Service Information Letter
Contents
1. 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 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 shows 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 con2. KELLY Service ae ne Information Letter 2900 Selma Highway Montgomery AL 36108 USA 334 386 5400 334 386 5450 FAX www kellyaerospace com Letter No A 135 Issue Date May 5 2010 ES10024 Alternator Continued Airworthiness ICA amp Brush Service Instructions INTRODUCTION The Kelly Aerospace Energy Systems LLC KAES alternator model ES10024 is of a new design coming into the general aviation market and it s applications though numerous are not extensive The newly produced overhaul and maintenance manual is not yet available to qualified repair stations and mechanics Therefore KAES is issuing this SIL to provide basic continued airworthiness instruction ICA for the ES10024 alternator when used in specific 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 overhaul of the alternator This Service Information Letter provides Instruction for Continued Airworthiness consisting of periodic inspection requirements general troubleshooting and instruction for removing inspecting and if necessary replacing the brush assembly in ES10024 alternator COMPLIANCE At each annual inspection not to exceed the applicable time in service requirement of periodic inspection Chart 1 on page 5 and or Any time it is n
3. ace Service Information Letter No A 135 Page 1 of 6 PROCEDURE cont d Inspection Chart 1 If an ES10024 alternator is installed the Periodic Inspections of Chart 1 found on page 5 apply 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 start at the ten 10 hour inspection If the unit was installed prior to release of this SIL and has 100 hours start at this inspection and so on If the time is unknown it is best to start with the 500 hour inspection to properly examine the brushes and other working components If the alternator is not an ES10024 proceed to Return to Service instruction 15 on page 3 f another alternator check the KAES website to see if a similar SIL exists for the alternator model you have For each inspection on Chart 1 requiring torque application refer to Table 1 on page 3 Troubleshooting Chart 2 on page 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 on page 6 before attempting any repair overhaul or replacement the alternator Chart 2 lists the five areas of trouble common to this alternator Choose the applicable symptom you are experiencing and follow the trouble shooting advice beneath as applicable For example your sy
4. ction applies to all new rebuilt or overhauled ES10024 alternators produced by Kelly Aerospace Energy Systems LLC Refer to information contained in SIL A 135 latest Rev for requirements for each specific inspection 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 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 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 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 Hours TIS and each 100 hours thereafter or each annual inspection not to exceed 100 hours
5. ecessary to inspect or replace the alternator brushes on a model ES10024 alternator EFFECTIVITY All Kelly Aerospace Energy Systems model ES10024 alternators when used in Type Certificated aircraft or engines Currently limited to Teledyne Continental Motors series O 550 and IOF 550 engines Includes but is not limited to Beechcraft Raytheon Cessna Cirrus Columbia and Lancair airplane applications PROCEDURE Inspection Chart 1 on page 5 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 It is required to reference the aircraft AFM or POH as well as the applicable service or maintenance manual as required when servicing this alternator Failure to do so may result in damage to the aircraft and equipment 1 Determine if your airplane uses a ES10024 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 For questions concerning this instruction please contact KAES Service Dept at 888 461 6077 Contact your local KAES distributor to purchase available service parts New Kelly Aerosp
6. er tension supplied by this clutch will allow slippage during high alternator output Consult engine service instructions Symptom Noisy in operation electrical Shorted rectifier magnetic noise Place oscilloscope on main electrical bus If AC is found 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 f 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 v
7. 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 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 nspect 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 Symptom Battery is overcharged Voltage regulator set too high for aircraft operating conditions Check the voltage regulator setting per the aircraft service manual Adj
8. ice information letter by completion of inspections per the periodic requirement of Chart 1 and or replacement of the alternator brush holder assembly make an appropriate log book entry of compliance MATERIAL REQUIRED As required one 1 each Brush Holder assembly part number ALE 3045BS for ES10024 1 or part number ALU 3045BS for ES10024B and two 2 each Screw part number 03C44209B15 New Brush holder assembly includes brushes If desired the following parts are available Nut output shaft P N 8X 4075 O ring shaft external P N 32B70247A01 Thru bolt P N 40426 Lock washer thru bolt P N 12X 3074 Nut Output terminal P N 8X 1063 Output terminal Lockwasher P N 12X 0199 Nut cupped Ground terminal P N 40298 Nut Aux terminal P N 8X 0173 Aux terminal Lockwasher P N 12X 0196 Gear clutch ass y TCM P N 646655 KAES P N 646655R PARTS AVAILABILITY Parts to support this service bulletin must be obtained from an authorized Kelly Aerospace Energy Systems Distributor of your choice Any supplementary part which may be required such as the TCM gear clutch assembly cooling ducts 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 KAES Limited Warranty Policy issued with the purchase of each new alternator see terms and conditions therein Issuance of this service bulletin in n
9. junction with this inspection Conditions found that require replacement parts other than the brush holder ass y drive gear or hardware will require overhaul of the alternator 2000 Hours TIS or 12 years and at any engine overhaul Recommend overhaul or replacement of alternator assembly This a maximum time in service actual overhaul time may vary based on cooling electrical load and conditions of use The airframe or engine manufacturer recommended TBO if less shall supercede this TBO Kelly Aerospace Service Information Letter No A 135 Page 5 of 6 Chart 2 GENERAL TROUBLESHOOTING FOR ES10024 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
10. mptom is low or no alternator output The possible cause would be loose terminal connections or worn or broken 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 returned for overhaul In addition if aircraft or engine work is required reference to the the applicable service or maintenance manual will be required Brush inspection and or replacement 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 Refer to Figure 1 amp 2 to locate and remove the brush holder assembly See material required section on page 4 for brush holder assembly and hardware part numbers Output Shaft Thru Bolts Brush Holder Ass y Nut Two Piece Field Terminal 7 Ground Terminal 3 Brush Holder Retaining Screws Brush Assembly amp WC 5 Aux Terminal 6 SRE Housing Removed for Clarity Battery Terminal 4 Figure 1 Brush Holder Location Figure 2 Remove Screws 11 Disconnect the F1 field wire by removing hardware Rem
11. 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 will occur to the alternator if nuts are over torqued Great care must be taken with the field terminal as the bottom nut torque is very low It is very easy to over torque the top nut when attaching the field wire Over torque will destroy the brush holder 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 reinstall safety wire When using aftermarket gear P N 646655R use output shaft torque in Table 1 When using TCM gear P N 646655 refer to TCM service documentation for installation and torque Table 1 Description Torque Value US Torque Value SI Attachment of Ground Battery Aux or Field wires from the engine or airframe 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 New Kelly Aerospace Service Information Letter No A 135 Page 3 of 6 RETURN TO SERVICE 16 Utilizing the applicable aircraft and engine manufacturers maintenance manuals install any portion of the aircraft removed to gain access 17 Upon successful completion of this serv
12. o way constitutes an implied or expressed warranty of any kind Other warranty may apply per the terms and conditions in the aircraft or engine manufacturers 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 electrical system CONTACT INFORMATION If you have any questions concerning this service information letter please contact Kelly Aerospace Energy Systems Technical Support at 888 461 6077 Or write at Kelly Aerospace Product Support 2900 Selma Highway Montgomery AL 36108 USA Website www kellyaerospace com For e mail go to the Kelly Aerospace website http www kellyaerospace 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 Page 4 of 6 Kelly Aerospace Service Information Letter No A 135 New New Chart 1 PERIODIC INSPECTION ES10024 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 inspe
13. oltage 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 Page 6 of 6 Kelly Aerospace Service Information Letter No A 135 New
14. ove the two screws retaining the brush holder assembly to the slip ring end housing Carefully remove the brush holder assembly so that the brushes do not fall into the alternator or fall out and chip or break Page 2 of 6 Kelly Aerospace Service Information Letter No A 135 New PROCEDURE cont d Brush inspection and or replacement 12 Remove brushes from holder and mark on side to indicate removed position Inspect brushes for chipping or other damage including spring cap or 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 black brush block New brushes measure 5 inch 1 27 cm To reuse the brush it must be a minimum 50 of new or 25 inch 635 cm If less than this figure replace brush holder with two new brushes 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 in the same position and orientation as removed Install a two inch stiff 22 gage insulated wire into the hole provided in side of the brush holder while pushing in each brush with a soft tool like a small wood or plastic dowel The wire will retain the brushes for installation of the holder New brushes shipped with retaining wire installed Install a new or the reu
15. sed brush holder assembly and two retaining screws Torque screws to 25 to 35 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 Measure the resistance between the field and ground terminals ES10024 1 or F1 and F2 ES10024B with an ohmmeter while rotating the shaft The ohmmeter must indicate a rotor resistance of between 7 and 20 ohms To complete brush replacement or inspection task re attach F1 field wire and torque per Table 1 below Torquing Hardware 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 below for all hardware that is part the alternator Hardware which retains aircraft terminals or the output shaft nut must be torqued to the specification called out by the engine or airframe manufacturer in their service instructions or manuals Table 1 data may be used if OE data cannot be found or original data is no longer available When checking for loose alternator hardware or when replacing terminal wires on their respective studs the following should be observed All nut torque applied from Table 1 are for the first bottom nut on each stud of the alternator When checking field ground aux and battery terminal nuts for looseness make sure that the bottom nut be held in place with a thin wrench to secure
16. ust 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 harness 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 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 Improp
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