SB13-8 - Continental Motors
Contents
1. If the alternator is not an ES 6012 6 amp ES 7024 11 amp 14 proceed to Return to Service instruction 20 For each inspection on Chart 1 requiring torque application refer to Table 1 or the latest revision of SIL A 125 Rev A Troubleshooting See Chart 2 6 Troubleshooting may help to determine the root cause and avoid unnecessary replacement of the alternator If there are conditions beyond those in the periodic inspection chart refer to Chart 2 General Troubleshooting before attempting any repair or replacement the alternator Chart 2 lists the five symptoms common to these alternators Choose the applicable symptom being experienced and follow the trouble shooting advice beneath as applicable For example the symptom is low or no alternator output The possible cause could be loose terminal connections improper belt tension or worn brushes After each cause a remedy is suggested The remedies suggested may require work on the alternator or work on the aircraft or engine Remember if corrective action on the alternator is beyond tightening hardware or replacing the brush holder assembly the alternator must be replaced In addition if aircraft or engine work is required reference to the applicable service or maintenance manual will be required Brush inspection and or replacement CAUTION BEFORE STARTING BRUSH INSPECTION OR REPLACEMENT REFER TO HET SERVICE INFORMATION LETTER SIL A125 REV A IT IS MANDATORY THAT SIL A 12. conditions of use The airframe or engine manufacturer recommended TBO if less shall supercede this TBO Page 6 of 7 Hartzell Engine Technologies SIL A 137 Rev New Chart 2 GENERAL TROUBLESHOOTING FOR ES 6012 6 OR ES 7024 11 amp 14 ALTERNATORS General troubleshooting consists of five symptoms 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 replaced 1 Symptom Low or no output Loose terminal connections Inspect the terminals if loose tighten if they will not tighten the alternator may need to be replaced 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 to less than 635 cm replace the brush holder assembly 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
3. 25 REV A OR LATEST BE COMPLIED WITH PRIOR TO OR IN CONJUNCTION WITH THIS SIL FAILURE TO DO SO MAY RESULT IN DAMAGE TO THE ALTERNATOR AND OR AIRCRAFT Upon achieving each 500 hours time in service or any time the alternator brushes need to be inspected or brush holder assembly replaced the following instructions apply Depending upon the reason for inspection or replacement brush holder removal and installation may be done with alternator on or off the aircraft engine 10 Assure all power is removed from the aircraft by disconnecting the battery and any ground power source Refer to Figure 1 amp 2 to locate and remove the brush holder assembly See material required section for brush holder assembly and hardware part numbers 11 To avoid the possibility of alternator damage loosen the first and second nut of the battery terminal red insulator prior to removing the back cover screws 12 Disconnect the F1 field wire by removing hardware Remove the three screws 3 and lock washers 32 that hold the back cover 27 in place and remove the back cover Page 2 of 7 Hartzell Engine Technologies SIL A 137 Rev New PROCEDURE cont d Brush inspection and or replacement Battery Terminal Field Terminal See Appendix for Special Instructions Regarding item 11 To SRE Brush Seal Housing Ground Terminal Auxiliary Terminal Torque 18 20 in Ibs Torque 20 25 in lbs 2 places Figure 1 Primary Locations Fig
4. CONTINENTAL MOTORS AIRCRAFT ENGINE CATEGORY 3 SERVICE BULLETIN SB13 8 Compliance Will Enhance Safety Technical Portions SUBJECT Hartzell Engine Technologies Service Information FAA Approved Letter A 137 PURPOSE Provides alternator continued airworthiness instructions and brush service instructions for the CMI P N 655997 12V 60A and 657199 24V 70A belt driven alternator assemblies COMPLIANCE As directed by HET Service Information Letter A 137 MODELS AFFECTED IOF 240 B IO 550 N IOF 550 N TSIO 550 K TSIOF 550 D I Background Hartzell Engine Technologies HET has issued Service Information Letter A 137 to provide continued airworthiness and brush service inspection for CMI P N 655997 12V 60A and P N 657199 24V 70A belt driven alternators HET holds the Parts Manufacture Authority PMA for the equivalent ES 6012 6 CMI P N 655997 and ES7024 2014 01 1514 CMI P N 657199 alternators Continental Motors requires compliance with this service bulletin as shown above Noncompliance with this bulletin may cause damage to the alternator and loss of electrical power in flight Il Warranty Normal warranty policies will apply to the replacement of any CMI supplied alternators Engines within warranty coverage that require alternator replacement should file a warranty claim through the CMI distributor furnishing the replacement alternator If a replacement alternator is purchased through a Hartzell Engine Technolog
5. UALS 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 APPLICABLE AIRCRAFT OR ENGINE MAINTENANCE MANUAL INDEX FOR THE MOST RECENT REVISION LEVEL OF THE OE A2 MAINTENANCE MANUAL For questions concerning this instruction please contact HET Service Dept at 888 461 6077 Contact your local HET distributor to purchase available service parts Rev New Hartzell Engine Technologies SIL A 137 Page 1 of 7 PROCEDURE cont d Inspection See Chart 1 1 Determine if the airplane uses a ES 6012 6 ES 7024 11 or ES 7024 14 alternator This may be done by observing the equipment list logbook or other airframe or engine paperwork If still undetermined it will be necessary to remove the cowling and observe the body of the alternator for the data tag If an ES 6012 6 ES 7024 11 or ES 7024 14 alternator is installed the Periodic Inspections of Chart 1 apply ES 6012 6 would be 12V and the ES 7024 11 amp 14 would be 24V Check the time in service on the unit and begin inspections at the nearest time interval and task For example if the unit is new or recently overhauled then start at the ten 10 hour inspection If the unit was installed prior to release of this SIL and has 100 hours then start at this inspection and so on Ifthe time is unknown perform the 500 hour inspection
6. e only the latest revision Hartzell Engine Technologies SIL A 137 Page 3 of 7 PROCEDURE cont d Torquing Hardware Note For more detail on hardware stacking and torque please refer to the latest revision of HET SIL A125 Rev A See caution note on page 2 18 When hardware is replaced nuts screws etc be sure to use an appropriate torque tool properly calibrated for the task Follow the torque settings recommended on Table 1 for all hardware that is part the alternator Hardware which retains aircraft terminals must be torqued to the specification called out by the engine or airframe manufacturer in their service instructions or manuals Table 1 data in parenthesis is recommended if OE data is no longer available CAUTION GREAT CARE MUST BE TAKEN WITH THE FIELD TERMINAL AS THE BOTTOM NUT TORQUE IS VERY LOW IT IS EASY TO OVER TORQUE THE TOP NUT WHEN ATTACHING THE FIELD WIRE OVER TORQUE MAY DESTROY THE BRUSH HOLDER DISABLING THE ALTERNATOR Re attach F1 field wire and torque Re torque the battery terminal nuts loosened in instruction 11 starting with first bottom nut then while securing with a wrench torque the second top nut Use Table 1 When checking for loose alternator hardware or when replacing terminal wires on their respective studs the following should be observed a Nut torques from Table 1 shown for the first bottom nut on each stud of the alternator b When checking field ground aux and ba
7. eck that the cooling air path is unobstructed to the alternator Make sure the alternator assembly is clear of interference with any engine or airframe structure Check all terminal hardware for tightness and insulators for condition Check the alternator to engine mounting bolts for proper torque Check the alternator belt for condition and tension Use the aircraft and or engine service instructions or maintenance manual as required Hours TIS one time Perform a check of the alternator assembly Note through bolt security and proper safety wire application re torque if bolts are found loose Check for signs of overheating or electrical arcing Check the alternator to engine mounting bolts for proper torque Check the alternator belt for condition and tension Use the aircraft and or engine service instructions or maintenance manual as required Check all terminal hardware for tightness and insulators for condition 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 wea
8. engine manufacturer s maintenance manuals install any portion of the aircraft removed to gain access Upon successful completion of this service information letter make an appropriate log book entry of compliance Page 4 of 7 Hartzell Engine Technologies SIL A 137 Rev New MATERIAL REQUIRED As required the following HET parts are available one 1 each Brush Holder assembly part number 40278 two 2 each Screw 37 part number 8X 0055 and two 2 each lock washer 31 part number 12X 0195 New Brush holder assembly includes holder with capacitor orange insulator hardware and brushes If desired the following HET parts are available quantities shown are per alternator one 1 each insulator orange part number 40297 one 1 each insulator red part number 40284 four 4 each flat washer part number AN 960 10 four 4 each flat washer part number AN 960 10L two 2 each cupped nut part number 40298 two 2 each cupped nut part number 40296 two 2 each shoulder washer insulating part number 40428 aux terminal early models one 1 each bushing insulating part number 40753 aux terminal later models one 1 each flat washer part number 40429 two 2 each nut part number 40427 ground terminal one 1 each nut part number 40298 four 4 each thru bolt part number 40282 three 3 each screw cover 3 part number 4339 1 two 2 each screw brush holder 35 part
9. gies website http www hartzellenginetech com and select CONTACT then follow instructions Questions concerning the aircraft or engine service or operation must be forwarded to the applicable manufacturer of that product Rev New Hartzell Engine Technologies SIL A 137 Page 5 of 7 Chart 1 PERIODIC INSPECTION ES 6012 6 ES 7024 11 amp ES 7024 14 ALTERNATORS 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 replacement ES 6012 6 or ES 7024 11 amp 14 alternators produced by Hartzell Engine Technologies LLC Refer to information contained in SIL A 137 latest Rev for maintenance allowed beyond replacement of the alternator Always use the aircraft and or engine service instructions or maintenance manual where applicable latest revision thereof Inspection Checks Refer to SIL A 137 Table 1 as required 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 alternator for general security Check for signs of overheating or electrical arcing Ch
10. ies distributor the warranty claim for the replacement alternator must be filed to Hartzell Engine Technologies through the supplying distributor All questions concerning the inspections and replacement required by this bulletin shall be directed to Hartzell Engine Technologies 2900 Selma Highway Montgomery AL 36108 1 888 461 6077 ISSUED REVISED PAGENO REVISION MM S A O ete 0 Box 90 Mobile AL 251 436 8299 SB13 8 2013 Continental Motors Inc HARTZELL Service Se Information Letter 2900 Selma Highway Montgomery AL 36108 USA 3 rol S44 he E100 Fas 334 306 6400 Letter No A 137 Issue Date March 9 2011 ES 6012 6 amp ES 7024 11 amp 14 Alternators Continued Airworthiness ICA amp Brush Service Instructions INTRODUCTION Hartzell Engine Technologies LLC HET formerly Kelly Aerospace Energy Systems LLC KAES alternators ES 6012 6 amp ES 7024 11 amp 14 are recent designs coming into the general aviation market HET is issuing this SIL to provide basic continued airworthiness instruction ICA for the ES 6012 6 amp ES 7024 11 amp 14 alternators as used on certified engines or aircraft Basic continued airworthiness consists of required periodic inspections general troubleshooting and brush inspection and or replacement instruction At this time any condition beyond the scope of this publication requires replacement of the alternator This Service Information Letter provides in
11. n the same position and orientation as removed Place the orange rubber seal 11 over brush holder using the seal special installation instructions in the appendix at the end of this SIL Depress each brush into it s pocket with a small wood or plastic dowel and slip a length of 22 gage insulated wire into the hole provided in side of the brush holder and seal See Fig 2 inset The wire will retain the brushes for installation of the holder A new brush holder assembly is shipped with retaining wire installed Install the new or refitted brush holder assembly with two retaining screws 35 and two new lock washers 32 Torque screws to 18 to 20 in lbs Spin rotor and check for interference between the brush holder and rotor Remove the brush retaining wire allowing the brushes to snap into place Reinstall the brush holder ground strap to the ground stud and torque per Table 1 Measure the resistance between the field orange insulator and ground terminal with an ohmmeter Spin the pulley and note ohmmeter reading Meter should read between 5 8 and 20 ohms while rotor is turning for a 24 volt alternator and between 2 8 and 20 ohms for a 12 volt alternator To complete the brush replacement install the back cover 27 with three screws 3 and three new lock Rev New washers 32 and torque to 20 to 25 in lbs Reinstall the alternator if removed per the engine or airframe manufacturer s service or maintenance instructions or manuals Us
12. 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 Aircraft electrical consumption may be exceeding the aircraft alternator load capability 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 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 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 f 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 harnes
13. number 8X 0055 five 5 each lock washer 32 part number 12X 0195 one 1 each Flexible Brush Assembly Seal 11 part number 40288 PARTS AVAILABILITY Parts to support this service bulletin must be obtained from an authorized Hartzell Engine Technologies Distributor of your choice Any supplementary part which may be required such as the alternator belt etc must be obtained from the engine or airframe manufacturer as applicable WARRANTY STATEMENT The sole warranty for the actions within this service bulletin are contained in the HET Limited Warranty Policy issued with the purchase of each new alternator See terms and conditions therein Issuance of this service bulletin in no way constitutes an implied or expressed warranty of any kind Other warranty may apply per the terms and conditions in the aircraft or engine manufacturer s Limited Warranty Policy contact the appropriate party to enquire This publication does not imply or state any responsibility for the workmanship of any person or entity performing work or maintenance on the alternator or aircraft electrical system CONTACT INFORMATION If you have any questions concerning this service information letter please contact Hartzell Engine Technologies Technical Support at 888 461 6077 Or write at Hartzell Engine Technologies 2900 Selma Highway Montgomery AL 36108 USA Website http Awww hartzellenginetech com For e mail go to the Hartzell Engine Technolo
14. r has occurred check slip rings for gouges or scratches Check that the cooling air path is unobstructed to the alternator Check all terminal hardware for tightness and insulators for condition Check the alternator belt for wear and general condition Re tension alternator belt to engine or airframe specifications Hours TIS and each 500 hours thereafter or each two years not to exceed 500 hours Remove each brush and check for wear or damage Brush length must not be less than 25 inch 635 cm must not have chips or damage or broken brush lead strands Replace brush holder assembly 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 Replace alternator belt as required by engine or airframe manufacturers recommendations or sooner if found worn or damaged Examine insulators for cracks or burns Inspect the aluminum housings for condi tion 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 Conditions found that require replace ment parts other than the brush holder ass y or hardware will require replacement of the alternator Hours TIS or 12 years and at any engine overhaul Recommended replacement of alternator assembly This a maximum time in service actual replacement time may vary based on cooling electrical load and
15. roken or the lead is coming out of brush or if brush is chipped or worn to less than 25 inch 635 cm replace the brush holder assembly Rough or damaged slip ring surface f the slip rings show minor surface roughness they may be polished If the slip rings are worn or damaged beyond limits replace the 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 There should be less than 2 ohm resistance Check breaker function Old circuit breakers may need to 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 Rev New Hartzell Engine Technologies SIL A 137 Page 7 of 7
16. s for shorts or open conditions If harness is burnt or shows signs of overheating replace harness If wiring is good replace voltage regulator Symptom Noisy in operation mechanical Foreign object in cooling path Check the air path to see if debris have entered the alternator and are rubbing or vibrating Loose mounting bolts Inspect mount points for damage and if found replace 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 If found replace 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 Symptom Noisy in operation electrical 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 b
17. struction for continued airworthiness of the alternator and consists of periodic inspection requirements general troubleshooting and if necessary instruction for removing inspecting and replacing the brush assembly in ES 6012 6 amp ES 7024 11 amp 14 alternators COMPLIANCE At each annual inspection not to exceed the applicable time in service requirement of periodic inspection Chart 1 and or any time it is necessary to inspect or replace the alternator brushes on an ES 6012 6 or ES 7024 11 or 14 alternator EFFECTIVITY All Hartzell Engine Technologies formerly Kelly Aerospace Energy Systems LLC ES 6012 6 amp ES 7024 11 or ES 7024 14 alternators when used on Type Certificated aircraft or engines They are currently used on specific Teledyne Continental Motors series IOF 240 ES 6012 6 and IO 550 and IOF 550 ES 7024 11 amp ES 7024 14 engines PROCEDURE Inspection See Chart 1 WARNING THE ALTERNATOR WHEN MOUNTED ON AN AIRCRAFT PRESENTS A PHYSICAL HAZARD FROM PROPELLERS AND ROTATING DEVICES THE ALTERNATOR PRODUCES A HIGH ELECTRICAL CURRENT OUTPUT WHICH PRESENTS AN ELECTRICAL SHOCK HAZARD THAT CAN RESULT IN SERIOUS INJURY IF PROPER SAFETY PROCEDURES ARE NOT FOLLOWED CAUTION DO NOT USE OBSOLETE OR OUTDATED INFORMATION PERFORM ALL INSPECTIONS OR WORK IN ACCORDANCE WITH THE MOST RECENT REVISION OF THE APPLICABLE AIRCRAFT OR ENGINE MAINTENANCE MANUAL INFORMATION CONTAINED IN THE APPLICABLE MAINTENANCE MAN
18. ttery terminal nuts for looseness make sure that the bottom nut must be held in place with a thin wrench to secure nut then apply the recommended torque to the top nut Torquing the top nut without holding the bottom may allow the bottom nut to be over torqued Permanent damage may occur to the alternator if nuts are over torqued Remove safety wire to check thru bolt torque Observe that the thru bolt has threads visible both above and below the mounting ears to prevent a false torque should the bolt bottom out Check torque at 180 to each bolt With torque correct properly install new safety wire When replacing or tensioning the belt use the engine and or airframer s service documentation Table 1 Description Torque Value US Torque Value SI Attachment of Ground Battery Aux or Field wires from the engine or airframe top nut will require proper torque from the applicable engine or aircraft service or maintenance manual Bottom nut must be held in place to achieve proper engine or airframe torque RETURN TO SERVICE 20 With alternator properly installed and proper belt tension assured reconnect aircraft battery Refer to 18 above as required Prepare the aircraft and make a performance run Check with both light and heavy electrical loads and determine proper operation per the applicable manufacturer s maintenance manuals and aircraft POH or AFM Examine installation for security Utilizing the applicable aircraft and
19. ure 2 Brush Removal CAUTION GREAT CARE MUST BE TAKEN WHEN REMOVING THE BRUSH HOLDER ASSEMBLY AS THE BRUSHES ARE SPRING LOADED THE BRUSHES MAY FALL INTO THE ALTERNATOR OR POP OUT AND CHIP OR BREAK NEVER RE USE DAMAGED BRUSHES AS THIS MAY LEAD TO ALTERNATOR NOISE OR OUTPUT FAILURE Remove the two screws 35 and washers 32 that attach the brush holder assembly 7 to the slip ring end housing Remove the nut from the ground stud that secures the brush holder assembly ground strap Remove the brush holder assembly from the slip ring end assembly and inspect f replacing brush holder ass y discard the ass y lock washers and lock nuts Remove brushes from holder and mark to indicate removed position and orientation Inspect brushes for chipping or other damage including spring cap and wire If damage appears to spring or there are broken strands in brush lead discard brush If no damage is apparent measure the length of the brush New brushes measure 5 inch 1 27 cm To reuse the brush it must be 25 inch 635 cm or greater If less than this figure replace brush holder assembly 7 Inspect the flexible brush holder seal 11 for damage and replace as required Never replace a single brush replace as a set only If it is determined that the brushes are reusable inspect the brush holder for cracks or other damage Never reuse a damaged brush holder even if the brushes are good Place each brush into the brush holder i
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