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Export Permitted Under NLR

COMPONENT MAINTENANCE MANUAL


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

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

NOTICE

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

HAMILTON SUNDSTRAND ASSUMES NO LIABILITY WHATSOEVER, WHETHER CONTRACTUAL, WARRANTY, TORT


OR OTHERWISE, FOR UNAUTHORIZED ALTERATIONS OR ALTERATIONS NOT PERFORMED IN ACCORDANCE
WITH HAMILTON SUNDSTRAND APPROVED PROCEDURES.

HAMILTON SUNDSTRAND
CAGE CODE 99167

24-20-76

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

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

DESCRIPTION OF CHANGE

All affected pages

Updated warnings. Added metric conversions.

Safety Advisory,
1, 2

Updated the Safety Advisory.

Introduction, 2

Added paragraph 4.

105

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

107, 108

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

501

Revised Figure 501 to show Impedance Bridge P/N TS460/u as being no


longer manufactured. Added Digibridge 1750 LCR Tester. Deleted and
added a note.

505, 507, 510, 512

Changed "Miami Repair Center" to "Shannon Repair Center" and added


corresponding address.

506

Revised paragraph 2.D.(2).

511

Revised paragraph 3.A.(4).


HIGHLIGHTS

24-20-76

Page 1
Feb 26/07

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

DESCRIPTION OF CHANGE

Repair, 601

Added the NOTEs after paragraph 1.C. Added the NOTE after paragraph
1.D.

602

Changed "Miami Repair Center" to "Shannon Repair Center" and added


corresponding address.

604, 605

Added a Military Spec for Commercial Tape and revised the Federal
Specification for Isopropyl Alcohol. Added CAGE Codes where applicable
in Figure 602. Revised the title of Figure 603.

Repair No. 5, 601

Changed "Miami Repair Center" to "Shannon Repair Center".

603, 604

Replaced the sealer in steps 2.J. and 2.T.

701

Added NOTEs after paragraphs 1.B and 1.C.

702, 703

Removed addresses and added CAGE Codes to Figure 701.

901, 903, 904

Added the NOTE after paragraph 1.A. Revised Figure 901 (Sheet 1 of 4) to
show Impedance Bridge P/N TS460/u as being no longer manufactured.
Added Digibridge 1750 LCR Tester. Removed addresses in the Vendor
Code section of Figure 901. Added a note. Revised company name in
note.

1001

Added paragraphs 1.B. and 1.C.

1003

Added paragraph 2.G.

1016 through 1031

Moved IPL Figure 1 to IPL Figure 1A to accommodate top assembly item


numbers. Deleted item 30 and added item 30A in IPL Figure 1A.

1033 through 1035

Moved IPL Figure 2 to IPL Figure 2A to accommodate top assembly item


numbers. Deleted item 430 and added item 430A in IPL Figure 1A.

1036 through 1042

Moved IPL Figure 3 to IPL Figure 3A to accommodate top assembly item


numbers. Deleted items 70 and 70C and added items 70A and 70D in
IPL Figure 3A.

1045 through 1050

Moved IPL Figure 4 to IPL Figure 4A to accommodate top assembly item


numbers. Deleted items 60 and 130 and added items 60A and 130A in
IPL Figure 4A.

The following Hamilton Sundstrand internal documents were included in this revision:
HCO-0010200914, SZA-0107251212, IH-041025-135044, NPC 93-0262 (IH-041026-93441),
C6032-AI37847 (C6038-A35762), NPC C06-0004-R (IH-06727-14292), SZA-0105241402.

HIGHLIGHTS

24-20-76

Page 2
Feb 26/07

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

Scope
A.

2.

This publication describes processes that may require the use of chemicals, solvents,
paints, or other materials that can affect a persons health or safety. It may also cover high
energy procedures that can affect a persons health or safety. Warnings are placed just
ahead of these procedures to bring attention to the existence of a procedure or material
that can be dangerous.

Significance of Material Safety Data Sheets (MSDS) and How to Obtain MSDS
WARNING: BEFORE USING ANY OF THE MATERIALS SPECIFIED IN HAMILTON
SUNDSTRAND MAINTENANCE PUBLICATIONS, BE AWARE OF ALL
HANDLING, STORAGE, AND DISPOSAL PRECAUTIONS RECOMMENDED BY
THE MANUFACTURER OR SUPPLIER. FAILURE TO COMPLY WITH
MANUFACTURER'S OR SUPPLIER'S RECOMMENDATIONS MAY RESULT IN
PERSONAL INJURY OR DISEASE.
THE USER OF THIS PUBLICATION SHOULD OBTAIN THE MATERIAL
SAFETY DATA SHEETS (OCCUPATIONAL SAFETY AND HEALTH ACT
(OSHA) FORM 20 OR EQUIVALENT) FROM THE MANUFACTURERS OR
SUPPLIERS OF MATERIALS TO BE USED. THE USER MUST BECOME
COMPLETELY FAMILIAR WITH THE MANUFACTURER OR SUPPLIER
INFORMATION AND ADHERE TO THE PROCEDURES,
RECOMMENDATIONS, WARNINGS, AND CAUTIONS OF THE
MANUFACTURER OR SUPPLIER FOR THE SAFE USE, HANDLING,
STORAGE, AND DISPOSAL OF THESE MATERIALS.

3.

A.

Refer to the materials list at the beginning of each section of this manual for materials
used to repair and maintain the covered equipment.

B.

If you do not have a copy of the manufacturers MSDS for the materials covered in the
materials list, contact the manufacturer and request that a MSDS be supplied before you
use the material.

Purpose
A.

The warnings bring your attention to the existence of a procedure that can affect a
persons health or safety.

B.

Short warnings are provided in this maintenance publication to alert operating and
maintenance personnel of potential hazards that could result in personal injury or health
hazards. The warnings do not replace the manufacturer's recommendations. When there
is a reference to the Warnings Registry 341-006, that publication will provide more
information about the dangers of the material. The information contained in the Warnings
Registry is a summary of the manufacturers MSDS. The full-length warnings provide
three principle parts of safety: (1) a listing of the known dangers, (2) what is needed to do
to protect you from the dangers, and (3) what to do if the dangers occur.
SAFETY ADVISORY

24-20-76

Page 1
Feb 26/07

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

4.

5.

C.

The detailed warnings in Warnings Registry 341-006 are a summary of the manufacturers
MSDS and are not intended to replace the material on the sheet, but are intended to
supplement them.

D.

Cautions are provided in the maintenance publication or service bulletin to alert operating
and maintenance personnel to conditions that could result in equipment damage.

Definitions Applying to Warnings


A.

Flammable: a material that can catch fire easily and can be explosive. These materials are
labeled according to the flash point of the material.

B.

Flash Point: the lowest temperature at which a flammable liquid gives off fumes that can
burn.

C.

Ignition Source: includes flames, sparks, or heat.


(1)

Flames: materials that are burning such as lit matches, propane torches, or pilot
lights.

(2)

Sparks: materials such as lighted cigarettes, electrical motors, or static electricity.

(3)

Heat: any source of energy that will raise the temperature of a flammable material to
its flash point and could include hot parts, heated tools, or direct sunlight.

D.

Corrosive: acidic or alkaline material that will remove human tissue or create chemical
reactions with other materials.

E.

Toxic: material that is poisonous.

F.

Reactive: material that will make fumes, burn, or can be explosive when mixed with
certain other materials.

G.

Shock (Electrical): the result of any source of electricity more than 50 volts that causes
current to flow through a person and can result in dangerous burns to human tissues or
death.

H.

Exposure: contact with the material or physical process without protection. Contact may
be by the eyes, breathing, touch, skin absorption, or swallowing.

I.

Irritation: any sense of pain, soreness, rash, or general discomfort.

Reporting Materials or Processes Not Covered


A.

You may contact Technical Publications personnel by email at


mailto:tech.pubs@hs.utc.com or fax at (860) 660-9014 if you find a material in a Hamilton
Sundstrand maintenance document that is known to be covered by a material safety data
sheet (MSDS), but is not covered by a warning in the procedure.

SAFETY ADVISORY

24-20-76

Page 2
Feb 26/07

HAMILTON SUNDSTRAND
COMPONENT MAINTENANCE MANUAL
PART NUMBER 976J497 AND 976J597
RECORD OF REVISIONS
REV
NO.

ISSUE
DATE

DATE
REV
INSERTED BY NO.

Sep 1/73 Sep 1/73

Sep 15/75 Sep 15/75

Jun 1/80

Jun 1/80

DATE
REV
INSERTED BY NO.

ISSUE
DATE

DATE
INSERTED BY

Aug 15/83 Aug 15/83

May 1/84 May 1/84

Nov 1/94 Nov 15/94

Dec 15/95 Dec 30/95

May 1/97 May 15/97 S

Jun 1/00

10

ISSUE
DATE

Jun 23/00 HS

Feb 25/03 Feb 26/03 HS

11 Feb 26/07 Feb 27/07 HS

RECORD OF REVISIONS

24-20-76

Page 1
Jun 1/00

HAMILTON SUNDSTRAND
COMPONENT MAINTENANCE MANUAL
PART NUMBER 976J497 AND 976J597
RECORD OF TEMPORARY REVISIONS
TEMPORARY
REV. NO.

PAGE
NUMBER

ISSUE
DATE

BY

DATE
REMOVED

BY

RECORD OF TEMPORARY REVISIONS

24-20-76

Page 1
Jun 1/00

HAMILTON SUNDSTRAND
COMPONENT MAINTENANCE MANUAL
PART NUMBER 976J497 AND 976J597
SERVICE BULLETIN LIST
The Service Bulletin List identifies the service bulletin number and revision number, if applicable, the
date of the service bulletin, and the date the service bulletin was incorporated in the manual (manual
revision date).
SB
SERVICE BULLETIN
SERVICE
DATE
REF NO.
NUMBER (REVISION NO.)
BULLETIN DATE
INCORPORATED
70-103

Oct 30/70

Sep 1/72

71-103 Rev. 1

Oct 1/72

Apr 15/75

72-101

Mar 15/72

Apr 15/75

78-103 Rev. 1

Feb 1/80

Mar 1/80

79-103

Nov 1/79

Mar 1/80

45

Sep 26/72

Apr 15/75

48

Oct 30/73

Apr 15/75

Service News Letter

SERVICE BULLETIN LIST

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Jun 1/00

HAMILTON SUNDSTRAND
COMPONENT MAINTENANCE MANUAL
PART NUMBER 976J497 AND 976J597
LIST OF EFFECTIVE PAGES
Subject

Page

Date

Title Page

Feb 26/07

Highlights

1
2

Feb 26/07
Feb 26/07

Safety Advisory

1
2

Feb 26/07
Feb 26/07

Record of Revisions

Jun 1/00

Record of Temporary
Revisions

Jun 1/00

Service Bulletin List

Jun 1/00

List of Effective Pages

1
2

Feb 26/07
Feb 26/07

Table of Contents

Jun 1/00

Introduction

1
2

Feb 26/07
Feb 26/07

Description and
Operation

1
2

Jun 1/00
Jun 1/00

Testing and
Fault Isolation

101
102
103
104
105
106
107
108

Jun 1/00
Jun 1/00
Jun 1/00
Jun 1/00
Feb 26/07
Jun 1/00
Feb 26/07
Feb 26/07

Automatic Test
Requirements

201

Jun 1/00

Disassembly

301
302
303
304

Jun 1/00
Jun 1/00
Jun 1/00
Jun 1/00

Cleaning

401

Jun 1/00

Check

501
502
503
504
505
506
507
508
509

Feb 26/07
Feb 26/07
Feb 26/07
Jun 1/00
Feb 26/07
Feb 26/07
Feb 26/07
Jun 1/00
Jun 1/00

Subject

Page

Date

510
511
512
513
514
515
516
517
518
519
520
521
522
523
524
525
526

Feb 26/07
Feb 26/07
Feb 26/07
Feb 26/07
Jun 1/00
Jun 1/00
Jun 1/00
Jun 1/00
Jun 1/00
Jun 1/00
Jun 1/00
Jun 1/00
Jun 1/00
Jun 1/00
Jun 1/00
Jun 1/00
Jun 1/00

Repair

601
602
603
604
605

Feb 26/07
Feb 26/07
Feb 26/07
Feb 26/07
Feb 26/07

Repair No. 1

601

Jun 1/00

Repair No. 2

601
602
603
604
605

Jun 1/00
Jun 1/00
Jun 1/00
Jun 1/00
Jun 1/00

Repair No. 3

601
602
603

Jun 1/00
Jun 1/00
Jun 1/00

Repair No. 4

601
602
603

Jun 1/00
Jun 1/00
Jun 1/00

Repair No. 5

601
602
603
604
605

Feb 26/07
Jun 1/00
Feb 26/07
Feb 26/07
Jun 1/00

Repair No. 6

601
602

Jun 1/00
Jun 1/00

Check (Continued)

LIST OF EFFECTIVE PAGES

24-20-76

Page 1
Feb 26/07

HAMILTON SUNDSTRAND
COMPONENT MAINTENANCE MANUAL
PART NUMBER 976J497 AND 976J597
Subject
Repair No. 7

Page
601

Date
Jun 1/00

Repair No. 8

601
602

Jun 1/00
Jun 1/00

Repair No. 9

601

Jun 1/00

Repair No. 10

601
602

Jun 1/00
Jun 1/00

Repair No. 11

601
602
603

Jun 1/00
Jun 1/00
Jun 1/00

Assembly

701
702
703
704
705
706
707
708

Feb 26/07
Feb 26/07
Feb 26/07
Feb 26/07
Feb 26/07
Feb 26/07
Feb 26/07
Feb 26/07

Fits and Clearances

801
802
803

Jun 1/00
Jun 1/00
Jun 1/00

Special Tools,
Fixtures, and
Equipment

901
902
903
904
905
906
907
908
909

Feb 26/07
Feb 26/07
Feb 26/07
Feb 26/07
Jun 1/00
Jun 1/00
Jun 1/00
Jun 1/00
Jun 1/00

Illustrated Parts List 1001


1002
1003
1004
1005
1006
1007
1008
1009
1010
1011
1012
1013
1014
1015

Feb 26/07
Feb 26/07
Feb 26/07
Feb 26/07
Feb 26/07
Feb 26/07
Feb 26/07
Feb 26/07
Feb 26/07
Feb 26/07
Feb 26/07
Feb 26/07
Feb 26/07
Feb 26/07
Feb 26/07

Subject
Page
Illustrated Parts List 1016
(Continued)
1017
1018
1019
1020
1021
1022
1023
1024
1025
1026
1027
1028
1029
1030
1031
1032
1033
1034
1035
1036
1037
1038
1039
1040
1041
1042
1043
1044
1045
1046
1047
1048
1049
1050

Date
Feb 26/07
Feb 26/07
Feb 26/07
Feb 26/07
Feb 26/07
Feb 26/07
Feb 26/07
Feb 26/07
Feb 26/07
Feb 26/07
Feb 26/07
Feb 26/07
Feb 26/07
Feb 26/07
Feb 26/07
Feb 26/07
Feb 26/07
Feb 26/07
Feb 26/07
Feb 26/07
Feb 26/07
Feb 26/07
Feb 26/07
Feb 26/07
Feb 26/07
Feb 26/07
Feb 26/07
Feb 26/07
Feb 26/07
Feb 26/07
Feb 26/07
Feb 26/07
Feb 26/07
Feb 26/07
Feb 26/07

LIST OF EFFECTIVE PAGES

24-20-76

Page 2
Feb 26/07

HAMILTON SUNDSTRAND
COMPONENT MAINTENANCE MANUAL
PART NUMBER 976J497 AND 976J597
TABLE OF CONTENTS
Subject

Page

Description and Operation .......................................................................................................... 1


Testing and Fault Isolation ...................................................................................................... 101
Automatic Test Requirements ................................................................................................. 201
Disassembly ........................................................................................................................... 301
Cleaning .................................................................................................................................. 401
Check ...................................................................................................................................... 501
Repair ..................................................................................................................................... 601
Assembly (Including Storage) ................................................................................................. 701
Fits and Clearances ................................................................................................................ 801
Special Tools, Fixtures, and Equipment .................................................................................. 901
Illustrated Parts List .............................................................................................................. 1001

TABLE OF CONTENTS

24-20-76

Page 1
Jun 1/00

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

General
A.

2.

This manual contains maintenance information for generators 976J497-1 and 976J597-1.
The AC Generator is manufactured by Hamilton Sundstrand, a United Technologies
Company, 4747 Harrison Ave., P.O. Box 7002, Rockford, IL 61125-7002, U.S.A.

Configuration Differences
A.

Differences among the various generator part numbers are listed below:
(1)

3.

Generator 976J497-1 has rotor and stator laminations made from conventional
silicon steel (AISI M-15). Generator 976J597-1 has rotor and stator laminations
made from CUBEX electrical sheet steel. The CUBEX steel parts are no longer
available. Reference Service News Letters 45 and 48 for discontinuance of this
generator.

List of Abbreviations

ABBREVIATION

DEFINITION

ABBREVIATION

DEFINITION

AC

Alternating Current

HP

Horsepower

Hz

Hertz

CCW

Counterclockwise

IPL

Illustrated Parts List

CFM

Cubic Feet Per Minute

kVA

Kilovolt Ampere

CT

Current Transformer

L-N

Line-to-Neutral

CW

Clockwise

mA

Milliampere

DC

Direct Current

MAX

Maximum

EFA

Exciter Field Current

MIN

Minimum

EFR

Exciter Field Resistance

Vdc

Volts Direct Current

EFV

Exciter Field Voltage

GCU

Generator Control Unit

INTRODUCTION

24-20-76

Page 1
Feb 26/07

HAMILTON SUNDSTRAND
COMPONENT MAINTENANCE MANUAL
PART NUMBER 976J497 AND 976J597
4.

Statement of Verification
SECTION
Testing and Troubleshooting
Disassembly
Assembly

METHOD
Review of source documentation
Review of source documentation
Review of source documentation

DATE
-------

INTRODUCTION

24-20-76

Page 2
Feb 26/07

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

Description
A.

The generator is a self-excited, air cooled, brushless machine designed for use in aerospace applications to provide alternating current power for aircraft electrical systems. It
consists of an exciter rotating armature, exciter stationary field, alternating current stationary armature, main rotating field, a three-phase full-wave rectifier bridge and a capacitor.
It is driven and held within the speed range by a constant speed transmission, which is in
turn driven by the aircraft engine.

B.

Specifications of the generator are shown in Figure 1 below.

Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 kVA


Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120/208 Volts AC
Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380/420 Hertz
Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83.3 Amperes
Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Power Factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.75
Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5700/6300 rpm
Rotation (facing end opposite drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CCW/CW
Phase Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T1, T2, T3/T2, T1, T3
Outline (Installation Drawing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 915F316
Size:
Maximum Length From Mounting Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.82 in. (300.22 mm)
Maximum Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.00 in. (279.40 mm)
Maximum Weight for 976J497-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 lbs (31.75 kg)
Maximum Weight for 976J597-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67.5 lbs (30.62 kg)
Specifications
Figure 1
2.

Operation
A.

The stationary exciter winding has permanent magnets between the coils. These permanent magnets provide a minimum residual voltage from the generator to the regulator to
assure buildup under all conditions. Turning the rotor produces a voltage buildup as a
result of the residual magnetism or flux from the permanent magnets. This produced voltage is fed to the voltage regulator.
The voltage regulator rectifies the voltage signal and returns a controlled signal to the generator through pins A- and F. This voltage excites the exciter field and produces a threephase alternating current voltage in the rotating exciter armature. This is then fed to the
three-phase full-wave rotating rectifier where it is rectified to direct current. This current
excites the main rotating field where it sets up a magnetic flux in the field poles. The magnetic field, cutting conductors in the stationary armature produces three-phase alternating
current output to the main terminals.

DESCRIPTION AND OPERATION

24-20-76

Page 1
Jun 1/00

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

The exciter, which provides power for the rotating field, uses a stationary direct current
field and a rotating alternating current armature. The stationary field has two windings in
parallel. A thermistor (negative temperature coefficient resistor) is placed, in series, with
one of the windings in order to provide near constant exciter field resistance over the temperature range encountered by the generator. The alternating current armature is
designed to have a high reactance so that its excitation requirements are dependent on
exciter load current rather than on exciter load voltage.

C.

The rotating rectifier consists of six silicon power diodes connected in a three-phase fullwave bridge. The diodes have a reverse voltage rating equal to 150 percent of the measured transient overvoltage under the most severe operating conditions. A capacitor is
connected across the direct current output of the full-wave bridge to provide transient voltage suppression. This is used to reduce the commutation voltage and to control other
overvoltages caused by system transients which could subject the diodes to excessive
peak reverse voltage.

D.

The main rotating field consists of eight sets of field coils, connected in series with alternate polarities. The coils are mounted on eight poles which are each an integral portion of
the main laminated or stacked core rotor. Each set of coils consists of two coils, a larger
and a smaller, which are assembled concentrically on a single pole and connected in like
polarity. Direct current excitation current from the rotating rectifier produces a flux in the
eight poles which in turn induces output voltage in the main stator windings. Amortisseur
(damper) windings are provided in longitudinal slots in the pole faces. Heavy, wedge
shaped amortisseur windings are mounted between the pole faces. They also function as
wedges to retain the field windings in place. These amortisseur windings are interconnected by circular copper rings on both sides of the rotor. The copper rings are reinforced
by steel bands fitted over them.

E.

In isolated generator operation, the amortisseur windings serve to reduce excessively


high voltage transients caused by the line-to-line system faults, to damp out torsional
vibration originating in the generator drive, and to decrease voltage unbalance during
unbalanced loads.

F.

The output windings or stationary armature of the main generator consist of lap wound coil
groups arranged in 120 degree phase belt windings on a slotted laminated stator. These
windings are wye connected, providing a three-phase alternating current output voltage of
208 volts line-to-line and 120 volts line-to-neutral at a frequency of 400 hertz with a nominal input speed of 6000 revolutions per minute. Both ends of each of the three phase
windings are brought out to a terminal board mounted externally on the generator frame.
The leads from the three stator phases are brought directly to the upper surface of the terminal board, thus aircraft wiring can be clamped directly against them without current
passing through the terminal studs.

DESCRIPTION AND OPERATION

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HAMILTON SUNDSTRAND
COMPONENT MAINTENANCE MANUAL
PART NUMBER 976J497 AND 976J597
TESTING AND FAULT ISOLATION
1.

Test
WARNING: THE TEST PROCEDURES OUTLINED IN THIS SECTION INVOLVE HIGH
VOLTAGE CIRCUITS. CARE SHOULD BE TAKEN TO AVOID CONTACT WITH
CONDUCTING PARTS OF THE CIRCUIT.
A.

B.

Preparation and Conditions for Test (See Figures 101 and 102)
(1)

The generator shall be mounted on a test stand having an intermittent four hour rating of not less than 65 horsepower at 6000 revolutions per minute and a maximum
acceleration rate of 1500 revolutions per minute per second. The stand shall permit
generator flange mounting in accordance with AND10266, Type XVI-C, with rotor
axis horizontal.

(2)

Cooling air shall be provided to the generator through adapter 938D844-3. The air
supply shall be capable of supplying up to 250 cubic feet per minute (118 liters per
second) and be adjusted to provide a constant head pressure of two inches (498
pascals) of water measured at the adapter.

(3)

The ambient temperature in the test area shall be 10 to 40 degrees Celsius (50 to
104 degrees Fahrenheit). The cooling air supply, measured at the adapter, shall not
be more than 10 degrees Celsius (18 degrees Fahrenheit) higher or lower than the
ambient temperature.

(4)

The load bank should be located so as not to appreciably affect the ambient temperature or cooling air temperature.

(5)

Provisions shall be made for a three-phase short circuit impedance sufficiently low
so that the voltage measured at the generator terminals does not exceed 15 volts
line-to-neutral. The impedance shall be balanced to obtain equal short circuit currents in each phase.

(6)

Before connecting the generator to the test stand, perform a continuity check
between generator terminals T1 and T4, T2 and T5, T3 and T6, and F and A-.

(7)

Check the resistance values between S and A-. It shall be 461 to 509 ohms for generators 976J497 and 446 to 494 for generator 976J597.

Test Procedure
The following tests are to be run in the sequence shown.
NOTE: During all tests, the three line-to-neutral load voltages shall be balanced within
one volt. The line voltage shall remain stable under both load switching and
steady state conditions.
(1)

Mount the generator on the test stand and connect to load bank metering and control circuits (See Figures 101 and 102) for connections to the regulator or generator
control unit being used for testing.
TESTING AND FAULT ISOLATION

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

A-67163
CB1
CB2
M1
M2
M3
M4

- Circuit Breaker, 3 phase, 3 pole, 220 volt, 400 hertz.


- Circuit Breaker, 3 phase, 3 pole, 220 volt, Nema size 4, 50 horsepower.
- Voltmeter, 0 to 50 volts direct current, 3 percent or better.
- Phase sequence indicator, 400 hertz, 115 volts line-to-neutral.
- Oscilloscope, 10 kilohertz bandwidth or better.*
- Voltmeter, 0 to 30, 0 to 150, 0 to 300, alternating current average or root-mean- square,
400 hertz 2 percent or better.
M5 - Ammeter, 600 Amperes, 400 hertz average or root-mean-square, 2 percent or better.
M6 - Ammeter, 0 to 5 amperes direct current, 2 percent or better.
R1 - Resistor, 0.5 1 percent ohms, 25 watt.
S1 - Switch, selector, 1 pole, 3 position, 2 ampere.
S2 - Switch, SPST, ON-OFF, 15 ampere at 125 volts, 10 amperes at 250 volts.
Load Bank - 3 phase, 1 percent balance, 30 kilowatts resistive.
Load Metering - Metering, transformers and switches to read up to 50 kilowatts total load and
individual phase currents up to 150 amperes.
* Leave oscilloscope ungrounded when testing with regulator 939D150.
Generator Test Circuit
Figure 101
TESTING AND FAULT ISOLATION

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HAMILTON SUNDSTRAND
COMPONENT MAINTENANCE MANUAL
PART NUMBER 976J497 AND 976J597
Test Circuit
Regulator
Regulator
GCU Regulator
Leads
905D977-3*
939D150*
915F212 **
T1
T1
1
A39
T2
T2
3
A41
T3
T3
5
A40
CT1
CT1
12
A42
CT2
CT2
13
A44
CT3
CT3
14
A43
F
F
19
B9
AA28
B3
S
S
--GND
G
7
-CURRENT
25B8904-2 OR
906D896-3
TRANSFORMER
950D968-3***
***
* Connect a 1.0 ohm resistor across terminals X1 and X2 of Regulator 905D977-3 or terminals 15
and 16 of Regulator 939D150.
** Make certain the GCR is closed in generator control unit before connecting into test circuit.
*** If CT package is used, short out all transformers that are not used.
Connections to Test Circuit
Figure 102
(2)

The normal phase sequence for connecting the generator shall be T1, T2, T3 for
counterclockwise rotation, as viewed from the end opposite the mounting flange.
For clockwise rotation change the generator connections to T1, T3, T2. In either
case, phase sequence at the regulator or generator control unit terminals shall be
T1, T2, T3.

(2A) Optional, based on local requirements. Make a copy of Figure 103 and use the
copy to record test results. This record shall be retained in accordance with airworthiness authority requirements.
NOTE: During all tests, the rotational speed of the generator shall be maintained within
15 RPM of that specified. The total KW load shall be within 2.25 % and the
average three phase load current shall be within 3% of that specified.
(3)

(4)

Test 1 - Warm-Up
(a)

Operate the generator at 6000 revolutions per minute, close the field switch
and apply 30 kilowatt load, 83.3 line amperes.

(b)

Allow the generator to stabilize for 20 minutes.

Test 2 - EFA, EFV Resistance Limits and Diode Check


(a)

After the generator has stabilized at 6000 revolutions per minute, 30 kilowatt,
unity power factor, check the exciter field current on M6. The current shall not
exceed 1.7 amperes maximum.
TESTING AND FAULT ISOLATION

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

Resistance

T1 - T4
T2 - T5
T3 - T6
(F) - (A-)
(S) - (A-)
(S) - (A-)

(OK)
S/N
(OK)
(OK)
ORDER _________
(OK)
(461/509 OHMS) (P/N 976J497)
(446/494 OHMS) (P/N 976J597)

Rotation

(CW) ONLY

Phase Sequence

(T1-T2-T3)

TEST
NO
1&2

PHASE
VOLTS *
A
B C

LINE

KILO-

EFA

EFV

EFR

AMPS

WATTS

AMPS

VOLTS

OHMS

120

83.3

30
0

1.7 MAX
----

----

6.2/8.0
----

----

----

----

3
15 max
4

250
MIN
0

5
120
6

83.3
0

30
0

1.7 MAX
----

6.2/8.0
----

----

RECORD
RPM
6000

NOTES
A

ACTUAL

6000

Phase
A Only

C
9000
6000

6000

12/19
(16/20 ccw)

* Output voltages should be balanced within 1.0 volt.


NOTES
A - Close field switch and allow 20 minutes warm-up under full load, then record readings. Observe
oscilloscope trace and record condition of diode assembly by comparing trace to Figures 104
and 105.
CAUTION: FAILURE TO OBSERVE NOTE B MAY RESULT IN DAMAGE TO THE MAIN
ARMATURE AND STATOR WINDINGS.
B - The three phase short circuit is to be on for 5 seconds maximum. Only the voltage and current for
phase A is to be measured and recorded.
C - Overspeed test is to be run only if armature rotor assembly has been replaced or repaired. Test
is to be performed with field switch open.
D - Stabilize for 5 minutes and then read meters.
E - Residual voltage test is run with field switch open and no load.
Test Record
Figure 103 (Sheet 1 of 2)

TESTING AND FAULT ISOLATION

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

OK

Dielectric Test (Reference Paragraph B.9


AC Windings to Ground - 900 Vac, 60 Hz

REJECT
(OK)

Phase to Phase - 900 Vac - 60 Hz


T1 - T2
T2 - T3
T1 - T3

(OK)
(OK)
(OK)

S/N
ORDER

This unit meets test criteria.


*TESTER

*Q.C. Acceptance

* Date & Sign


Test Record
Figure 103 (Sheet 2 of 2)

TESTING AND FAULT ISOLATION

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

The exciter field resistance shall be between 6.2 and 8.0 ohms when calculated by dividing the exciter field voltage on M1 by the exciter field current.

(c)

The exciter field current shall appear as shown in Figure 104. If it appears as
shown in Figure 105, a defective diode or open exciter armature winding is
indicated. Diode test set 939D192-1, may be used as an alternate method of
checking the diodes.

A-67164
Oscilloscope View of Exciter Current (EFA), Good
Figure 104

A-67165
Oscilloscope View of Exciter Current (EFA), Bad
Figure 105
(5)

Test 3 - Short Circuit Capacity


(a)

Operate the generator at 6000 revolutions per minute and apply a short circuit
on the generator by closing CB2 for 5 seconds.

(b)

The line voltages, measured at the generator terminals, shall not exceed 15
volts and the short circuit current on M5 shall not be less than 250 amperes per
phase.
TESTING AND FAULT ISOLATION

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HAMILTON SUNDSTRAND
COMPONENT MAINTENANCE MANUAL
PART NUMBER 976J497 AND 976J597
(6)

(7)

(8)

Test 4 - Overspeed (Optional - required only if the armature-rotor assembly has


been replaced or if major repairs have been made on the rotor windings.)
(a)

Operate the generator at 9000 revolutions per minute for 5 minutes, with the
field circuit open and no load on the generator. After 5 minutes reduce
generator speed to 5,700 revolutions per minute.

(b)

The generator shall show no signs of mechanical or electrical failure.

Test 5 - Recheck of Short Circuit Capacity


(a)

Stabilize at 6000 revolutions per minute for 5 minutes to recheck the generator
following short circuit and overspeed tests.

(b)

Repeat Test 2.

Test 6 - Residual Voltage


(a)

Operate the generator at 6000 revolutions per minute, no load, with the field
switch open.
NOTE: Clockwise rotational check is only required for older applications (707
or 720) where the generator operates clockwise.

(b)
(9)

The generator terminal voltage (residual) on M4 shall be 12 to 19 for clockwise


rotation and 16 to 20 for counterclockwise rotation.

Dielectric Test
(a)

Before preceding with this test, remove the generator from the test stand and
disconnect all wires. Make the following tests.

WARNING: ELECTRIC SHOCK CAN OCCUR WHEN USING A HIGH


POTENTIAL TESTER. DO NOT TOUCH EXPOSED UNINSULATED
CONNECTIONS, COMPONENETS BEING TESTED OR THE
TESTING SURFACE. PERSONNEL WORKING WITH ELECTRICITY
SHALL HAVE ANOTHER PERSON SKILLED IN MODERN
METHODS OF FIRST AID AND RESUSCITATION NEAR BY.
CAUTION: DO NOT REMOVE OR APPLY THE PROBES OF THE INSULATION
BREAKDOWN TEST SET EXCEPT AT ZERO VOLTAGE.
(b)

Connect the AC terminals T4, T5, and T6 together and use insulation
breakdown test set 103MP-2.5DJU, 13700-1C, 60B4-1or 2512 to ground
check between the terminals and the frame. Apply a test potential of 900 volts
root-mean-square, 60 hertz, for one minute. Slowly increase test potential
from zero at a rate not to exceed 500 volts per second. Reduce at same rate
before removing connections. There shall be no breakdown in insulation.
TESTING AND FAULT ISOLATION

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

Remove jumper from T4, T5, and T6. Use insulation breakdown test set and
the same rate of application to check for phase-to-phase shorts by applying a
test potential of 900 volts root-mean-square, 60 hertz, for one minute between
phases as follows:
Terminals T1 and T2
Terminals T2 and T3
Terminals T1 and T3
There shall be no more than 5 milliamperes compensated current leakage
breakdown in insulation.
NOTE:

Proper compensation requires adjusting the Control Knob on the


Slaughter test set for the lowest microampere indication possible with
the windings connected to the test lead.

(10) Final Inspection


(a)
2.

Carefully inspect the generator and determine that all screws (inside and out)
are safety wired or otherwise securely locked.

Fault Isolation
A.

General
(1)

Locate fault symptom, probable cause, and corrective action in Figure 106.

FAULT SYMPTOM

PROBABLE CAUSE

CORRECTIVE ACTION

Sheared generator spindle.


Faulty external connections.
Exciter Winding.
Exciter Armature.
Rotating Field.

1.
2.
3.
4.
5.

Replace spindle.
Check connections.
Check for opens or shorts.
Check for opens or shorts.
Check for opens or shorts.

No voltage buildup.

1.
2.
3.
4.
5.

High exciter field current.

Shorted diode in rectifier


assembly.

See CHECKS.

Waveforms for field current


not as shown.

1. Faulty diodes.
2. Fault exciter armature.

1. See CHECKS.
2. See CHECKS.

Low residual voltage

Faulty permanent magnets

Replace exciter stator.

Troubleshooting Chart
Figure 106

TESTING AND FAULT ISOLATION

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HAMILTON SUNDSTRAND
COMPONENT MAINTENANCE MANUAL
PART NUMBER 976J497 AND 976J597
AUTOMATIC TEST REQUIREMENTS (ATLAS)
1.

General
There are no (ATLAS) requirements for AC Generators P/N 976J497-1 or 976J597-1.

AUTOMATIC TEST REQUIREMENTS (ATLAS)

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

General
This section contains disassembly procedures. When necessary, disassembly illustrations are
also provided. References to item numbers in the text and accompanying illustrations are identical to those in the ILLUSTRATED PARTS LIST. Refer to Standard Practices Manual,
24-10-00, DISASSEMBLY, for general disassembly procedures. Refer to FITS AND CLEARANCES for summarized disassembly information.
NOTE: Reference to item numbers in text implies that alpha variant items listed in the IPL may
be used as determined by the effect code for that item. For example, reference to item
(1) means that procedures also apply to alpha variant items (-1A, -1B, and -1C).
A.

An AC generator that is in for overhaul (approximately 6,000 operational hours) should be


disassembled to the complete extent of DISASSEMBLY, thoroughly cleaned, checked,
and have the bearings replaced.

B.

An AC generator removed for fault prior to the overhaul interval should be visually examined for for obvious damage. The input shaft should turn freely and with no excess noise.
If no fault is found the AC generator should be tested to verify that a fault exists before
starting disassembly. Disassemble the AC generator only to the extent required to correct
faults.

C.

Special tools used for disassembly are listed in Figure 301. Equivalent tools may be used.

D.

Parts recommended for discard are listed in Figure 302.

Tool Number

Description

908C714-1
910C176-1

Spline Wrench
Mechanical Puller

916B366-11

Step Plate

916B366-17

Step Plate

918B448-1

Adapter

922B865-2

Spanner Wrench

See Figure 901

Generator Support

See Figure 902

Cradle Fixture

See Figure 903

End Bell Removal Tool


Special Tools and Equipment
Figure 301

DISASSEMBLY

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HAMILTON SUNDSTRAND
COMPONENT MAINTENANCE MANUAL
PART NUMBER 976J497 AND 976J597
IPL Figure
1

Nomenclature and Item Number

Preformed Packing (3)


Machine Screw (6)

Preformed Packing (7)

Screw (9 or 9A)

Bearings (36)

Shields (37)

Screw (54 or -54A)

Key Washer (39)

Preformed Packing (6)

Preformed Packing (7)


Parts Recommended for Discard
Figure 302

2.

Disassembly
A.

Place AC generator on its side in a horizontal position.

B.

Remove retaining ring (2, IPL Figure 1) using retaining ring plier.

C.

Remove spindle cover (1) carefully using a pick or scribe to lift around the outside diameter of the spindle cover. Remove and discard packing (3).

D.

Remove machine screw (6) using spline wrench 908C714-1 to hold spline adapter (4).

E.

Remove spline adapter (4), shouldered washer (5), and packing (7).
CAUTION: DO NOT REMOVE THE SIX SCREWS THAT HAVE EPOXY COMPOUND IN
THEIR HEADS. THESE SCREWS HOLD THE END BELL TOGETHER AND
SHOULD NEVER BE REMOVED.

F.

Remove six screws (9) and backing ring (8).


NOTE: Do not use an allen wrench with ball head or chamfered head to remove screws
(9A) as these types of wrench heads cause the wrenching surface of the screws
to distort and make it difficult to obtain the correct torque and will make it difficult
to remove these screws.

G.

Place the AC generator drive end down on generator support (See Figure 901).

DISASSEMBLY

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

Remove end bell (30) using puller 910C176-1 and adapter 918B448-1.
NOTE: Do not use an allen wrench with ball head or chamfered head to remove screws
(10) as these types of wrench heads cause the wrenching surface of the screws
to distort and make it difficult to obtain the correct torque and will make it difficult
to remove these screws.

I.

Remove screws (11), washers (12), and bearing cover (10).

J.

Lift AC generator so that the armature-rotor spindle rests on the generator support (not in
the hole) and press down on generator stator until the drive end bearing (36) is pressed
out of end bell (52).
CAUTION: DO NOT SET ROTATING COMPONENTS DIRECTLY ON THE WORK
BENCH AS THEY MAY ROLL OFF THE BENCH AND THUS BE DAMAGED.

K.

Remove rotating parts (36 through 42) and set in cradle fixture (See Figure 902).
WARNING: WEAR GOGGLES WHEN REMOVING LOCKWIRE.

L.

Cut and remove lockwire from screws (54).


NOTE: Do not use an allen wrench with ball head or chamfered head to remove screws
(54) as these types of wrench heads cause the wrenching surface of the screws
to distort and make it difficult to obtain the correct torque and will make it difficult
to remove these screws.

M.

Remove screws (54), and washers (53).


CAUTION: DO NOT TAP END BELL TOO HARD AS IT MAY DISTORT THE END BELL
WHICH CAN CAUSE SUBSEQUENT BEARING DAMAGE.

N.

Remove end bell (52) using end bell removal tool (See Figure 903) to gently tap around
inside of the end bell outside diameter.
NOTE: The tool must be slightly curved in order to reach under the stator windings and
out to the outside diameter of the end bell.

O.

Remove retaining ring (38) using retaining ring plier.

P.

Remove one shield (37).

Q.

Remove drive-end bearing (36) using step plate 916B366-11 and puller 910C176-1.

R.

Remove one shield (37) and bearing cover (41).

S.

Bend tab of key washer (39) out of nut (40).

T.

Remove nut (40) using spanner wrench 922B865-2.

U.

Remove key washer (39) and one shield (37).


DISASSEMBLY

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

Remove antidrive-end bearing (36) using step plate 916B366-17 and puller 910C176-1.

W.

Remove one shield (37) and bearing cover (41).

X.

Remove screws (2, IPL Figure 3).

Y.

Remove stub shaft (1) using a rawhide or soft-faced mallet to tap around the flange of the
stub shaft.

Z.

Remove retaining ring (5) using retaining ring plier.

AA. Remove spindle (3) and retainer seal (4) using a rawhide or soft-faced mallet to tap on the
spindle.
NOTE: No farther disassembly is required at overhaul unless checks indicate a defective
part. For further disassembly, refer to REPAIR.

DISASSEMBLY

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

General
Refer to Standard Practices Manual, 24-10-00, CLEANING, for the general procedures used to
clean parts. Special instructions to clean parts are given in paragraph 2. Refer to Figure 201
for materials used to clean parts.

Material

Source

Detergent

Commercially Available

Water, Soft

Commercially Available

Tape, Pressure Sensitive

Commercially Available

Ultrasonic Cleaning Equipment


or equivalent

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

Indicator papers or pH meter

Commercially Available
Cleaning Materials
Figure 401

WARNING: WHEN USING COMPRESSED AIR FOR CLEANING OR DRYING, REGULATE


PRESSURE TO 29 POUNDS PER SQUARE INCH (200 KILOPASCALS) OR
LESS. WEAR GOGGLES OR FACE SHIELD TO PROTECT EYES.
NOTE: Remove particles from the permanent magnet poles with pressure-sensitive tape or
with compressed air.
2.

Ultrasonic Cleaning - Alternate Method


Refer to Standard Practices Manual, 24-10-00, CLEANING, for Ultrasonic Cleaning method.

CLEANING

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

General
A.

Visually check all parts for obvious wear or damage. Refer to Standard Practices Manual
24-10-00, CHECK, for general check information. See FITS AND CLEARANCES for
applicable wear tolerances. Special tools and equipment required for checks are listed in
Figure 501.
NOTE: Reference to item numbers in text implies that alpha-variant items listed in the
IPL may be used as determined by the effect code for that item. For example,
reference to item (1) means that procedures also apply to alpha-variant items
(-1A, -1B, and -1C).

B.

Special tools, fixtures, and equipment used in this section are listed in Figure 501. Refer
to Standard Practices Manual, 24-10-00, STANDARD TOOLS, FIXTURES, AND
EQUIPMENT for general equipment information.
NOTE: Equivalent tools, fixtures, and equipment can be used provided they meet the
requirements of ARINC Report 668.
NUMBER

DESCRIPTION

60087019
60060562
903J801-1
4286
976J552-4
103MP-2.5DJU
60B4-1
13700-C1
2512
TS460/u
Digibridge 1750 LCR Tester

Air Snap Gage


Master Setting Disks with Hose Assembly
Checking Fixture
Kelvin Bridge (Note 1)
Surge Comparison Test Set
Insulation Breakdown Test Set (Note 2)
Insulation Breakdown Test Set
Insulation Breakdown Test Set
Insulation Breakdown Test Set
Impedance Bridge, Type 1650A (Note 2)
Quad Tech Digibridge 1750 LCR Tester *
* Replaces Impedance Bridge, Type 1650A
H20B
Dynamic Balancing Machine
5220A
Direct Current Hypot
1700
Digital Converter (Note 1)
1701B
Low Ohm Meter, Plug-In Model (Note 1)
Model 78
Multimeter
NOTE 1: Use Electro Scientific Industries Low Ohm Meter, Plug-in Model 1701B, and Digital
Converter 1700, as preferred option to Kelvin Bridge 4286.
NOTE 2: No longer manufactured, continued use authorized by Hamilton Sundstrand.
Check Special Tools and Equipment
Figure 501
CHECK

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HAMILTON SUNDSTRAND
COMPONENT MAINTENANCE MANUAL
PART NUMBER 976J497 AND 976J597
2.

Overhaul Check
A.

Visually check all components for structural damage such as cracks, bends, worn parts,
stripped threads, frayed wires, corrosion, and obstructed air passages. Inspect the leads
for damaged insulation or broken conductors.
NOTE: See FITS AND CLEARANCES for complete listing of all mechanical fits and
clearances called for in this section.

B.

Check adapter (4, IPL Figure 1), spindle (3, IPL Figure 3), and stub shaft (1, IPL Figure 3)
for spline wear as follows:
NOTE: Splined parts must be thoroughly cleaned to remove all traces of lubrication,
corrosion, or other foreign matter prior to inspection.
NOTE: Since mating splines tend to wear evenly, it is not desirable to replace one spline
without replacing the mating spline.
(1)

Preferred Method
(a)

(2)

Place appropriate size pins between teeth 180 degrees apart. Using standard
micrometers, measure diameter (Refer to FITS AND CLEARANCES).

Alternate Method
(a)

Check splines visually using a 5 to 10 power magnifying glass (or precision


magnifying-measuring equipment, if available). Determine the percentage of
wear on the original spline width outer diameter face as shown in "enlarged
view of spline, Figure 502.

CHECK

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

A-67166
Typical Example of Spline Wear
Figure 502
(3)

C.

Visually check for pitting or rough finish in accordance with Hamilton Sundstrand
Standard Practices Manual 24-10-00 General Check Procedures and Spline
Inspection. Replace if drive surface condition exceeds limits in FITS AND
CLEARANCES.

Check armature-rotor (42, IPL Figure 1) as follows:


(1)

Use air snap gage 60087019, and masting setting disks with the hose assembly
60060562, to check the anti-drive end bearing shaft journals for wear (see Figure
503).
NOTE: As an alternate method, use a standard micrometer and check journals.

CHECK

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

A-67167-1
Armature-Rotor Check Criteria
Figure 503 (Sheet 1 of 2)

CHECK

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COMPONENT MAINTENANCE MANUAL
PART NUMBER 976J497 AND 976J597

A-73038
Armature-Rotor Check Criteria
Figure 503 (Sheet 2 of 2)
(2)

Place rotor in checking fixture 903J801-1, and check concentricity of rotor cores with
respect to bearing journals (see Figure 503).
NOTE: Armature-rotors requiring repair can be sent to the Hamilton Sundstrand
Shannon Repair Center at the following address:
Hamilton Sundstrand Shannon Repair Center
World Aviation Park
Shannon, Co. Clare
Ireland

(3)

Optional, check holding wedges (See View A-A, Top View of Holding Wedge, and
View B-B) as follows:
(a)

Hairline cracks that extend completely through the thickness of the holding
wedge or extend from the stamped area to the edge of the holding wedge are
not allowed.
CHECK

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

Ridges, die, or draw marks are allowed on the stamped areas as long as they
are not in the range defined in step (3)(a).
NOTE: If is recommended that when a holding wedge is suspected to be
faulty, that the armature-rotor be returned to Hamilton Sundstrand for
evaluation and possible repair. Holding wedges can not be removed
without damaging the armature-rotor insulation to the extent of
requiring a complete rewind. Attempts at braze repair will result in
temperatures that take the holding wedges out of the required
hardness range and result in eventual failure of the armature rotor.

D.

Check Generator Stator (55, IPL Figure 1) as follows:


(1)

Check the resistance between terminals T1 and T4, T2 and T5, and T3 and T6 with
Electro-Scientific meters 1700 and 1701B or optional Kelvin Bridge 4286. These
resistance values should be 0.039 to 0.047 ohms (for 976J497-1) and 0.038 to
0.046 ohms (for 976J597-1) per phase at 25 degrees Celsius (77 degrees
Fahrenheit).
NOTE: As an alternate method, the generator stator can be checked by
comparison to a new generator stator using surge comparison test set
976J552-4.
WARNING: ELECTRIC SHOCK CAN OCCUR WHEN USING A HIGH
POTENTIAL TESTER. DO NOT TOUCH EXPOSED UNINSULATED
CONNECTIONS, COMPONENTS BEING TESTED OR THE
TESTING SURFACE. PERSONNEL WORKING WITH ELECTRICITY
SHALL HAVE ANOTHER PERSON SKILLED IN MODERN
METHODS OF FIRST AID AND RESUSCITATION NEAR BY.

(2)

Tie terminals T4, T5, and T6 together and connect to insulation breakdown test set
103MP-2.5DJU, 13700-1C, 60B4-1 or 2512. Connect the frame of the stator to the
other terminal of the test set. Apply a test potential of 900 volts rms, 60 hertz,
starting from zero, at a rate not to exceed 500 volts per second, for one minute.
Reduce voltage to zero at the same rate before disconnecting.
There shall be no more than 5 milliamperes compensated current leakage
breakdown in insulation.

(3)

Remove jumper from T4, T5, and T6. Check for phase-to-phase faults by applying
900 volts rms, 60 hertz, for one minute between the phases as follows:
Terminals T1 and T2
Terminals T2 and T3
Terminals T1 and T3

(4)

Check the terminal studs (51, IPL Figure 1) for mounting looseness in the terminal
board (48).

(5)

Check for frayed, worn, or missing insulation or ties.


CHECK

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HAMILTON SUNDSTRAND
COMPONENT MAINTENANCE MANUAL
PART NUMBER 976J497 AND 976J597
(6)

Check for cracked, cut, or degraded insulation sleeves (61, 62, or 63).

CAUTION: NO WELD REPAIRS OF THE LUG HOLES IS ALLOWED. THE HEAT FROM
WELDING REDUCES THE REQUIRED STRENGTH OF THE FLANGE.
(7)

Check mounting lug holes for cracks. There shall be no more than three holes with
cracks and no two may be in lug holes next to each other (see Figure 504).

(8)

Check the inside diameter of the stator for evidence of rubs from the armature-rotor.
If present, check critical diameters (see Figure 504).

(9)

Check the mounting diameter dimension (see Figure 504) at several points around
the outside diameter. Measurements exceeding the maximum diameter indicate an
out-of-round frame.

(10) Check stator leads for cracks or breaks near to braze joint. If cracks or breaks exist,
the stator must be replaced or rewound.
(11) If the generator stator has any of the above faults, they must be corrected in
accordance with REPAIR or replaced.
NOTE: Generator stators may be rewound or have the frames replaced at the
Hamilton Sundstrand Shannon Repair Center at the following address:
Hamilton Sundstrand Shannon Repair Center
World Aviation Park
Shannon, Co. Clare
Ireland
E.

Check end bell (52, IPL Figure 1) as follows:


(1)

Visually check end bell diaphragm for bends or dents which would affect
concentricity or axial run-out.

(2)

Check for any cracks or breaks.

(3)

Check bearing insert for 2.4407 to 2.4412 in. (61.9938 to 62.0065 mm) using air
gage set. Rotate gage to check entire diameter.
NOTE: As an alternate method, use a standard micrometer to check bearing
insert, making sure to check entire diameter.

F.

Check end bell (30, IPL Figure 1) and exciter stator (27, IPL Figure 1) as follows:
NOTE: If the end bell or exciter stator assembly fails to meet any of the following checks,
disassemble and repair in accordance with REPAIR.
(1)

Push and pull exciter stator assembly to determine any axial or radial movement
with respect to the end bell. No movement shall be detected.

(2)

Check exciter stator mounting screws (28) for 45 to 55 lb-in. (5.1 to 6.2 Nm) torque.
Screws shall not move more than 1/4 turn.

(3)

Check exciter field coils for movement with respect to the field poles. Check field
poles for movement with respect to the exciter stator ring. No movement shall be
detected.
CHECK

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HAMILTON SUNDSTRAND
COMPONENT MAINTENANCE MANUAL
PART NUMBER 976J497 AND 976J597
WARNING: EPOXY RESIN IS TOXIC AND FLAMMABLE. DO NOT BREATHE
VAPORS. USE IN WELL VENTILATED AREA FREE FROM SPARKS,
FLAME OR HOT SURFACES. WEAR SPLASH GOGGLES, SOLVENTRESISTANT GLOVES AND OTHER PROTECTIVE GEAR. IN CASE OF
EYE CONTACT, FLUSH WITH WATER FOR 15 MINUTES AND SEEK
MEDICAL ATTENTION. IN CASE OF SKIN CONTACT, WASH WITH
SOAP AND WATER.
(4)

Check the condition of the epoxy coating on anti-drive end of the coils. If coating
shows signs of severe wear, refer to REPAIR.

(5)

Check exciter terminal board (20) for cracks and stripped threads.

(6)

Check bearing insert bore for 2.4407 to 2.4412 in. (61.9938 to 62.0065 mm) using
an air gage set. Rotate gage to check entire diameter.
NOTE: As an alternate method, use a standard micrometer to check bearing
insert, making sure to check entire diameter.

CHECK

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

A-67168
Generator Stator Check Criteria
Figure 504
CHECK

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HAMILTON SUNDSTRAND
COMPONENT MAINTENANCE MANUAL
PART NUMBER 976J497 AND 976J597
(7)

Check the resistance of the coils in exciter stator by placing a jumper around the
thermistor to shunt it out. The resistance between A- (black) and F (yellow), as read
on an impedance bridge TS460/u, shall be 5.0 to 6.1 ohms (for 976J497-1) and 5.6
to 6.7 ohms (for 976J597-1). With jumper removed, the resistance shall increase
slightly (1.0 to 2.0 ohms at 77 degrees Fahrenheit [25 degrees Celsius]). The
resistance of the stabilizing winding, S (red), and A- (black), shall be between 450
and 560 ohms (for 976J497-1) and 423 to 517 ohms (for 976J597-1).
NOTE: Exciter stators may be repaired at the Hamilton Sundstrand Shannon
Repair Center at the following address:
Hamilton Sundstrand Shannon Repair Center
World Aviation Park
Shannon, Co. Clare
Ireland

(8)

3.

Dielectric check excitor stator at 900 volts, rms, 60 hertz for one minute. Check from
any lead to the stator frame. Make sure no terminal is touching the frame during this
test.

Optional Checks
The optional checks may facilitate troubleshooting and repair procedures. See Figure 505 for a
schematic.
A.

Check rotor windings resistance and dielectric as follows:


(1)

Disconnect rotor winding leads (two direct current field and three alternating current
armature) from the semiconductor device set by removing the screws, washers, and
bushings (9, 10, 11, and 12, IPL Figure 3) before checking resistance or dielectric of
the windings.

A-67169
Schematic
Figure 505
CHECK

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HAMILTON SUNDSTRAND
COMPONENT MAINTENANCE MANUAL
PART NUMBER 976J497 AND 976J597
(2)

Use Electro Scientific Industries meters 1700 and 1701B or optional Kelvin Bridge
4286, and check the resistance across two direct current field leads. Resistance
shall be 0.176 to 0.214 ohms (for 976J497-1) and 0.165 to 0.201 ohms (for
976J597-1).

(3)

Using Electro Scientific Industries meters 1700 and 1701B or optional Kelvin Bridge
4286, check resistance across each pair (1 - 2, 2 - 3, 1 - 3) of three alternating
current armature leads. Phase-to-phase resistance (each pair) must be 0.057 to
0.070 ohms (for 976J497-1) and 0.052 to 0.064 ohms (for 976J597-1).

WARNING: DO NOT TOUCH THE EXPOSED UNINSULATED CONNECTIONS, THE


COMPONENTS TO BE TESTED OR THE TESTING SURFACE WHEN
YOU USE A DIELECTRIC TESTER. ELECTRIC SHOCK CAN OCCUR.
PERSONEL WORKING WITH ELECTRICITY SHALL HAVE ANOTHER
PERSON SKILLED IN MODERN METHODS OF FIRST AID AND
RESUSCITATION NEARBY.
CAUTION: BEFORE DIELECTRIC CHECK, BE SURE WINDING LEADS ARE ALL
DISCONNECTED FROM SEMICONDUCTOR DEVICE SET OR RECTIFIER
ASSEMBLY AS HIGH CURRENT MAY BURN OUT THE DIODES.
(4)

Using insulation breakdown test set 103MP-2.5DJU, 13700-1C, 60B4-1or 2512


dielectric check from direct current windings to rotor shaft. Starting from zero,
increase voltage to 900 volts, rms, 60 hertz, at a rate not to exceed 500 volts per
second, for one minute. Reduce voltage to zero at same rate before disconnecting
leads. Repeat for alternating current windings.
There shall be no more than 5 milliamperes compensated current leakage
breakdown in insulation.

B.

Check armature-rotor dynamic balance as follows:


NOTE: This check shall be performed if: stub shaft (1, IPL Figure 3), or exciter armature
(13) has been replaced; the semiconductor device set or rectifier assembly (8 or
8A) has been removed and reinstalled; or the main rotor (42, IPL Figure 1)
windings have been repaired.
(1)

Use dynamic balancing machine, Type H20B, or equivalent.

(2)

Support the rotor assembly on its bearing journals. Balance in both planes (each
end of main direct current field) using balance weights (14, 15, 16, IPL Figure 3) at a
balancing speed of 1800 revolutions per minute. Balance one plane at a time by
treating each correction plane as a single plane problem using the nearest bearing
journal for the vibration readings. The remaining unbalance limit is 0.30 ounce-inch
(216 gram-millimeter) square maximum.

CHECK

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

C.

(3)

Before inserting balance weights, clean out holes in wedges to 0.135 in. (3.429 mm)
maximum for holes numbered 1 and 6, which use weights (14, IPL Figure 3); 0.147
inch (3.773 mm) maximum for holes numbered 2 and 5, which use weights (15, IPL
Figure 3); and 0.188 inch (4.775 mm) maximum for holes numbered 3 and 4, which
use weights (16, IPL Figure 3). Weights shall not extend beyond face of wedge.
Stake balance weights across ends after insertion to prevent loosening and falling
out.

(4)

To calibrate the balancing machine, begin with a perfectly balanced rotor where no
unbalance can be measured. Add a balance weight (14, IPL Figure 3) in each
correction plane 180 degrees apart. The reading in each plane will indicate an
unbalance of 0.30 oz-in. (216 gram-millimeter) squared.

Check semiconductor device set or rectifier assembly (8 or 8A, IPL Figure 3) as follows:
NOTE: Semiconductor device set or rectifier assembly may be repaired at the Hamilton
Sundstrand Shannon Repair Center at the following address:
Hamilton Sundstrand Shannon Repair Center
World Aviation Park
Shannon, Co. Clare
Ireland
(1)

Remove the semiconductor device set (8 or -8A, IPL Figure 3) from the armaturerotor (42, IPL Figure 1) in accordance with REPAIR.

(2)

Disconnect one of the soldered connections to the capacitor.


(a)

Check the capacitance of the capacitor by connecting a Fluke 87 True RMS


Multimeter between the disconnected capacitor lead and DC - (terminal 4).
(Refer to Figure 506.)

A-67170
Semiconductor Device Set or Rectifier Assembly Electrical Connection Terminals
Figure 506
CHECK

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

(3)

(b)

The capacitor should measure 0.22 +20 percent to -10 percent microfarads.

(c)

If the capacitance is out-of-limits, move the one meter probe from the DC connection to the DC + (terminal 2) connection. If the capacitor is still out
limits, replace the capacitor.

(d)

If the capacitor checks good, then check continuity between the other side of
the unsoldered connection and the appropriate direct current terminal. (Refer
to Figure 507.)

(e)

Then leave the capacitor disconnected for the following checks.

Check forward voltage drop as follows:


(a)

Connect positive lead of the DC current supply to DC - (terminal 4).

(b)

Connect negative lead to the AC (terminal 1).

(c)

Connect the positive lead of DC voltmeter (Fluke 8026B) to DC - (terminal 4).

(d)

Connect negative lead to the AC (terminal 1).

(e)

Turn on the direct current supply and increase the current to 10.0 0.20
amperes.

CHECK

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

A-67171

A-67172
Diode Continuity Check
Figure 507

CHECK

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

Observe the voltage reading on the DC voltmeter then immediately decrease


the current to zero. The forward voltage drop should be 1.0 volts direct current
maximum.

(g)

Move the negative leads of the direct current supply and the DC voltmeter to
the AC (terminal 3). Repeat steps e and f.

(h)

Move the negative leads of the direct current supply and the DC voltmeter to
the AC (terminal 5). Repeat steps e and f.

(i)

Connect the negative lead of the direct current supply to the DC + (terminal 2),
and connect positive lead to the AC (terminal 1). Connect the negative
lead of DC voltmeter to the DC + (terminal 2) and connect positive lead to the
AC (terminal 1). Repeat steps e and f.

(4)

(j)

Move the positive leads of the direct current supply and DC voltmeter to the AC
(terminal 3). Repeat steps e and f.

(k)

Move the positive leads of the direct current supply and the DC voltmeter to the
AC (terminal 5). Repeat steps e and f.

Check reverse voltage leakage current as follows:


(a)

Connect the DC Hypot high voltage lead (positive lead) to the DC + (terminal
2), and connect the metered return lead to the AC point (terminal 1).

(b)

Connect the positive lead of DC voltmeter to the DC + (terminal 2).

(c)

Connect the negative lead to the AC (terminal 1).

(d)

Connect (safety ground) terminal to building ground.


NOTE: Leave the Bypass Return terminal and the Ground terminal unconnected.
NOTE: Follow the manufacturers operating directions to turn on and warm up
DC hypot.
WARNING: ELECTRIC SHOCK CAN OCCUR WHEN USING A VOLTMETER. DO NOT TOUCH EXPOSED UNINSULATED CONNECTIONS, COMPONENTS TO BE TESTED OR THE TESTING
SURFACE. PERSONNEL WORKING WITH ELECTRICITY
SHALL HAVE ANOTHER PERSON SKILLED IN MODERN
METHODS OF FIRST AID AND RESUSCITATION NEAR BY.
CAUTION: DO NOT APPLY MORE THAN THE SPECIFIED DC VOLTAGE TO
DIODES OR THEY MAY BE DAMAGED. DO NOT APPLY
ALTERNATING CURRENT.

(e)

With the kilovolts switch in the low position, and with the voltage control knob in
the full counterclockwise position and the current range in the 2000 A position, slowly turn the knob clockwise until the voltmeter reads 390 volts minimum to 400 volts maximum.
CHECK

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HAMILTON SUNDSTRAND
COMPONENT MAINTENANCE MANUAL
PART NUMBER 976J497 AND 976J597
NOTE: After making the voltage setting, remove the voltmeter or the leakage
current reading will be erroneously high. The voltmeter must be reconnected for each diode to check on the voltage setting, but the voltmeter must not be connected while a leakage current reading is being
taken.
(f)

Change the current range as required to obtain a leakage current reading. The
limit is 75 microamperes maximum.

(g)

Remove the voltage by turning the high voltage switch off. Do not touch the
voltage control knob.

(h)

Move the metered return lead to the AC (terminal 3), and put the current
range switch in the 2000 A position.

(i)

Turn the high voltage switch on. Change the current range as required to
obtain a leakage current reading. The limit is 75 microamperes maximum.

(j)

Turn the high voltage switch off.

(k)

Move the metered return lead to the AC (terminal 5), and put the current
range switch in the 2000 A position.

(l)

Repeat steps i and j.

(m) Move the metered return lead to the DC - (terminal 4), and move the high
voltage lead to the AC (terminal 1). Put the current range switch in the 2000
A position.

(5)

(n)

Repeat steps i and j.

(o)

Move the high voltage lead to the AC (terminal 3), and put the current range
switch in the 2000 A position.

(p)

Repeat steps i and j.

(q)

Move the high voltage lead to the AC (terminal 5), and put the current range
switch in the 2000 A position.

Repeat steps i and j. Check individual diodes before they are installed or if they are
removed for suspected defect for forward voltage drop as follows:
(a)

Connect the positive lead of the direct current supply to the anode of the diode,
and connect the negative lead to the cathode of the diode (refer to Figures 508
and 509).

CHECK

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

A-67173
Diode Polarity
Figure 508
(b)

Connect the positive lead of the DC voltmeter to the anode of the diode, and
connect the negative lead to the cathode of the diode.

(c)

Turn on the DC current supply and increase the current to 10.00 0.20
amperes.

(d)

Observe the voltage reading on the DC voltmeter, then immediately decrease


the current to zero. The forward voltage drop should be 1.0 volt direct current
maximum.

A-67174
Schematic for Checking Forward Voltage Drop Across Diode
Figure 509
CHECK

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HAMILTON SUNDSTRAND
COMPONENT MAINTENANCE MANUAL
PART NUMBER 976J497 AND 976J597
(6)

Check individual diodes before they are installed or if they are removed for suspected defect for reverse voltage leakage current as follows:
(a)

Connect the DC Hypot high voltage lead (positive lead) to the cathode of the
diode, and connect the metered return lead to the end of the diode (refer to
Figure 508 and 510).

(b)

Connect the positive lead of the DC voltmeter to the cathode of the diode, and
connect the negative lead to the anode of the diode.
NOTE: Leave the Bypass Return terminal and the Ground terminal unconnected.
NOTE: Follow the manufacturers operating instructions to turn on and warm
up DC Hypot.
WARNING: ELECTRIC SHOCK CAN OCCUR WHEN USING A VOLTMETER. DO NOT TOUCH EXPOSED UNINSULATED CONNECTIONS, COMPONENTS BEING TESTED OR THE TESTING
SURFACE. PERSONNEL WORKING WITH ELECTRICITY
SHALL HAVE ANOTHER PERSON SKILLED IN MODERN
METHODS OF FIRST AID AND RESUSCITATION NEAR BY.
CAUTION: DO NOT APPLY MORE THAN THE SPECIFIED DC VOLTAGE TO
DIODES OR THEY MAY BE DAMAGED. DO NOT APPLY
ALTERNATING CURRENT.

(c)

With the kilovolts switch in the low position, the voltage control knob in the full
counterclockwise position, and the current range in the 2000 A position,
slowly turn the knob clockwise until the voltmeter reads 390 volts minimum to
400 volts maximum.
NOTE: After making this voltage setting, remove the voltmeter or the leakage
current reading will be erroneously high.

CHECK

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

A-67175-1
Schematic for Checking Leakage Current Through Diode
Figure 510
(d)

Change the current range as required to obtain a leakage current reading. The
limit is 50 microamperes maximum.

(e)

Remove the voltage by turning the high voltage switch off.

(7)

Reconnect any leads that were disconnected.

(8)

Using the test set-up of Figure 512, run steps (a) through (c) in sequence.
NOTE: During either of the alternate tests, the three-phase alternating current
input voltages shall be balanced within one volt (line-to-neutral). Supply
cooling air to the semiconductor device set/ rectifier assembly by blowing a
minimum of 20 cubic feet per minute (9.44 liters per second) of air at room
temperature across the cooling fins of the device.
(a)

Apply 9.8 1 volt line-to-neutral (17 1 volts line-to-line) to the input terminals
of the unit under test. Measure input voltage on M1.

(b)

Close S2 and measure the direct current amperes on M2. The current shall be
between 17.9 and 22.6 amperes.

CHECK

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

Measure the unit under test output on M3. The output shall appear as shown
in Figure 513. If it appears as shown in Figure 514 or 515, one or more diodes
may be defective and the unit under test shall be rejected. For rejected units,
repeat as required steps 1 through 7.

WARNING: ELECTRIC SHOCK CAN OCCUR WHEN USING A HIGH POTENTIAL TESTER. DO NOT TOUCH EXPOSED UNINSULATED CONNECTIONS BEING TESTED OR THE TESTING SURFACE.
PERSONNEL WORKING WITH ELECTRICITY SHALL HAVE
ANOTHER PERSON SKILLED IN MODERN METHODS OF FIRST
AID AND RESUSCITATION NEAR BY.
(9)

Check the capacitor at 1000 hertz, 25 degrees Celsius (77 degrees Fahrenheit) for
0.22, -10 percent, +20 percent microfarads. Capacitor rating is 400 working volts
direct current at 85 degrees Celsius (185 degrees Fahrenheit). Refer to Figure 511
for values.

Microfarads at 1000 Hz (25 C)

Tolerance %

WVDC at 85 C

0.22

-10, +20

400

Capacitor Values
Figure 511
D.

Check end bell (30, IPL Figure 1) and exciter stator (27, IPL Figure 1) as follows:
(1)

Remove exciter stator from end bell in accordance with REPAIR.

(2)

Disassemble the thermistor (see IPL Figure 2) and check element (1). Discard if
any cracks are visible.
WARNING: ELECTRIC SHOCK CAN OCCUR WHEN USING A HIGH POTENTIAL TESTER. DO NOT TOUCH EXPOSED UNINSULATED CONNECTIONS BEING TESTED OR THE TESTING SURFACE.
PERSONNEL WORKING WITH ELECTRICITY SHALL HAVE
ANOTHER PERSON SKILLED IN MODERN METHODS OF FIRST
AID AND RESUSCITATION NEAR BY.

(3)

Connect one lead from insulation breakdown test set 103MP-2.5DJU, 13700-1C
60B4-1 or 2512 to the A- terminal and the other to the frame of the stator. Apply 600
volts rms, starting from zero, at a rate not to exceed 500 volts per second, for one
minute. Reduce voltage to zero at same rate before disconnecting.

(4)

Check the inside diameter of the exciter stator (ground surface of main poles) and
mounting tab outside diameter (see Figure 516).

(5)

Use an indicator and check the runout of the mating surface of tabs on exciter stator
in relation to bore (see Figure 516).
CHECK

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

E.

(6)

Check the inside diameter of the end bell at mounting pads (see Figure 517).

(7)

Use an indicator to check the six mounting pads in the end bell for runout. Check
from the end bell generator stator mating fit to the pads (see Figure 517).

Check Dimensions as follows:


(1)

Check the outside diameter of the main rotating field of armature-rotor (42, IPL Figure 1) for minimum diameter (see Figure 503).

(2)

Check the outside diameter of the exciter armature (13, IPL Figure 3) for minimum
diameter (see Figure 503).

(3)

Check the inside diameter of the generator stator (55, IPL Figure 1) for maximum
diameter (see Figure 504).

CHECK

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

A-67176-1
PS1 - Power Supply 1; 3-phase alternating current; 400 hertz; 20 amperes; 20 volts or 3-phase,
200/110 volt, 50 or 60 hertz stepped down with a variac to 20 volts at 20 amperes.
S1 - Switch 1, selector; 1 pole, 3 position
S2 - Switch 2, on-off; SPST
M1 - Metering 1, voltmeter; 0 to 30 alternating current root-mean-square, 400 hertz 2 percent.
M2 - Metering 2, ammeter; 0 to 30 amperes direct current 2 percent
M3 - Metering 3, oscilloscope; 10 kilohertz or better
R1 - Resistor 1, 1.0 0.1 ohms, 575 watt (minimum)
NOTE: Switch ratings to be selected for proper operation.
NOTE: The oscilloscope ground shall be isolated from the alternating current power supply ground.
NOTE: The unit under test is to be cooled by blowing a minimum of 20 cubic feet per minute (9.44
liters per second) of air at room temperature across the device.
Semiconductor Device Set or Rectifier Assembly
Figure 512
CHECK

24-20-76

Page 522
Jun 1/00

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

A-66110
Waveform for Good Semiconductor Device Set or Rectifier Assembly
Figure 513

A-66111
Waveform for Semiconductor Device Set or Rectifier Assembly
with an Open Diode or Rectifier
Figure 514

CHECK

24-20-76

Page 523
Jun 1/00

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

A-66112
Waveform for Semiconductor Device Set or Rectifier Assembly with a Short
Figure 515

CHECK

24-20-76

Page 524
Jun 1/00

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

A-67177
Exciter Stator Check Criteria
Figure 516

CHECK

24-20-76

Page 525
Jun 1/00

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

A-67178
Stator Exciter End Bell Check Criteria
Figure 517

CHECK

24-20-76

Page 526
Jun 1/00

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

General
A.

This section contains repair procedures required to return the generator assembly to serviceable condition. Replace all parts that do not meet requirements after repair. Refer to
Standard Practices Manual, 24-10-00, REPAIR, for general repair information.

NOTE: Reference to item numbers in text implies that alpha variant items listed in the IPL may
be used as determined by the effect code for that item. For example, reference to item
(1) means that procedures also apply to alpha variant items (-1A, -1B, and -1C).
B.

A list of repairs is provided in Figure 601.

C.

Materials required for repair are listed in Figure 602.


NOTE: Maintenance personnel must use the specified consumable material for the
specified task. These consumable materials are known to align with all of the
design and qualification requirements. Only approved materials engineering can
make equivalent consumable material decisions and these materials are used at
the risk of the organization who makes the decision.
NOTE: The full address and other information regarding vendors or suppliers listed in
Figure 602 can be obtained by using the World Wide Web (www) at the following
URL http://www.bpn.gov/bincs/begin_search.asp. Other CAGE Code sites are
also available on the web.

D.

Special tools, fixtures, and equipment required for repair are listed in Figure 603.
NOTE: Equivalent tools, fixtures, and equipment can be used if they align with the
requirements of ARINC Report 668.

REPAIR

24-20-76

Page 601
Feb 26/07

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

Refer to Hamilton Sundstrand Standard Practices Manual 24-10-00 for replacement of


helical inserts.
NOTE: Install helical insert (3M, IPL Figure 3) into the drive-end (smaller spline) of
generator spindle (3) with the drive tang out. Be sure to carefully remove drive
tang after helical insert is installed.
NOTE: Hamilton Sundstrand Shannon Repair Center has developed a series of
proprietary repairs for armature-rotor part numbers 915F306-1 and 915F508-1;
exciter stator part number 915F262-1 and 915F511-1; stator 915F469-1,
915F469-2, and 915F512-2; semiconductor devise set 946F177-1.
For an incoming inspection and written quote, send parts requiring repair or
rewind to:
Hamilton Sundstrand Shannon Repair Center
World Aviation Park
Shannon, Co. Clare
Ireland
For example; the rotor repair typically includes stripping, pre-wind inspection,
rewind, pre-dip inspection, varnish dip and bake, dynamic balance of complete
rotor, paint, final inspection and certification, and polyurethane foam export pack
for shipping.

2.

Repair
A.

Perform repair of components listed in Figure 601 that do not meet requirements in
CHECK according to the specified repair number.

REPAIR

24-20-76

Page 602
Feb 26/07

HAMILTON SUNDSTRAND
COMPONENT MAINTENANCE MANUAL
PART NUMBER 976J497 AND 976J597
REPAIR NO.

TITLE

DESCRIPTION

End bell and exciter stator


(13 through 35, IPL Figure
1)

Replacement of damaged or missing terminal parts (13 through 23, IPL Figure 1)

End bell and exciter stator


(13 through 35, IPL Figure
1)

Replacement of exciter stator (24 through


29A, IPL Figure 1)

End bell (30 or -30A) and


exciter stator (13 through
35, IPL Figure 1)

Replacement of bearing insert (30F),


retainer, and screws (24 through 29A, IPL
Figure 1)

Exciter stator

Replacement of thermal resistance element,


terminals, and insulation (1 through 11, IPL
Figure 2)

Armature-rotor (42, -42A, or


-42B, IPL Figure 1)

Repair or replacement of semiconductor


device set or rectifier assembly (8 or -8A, IPL
Figure 3)

Armature-rotor (42 or -42A,


IPL Figure 1)

Replacement of wound armature (9 through


13M, IPL Figure 3)

Stator terminal

Replacement of damaged or missing stator


terminal parts (43 through 51, IPL Figure 1)

Stator

Replacement of electrical terminals, insulation, screws, and helical inserts (56 through
66, IPL Figure 1)

Stator

Identification plate (-67A through 69)

10

Terminal Board (48, IPL Figure 1)

Repair of terminal block separators

11

Wound Armature (13 or


-13A, IPL Figure 3)

Wound Armature (13 or -13A, IPL Figure 3).

Repair List
Figure 601

REPAIR

24-20-76

Page 603
Feb 26/07

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

SOURCE

Resin, Scotchcast 253

3M
3M Center
St. Paul, MN 55101

Resin, Epoxy, D-163B (replacement for Resin,


Scotchcast 253)

Nu-Brite Chemical Co. Inc.


Sterling Division
CAGE Code: 78580

Lockwire, MS20995C32

Commercially Available

Chemical Film (MIL-C-5541, Class 3)

Commercially Available

Adhesive A701

Resin Technology Group, Inc.


CAGE Code: 0JVX9

Brazing Alloy (Federal Specification QQ-B-654,


Grade III)

Commercially Available

Pure Tin Solder and Flux, (Military Specification


MIL-F-14256, Type A) (99.75% Pure Tin)

Commercially Available

Sealer, Glyptal 1201EW

Brownell Electro, Inc.


Subsidiary of Avnet Inc.
CAGE Code: 2Y601

Lacing Tape 0.015 by 0.125 inch (0.381 by 3.175 mm)


and
0.010 by 0.048 inch (0.254 by 1.219 mm)

Arkins and Pearce Mfg. Co.


537 East Pearl Street
Cincinnati, Ohio 45202

Silicone Rubber Sealant (Military Specification


MIL-L-46106, Type I)

Commercially Available

Commercial Tape (Military Specification MIL-Y-1140,


Type ECC-A, Form 5, 450 Yarn)
0.007 x 0.500 inch (0.177 x 12.700 mm)

Commercially Available

Oil, Lubricating (Military Specification MIL-L-46014,


Type II)

British Petroleum Oil Co.


CAGE Code: 0D3L4

Silver Solder (Federal Specification QQ-S-571,


Type Sn96Ag04WRMAP3)

Commercially Available

Dry Ice

Commercially Available
Repair Materials
Figure 602 (Sheet 1 of 2)
REPAIR

24-20-76

Page 604
Feb 26/07

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

SOURCE

Zinc Chromate Primer (Military Specification


MIL-P-15328)

Commercially Available

Brazing Rod (Military Specification MIL-B-7883)


Alloy QQ-B-654, CL BCUP-5

Commercially Available

Alcohol, Isopropyl (Federal Specification ASTM-D770)

Commercially Available

Insulation Sleeving, (Military Specification


MIL-I-23053, Class 1) 0.187 inch minimum I.D., Black

Commercially Available

P/N M23053/6-105-0
Fluoropolymer-Insulated Electrical Wire (Military
Specification MIL-W-22759) Black
P/N M22759/7-12-0
Epoxide Resin, available from the following:
Shell Epon 828 or 8280

Commercially Available

Shell Chemical Company


A Division of Shell Oil Co.
CAGE Code: 86961

Araldite 6010 or GY2600

Ciba-Geigy Corp.
CAGE Code: 5S850

DER 331

Dow Corning Corporation


CAGE Code: 71984

Reactive Polyamide Resin, Versamid 125

Henkel Corp., Polymers Div.


CAGE Code: 1U766

Repair Materials
Figure 602 (Sheet 2 of 2)
TOOL NUMBER

DESCRIPTION

Type 12-062 or 12-064

Brazing Set

909C499-1

Curing Fixture

928A903-3

Adapter Set

Special Tools, Fixtures, and Equipment


Figure 603
REPAIR

24-20-76

Page 605
Feb 26/07

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

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

2.

A.

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

B.

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

C.

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

D.

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

Assembly
A.

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

B.

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

C.

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

D.

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

E.

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

F.

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

Replacement of Damaged or Missing Exciter


Stator Terminal Parts

24-20-76

REPAIR
Repair No. 1
Page 601
Jun 1/00

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

Disassembly
A.

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

B.

Push the three exciter stator leads through grommet (24) to the inside of end bell (30 or
-30A).
WARNING: WEAR GOGGLES WHEN REMOVING LOCKWIRE.

C.

Cut and remove lockwire from screws (28).

D.

Remove screws (28) and washers (29).


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

E.
2.

Heat unit to 93 to 121 degrees Celsius (200 to 250 degrees Fahrenheit) to help remove
exciter stator (27 or -27A) from end bell (30 or -30A).

Assembly
WARNING: PRIMER IS TOXIC AND FLAMMABLE. DO NOT BREATHE VAPORS.
USE IN WELL VENTILATED AREA FREE FROM SPARKS OR FLAME. IN
CASE OF EYE CONTACT, FLUSH WITH WATER FOR 15 MINUTES AND
SEEK MEDICAL ATTENTION. IN CASE OF SKIN CONTACT, WASH WITH
SOAP AND WATER.
A.

If the zinc chromate primer on the inside diameter has been worn away or removed, apply
a coating of primer as follows:
NOTE: Quantity of primer to be mixed should be determined by how much will be used
under the either of the following conditions. If the temperature is under 32
degrees Celsius (90 degrees Fahrenheit) the primer must be used within 4 hours.
If the temperature is above 32 degrees Celsius the primer must be used within 2
hours.
(1)

Clean the exciter stator in accordance with CLEANING.

(2)

Mask areas that are not to be coated.

(3)

Obtain 4 parts by volume of the resin component, 1 part by volume of the acid component, and 2 parts alcohol.

(4)

Stir the resin component thoroughly.

NOTE: The acid component is not a thinner, it is a necessary activator and must be used
in exact proportions indicated above.
(5)

Then slowly add the acid component while stirring.

(6)

Then slowly add the alcohol while stirring.

(7)

Spray a thin film of primer on surfaces shown. The film should be 0.0003 to 0.0005
in. (0.0076 to 0.0127 mm) thick when dry.
Repair or Replacement of End Bell Components
(Sheet 1 of 5)

24-20-76

REPAIR
Repair No. 2
Page 601
Jun 1/00

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

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

(9)

Remove masking materials.

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

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

C.

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

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

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

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

(3)

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

(4)

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

(5)

Stir the Epoxy Resin thoroughly before applying it.


NOTE: Apply resin to anti-drive end of coils only. The other coils do not get coated.

D.

(6)

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

(7)

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

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

24-20-76

REPAIR
Repair No. 2
Page 602
Jun 1/00

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

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

(2)

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

(3)

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

E.

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

F.

Insert exciter stator leads through the grommet.

G.

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

Repair or Replacement of End Bell Components


(Sheet 3 of 5)

24-20-76

REPAIR
Repair No. 2
Page 603
Jun 1/00

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

A-67983-1

Repair or Replacement of End Bell Components


(Sheet 4 of 5)

24-20-76

REPAIR
Repair No. 2
Page 604
Jun 1/00

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

A-67984-1

Repair or Replacement of End Bell Components


(Sheet 5 of 5)

24-20-76

REPAIR
Repair No. 2
Page 605
Jun 1/00

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

Disassembly
A.

Place end bell (30 or -30A) in an oven for one hour at 175 5 degrees Celsius (350 10
degrees Fahrenheit).
WARNING: WEAR INSULATED GLOVES AND OTHER SUITABLE PROTECTION
WHEN HANDLING HEATED OR COOLED PARTS.

B.
2.

Remove end bell (30 or -30A) from oven and press out bearing insert (30F).

Assembly
A.

Install new bearing insert (30F) in accordance with the following instructions:
(1)

Place end bell (30 or -30A) in an oven for 1 hour at 175 5 degrees Celsius (350
100 degrees Fahrenheit).
NOTE: The bearing insert can be cooled with dry ice or a deep freeze unit to help
with assembly.

3.

(2)

Press bearing insert (30F) into end bell (30 or -30A) until it is seated tight against the
end bell rib areas.

(3)

Check that a 0.003 in. (0.076 mm) feeler gage can not enter between bearing insert
flange and end bell at any rib areas.

(4)

Hold insert in place under pressure a minimum of 30 seconds.

(5)

Allow end bell to cool for a minimum of 1 hour at -50 5 degrees Celsius (-60 10
degrees Fahrenheit) before machining to stabilize steel contraction and expansion.

Machining Procedure
A.

Finish machine inside diameter of bearing insert in accordance with dimensions.

B.

Drill six holes in bearing insert in accordance with dimensions.

C.

Penetrant check.

D.

Clean thoroughly.

E.

Check according to notes and dimensions.

F.

After machining, touch up nicks and scratches on surface of end bell with chemical film
(MIL-C-5541, Class 3).

Replacement of Bearing Insert


(30F, IPL Figure 1)
Sheet 1 of 3)

24-20-76

REPAIR
Repair No. 3
Page 601
Jun 1/00

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

A-67181

Replacement of Bearing Insert


(30F, IPL Figure 1)
(Sheet 2 of 3)

24-20-76

REPAIR
Repair No. 3
Page 602
Jun 1/00

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

A-67182

Replacement of Bearing Insert


(30F, IPL Figure 1)
(Sheet 3 of 3)

24-20-76

REPAIR
Repair No. 3
Page 603
Jun 1/00

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

2.

Disassembly
A.

Remove screw (2, IPL Figure 2), spring tension washer (3), washer (4), insulator washer
(5), terminal lug (6), flat washer (7), thermal resistance element (1), terminal lug (6), and
insulator washer (5).

B.

Check the condition of terminal lugs (6, 9, and 11) and insulation sleeves (10). Replace if
damaged or loose.

Assembly
A.

If damaged or missing replace insulation sleeves (10). Terminal lugs (6, 9, and 11) must
be tightly crimped to retain them on the appropriate lead.
NOTE: It may be desirable to install terminal lugs (11) after the exciter stator has been
installed in the end bell.

B.

Install insulation bushing (8), insulator washer (5), black lead terminal lug (6), flat washer
(7), thermal resistance element (1), flat washer (7), terminal lug (6), insulator washer (5),
washer (4), spring tension washer (3), and screw (2).
WARNING: WEAR INSULATED GLOVES AND OTHER SUITABLE PROTECTION
WHEN HANDLING HEATED PARTS.

C.

Place terminal lugs (6) as shown. Be sure necessary clearance between terminal lugs (6)
and terminal lugs (9) exist and braze the lugs together. Torque screw (2) 12 to 14 lb-in.
(1.4 to 1.5 Nm).

Repair of Replacement of Exciter Stator Components


(Sheet 1 of 3)

24-20-76

REPAIR
Repair No. 4
Page 601
Jun 1/00

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

A-67985-1
Repair of Replacement of Exciter Stator Components
(Sheet 2 of 3)

24-20-76

REPAIR
Repair No. 4
Page 602
Jun 1/00

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

A-67986-1
Repair of Replacement of Exciter Stator Components
(Sheet 3 of 3)

24-20-76

REPAIR
Repair No. 4
Page 603
Jun 1/00

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

Disassembly
NOTE: Original 915F199-1 is a cemented assembly without a snap ring (1, IPL Figure 4). If
repair is required, modify to 946F177-1 in accordance with Service Bulletin 71-103.
NOTE: Due to the complexity and the special equipment and tooling required to repair
Semiconductor Device Set 949F283-1, it is recommended that repair of this item be
accomplished by the Hamilton Sundstrand Shannon Repair Center.
A.

Remove screws (9, IPL Figure 3), washers (10), and bushings (11 and 12).

B.

Disconnect rotor winding leads (two DC field and three AC armature leads) from the
semiconductor device set.

C.

Lightly tap the semiconductor device set (8) out of the armature-rotor shaft with a 3/4 inch
(19 millimeter) diameter phenolic rod and a soft-faced mallet.

D.

To remove assembled items (4 through -15F, IPL Figure 4) from insulating tube (18)
proceed as follows:
(1)

Cut the lacing tape holding capacitor leads to capacitor fixture (15) and unsolder the
capacitor connections.

(2)

Remove retaining ring (1) and spacer (2).


NOTE: It may be necessary to use a sharp pointed instrument to cut holding
material for spacer (2).

(3)

Remove assembled items (4 through -15F) from insulating tube (18).

E.

Remove lead connections to bus ring tube (3) using brazing set, Type 12-062 or 12-064,
to heat the brazed joint.

F.

Remove diodes (4 and 5) and holders (8) can be removed from bus ring tube (3).

G.

Remove nuts (6), washers (7), and diodes (4 or 5).


NOTE: The diodes are numbered consecutively from 1 to 6 beginning at the capacitor
end.

H.

To remove the lead from a diode, drill out rivet (13) with a Number 35 drill.

Semiconductor Device Set


(Sheet 1 of 5)

24-20-76

REPAIR
Repair No. 5
Page 601
Feb 26/07

HAMILTON SUNDSTRAND
COMPONENT MAINTENANCE MANUAL
PART NUMBER 976J497 AND 976J597
2.

Assembly
CAUTION: TO PREVENT DAMAGE TO THE DIODE WHEN RIVETING, HOLD DIODE BY
RIVET TERMINAL NOT BY THE CASE.
A.

If missing or damaged, attach new leads (9 through 12) to diodes (4 and 5) using rivets
(13) and spring washers (14)

B.

Install diodes (4 or 5) in holder (8) and attach with washer (7) and nut (6). Torque nut 25 to
30 lb-in. (2.9 to 3.3 Nm).

C.

Bend terminal of bus ring tube as shown in illustration. This is to provide clearance
between lead wires and insulating tube (3), also provide clearance with spacer (2).
WARNING: WEAR INSULATED GLOVES AND OTHER SUITABLE PROTECTION
WHEN HANDLING HEATED PARTS.

D.

Braze the diode leads to bus ring tube (3) using brazing set, Type 12-062 or 12-064.
Braze in accordance with Military Standard MIL-B-7883. Hold the assembly with diode
position 6 at the end near you and with the split in bus ring tube (3 or -3A) at the twelve
o'clock position (refer to illustrations) connect leads as follows:
NOTE: Diodes in positions 1, 2, and 3 have black leads and connect to the bus tabs closest to the capacitor end. Diodes in positions 4, 5, and 6 have white leads and
connect to the bus tabs farthest from the capacitor end. Diodes in positions 1 and
4 have two leads, the smaller lead is for connection to the capacitor.
(1)

Braze larger lead from diode in position 4 to the terminal at twelve o'clock position
on the near end of bus ring tube (3 or -3A).

(2)

Braze larger lead from diode in position 1 to the terminal at twelve o'clock position
on the far end of bus ring tube (3 or -3A).

(3)

Braze lead from diode in position 5 to the terminal at four o'clock position on the
near end of bus ring tube (3 or -3A).

(4)

Braze lead from diode in position 2 to the terminal at four o'clock position on the far
end of bus ring tube (3 or -3A).

(5)

Braze lead from diode in position 6 to the terminal at eight o'clock position on the
near end of bus ring tube (3 or -3A).

(6)

Braze lead from diode in position 3 to the terminal at eight o'clock position on the far
end of bus ring tube (3 or -3A).

(7)

Perform a continuity check for proper diode polarity and/or shorts.

Semiconductor Device Set


(Sheet 2 of 5)

24-20-76

REPAIR
Repair No. 5
Page 602
Jun 1/00

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

If necessary to replace ring (16), capacitor fixture (15), or insulating tube (18), bond as follows:
WARNING: ADHESIVE, STRUCTURAL, IS TOXIC. USE IN WELL-VENTILATED AREA.
PREVENT EYE AND SKIN CONTACT AND DO NOT BREATHE VAPORS.
IN CASE OF EYE CONTACT, FLUSH WITH WATER FOR 15 MINUTES
AND SEEK MEDICAL ATTENTION. IN CASE OF SKIN CONTACT, WASH
WITH SOAP AND WATER.
(1)

Apply adhesive A701 to ring (16) and capacitor fixture (15) to insulating tube (18).

(2)

Install parts in curing fixture 909C499-1.

(3)

At the capacitor end, bond insulating tube (18) to capacitor fixture (15) at the 0.12 in.
(3.04 mm) diameter holes in the tube.

(4)

No adhesive is to extend above the outside diameter of the tube. The diameter of
the ring, tube, and capacitor must be concentric within 0.020 in. (0.508 mm) total
indicated reading (See flag note 1 of illustration).

WARNING: PUT ON THERMALLY INSULATED GLOVES AND OTHER SUITABLE


PROTECTION TO PREVENT BURNS WHEN LOADING PARTS INTO A
PREHEATED OVEN OR HANDLING HEATED OR CHILLED PARTS.
(5)

Cure adhesive at 150 degrees Celsius (300 degrees Fahrenheit) for 6 hours.

F.

Install assembled parts (4 through -15F) into insulating tube (18), aligning five swage nuts
of bus ring tube (3) and holders (8) with five 0.496 to 0.510 in. (12.598 to 12.954 mm)
holes in insulating tube (18).

G.

Install insulation sleeve (-15F) over capacitor leads.

H.

Solder capacitor leads in accordance with Military Standard MIL-S-6872 using pure tin
solder.

I.

Slide sleeving (-15F) over connection and tie to leg of capacitor fixture (15) with lacing
tape (0.015 by 0.125 in. [0.381 by 3.175 mm]). Leads must not protrude outside capacitor
holder leg more than 0.06 in. (1.52 mm).

WARNING: ENAMEL IS TOXIC AND FLAMMABLE. DO NOT BREATHE VAPORS. USE IN


WELL-VENTILATED AREA FREE FROM SPARKS, FLAME, OR HOT
SURFACES. PUT ON SPLASH GOGGLES, SOLVENT-RESISTANT GLOVES,
AND OTHER PROTECTIVE GEAR. IN CASE OF EYE CONTACT, FLUSH WITH
WATER FOR 15 MINUTES AND SEEK MEDICAL ATTENTION. IN CASE OF
SKIN CONTACT, WASH WITH SOAP AND WATER.
J.

Apply a coating of Glyptal 1201EW Sealer over the taped connection.

Semiconductor Device Set


(Sheet 3 of 5)

24-20-76

REPAIR
Repair No. 5
Page 603
Feb 26/07

HAMILTON SUNDSTRAND
COMPONENT MAINTENANCE MANUAL
PART NUMBER 976J497 AND 976J597
CAUTION: DO NOT ROUTE ANY LEAD DIRECTLY UNDER A SWAGE NUT OR
AGAINST THE HEX BASE OF A DIODE BECAUSE THE LEAD MAY FRAY
AND SHORT IN SERVICE.
K.

Where capacitor leads must pass by a swage nut, bond the lead to the holder with a small
amount of silicone rubber sealant.

L.

Bond holders (8) to insulating tube (18) in locations and lengths shown in illustration

M.

Temporarily insert spacer (2) and retaining ring (1). The spacer must be tight against
holder (8) when retaining ring is in place.

N.

Remove retaining ring (1) and spacer (3).

O.

Place a small amount of silicone rubber sealant to spacer (2) in three equally spaced
places. Install spacer (2) and retaining ring (1).

P.

Check repaired semiconductor device set in accordance with CHECK.

Q.

Assemble semiconductor device set (8, IPL Figure 3) into armature-rotor shaft by pressing
on metal end ring until the holes in the semiconductor device set or rectifier assembly line
up with the holes in the shaft.

R.

Install bushings (11 and 12) washers (10), and screws (9).

S.

Shape lead from the exciter armature to be under the end turns of the exciter armature
before tightening screws (9). Torque screws 15 to 17 lb-in. (1.7 to 1.9 Nm). Be sure
screws are fully seated, check for clearance with a 0.001 in. (0.025 mm) feeler gauge.

WARNING: ENAMEL IS TOXIC AND FLAMMABLE. DO NOT BREATHE VAPORS. USE IN


WELL-VENTILATED AREA FREE FROM SPARKS, FLAME, OR HOT
SURFACES. PUT ON SPLASH GOGGLES, SOLVENT-RESISTANT GLOVES,
AND OTHER PROTECTIVE GEAR. IN CASE OF EYE CONTACT, FLUSH WITH
WATER FOR 15 MINUTES AND SEEK MEDICAL ATTENTION. IN CASE OF
SKIN CONTACT, WASH WITH SOAP AND WATER.
T.
3.

Tie leads from AC Generator rotating field to shaft using commercial tape, 0.007 x 0.500
in. (0.177 x 12.700 mm). Coat tape with Glyptal 1201EW Sealer.

After complete assembly of the rotor-armature, perform a dynamic balance in accordance with
CHECK.

Semiconductor Device Set


(Sheet 4 of 5)

24-20-76

REPAIR
Repair No. 5
Page 604
Feb 26/07

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

A-67186

Semiconductor Device Set


(Sheet 5 of 5)

24-20-76

REPAIR
Repair No. 5
Page 605
Jun 1/00

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

Disassembly
A.

To remove wound armature (13 or -13A), disconnect the armature-rotor leads in accordance with CHECK.

B.

Use adapter set 928A903-3, to press off wound armature (13 or -13A)as follows:
NOTE: The adapter set contains a base support, adapter plate, and press adapter to
facilitate exciter removal.

2.

(1)

Place base support 944B450-2, on an arbor press and place padding in the bottom
to protect the armature-rotor.

(2)

Place armature-rotor (IPL Figure 3)into base support with drive end down.

(3)

Lift the armature-rotor out of the base support high enough to slide adapter
944B451-2 between the exciter winding and the main alternating current winding.
The armature-rotor will now rest on the base support and the adapter.

(4)

Place press adapter 909C497-1, on anti-drive end of armature-rotor and press off
wound armature (13 or -13A).

Assembly
CAUTION: DO NOT INTERCHANGE WOUND ARMATURE (EXCITER) OF GENERATOR
976J598-1 (CUBEX STEEL) WITH PARTS OF ANY OTHER GENERATORS COVERED IN THIS MANUAL (REFERENCE SERVICE NEWS LETTER 45). THE
CUBEX PARTS ARE SHORTER IN LENGTH THAN THE OTHER PARTS AND
THIS DIFFERENCE IN LENGTH CAUSES CIRCULATING CURRENTS IN THE
ROTOR BANDS THAT RESULT IN OVERHEATING THAT CAN DAMAGE THE
GENERATOR.
A.

Use adapter set 928A903-3, to assemble wound armature (13 or -13A) on armature- rotor
shaft as follows:
NOTE: The adapter set contains a base support and a press adapter to facilitate wound
armature (13 or -13A) installation.
(1)

Place armature-rotor on base support 909C498-1, with drive end towards support.
CAUTION: DO NOT INTERCHANGE WOUND ARMATURE (EXCITER) OF GENERATOR 976J598-1 (CUBEX STEEL) WITH PARTS OF ANY OTHER
GENERATORS COVERED IN THIS MANUAL (REFERENCE SERVICE
NEWS LETTER 45). THE CUBEX PARTS ARE SHORTER IN LENGTH
THAN THE OTHER PARTS AND THIS DIFFERENCE IN LENGTH
CAUSES CIRCULATING CURRENTS IN THE ROTOR BANDS THAT
RESULT IN OVERHEATING THAT CAN DAMAGE THE GENERATOR.

(2)

Heat wound armature (13 or -13A) to 160 10 degrees Celsius (325 25 degrees
Fahrenheit).
Wound Armature Replacement
(Sheet 1 of 2)

24-20-76

REPAIR
Repair No. 6
Page 601
Jun 1/00

HAMILTON SUNDSTRAND
COMPONENT MAINTENANCE MANUAL
PART NUMBER 976J497 AND 976J597
WARNING: WEAR INSULATED GLOVES AND OTHER SUITABLE PROTECTION WHEN HANDLING HEATED PARTS.
CAUTION: BE SURE ADAPTER IS PRESSING ON THE STEEL CORE WHEN
PRESSING ON THE WOUND ARMATURE.
(3)

Set wound armature (13 or -13A) on shaft while it is still hot, aligning the three leads
with the three terminal connection points. Press the wound armature onto the shaft
with press adapter 962C206-1, until it bottoms against the shoulder of the armaturerotor shaft.

(4)

Grind outside diameter of wound armature to 3.850 to 3.854 in. (97.790 to 97.890
mm). Maximum run out of cores must be within 0.002 in. (0.050 mm) total indicated
reading from the bearing journals.
WARNING: ZINC CHROMATE PRIMER IS TOXIC AND FLAMMABLE. DO NOT
BREATHE VAPORS. USE IN WELL VENTILATED AREA FREE
FROM SPARKS, FLAME OR HOT SURFACES. WEAR SPLASH
GOGGLES, SOLVENT RESISTANT GLOVES AND OTHER PROTECTIVE GEAR. IN CASE OF EYE CONTACT, FLUSH WITH
WATER FOR 15 MINUTES AND SEEK MEDICAL ATTENTION. IN
CASE OF SKIN CONTACT, WASH WITH SOAP AND WATER.

(5)

After grinding wound armature (13), apply one coat of MIL-P-15328 (zinc chromate
primer finish) to the outside diameter. The outside diameter shall not exceed 3.855
in. (97.917 mm) diameter after application. Over spray is permissible on all areas
except bearing journals.

(6)

Install items (9 through 12, IPL Figure 3) in accordance with Repair 6.

(7)

Check armature-rotor balance in accordance with CHECK.

Wound Armature Replacement


(Sheet 2 of 2)

24-20-76

REPAIR
Repair No. 6
Page 602
Jun 1/00

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

Disassembly
A.

Remove terminal board cover (43, IPL Figure 1).

B.

Remove screws (49) and washers (50).

C.

Remove self-locking nuts (44), lock washers (45), flat washers (46), and square shouldered washers (47) from any stud (51) that is to be removed.
NOTE: The studs are assembled from the underside of the terminal board and the stud
heads are bonded in place (on underside only).
WARNING: WEAR INSULATED GLOVES AND OTHER SUITABLE PROTECTION
WHEN HANDLING HEATED PARTS.

D.

2.

To replace a stud (51), heat the terminal board at 150 degrees Celsius (300 degrees Fahrenheit) until the bonding material is soft and the stud can be pressed out of the terminal
board.

Assembly
A.

Apply A701 adhesive around head of stud (51), completely covering the head. The
threads must be free of any adhesive.
WARNING: WEAR INSULATED GLOVES AND OTHER SUITABLE PROTECTION
WHEN HANDLING HEATED PARTS.
NOTE: Parts may be preheated to 65 degrees Celsius (150 degrees Fahrenheit) to aid
the flow of adhesive.

B. Install stud (51) through the bottom of terminal board (48 or -48A).
WARNING: WEAR INSULATED GLOVES AND OTHER SUITABLE PROTECTION
WHEN HANDLING HEATED PARTS.
C.

Cure by baking at 150 degrees Celsius (300 degrees Fahrenheit) for 6 hours.

D.

After the assembly has cooled, check that studs (51) are securely bonded into terminal
board (48).

E.

Install square shouldered washers (47), flat washers (46), lock washers (45), and selflocking nuts (44) on stud (51). Do not torque self-locking screws, they are tightened after
either test leads or aircraft leads are installed.
NOTE: Screws attaching terminal board have lockwire holes, but do not need to be wired
since they go into self-locking helical inserts.

F.

Install terminal board (48) on generator stator (55) with washers (50) and screws (49).
Torque screws 30 to 36 lb-in. (3.4 to 4.0 Nm).
Repair of Stator Terminal

24-20-76

REPAIR
Repair No. 7
Page 601
Jun 1/00

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

2.

Disassembly
WARNING: WEAR INSULATED GLOVES AND OTHER SUITABLE PROTECTION WHEN
HANDLING HEATED PARTS.
A. Using localized heat (refer to Hamilton Sundstrand Standard Practices Manual 24-10-00)
disconnect brazed lead from any defective terminal (56 through 60, IPL Figure 1).
B. Remove terminal and insulating sleeve (61 through 63)
Assembly
A. Install the appropriate insulation sleeve (61 through 63) for the the terminal (56 through
60) that is being replaced.
B. Install terminal in stator (55) to the height and clearance shown. For terminal T4, bend the
terminal as shown to provide later assembly clearance.
WARNING: WEAR INSULATED GLOVES AND OTHER SUITABLE PROTECTION
WHEN HANDLING HEATED PARTS.
C. Braze lead to terminal lug in accordance with Military Standard MIL-B-7883.
WARNING: PRIMER IS TOXIC AND FLAMMABLE. DO NOT BREATHE VAPORS.
USE IN WELL-VENTILATED AREA FREE FROM SPARKS, FLAME, OR
HOT SURFACES. WEAR SPLASH GOGGLES, SOLVENT-RESISTANT
GLOVES, AND OTHER PROTECTIVE GEAR. IN CASE OF EYE CONTACT, FLUSH WITH WATER FOR 15 MINUTES AND SEEK MEDICAL
ATTENTION. IN CASE OF SKIN CONTACT, WASH WITH SOAP AND
WATER.
D. If the primer on the inside diameter has been worn away or removed, apply a 0.001 to
0.003 in. (0.025 to 0.076 mm) thick coating of primer. Do not exceed the minimum inside
clearance requirement shown.
E. If damaged or missing, replace helical inserts (64 and 65) in accordance with Hamilton
Sundstrand Standard Practices Manual 24-10-00.
F.
If damaged or missing, replace screw (66) as follows:
(1) Using an 82 degree countersink remove any burrs from old staking of the screw.
(2) Lubricate screw threads with lubricating oil and install screw. Torque screw to 140
lb-in. (15.9 Nm).
(3) Stake the screw so that a minimum of 0.016 in. (0.406 mm) of stator housing material is displaced into the screw slot.
WARNING: CHEMICAL CONVERSION COATING IS CORROSIVE TO HUMAN TISSUE. DO NOT BREATHE VAPORS. USE IN WELL-VENTILATED AREA.
WEAR SPLASH GOGGLES, SOLVENT-RESISTANT GLOVES, AND
OTHER PROTECTIVE GEAR. IN CASE OF EYE CONTACT, FLUSH WITH
WATER FOR 15 MINUTES AND SEEK MEDICAL ATTENTION. IN CASE
OF SKIN CONTACT, WASH WITH SOAP AND WATER. RINSE APPLICATOR WITH WATER BEFORE DISPOSAL. THE COATING RESIDUE
MAYBE EASILY IGNITED WHEN DRY.
G. Touch up any bare or scratched metal by applying chemical conversion coating in accordance with MIL-C-5541, Class 3.
Repair of Stator
(Sheet 1 of 2)

24-20-76

REPAIR
Repair No. 8
Page 601
Jun 1/00

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

A-67187
Repair of Stator
(Sheet 2 of 2)

24-20-76

REPAIR
Repair No. 8
Page 602
Jun 1/00

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

2.

Disassembly
A.

Remove screws (68), washers (69), and identification plate (67).

B.

Mark the new identification plate (-67A) with all information such as serial number using
either steel stamps or vibro-etch method.

Assembly
A.

Lubricate threads of screws (68) with lubricating oil.

B.

Install identification plate (-67A), washers (69), and screws (68). Torque screws 4 to 5 lbin. (0.4 to 0.5 Nm).

Replacement of Identification Plate

24-20-76

REPAIR
Repair No. 9
Page 601
Jun 1/00

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

A-69060

Repair of Terminal Block Separators


(Sheet 1 of 2)

24-20-76

REPAIR
Repair No. 10
Page 601
Jun 1/00

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

Repair terminal block separators as follows:


WARNING: ISOPROPYL ALCOHOL IS TOXIC AND FLAMMABLE. DO NOT BREATHE
VAPORS. USE IN WELL VENTILATED AREA FREE FROM SPARKS, FLAME,
OR HOT SURFACES. WEAR SPLASH GOGGLES, SOLVENT-RESISTANT
GLOVES, AND OTHER PROTECTIVE GEAR. IN CASE OF EYE CONTACT,
FLUSH WITH WATER FOR 15 MINUTES AND SEEK MEDICAL ATTENTION. IN
CASE OF SKIN CONTACT, WASH WITH SOAP AND WATER.
NOTE: The following procedure can only be used on the separators of the terminal block. The
base of the rib must be intact. Broken sections and chips can be bonded to the separator. Missing pieces with an area of 0.3 square inch (193.5 mm) or less each can be
built up to the original contour.
A.

If necessary, remove any glossy or shiny finish from the terminal block separators with fine
sandpaper. Clean the terminal block with isopropyl alcohol to remove dirt, grease, and oil.
Allow the part to dry.
WARNING: REACTIVE POLYAMIDE RESIN AND EPOXIDE RESIN ARE TOXIC AND
FLAMMABLE. DO NOT BREATHE VAPORS. USE IN WELL VENTILATED
AREA FREE FROM SPARKS, FLAME, OR HOT SURFACES. WEAR
SPLASH GOGGLES, SOLVENT-RESISTANT GLOVES, AND OTHER PROTECTIVE GEAR. IN CASE OF EYE CONTACT, FLUSH WITH WATER FOR
15 MINUTES AND SEEK MEDICAL ATTENTION. IN CASE OF SKIN CONTACT, WASH WITH SOAP AND WATER.

B.

Mix 30 parts by weight of Reactive Polyamide Resin with 70 parts by weight of epoxide
resin. Stir the mixture gently until the color is uniform.
NOTE: The pot life of the mixture is approximately 30 minutes.

C.

Apply the epoxy mixture with a brush or spatula as necessary to seal cracks, bond broken
pieces, or build up the separator to the original contour.
WARNING: WEAR INSULATED GLOVES AND OTHER SUITABLE PROTECTION
WHEN HANDLING HEATED PARTS.

D.

Cure the terminal block in an oven at 149 15 degrees Fahrenheit (65 8 degrees Celsius) for 2 hours minimum, or at 176 15 degrees Fahrenheit (80 8 degrees Celsius) for
30 minutes minimum.
NOTE: Cure time begins after the part reaches oven temperature.

E.

Check (refer to the view).

F.

If necessary, use sandpaper to restore the contour of the repaired area.

Repair of Terminal Block Separators


(Sheet 2 of 2)

24-20-76

REPAIR
Repair No. 10
Page 602
Jun 1/00

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

A-71618

Wound Armature Lead Wire Repair


(Sheet 1 of 3)

24-20-76

REPAIR
Repair No. 11
Page 601
Jun 1/00

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

Remove wound armature (13 or -13A) in accordance with Repair No. 7.

2.

Locate broken lead and cut it as close as possible to the break.


NOTE: There must be a minimum of 1 in. (25.4 mm) of lead extending from wound armature
(13 or -13A). Also allow a minimum of 1 in. (25.4 mm) length of new lead.

3.

Strip insulation from existing lead to dimension shown in accordance with Hamilton Sundstrand
Standard Practice Manual, 24-10-00, repair number SP R9.

4.

Prepare the replacement lead to achieve the total lead length shown.

5.

Strip insulation from both ends of the new lead to dimension shown in accordance with
Hamilton Sundstrand Standard Practice Manual, 24-10-00, repair number SP R9.
WARNING: ISOPROPYL ALCOHOL IS TOXIC AND FLAMMABLE. DO NOT BREATHE
VAPORS. USE IN WELL VENTILATED AREA FREE FROM SPARKS, FLAME
OR HOT SURFACES. WEAR SPLASH GOGGLES, SOLVENT-RESISTANT
GLOVES, AND OTHER PROTECTIVE GEAR. IN CASE OF EYE CONTACT,
FLUSH WITH WATER FOR 15 MINUTES AND SEEK MEDICAL ATTENTION.
IN CASE OF SKIN CONTACT, WASH WITH SOAP AND WATER.

6.

Clean bare wires with cotton swabs soaked with isopropyl alcohol and allow to air-dry.
CAUTION: WEAR CLEAN GLOVES TO HANDLE THE CLEANED WIRE. DO NOT TOUCH
THE CLEANED WIRES WITH BARE SKIN AS OILS IN THE SKIN MAY WEAKEN
THE BRAZED OR SILVER SOLDERED JOINT.

7.

Clamp the bare wire of the new lead to the bare wire of the existing lead.

8.

Verify the length of the combined leads will meet the dimension shown.
WARNING: WEAR INSULATED GLOVES AND OTHER SUITABLE PROTECTION WHEN
HANDLING HEATED PARTS.

9.

Braze the wires together in accordance with Military Specification MIL-B-7883 or silver solder in
accordance with Hamilton Sundstrand Standard Practices Manual, 24-10-00, repair number SP
R10.

10. Install an appropriate length of insulation sleeving (heat shrink tubing) over the solder joint and
shrink tubing using a heat gun at 230 to 275 degrees Fahrenheit (110 to 135 degrees Celcius)
for approximately 10 seconds until the sleeving is snug.
11. Install lug terminal (13M, IPL Figure 3) and crimp onto the lead wire using appropriate crimping
tool.
12. If the tape used to secure the lead where it exits the coil has been removed or damaged, apply
new adhesive glass tape as shown.
Wound Armature Lead Wire Repair
(Sheet 2 of 3)

24-20-76

REPAIR
Repair No. 11
Page 602
Jun 1/00

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

Wound Armature Lead Wire Repair


(Sheet 3 of 3)

24-20-76

REPAIR
Repair No. 11
Page 603
Jun 1/00

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

General
A.

This section contains assembly procedures. When necessary, assembly illustrations are
also provided. Reference to item numbers in the text and accompanying illustrations are
identical to those in the ILLUSTRATED PARTS LIST. Refer to Standard Practices Manual
24-10-00, ASSEMBLY, for general assembly procedures. Refer to FITS AND
CLEARANCES for summarized assembly procedures and torque values. Storage
instructions are also included in this section.
NOTE: Reference to item numbers in text implies that alpha variant items listed in the
IPL may be used as determined by the effect code for that item. For example,
reference to item (1) means that procedures also apply to alpha variant items
(-1A, -1B, and -1C).

CAUTION: DO NOT INTERCHANGE ROTOR-ARMATURE (COMPLETE ASSEMBLY),


WOUND ARMATURE (EXCITER), EXCITER STATOR, OR GENERATOR STATOR
OF GENERATOR 976J598-1 (CUBEX STEEL) WITH PARTS OF ANY OTHER
GENERATORS COVERED IN THIS MANUAL (REFERENCE SERVICE NEWS
LETTER 45). THE CUBEX PARTS ARE SHORTER IN LENGTH THAN THE
OTHER PARTS AND THIS DIFFERENCE IN LENGTH CAN CAUSE
CIRCULATING CURRENTS IN THE ROTOR BANDS WITH RESULTANT
HEATING IN THE BANDS THAT CAN DAMAGE THE GENERATOR.
B.

Materials required for assembly are listed in Figure 701.


NOTE: Maintenance personnel must use the specified consumable material for the
specified task. These consumable materials are known to align with all of the
design and qualification requirements. Only approved materials engineering can
make equivalent consumable material decisions and these materials are used at
the risk of the organization who makes the decision.
NOTE: The full address and other information regarding vendors or suppliers listed in
Figure 701 can be obtained by using the World Wide Web (www) at the following
URL http://www.bpn.gov/bincs/begin_search.asp. Other CAGE Code sites are
also available on the web.

C.

Special tools and equipment used for assembly are listed in Figure 702.
NOTE: Equivalent tools, fixtures, and equipment can be used if they align with the
requirements of ARINC Report 668.

2. Assembly of Semiconductor Device Set or Rectifier Assembly (IPL Figure 4)


NOTE: Refer to REPAIR for assembly of Semiconductor Device Set or Rectifier Assembly.
3.

Assembly of Armature-Rotor (IPL Figure 3)


NOTE: For replacement of parts not covered in the following assembly procedures, refer to
REPAIR.
ASSEMBLY

24-20-76

Page 701
Feb 26/07

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

Place armature-rotor components (8 through 16, IPL Figure 3) in adapter 919B555-1.

B.

Lubricate packings (6 and 7) with preformed packing lubricant.


NOTE: The O ring guide should be used to prevent cutting the packing while installing it
over splines.

C.

Install packing (6) on generator spindle (3) using O ring guide 919B555-1 until the
packing is in the groove next to the large spline.
MATERIAL

SOURCE

Preformed Packing Lubricant NS6074R

Syn-Tech Limited
CAGE Code: 53592

or
Preformed Packing Lubricant Assembly Fluid
No. 1

Ultrachem, Incorporated
CAGE Code: 56385

or
Preformed Packing Lubricant
Royco HF825

Royal Lubricants Company, Inc.

Lubricant, Grease Aero Shell No. 14


MIL-G-25537

CAGE Code: ER096


Shell Oil Co.
CAGE Code: 3L586

and
Lubricant, Molybdenum Disulfide MIL-M-7866

Dow Corning Corp.


CAGE Code: 71984

or
Antifretting Compound, Part Number 730691
730691-1 = 5cc tubes
730691-2 = 16 oz container
730691-3 = 5 cc polyethylene bag
730691-4 = 24 oz cartridge
730691-5 = 25 cc tube
730691-6 = 30 cc plastic syringe
Wire, Lock, 0.032 inch diameter, MS20995C32
Compound, Antiseize Compound(C-6380)
MIL-T-22361

Hamilton Sundstrand
CAGE Code: 99167

Commercially Available
Federal-Mogul Corp.
Fel-Pro Gasket Division
CAGE Code: 73165

Assembly Materials
Figure 701 (Sheet 1 of 2)
ASSEMBLY

24-20-76

Page 702
Feb 26/07

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

SOURCE

Resin, Scotchcast 253

3M

Resin, Epoxy D-163B (replacement for Resin,


Scotchcast 253)

CAGE Code: 76381


Nu-Brite Chemical Co., Inc.
Sterling Division
CAGE Code: 78580

Assembly Materials
Figure 701 (Sheet 2 of 2)
D.

Install packing (7) on seal retainer (4).

E.

Prepare antifretting compound by thoroughly mixing equal parts by weight of molybdenum


disulfide and lubricant (MIL-G-25537).

F.

Fill splines of stub shaft (1) and generator spindle (3) with antifretting compound. Be sure
all voids are filled with antifretting compound.

G.

Install generator spindle (3), packing (7), seal retainer (4) into stub shaft (1).
NUMBER

DESCRIPTION

918B450-1
919B555-1
922B865-2
See Figure 901
See Figure 905
See Figure 906

Adapter (2 required)
"O" Ring Guide
Spanner Wrench
Generator Support
Alignment Pin
Alignment Pin

Assembly Special Tools and Equipment


Figure 702
H.

Install retaining ring (5) using retaining ring plier so that the sharp outside diameter of the
ring faces away from the spindle.
NOTE: Some stub shafts may have a slight interference fit.

I.

Be sure that stub shaft (1) screw holes are aligned with screw holes in the armature-rotor
and if necessary use a soft-faced mallet to tap stub shaft into armature-rotor.

J.

Lightly coat screws (2) with anti-seize compound and install. Torque screws 40 to 50 lb-in.
(4.6 to 5.6 Nm).
WARNING: WEAR GOGGLES WHEN INSTALLING LOCKWIRE.

K.

Install lockwire on screws (2).

L.

Balance the armature in accordance with procedure in CHECK.

ASSEMBLY

24-20-76

Page 703
Feb 26/07

HAMILTON SUNDSTRAND
COMPONENT MAINTENANCE MANUAL
PART NUMBER 976J497 AND 976J597
4.

Assembly of Exciter Stator (IPL Figure 2)


NOTE: Refer to REPAIR for assembly of Exciter Stator.

5.

Assembly of AC Generator (IPL Figure 1)


NOTE: For replacement of parts not covered in the following assembly procedures, refer to
REPAIR.
NOTE: Armature-rotor (42) can only be used for generator 976J497-1. Armature-rotor (-42A)
can only be used on Cubex generator 976J597-1.
CAUTION: DO NOT INTERCHANGE ROTOR-ARMATURE (COMPLETE ASSEMBLY) OR
WOUND ARMATURE (EXCITER) OF GENERATOR 976J598-1 (CUBEX STEEL)
WITH PARTS OF ANY OTHER GENERATORS COVERED IN THIS MANUAL
(REFERENCE SERVICE NEWS LETTER 45). THE CUBEX PARTS ARE
SHORTER IN LENGTH THAN THE OTHER PARTS AND THIS DIFFERENCE IN
LENGTH CAN CAUSE CIRCULATING CURRENTS IN THE ROTOR BANDS
WITH RESULTANT HEATING IN THE BANDS THAT CAN DAMAGE THE
GENERATOR.
A.

Install bearing cover (41) on drive-end shaft of armature-rotor (42 or -42A).

B.

Install one bearing shield (37) as shown in Figure 703.

A-73037
Installation of Bearing Shield
Figure 703
ASSEMBLY

24-20-76

Page 704
Feb 26/07

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

Apply a thin coat of antifretting compound to both the inner and outer races of bearing
(36).
CAUTION: BE SURE BEARING STARTS SQUARE ON THE SHAFT. IF THE BEARING
IS NOT SQUARE TO THE SHAFT IT MAY BIND AND REQUIRE EXCESS
FORCE THAT CAN DAMAGE THE BEARING. IF FORCE IS HIGH, STOP
AND REMOVE BEARING APPLYING REMOVAL FORCE ONLY TO THE
INNER RACE.

D.

Place bearing (36) in the second adapter 918B450-1. Position bearing (36) squarely on
armature-rotor shaft and press until seated against shoulder of the shaft. Remove adapter
918B450-1.

E.

Install a second bearing shield (37) as shown in Figure 703.

F.

Install bowed retaining ring (38) using retaining ring plier so that the tang of the bowed
retaining ring contacts bearing shield (37).

G.

Turn armature-rotor (42 or -42A) so that drive-end is in adapter 918B450-1.

H.

Install bearing cover (41) on shaft of armature-rotor (42 or -42A).

I.

Install one bearing shield (37) as shown in Figure 703.

J.

Apply a thin coat of a mixture of antifretting compound to both the inner and outer races of
bearing (36).
CAUTION: BE SURE BEARING STARTS SQUARE ON THE SHAFT. IF THE BEARING
IS NOT SQUARE TO THE SHAFT IT MAY BIND AND REQUIRE EXCESS
FORCE THAT CAN DAMAGE THE BEARING. IF FORCE IS HIGH, STOP
AND REMOVE BEARING APPLYING REMOVAL FORCE ONLY TO THE
INNER RACE.

K.

Place bearing (36) in the second adapter 918B450-1. Position bearing (36) squarely on
armature-rotor shaft and press until seated against shoulder of the shaft.

L.

Install a second bearing shield (37) as shown in Figure 703.

M.

Install key washer (39) with inside tab aligned with slot in armature-rotor (42 or -42A) shaft
and outside tabs away from bearing (36).

N.

Apply a thin coat of antifretting compound to the chamfered face and threads of nut (40).

O.

Install nut (40) with chamfered face toward bearing (36).

P.

Torque nut (40) 43 to 53 lb-ft. (59 to 71 Nm) using spanner wrench 922B865-2 while
aligning one outside tab of key washer (39) with slot on side of the nut.

Q.

Bend one tab of key washer (39) into a slot on the side of nut (40).

R.

Install two alignment pins (see Figure 905) on bearing cover (41).
NOTE: End bell (30) can only be used with generator stator (55).

ASSEMBLY

24-20-76

Page 705
Feb 26/07

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

Align the screw holes in end bell (30 or -30A) over the alignment pins in bearing cover (41)
and install it on armature-rotor (42 or -42A).

T.

Lightly coat threads of screws (-11A) with lubricating oil.


NOTE: Do not use allen wrench with ball head or chamfered head to install screws (11A)
as these types of wrench heads cause the wrenching surface of the screws to
distort and make it difficult to obtain the correct torque and will make it difficult to
remove these screws.
NOTE: If cover (10) has not been modified to cover (-10A) refer to Service Bulletin
79-103.

U.

Install cover (-10A), four washers (12), and four screws (-11A).

WARNING: WEAR GOGGLES WHEN INSTALLING LOCKWIRE.


V.

Remove the two alignment pins and install the remaining washers (12) and screws (-11A).
Torque screws 30 to 36 lb-in. (3.4 to 4.0 Nm). Install lockwire on screws.
NOTE: Generator stator (55) can only be used with end bell (30) - Generator 976J497-1.
Generator stator (-55A) can only be used with armature-rotor (-42A) - Generator
976J597-1 Cubex.

CAUTION: DO NOT INTERCHANGE ROTOR-ARMATURE (COMPLETE ASSEMBLY),


WOUND ARMATURE (EXCITER), EXCITER STATOR, OR GENERATOR STATOR
OF GENERATOR 976J598-1 (CUBEX STEEL) WITH PARTS OF ANY OTHER
GENERATORS COVERED IN THIS MANUAL (REFERENCE SERVICE NEWS
LETTER 45). THE CUBEX PARTS ARE SHORTER IN LENGTH THAN THE
OTHER PARTS AND THIS DIFFERENCE IN LENGTH CAN CAUSE CIRCULATING CURRENTS IN THE ROTOR BANDS WITH RESULTANT HEATING IN THE
BANDS THAT CAN DAMAGE THE GENERATOR.
W.

Place generator stator (55, -55A, or -55B) with terminal end up on generator support (see
Figure 901).

CAUTION: DO NOT ALLOW SURFACES OF THE ROTOR TO TOUCH SURFACES OF THE


STATOR AS IT MAY DAMAGE PROTECTIVE COATINGS ON EITHER PART
RESULTING IN ELECTRICAL DAMAGE DURING OPERATION.
X.

Carefully align and lower assembled components (-10A through -42A) into generator
stator (55, -55A, or -55B).

Y.

Lightly coat threads of screws (25) with lubricating oil.

WARNING: WEAR GOGGLES WHEN INSTALLING LOCKWIRE.


Z.

Install washers (-26A) and screws (-25A). Torque screws 27 to 33 lb-in. (3.1 to 3.7 Nm).
Install lockwire on screws.

AA. Turn the AC generator so the drive-end is up.


ASSEMBLY

24-20-76

Page 706
Feb 26/07

HAMILTON SUNDSTRAND
COMPONENT MAINTENANCE MANUAL
PART NUMBER 976J497 AND 976J597
AB. Install two alignment pins (see Figure 905) on bearing cover (41) 180 degrees apart.
AC. Install two alignment pins (see Figure 906) on generator stator (55, -55A or -55B) 180
degrees apart.
CAUTION: FAILURE TO USE PROPER TOOL TO POSITION AND SEAT END BELL
PROPERLY BEFORE TIGHTENING SCREWS CAN RESULT IN STRESSES
IN THE END BELL WHICH COULD LEAD TO FAILURE OF THE END BELL
OR THE BEARINGS.
AD. Align end bell (52 or 52A) over the four alignment pins and using end bell assembly tool
(see Figure 904) installed over the end bell, gently tap around the outside diameter until
the end bell is fully seated in generator stator (55, -55A, or -55B) and over bearing (36).
AE. Lightly coat threads of screws (-54A) with lubricating oil.
NOTE: Do not use allen wrench with ball head or chamfered head to install screws
(-54A) as these types of wrench heads cause the wrenching surface of the
screws to distort and make it difficult to obtain the correct torque and will make it
difficult to remove these screws.
AF. Install at least two washers (-53A) and screws (-54A). Remove alignment pins from
bearing cover (41) and generator stator (55, -55A, or -55B).
AG. Install remaining washers (-53A) and screws (-54A). Torque screws 30 to 36 lb-in. (3.4 to
4.0 Nm).
AH. Lightly coat threads of screws (9 or 9A) with lubricating oil.
NOTE: If end bell (52) is used install backing ring (8) and screws (9). If end bell (52A) is
used install screws (9A).
NOTE: Do not use allen wrench with ball head or chamfered head to install screws (9A)
as these types of wrench heads cause the wrenching surface of the screws to
distort and make it difficult to obtain the correct torque and will make it difficult to
remove these screws.
AI.

Torque screws (9) 30 to 36 lb-in. (3.4 to 4.0 Nm). Torque screws (9A) 45 to 55 lb-in. (5.1
to 6.2 Nm).
WARNING: WEAR GOGGLES WHEN INSTALLING LOCKWIRE.

AJ. Install lockwire on screws (54 or -54A) and (9 or 9A).


AK. Lightly coat packing (7) with performed packing lubricant and install on the armature-rotor
(42 or -42A) shaft using "O" ring guide 919B555-1.
AL. Apply a thin coat of anitfretting compound to the splines of adapter (4).
ASSEMBLY

24-20-76

Page 707
Feb 26/07

HAMILTON SUNDSTRAND
COMPONENT MAINTENANCE MANUAL
PART NUMBER 976J497 AND 976J597
AM. Install adapter (4), washer (5), and screw (6). Torque screw 83 to 103 lb-in.
(9.4 to 11.6 Nm).
AN. Lightly coat packing (3) with performed packing lubricant and install on cover (1).
AO. Install cover (1) and retaining ring (2) using retaining ring plier.

ASSEMBLY

24-20-76

Page 708
Feb 26/07

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

General
This section contains dimensional requirements and wear tolerances. Summarized disassembly and assembly views are also provided for the mechanic experienced in component maintenance procedures. Numerical notes referenced in the summarized views refer to notes
provided in the CHECK and REPAIR sections. Item numbers used are identical to those shown
in the referenced Illustrated Parts List Figure. The summarized views may also be used to
check torque values and special maintenance procedures.

2.

Reference CHECK. (Refer to Figures 801 and 802).


Pin diameter for spline adapter (internal) is 0.0720 in. (1.8288 mm). All other parts require pin
diameter of 0.0864 in. (2.1946 mm).

Time to
next
overhaul

1000
hrs or
less

1500
hrs

2000
hrs

3000
hrs

4000
hrs

6000
hrs

Spline Adapter

% wear

25

22.5

20

14

10

(Internal)

max inch
(mm)

0.7680
(19.5072
mm)

0.7639
(19.4031
mm)

0.7598
(19.2989
mm)

0.7498
(19.0449
mm)

0.7432
(18.8773
mm)

0.7267
(18.4582
mm)

Spline Adapter

% wear

25

22.5

20

14

10

(External)

max inch
(mm)

1.2781
(32.4637
mm)

1.2810
(32.5374
mm)

1.2853
(32.6466
mm)

1.2906
(32.7812
mm)

1.2966
(32.9336
mm)

1.3080
33.2232
mm)

Spindle

% wear

25

22.5

20

14

10

16 Teeth

max inch
(mm)

0.8787
(22.3190
mm)

0.8815
(22.3901
mm)

0.8842
(22.4587
mm)

0.8907
(22.6238
mm)

0.8951
(22.7355
mm)

0.9060
(23.0124
mm)

Spindle

% wear

25

22.5

20

14

10

24 Teeth

max inch
(mm)

1.2781
(32.4637
mm)

1.2810
(32.5374
mm)

1.2853
(32.6466
mm)

1.2906
(32.7812
mm)

1.2966
(32.9336
mm)

1.3080
(33.2232
mm)

Stub Shaft

% wear

25

22.5

20

14

10

max inch
(mm)

1.1242
(28.5547
mm)

1.1204
(28.4582
mm)

1.1160
(28.3464
mm)

1.1074
(28.1280
mm)

1.1013
(27.9730
mm)

1.0860
(27.5844
mm)

Wear Limit Chart - Splined Parts


Figure 801

FITS AND CLEARANCES

24-20-76

Page 801
Jun 1/00

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

Item Checked

Dimensions

1. Bearing Shaft Journals

1.1809/1.1814 in. (29.9949/30.0076 mm)

2. Rotor Core Concentricity

Within 0.002 T.I.R.* (0.050 mm)

3. Bearing Inserts

2.4407/2.4412 in. (61.9938/62.0065 mm)

* See CHECK.
Wear Limit Chart - Critical Diameters
Figure 802
2.

Other Diameters (Refer to Figure 803 and REPAIR)

3.

Torque Values
Reference Figure 804 for the torque values required for assembly. (See CHECK and ASSEMBLY AND STORAGE.)

1.
2.
3.
4.
5.
6.
7.

Item Checked
Armature - Rotor Dynamic Balance
Exciter Stator I.D.
Exciter Stator Mounting Tab O.D.
Exciter Stator Mounting Tab Runout
Anti-Drive End Bell I.D. for Exciter Stator Fit
Main Rotating Field O.D.
Exciter Armature O.D.

8. AC Stator I.D.

Dimensions
0.30 ounce-inch square (216 gram-millimeter)
3.901 to 3.903 inches (99.085 to 99.136 mm)
7.609 to 7.611 inches (193.268 to 193.319 mm)
0.005 inch T.I.R. (0.127 mm)
7.611 to 7.613 inches (193.319 to 193.370 mm)
6.922 inches minimum (175.818 mm)
3.850 to 3.854 inches (97.790 to 97.891 mm)
(3.855 inches [97.917 mm] over paint)
6.974 inches maximum (177.139 mm)

Wear Limit Chart - Repair Diameters


Figure 803

FITS AND CLEARANCES

24-20-76

Page 802
Jun 1/00

HAMILTON SUNDSTRAND
COMPONENT MAINTENANCE MANUAL
PART NUMBER 976J497 AND 976J597
IPL Figure
& Item No.
1-6
1-9
1 - 9A
1 - 11
1 - 11A
1 - 14
1 - 14A
1 - 16
1 - 21
1 - 25
1 - 25A
1 - 28
1 - 40
1 - 49
1 - 54
1 - 54A
1 - 66
1 - 68
2-2
3-2
3-9
4-6

Item
Screw
Screw
Screw
Screw
Screw
Screw
Screw
Nut
Screw
Screw
Screw
Screw
Nut
Screw
Screw
Screw
Screw
Screw
Screw
Screw
Screw
Nut

Torque
83 - 103 lb-in. (9.4 to 11.6 Nm)
30 - 36 lb-in. (3.4 to 4.0 Nm)
45 - 55 lb-in. (5.1 to 6.2 Nm)
30 - 36 lb-in. (3.4 to 4.0 Nm)
30 - 36 lb-in. (3.4 to 4.0 Nm)
No torque at this level of maintenance
No torque at this level of maintenance
No torque at this level of maintenance
16 - 20 lb-in. (1.9 to 2.2 Nm)
27 - 33 lb-in. (3.1 to 3.7 Nm)
27 - 33 lb-in. (3.1 to 3.7 Nm)
45 - 55 lb-in. (5.1 to 6.2 Nm)
43 - 53 lb-in. (4.9 to 5.9 Nm)
30 - 36 lb-in. (3.4 to 4.0 Nm)
30 - 36 lb-in. (3.4 to 4.0 Nm)
36 - 40 lb-in. (4.1 to 4.5 Nm)
To 140 lb-in. (15.9 Nm)
4 - 5 lb-in. (0.4 to 0.5 Nm)
12 - 14 lb-in. (1.4 to 1.5 Nm)
40 - 50 lb-in. (4.6 to 5.6 Nm)
15 to 17 lb-in. (1.7 to 1.9 Nm)
25 - 30 lb-in. (2.9 to 3.3 Nm)
Torque Values
Figure 804

FITS AND CLEARANCES

24-20-76

Page 803
Jun 1/00

HAMILTON SUNDSTRAND
COMPONENT MAINTENANCE MANUAL
PART NUMBER 976J497 AND 976J597
SPECIAL TOOLS, FIXTURES AND EQUIPMENT
1.

General
A.

Special tools, fixtures, and equipment used in this manual are listed in Figure 901. Refer
to Standard Practices Manual, 24-10-00, STANDARD TOOLS, FIXTURES, AND
EQUIPMENT for general equipment information.
NOTE: Equivalent tools, fixtures, and equipment can be used provided they meet the
requirements of ARINC Report 668.

2.

Test Equipment
A.

3.

Requirements for test equipment are listed in TESTING AND TROUBLESHOOTING. This
list includes information about equipment requirements, accuracy, and sources.

Environmental Conditions
A.

The environmental conditions present in any certified aircraft turbine engine overhaul shop
are acceptable for reconditioning of the ac generator.

PART NUMBER

NOMENCLATURE

SUPPLIER

Model 5220A
Model 78
Model 1700
Model 1701B
933A819
H20B
TS460/u

Hypot Tester
Multimeter
Digital Converter
Plug-In low Ohm Meter
Ultrasonic Cleaner (CLEANING)
Balancing Machine (CHECK)
Impedance Bridge, Type 1650A*
* No longer manufactured. Continued use
authorized by Hamilton Sundstrand. Replaced by
Quad Tech Digibridge 1750 LCR Tester.

04237
89536
8M267
8M267

12-062 or 12-064
L-2926
12-066
12-068

Brazing Set (REPAIR)


. Electrodes
. Lead Set
. Fork Attachment

30119

1227-6
3581-3
4286
60B4-1

Extraction Tool (REPAIR)


Breakoff Tool (REPAIR)
Kelvin Bridge (CHECK)*
Insulation Test Set (CHECK & TESTING)*
* No longer manufactured. Continued use
authorized by Hamilton Sundstrand.
Insulation Test Set

26344
26344
31922
19315

Model 2512

30218
24655

05611

Special Tools, Fixtures, and Equipment


Figure 901 (Sheet 1 of 4)
SPECIAL TOOLS, FIXTURES AND EQUIPMENT

24-20-76

Page 901
Feb 26/07

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

NOMENCLATURE

SUPPLIER

103MP-2.5DJU

Insulation Test Set*


* No longer manufactured. Continued use authorized by
Hamilton Sundstrand.

05611

7552-3
903J801-1
908C714-1
909C499-1
910C176-1
916B366-11
916B366-17
918B448-1
918B450-1
919B555-1

Installation Tool (REPAIR)


Checking Fixture (CHECK)
Wrench (DISASSEMBLY)
Curing Fixture (REPAIR)
Mechanical Puller (DISASSEMBLY)
Step Plate (DISASSEMBLY)
Step Plate (DISASSEMBLY)
Adapter (DISASSEMBLY)
Adapter (ASSEMBLY) (2 required)
Sleeve Tool (ASSEMBLY)

91767

S-171
922B865-2
928A903-3
944B450-2
944B451-2
909C497-1
962C206-1
909C498-1
938D844-3
939D192-1

Riveting Tool (ASSEMBLY)


Spanner Wrench (DISASSEMBLY & ASSEMBLY)
Adapter Set (REPAIR)
. Base Support
. Adapter Plate
. Adapter
. Adapter
. Support
Adapter - Gen. to Air Duct (TESTING)
Diode Test Set (TESTING) *
* No longer manufactured. Continued use authorized by
Hamilton Sundstrand.
Diode Test Set (TESTING) with Harness 4401B51-2
Surge Comparison Test Set (CHECK)*
* No longer manufactured. Continued use authorized by
Hamilton Sundstrand.

42838

948F859-1
976J552-4

6910 with opt,


model TS-10
Figure 902
Figure 903
Figure 904
Figure 905
Figure 906
Figure 907
Figure 908

Surge Tester (with optional 3-phase switch) (CHECK)


Support - Generator (DISASSEMBLY & ASSEMBLY)
Cradle Fixture (DISASSEMBLY)
End Bell Removal Tool (DISASSEMBLY)
End Bell Assembly Tool (ASSEMBLY)
Alignment Pin (2 required)
Alignment Pins (2 required)
Alignment Pins (6 required)
Special Tools, Fixtures, and Equipment
Figure 901 (Sheet 2 of 4)
SPECIAL TOOLS, FIXTURES AND EQUIPMENT

24-20-76

Page 902
Feb 26/07

HAMILTON SUNDSTRAND
COMPONENT MAINTENANCE MANUAL
PART NUMBER 976J497 AND 976J597
PART NUMBER
60109148
601091052
60069565
60102149
60069562
60102175
60107601
60087019
None
None
None

NOMENCLATURE

SUPPLIER

Air Gage Set (CHECK)


. Single Column
. Double Column
. Hose Assembly - Spindle
. Connector
. Hose Assembly Air Snap
. Handle
. Spindle (2.4407/2.4411)
. Air Snap Gage

54465

. High Speed Steel Gage Measuring Wire (0.0720 in. dia.


and 0.0864 in. dia.)
. Master Setting Ring (2.4407 diameter)
. Master Setting Ring (2.4411 diameter)*
* After the setting of 2.4411 has been determined on
Column, 60106869, raise the scale marker on the column
0.0003 in. (0.0076 mm) for upper limit.

62679

None
None

. Master Setting Disk (1.1809 diameter)


. Master Setting Disk (1.1814 diameter)
(Above no P/N's made from AGD Cylindrical Class XX
Steel)

Digibridge 1750
LCR Tester

Quad Tech Digibridge 1750 LCR Tester *


* Replaces Impedance Bridge, Type 1650A

0H4A4

Special Tools, Fixtures, and Equipment


Figure 901 (Sheet 3 of 4)

SPECIAL TOOLS, FIXTURES AND EQUIPMENT

24-20-76

Page 903
Feb 26/07

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

SUPPLIER

04237

Associated Research Inc.

05611

Slaughter Company

0H4A4

Quad Technologies

24655

Genrad Inc.

26344

New Haven Mfg. Corp.

30119

Ideal Industries

30218

Schenk Corp.

31922

Leeds and Northrup Co.

42838

National Rivet & Mfg. Co.

54465

Warner and Swasey Co.


Sheffield Measurement Div.

56477

P J Electronics Inc.

62679

Van Keuren Co.

8M267

Electro Scientific Industries Inc.

89536

Fluke Corp.

NOTE: Unless otherwise noted (CAGE Code Listed), the drawings for the tools listed above are
available from Hamilton Sundstrand on request. Forward requests for the drawings to
the local Hamilton Sundstrand field service representative or request drawings from
Hamilton Sundstrand, 4747 Harrison Avenue, P.O. Box 7002, Rockford, IL 61125-7002,
Attention: Contract Data Management, Dept. 775.
When you order a special tool listed above, you may get hardware with a build letter
suffix added to the tool part number (e.g. AGEXXXXXA). This hardware is the newest
tool/equipment design and is equivalent to, or better than, the part number in the list
above.
NOTE: To request a quotation for Ground Support Equipment, use the online order request
website listed here: http://www.hamiltonsundstrand.com/gse.
NOTE: The full address and other information regarding vendors or suppliers listed above can
be obtained by using the World Wide Web (www) at the following URL http://
www.bpn.gov/bincs/begin_search.asp. Other CAGE Code sites are also available on the
web.
Special Tools, Fixtures, and Equipment
Figure 901 (Sheet 4 of 4)
SPECIAL TOOLS, FIXTURES AND EQUIPMENT

24-20-76

Page 904
Feb 26/07

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

A-67188
Generator Support
Figure 902

SPECIAL TOOLS, FIXTURES AND EQUIPMENT

24-20-76

Page 905
Jun 1/00

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

A-67189
Cradle Fixture
Figure 903

SPECIAL TOOLS, FIXTURES AND EQUIPMENT

24-20-76

Page 906
Jun 1/00

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

A-67190
End Bell Removal Tool
Figure 904

SPECIAL TOOLS, FIXTURES AND EQUIPMENT

24-20-76

Page 907
Jun 1/00

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

A-67191
End Bell Assembly Tool
Figure 905

A-67192
Alignment Pin
Figure 906
SPECIAL TOOLS, FIXTURES AND EQUIPMENT

24-20-76

Page 908
Jun 1/00

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

A-67193
Alignment Pin
Figure 907

A-67194
Alignment Pin
Figure 908

SPECIAL TOOLS, FIXTURES AND EQUIPMENT

24-20-76

Page 909
Jun 1/00

HAMILTON SUNDSTRAND
COMPONENT MAINTENANCE MANUAL
PART NUMBER 976J497 AND 976J597
ILLUSTRATED PARTS LIST
1.

Introduction
A.

The Illustrated Parts List (IPL) provides a breakdown of the equipment covered by this
manual. All parts are listed in order of disassembly, showing relationships to higher and
lower assemblies, and are identified by corresponding index numbers on board-layout and
exploded view illustrations.

B.

The part numbers identified in this Illustrated Parts List have been shown to comply with
the applicable Federal Aviation Regulations and, when purchased from Hamilton
Sundstrand, are FAA-approved under a Hamilton Sundstrand FAA Production Certificate
(PC), Technical Standard Order (TSO), or Parts Manufacture Approval (PMA) for use in
the component listed.

C.

This IPC (or IPL) does not constitute a grant of direct-ship authority, or otherwise confer
FAA-approval under FAR 21.303 for parts and assemblies purchased directly from a listed
vendor. Installation eligibility of all parts and assemblies purchased directly from a listed
vendor must be supported by the vendor's Parts Manufacture Approval (PMA).

D.

All items are assigned an item number. Items listed but not illustrated are identified by a
dash (-) preceding the item number.

E.

For identification of detail parts and assemblies, the NOMENCLATURE column employs
the indenture system. Each assembly is listed with its detailed parts list in the next
indenture below and to the right. Conversely, the next higher assembly of any detail part
may be determined by its location in the indenture above and to the left.

F.

Attaching parts immediately follow the part or assembly which they attach and have the
same indenture. They are preceded by the words ATTACHING PARTS and are followed
by three asterisks (* * *).

G.

Effectivity codes (A, B, C...) are assigned and listed in the EFF CODE column, when two
or more similar assemblies are broken down in the same IPL figure. These codes show
that a part of subassembly is used only on the assembly(ies) with the same effectivity
code(s). A part or subassembly with no effectivity code is used on all of the assemblies
listed in that figure.
Although the same effectivity codes may be used in more than one IPL figure, there is no
relation between the codes of one figure and the codes of any other figure.
To determine end-item effectivity (on which end item a part, subassembly, or assembly is
used when multiple end items are listed), find the effectivity code(s) of the item in
question. This lead to the assembly(ies) on which the item is used, to the next higher
assembly (NHA), and subsequently to the end-item figure and the end item(s).

ILLUSTRATED PARTS LIST

24-20-76

Page 1001
Feb 26/07

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

2.

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

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

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

B.

OPTIONAL (OPT). Indicates a choice of interchangeable parts, subassemblies,


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

C.

REPLACES/REPLACED (REPLS/REPLD). A part, subassembly, assembly, or unit is


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

D.

SUPERSEDES/SUPERSEDED (SUPSDS/SUPSD). A part, subassembly, assembly, or


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

E.

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

24-20-76

Page 1002
Feb 26/07

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

3.

F.

ELECTROSTATIC DISCHARGE SENSITIVE (ESDS) DEVICES. Electronic parts,


assemblies, and equipment that are susceptible to damage from electrostatic discharge.
Electrostatic discharge sensitive devices are identified in the NOMENCLATURE column
as (ESDS). Refer to REPAIR for information on ESDS.

G.

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

Equipment Designator Index


A.

4.

Numerical Index
A.

5.

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

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

Manufacturers' Code, Name, and Address


A.

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

00779

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

78189

Illinois Tool Works, Inc.


Shakeproof Division
St. Charles Road
Elgin, IL 60120

04866

N-D Industries, Inc.


1893 Barrett Rd.
Troy, MI 48084

79568

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

16941

Long-Lok Fasteners Corp.


10630 Chester Rd.
Cincinnati, OH 45215-1206

80205

National Aerospace Standards


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

24-20-76

Page 1003
Feb 26/07

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

National Rivet & Mfg Co.


1-21 East Jefferson St.
Waupun, WI 53963-2038

81349

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

45681

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

83186

Victory Engineering Corp.


Victory Rd.
Springfield, NJ 07081-1314

50157

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

21335

Torrington Co. Fafnir Bearings Div.


59 Field St.
Torrington, CT 06790-1008

70472

Barnes Group Inc.


123 Main St.
Bristol, CT 06010-6307

86579

Precision Rubber Products Corp.


Dayton, OH 45401

73682

Garrett George K. Co.


Div. MSL Industries Inc.
Philadelphia, PA 19092

88044

Aeronautical Standards Group


Dept. of Navy and Air Force

91265

Goshen Rubber Co., Inc.


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

96906

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

99167

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

ILLUSTRATED PARTS LIST

24-20-76

Page 1004
Feb 26/07

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

PART NUMBER
A116COMPSR277-20
A116COMP-SR277-70
AN500A8-7
AN502-10-10

AN502-10-12
AN502-10-14
AN502-10-6
AN503-8-10

AN503-8-12

AN960-10

AN960-10L
AN960-416L
AN960-616
AN960-8

GRC513-215COMP
GRC513-215-COMP-PV1504

AIRLINE
PART NO.

FIG.
1A
1
1A
1
1A
1
1
1A
1A
1
1A
1
1A
1
1A
1
1
1
1A
1A
1A
1
3
1A
3A
1
1
1A
1A
1
1A
4
4A
1
1A
1
1
1
3
1A
1A
1A
3A
3A
3
3A

ITEM
30A
3
30
24G
240G
28
49
280
490
9
90
9A
90A
54
540
11A
21A
25A
110A
210A
250A
21
9
210
90
50
53
500
530
18
180
7
70
46
460
15
22
24K
10
150
220
240K
100
70A
7
70

TTL
REQ
1
1
6
6
6
4
6
4
6
6
6
6
8
8
6
2
12
6
2
12
2
5
2
5
4
8
4
8
4
4
6
6
6
6
2
2
6
5
2
2
6
5
1
1
1

NUMERICAL INDEX

24-20-76

Page 1005
Feb 26/07

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

PART NUMBER
L591-19357

LP500-8-6
M83248-1-116
MS122159
MS124655
MS16625-1093
MS16625-1131
MS16625-1168
MS16628-4118
MS21042-L4
MS21042L4
MS21208F1-20
MS21209C0-815
MS21209F1-15

MS24677-16

MS24678-9
MS24678-15
MS25036-108

MS25036-56
MS35338-40
MS35338-43

AIRLINE
PART NO.

FIG.
1
3
1A
3A
1
1A
1
1A
1
1A
1
1A
1
1A
3
3A
4
4A
1
1A
4
4A
4A
1
1A
1
1A
1
1
1A
1A
1
1
1A
1A
1
1A
1A
1
2
1A
2A
3
3A
1
1A
1
1A

ITEM
7
6
70
60
14A
140A
3C
30D
65
650
64
640
2
20
5
50
1
10
38
380
6
60
60A
32
320
31
310
11B
33
110B
330
11
25
110
250
54A
540A
110B
29A
11
290A
110
13M
130M
69
690
17
170

TTL
REQ
1
1
1
1
2
2
1
1
12
12
8
8
1
1
1
1
1
1
1
1
6
6
6
6
6
4
4
6
6
6
6
6
12
6
12
8
8
6
3
3
3
3
3
3
4
4
4
4

NUMERICAL INDEX

24-20-76

Page 1006
Feb 26/07

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

PART NUMBER
MS35338-46
MS35458-30
MS35650-305T
NAS679A3W
NAS679A6
NAS679A6W
NK500-8-6CC
PMW206PPC4FA-52695S8
TC1-6-ST
TC1-6ST
W-06
109P938
109P938-1
116COMP17107
11X1
14C4796-7
15C7989-2
15C7989-38
15C7989-45
15C8030-7
15C8095-55
18B1766-18
18B1766-23
18B1766-24
19C8355-33
2-116COMPV747
2-215-V747
2-215V747
215COMP19357
28B8800-3

AIRLINE
PART NO.

FIG.
ITEM
1
45
1A
450
1
6
1A
60
1
19
1A
190
1
16
1A
160
1
44A
1A
440A
1
44
1A
440
1
14
1A
140
1
36
1A
360
4
13
4A
130
4A
130A
1
39
1A
390
1
67A
1A
670A
1A
670B
1
3A
1A
30B
2
1B
2A
10B
SEE W-06
SEE MS24677-16
SEE MS24678-9
SEE AN503-8-10
1
40
1A
400
SEE MS35458-30
SEE MS16625-1093
SEE MS16625-1131
SEE MS16625-1168
SEE TC1-6-ST
1
3B
1A
30C
3
7B
3A
70C
3A
70D
3
7A
3A
70B
1
68
1A
680

TTL
REQ
6
6
1
1
4
4
4
4
6
6
2
2
6
6
6
1
1
1
1
1
1
1
1
1

1
1

1
1
1
1
1
1
1
4
4

NUMERICAL INDEX

24-20-76

Page 1007
Feb 26/07

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

PART NUMBER
28B8802-33
28B8802-34
28B8802-6
28B8802-9
28B8803-45
28B8803-90
28B8803-91
28B8803-93
28B8803-99
28B9560-3
2W756
2WD1007501
3-243650-2-323
31398
3530-05-03
5908349
5908350
5911588
5911589
62276
769450
8C7714-34
908C828-1
908C832-1
908D049-1
908D049-2
910C331-10
910C331-11
910C331-16
910C331-8
910C331-9

AIRLINE
PART NO.

FIG.
ITEM
SEE AN503-8-12
SEE AN503-8-10
1
35
1A
350
2
2
2A
20
SEE MS24677-16
SEE AN502-10-12
SEE AN502-10-14
SEE AN502-10-10
SEE AN502-10-6
SEE NK500-8-6CC
SEE LP500-8-6
2
1
2A
10
2
1A
2A
10A
2
3
2A
30
2
9
2A
90
4
14
4A
140
4
4A
4A
40A
4
5A
4A
50A
4
4B
4A
40B
4
5B
4A
50B
1
67
1A
670
3
1B
3A
10B
1
36A
1A
360A
1
13
1A
130
1
20
1A
200
1
43
1A
430
1A
430A
SEE AN960-10
SEE AN960-416L
SEE AN960-616
SEE AN960-8
SEE AN960-10L

TTL
REQ

2
2
1
1

1
1
1
1
1
1
2
2
6
6
3
3
3
3
3
3
3
3
1
1
1
1
2
2
1
1
1
1
1
1
1

NUMERICAL INDEX

24-20-76

Page 1008
Feb 26/07

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

PART NUMBER
910C605-1
910C886-1

911C207-15
911C207-3
911C207-9
915F262-1

915F306-1

915F306-2

915F469-1
915F469-2
915F508-1

915F511-1

915F512-2
916B631-1
916B631-2
916B631-3
916B821-1
916B822-1
916B825-2
917B106-1
917B119-11
917B119-3
917B119-6
917B453-5

AIRLINE
PART NO.

FIG.
ITEM
1
4
1A
40
SEE A116COMP-SR277SEE 116COMP17107
SEE M83248-1-116
SEE 2-116COMPV747
SEE MS35338-46
SEE MS35338-40
SEE MS35338-43
1
27
1A
270
2
2A
1
1
42
1A
420
3
3A
1
1
42B
1A
420B
3
3A
1B
1
55
1A
550
1
55A
1A
550A
1
42A
1A
420A
3
3A
1A
1
27A
1A
270A
2
2A
1A
1
55B
1A
550B
SEE MS21209F1-15
SEE MS21209C0-815
3
3M
3A
30M
2
4
2A
40
2
7
2A
70
SEE 2W756
SEE 2WD1007501
SEE 11X1
SEE 31398
SEE MS122159
SEE MS124655
SEE MS21208F1-20
SEE MS16628-4118

TTL
REQ
1
1

1
1
RF
RF
1
1
RF
RF
1
1
RF
RF
1
1
1
1
1
1
RF
RF
1
1
RF
RF
1
1
1
1
1
1
2
2

NUMERICAL INDEX

24-20-76

Page 1009
Feb 26/07

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

PART NUMBER
917B579-1
917B596-1
917B597-1
917B599-1
917B621-1

918B105-2
918B105-4
919B113-1
920B836-1
9206WX7C0XG-29
922B314-1
927A402-19
927A402-25
929A939-1

931A052-1
931A052-2
936C235-1
938D679-11
938D679-12
939D982-1
940D366-1
941D586-2
942D262-2
943D450-1
944B718-1
944B791-1

AIRLINE
PART NO.

FIG.
ITEM
1
23
1A
230
2
6
2A
60
SEE 3-243650-2-323
1
24
1A
240
2
10
2
10A
2A
100
2A
100A
SEE NAS679A3W
SEE NAS679A6W
1
1
1A
10
1
37
1A
370
1
36B
1A
360B
1
5
1A
50
SEE MS25036-108
SEE MS25036-56
1
26
1
26A
1A
260
1A
260A
4
15E
4A
150E
4
15F
4A
150F
1
10
1A
100
4
4
4A
40
4
5
4A
50
3
2
3A
20
3
1
3A
10
3
13
3A
130
3
13A
3A
130A
1
30A
1A
300A
1
8
1A
80
1
47
1A
470

TTL
REQ
4
4
2
2
1
1
3
2
3
2
1
1
4
4
2
2
1
1
6
12
6
12
2
2
2
2
1
1
3
3
3
3
8
8
1
1
1
1
1
1
1
1
1
1
6
6

NUMERICAL INDEX

24-20-76

Page 1010
Feb 26/07

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

PART NUMBER
944B851-1
944B852-1
945B161-1

945B477-1
945B527-1
945B527-2
945B550-1
945B985-1
946F177-1

946F177-3

947B438-1
947B449-1
947B450-1
947B451-1
947B473-1
947B495-1
947B529-1
947B529-6
947B529-7
947B872-2

AIRLINE
PART NO.

FIG.
ITEM
2
8
2A
80
2
5
2A
50
1
7A
1A
70A
3
6A
3A
60A
SEE L591-19357
1
30F
1A
300F
3
3
3A
30
3
3A
3A
30A
3
4
3A
40
1
51
1A
510
3
8
3A
80
4
4A
1
3
8A
3A
80A
4
4A
1A
3
13R
3A
130R
3
12
3A
120
3
11
3A
110
4
3M
4A
30M
4
8
4A
80
1
12
1A
120
1
61
1A
610
1
63
1A
630
1
62
1A
620
4
14A
4A
140A
SEE 947B872-2
SEE 3530-05-03

TTL
REQ
1
1
2
2
1
1
1
1
1
1
1
1
1
1
1
1
6
6
1
1
RF
RF
1
1
RF
RF
16
16
5
5
5
5
2
2
3
3
6
6
2
2
1
1
3
3

NUMERICAL INDEX

24-20-76

Page 1011
Feb 26/07

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

PART NUMBER
948B029-1

948B031-1
948B032-1
948B034-1
948B212-1
948B213-1
948B214-1
948B215-1
948B216-1
949B105-3
949B105-5
949B105-6
949B352-1
949B362-1
949B363-1
949F308-1
949F363-1
955C170-86
955C551-14
959C442-2
959C711-5
961C451-1
961C730-1

AIRLINE
PART NO.

FIG.
ITEM
1
12A
1
29
1
53A
1A
120A
1A
290
1A
530A
4
12
4A
120
4
9
4A
90
4
10
4A
100
1
57
1A
570
1
60
1A
600
1
58
1A
580
1
59
1A
590
1
56
1A
560
3
14
3A
140
3
15
3A
150
3
16
3A
160
4
2
4A
20
4
11
4A
110
4
10B
4A
100B
3
1A
3A
10A
4
10A
4A
100A
1
66
1A
660
SEE MS35650-305T
SEE GRC513-215-COMPSEE 215COMP19357
SEE 2-215-V747
SEE MS21042-L4
4
15
4A
150
1
52
1A
520

TTL
REQ
6
6
8
6
6
8
2
AR
2
AR
1
1
1
1
1
1
2
2
1
1
1
1
AR
AR
AR
AR
AR
AR
1
1
1
AR
1
AR
1
1

3
3

1
1
1
1

NUMERICAL INDEX

24-20-76

Page 1012
Feb 26/07

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

PART NUMBER
962C235-3
962C261-1
962C265-1
962C279-1
963C047-1
963C054-1
963C055-1
964C157-2
964C592-1
966C576-1
976J497-1
976J597-1

AIRLINE
PART NO.

FIG.
1
1A
1
1A
4
4A
1
1A
1
1A
1
1A
1
1A
4
4A
4
4A
1
1A
1
1A
1
1A

ITEM
10A
100A
41
410
3
30
24D
240D
30
300
48
480
34
340
16
160
18
180
52A
520A
1
1A

TTL
REQ
1
1
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
RF
RF
RF
RF

NUMERICAL INDEX

24-20-76

Page 1013
Feb 26/07

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

A-68064
AC Generator
Figure 1 (Sheet 1 of 2)

ILLUSTRATED PARTS LIST

24-20-76

Page 1014
Feb 26/07

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

A-67987
AC Generator
Figure 1 (Sheet 2 of 2)

ILLUSTRATED PARTS LIST

24-20-76

Page 1015
Feb 26/07

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

FIG.
ITEM

PART
NUMBER

1234567

NOMENCLATURE

EFF
CODE

UNITS
PER
ASSY

RF

RF

1
976J497-1
976J597-1

GENERATOR, AC
(MOVED TO ITEM 1 IPL FIGURE 1A)
GENERATOR, AC
(MOVED TO ITEM 1A IPL FIGURE 1A)
COVER, SPINDLE
(MOVED TO ITEM 10 IPL FIGURE 1A)

919B113-1

MS16625-1093

A116COMP-SR277-70

-3A

116COMP17107

-3B

2-116COMPV747

-3C

M83248-1-116

910C605-1

922B314-1

MS35458-30

L591-19357

-7A

945B161-1

944B718-1

AN502-10-12

9A

AN502-10-14

- ITEM NOT ILLUSTRATED

ATTACHING PARTS
RING, RETAINING
(MOVED TO ITEM 20 IPL FIGURE 1A)
-----*----PACKING, PREFORMED
(MOVED TO ITEM 30 IPL FIGURE 1A)
PACKING, PREFORMED
(MOVED TO ITEM 30B IPL FIGURE 1A)
PACKING, PREFORMED
(MOVED TO ITEM 30C IPL FIGURE 1A)
PACKING, PREFORMED
(MOVED TO ITEM 30D IPL FIGURE 1A)
ADAPTER, SPLINE
(MOVED TO ITEM 40 IPL FIGURE 1A)

ATTACHING PARTS
WASHER, SHOULDERED
(MOVED TO ITEM 50 IPL FIGURE 1A)
SCREW, MACHINE
(MOVED TO ITEM 60 IPL FIGURE 1A)
-----*----PACKING, PREFORMED
(MOVED TO ITEM 70 IPL FIGURE 1A)
PACKING, PREFORMED
(MOVED TO ITEM 70A IPL FIGURE 1A)
RING, BACKING
(MOVED TO ITEM 80 IPL FIGURE 1A)

ATTACHING PARTS
SCREW
(MOVED TO ITEM 90 IPL FIGURE 1A)
-----*----

SCREW
(MOVED TO ITEM 90A IPL FIGURE 1A)

1
1
1
1
1

1
1

1
1
1

ILLUSTRATED PARTS LIST

24-20-76

Page 1016
Feb 26/07

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

FIG.
ITEM

PART
NUMBER

1234567

1
10

936C235-1

-10A

962C235-3

11

MS24677-16

-11A

AN503-8-10

-11B

MS24678-15

12

947B495-1

-12A

948B029-1

13

908C828-1

14

NK500-8-6CC

-14A

LP500-8-6

15

AN960-8

16

NAS679A3W

17

MS35338-43

18

AN960-10L

19

MS35650-305T

- ITEM NOT ILLUSTRATED

NOMENCLATURE

COVER, BEARING
(MOVED TO ITEM 100 IPL FIGURE 1A)
COVER, BEARING
(MOVED TO ITEM 100A IPL FIGURE 1A)

ATTACHING PARTS
SCREW
(MOVED TO ITEM 110 IPL FIGURE 1A)
SCREW
(MOVED TO ITEM 110A IPL FIGURE 1A)
SCREW
(MOVED TO ITEM 110B IPL FIGURE 1A)
WASHER, FLAT
(MOVED TO ITEM 120 IPL FIGURE 1A)
WASHER, FLAT
(MOVED TO ITEM 120A IPL FIGURE 1A)
-----*----COVER, TERMINAL BOARD
(MOVED TO ITEM 130 IPL FIGURE 1A)

ATTACHING PARTS
SCREW, SELF LOCKING, MACH., 8-32
UNC-2A X 0.375 CD PL
(MOVED TO ITEM 140 IPL FIGURE 1A)
SCREW, SELF LOCKING, MACH., 8-32
UNC-2A X 0.375 CD PL
(MOVED TO ITEM 140A IPL FIGURE 1A)
WASHER, FLAT
(MOVED TO ITEM 150 IPL FIGURE 1A)
-----*----NUT, SELF LOCKING
(MOVED TO ITEM 160 IPL FIGURE 1A)
WASHER, LOCK
(MOVED TO ITEM 170 IPL FIGURE 1A)
WASHER, FLAT
(MOVED TO ITEM 180 IPL FIGURE 1A)
NUT, PLAIN HEX
(MOVED TO ITEM 190 IPL FIGURE 1A)

EFF
CODE

UNITS
PER
ASSY
1
1

6
6
6
6
6

4
4
4
4

ILLUSTRATED PARTS LIST

24-20-76

Page 1017
Feb 26/07

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

FIG.
ITEM

PART
NUMBER

1234567

1
20

908C832-1

21

AN503-8-12

21A

AN503-8-10

22

AN960-8

23

917B579-1

24

917B599-1

-24D

962C279-1

-24G

AN500A8-7

-24K

AN960-8

25

MS24677-16

-25A

AN503-8-10

26

929A939-1

26A

929A939-1

27

915F262-1

-ITEM NOT ILLUSTRATED

NOMENCLATURE

EFF
CODE

TERMINAL BOARD
(MOVED TO ITEM 200 IPL FIGURE 1A)

ATTACHING PARTS
SCREW, MACHINE
(MOVED TO ITEM 210 IPL FIGURE 1A)
SCREW, MACHINE
(MOVED TO ITEM 210A IPL FIGURE 1A)
WASHER, FLAT
(MOVED TO ITEM 220 IPL FIGURE 1A)
-----*----TERMINAL, STUD
(MOVED TO ITEM 230 IPL FIGURE 1A)
GROMMET
(MOVED TO ITEM 240 IPL FIGURE 1A)
FLANGE (NP)
(MOVED TO ITEM 240D IPL FIGURE 1A)

2
2

ATTACHING PARTS
SCREW, MACH, FIL H
(MOVED TO ITEM 240G IPL FIGURE 1A)
WASHER
(MOVED TO ITEM 240K IPL FIGURE 1A)
-----*----

SCREW, MACH
(MOVED TO ITEM 250 IPL FIGURE 1A)
SCREW, MACHINE
(MOVED TO ITEM 250A IPL FIGURE 1A)
WASHER
(MOVED TO ITEM 260 IPL FIGURE 1A)
WASHER, FLAT
(MOVED TO ITEM 260A IPL FIGURE 1A)
STATOR, EXCITER
(MOVED TO ITEM 270 IPL FIGURE 1A)

UNITS
PER
ASSY

1
A

12
12
6
12
A

ILLUSTRATED PARTS LIST

24-20-76

Page 1018
Feb 26/07

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

FIG.
ITEM
1
-27A

PART
NUMBER
915F511-1

1234567

STATOR, EXCITER (CUBEX)


(MOVED TO ITEM 270A IPL FIGURE 1A)

UNITS
PER
ASSY

ATTACHING PARTS
SCREW, MACHINE
(MOVED TO ITEM 280 IPL FIGURE 1A)
WASHER, FLAT
(MOVED TO ITEM 290 IPL FIGURE 1A)
-----*-----

28

AN502-10-10

29

948B029-1

29A

MS25036-108

30

963C047-1

-30A

943D450-1

30F

945B477-1

31

MS21209C0-815

32

MS21208F1-20

33

MS21209F1-15

34

963C055-1

35

28B8802-6

36
-36A

PMW206PPC4FA52695S8
8C7714-34

-36B

9206WX7C0XG-29

- ITEM NOT ILLUSTRATED

NOMENCLATURE

EFF
CODE

TERMINAL LUG
(MOVED TO ITEM 290A IPL FIGURE 1A)
END BELL, ELEC. ROTATING
(MOVED TO ITEM 300 IPL FIGURE 1A)
END BELL, ELEC. ROTATING
(MOVED TO ITEM 300A IPL FIGURE 1A)
INSERT, BEARING
(MOVED TO ITEM 300F IPL FIGURE 1A)
INSERT, SCREW THREAD
(MOVED TO ITEM 310 IPL FIGURE 1A)
INSERT, SCREW THREAD
(MOVED TO ITEM 320 IPL FIGURE 1A)
INSERT, SCREW THREAD
(MOVED TO ITEM 330 IPL FIGURE 1A)
RETAINER
(MOVED TO ITEM 340 IPL FIGURE 1A)

ATTACHING PARTS
SCREW, FIL H 8-32 UNC-2A X 0.44 CD PL
(MOVED TO ITEM 350 IPL FIGURE 1A)
-----*----DELETED (BEARING, BALL)
(MOVED TO ITEM 360 IPL FIGURE 1A)
BEARING, BALL
(MOVED TO ITEM 360A IPL FIGURE 1A)
BEARING, BALL
(MOVED TO ITEM 360B IPL FIGURE 1A)

6
6

3
A

1
1
4
6
6
1

2
2

ILLUSTRATED PARTS LIST

24-20-76

Page 1019
Feb 26/07

HAMILTON SUNDSTRAND
COMPONENT MAINTENANCE MANUAL
PART NUMBER 976J497 AND 976J597
FIG.
ITEM
1
37

PART
NUMBER
920B836-1

1234567

SHIELD, BEARING
(MOVED TO ITEM 370 IPL FIGURE 1A)

MS16628-4118

39

W-06

40

15C8030-7

41

962C261-1

42

915F306-1

-42A

915F508-1

-42B

915F306-2

43

908D049-1

44

NAS679A6W

-44A

NAS679A6

45

MS35338-46

46

AN960-616

47

944B791-1

48

963C054-1

49

AN502-10-10

50

AN960-10

COVER, BEARING
(MOVED TO ITEM 410 IPL FIGURE 1A)
ARMATURE-ROTOR
(MOVED TO ITEM 420 IPL FIGURE 1A)
ARMATURE-ROTOR (CUBEX) (NP)
(MOVED TO ITEM 420A IPL FIGURE 1A)
ARMATURE-ROTOR
(MOVED TO ITEM 420B IPL FIGURE 1A)
COVER, TERMINAL BOARD
(MOVED TO ITEM 430 IPL FIGURE 1A)
DELETED (NUT)
(MOVED TO ITEM 440 IPL FIGURE 1A)
NUT, SELF LOCK
(MOVED TO ITEM 440A IPL FIGURE 1A)
WASHER, LOCK
(MOVED TO ITEM 450 IPL FIGURE 1A)
WASHER, FLAT
(MOVED TO ITEM 460 IPL FIGURE 1A)
WASHER, SHOULDERED, SQUARE
(MOVED TO ITEM 470 IPL FIGURE 1A)
TERMINAL BOARD
(MOVED TO ITEM 480 IPL FIGURE 1A)

ATTACHING PARTS
SCREW, MACHINE
(MOVED TO ITEM 490 IPL FIGURE 1A)
WASHER, FLAT
(MOVED TO ITEM 500 IPL FIGURE 1A)
-----*-----

UNITS
PER
ASSY
4

ATTACHING PARTS
RING, RETAINING
(MOVED TO ITEM 380 IPL FIGURE 1A)
WASHER, KEY
(MOVED TO ITEM 390 IPL FIGURE 1A)
NUT, PLAIN, ROUND
(MOVED TO ITEM 400 IPL FIGURE 1A)
-----*-----

38

- ITEM NOT ILLUSTRATED

NOMENCLATURE

EFF
CODE

1
1
1

2
A

1
1

6
6
6
6
1

4
4

ILLUSTRATED PARTS LIST

24-20-76

Page 1020
Feb 26/07

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

FIG.
ITEM

PART
NUMBER

1234567

1
51

945B985-1

52

961C730-1

52A

966C576-1

53

AN960-10

-53A

948B029-1

54

AN502-10-6

-54A

MS24678-9

55

915F469-1

-55A

915F469-2

-55B

915F512-2

56

948B216-1

57

948B212-1

58

948B214-1

59

948B215-1

60

948B213-1

61

947B529-1

62

947B529-7

63

947B529-6

64

MS124655

65

MS122159

- ITEM NOT ILLUSTRATED

NOMENCLATURE

EFF
CODE

STUD, MACHINE, HEX HD


(MOVED TO ITEM 510 IPL FIGURE 1A)
END BELL, ELEC. ROTATING
(MOVED TO ITEM 520 IPL FIGURE 1A)
END BELL, ELEC. ROTATING
(MOVED TO ITEM 520A IPL FIGURE 1A)

1
1

ATTACHING PARTS
WASHER
(MOVED TO ITEM 530 IPL FIGURE 1A)
WASHER, FLAT
(MOVED TO ITEM 530A IPL FIGURE 1A)
SCREW
(MOVED TO ITEM 540 IPL FIGURE 1A)
SCREW
(MOVED TO ITEM 540A IPL FIGURE 1A)
-----*-----

STATOR, GENERATOR
(MOVED TO ITEM 550 IPL FIGURE 1A)
STATOR, GENERATOR
(MOVED TO ITEM 550A IPL FIGURE 1A)
STATOR, GENERATOR (CUBEX) (NP)
(MOVED TO ITEM 550B IPL FIGURE 1A)
TERMINAL, ELECTRICAL
(MOVED TO ITEM 560 IPL FIGURE 1A)
TERMINAL, ELECTRICAL
(MOVED TO ITEM 570 IPL FIGURE 1A)
TERMINAL, ELECTRICAL
(MOVED TO ITEM 580 IPL FIGURE 1A)
TERMINAL, ELECTRICAL
(MOVED TO ITEM 590 IPL FIGURE 1A)
TERMINAL, ELECTRICAL
(MOVED TO ITEM 600 IPL FIGURE 1A)
INSULATION, SLEEVING
(MOVED TO ITEM 610 IPL FIGURE 1A)
INSULATION, SLEEVING
(MOVED TO ITEM 620 IPL FIGURE 1A)
INSULATION, SLEEVING
(MOVED TO ITEM 630 IPL FIGURE 1A)
INSERT
(MOVED TO ITEM 640 IPL FIGURE 1A)
INSERT
(MOVED TO ITEM 650 IPL FIGURE 1A)

UNITS
PER
ASSY

8
8
8

1
1
1
2
1
1
2
3
1
8
12

ILLUSTRATED PARTS LIST

24-20-76

Page 1021
Feb 26/07

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

PART
NUMBER

1
66

955C170-86

67

62276

-67A

109P938

-67B

109P938-1

68

28B8800-3

69

MS35338-40

1234567

NOMENCLATURE

SCREW
(MOVED TO ITEM 660 IPL FIGURE 1A)
PLATE, IDENTIFICATION (NP)
(MOVED TO ITEM 670 IPL FIGURE 1A)
PLATE, IDENTIFICATION
(MOVED TO ITEM 670A IPL FIGURE 1A)
PLATE, IDENTIFICATION
(MOVED TO ITEM 670B IPL FIGURE 1A)

ATTACHING PARTS
SCREW, MACHINE, FIL HD STL,
CD PL 4-40 X 1/4 INCH LG
(MOVED TO ITEM 680 IPL FIGURE 1A)
WASHER, LOCK
(MOVED TO ITEM 690 IPL FIGURE 1A)
-----*-----

EFF
CODE

UNITS
PER
ASSY
3
1
1
1

ILLUSTRATED PARTS LIST

24-20-76

Page 1022
Feb 26/07

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

THIS PAGE INTENTIONALLY LEFT BLANK

ILLUSTRATED PARTS LIST

24-20-76

Page 1023
Feb 26/07

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

HE-242076-68064-A
AC Generator
Figure 1A (Sheet 1 of 2)
ILLUSTRATED PARTS LIST

24-20-76

Page 1024
Feb 26/07

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

HE-242076-67987-A
AC Generator
Figure 1A (Sheet 2 of 2)

ILLUSTRATED PARTS LIST

24-20-76

Page 1025
Feb 26/07

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

FIG.
ITEM

PART
NUMBER

1234567

NOMENCLATURE

1A
-1
-1A
10

976J497-1
976J597-1
919B113-1

GENERATOR, AC
GENERATOR, AC
COVER, SPINDLE

20

MS16625-1093

30
-30A

A116COMP-SR277-70
A116COMPSR277-70

-30B

116COMP17107

-30C

2-116COMPV747

-30D

M83248-1-116

40

910C605-1

DELETED (PACKING, PREFORMED)


PACKING, PREFORMED
(V95272) (910C886-1)
IDENT AS A116COMP-SR277-70
PACKING, PREFORMED
(V25184) (910C886-1)
PACKING, PREFORMED
(V45681) (910C886-1)
PACKING, PREFORMED
(910C886-1)
ADAPTER, SPLINE

50
60

922B314-1
MS35458-30

70

L591-19357

-70A

945B161-1

- ITEM NOT ILLUSTRATED

EFF
CODE
A
B

ATTACHING PARTS
RING, RETAINING
(18B1766-18)
-----*-----

UNITS
PER
ASSY
RF
RF
1

ATTACHING PARTS
WASHER, SHOULDERED
SCREW, MACHINE
(15C8095-55)
-----*-----

1
1
1
1

1
1

PACKING, PREFORMED
(V86579) (945B161-1)
PACKING, PREFORMED
(V45681)

ILLUSTRATED PARTS LIST

24-20-76

Page 1026
Feb 26/07

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

FIG.
ITEM
1A
80

PART
NUMBER
944B718-1

90

AN502-10-12

90A

AN502-10-14

100

936C235-1

-100A

962C235-3

1234567

RING, BACKING
(USED WITH END BELL 961C730-1, ITEM
520. END BELL AND RING REPLD BY
966C576-1, ITEM 520A. USE UP SPARES)
(S.B. 78-103)

ATTACHING PARTS
SCREW (28B8803-90)
(USED WITH ITEMS 520 AND 80. REPLD
BY ITEM 520A. SCREWS REPLD BY ITEM
90A.)
(S.B. 78-103)
-----*----SCREW (28B8803-91)
(USED WITH ITEM 520A.)
(S.B. 78-103)
COVER, BEARING
(REPLD BY ITEM -100A)
(S.B. 79-103)
COVER, BEARING
(REPLS ITEM 100)
(S.B. 79-103)

MS24677-16

-110A

AN503-8-10

-110B

MS24678-15

120

947B495-1

-120A

948B029-1

UNITS
PER
ASSY
1

110

- ITEM NOT ILLUSTRATED

NOMENCLATURE

EFF
CODE

ATTACHING PARTS
SCREW
(28B8803-45)
(REPLD BY ITEM 110A)
(S.B. 84-103)
SCREW
(15C7989-45)
(REPLS ITEM 110)
(REPLD BY ITEM 110B)
SCREW
(15C7989)
(REPLS ITEM 110A)
WASHER, FLAT
(REPLD BY ITEM -120A)
(S.B. 84-103)
WASHER, FLAT
(REPLS ITEM 120)
-----*-----

ILLUSTRATED PARTS LIST

24-20-76

Page 1027
Feb 26/07

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

FIG.
ITEM

PART
NUMBER

1234567

1A
130

908C828-1

140

NK500-8-6CC

-140A

LP500-8-6

150

AN960-8

160

NAS679A3W

170

MS35338-43

180

AN960-10L

190

MS35650-305T

200

908C832-1

210

AN503-8-12

-210A

AN503-8-10

220

AN960-8

230
240
-240D

917B579-1
917B599-1
962C279-1

-240G
-240K

AN500A8-7
AN960-8

-250

MS24677-16

250A

AN503-8-10

- ITEM NOT ILLUSTRATED

NOMENCLATURE

EFF
CODE

COVER, TERMINAL BOARD

UNITS
PER
ASSY
1

ATTACHING PARTS
SCREW, SELF LOCKING, MACH., 8-32
UNC-2A X 0.375 CD PL
(V04866) (28B9560-3)
SCREW, SELF LOCKING, MACH., 8-32
UNC-2A X 0.375 CD PL
(V16941) (28B9560-3)
WASHER, FLAT
(910C331-8)
-----*-----

NUT, SELF LOCKING


(918B105-2)
WASHER, LOCK
(911C207-9)
WASHER, FLAT
(910C331-9)
NUT, PLAIN HEX
(955C551-14)
TERMINAL BOARD

4
4
4
4
1

ATTACHING PARTS
SCREW, MACHINE
(28B8802-33)
SCREW, MACHINE
(28B8802-34)
WASHER, FLAT
(910C331-8)
-----*-----

2
2

TERMINAL, STUD
GROMMET
FLANGE (NP)

4
1
1

A
A

6
6

ATTACHING PARTS
SCREW, MACH, FIL H
WASHER
-----*---- SCREW, MACH
(15C7989-2)
SCREW, MACHINE
(28B8802-34)

12
12

ILLUSTRATED PARTS LIST

24-20-76

Page 1028
Feb 26/07

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

FIG.
ITEM

PART
NUMBER

1234567

NOMENCLATURE

1A
-260
260A
270

929A939-1
929A939-1
915F262-1

-270A

915F511-1

280
290

AN502-10-10
948B029-1

290A
300
-300A
300F
310

MS25036-108
963C047-1
943D450-1
945B477-1
MS21209C0-815

320

MS21208F1-20

330

MS21209F1-15

340

963C055-1

350

28B8802-6

ATTACHING PARTS
SCREW, FIL H 8-32 UNC-2A X 0.44 CD PL
-----*-----

360

DELETED (BEARING, BALL)

-360A
-360B
370

PMW206PPC4FA52695S8
8C7714-34
9206WX7C0XG-29
920B836-1

380
390

MS16628-4118
W-06

400

15C8030-7

410

962C261-1

- ITEM NOT ILLUSTRATED

WASHER
WASHER, FLAT
STATOR, EXCITER
(SEE IPL FIGURE 2A FOR DETAILS.)
STATOR, EXCITER (CUBEX)
(SEE IPL FIGURE 2A FOR DETAILS.)

EFF
CODE

UNITS
PER
ASSY

6
12
1

ATTACHING PARTS
SCREW, MACHINE (28B8803-93)
WASHER, FLAT
-----*-----

6
6

TERMINAL LUG (927A402-19)


END BELL, ELEC. ROTATING
END BELL, ELEC. ROTATING
INSERT, BEARING
INSERT, SCREW THREAD
(V96906) (916B631-2)
INSERT, SCREW THREAD
(V96906) (917B119-6)
INSERT, SCREW THREAD
(V96906) (916B631-1)
RETAINER

A
B

6
6
1

BEARING, BALL
BEARING, BALL
SHIELD, BEARING

2
2
4

ATTACHING PARTS
RING, RETAINING (917B453-5)
WASHER, KEY
(V79568) (14C4796-7)
NUT, PLAIN, ROUND
-----*----

3
1
1
1
4

1
1
1

COVER, BEARING

ILLUSTRATED PARTS LIST

24-20-76

Page 1029
Feb 26/07

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

FIG.
ITEM

PART
NUMBER

1234567

1A
420

915F306-1

-420A

915F508-1

-420B

915F306-2

430

908D049-1

-430A

908D049-2

440
-440A

NAS679A6W
NAS679A6

450

MS35338-46

460

AN960-616

470
480

944B791-1
963C054-1

490

AN502-10-10

500

AN960-10

510
520

945B985-1
961C730-1

520A

966C576-1

530

AN960-10

- ITEM NOT ILLUSTRATED

NOMENCLATURE

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

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

UNITS
PER
ASSY

1
1
1

6
6
6
6
1

4
4

STUD, MACHINE, HEX HD


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

EFF
CODE

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

6
1

ILLUSTRATED PARTS LIST

24-20-76

Page 1030
Feb 26/07

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

PART
NUMBER

1234567

1A
-530A

948B029-1

540

AN502-10-6

-540A

MS24678-9

550
-550A
-550B

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

560
570
580
590
600
610
620
630
640

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

650

MS122159

660
670

955C170-86
62276

-670A

109P938

-670B

109P938-1

680

28B8800-3

690

MS35338-40

- ITEM NOT ILLUSTRATED

NOMENCLATURE

EFF
CODE

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

UNITS
PER
ASSY

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

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

A
A
B

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

4
4

ILLUSTRATED PARTS LIST

24-20-76

Page 1031
Feb 26/07

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

A-67988
Exciter Stator
Figure 2

ILLUSTRATED PARTS LIST

24-20-76

Page 1032
Feb 26/07

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

FIG.
ITEM

PART
NUMBER

1234567

NOMENCLATURE

EFF
CODE

UNITS
PER
ASSY

AC

RF

RF

2
915F262-1
915F511-1
1

2W756

-1A

2WD1007501

-1B

11X1

STATOR, EXCITER
(MOVED TO ITEM 1 IPL FIGURE 2A)
STATOR, EXCITER (CUBEX)
(MOVED TO ITEM 1A IPL FIGURE 2A)
RESISTANCE ELEMENT, THERMAL
(MOVED TO ITEM 10 IPL FIGURE 2A)
RESISTANCE ELEMENT, THERMAL
(MOVED TO ITEM 10A IPL FIGURE 2A)
RESISTANCE ELEMENT, THERMAL
(MOVED TO ITEM 10B IPL FIGURE 2A)

28B8802-9

3-243650-2-323

916B821-1

944B852-1

917B596-1

916B822-1

944B851-1

31398

10

917B621-1

-10A

917B621-1

11

MS25036-108

- ITEM NOT ILLUSTRATED

1
1
1

ATTACHING PARTS
SCREW, MACHINE, FIL HD STL, CD PL, 8-32
X 5/8 INCH LG
(MOVED TO ITEM 20 IPL FIGURE 2A)
WASHER, SPRING TENSION
(MOVED TO ITEM 30 IPL FIGURE 2A)
WASHER, FLAT
(MOVED TO ITEM 40 IPL FIGURE 2A)
INSULATOR, WASHER
(MOVED TO ITEM 50 IPL FIGURE 2A)
TERMINAL, LUG
(MOVED TO ITEM 60 IPL FIGURE 2A)
WASHER, FLAT
(MOVED TO ITEM 70 IPL FIGURE 2A)
INSULATOR, BUSHING
(MOVED TO ITEM 80 IPL FIGURE 2A)
-----*-----

TERMINAL, LUG
(MOVED TO ITEM 90 IPL FIGURE 2A)
INSULATION, SLEEVING
(MOVED TO ITEM 100 IPL FIGURE 2A)
INSULATION, SLEEVING
(MOVED TO ITEM 100A IPL FIGURE 2A)
TERMINAL, LUG
(MOVED TO ITEM 110 IPL FIGURE 2A)

1
1
2
2
2
1

2
AC

ILLUSTRATED PARTS LIST

24-20-76

Page 1033
Feb 26/07

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

HE-242076-67988-A
Exciter Stator
Figure 2A

ILLUSTRATED PARTS LIST

24-20-76

Page 1034
Feb 26/07

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

FIG.
ITEM

PART
NUMBER

2A
-1

915F262-1

-1A

915F511-1

10

2W756

-10A

2WD1007501

-10B

11X1

1234567

STATOR, EXCITER
(SEE ITEM 270, IPL FIGURE 1A FOR NHA)
STATOR, EXCITER (CUBEX)
(SEE ITEM 270A, IPL FIGURE 1A FOR NHA)
RESISTANCE ELEMENT, THERMAL
(V50157) (916B825-2)
(REPLD BY ITEM -10A)
RESISTANCE ELEMENT, THERMAL
(V50157) (916B825-2)
(REPLS ITEM 10)
RESISTANCE ELEMENT, THERMAL
(V83186) (916B825-2)
(ALTERNATE TO ITEM -10A)

20

28B8802-9

30

3-243650-2-323

40
50
60
70
80

916B821-1
944B852-1
917B596-1
916B822-1
944B851-1

90

31398

100
-100A
110

917B621-1
917B621-1
MS25036-108

- ITEM NOT ILLUSTRATED

NOMENCLATURE

EFF
CODE

UNITS
PER
ASSY

RF

RF
1

ATTACHING PARTS
SCREW, MACHINE, FIL HD STL, CD PL, 8-32
X 5/8 INCH LG
WASHER, SPRING TENSION
(V73682) (917B597-1)
WASHER, FLAT
INSULATOR, WASHER
TERMINAL, LUG
WASHER, FLAT
INSULATOR, BUSHING
-----*-----

TERMINAL, LUG
(V00779) (917B106-1)
INSULATION, SLEEVING
INSULATION, SLEEVING
TERMINAL, LUG
(927A402-19)

1
1
1
2
2
2
1

2
A
B
B

3
2
3

ILLUSTRATED PARTS LIST

24-20-76

Page 1035
Feb 26/07

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

A-67989
Armature-Rotor
Figure 3
FIG.
ITEM

PART
NUMBER

1234567

NOMENCLATURE

EFF
CODE

UNITS
PER
ASSY

RF

RF

RF

3
915F306-1
915F508-1
915F306-2
1

940D366-1

-1A

949F308-1

-1B

769450

939D982-1

- ITEM NOT ILLUSTRATED

ARMATURE-ROTOR
(MOVED TO ITEM 1 IPL FIGURE 3A)
ARMATURE-ROTOR (CUBEX)
(MOVED TO ITEM 1A IPL FIGURE 3A)
ARMATURE-ROTOR
(MOVED TO ITEM 1B IPL FIGURE 3A)
SHAFT, STUB
(MOVED TO ITEM 10 IPL FIGURE 3A)
SHAFT, STUB
(MOVED TO ITEM 10A IPL FIGURE 3A)
SHAFT, STUB
(MOVED TO ITEM 10B IPL FIGURE 3A)

ATTACHING PARTS
SCREW, CAP, HEX HD, DRILLED
(MOVED TO ITEM 20 IPL FIGURE 3A)
-----*-----

1
1
1

ILLUSTRATED PARTS LIST

24-20-76

Page 1036
Feb 26/07

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

FIG.
ITEM

PART
NUMBER

1234567

3
3

945B527-1

3M

916B631-3

945B550-1

MS16625-1131

L591-19357

-6A

945B161-1

-7A

GRC513-215-COMPPV1504
215COMP19357

-7B

2-215-V747

946F177-1

-8A

946F177-3

AN503-8-12

10

AN960-8

11

947B450-1

12

947B449-1

13

941D586-2

-13A

942D262-2

13M

MS25036-56

- ITEM NOT ILLUSTRATED

NOMENCLATURE

EFF
CODE

SPINDLE, GENERATOR
(MOVED TO ITEM 30 IPL FIGURE 3A)
INSERT, SCREW THREAD
(MOVED TO ITEM 30M IPL FIGURE 3A)
RETAINER, SEAL
(MOVED TO ITEM 40 IPL FIGURE 3A)

1
1

ATTACHING PARTS
RING, RETAINING
(MOVED TO ITEM 50 IPL FIGURE 3A)
-----*----PACKING, PREFORMED
(MOVED TO ITEM 60 IPL FIGURE 3A)
PACKING, PREFORMED
(MOVED TO ITEM 60A IPL FIGURE 3A)
PACKING, PREFORMED
(MOVED TO ITEM 70 IPL FIGURE 3A)
PACKING, PREFORMED
(MOVED TO ITEM 70B IPL FIGURE 3A)
PACKING, PREFORMED
(MOVED TO ITEM 70C IPL FIGURE 3A)
SEMICONDUCTOR DEVICE SET
(MOVED TO ITEM 80 IPL FIGURE 3A)
SEMICONDUCTOR DEVICE SET
(MOVED TO ITEM 80A IPL FIGURE 3A)

1
1
1
1
1
1
1

ATTACHING PARTS
SCREW, FIL HD
(MOVED TO ITEM 90 IPL FIGURE 3A)
WASHER, FLAT
(MOVED TO ITEM 100 IPL FIGURE 3A)
BUSHING, INSULATION
(MOVED TO ITEM 110 IPL FIGURE 3A)
BUSHING
(MOVED TO ITEM 120 IPL FIGURE 3A)
-----*----ARMATURE, WOUND
(MOVED TO ITEM 130 IPL FIGURE 3A)
ARMATURE, WOUND (CUBEX) (NP)
(MOVED TO ITEM 130A IPL FIGURE 3A)
TERMINAL, LUG (927A402-25)
(MOVED TO ITEM 130M IPL FIGURE 3A)

UNITS
PER
ASSY

5
5
5
5

1
3

ILLUSTRATED PARTS LIST

24-20-76

Page 1037
Feb 26/07

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

PART
NUMBER

3
13R

947B438-1

14

949B105-3

15

949B105-5

16

949B105-6

- ITEM NOT ILLUSTRATED

1234567

NOMENCLATURE

WEDGE
(MOVED TO ITEM 130R IPL FIGURE 3A)
WEIGHT, BALANCING
(MOVED TO ITEM 140 IPL FIGURE 3A)
WEIGHT, BALANCING
(MOVED TO ITEM 150 IPL FIGURE 3A)
WEIGHT, BALANCING
(MOVED TO ITEM 160 IPL FIGURE 3A)

EFF
CODE

UNITS
PER
ASSY
16
AR
AR
AR

ILLUSTRATED PARTS LIST

24-20-76

Page 1038
Feb 26/07

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

THIS PAGE INTENTIONALLY LEFT BLANK

ILLUSTRATED PARTS LIST

24-20-76

Page 1039
Feb 26/07

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

HE-242076-67989-A
Armature-Rotor
Figure 3A

ILLUSTRATED PARTS LIST

24-20-76

Page 1040
Feb 26/07

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

FIG.
ITEM

PART
NUMBER

1234567

3A
-1

915F306-1

-1A

915F508-1

-1B

915F306-2

10

940D366-1

-10A

949F308-1

-10B

769450

20

939D982-1

30
30M
40

945B527-1
916B631-3
945B550-1

50

60
-60A
70
-70A

-70B
-70C
-70D

NOMENCLATURE

ARMATURE-ROTOR
(SEE ITEM 420, IPL FIGURE 1A FOR NHA)
ARMATURE-ROTOR (CUBEX)
(SEE ITEM -420A, IPL FIGURE 1A FOR NHA)
(SEE SERVICE NEWS LETTER 48.)
ARMATURE-ROTOR
(SEE ITEM -420B, IPL FIGURE 1A FOR NHA)
SHAFT, STUB
(REPLD BY ITEM -10A)
SHAFT, STUB
(REPLD BY ITEM -10B)
SHAFT, STUB
(REPLS ITEM -10A)
ATTACHING PARTS
SCREW, CAP, HEX HD, DRILLED
-----*-----

- ITEM NOT ILLUSTRATED

UNITS
PER
ASSY

RF

RF

RF
1
1
1

SPINDLE, GENERATOR
INSERT, SCREW THREAD
RETAINER, SEAL

1
1
1

ATTACHING PARTS
RING, RETAINING
(18B1766-23)
-----*----L591-19357
PACKING, PREFORMED
(V86579) (945B161-1)
945B161-1
PACKING, PREFORMED
(V45681)
GRC513-215-COMP- DELETED (PACKING, PREFORMED)
PV1504
GRC513-215COMP
PACKING, PREFORMED
(V91265) (959C442-2)
IDENT AS GRC513-215-COMP-PV1504
PACKING, PREFORMED
215COMP19357
(V86579) (959C442-2)
2-215-V747
DELETED (PACKING, PREFORMED)
2-215V747
PACKING, PREFORMED
(V45681) (959C442-2)
IDENT AS 2-215-V747
MS16625-1131

EFF
CODE

1
1

ILLUSTRATED PARTS LIST

24-20-76

Page 1041
Feb 26/07

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

FIG.
ITEM

PART
NUMBER

3A
80

946F177-1

-80A

946F177-3

1234567

AN503-8-12

100

AN960-8

110
120

947B450-1
947B449-1

130
-130A
130M

941D586-2
942D262-2
MS25036-56

130R
140
150
160

947B438-1
949B105-3
949B105-5
949B105-6

UNITS
PER
ASSY
1

SEMICONDUCTOR DEVICE SET


(SEE IPL FIGURE 4A FOR DETAILS.)
(S.B. 71-103)
(FORMERLY 915F199-1. USE UP
SPARES.)
SEMICONDUCTOR DEVICE SET
(SEE IPL FIGURE 4A FOR DETAILS.)

90

- ITEM NOT ILLUSTRATED

NOMENCLATURE

EFF
CODE

ATTACHING PARTS
SCREW, FIL HD
(28B8802-33)
WASHER, FLAT
(910C331-8)
BUSHING, INSULATION
BUSHING
-----*-----

5
5
5
5

ARMATURE, WOUND
ARMATURE, WOUND (CUBEX) (NP)
TERMINAL, LUG
(927A402-25)
WEDGE
WEIGHT, BALANCING
WEIGHT, BALANCING
WEIGHT, BALANCING

A
B

1
1
3
16
AR
AR
AR

ILLUSTRATED PARTS LIST

24-20-76

Page 1042
Feb 26/07

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

THIS PAGE INTENTIONALLY LEFT BLANK

ILLUSTRATED PARTS LIST

24-20-76

Page 1043
Feb 26/07

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

A-67199
Semiconductor Device Set
Figure 4
ILLUSTRATED PARTS LIST

24-20-76

Page 1044
Feb 26/07

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

FIG.
ITEM

PART
NUMBER

1234567

NOMENCLATURE

EFF
CODE

UNITS
PER
ASSY

4
946F177-1
946F177-3
1

MS16625-1168

949B352-1

962C265-1

3M

947B451-1

938D679-11

-4A

5908349

-4B

5911588

938D679-12

-5A

5908350

-5B

5911589

MS21042-L4

AN960-416L

947B473-1

948B032-1

10

948B034-1

-10A

949F363-1

-10B

949B363-1

11

949B362-1

- ITEM NOT ILLUSTRATED

SEMICONDUCTOR DEVICE SET


(MOVED TO ITEM 1 IPL FIGURE 4A)
SEMICONDUCTOR DEVICE SET
(MOVED TO ITEM 1A IPL FIGURE 4A)
RING, RETAINING
(MOVED TO ITEM 10 IPL FIGURE 4A)
SPACER
(MOVED TO ITEM 20 IPL FIGURE 4A)
TUBE, BUS RING
(MOVED TO ITEM 30 IPL FIGURE 4A)
BUSHING
(MOVED TO ITEM 30M IPL FIGURE 4A)
SEMICONDUCTOR DEVICE, DIODE
(MOVED TO ITEM 40 IPL FIGURE 4A)
SEMICONDUCTOR DEVICE, DIODE
(MOVED TO ITEM 40A IPL FIGURE 4A)
SEMICONDUCTOR DEVICE, DIODE
(MOVED TO ITEM 40B IPL FIGURE 4A)
SEMICONDUCTOR DEVICE, DIODE
(MOVED TO ITEM 50 IPL FIGURE 4A)
SEMICONDUCTOR DEVICE, DIODE
(MOVED TO ITEM 50A IPL FIGURE 4A)
SEMICONDUCTOR DEVICE, DIODE
(MOVED TO ITEM 50B IPL FIGURE 4A)
ATTACHING PARTS FOR ITEMS 4 & 5
NUT, SELF LOCK
(MOVED TO ITEM 60 IPL FIGURE 4A)
WASHER, FLAT
(MOVED TO ITEM 70 IPL FIGURE 4A)
-----*----

HOLDER, DIODE
(MOVED TO ITEM 80 IPL FIGURE 4A)
LEAD, ELECTRICAL
(MOVED TO ITEM 90 IPL FIGURE 4A)
LEAD, ELECTRICAL
(MOVED TO ITEM 100 IPL FIGURE 4A)
DELETED (LEAD, ELECTRICAL)
(MOVED TO ITEM 100A IPL FIGURE 4A)
LEAD, ELECTRICAL
(MOVED TO ITEM 100B IPL FIGURE 4A)
LEAD, ELECTRICAL (S.B. 71-103)
(MOVED TO ITEM 110 IPL FIGURE 4A)

RF
RF
1
1
1
2
3
3
3
3
3
3

6
6

3
AR
1

AR
AR

ILLUSTRATED PARTS LIST

24-20-76

Page 1045
Feb 26/07

HAMILTON SUNDSTRAND
COMPONENT MAINTENANCE MANUAL
PART NUMBER 976J497 AND 976J597
FIG.
ITEM
4
12

PART
NUMBER
948B031-1

13

TC1-6-ST

14

3530-05-03

-14A

947B872-2

15

961C451-1

15E

931A052-1

-15F

931A052-2

16

964C157-2

17
18

DELETED
964C592-1

- ITEM NOT ILLUSTRATED

1234567

NOMENCLATURE

LEAD, ELECTRICAL
(MOVED TO ITEM 120 IPL FIGURE 4A)

ATTACHING PARTS FOR ITEMS 9, 10, 11 &


12
RIVET, TUBULAR
(MOVED TO ITEM 130 IPL FIGURE 4A)
WASHER, SPRING
(MOVED TO ITEM 140 IPL FIGURE 4A)
DELETED (SPRING, WASHER)
(MOVED TO ITEM 140A IPL FIGURE 4A)
-----*---- CAPACITOR FIXTURE
(MOVED TO ITEM 150 IPL FIGURE 4A)
INSULATION, SLEEVING
(MOVED TO ITEM 150E IPL FIGURE 4A)
INSULATION, SLEEVING
(MOVED TO ITEM 150F IPL FIGURE 4A)
RING
(MOVED TO ITEM 160 IPL FIGURE 4A)
(MOVED TO ITEM 170 IPL FIGURE 4A)
TUBE, INSULATING
(MOVED TO ITEM 180 IPL FIGURE 4A)

EFF
CODE

UNITS
PER
ASSY
AR

6
6

1
2
2
1

ILLUSTRATED PARTS LIST

24-20-76

Page 1046
Feb 26/07

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

THIS PAGE INTENTIONALLY LEFT BLANK

ILLUSTRATED PARTS LIST

24-20-76

Page 1047
Feb 26/07

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

HE-242076-67199-A
Semiconductor Device Set
Figure 4A
ILLUSTRATED PARTS LIST

24-20-76

Page 1048
Feb 26/07

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

FIG.
ITEM

PART
NUMBER

4A
-1

946F177-1

-1A

946F177-3

10

MS16625-1168

20

949B352-1

30
30M
40

962C265-1
947B451-1
938D679-11

-40A

5908349

-40B

5911588

50

938D679-12

-50A

5908350

-50B

5911589

60
-60A

MS21042-L4
MS21042L4

70

AN960-416L

80
90

947B473-1
948B032-1

100

948B034-1

- ITEM NOT ILLUSTRATED

1234567

NOMENCLATURE

SEMICONDUCTOR DEVICE SET


(SEE ITEM 80, IPL FIGURE 3A FOR NHA)
(S.B. 71-103)
SEMICONDUCTOR DEVICE SET
(SEE ITEM -80A, IPL FIGURE 3A FOR NHA)
RING, RETAINING
(18B1766-24)
(S.B. 71-103)
SPACER
(S.B. 71-103)
TUBE, BUS RING
BUSHING
SEMICONDUCTOR DEVICE, DIODE
(S.B. 71-103)
(REPLD BY ITEM -40A)
SEMICONDUCTOR DEVICE, DIODE
(REPLS ITEM 40)
(REPLD BY ITEM 4B)
SEMICONDUCTOR DEVICE, DIODE
(REPLS ITEM 40A)
SEMICONDUCTOR DEVICE, DIODE
(S.B. 71-103)
(REPLD BY ITEM -50A)
SEMICONDUCTOR DEVICE, DIODE
(REPLS ITEM 50)
(REPLD BY ITEM 50B)
SEMICONDUCTOR DEVICE, DIODE
(REPLS ITEM 50A)
ATTACHING PARTS FOR ITEMS 40 & 50
DELETED (NUT, SELF LOCK)
NUT, SELF LOCK
(959C711-5)
IDENT AS MS21042-L4
WASHER, FLAT
(910C331-11)
-----*----HOLDER, DIODE
LEAD, ELECTRICAL
(REPLD BY MIL-SPEC WIRE)
LEAD, ELECTRICAL
(REPLD BY ITEM -100A)

EFF
CODE

UNITS
PER
ASSY

RF

RF
1

1
1
2
3

3
3

3
AR

ILLUSTRATED PARTS LIST

24-20-76

Page 1049
Feb 26/07

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

PART
NUMBER

4A
-100A
-100B

949F363-1
949B363-1

110

949B362-1

120

948B031-1

130
-130A

TC1-6-ST
TC1-6ST

140

3530-05-03

-140A

947B872-2

150
150E

961C451-1
931A052-1

-150F

931A052-2

160

964C157-2

-170
180

DELETED
964C592-1

- ITEM NOT ILLUSTRATED

1234567

NOMENCLATURE

DELETED (LEAD, ELECTRICAL)


LEAD, ELECTRICAL
(REPLS ITEM 100)
(REPLD BY MIL-SPEC WIRE)
LEAD, ELECTRICAL
(S.B. 71-103)
(REPLD BY MIL-SPEC WIRE)
LEAD, ELECTRICAL
(REPLD BY MIL-SPEC WIRE)

UNITS
PER
ASSY

AR

AR

AR

ATTACHING PARTS FOR ITEMS 90, 100, 110


& 120
DELETED (RIVET, TUBULAR)
RIVET, TUBULAR
(V42838) (19C8355-33)
IDENT AS TC1-6-ST
WASHER, SPRING
(V78189)
DELETED (SPRING, WASHER)
-----*---- CAPACITOR FIXTURE
INSULATION, SLEEVING
(REPLD BY ITEM -150F. DISCARD ANY
REMAINING STOCK AND USE ITEM
-150F).
INSULATION, SLEEVING
(REPLS ITEM 150E)
RING
(S.B. 71-103)

EFF
CODE

TUBE, INSULATING
(S.B. 71-103)

1
2

2
1

ILLUSTRATED PARTS LIST

24-20-76

Page 1050
Feb 26/07