test should be performed to
locate any high resistance connections, which would affect starting motor efficiency. This
test is performed with a low reading voltmeter while cranking the engine or at
approximately 100 amperes. The following limits should be observed:
a. Voltage loss from insulated battery post to starting motor terminal -0.3 volt maximum.
b. Voltage loss from battery ground post to starter frame 0.1 volt maximum.
If voltage loss is greater than the above limits, then additional tests should be made over
each part of the circuit to locate the high resistance connections.

3. Lubrication - No lubrication is required on the starter motor except at the time of overhaul.
The Bendix shaft should receive a thin film of Lubriplate #777 or equivalent on the Bendix
portion of the shaft annually, and more frequently when the aircraft is operated in abusive
environments, such as dirty conditions, snow, and high moisture areas. If the pinion teeth
are worn or damaged, then replace with new. Service Drive Assembly & Shaft each 50
Hours. Wash clean with mineral spirits and lubricate with spray silicone. (Do Not use oil
or graphite)
4. Drive Operation - The starter motor should be operated for a few seconds (not to exceed 10
seconds) with the ignition switch off to make sure that the pinion engages properly and that
it turns freely without binding or excessive noise. Then the engine should be started two
or three times to see that the pinion disengages properly when the engine is turned off.


Gear Reduction Starting Motor
…………………………………………………………
Covers Starter Series: All MagnaFlite Starter Series ES2003
NOTE:
GENERAL:

with a minimum loss of voltage. This circuit includes
the battery, solenoid starting switch, manual starting
switch, starter, the connecting wiring and the aircraft
frame. The starter cranks the engine for starting
while the battery supplies the power. The manual
switch and solenoid starting switch control the
operation.
The starter must develop a high cranking torque for a Figure 1 - Gear Reduction Starting
Motor, MagnaFlite Starter.
limited period of time when the starting switch is
closed. The starter has designed into it a means of
engaging it’s pinion with the flywheel ring gear on
the engine with which it is used, and disengaging the
pinion as soon as the engine starts. See (Figure 1).

Figure 2 -
Principle
Components
4
of Gear
6
1
Reduction 5
Starting
Motor,
Lycoming 1
Style
3
MagnaFlite. 2

The gear reduction starter motor consists of six major components (Figure 2): (1) The
Commutator End Head Assembly, (2) The Armature, (3) The Housing Assembly, (4) The Gear
Track, (5) The Pinion Housing, and (6) The Starter Drive Assembly. See (Figure 2).
When the starting circuit is energized, battery current is applied to the starter terminal.
Current flows through the brushes to the armature windings to ground. Permanent magnets
are used to create a strong magnetic field. The magnetic force created begins to turn the
armature.
The gear cut on the drive end of the armature shaft extends into the planetary gear assembly
that drives the shaft assembly which is connected to the bendix assembly with a roll pin.
When the armature turns, the Bendix drive pinion meshes with the flywheel ring gear by
inertia and action of the screw threads within the bendix sleeve. A detent pin engages in a
notch in the screw threads which prevents de-meshing if the engine fails to start when the
starting circuit is de-energized.
When the engine reaches a pre-determined speed, centrifugal action forces the detent pin out
of the notch in the screw shaft and allows the pinion to de-mesh from the flywheel.
STARTER MAINTENANCE:
determined by the amount of service and the conditions under which the aircraft is operated.
It is recommended that such inspection be made at least twice a year and should include the
following:
1. Battery - The battery should be checked with a hydrometer to be sure it is fully charged,
and filled to the proper level with appropriate water. A load test should be done to
determine battery condition. If dirt and corrosion have accumulated on the battery, it
should be cleaned with a solution of baking soda and water. Be sure none of the solution
enters the battery cells.
2. Wiring – The starting circuit wiring should be inspected to be sure that all connections are
clean and tight and that the insulation is sound. A voltage loss test should be made to
locate any high resistance connections that would affect starter efficiency. This test is
made with a low reading voltmeter while cranking the engine at approximately 100
amperes, then the following limits should be used:
a. Voltage loss from insulated battery post to starter terminal – 0.3 volt maximum.
b. Voltage loss from battery ground post to starter frame – 0.1 volt maximum.
If voltage is greater than the above limits, additional tests should be made over each part
of the circuit to locate the high resistance connections.

3. Lubrication – No lubrication is required on the starter except at the time of overhaul. Then
lubricate the entire shaft under the bendix drive, fill grooves in armature drive gear, and
apply a small amount of Chevron SRI #2 into planetary gears and gear track.
4. Drive Operation – The starter should be operated for a few seconds (not to exceed 10
seconds) with the magneto switch off to make sure that the pinion engages properly and
that it turns freely without binding or excessive noise. Then the engine should be started
two or three times to see that the pinion disengages properly when the engine is turned
off.
STARTER REMOVAL INSTRUCTIONS:

To remove the starter from the engine, first disconnect the ground cable from the battery
post to prevent short circuiting. Disconnect the cable from the starter positive terminal,
and then take out the mounting bolts. The starter can then be lifted off and taken to the
bench for service.
!
DAMAGE TO THE STARTER OR OTHER ELECTRICAL SYSTEM COMPONENT.
If, during the inspection, any indication of starter difficulty is noted, the starter should be
removed from the engine for cleaning and repair.
NOTE 1:
Throughout this procedure, refer to the Specifications and Limitation Table for
tolerances on the parts removed and inspected for wear.

NOTE 2: 1. Bearing, Commutator End
2. Bearing, Bendix Drive Shaft
3. Bearing, Bendix Housing
4. Bendix Drive
5. Gear Track
6. Planetary Gears
* See Section 6 For additional 100% replacement items.

1. Remove insulators
and hardware on
battery terminal. See
(Figure 3).
2. Remove screw, star
Figure 3 - Insulator and Figure 4 - Screw and

washer and flat washer
from commutator end
plate. This screw secures Hardware Removal. Washer Removal.
the brush assembly to
the end plate. See
(Figure 4).
3. Remove commutator end plate with thru-bolts (2)

together. Note the insulation on the thru-bolts for re-
assembly. See (Figure 5).
4. Remove rubber insulator (if present).
Figure 5 - Brush Holder

5. Remove brush holder assembly with brush stud and
Removal.
insulators.
!
CAUTION: BRUSH SPRINGS MAY FLY
OUT. SEE (FIGURE 5).
6. Remove armature by pulling straight out. Note

position of blue insulation in armature housing.
Figure 6 - Armature
Housing Removal.
7. Remove armature housing. See (Figure 6).
8. Remove planetary gear cover.
9. Remove planetary gears, bearings and thrust

ball. See (Figure 7).
10. R e m o v e
Figure 7 - Planetary
bendix drive,
Gear Removal.
shaft and gear
track as one
assembly
Figure 8 - Bendix Drive, Shaft

(sub shaft assembly) by gently prying gear track out
and Gear Track Removal.

with a small screwdriver. Be careful not to lose washer
at end of shaft. See (Figure 8).

11. Holding the large
end of the bendix
assembly under the
gear track, rotate
the drive gear at the
other end until the
Figure 9 Figure 10 - Drive

roll pin that holds
the shaft in the
bendix becomes Out The Roll Pin.
visible in the hole.
See (Figure 9).
12. Use a drift pin punch to carefully drive out the roll pin, and remove the shaft, gear track
and washer from the bendix. See (Figure 10).
13. Wipe all parts clean with a clean cloth.

1. Oil and dirt should be removed from the insulation and insulators. Check insulation and
all insulators for wear.
2. Inspect all parts for wear using the Specifications and Limitations Table for tolerances.
3. Check the brushes to see that they slide freely in the holder and make full contact on the
commutator. If worn to a length of .250” or less, they should be replaced.
4. Check the armature commutator for uneven wear, excessive glazing or evidence of
excessive arcing. If only slightly dirty, the commutator can be cleaned with 00 or 000
sandpaper. If the commutator is rough or worn, it should be turned in a lathe. The
armature shaft should be inspected for rough bearing surfaces and rough or damaged
gear splines.
To test the armature for grounds, a set of test probes connected in series with a 110 volt
light should be used. Touch one probe to a commutator segment and the other to the
armature core. If the lamp lights, the armature is grounded and should be replaced.
NOTE:
Exercise extreme caution when using 110 volt test light or any other high
voltage test equipment.
To test for shorted armature coils, a growler is used. The armature is placed on the
growler and slowly rotated by hand while a steel strip is held over the core so that it
passes over each armature core slot. If a coil is shorted, the steel strip will vibrate.

An alternate method for testing the rotor for grounded or shorted windings is to utilize
an appropriate surge/hipot tester, such as the Baker instrument, model ST106A. Refer
A quick check for opens can be made by inspecting the trailing edge ( in direction of
rotation ) of the commutator segments for excessive discoloration. This condition
indicates an open circuit.
5. Check the pinion housing for cracks and the brass bushing for excessive wear. Remove
any rust, paint or grease from mounting surfaces.
6. The Bendix Drive should be wiped clean with a dry cloth. The pinion should turn
smoothly in one direction and should lock in the other direction.
7. Check gauss strength of magnets in armature housing using the Specifications and
Limitations Table (Chapter 9) for tolerances.
STARTER ASSEMBLY:
NOTE:
When assembling the starter, always use an arbor press and the proper bearing
arbor for installing graphitized bronze and roller bearing. The Bendix shaft
should have a thin film of Lubriplate #777 or equivalent on the Bendix portion of
the shaft.
Commutator End Assembly:

1. Install bearing flush to top of bearing bore seat. Make sure bearing is positioned and
seated properly. Apply small amount of Chevron SRI #2 grease to the commutator end
bearing assembly.
Sub Shaft Assembly:

1. Install bearing.
2. Apply a light amount of grease next to shaft flange. Apply small amount of Chevron
SRI #2 grease.
3. Install gear track, axle pins should be to the inside of the gear track.
4. Install washer. See (Figure 11).
5. Lubricate shaft with the Lubriplate 777

where Bendix Drive pinion rides and install
Bendix Drive.
6. Apply a light coat of Chevron SRI #2 grease

to the inside of gear track. Figure 11 - Washer Installation.

7. Install bearings to gears, apply light coat of Chevron SRI #2
grease to bearing.
8. Use a drift pin punch to carefully drive in the roll pin to shaft
through hole in Bendix. See (Figure 12).
Check to make sure Bendix Drive rotates readily in one

direction and locks in the opposite direction.
FINAL ASSEMBLY:
Figure 12 - Drive
In Roll Pin.
1. Install washer to top of sub-shaft assembly.
2. Apply a light coat of Lubriplate 777 grease to top of sub shaft.
3. Install sub-shaft assembly to drive end head assembly, making certain alignment pins
of gear track seat properly.
4. Position drive end head assembly into holding

fixture nose down. See (Figure 13).
5. Install gear assemblies onto the axle pins of

sub-shaft assembly and insert thrust ball.
6. Install
planetary
Figure 13 - Positioning
gear cover.
Drive End Head Assembly.

Small tabs
on gear
cover shall
be pointed
Figure 14 - Planetary Gear

out when
Cover Installation.
installed. See
(Figure 14).
Check that armature rotates freely.
7. Install armature housing over armature and

position to drive end head assembly. See
(Figure 15).
Figure 15 - Armature
8. Install rubber insert (If required).
Housing Installation.

9. Install brush and stud assemblies to brush
holder.
10. Install brush holder assembly to armature

housing.
11. Install brush springs. See (Figure 16).
12. Install brush retainer.
Figure 16 - Brush Spring

Installation.
13. Install insulator on to

battery terminal.
14. Insert thru-bolts through

commutator end assembly,
install insulator sleeves and
a small amount of
Vibratite® Formula #3 Figure 17 - Insulator Figure 18 - Commutator
Sleeve Installation. End Assembly Installation.
(ND Industries, Troy
Michigan) to the threads.
See (Figure 17).
15. Install commutator end assembly on to the housing assembly. See (Figure 18).
16. Tighten and torque thru-bolts to 21-25 in.-lbs.
17. Install star washer, flat washer and screw through the commutator end assembly to the
brush holder assembly. Torque to 17–25 in.-lbs.
18. Install insulators and hardware to the battery terminal. Torque nut to 78–80 in.-lbs.
Check to see that the notch on the commutator end assembly is squarely seated to the
armature housing.
19. Test unit.

After the starter is reassembled, it should be tested. When tested on a starter tester, if current
is too high, check the bearing alignment and end play to make sure there is no binding or
interference. Never perform a no load current test on this starter as the planetary gears will
be destroyed in this test.

If no difficulty is indicated in the above test, a small torque test may be made to see if the
starter is producing it’s rated cranking power. Using a starter tester such as a Crumbliss
(various models available) that provides dynamic load to the pinion, check for start from rest
torque and running load torque. If torque and current are not within specifications (see
chapter 7), check the seating of the brushes and internal connections for high resistance, if
these checks are made and everything is found to be in good order, replace brushes and
commutator end plate and re-test.
INSPECTION OF STARTER CONTROL CIRCUIT:

Inspect the control circuit wiring between the battery, solenoid and manual starting switches
for breaks, poor connections and faulty insulation. Tighten all connections and make sure
solenoid is firmly mounted and makes a good ground connection.
Check the voltage loss across the switch contacts during normal starting. If loss is in excess
of 0.2 volts per 100 amperes, the solenoid should be replaced.
If solenoid fails to operate when the manual switch is turned on or it fails to release when the
manual switch is released, it should be removed and tested to specifications. If either opening
or closing voltages are not as specified, replace the solenoid.


ES646 Series Starter
…………………………………………………………
Covers Starter Series: ES646238-( ) & ES646275-( )
Circled items in this chapter represent

NOTE: replacement parts required at each
overhaul. When marked with a ∆, replace
with new whenever parts are removed.
GENERAL:
The starting circuit is designed to carry high current with a
minimum loss of voltage. The starting circuit includes the
battery, solenoid switch, manual starting switch, starter
motor, wiring and frame. The starter motor cranks the
engine for starting while the battery supplies the power
and the manual key-switch and solenoid starting switch Figure 1-12/24 Volt Starter
control the operation.
The starter must develop a high cranking torque for a limited period of time when the
starting switch is closed. The ES646 series starters are basically powerful electric motors
used to turn the engine over to provide a start. When the starting circuit is energized,
battery current is applied to the starter terminal. Current flows through the brushes to the
commutator through the armature windings to ground. This creates a strong magnetic field.
The magnetic force created begins to turn the armature. This in turn will engage the vendor
supplied starter adapter which will transmit drive torque to the engine accessory gear. After
engine start, the engine’s starter adapter clutch mechanism allows the engine to over-run the
starter until it is de-energized.
Figure 2:
Principle
Components
of Typical
3
ES646 Series
Direct Drive
2
Starter
1 6
5

The starter assembly consists of six main components: (1) The Drive End Flange with
Bearing & Oil Seal, (2) The Armature with shaft, (3) The Housing with Field Coil Assembly,
(4) The Power Input Stud with hardware, (5) The Brush Holder Plate with Brushes, and
(6) The Commutator End Cover (CE) with Bearing. See (Figure 2).
ground. The magnetic forces created in the armature and in the field windings, react with one
another creating a rotational force (torque) which is coupled to the starter drive adapter.
1. The Drive End Flange the drive-end flange assembly provides the mounting flange for
attachment of the starter to the engine (or starter adapter) and supports the bearing through
which the armature shaft rotates.
each other and from the armature shaft. The armature shaft extends through the drive end
flange with a blade end that engages the engine starter adapter.
3. The Housing and Field Coil Assembly includes the housing - which physically supports the
other components of the starter, the field coils, the brush holder plate with brushes, and
the pole shoes. The field coils supply the magnetic field required for producing torque
while the pole shoes and housing provide the path for magnetic flux flow. The housing
contains the brush holder plate with brushes.
4. The Power Input Stud provides a path for electrical current (+) to flow into the starter and
out (-) through the Drive End Flange.
5. The Brush Holder Plate is a plate containing two brush holder assemblies. The brush
holder is a one-piece device which provides placement and spring loading of the brushes.
6. The Commutator End Cover the commutator-end cover assembly contains a bearing in
which the commutator end of the armature shaft is supported for rotation.

CAUTION:
WHEN SERVICING THE STARTER, ALL REPLACEMENT PARTS MUST BE
!
ORIGINAL EQUIPMENT PARTS MANUFACTURED BY HET OR AN APPROVED
HET SOURCE. FAILURE TO USE GENUINE HET REPLACEMENT PARTS MAY
RESULT IN SERIOUS DAMAGE TO THE STARTER OR OTHER ELECTRICAL
SYSTEM COMPONENT AND MAY RESULT IN INJURY.
During overhaul the following components required to be replaced with new:

NOTE 1
1. Drive End Bushing
2. Starter Drive Oil Seal
4. Brush Set
5. Field Coil Ass’y
6. Solenoid (if equipped)
7. Terminal Stud
8. Hardware
Before removing the starter assembly from the engine, disconnect the ground (-) cable
from the battery post to prevent short circuiting. Disconnect the electrical cable from the
NOTE 2 starter terminal (+), then remove the mounting bolts and nuts. The starter motor can then
be removed and taken to the bench for overhaul.
The ES646 series starters are an accessory designed as a replacement component. HET
NOTE 3 recommends replacement with a new exchange starter as the most economic means
of repair. However, the manual contains test procedures, service components, and
replacement requirements should repair or overhaul be desired.
ES646 Series Direct Drive Starter:
As the starter is disassembled, each part should be cleaned and inspected for excessive
wear or damage. Bushings must be replaced during overhaul. Oil and dirt should
NOTE be removed from insulation and the condition of insulation should be checked. The
armature should be checked for shorts, grounds or open circuits. Refer to step 13 if a
solenoid is installed on the starter.
1. Refer to the ES646 Series IPC in chapter 6 for part item number reference.
2. Remove the battery terminal (+) stud nuts, lockwashers, and insulators from the terminal
stud. Discard nuts (13), lockwashers (14) and insulators (11 & 15). See step 13 below if an
ES646238-1 or -3 is being disassembled as the solenoid (25) must be removed first.

3. Remove the thru-bolts (20) from the field housing (8) and discard the lockwashers (23).
Removal may require heat as thru-bolts are secured with Loctite® adhesive.
4. Remove the commutator end head ass’y (22A) from the field housing (8).
5. Remove the three screws (24) that secure the brush plate assembly (17) to the field housing (8),
and extend the brush plate assembly out of the housing. On 28-volt ES646 starters there is a
field shunt screw (24) that must be removed before the brush plate assembly can be removed
from the field housing.
6. Unload the brush spring tension from the positive (insulated) field brushes, and remove the
brushes from the brush plate assembly.
7. Carefully bend the negative brush shunt clamps out, and remove the brushes.
8. Remove the armature (19) from the field housing (8) and three fiber washers (5) at the drive
end. The fiber washers (21) at the comm. end are shims and may be one or more.
9.
Place drive end (2) in a fixture and remove the bushing (5) using an arbor press with a .8437”
Dia. barstock rod.
10. To remove oil seal (1) from drive end (2), carefully bend one-half (1/2) the diameter of the steel
oil seal retainer down using a small, sharp chisel and mallet. Grasp bent retainer with pliers and
pull the seal out.
11. Remove the four screws (9) that hold the field pole shoes to the field housing. Remove the field
coil assembly (4) and discard.
Strike the pole shoe screws once or twice firmly with hammer and drift pin punch to loosen
NOTE
the screws for ease of removal. De-solder Battery terminal from field coil assembly.
12. Remove the battery (+) terminal stud (16) from the field housing, and discard.
13. If an ES646238-1 or -3 is being disassembled, the solenoid (25) must be removed.
14. Remove the positive terminal (+) stud nuts and lockwashers, from the terminal to free the
connector (26) cable from the starter.
15. Remove the connector (26) cable from the solenoid and visually inspect. Retain cable if
terminals and insulation are not damaged or burnt. If damaged, replace cable assembly.
16. Remove screws (27) from the bracket holding the solenoid to the starter and discard solenoid.
Upon completion of disassembly, all parts should be cleaned and visually inspected for cracks, wear,
distortion and any signs of overheating or mechanical interference. Any cracked, worn, or distorted
parts must be discarded and replaced with new HET parts. Refer to the Specifications and Limitation
Table for tolerances on the parts removed and inspected for wear.

CAUTION:
! EXERCISE EXTREME CAUTION WHEN USING 110 VOLT TEST LIGHT OR ANY
OTHER HIGH VOLTAGE TEST EQUIPMENT.
1. Armature - To test the armature for grounds, use a set of test probes connected in series with a
110 volt light. Touch one probe to a commutator segment
and the other to the armature core. If the test lamp lights,
then the armature is grounded and MUST be replaced.
To test for shorted armature coils, use a growler (Fig.
3). Place the armature in the growler and slowly rotate
by hand while a holding steel strip over the core so that it
passes over each armature core slot. If a coil is shorted,
the steel strip will vibrate. A quick check for opens can
be made by inspecting the trailing edge (with respect to
normal rotation) of the commutator segments for excessive Figure 3 - Armature
discoloration. This condition indicates an open circuit. on Growler.
An alternate method for testing the armature for grounded

or shorted windings is to use an appropriate surge/hipot tester, such as the Baker Instrument,
Model ST106A. Refer to the manufacturer for suitable instructions and settings.
Check the commutator for uneven wear, excessive glazing or evidence of excessive arcing.
If it is only slightly dirty, glazed or discolored, then the
commutator can be cleaned with 00 or 000 sandpaper.
If the commutator is rough or worn, then it should be
turned on a lathe (Figure 4). The armature shaft should
be inspected for rough journal surfaces and rough or
damaged splines. (Refer to Chapter 9, Tolerances and
Specifications.)
2. Brush Holders - To test brush holders use a set of test Figure 4 - Commutator
probes connected in series with a 110 volt light. Touch one in Lathe.
test probe to the frame or brush plate and the other to each
brush holder. The test lamp should light when the negative
brush holders are touched and should not light when the positive (insulated) brush holders are
touched.
3. Drive End Head - Inspect flange for cracks and wear on the flange pilot to housing. Inspect
flange for worn or oblong mounting holes and replace drive end head if found. Check drive end
bushing bore for proper dimension found in Chapter 9 when bushing is removed. (bushing is
replaced at starter overhaul) Remove grease or corrosion from mounting surfaces.
Commutator End Head - If the starter is being repaired and is equipped with either P/N 50796
4.
(billet) or P/N ES646502 (cast) commutator end head with no cracks or damage, it may be
reused provided the proper dimensions for the bushing bore will allow the installation of a new
P/N 50044 bushing. (Refer to Chapter 9, Tolerances & Specifications).
NOTE: Part number 50033 (stamped steel) commutator end head is no longer available and
must be discarded and replaced with P/N 50796 (billet) version if bushing is worn or damaged.
See Figure 5 for cast CE, Figure 5a for billet CE, and Figure 6 for stamped CE identification.

Figure 5 - Cast Type CE Figure 5a - Billet Type CE Figure 6 - Stamped Type CE
(Aluminum) P/N ES646502 (Aluminum) P/N 50796 (Steel) P/N 50033
STARTER ASSEMBLY:
ES646 Series Direct Drive Starter:
When installing the absorbent bronze bushings, always use the proper arbor to
NOTE: obtain the proper fit. Refer to step 19 if a solenoid is installed on the starter.
1. Install a new battery terminal stud package into the field

housing, being sure to assemble washers, spacers, and nuts
in the proper order (Figure 7).
2. Install new field coils

(4) into the pole shoes
(Figure 8). Install the
pole shoes in the field
housing, using new
screws (9). Tighten the Figure 7 - Battery Terminal
four pole shoe screws Stud Package Installation.
evenly to a dry torque
of 25-40 ft.-lbs (33.9-
Figure 8 - Field Coil 54.2 Nm). Note: The pole shoes must be installed so that
the longer edge is pointed in the same direction as armature
Installation.
rotation. Refer to Chapter 7, Figure 1 “Pole Shoe”.
Positive brushes are included with field coil package (4).
3. Install new negative brush shunts into the clamps, and bend the clamps back around the brush shunt (Figure
9). While holding the brush shunt close to the clamp with pliers, carefully solder negative brush shunts to the
clamps (Figure 10). Make sure that the solder does not wick up the brush shunt. Use 60/40 rosin core solder.
4. Install the negative brushes into the brush plate assembly. The brushes and springs are
included and attached if replacing the plate assembly (17).
5. On 28-v ES646 starters, secure the field shunt to the field housing with screw (24).

Figure 9 - Negative Brush Shunt Installation. Figure 10 - Negative Brush Shunt Solder.
6. Install a new bushing (22B) into the commutator end head (22A) so that it is flush to 0.6 in.
below the surface. Apply a thin coat of Lubriplate® #777 grease, or equivalent to the inside of
the bushing (22B) prior to installation.
NOTE: If starter was equipped with P/N 50033 (stamped CE), replace entire commutator end
head with P/N 50796.
7. Install a new bushing (5) into the drive end head ass’y (2). Press bushing into the drive end
housing so that it is 0.06” below flush with the edge of the oil seal bore (refer to Chapter 7, Figure
5). Apply a thin coat of thin coat of Lubriplate® #777 grease, or equivalent to the inside of the
bushing.
8. Install a new oil seal (1) by pressing the flat portion of the seal to bottom of the bore in the drive
end head assembly (2). (Refer to Chapter 7, Figure 4).
9. Install three fiber washers (6) onto the drive end of the armature shaft. Any time the starter is
dissembled the fiber washer(s) must be replaced.
10. Place the drive end head assembly (2) on a stable support, and install the armature into the
drive end bushing.
11. Assemble the field housing (8) onto the drive end head assembly, and secure on pilot flange.
12. Install the two field coil brushes into the brush holder plate assembly. Load the springs onto
the 4 brushes.
13. Install the brush plate assembly (pg. 6-40-01, ITM #17) into the field housing (8) with retaining
tabs facing the housing, secure with three screws (24).
14. Install fiber washer (21) onto the armature shaft at commutator end. Insure washer(s) are
installed in the same number as removed. (The fiber washer is used as a shim to obtain proper
end play and may be one or more in number.) Any time the starter is dissembled the fiber
washer(s) must be replaced.
15. Install the thru-bolts (20) through the commutator end head and assemble to the field housing
and drive end head securing the thru-bolts finger tight.
16. Rotate starter shaft 360° to insure free movement and to square up end housings.

17. Remove the thru-bolts (20) one at a time and apply Loctite® 271 adhesive. Reinsert the
thru-bolts and torque to 35-45 in-lbs. Test the starter for proper operation.
18. If starter meets test requirements, operates without excessive noise and the shaft turns
with less than 5 in-Ibs. of torque, the starter should function satisfactorily on the engine.
19. If an ES646238-1 or -3 is being reassembled with a solenoid (25) it must be replaced.
20. Place solenoid with the terminals facing the starter terminal and install two screws (27)
through the solenoid bracket and secure to the starter.
21. Install the connector (26) cable between the solenoid terminal and the starter terminal
and secure each terminal with lockwasher and nut holding the bottom nut secure.

After the starter is reassembled, it
should be checked to see that the
no-load current at a certain voltage
falls within the test specifications
given on page 7-40-01. To make
this test, connect the assembled
unit as shown in (Figure 11). If
current is too high, check the
bushing alignment and end-play Ground
as described below to make sure
there is no binding or interference. Ground

If no difficulty is indicated in the
test.
If the torque and current are not within specifications, check the seating of the brushes and
internal connections for high resistance. If these checks are made and found to be in good
order, replace the armature assembly and retest the starter.
T o r q u e & D r i v e S h a f t T o l e r a n c e:
The torque and drive shaft tolerance checks may be done anytime the starter is removed or
when symptoms of noise or poor starter performance occur.
Specifications
1. See Figure 12 for the starter drive shaft specifications and torque.

Drive shaft “at rest” torque check
1. Check the drive shaft “at
rest” torque first, as any
discrepancy found will
require repair or overhaul of
the starter.
2. Rotate the starter drive shaft

by hand several turns
clockwise (CW) as viewed
from the drive end.
Figure 12 - Starter Shaft Specifications

3. Use a suitable tool with a
properly calibrated in-lbs
torque wrench to check
torque. A tool can be made
using an appropriately sized clevis bolt with a nut tightened securely on the thread end.
4. Slowly rotate the inch-pound torque wrench clockwise (CW) through 360˚ or more. The
torque indication must be 5 inch pounds or less. The starter must be repaired or
overhauled if rotational torque is higher.
Drive Shaft Position Check

1. Check the position of the drive shaft with respect to the housing for min. and max.
tolerance using a dial indicator. Any style of dial indicator set up is permissible
provided that the indicator reads to a minimum of 0.001 inch resolution.
2. The set up requires the starter be held vertically with the drive end up and then
vertically with the drive end down.
(a) Placing the starter vertical with drive end up allows a check of the length of the
drive shaft from the starter mounting flange.
(b) Placing the starter vertical with the drive end down allows a check of the drive shaft
end play by measurement and calculation.
3. Check the starter drive shaft minimum length by setting the starter on blocks vertically
with the drive end up.
(a) Size the blocks of equal measure and width so the starter is stable.
(b) Place the back side of the mounting flange on the blocks.
(c) Tap gently on the drive shaft with a plastic mallet.

adapter, zero the indicator. Refer to Figure 13.
Figure 13 - Set Dial at Zero

drive shaft and record measurement. Refer to
Figure 14.
between 0.580 inch and 0.630 inch
inclusive of the starter end play allowance
shown in specifications.
Figure 14 - Record No. at Apex

Drive Shaft Maximum Length Check
1. Check the starter drive shaft maximum
length by setting the starter vertically with
the drive shaft down.
(a) Rotate the drive shaft by hand through one
revolution.
(b) Size the blocks of equal measure and
(c) Place the mounting flange (flange mating
to starter drive) on the blocks.
Figure 15 - Set Dial at Zero

(d) Tap gently on the drive shaft rear cover
with a plastic mallet.
adapter, zero the indicator. See Figure 15.
drive shaft and record measurement. See
Figure 16.
in between 0.580 inch and 0.630 inch
which is inclusive of the starter end
play allowance.
Figure 16 - Record No. at Top

Drive End Play Determination
1. Determine if the starter falls into the allowable end play measurement by making a
calculation. This is done by taking the maximum measurement found in “Drive Shaft
Maximum Length Check” step 3 and subtracting the minimum measurement found in
“Drive Shaft Position Check” step 5.
(a) For example, if the shaft maximum measurement was 0.610 inch and the minimum
measurement was 0.585 inch then subtracting 0.585 inch from the 0.610 inch will
result in 0.025 inch end play. This is acceptable as the allowable end play range
is 0.005 to 0.050 inch.
2. If the starter drive shaft end play is out of allowable range of 0.005 to 0.050 inch or
the drive shaft length is beyond the min 0.580 or max 0.630 inch, repair or overhaul
of the starter is recommended. Do not install starters outside of these limits on any
starter drive or application.

Operation - The starter should be operated for a few seconds (not to exceed 10 seconds) with
the ignition disabled to make sure that the starter adapter engages properly and that it turns
freely without binding or excessive noise. To do this, connect a jumper lead to the “P”
(primary) lead of both magnetos while connecting the other end to a convenient clean engine
grounding point. The engine will now be inoperative until the jumper lead is removed. After
making the above test, remove the jumper lead. Engines incorporating the starter drive
adapter assembly should be started two or three times to see that the starter disengages
properly when the engine is turned off.

Starter Specifications
and Tolerances
………………………………………………………… 9
INCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-30-01
Lycoming Style Starters (Except MagnaFlite Lightweight Starters) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-30-01
CMI Style Starters (Except MagnaFlite & ES646 Series Starter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-50-01
MagnaFlite Lightweight Starters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-60-01
MILLIMETERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-70-01
Lycoming Style Starters (Except MagnaFlite Lightweight Starters) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-70-01
CMI Style Starters (Except MagnaFlite & ES646 Series Starter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-90-01
MagnaFlite Lightweight Starters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-100-01
INCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-110-01
ES646 Series (CMI Style) Starters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-110-01
MILLIMETERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-120-01
ES646 Series (CMI Style) Starters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-120-01


Starter Specifications
And Tolerances
………………………………………………………… 9
Lycoming Style Starters (Except MagnaFlite Lightweight Starters):
Part Description Description Dimension
Part Number Maximum Minimum
Drive End Head Assembly Bushing Area

PS1432C Without Bushing .534
PS1432E With Bushing .4090 .4080
PS1437B
PS2432B
Gear Housing Seat 3.1260 3.1230
Mounting Lug Thickness with Flatness of .005 Both Ends .6400
Mounting Face Surface Any visible wear is cause for
rejection. This dimension is
critical for the relationship of
the face to the ring gear.
Drive End Head Assembly

PS1435 Bushing Area
Without Bushing .7520
With Bushing .6270 .6260
Intermediate Housing Assembly Seat 2.8150 2.8120
Mounting Lug Thickness .650
Commutator End Head Ass'y.

MZ-2400 Bearing Bore 1.2593 1.2588
MHB-2400
Housing Seat O.D. 3.4902
Commutator End Head Ass'y. Bushing Bore

MBP-2002D Without Bushing .7520
MZ-2002U With Bushing .63850 .63750
MZ-2002V
Housing Seat 3.4940
Gear Housing Assembly Large Bearing Bore 1.0610 1.0620

Small Bearing Bore .6870 .6860
Drive End Head Assembly Seat O.D. 3.1190

Lycoming Style Starters (Except MagnaFlite Lightweight Starters) (Cont.):
Armature Assembly Commutator Diameter 1.5000
MHB-2399
MMU-2386 Commutator Surface Finish 50 Microinch
MZ-2386
MZ-2399 Commutator Total Indicator Run .0020
MZ2412 Out Measuring From Bearing Journals
Shaft Journals (MZ-2399 & MHB-2399)

Commutator End .4720
Drive End .8120
Shaft Journals (MZ-2412)

Drive End .7460
Shaft Journals (MZ-2386 & MMU-2386)

Drive End .6250
Drag Marks on Lamination are Cause for Rejection
Teeth Wear (MZ-2399, MHB-2399, & MZ-2412)
Testing Winding (all models)
Drive Shaft Small Bushing Area O.D. .4060

Starter Drive Bushing Area O.D. .4680
Bearing Journal O.D. .4990
Drive Gear Drive Shaft O.D. .5020

Woodruff Key Slot Width .1290
O.D. Measuring of Two .1250 Pins 1.8850
Teeth Wear
Intermediate Housing Ass'y. O.D. of Plate 2.8080
Intermediate Housing Ass'y. Overall Length .7720

Bushing Hole O.D. .7490
Bushing I.D. .6280/.6300

CMI Style Starters (Except MagnaFlite & ES646 Series):
Drive End Head Assembly Bushing Bore .8740
Bushing I.D. .7505 .7495
Oil Seal Seat I.D. 1.3760
Commutator End Head Ass'y Bushing Bore .7520

Bushing I.D. .6290 .6270

Commutator Surface Finish 50 Microinch
Commutator Total Indicator Run Out-Measure From Bearing Journals .0020
Shaft Journals
Drive End .7450
Shaft Blade Width - .005 Wear Permissible At Ends .3050
Test Winding

MagnaFlite Lightweight Starters:
Without Bushing .5335
With Bushing .4090 .4080
Gear Track Seat 2.8700 2.8650
Armature Housing Seat 3.0650 3.0600
Mounting Lug Thickness With Flatness of .005 Both Ends .6400
Commutator End Head Ass'y Bearing Race .7085

Housing Seat Thickness With Flatness of .005 All Around .1800
Armature Housing Ass'y Visual Magnets for drag marks or cracks. Strength of magnets. 1600 Gauss
or better
Drive Shaft Assembly Small Bushing Area O.D. .4060

Starter Drive Bushing Area O.D. .4680
Pin O.D. .2360
Do Not Remove Pins From Shaft. Replace Shaft If Pins Are Worn.
Drive Shaft Ass'y Bearing Bore I.D. .5515

Commutator Surface Finish 50 Microinch
Commutator Total Indicator Run .0020
Out Measuring From Bearing Journals
Shaft Journals
Commutator End .4690 .4730
Drive End .3930 .3942
Dragging Marks on Lamination Are Cause For Rejection

Lycoming Style Starters (Except MagnaFlite Lightweight Starters):


PS1432C Without Bushing 13.56
PS1432E With Bushing 10.39 10.36
PS1437B
PS2432B
Gear Housing Seat 79.40 79.32
Mounting Lug Thickness with Flatness of .127 Both Ends 16.26
Drive End Head Assembly

PS1435 Bushing Area
Without Bushing 19.10
With Bushing 15.93 15.90
Intermediate Housing Assembly Seat 71.50 71.42
Mounting Lug Thickness 16.51
Commutator End Head Ass'y.

MZ-2400 Bearing Bore 31.99 31.97
MHB-2400
Commutator End Head Ass'y. Bushing Bore

MBP-2002D Without Bushing 19.10
MZ-2002U With Bushing 16.218 16.193
MZ-2002V
Housing Seat 88.75
Gear Housing Assembly Large Bearing Bore 26.95 26.97

Small Bearing Bore 17.45 17.42
Drive End Head Assembly Seat O.D. 79.22

Lycoming Style Starters (Except MagnaFlite Lightweight Starters) (Cont.):
MHB-2399
MMU-2386 Commutator Surface Finish 1.27 Micrometer
MZ-2386
MZ-2399 Commutator Total Indicator Run .051
MZ2412 Out Measuring From Bearing Journals
Shaft Journals (MZ-2399 & MHB-2399)

Commutator End 11.99
Drive End 20.62
Shaft Journals (MZ-2412)

Drive End 18.95
Shaft Journals (MZ-2386 & MMU-2386)

Drive End 15.88
Drag Marks on Lamination are Cause for Rejection
Teeth Wear (MZ-2399, MHB-2399, & MZ-2412)
Testing Winding (all models)
Drive Shaft Small Bushing Area O.D. 10.31

Starter Drive Bushing Area O.D. 11.89
Bearing Journal O.D. 12.67
Drive Gear Drive Shaft O.D. 12.75

Woodruff Key Slot Width 3.28
O.D. Measuring of Two 3.18 Pins 47.88
Teeth Wear
Intermediate Housing Ass'y. O.D. of Plate 71.32
Intermediate Housing Ass'y. Overall Length 19.61

Bushing Hole O.D. 19.02
Bushing I.D. 15.95/16.00

CMI Style Starters (Except MagnaFlite & ES646 Series):
Drive End Head Assembly Bushing Bore 22.20
Bushing I.D. 19.06 19.04
Oil Seal Seat I.D. 34.95
Commutator End Head Ass'y Bushing Bore 19.10

Bushing I.D. 15.98 15.93

Commutator Surface Finish 1.27 Micrometer
Shaft Journals
Drive End 18.92
Shaft Blade Width - .005 Wear Permissible At Ends 7.75
Test Winding

MagnaFlite Lightweight Starters:
Without Bushing 13.55
With Bushing 10.39 10.36
Gear Track Seat 72.90 72.77
Armature Housing Seat 77.85 77.72
Mounting Lug Thickness With Flatness of .005 Both Ends 16.26
Commutator End Head Ass'y Bearing Race 17.10

Housing Seat Thickness With Flatness of .005 All Around 4.57
Armature Housing Ass'y Visual Magnets for drag marks or cracks. Strength of magnets. 1600 Gauss
or better
Drive Shaft Assembly Small Bushing Area O.D. 10.31

Starter Drive Bushing Area O.D. 11.89
Pin O.D. 5.99
Do Not Remove Pins From Shaft. Replace Shaft If Pins Are Worn.
Drive Shaft Ass'y Bearing Bore I.D. .5515

Commutator Surface Finish 1.27 Micrometer
Commutator Total Indicator Run .051
Out Measuring From Bearing Journals
Shaft Journals
Commutator End 11.91 12.01
Drive End 9.96 10.01
Dragging Marks on Lamination Are Cause For Rejection

ES646 Series (CMI Style) Starters:
Part Description Description Dimension (Inches)
Drive End Head Assembly Bushing Bore 0.8765 0.8755

Bushing I.D. (Installed) 0.7505 0.7495
Oil Seal Seat I.D. 1.3760 1.3740
Housing Seat O.D. 3.8680 3.8670
Commutator End Head Ass’y Bushing Bore 0.6255

Housing Seat O.D. (ES646502 only) 3.990 3.885
Armature Assembly
Commutator Diameter 1.500
Commutator Surface Finish 50 µin
Commutator Total Indicator Run Out-Measure From Bearing Journals 0.002
Commutator Undercut 0.003

Shaft Journals
Drive End 0.7460

Shaft Blade Width - .005 Wear Permissible At Ends .3050
Shaft Length 0.630 0.580

Shaft End Play - with 360 degree rotation 0.050 0.005
Shaft at Rest Torque - 360 degree rotation 5 in-lbs
Test Winding

ES646 Series (CMI Style) Starters:
Part Description Description Dimension (Millimeter)
Drive End Head Assembly Bushing Bore 22.263 22.237

Oil Seal Seat I.D. 34.95 34.90
Housing Seat O.D. 98.25 98.22
Commutator End Head Ass’y Bushing Bore 15.888

Housing Seat O.D. (ES646502 only) 101.35 98.68

Commutator Surface Finish 1.27 µm
Commutator Undercut 0.076
Shaft Journals
Drive End 18.948

Shaft Blade Width - .005 Wear Permissible At Ends 7.82 7.44
Shaft Length 16.002 14.732

Shaft End Play - with 360 degree rotation 1.270 0.127
Shaft at Rest Torque - 360 degree rotation 0.565 N-m
Test Winding

Service Bulletins
and Other Publications
………………………………………………………… 10
Service Bulletin #016 Rev. A (Obsolete & Incorporated into manual) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-01
Service Bulletin #021 Rev. A (OE-A1 Superseded) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-01
Service Bulletin #033 (Deleted - Does Not Apply) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-290-01
Service Bulletin #038 Rev. A (Deleted - Does Not Apply) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-330-01
Service Bulletin #044 (Alternator Wave Clip ALX-9525B & BR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-770-01
Service Bulletin A-112 Rev. A (Expired & Obsolete) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150-01
Service Information Letter A-115 (Expired & Obsolete) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-230-01
Service Information Letter A-116 (Obsolete & Incorporated into manual) . . . . . . . . . . . . . . . . . . . . . . . . . . 10-250-01
Service Information Letter A-118 (Obsolete & Incorporated into manual) . . . . . . . . . . . . . . . . . . . . . . . . . . 10-270-01
Service Information Letter A-125 Rev. A (Deleted - Does Not Apply) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-370-01
Service Information Letter A-126 (Starter Eligibility) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-410-01
Service Information Letter A-132 (Deleted - Does Not Apply) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-710-01
Service Information Letter A-140 Rev A (Shipping Spacer on Gear Driven Alternators) . . . . . . . . . . . . . . . 10-830-01
Service Information Letter A-141 (Obsolete & Incorporated into manual) . . . . . . . . . . . . . . . . . . . . . . . . . 10-910-01
Service Letter 024 Rev. A (Obsolete) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-730-01
Service Letter 025 (Starter Supersedure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-750-01


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Service Bulletin
Bulletin No. 021 Issue Date: February 26, 2004
Technical Content is FAA Approved
SUBJECT: 1) Notification of the applicability of the Kelly Aerospace OE-A2 Starter and
Alternator Overhaul Manual.
2) Notification that the OE-A1 Overhaul Manual is superceded and obsolete.
REASON: To notify and clarify the relevant IFCA data to be used for the overhaul of Kelly
Aerospace Electrical accessories.
PRODUCTS
AFFECTED: All Kelly Aerospace Electrical Accessories (Starters & Alternators)
COMPLIANCE: Effective Immediately
OE-A2 Overhaul Manual (Starters & Alternators)
On May 1, 2003, Kelly Aerospace Power Systems, Inc. released new IFCA (Instructions for Continued
Airworthiness) data to be used to overhaul and maintain various electrical accessory components
manufactured by Kelly Aerospace Power Systems. This OE-A2 Overhaul Manual supercedes and
replaces the OE-A1 Manual originally issued by Prestolite Electric Company several years ago.
THE OE-A2 MANUAL OBSOLETES AND SUPERCEDES THE OE-A1 MANUAL
Kelly Aerospace has been advised by the FAA that field overhaul facilities have been reported to be
continuing to use the OE-A1 Manual information and data to overhaul starters and alternators even
though they have acquired subscriptions to the superceding OE-A2 Manual and/or are aware of the
availability of the new IFCA data (OE-A2 Manual) and its applicability.
This bulletin is intended to clarify the fact that the OE-A1 Manual is obsolete and superceded, and
cannot be used as the FAA approval basis for component overhauls. All OE-A1 Manuals should be
discarded or clearly marked “OBSOLETE”.
For those organizations which have not yet subscribed to the new OE-A2 Manual, it can be ordered
through the Kelly Aerospace Customer Service/Sales Group by calling toll free, 877-359-5355, or
334-286-6994. The initial subscription price includes one year of revisions.
February 26, 2004 Kelly Aerospace Power Systems, Inc. Service Bulletin No. 021 Page 1 of 1


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Service Letter
2900 Selma Highway
Montgomery, AL 36108 USA Letter No. 025 Issue Date: Feb. 12, 2008
Tel: 334-386-5400 Fax: 334-386-5450
ANNOUNCEMENT OF SUPERCEDURE OF CERTAIN

HARTZELL ENGINE TECHNOLOGIES MAGNA FLITE STARTERS
INTRODUCTION:
Hartzell Engine Technologies LLC (HET) R & D engineering group has designed a new series of starters for
Lycoming engines that are now available for sale. The E-Drive, inline starter which was introduced in
December 2006 and the X-Drive external solenoid starter are being phased in to replace our factory new
Magnaflite starters. The Magnaflite starters were introduced over a decade ago and became the top selling
starter in the world for Lycoming engines. The new E & X Drive starters add another progression to aviation
by providing high quality, powerful and lightweight aircraft starters, adding to the legacy of the highly
successful Magnaflite series. Our website, www.hartzellenginetech.com offers technical and application
information, warranty policy, and starter comparisons as well as general information about Hartzell Engine
Technologies LLC.
This service letter announces the supercedure of the below Hartzell Engine Technologies Magnaflite
lightweight starter by the newly available E & X Drive starters.
PROCEDURE:
Effective with issuance of this Service Letter, the Magnaflite lightweight starter listed in the table below will
be superceded by the E-Drive and/or X-Drive starter listed therein. All Magnaflite P/N’s listed below that are
currently installed, being installed or in inventory are in no way affected. Standard Limited Warranty, is in
effect and returns for reason of supercedure will not be accepted.
HET (Kelly) X-Drive X-Drive E-Drive

Part Number Left Hand Solenoid Right Hand Solenoid
MHB-6016 SRB-9021 SRB-9031 ERB-8011
MHB-6018 SRB-9021 SRB-9031 ERB-8011
MMU-6001 SRB-9022 SRB-9032 ERB-8012
MZ-6204 SRZ-9022 SRZ-9032 ERZ-8012
MZ-6222 SRZ-9021 SRZ-9031 ERZ-8011
MZ-6224 SRZ-9021 SRZ-9031 ERZ-8011
MZ-6226 SRZ-9021 N/A ERZ-8011
Information pertaining to specific application of the starters listed in the table above may be found
in the “Application Guide” which may be viewed or downloaded from www.hartzellenginetech.com.
Questions? Contact Customer Service at (877) 359-5355 or (334) 386-5450 FAX
New Hartzell Engine Technologies Service Letter #025 Page 1 of 1


Service Information Letter
Service Information Letter A-140 Rev. 1
2900 Selma Highway Gear Driven Alternator
Shipping Hardware
Montgomery, AL 36108 USA
Tel: 334-386-5400 Fax: 334-386-5450
TRANSMITTAL SHEET
This page transmits the revision of Service Information Letter A-140 Rev. New to Service
Information Letter A-140 Rev. 1, dated July 7, 2014.
• Revision SIL A-140 Rev. New, dated March 11/11
• Revision SIL A-140 Rev. 1, dated July 7/14
HET has approved the technical data presented in this publication.
Changes are shown by a change bar in the left or right margins coinciding with the change in
the affected page.
Some of these changes that do not affect technical content may not be highlighted in this
transmittal sheet.
The Gear Driven Alternator Shipping Hardware shown in a previous revision of this Service
Information Letter has changed.
This revision is issued to change the following in the Service Information Letter:
- Revise formatting to remove sections not required.
- Revise to update OE information.
- Revise to clarify the type of shipping hardware now in use.
All pages of this Service Information Letter have been revised.
Rev. 1: July 7/14 SIL A-140

© 2014 - Hartzell Engine Technologies. - All rights reserved Page i

Service Information Letter No. A-140 Rev. 1
Gear Driven Alternator Shipping Hardware
Intentionally Left Blank
SIL A-140 Rev. 1: July 7/14

Page ii © 2014 - Hartzell Engine Technologies. - All rights reserved

Service Information Letter A-140 Rev. 1
2900 Selma Highway Gear Driven Alternator
Shipping Hardware
Montgomery, AL 36108 USA
Tel: 334-386-5400 Fax: 334-386-5450
1. Planning Information
A. Effectivity
(1) Gear driven alternators, series ALT, ALU, ALV, ALX, ES-4000, and DOFF10300
shipped from Hartzell Engine Technologies LLC (HET) are affected by this Service
Information Letter (SIL).
WARNING: DO NOT USE OBSOLETE OR OUTDATED INFORMATION. PERFORM ALL
INSPECTIONS OR WORK IN ACCORDANCE WITH THE MOST RECENT
REVISION OF THIS SERVICE INFORMATION LETTER (SIL). INFORMATION
CONTAINED IN THIS SIL MAY BE SIGNIFICANTLY CHANGED FROM EARLIER
REVISIONS. USE OF OBSOLETE INFORMATION MAY CREATE AN UNSAFE
CONDITION THAT MAY RESULT IN DEATH, SERIOUS BODILY INJURY, AND/
OR SUBSTANTIAL PROPERTY DAMAGE. REFER TO THE HET WEBSITE
FOR THE MOST RECENT REVISION OF THIS SERVICE INFORMATION
LETTER.
B. Concurrent Requirements
(1) Additional service documents may apply to the gear driven alternators affected by this
Service Information Letter. Compliance with additional service documents may be necessary
in conjunction with the completion of the Accomplishment Instructions in this SIL.
C. Reason
(1) During installation of gear driven alternators, there have been reports of the shipping
washer, the spacer and/or a combination of both being installed and not discarded.
(2) All gear driven alternators are shipped with a shipping spacer and some with a spacer and
washer combination.
(3) It is imperative that this shipping hardware be discarded when installing the drive coupling.
(4) Improper installation may lead to the degradation or loss of alternator function and/or
damage to the engine.
D. Description
(1) This publication provides Additional Maintenance Information (AMI).
(2) This Service Information Letter is being issued to advise installers of gear driven alternators
procured from HET for aircraft engines, that all shipping hardware must be removed and
discarded prior to installation of the alternator drive coupling.
(3) This Service Information Letter also announces that gear driven alternators are being
shipped with a non-metallic shipping spacer and without a shipping washer. This method
avoids confusion with alternator hardware. Refer to Figure 3 & 4 example.

© 2014 - Hartzell Engine Technologies. - All rights reserved Page 1 of 6

E. Approval
(1) This technical publication has been approved by Hartzell Engine Technologies LLC.
F. References
(1) Applicable Engine Maintenance Manual.
(2) Continental Motors. Inc. (CMI) Service Information Letter SIL13-2.
(3) Continental Motors. Inc. (CMI) Service Bulletins SB11-3 or SB95-3B.
G. Other Publications Affected

(1) Prestolite Service Bulletin ASM-14, dated June 20, 1990, is superseded by SIL A-140 Rev. 1.
2. Accomplishment Instructions
A. Identify the shipping hardware.
(1) Gear driven alternators may or may not have a shipping washer included.
(a) Identify the shipping washer. These are all large thin washers with a notch cut in the
inside diameter to allow the washer to slip over the woodruff key. Not all alternators
will have a shipping washer included. Discard this washer prior to any installation
work. (Refer to Figure 2).
(b) The ALV-9510R alternator (only) is shipped with an HET P/N ALV-74 washer
located at the base of alternator drive shaft. This washer does not have a notch
cut into it and must be retained to allow proper fit of the drive coupling. (The HET
P/N ALV-74 is not a shipping washer.) Refer to Figure 5.
NOTE: Alternators are currently shipped with non-metallic tubes as the shipping spacer and
will not have a shipping washer. Existing alternator inventory may have a previous
shipping hardware configuration.
(2) All gear driven alternators are shipped with a shipping spacer.
(a) The shipping spacer may be a phenolic or cardboard tube fitted closely over the
shaft and woodruff key, or a thin metal barrel formed to fit over the woodruff key
with a slot on the opposite side. Discard this shipping spacer. Refer to Figure 2.
(b) If the shipping spacers are cardboard as shown in Figure 3 or phenolic type as
shown in Figure 4, they may still have a metal shipping washer.
CAUTION: HET DOES NOT PROVIDE ALTERNATOR OR ALTERNATOR DRIVE COUPLING

INSTALLATION PROCEDURES. TO AVOID DAMAGE OR INJURY, CONSULT
THE LATEST REVISION OF THE APPLICABLE ENGINE OR AIRCRAFT
SERVICE OR MAINTENANCE INSTRUCTIONS TO COMPLETE THE
INSTALLATION OF THE ALTERNATOR DRIVE COUPLING AND ALTERNATOR.
B. When installing a coupling onto an HET gear driven alternator, observe the latest revision of
Continental Motors, Inc. service bulletins SB11-3 or SB95-3B as applicable for alternator
and drive coupling installation on CMI engines.

Page 2 of 6 © 2014 - Hartzell Engine Technologies. - All rights reserved

Typical
Figure 1 - Previous Shipping Hardware Installation
Typical
Notch Cut
in Washer
Figure 2 - Metal Shipping Spacer & Washer


Shipping Washer
Phenolic
Spacer
Figure 3 - Phenolic Shipping Spacer & Metal Shipping Washer
Cardboard
Spacer
Figure 4 - Shipping Spacer Only (cardboard type)


Figure 5 - ALV-9510 Alternator ONLY
3. Contact Information
A. Contact HET Product Support for all communications regarding the technical content of this
Service Information Letter.
(1) Phone +1.334.386.5441
(2) Fax +1.334.386.5410
(3) E-mail at techsupport@HartzellEngineTech.com
(4) Address:
Hartzell Engine Technologies LLC
2900 Selma Highway,
Montgomery, AL 36108, USA.


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Hartzell Engine Technologies LLC

2900 Selma Highway

Overhaul Manual - Aircraft Alternators & Starters

Overhaul Manual - Aircraft Alternators & Starters

WARNING: IMPROPER OR UNAUTHORIZED APPLICATIONS OF INFORMATION

Overhaul Manual - Aircraft Alternators & Starters

If Units Ends With: Then Unit Is:

Overhaul Manual - Aircraft Alternators & Starters

TR-001 2-700-01 & 2-710-01 8-05-15 HET 4-28-16 HET

Overhaul Manual - Aircraft Alternators & Starters

Overhaul Manual - Aircraft Alternators & Starters

CONTENT OF PAGES PAGES REV & DATE

Overhaul Manual - Aircraft Alternators & Starters

Overhaul Manual - Aircraft Alternators & Starters

Overhaul Manual - Aircraft Alternators & Starters

CONTENT OF PAGES PAGES REV & DATE

Overhaul Manual - Aircraft Alternators & Starters

CONTENT OF PAGES PAGES REV & DATE

Overhaul Manual - Aircraft Alternators & Starters

Overhaul Manual - Aircraft Alternators & Starters

Overhaul Manual - Aircraft Alternators & Starters

Overhaul Manual - Aircraft Alternators & Starters

Overhaul Manual - Aircraft Alternators & Starters

-05 (Continued) 6/18/13

Overhaul Manual - Aircraft Alternators & Starters

-05 (Continued) 6/18/13

Overhaul Manual - Aircraft Alternators & Starters

Overhaul Manual - Aircraft Alternators & Starters

Overhaul Manual - Aircraft Alternators & Starters

Overhaul Manual - Aircraft Alternators & Starters

-05 (Continued) 6/18/13

Overhaul Manual - Aircraft Alternators & Starters

Overhaul Manual - Aircraft Alternators & Starters

Overhaul Manual - Aircraft Alternators & Starters

Overhaul Manual - Aircraft Alternators & Starters

Overhaul Manual - Aircraft Alternators & Starters

-07 (cont’d) 4/28/16

Overhaul Manual - Aircraft Alternators & Starters

Overhaul Manual - Aircraft Alternators & Starters

-11 (cont.) 9 -110-01 12/15/21 Armature Assy., change 1.27 Micrometer

Overhaul Manual - Aircraft Alternators & Starters

ALTERNATOR SERVICE PARTS LIST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

ALTERNATOR SERVICE INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Overhaul Manual - Aircraft Alternators & Starters

Intentionally Left Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-390-01

ALTERNATOR MAINTENANCE AND OVERHAUL INFORMATION . . . . . . . . . . . . 4

Overhaul Manual - Aircraft Alternators & Starters

Lightweight MHB Series (24 Volt Starter). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-190-01

Overhaul Manual - Aircraft Alternators & Starters

Overhaul Manual - Aircraft Alternators & Starters

WARNING: EXTREME CARE SHOULD BE USED AT ALL TIMES TO AVOID

Overhaul Manual - Aircraft Alternators & Starters

WARNING: WARNINGS ARE USED IN SITUATIONS WHERE PERSONAL INJURY TO THE

CAUTION: CAUTIONS ARE USED IN SITUATIONS WHERE DAMAGE RESULTING FROM

Overhaul Manual - Aircraft Alternators & Starters

Overhaul Manual - Aircraft Alternators & Starters

Overhaul Manual - Aircraft Alternators & Starters

Overhaul Manual - Aircraft Alternators & Starters

Overhaul Manual - Aircraft Alternators & Starters

Overhaul Manual - Aircraft Alternators & Starters

Overhaul Manual - Aircraft Alternators & Starters

Alternators and their corresponding parts shown

ALE-8406 Use ALE-8520 ALE-8520R Lycoming