TALLER AERONÁUTICO DE REPARACIONES

“AEROANDES S.A.”
MANUAL DE PROCEDIMIENTOS DE INSPECCIÓN
TEMA PAGINA D- 640
GUÍA ALTERNADOR ES-1007 FORMATO D- 121

DATE: WORK ORDER:

COMPONENT: ALTERNADOR ES-1007 CUSTOMER:
PARTE Nº: T.T:
SERIAL Nº: T.DURG:

DISASSEMBLY GUIDE

DESCRIPCION FECHA TECN. INSP

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
2. Using a marker, scribe across the stator and front and rear housings to determine
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. 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.
Retrieve brush springs from rear hosing. Wipe away any bearing grease that brushes may
have acquired during removal.
3. Remove nut and washer assemblies from studs protruding through rear hosing. Remove
three terminal insulators. Separate stator core from rear housing.
Push rectifier studs through holes in rear housing and remove housing. Remove two
insulating spacers from rectifier studs. Remove radio noise suppression capacitor.
4. To remove brush holder from rear housing, remove two screws that attach the brush
holder and grounded brush wire terminal to rear housing. Remove brush holder from rear
housing. Remove square headed terminal screw, brush, and insulator from rear hosing.
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. Remove and discard the slip ring end bearing
6. Remove rectifier assembly from stator assembly. Unsolder three stator lead wires
from rectifier assembly. 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.
8. Using a slide hammer remove rive end seal from end housing. Exercise care not to
distort or deform the pilot diameter of the end hosing.
CLEANING
1. As specified page 4-770-0, Item 1-15, manual OE-A2

OBSERVACIONES DURANTE EL DESENSAMBLE: _______________________________________________________

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
ACEPTADO UAEAC.
REVISIÓN: OCTAVA
PMI AEROANDES
 FECHA: 25/SEPTIEMBRE/15
 TALLER AERONÁUTICO DE REPARACIONES
“AEROANDES S.A.”
MANUAL DE PROCEDIMIENTOS DE INSPECCIÓN
TEMA PAGINA D- 640
GUÍA ALTERNADOR ES-1007 FORMATO D- 121

DATE: WORK ORDER:

COMPONENT: ALTERNADOR ES-1007 CUSTOMER:
PARTE Nº: T.T:
SERIAL Nº: T.DURG:

DESCRIPTION QTY S R G E
PARTE N°
ES-4142 Drive seal 1

ES-4140 O’ring seal 1

ES-4612 Front bearing 1

ES-4118 Brush Kit 1

X-4130 Rear Bearing 1

ES-4122 Fiel insulator 1

ES-4147 Stator Assy 1

EQ-6558 Kit drive 1

MS24665-151 Pin cotter 1

632050 Amortiguador 1


ACEPTADO UAEAC.
REVISIÓN: OCTAVA
PMI AEROANDES
 FECHA: 25/SEPTIEMBRE/15
 TALLER AERONÁUTICO DE REPARACIONES
“AEROANDES S.A.”
MANUAL DE PROCEDIMIENTOS DE INSPECCIÓN
TEMA PAGINA D- 640
GUÍA ALTERNADOR ES-1007 FORMATO D- 121

DATE: WORK ORDER:

COMPONENT: ALTERNADOR ES-1007 CUSTOMER:
PARTE Nº: T.T:
SERIAL Nº: T.DURG:

ASSEMBLY GUIDE
DESCRIPCION FECHA TECN. INSP
1. Prior to installing the drive end (front) bearing, Thoroughly clean the bearing
bore and the O.D. of the bearing itself. This bearing is a line to line press-fit in the
housing. Under normal circumstances, bearing can be installed with only finger
pressure. However, in come instances, application of light pressure in a press will be
expedient, using extreme care not to damage the bearing.
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 flange 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 rotor 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.
4. Install the slip ring end bearing in the rear bearing housing making certain to
properly support the slip ring housing. Position rear housing in press and support with
1 inch I.D. pipe. 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. Install stator terminal screw and an
insulating washer. 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 hosing.
NOTE: Silicone RTV may be used to stabilize stator wires and capacitor
6. 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.
7. Install stator and rectifier assembly to rear hosing. Install small stepped insulator
to stator terminal screw. Position the radio noise suppression capacitor to the rectifier
terminals. Install the large stepped insulator on the battery terminal stud. Position
stator and rectifier assembly in rear housing with the large stud inserted into the
largest terminal ( 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 ¼-20 nut with integral dished washer, torque to 45 to 60 in-
lbs.; and the black terminal insulator to the STA terminal using a nut with integral
dished washer, torque to 25-35 in-lbs. Install two nut and washer assemblies to the
two remaining studs.

ACEPTADO UAEAC.
REVISIÓN: OCTAVA
PMI AEROANDES
 FECHA: 25/SEPTIEMBRE/15
 TALLER AERONÁUTICO DE REPARACIONES
“AEROANDES S.A.”
MANUAL DE PROCEDIMIENTOS DE INSPECCIÓN
TEMA PAGINA D- 640
GUÍA ALTERNADOR ES-1007 FORMATO D- 121
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 housing. 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.
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.
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.
Safety wire should be installed in the thru-bolts only after the unit has been bench
tested for output.

MECHANIC:

INSPECTOR:

DATE:


ACEPTADO UAEAC.
REVISIÓN: OCTAVA
PMI AEROANDES
 FECHA: 25/SEPTIEMBRE/15
 TALLER AERONÁUTICO DE REPARACIONES
“AEROANDES S.A.”
MANUAL DE PROCEDIMIENTOS DE INSPECCIÓN
TEMA PAGINA D- 640
GUÍA ALTERNADOR ES-1007 FORMATO D- 121

DATE: WORK ORDER:

COMPONENT: ALTERNADOR ES1001 CUSTOMER:
PARTE Nº: T.T:
SERIAL Nº: T.DURG:

ALTERNADOR OUTPUT TEST SPECIFICATIONS

ALTERNATOR OUTPUT OUTPUT MINIMUM

SERIES VOLTAGE AMPERAGE ALTERNATOR
RPM.

MECHANIC:

INSPECTOR :
DATE:


ACEPTADO UAEAC.
REVISIÓN: OCTAVA
PMI AEROANDES
 FECHA: 25/SEPTIEMBRE/15
 TALLER AERONÁUTICO DE REPARACIONES
“AEROANDES S.A.”
MANUAL DE PROCEDIMIENTOS DE INSPECCIÓN
TEMA PAGINA D- 640
GUÍA ALTERNADOR ES-1007 FORMATO D- 121

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 DATE: Escriba el nombre del propietario.

 COMPONENT: Escriba el nombre del componente.

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 T.T: Horas totales

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
ACEPTADO UAEAC.
REVISIÓN: OCTAVA
PMI AEROANDES
 FECHA: 25/SEPTIEMBRE/15