File Catalog:

Service Publications

Publica ion No. R73-12

Overhaul

Instructions

for

6-1-A

16-3-C

30

16-13-C

RED BANK D
.

EATO:siTOL:N,

ON

CO

NEW

TiCN

JE

SEY

Generators

Current

Direct

OF CONTENTS

TABLE

Page

Section

II

INTRODUCTIONANDDESCRIPTION...............................

1
1

1-1.

General...........................................

1-2.
1-3.

PurposeofEquipment
Difference
Data Sheets

1-4.

Specifications........................................

2-2.

2-3.
2-4.
2-5.
2-6.
2-7.
2-8.
2-9.
2-10.

SpecialTools....
Disassembly

1
1

2
2
3

....................................

........................................

Cleaning...........................................
Inspection
.

General

Tolerances

ArmatureAssembly

5
.

DriveShaftAssembly....................................
HousingandFieldCoilAssembly
Testing

General...........................................
Armature.Assembly.....................................
Anti-DriveEndHeadAssembly
Housing and Field Coil Assembly
CondenserAssembly....................................
Spring............................................
Repair or Replacement

General

2-24.
2-25.

Lubrication
Reassembly.

5
5

5
5

6
6
6
6
6
6
7

..

...

....

..

8
8
9
9

..........................................

..

..

..

TEST PROCEDURES..

..

..

..

..

...

TestEquipment.
Test Preparations

3-3.

MountingtheGenerator...................................

3-4.
3-5.
3-6.

ElectricalTestConnections

....

...

..

...

..

...

..

.....

..

..

..

3-1.
3-2.

3-12.
3-13.
3-14.
3-15.
3-16.

ResurfacingtheCommutator..

3-9.

2-23.

3-10.
3-11.

.............................

2-21.
2-22.

3-7.
3-8.

..............................

Soldering
Anti-Drive
End Head Assembly
BackHead..........................................
Housing and Field Coil Assembly

2-20.

...........................................

2-11.

2-19.

....................................

2-12.
2-13.
2-14.
2-15.
2-16.
2-17.
2-18.

IV

OVERHAULPROCEDURE...:.................................

2-1.

IU

...................................

..

..

...

..

..

..

..

.....

..

..

..

...

..

...

..

..

..

..

...

...

....

..

..

9
11
11
11
13

..

...

13

13
13

CompoundingandCommutation...............................

13
13
13
13
13
14
15
15
16
16

OverspeeLLRun
DielectricStrength.....................................

17

PolarityCheck

17

FlashingtheField

.....................................

ThermometerAttachment

................................

.................................

AirBlastCoolingAttachment
PreliminaryRunningCheck
BrushSeating........................................

...............................

................................

Tests
HeatRun
HotMinimumSpeed.....................................
...........,.................................

..........................................

........................................

.......................................

DIFFERENCEDATASHEETS...................................

17

19/20
i

Current

Direct

Generators

LIST OF ILLUSTRATIONS

Figure

Page

1-1

Type 30E16-1-A

2-1

Exploded

View

Direct

Current

Generator

Direct

Current

Generator

2-2

Reassembly

2-3

Lieasuring
the Voltage Drop in the Interpole
CompensatingWinding.........................

2-4

Internal

of Anti-Drive

\Viring

Diagrana

2-5

Diamond-Tipped

2-6

Mounting of Commutator

2-7

Carboloy-Tipped

3-1

Schenaatic

3-2

Blower

3-3

Type 30E16-3-A

4-2

Exploded

Seating

11

11

.21

Current

Type 30E16-13-C
Exploded View
Showing Differences

14
15
.

16

22

24

Generator

Current

Direct
.

Current

Direct

12

Generator
.23

10

4-4

Direct

30E16-3-C

iv

Exploded

4-3

Type

Generator.

Type 30E16-3-A
View
Showing Differences
View

Current

Cutting Tool

Direct

Tool

Cutting

Diagrana

and

Cutting Tool.

Commutator

Diagram.

4-1

Commutator

Test

Brush

End Head Assembly

Generator
.

27/28

iii

blicat

12

e 30gl6,

iV

1 4

et

feat

to

Direct

SECTION

Current

Generators

INTRODUCTION AND DESCRIPTION

1-1. GENERAL.
This handbook
disassembly,
covers
inspection,
repair,
reassembly,
and test procedures
forthe
Bendix Red Bank types 30E16-1-A,
30E16-1-C,
30E16-3-A,
30E16-3-C,
Direct Curand 30E16-13-C
rent
These
Generators.
units are manufactured
by
the Red Bank Division, Bendix Aviation Corporation
Eatontown,
New Jersey.

(Viewing Drive

1-2.

DRIVE

'

PURPOSE
OF EQUIPMENT.
The Bendix
Red
30E16-1-A,
30E16-3-A,
types
30E16-1-C,
30E16-3-C, and 30E16-13-C Direct
Current Generators areused
as engine-driven
sources of direct current in 24-volt electrical
systems.

TABLE I. LEADING
PERFORMANCE

PARTICULARS
AND
RATINGS (cont)

ROTATION:
.

End)

SPLINE:

Counterclockwise
.

Bank

MOUNTING FLANGE:
Shape

4-7/32

inches

square

1-3.

DIFFERENCE
DATA SHEETS.
contain
a. Sections II and III of this handbook
overhaul instructions
and test procedures
for the Bendix
Red Bank type 30E16-1-A
Direct Current Generator.
and test procedures
Overhaul instructions
for addiin Section IV by the use of
tional types are provided
Difference
Data Sheets.
The additional
types covered
in Section IV are listed in Section IV.
b. Overhaul
instructions
and test procedures
for
types covered in Section IV are the same as those

given in Sections
differences
noted

II and III, except

by the applicable

Sheet.
1-4.

for the specific

Difference

Number

of Holes

Diameter
Pilot
Bolt

of Holes

Diameter

Diameter

Circle

SPECIFICATIONS. Refer to table

ratings
of the generator.

I for

0.343 inch

3.249 inches
5.000 inches

COOLING

Data
Type........

formance

6 teeth

the

........Airblast

Inlet Pressure

per-

6-inch H2O pressure

plus velocity)
at 20C (68F)
to 30C (86F)

(static

head

TABLE

I. LEADING PARTICULARS
RATINGS

AND

PERFORMANCE

Volume.
OUTPUT:

30 Volts

100 cubic feet per

minute

100 Amperes

Air Spout

-.

Round, 2-inch OD

SPEED:
WIRING:...................Insulated

Rated..................2500-4500rpm

Regulation
Regulation

Overspeed

(minimum)
.

(maximum).

2500 rpm

.5500
.

rpm

.7000
.

rpm

WEIGHT:

33 pounds

*Do notconfuse
therated voltageof
the setting of the voltage regulator
by the procuring
agency.

(maximum)
with
is specified

the generator
which

No. R73-12

Publication

SECTION
OVERHAUL

2-1. SPECIAL
ment required
in table II.

TOOLS.

Special

tools

TABLE
PART

and

to overhaul the generator

Standard
.tools and test

NO.

IL

II

PROCEDURE

equip-

are

are listed
equipment

the

test

Spanner

QB80000-1

Screwdriver

table

Refer to Section
performing
when

III

SPECIAL TOOLS

for

test

procedures.

& TEST EQUIPMENT

NOMENCLATURE

QB72370-2

III.
materials

listed
in
required

APPLICATION

Wrench

To adjust

Press

brush spring tension

Used with screwdriver

bit, pushers, pullers,
generator
or disassemble

and other adapters

to assemble
QB80001-7

Bearing

Pusher

lock ring pilot

1. Used with QB80097-1
2. Used with QB80000-1 press to remove
ing (70,figure 2-1) from back head

QB80004-1

Spring

QB80005-34

Plug

Gage

To check pole

QB80008-4

Pole

Shoe Expander

To expand
screws

QB80009-5

Piloted

Scale

To check brush

Bearing

Pusher

spring
shoe

pole

settings

shoe while

tightening or

Used with QB80000-1

screwdriver
press
2-1) into anti-drive
end head

Piloted

QB80027-1

Screwdriver

QB80028-1

Vee Block Adapter

To support

QB80059-1

Splined

For holding
available

QB80063-2

6-Spline

Bearing

Pusher

Used with QB80000-1

into back head

Bit

Wrench

Shaft Holder

1.

To support

2. To prevent
nut

to

QB80097-1

Lock

QB80100-1

Brush

QB80110-1

Swivel Adapter

Used with QB80000-1

erator

QB80277-1

Hook

To lift brush

Ring Pilot
Spring

Expander

Anvil

Used

assembly

shaft

together to

assemble

spring

UsedwithpusherQB80001-7
To expand

when

to

and remove

spring

brush
press

when

press

bearing

press

spline

shoe

(27,

figure

2-1)

staked

pole

shaft

removing

holder

is not

or tightening

and sleeve

shaft snap ring

from sleeve

to assemble
removing

bearing

(70,

remove

installarmature

spring

pole

or disassembly

unit by drive shaft

shaft from moving when

Brush
Brush

Pilot
Assembly

during

removing

to install or

press

armature

QB80078-2
QBSOO79-1

Spring
Spring

to

press

Used with QB80000-1

shoe screws
housing

with bear-

tension

figure
QB80009-6

armature

or disassemble

or installing

brushes

gen-

Direct

TABLE

Plug

QB80513-1

Brush

1106900-1-A

Insulation

2-2.

To align

Box Aligner

brush

box and post assemblies

To test insulation

Tester

TOOLS

STANDARD

for breakdown

AND TEST

EQUIPMENT
APPLICATION

NOMENCLATURE

NO.

Model AGT-2*
Co,
Sun Electric
Chicago 31, Ill

Aircraft

Cat. No. 4020-A*

Plomb-Tool Co,
Jamestown, NY

Puller-Medium

Cat. No. 70A*

Snap-On Tools Inc,
Kenosha, Wis

Brake

direct

from

Generator

To check performance

Tester

To remove

Key Pliers

the

of generator

Used with plug QB80311-1

2 Jaw

drive

in disassembly

end snap ring

supplier.

DISASSEMBLY.

a. Remove all external safety wire.

b. Remove screws (1, figure 2-1) and washers
(2),
and detach air spout (3).
c. Remove screw (4) and window strap assembly (5).
The window strap pins (6 and 7) may now be removed,
if necessary
for replacement.
d. Remove the screws (8) and lock washers
(9)which

attach the jumper assemblies

(32)and brushes (10)to
the brush boxes (38 and 39). Using hook QB80277-1,
lift up the brush springs (42)and remove the brushes
(10).
(10)from the brush boxes. Discard thebebrushes
removed
at
The two jumper assemblies
(32)cannot
this time since they are secured by clamps (31).

screws
(11), washers (12), bearing cover
retainer
bearing
(14).
holder
shaft
in 6-spline
f. Mount the generator
holder
is not available,
QB80063-2.
If spline shaft
thedrive
QB80059-1 toimmobilize
use splinedwrench
Straighten
shaft.
tabs of tab lock (16), and remove
nut (15)and tab lock (16). Remove dirt slinger (26).
selfand remove
spring (19) slightly,
g. Compress
locking nut (17),washer (18), and spring (19). Remove
drive shaft assembly (20) from the drive end of the
Separate
front plate (21) and lining (22)
generator.
from the drive shaft.
e.

(cont)

APPLICATION

TABLE III.

*May be purchased

Generators

Usod with 4020A puller to:

from armature
end head and bearing
anti-drive
1. Remove
shaft
shaft
2. Remove back head from armature
(70, figure 2-1) from armature shaft
3. Remove ball bearing

QB80311-1

PART

EQUIPMENT

& TEST

NOMENCLATURE

NO.

PART

TOOLS

SPECIAL

II.

Current

Remove

(13),and

CAUTION

the back plate from

Do not attempt to remove
assembly,
since the plate is
drive
shaft
the
pressed on the drive shaft.

h. Remove screws (23) and washers

(24) which seend head assembly
(25) to the
cure
the anti-drive
QB80000-1,
housing
press
(79). Using screwdriver
and plug QB80311-1,
medium duty puller No. 4020-A,
end head assembly
pull anti-drive
(25) and ball bearPress
shaft.
out ball bearing
ing (27)off the armature
QB80000-1,
swivel
screwdriver
using
press
(27),
and piloted bearpuller 4020-A,
QB80110-1,
adapter
QB80009-5.
Remove slinger
(26).
ing pusher
end head asthe anti-drive
i. Do not disassemble
sembly
(25) unless damaged parts are found during
is necessary,
inspection
or testing. If disassembly
2-20.
refer to paragraph
j. Remove screws (45)and clamp (47). Remove bolts
(48),lock washers (49),"B" If post connector is (50),and
necesreplacement
condenser assembly
(51).
unsolder
terminals (52 and 53) from capacitor
sary,

(54).

k. Remove
(56). Remove
screws
(55) and bracket assembly
(59).
bolts (57),lock washers
(58) and lead
terminals
unsolder
is necessary,
If replacement
(61
and 62) from lead (60).
1. Straighten
tabs of tab lock (64) and remove bolt
and
lock
(64). Remove bolts (65), and lift tertab
(63)
minal board assembly
(66) from housing (79). Do not
board posts nor insert assemblies
terminal
remove
of these parts
If replacement
from terminal board.
replace
is necessary,
the entire terminal board as-

sembly (66).
m. Using screwdriver

medium
press QB80000-1,
dutypullerNo.4020-A,andbearingpusherQB80001-7,
press
the armature assembly (67) and ball bearing

5
42

50

43
41
38
37
63

35

56

4-55

59

--

60

36

-,)

64

3l

40
2

70
6

13
3
2
|

6-

72
11

2
-5

Figure

2-1.

Exploded

View

Direct

Current

Generator

Direct

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20

Screw

22 Lining

Washer
Air sliout
Screw
.
Window strap
assembly
Window strap
Window strap
Screw
Lock washer
Brush

23 Screw

pin
pin

-locking

Washer
Bearing
cover
retainer
Bearing
Nut
Tab lock

31
32
33
34

Clamp

Jumper
assembly
Lead
Terminal
lug
35 Brush box insulator
36 Plate
37 Bushing insulator
assembly
hand)

57
58
59
60
61

(left

39 Brush box and post

assembly (right

Drive shaft
assembly

hand)

plate

(70)out of back head (72). Using brake key pliers No.

slinger
lock ring (68). Remove
70-A, remove
(69).
QB80000-1,
medium puller
Using screwdriver
press
ball bearing
4020-A, and plug QB80311-1,
(70)
remove
Remove
slinger
assembly.
from the armature
(69).
screws
(71) and separate back head (72)
n. Remove
from housing (79).
unsolder
is necessary,
terminals
o. If replacement
"E"
post
77)
connector
and
and
(78) from the
(76
assembly(75).
complete
fieldcoil
Donot disassemble
the housing and field coil assembly
(73) unless it is
either the housing (79) or the
to replace
necessary
is
complete field coil assembly (75). If disassembly
2-22.
refer to paragraph
necessary,
2-3.

CLEANING.

use sola. Where a cleaning solvent is necessary,

solvent,
dry cleaning
such as Esso "Varsol"
vents
trichlorethylene, naphtha or an aliphatic hydrocarbon.
Do not allow the parts
to soak or remain in the soland
Using a paint brush, wash the armature,
vent.
Remove any carhousing and field coil assemblies.
in the
bon or copper particles
v hich may be imbedded
bars of the
between the commutator
mica insulation
armature assembly.
purchased
from
cleaning equipment
b. Ultrasonic
Division, Bendix Aviation CorporaPioneer-Central
ConIowa, may be used if available.
tion, Davenport,
sult the manufacturer
of this equipment for the proper
and methods
to be used.
cleaning solutions
assembly and the housing and
c. Bake the armature
in an oven for two hours at 121C
field coil assembly
(200F).
(250F)
Apply a
or for three hours at 93C
preparation.
light film of oil or anti-corrosion
to all
ferrous metal surfaces
to prevent rusting.
2-4.

INSPECTION.
GENERAL.

2-5.
a. Closely
damage.

examine

all generator

52 Jumper terminal
53 Jumper terminal
54 Capacitor
55 Screw
56 Bracket
Bolt
Lock washer
Lead assembly
Lead

38 Brush box and post

nut

Washer
Spring

21 Front

~
.

parts for wear and

Generators

2-1

40 Bolt
41 Cotter pin
42 Brush spring
43 Sleeve
end head
44 Anti-drive
45 Screw
46 Not used
47 Clamp
48 Bolt
49 Lock washer
50 "B" post connector
51 Condenser
assembly

24 Washer
end
25 Anti-drive
head assembly
26 Dirt slinger
27 Ball bearing
28 Self
nut
29 Lock washer
30 Washer

Screw

Self-locking

KEY TO FIGURE

Current

Terminal

62 Terminal
63 Bolt
64 Tab lock
65 Bolt
board
66 Terminal
assembly
67 Armature
assembly
68 Lock ring
69 Dirt slinger
70 Ball bearing
71 Screw
72 Back head
73 Housing and field
coil assembly
74 Screw
75 Complete field
coil assembly
76 Terminal
77 Terminal
78 "E" post
connector
79 Housing

and tapped parts for stripped

b. Check all threaded
and crossed
threads, or round corners.
screws, dirt slingers,
c. Check for bent washers,
and lock ring.
jumper or lead terd. Check for worn or damaged
minals.

TOLERANCES.
a. Refer to table IV for dimensions

2-6.

when the generIf

inspected.
being
the
clearance beare
exceeds
the permissible
tween two mating surfaces
specified
the
in table IV, replace
clearance
worn
part or parts which are worn beyond the permissible
dimensions.
liner
is worn
end head bearing
b. If the anti-drive
replace
dimension,
the antibeyond the permissible
drive end head (44, figure 2-1).
liner is worn beyond the
c. If the back head bearing
replace
dimension,
permissible
the back head (72).
ator

parts

2-7.

ARMATURE

ASSEMBLY.

a. Check the spline inside the commutator end of the

Assemble
shaft for scoring.
armature
the drive shaft
Replace
shaft.
asinto the armature
the armature
sembly if the drive shaft does not fit freely due to a
shaft spline.
scored armature
b. Be sure banding wire and clips are tight and
firmly soldered.
bars
are tight, and in
c. Be sure the commutator
if high
assembly
alignment.
Replace the armature
Measure
the depth of the
bars are found.
commutator
If the
bars.
undercutting
between
the commutator
to a depth bedepth is less than 0.021 inch, undercut
tween 0.021 and 0.036 inch, and to a width of 0.025
is
surface
of the commutator
If the contact
inch.
rough, pitted, scored, burned,
or covered with a hard
film of carbon or oil which cleaning fails to remove,
2-23).
(Refer to paragraph
resurface
the commutator.
If the
bars.
burned
commutator
for
d. Check
badly
assembly
bereplace
armature
bars
burned,
the
are
5

Publication

No. R73-12

TABLE
i

LOCATION

Armature
shaft
in anti-drive
end

CHECK

POINTS

Armature

shaft OD

head ball bearing

Ball bearing

Armature
shaft
in back head ball
bearing

Armature
Ball

shaft

bearing

Ball bearing in
anti-drive
end

Ball bearing

head bearing

Bearing

liner

Ball bearing in
back head
bearing liner
Drive

shaft
splines

OD

NEW
DIMENSION

min

max

0.7875

0.7877
0.7874

0.9843

0.9846

0.0007

------

WORN
CLEARANCE

0.0001 T

------

0.7874

0.9843

------

0.0000 T

to
0.9843

0.0000

OD

1.8500

1.8504

0.0004 T

liner ID

0.7875

PERMISSIBLE

to

0.9839

OD

PERMISSIBLE
WORN DIMENSION
min
max

0.0007 T

0.7870

1.8503

0.0003

2.0470

2.0472

0.0004 T

2.0468

2.0471

Anti-drive end,
over 2 pins 0.072
0
dia

0.549

0.552

Drive end

0.863

0.865

NOTE

The Magnaflux Corporation,

5908 Northwest
Highway,
Chicago, Illinois,
is the developer
of
the Magnaflux process, andwill provide a con
sulting engineer, for proper methods
to be
used, if necessary.
Pay particular
attention
to proper cleaning of the parts and removal of
foreign matter
from cracks alid fissures,
HOUSING AND FIELD COIL ASSEMBLY.
If any insulation
a. Closely examine
all windings..
is
worn or damaged, replace
the complete field coil as-

------

1.8500

0.9843
------

0.0003 L

to

1.8500

2-8. DRIVE SHAFT ASSEMBLY.

Procedure
for inspection of the drive shaft is given in table IV. When
inspecting
for evidence
of overheating, bear in mind
that, although discoloration
may indicate a weakened
shaft, the condition can also be present
in a sound
shaft. Uniform
discoloration
along the pencil section
of a new shaft may be disregarded;
if, however,
localized or blotchy
discoloration
is noted, overheating
in service
is indicated.
If slight blueing has occurred,
the shaft may still be serviceable,
provided
a Magnaflux inspection
reveals
cracks.
no surface
If black
discoloration
is present,
the shaft should be discarded.
Steps should also be taken
to eliminate
the cause of
the condition, such as overload or excessive
vibration.

NEW
CLEARANCE

.
0.0001

coils may be open circuited.

cause the armature
e. Inspectthearmatui'ewindingsforwornordamaged
insulation.
Be sure all conductors are firmly brazed
to the commutator risers.
The depths of the conductors in the slots of the armature
core should be approximately
equal. Check for flaring of the conductors at the drive end of the armature
core.

2-9.

TOLERANCES

ID

liner ID

Ball bearing
Bearing

ID

IV.

------

2.0470

1.8503

------

0.0001 L

to
0.0001 L

2.0471

------

0.549

0.863

------

------

sembly.
Refer to paragraph
2-22 for disassembly
of
complete
field coil assembly
from the housing.
b. Replace
terminals
or resolder
(76 and 77, figure
2-1) and the "E" post connector
(78), if they are broken or loose.
(Refer to paragraph
2-19 or soldering
procedure.)
c. Be sure all pole shoe and interpole
screws .are

the

tight.
2-10.

TESTING.

2-11. GENERAL.
Insulation tester 1106900-1-A
or a
series
test lampcircuit
may beused when performing
electrical
tests. When a sefies
test lamp circuit is
used for electrical
testing, use sharp pointed prods
on the test leads to insure good contact with anodized
parts.
Connect a 10-watt lamp in series
or painted
with one lead, and plug the circuit into
a 110-volt ac
commercial
power source.
2-12.

ARMATURE

ASSEMBLY.

assembly
for ground using the
a. Test the armature
series test lamp circuit.
Touch one prod to the armature
shaft, and touch the other prod to
any bar of
If the lamp lights, the armature
the commutator.
assembly is grounded
and should be replaced.
b. Using a " growler
", test the armature for shorts.
Place
assembly
in the "growler ", and
the armature

holding a thin strip of steel (such as a hacksaw

blade)
over the armature
rotate
core, slowly
the armature
assembly.
If the steel strip
vibrates,
the armature
is short
assembly
circuited,
and shouldbe replaced.
ANTI-DRIVE
2-13.
END HEAD ASSEMBLY.
a. Be sure that brush boxes are firmly attached

the anti-drive

end head.

to

Current

Direct

Generators

QB72370-2
alter
the position of the sleeve until the
28 and 32
between
brush spring
tension measures
is
made,
the
adjustment
When
secure
the
ounces.
sleeve (43)with the cotter pin (41).
to between
f. If the spring tension cannot be adjusted
the brush spring (42) with
28 and 32 ounces, replace
described
in
a new one, and adjust the tension as
step e.
check for cong. Using the series test lamp circuit,
tinuity of the jumper assemblies (32). Touch one test
If the lamp fails to
prod to each jumper terminal.
is open and should be
light, the jumper assembly

b. Using the series

test lamp circuit, check for
end
prod to the anti-drive
Touch
test
ground.
one
head, and touch the other test prod to each brush box
If the lamp lights,
in succession.
the brush box is
2-20 for disassembly,
Refer to paragraph
grounded.
Use new
parts.
and replace
the damaged insulating
and repeat the test
insulating
parts for reassembly,
for ground.
the tenc. Using spring scale OB80004-1, measure
Hook the scale underneath
sion of each brush spring.
thebrushspring arm, and lift the arm until its bottom
surface is 7/32 inch above the top of the brush box.
between 28
The tension at this point should measure
and 32 ounces. (See figure 2-2.)
d. If the measured
tension of the brush spring is not
between 28 and 32 ounces, adjust the tens,ion.
the sleeve (43, figure 2-1) from turning,
e. Keeping
remove
the cotter pin (41),and using spanner wrench

replaced.

2-14. HOUSING AND FIELD COIL ASSEMBLY.

resistance
bridge
or similar
a. Using a Wheatstone
of the field
measuring
device, check the resistance

DIRECTION OF PULL FOR

SETTING SPRING PRESSURE

SPR1NG PRESSURE TO BE
28-32 OUNCES WITH SPRING
IN POSITION SHOWN

SEE PLAN VIEW FOR LOCATION

SEE NOTE

PRE-SCRlBED LINE
IN FLANG

34

LOCATION OF JUMPER
CALRAR

S WITH
PAINT BETWEEN
G.E. CO'S. NO.120\ RED GLYPTAL
(8 MOUNTING BOLTS)

SECTION A-A
A
NOTE
COAT BUSHINGSAND INSULATING WASHERS WITH RED GLYPTAL BEFORE ASSEMBLY
TIGHTEN NUT AND PAINT BETWEEN ARROWS AS SHOWN-BAKE FOR ONE HOUR AT
RETIGHTEN NUTS T,9 4OIN. LBS. WHILE HOT. (8 MOUNTINGS)
121.l*C (250F).

1 Cotter pin, 4 reqd

reqd
2 Washer,14

6 Plate,

4 reqd
8 reqd
16 reqd

7 Insulator,
8 Insulator,

,,

3 Clamp, 2 reqd
4 Nut, 8 reqd
8 reqd
5 Lock washer,

2-2.

Reassembly

4 reqd
4 reqd

12 Brush box and

post

9 Bolt, 8 reqd

Figure

10 Spring,
11 Sleeve,

assembly

(LH), 2 reqd
of Anti-Drive

13 Brush box and

post assembly
(RH), 2 reqd
14 Anti-drive end
head, 1 reqd

End Head Assembly

7

Publication

No. R73-12

coil assembly.

The resistance
should measure
1.935 and 2.365 ohms at 20C (68F).

tween

be-

NOTE

e. Touch millivoltmeter
(5) test procs to thetwo termnals of the compensating
circuit.
The millivoltmeter (5) should read between 1.9 and 2.1 volts at 25C
(77F).

When connectingany
deviceusing
a d-c source
to check theresistanceof the fioldcoil assembly, connect the terminals of the device to the
terminals of like polarity of the field coil assembly.
This is to prevent
the reversal
or
demagnetization
of the generator
field.
b. Check theinterpoleand
winding
compensating
cirby measuring
the voltage drop while allowing
current
to flow through the circuit.
(See figure 2-3.)
An internal
", if available, may also be used
"growler
as described
in paragraph
2-12, step b,, to check.the
windings
of the field coil and pole assembly
for short
circuits.
Tomeasure
thevoltage drop of the compensating
circuit (figure 2-3) proceed
in
as described

f. Disconnect

c.

(2,figure 2-3)
(2)for

ammeter

1 D-c ammeter
with 200 ampere external
shunt
Weston Electrical
Instrument Corp, Newark, N J,
Model 45

2 Compression carbon rheostat,

rating: 400 amperes,
0.01 to 2 ohms, 1500 watts
James G Biddle Co, Philadelphia,
Pa,
Catalog No. 30
3 Suitable
4 12-volt

single-pole,

single-throw

knife

6 Housing

and field coil assembly

N J,

NOTE
All cables except millivoltmeter
be AWG size 00

Figure

2-3.
Interpole

Measuring

the

test leads

are to

Voltage Drop in the

Winding

and Compensating

2-15.
CONDENSER
ASSEMBLY.
available
condenser-testing
a. Using
equipment,
.
check for dielectric
breakdown.
b. Apply 110 volts de across the two terminalsoi the
capacitor for one minute.
c. Check between
each terminal and the housir.;
(ground). Neither test should indicate continuity.

ratine
dc.

which

should

be 4.

2-16.

SPRING. Compress
spring
(19, figure 2-1) to a
of 7/8 inch.
If the compression
force required
doesnot
between42.75
measure
and 47.25 pounds, replace the spring.
,
iength

REPAIR

OR REPLACEMENT.

5 D-c millivoltmeter
Electrical
Instrument Corp, Newark,
Model 280, ranges 0 to 1 and 0 to 10 volts

lamp circuit, check the housg. Using theseriestest

and field coil assembly
for ground.
Touch one
test prod to the housing and the other test prod to the
end of any one of the free leads of the windings.
If the
lamp lights,
it indicates
either a grounded
shunt field
coil or compensating
circuit.

2-18.
GENERAL.
a. Refer to table V for replacement
of parts.
b. Replace
all screws,
nuts, and bolts with
stripped
threads.

battery

Weston

(3).

ing

2-17.

switch

switch

Proccod with care in order to prevent damage

to the meter
in the event of a high resistance
Uso calibrated
or open winding.
test leads
with the millivoltmeter
to insure accuracy of
measurement.

d. Check the capacitor

microfarads,
150 volts

COMPENSATING
CIRCUH lERMINALS

(5) and open

CAUTION

cuit

steps c through f.
c. Adjust compressioncarbonrheostat
for maximum resistance.
d. Close switch (3). Adjust rheostat
(1)reading of 100 amperes.

millivoltmeter

worn or

2-19. SOLDERING.
a. When soldering

terminals
(34, figure 2-1) to leads
(33) and terminal (77) to complete field coil assembly
No. 9 Grade 11, which consists
(75), use Eclipsoloy

of 100 percent
tin solder.
b. When silver soldering
terminal (76) and "E" post
connector (78) to complete
field
coil assembly
(75)
No. 27 Grade 3, which consists
use Eclipsoloy
of 15
percent
silver, 80 percentcopper,
and 5 percent phosphorous,
brazing anoy.
c. When silver soldering,
as in step b, do not use any
flux. When soft soldering,
as in step a, use a ilux
composed of 50 percent
rosinand
50 percent ethyl alcohol or turpentine by weight,

Direct
TABLE

Capacitor
assembly

Leads

Complete

terminal lugs and

fieldcoilassembly

d. After

34, 50, 52, 53,

61, 62, 76, 77, 78

79

soldering,

traces of
to be sure

clean joints with alcohol to rerosin or other

foreign
matter.
insulation

was not burned

overhaul
plate,
spline

back
scored

discolored

Worn

(Refer

to paragraph

2-15)

or damaged

insulation

Cracked

or corroded

Grounded

or shorted

Cracked
j. Connect the jumper assemblies
(32) between
(See figure 2-4.)
posite brush boxes.

op-

during

END HEAD ASSEMBLY

2-20. ANTI-DRIVE
a. If it is necessary to replace a damaged part, proceed as described in the following steps.
self-locking
nuts
b. Remove
(28, figure 2-1), lock
washers
(30), clamps (31) and jumper
(29), washers
assemblies
(32).
c. Remove brush box insulators
(35),plate (36),bushing insulators
brush
post assemblies
box
and
(37),
(38
and 39), and bolts (40).
d. It it is necessary
to replace brush spring (42),remove cotter pins (41)from sleeves
(43),and separate
sleeves (43) and brush springs
(42) from brush box
and post assemblies
(38and 39). Using brush spring
expander
QB80100-1, remove brush springs (42)from

sleeves (43).
the antie. If the bearing liner is damaged, replace
drive end head.
f. Replace the damaged part or parts, and reassemble
in steps
g through j, and as shown in
as described
figure 2-2
and brush
g. Using brush spring pilot QB80078-2
spring assembly anvil QB80079-1,
assemble the brush
springs (42)and sleeves (43)into brush box and post
assemblies
(38and 39) with cotter pins (41).
h. Attach brush
box and post assemblies
(38 and 39)
to anti-drive end head (44),with bolts (40), nuts (28),
lock washers
(29),washers (30),clamps (31), jumper
assemblies (32),insulators
(35and 37), and plates (36).
(See figure 2-2.) Using brush
box aligner QB80513-1,
.
align brush boxes.
i. Adjust brush springs
(42)so that each spring has
a tension of between 28 and 32 ounces when its arm is
lifted 7/32 inch above the top of the brush box. Check
the tension using spring scale QB80004-1. (Refer to
paragraph
2-13, step e.)
.

or

or shorted

2-21.
BACK HEAD. If
replace
the back head.

cracked

or damaged

Grounded

75

Housing

move all
e. Check
soldering.

Commutator

33, 60

At each

Leaky

67

overhaul

If bent

54

At each

Loose
shaft,

26, 69

Dirt slingers

Terminals,
connectors

20

Drive sha.ft assembly

REPLACE

27, 70

bearings

Generators

AND REPLACEMENT

REPAIR

10

Brushes

Armature

REPAIR

FIGURE 2-1
(Index No.)

NOMENCLATURE

Ball

V.

Current

bearing

the

liner

is damaged,

2-22. HOUSING AND FIELD COIL ASSEMBLY.

to replace the housing, or the
a. If it is necessary
proceed
complete field coil assembly,
as described
in the following
steps.
b. Place
the housing and field coil assembly
(73,
QB80028-1.
figure
2-1) in vee block adapter
Using
QB80000-1
screwdriver
and screwdriver
bit
press
QB80027-1,
remove
the screws (74).
c. Bake the housing and field coil assembly
(73) for
121C (250F), in order to
one hour at approximately
and facilitate
the removal
loosen the varnish
of the
complete field coil assembly
(75)from the housing (79).
d. Separate
the complete
field coil assembly
(75) from
the housing (79) noting the position
of the insulating
strips
on each field coil connection.
field coil assembly
is being ree. If the complete
placed,
all varnish
of the
from the inside
remove
housing,
with naphtha.
using a rag moistened
in
f. Place the new complete
field coil assembly
(74).
the housing and assemble loosely with screws
strips
Be sure that the insulating
on the field coil
noted at disasconnections
are in the same position
sembly.
Tighten
the pole shoe screws enough to hold
the coil in place.
.
Repeat
in paragraph
the ground check described
2-14, step g.
h. Dip the housmg
and field coil assembly
(73) in
manufactured
by Sterline
Varnish
M-830,
Sterline
Co, Hayesville,
Varnish
Pa, (specific gravity between
0.850 and 0.860), for one-half hour.
.

CAUTION
Protect
Do not dip the leads.
varnish
hardening
to prevent

them from the

after

baking.
9

Publication

No. R73-12

i. Drain the assembly

for one-half
hour. Wipe the
from the housing, using a cloth moisexcess varnish
ned with naphtha.
Bake the entire assembly
from 10 to 12 hours at
approximatelyl21C(250F).
Removetheunitfrom
the
it to cool forbetweenoneand
ovenandallow
twohours.
k. Repeat steps
h and i. Invert the position
of the
unit in the oven and repeat step j to insure
uniform

place,

shoe screws.
Repeat this oppole shoes.
and using plug gage QB80005m.
ar:Lature
34, check for proper
The inside
clearance.
diameter
between
pole shoes should be
the opposite
between 3.863 and 3.865 inches.
andground
checks described
n. Repeat the continuity
in paragraph
2-14 to be sure that the new field coil
assembly
has not been grounded or opened during assembly into the housing.
o. Stake each pole shoe screw
to the housing in two
places.

Laking.
1. While the unit is still hot from. baking, use pole
shoe expander QB80008-4
to expand any two opposite
pole

shoes

against

the

housing.

With

the

expander

tighten the pole

for the remaining
Remove the expander,

eration

in

\BA

DE

O
ma mass ma
masams-

GENERATOR

GENERATOR
EQUALIZER

OUTPUT
CTRCUIT
SHUNT FIELD CIRCUIT

CIRCUIT

--

USED

TN PARALLEL

SYSTEMS ONLY

1 Compensating
winding
2 Interpole

4 Shunt field
assembly
5 Pole shoe

winding

3 Interpole
Figure

10

2-4.

Internal

Wiring

Diagram

coil

Direct

2-23.

RESURFACING THE COMMUTATOR.

a. Mount the armature
assembly in a lathe. The arshaft bearing surfaces
mature
should run true.
b. To remove oil or carbon film, take a single light
cut at a speed of approximately
600 surface-feet
per
minute.
If the commutator
is scored or pitted, take a
series of light cuts at a speed of approximately
200
surface-feet
A diamond-tipped
per minute.
cutting
tool (figure 2-5) is recommended.
The point of the
cutting tool must be held on the center line of the armature
shaft. (See figure 2-6.) If a Carboloy-tipped
cutting
tool (figure2-7) is used, the point of the cutting tool must be held 1/32 inch below the center line
of the armature
shaft.
diameter
c. The minimum
to which the commutator
If it is necessary
may be turned down is 2.700 inches.
to remove metal beyond this point, replace the arma-

ture assembly.
.
d. After turning down the commutator
measure
the
depth of the undercutting
between the commutator
bars.
If the depth of the undercutting
is less than 5
0.021 inch,undercut
the mica to adepth between 0.021
and 0.036 inch, and to a width of 0.025 inch.
e, After undercutting
the commutator,
take a final
cut of not more than 0.001 inch across the face of the
commutator
If a Carboloy-tipped
to remove burrs.
cutting tool is used, make the final cut with a freshly
honed tool. The cutting speed should be approximately
600 surface-feet
per minute with either type of tool.

Do not use
face.
After
commutator

polishing

abrasives

on the commutator
burrs from between
remove
with a strip of fiber.

the final cut,

bars

10

COMMERCIAL DIAMOND
APPROX
CARAT
-

Current

Generators

f. Check the concentricity

of the commutator
with
surfaces
of the armature
shaft.
The diameters
should be concentric
within 0.0003 inch, full

the bearing
indicator

reading,
NOTE

Clean the resurfaced

commutator
before reassembling the generator.
Remove all traces
of oil, grease or other
harmful
substances.
g. Check to be sure that the diameter
of the refinished commutator
is not less than 2.700 inches.
If it
is, replace the armature
assembly.
2-24.
LUBRICATION.
a. Lubricate the splines of the drive shaft and armaNo. 31 spline lubricant
ture shaft with Pioneer
(obtainablefrom Red Bank Division,BendixAviationCorporation,
Eatontown,
New Jersey).

2-25.

REASSEMBLY.
a. Using screwdriver
press QB80000-1, swivel adapter QB80110-1, and piloted bearing pusher QB80009-5,
press ball bearing (27. figure 2-1) into anti-drive
end
head assembly (25). Using the same tools, press the
assembly
onto the commutator
end o armature
assembly
(67).
b. Assemble
tab lock (16) and nut (15) onto shaft of
assembly
armature
assembly
(67). Insert armature
into the housing and field coil assembly
(73). Fasten
by attaching
the assemblies
anti-drive
head assembly
(25) to housing and field coil assembly
(73)
with screws
(23) and washer (24).
ing screwdriver
press QB80000-1, swivel adaptand piloted
er QB80110-1
bearing pusher QB80009-6,
press ball bearing (70) into back head (72).
d. Install
dirt slinger
(69) on the shaft of armature
assembly
(67). Using the same tools as in step c,
press ball bearing
(70) and back head (72) onto shaft
of armature
assembly
(67). Fasten the head to the
housing (79). Install dirt slinger
(69), and using lock

O.OlO R MAX

30o

sTEEL
TOOL

90

BIT

Figure

2-5.

Diamond-Tipped
Cutting Tool

Commutator
Figure

2-6.

Mounting of Commutator

Cutting Tool
11

Publication

No. R73-12

6-APPROX

15
0

32

Figure

2-7.

32

Carboloy-Tipped

ring pilot QB80097-1

and bearing pusher QB80001-7,
install lock ring (68).
.
e. Fasten terminal board assembly
(66)and bracket
(56) to housing (79). Using clamp (47), attach condenser assembly
(51)to bracket (56).
f. Position "E" post connector
(78) under jumper
terminal (53),and fasten both to terminal board assembly (66).
"B" post connector (50) to anti-drive
end
g. Fasten
head assembly
(25). Position other end of "B" post
connector
(50)under jumper terminal (52)and fasten
both to terminal board assembly
(66). Attach lead assembly (59) to terminal board assembly (66). (See

figure 2-4.)
h. Assemble
shaft

(22)and front plate (21) on drive

(20). Be sure front plate (21), lining
the back plate of drive shaft assembly
(20)
against
lining

assembly

(22),and
fit snugly
each other.
Slide drive
sembly (20) into tubular shaft of armature

12

shaft asassembly

Commutator

(67). Using

Cutting Tool

splined wrench QB80059-1 to prevent the

from moving, install
spring (19), washer
nut (17). Install
(18), and self-locking
tab lock (16)
shaft.
and nut (15) on armature
Tighten self-locking
nut (17) and nut (15) while
holding
the drive shaft
immobile.
i. Slowly rotate
assembly
the armature
by hand. It
should rotate quietly with a slight and uniform
drag
caused by the grease in the ball bearings.
If the armature does not rotate freely, disassemble
the generator and recheck
the tolerances specified in table
IV. Be sure the trouble is eliminated
before performing the test procedures.
j. Using hook QB80277-1,
lift up brush springs (42)
and install brushes (10).
bearing
k. Fasten
retainer
(14) and bearing cover
end head
(13) to anti-drive
assembly
(25). Fasten
window strap assembly
(5),with the pins (6 and 7) and
screw (4). Install air spout (3).
drive

shaft

Direct

SECTION
TEST

3-1. TEST EQUIPMENT.

a. See figures 3-1 and 3-2 for the recommended
equipment.
b. Throughout
the tests,the
should be counterclockwise
tor drive end).

rotation

using

suitable

external

shunts

these

meters

THERMOMETER
ATTACHMENT.
Use a laboratory-typethermometer
to measure the temperature
during
rise of the generator
the heat run. Insert the
bulb end of the thermometer
through a. slotted felt
pad, and set the bulb against
Tie
a pole shoe screw.
the pad firmly in place against the housing.

genera-

NOTE
Do not attach
the
side of the generator

TEST PREPARATIONS.
Mount

bracket.
assembly

the gen-

AIR BLAST COOLING ATTACHMENT.

a. Make the connections for supplying
the cooling air
as shown in figure 3-2. Place the pitot tube in the air
blast tube at a point 12 inches from the generator air
securely.
spout. Clamp all air duct connections
b. Close the blower switch and adjust the air intake
of the blower until the outlet pressure
(static plus
velocity)
head measures
of water
six inches
on the
The maximum
manometer.
permissible
temperature
of the cooling air is 30C (86F).

CAUTION

3-4. FLASHING THE FIELD.

a. Using a 12-volt battery, flash the shunt field circuit to be sure that the magnetic circuit of the genmagnetism
sufficient residual
erator retains
to allow
voltage to build up properly.
the generator
b. Connect the negative
battery terminal to the "E"
Connect the positive
terminal post of the generator.
battery terminal through a single-pole,
single-throw
knife switch to the "A" terminal post. Apply battery
current to the field for approximately
five seconds by
closing and opening the knife switch.
c. Repeat theoperation several times to make certain
that the field is properly flashed.

If, during

any test, smoking or excessive

sparking
is observed,
unusual
noises
are
heard,
does not meet any of
or the generator
immediately
thespecified performancevalues,
and shut down the driving
open all switches
If visual
inspection
does not disclose
motor.
the cause of the trouble, disassemble
the genand repeat
erator
and testing as
inspection
instructed
in Section III. After reassembling,
repeat the test procedure
from the beginning.
a. Turn on the blower (8, figure 3-2).
b. Move the shunt field switch (9, figure 3-1) to the
connecting
"X" position,
the generator
through the
regulator
for automatic
carbon pile voltage
voltage

CAUTION
It is necessary that a knife switch beused when
flashing
the field, since opening the circuit at
the generator or battery terminals may result
in severe damage to the terminals, or explo..

Make the
ELECTRICAL TEST CONNECTIONS.
in figconnections as shown schematically
Keepallconnectionsasshortasconveniently

electrical
ure3-1.
possible.

same

3-8. PRELllvINARY
RUNNING CHECK. Perform
a
check using the voltage,
brief running
and
current,
speed values
specified in table VI. The generator
may be considered in good running condition for further testing if a load can be applied as per caution.
With all switches open, proceed as follows:

to the

without the window

Operation of the generator
air blast
strap assembly,
cooling
or without
will result in excessive heating.

3-5.

to the
spout.

Attach

CAUTION

sion of the battery.

as the air

3-7.

Be sure millivolt-drop
rating
of meter and
shunt correspond.
.Use calibrated shunt leads.

3-3. MOUNTING THE GENERATOR.

erator on the test stand mounting
the air spout and the window strap
generator.

thermometer

may be

of application.
CAUTION

3-2.

III

3-6.

test

c. Use any load bank having graduated load steps and

a continuous rating of at least 100 amperes at 30 volts.
d. Adjust the carbon pile voltage regulator
(3, figure
3-1) for regulation
between 27.0 and 28.4 volts.
without internal
shunts,
e. Use ammeters
so that by

used over a wide range

Generators

PROCEDURES

of the generator

(viewedfrom the

Current

regulation.
motor
and gradually increase
c. Start
the driving
the driven speed of the generator
to 2500 rpm. The
reading
of line voltmeter
(6, figure 3-1) should remain at approximately
30 volts.
d. Close load switch (5) and apply a load of approximately 10 amperes
by closing the appropriate
switch
of load bank (8). The reading
of line voltmeter
(6)
should remainat
approximately30volts,and
the reading of load ammeter(4)
should be approximatelyl0

amperes.
13

Publication

No. R73-12

e. Gradually
increase
the applied load to not more
100 amperes
by closing switches of load bank
(8).
The reading
of line voltmeter
(6) should remain at
approximately30
volts,and
the shunt field current, as
indicated
by field ammeter
(2), should not

3-9.
BRUSH SEATING.
a. Use voltage, current,
speed, and temperature values specified in table VII when seating
the brushes.

than

exceed 8.00
amperes.
f. After completing the test,
open all load switches
and turn off the driving motor and
blower.
TABLE VI. PRELIMINARY

CAUTION
Do

RUNNING

CHECK

FIELD AMMETER
Amperes (Max)

SPEED

2500 to 4500 rpm

not

abrasives

use

at any time to aid in

brush seating.
PERFORMANCE

VALUES

LOAD AMMETER

Amperes

8.00

LINE VOLTMETER

(Max)

Regulated

100

Volts

30

TABLE VII. BRUSH SEATING

SPEED
rpm

FIELD
AMMETER
Amperes

2500

LOAD AMMETER
Amperes (Max)

(Max)

First

8.00

1/2 hour

LINE
VOLTMETER

Balance

of run

Regulated

HOUSING
TEMPERATURE

Volts

(Max)*

50

100
30
*Do, not confuse maximum housing
temperature with normal rise in temperature.
temperatures exceeding the value specified
may result in damage to its windings.

110C

Operating

G NERATOR

TESTER

OC

LOA

KO

SW

GNO
RHEO

CARBON PILE
REGULATOR

10

1 Aircraft
Generator Tester, Sun Electric Co,
Chicago 31, Ill
2 D-c ammeter (field)with15
ampere external
shunt, Weston Electrical
Instrument Corp,
Newark,
N J, model 45
3 Carbon pilevoltageregulator,
Red Bank Division, Bendix Aviation
Corp, Eatontown-, N J,
type 1589 model 1 for 30 volt operation
4 D-c ammeter (load)with 75
ampere
external
shunt, Weston Electrical
Instrument Corp,
Newark, N J, model 45,

Figure
14

generator

AIRCRAFT
GENERATOR

the

(230F)

3-1.

Schematic

5 Suitable
6

7
8

9
10

00

00

LOAD BANK

single-pole,
single-throw
knife
switch (load)
D-c voltmeter
(line), Weston Electrical
Instrument
Corp, Newark,
N J, model 45,
range 0-30 volts
AWG size 00 cable
Load bank (Refer to paragraph
3-1, step c)
Suitable
single-pole,
single-throw
knife
switch (pile shorting)
D-c voltmeter
(field),Weston Electrical
Instrument
Corp, Newark,
N J, model 45,
range 0-30 volts

Test

Diagram

at

Direct

Current

Generators

NOTE
The blower should provide a minimum
of 100 cubic feet of cooling air per
minute at a maximum
temperature of
30C
(86F)
and a total pressure
(static plus velocity) head of 6 inches
of water.

10

GENERATOR

AIRCRAFT
GENERATOR

6 IN. OF WATER

TESTER

1 Air spout
2 Laboratory-type

12 IN.

thermometer

3 Flexible hose
4 Pitot tube
5 Air blast tube (inside
to be smooth) 1. 91inch

ID

hose with
reducers
suitable
7 Water manometer
Blower
8 Blower, American
Corp, Detroit, Mich
size D, type P or equivalent (see note)
9 Felt strip for mounting

24 IN.

6 Flexible

5
6

C=

thermometer
10 Laboratory-type

thermometer
Figure

3-2.

b. Turn on air blast cooling

blower (8, figure 3-2).
shunt field switch (9, figure 3-1)
c. Move generator
voltage regulation.
to the "X" position for automatic
d. Start the driving motor and gradually increase
the
driven speed of the generator
to 2500 rpm.
e. The line voltmeter
(6, figure 3-1) reading should
be approximately
30 volts.
f. Close load switch (5) and apply a load of not more
switches of
by closing appropriate
than 50 amperes
by load
load bank (8). The load valuewill be indicated

ammeter (4).
g. Operate the generator

for approximately
30 minIncrease
utes at this load.
the applied load to not
At 15-minute intervals,
more than 100 amperes.
turn
and air blast cooling
blower.
motor
off the driving
Remove
and examine the
the window strap assembly,
brush seating.
until the face
Continue this procedure
of each brush appears to contact its commutator
surof commutator
face over its entire height (in direction
rotation),
and at least 75 prcent of its width (parallel
to the shaft). (See figure 3-3.)
and temperature
h. Be sure
the voltage, current,
values specified in table VII are not exceeded during
the brush seating run,

Blower Diagram

3-10.

TESTS.

3-11. HEAT RUN.

heat run to be sure the gena 60-minute
a. Perform
erator
can carry the full rated load at minimumrated
Refer to.table VIIIfor
speed without overheating.
the
proper test values.
NOTE
If the generator
fails to meet
of performance
ified values
discontinuethe
test until the

any of the specduring

any test,
trouble is located

and corrected.
cooling
blower (8, figure 3-2).
is maincooling
air
pressure
blast
the proper
throughout the heat run.

b. Turn
Be sure

tained

on air

blast

CAUTION
Do not allow the temperature of the housing to
since operation of
rise above 110C (230F),
the generator at temperatures above this value
may damage the windings.

15

Publication

No. R73-12

TABLE
FIELD
SPEED

(Max)

Amperes

rpm

2500

Volts (Max)

8.00

*The final
paragraph

is based

on an initial

rect

the trouble.

NOTE

The maximum
housing temperature of 110C
(230F) for the heat
run is based upon cooling
air temperature (measuredas shown in figure
3-2) of 30C (86F). If the cooling air during
the test is above 30C (86F), reduce the full
load current
by 12 amperes for every 10C
(18F) rise in air temperature
above 30C
(86F).

RUN

LINE
Regulated

100

shunt field switch (9, figure

c. Move the generator
3-1) to the "X" position.
Record
the temperature
indicated
on the housing thermometer.
d. Start the driving motor and gradually increase
the
driven speed of the generator to 2500 rpm. The line
voltmeter
30 volts.
(6) reading should be approximately
e. Close load switch (4) and apply full rated load of
100 amperes by closing appropriate
switches of load
bank (8)
f. Operate the generator for 60 minutes.
Throughout
the run, check that the reading of shunt field ammeter
(2) does not exceed 8.00 amperes, and the.reading of
field voltmeter (10)does not exceed 24 volts.
g. After completing the 60-minute heat run, record
the temperature indicated on the housing thermometer.
The final temperature reading
should not exceed
the
initial
(126F).
bymorethan70C
temperature(stepc)
The final temperature of the housing must not be above
110C (230F).
If the temperature
rise or the final
housing temperature is excessive,
disassemble
the
generator as described
in Section II. Locate and cor.

HEAT

VOLTMETER

(Max)

Amperes

24

housing temperature
3-11, step g.

0-MINUTE

LOAD
AMMETER

FIELD
VOLTMETER

AMMETER

VIII.

Volts

30
housing

TEMP
RISE

FINAL HOUSING
TEMP

MIN
SPEED

(Max)

(Max)*

(Hot)

70C
(126F)

(230F)

110C

of 30C (86F).

temperature

Less

than

2500 rpm

Refer

to

under

note

performance
h. If the generator
during the heat run
issatisfactory,
perform
the hot minimum speed check
(paragraph3-12) while the generator is still hot.

3-12. HOT MINIMUM SPEED.

a. Open the load switch (5, figure 3-1).
b. Reduce the driven speed of the generator
to less
than 2300 rpm.
shunt field switch (9) to the
c. Move the generator
shorting
Y" position,
out the carbon pile regulator
and connecting
in series
the 3/4-ohm fixed resistor
with the generator
shunt field coils.
d. Close load switch (5) and apply full rated load of
100 amperes.
Gradually increase
the driven speed of
until lme voltmeter
the generator
(6) reading is 30

Volts.

The driven

2300 rpm.

speed

at

this

point

must

not exceed

3-13.

COMPOUNDING AND COMMUTATION.

a. Move the shunt field switch (9, figure 3-1) to the
"X" position for automatic
voltage
regulation.
b. Using thevalues specified intable IX, perform the
compounding
checks.
Record the readings
for each
section
in table IX.
within the speed range, the field curc. At anyspeed
rent must increase
load increases.
as the generator
d. If the field current
at no load is greater
than that
at full load, check to make certain
the brush seating
is satisfactory.
If the brush
seating
is satisfactory,
disassemble
the generator and repeat the inspection
and testingsteps of theoverhaul
II.
procedure,Section
The possibility
in the armature
of shorts
and field
windings
should be given special attention.
NOTE

100%

NEW BRUSH

75%

SAT SFACTORILY

00%
SEATED BRUSHES

If it is necessary
to replace the armature
assembly, anti-drive
end head, or complete
field
COil assembly,
repeat the entire test procedure.

fenblow

t
UNSATSFACTORILY

LEGEND

Figure
16

SEATED BRUSHEs

rs

tch (4)e'3st

the

driving

motor,.and

rn

f. Remove
the window strap
brushes
can be observed during

assembly

so

the commutation

that the
check.

NON

SEKrED AREAS
SEATED AREAS

3-3.

Brush Seating

NOTE
Do not operate the generator
with the window
strap assembly removed
any longer than necessary for making the commutation check.

Direct
TABLE

SPEED

(rpm)

LINE
VOLTMETER
(Volts)

IX.

COMPOUNDING

LOAD
AMMETER
(Amperes)

Current

Generators

AND COMMUTATION
FIELD

VOLTMETER
(Volts)

FIELD
AMMETER
(Amperes)

COMMUTATION

2500

30

2500

30

2500
3500
3500
3500
4500
4500
4500

50

30
30
30
30

100

*
*

Note:

Sections

each unit.

30

30
30
marked with an asterisk

50
100
0
50
100

(*.)are to

be recorded

g. Repeat thetests
IX, and recording

using thevaluesspecified
in table
the commutation
at each value.
There should be no more than fine pin point sparking
at the brushes during the check. Multiple
pin points

and occasional
streamers
are permissible
at higher
speeds, if the speeds are maintained.
h. If excessive sparking is observed,
check the brush
seating, and if necessary,
disassemble
the generator
to locate and correct the trouble. Give special attention to possible
unsatisfactory
armature or complete
field coil assemblies.
i. After completing the compounding and
commutation checks, open load switch (4) and shut down the
driving motor.
Remove all test connections
from the
generator.
Install the window strap assembly.

3-14. OVERSPEED RUN.

a. Start the driving motor and, with no external
connections to the generator
(field circuit open and no
load applied), increase
the generator speed to 7000
rpm.
b. Operate the generator at this speed for five min-

utes.

c. After completing the overspeed run, shut down the

drivingmotor,detachthethermometerfromthehousing, and dismount the generator
from the test stand
mounting bracket.

at the time of testing.

3-15.

DIELECTRIC

Readings will vary

with

STRENGTH.

a. While the generator

is still hot from the preceding
tests, check for dielectric
strength
using insulation
tester 1106900-1-A.
Apply 250 volts at a commercial
frequency
(60 cps) for one minute between the housing
and each terminal post in succession.
b. If the insulation
breaks
down, disassemble
the
generator to locate and correct
the trouble. (Refer to
Section II.)

3-1

2OLARITY
CHECK.
a. Remount thegeneratoron
thetest stand. Make the
electrical
test connections
from the voltage regulator
to the "A" and "B" terminal posts of the generator.
(See figure 3-1.)
b. Connect the positive
and negative terminals of
line voltmeter
(6)to the "B" and "E" terminal posts
respectively.
c. Operate the generator at a speed between 2500 and
4500 rpm.
The voltmeter
reading
should be in the
proper direction.
d. If it is necessary
to reverse
the meter connections
to obtain a proper reading, the polarity of the generator is reversed.
is reversed,
e. If the polarity
flash the field in the
(Refer to paragraph
proper direction.
3-4.)
f. After completing the polarity check, remove
all
.

test connections
test stand.

and'dismount

the generator

from the

17/18

Direct

SECTION
DIFFERENCE

Current

Generators

IV

DATA SHEETS

Overhaul instructions
and test procedures
for types
included in this section are the same as those for
Type 30E16-1-A Direct
Current Generator, except for
noted by the applicable Difthe specific differences
ference Data Sheet. Sections II and III contain completeoverhauland
test informationfor
type 30E16-1-A
Direct Current Generator.
INDEX
Type

OF TYPES

Page

30E16-1-C

21/22

30E16-3-A

23/24

30E16-3-C

25/26

30E16-13-C

27/28

19/20

Direct

DIRECT CURRENT GENERATOR

THE INSTRUCTIONS

APPLY EXCEPT
PARTICULARS.

Same as for type 30E16-

SPECIAL

TOOLS.

as

CLEANING.

Same

INSPECTION.
for

type

30E16-1-A.

TESTING.
DISASSEMBLY. Same as for type 30E16-1-A
four washers
(12,figure 2-1) are not used.

except

NOTE

TYPE

30E16-1-C

4-1.

''ype30E16-3-A

as for type 30E16-1-A.

Same as for type 30E16-1-A.

Same as for type 30E16-1-A.

REPAIR
OR
30E16-1-A.
LUBRICATION.

The drive shaft assembly (20)and lining (22)

have beenchangedslightly
toprovideadditional
clearance between the drive shaft and the front
plate (21).

Figure

Generators

CONTAINED
IN PRECEDING SECTIONS OF THIS HANDBOOK
FOR THE DIFFERENCES
LISTED IN THIS DATA SHEET.

LEADING
1-A.

Same

Current

REPLACEMENT.

Same

as for

Same as for type 30E16-1-A.

REASSEMBLY. Same as for type 30E16-1-A

four washers (12,figure 2-1) are not used.
TEST PROCEDURES.

Direct

Current

type

except

Same as for type 30E16-1-A.

Generator

21/22

Direct

DIRECT

CURRENT

Current

GENERATOR

Generators

TYPE 30E16-3-A

THE INSTRUCTIONS

APPLY EXCEPT

CONTAINED
SECTIONS OF THIS HANDBOOK
IN PRECEDING
LISTED IN THIS DATA SHEET.
FOR THE DIFFERENCES

SPECIAL

TOOLS.
Same as for type 30E16-1-A except
16-spline shaft holder QB80063-1 is used in place of
6-spline shaft holder QB80063-2.

DISASSEMBLY.

'

Same

as follows:

as for type 30E16-1-A

a. Two washers
are used
hold clamp (47).

with

screws

to

b. See figure 4-2 for parts different

1 Drive

end head

2 Housing

Figure 4-2. Exploded View

Type 30E16-3-A
Direct Current Generator Showing Differences
-

LEADING PARTICULARS.
1-A except as follows:
a.

The drive

shaft

b. The housing
4-1.)

Same as for type 30E16-1-A.

INSPECTION.
check the drive
pins 0.0864 0
ameter is 0.908
TESTING.
REPAIR
30E16-1-A.

Same as for type 30E16-1-A except

end of the drive shaft spline over two
dia. The minimum
permissible
diinch.

Same as for type 30E16-1-A.

OR REPLACEMENT.
Same

has a different

shape.

spline,
(See figure

Same

as for type 30E16-1-A.

REASSEMBLY.

Same

as for

as follows:
a. Two washers

are used

type

30E1-1-A

with screws

to hold clamp ( i).

b. A round drive end head
of the back head.
c. A different type housing

place

c. The drive end head has a six-inch, round mounting

flange with six button-type mounting holes to facilitate
installation.
(See figure .4-1.)

as for

LUBRICATION.

Same as for type 30E16-

has a 16-tooth drive

(45,figure 2-1)

from type 30E16-

1-A.

CLEANING.

except

TEST PROCEDURES.

(1, figure
(2) is

type

except

(45, figure 2-1)

4-2) is used

in

used.

Same as for type 30E16-1-A.

23/24

Direct

DIRECT

CURRENT

GENERATOR

THE INSTRUCTIONS
APPLY EXCEPT

CONTAINED IN PRECEDING
FOR THE DIFFERENCES

Current

Generators

TYPE

30E16-3-C

SECTIONS
OF THIS HANDBOOK
LISTED IN THIS DATA SHEET.

DISASSEMBLY. Same as for type 30E16-1-A except

as follows:
a. Two washers
are used with screws (45,figure 2-1)
to hold clamp (47).
b. See figure 4-3 for parts different
from type 30E161-A.

(m

NOTE
'

The drive shaft assembly

(20, figure 2-1) and
lining (22)have been changed
slightly to provide additional
clearance
between the drive
shaft and the front plate (21).

CLEANING.
1 Drive
Figure

Direct

end head

2 Housing

4-3. Exploded View

Type 30E16-3-C
Current Generator Showing Differences

Same as for type 30E16-1-A.

INSPECTION.
Same as for type 30E16-1-A
except
check the drive end of the drive shaft spline
over two
pins 0.0864 0 dia. The minimum permissible
diameter
is 0.908 inch.

TESTING.
REPAIR

Same
OR

as for type 30E16-1-A.

REPLACEMENT.

30E16-1-A.
LEADING PARTICULARS.
Same as for type 30E161-A except as follows:
a. The drive shaft has a 16-tooth drive spline.
b. The housing has a different
shape.
(See figure

4-1.)

c. The drive end head has a six-inch, round mounting

flange with six button-type mounting holes to facilitate
(See figure 4-1.)
installation.
SPECIAL

TOOLS.
Same as for type 30E16-1-A
except
16-spline shaft holder QB80063-1
is used in place of
6-spline shaft holder QB80063-2.

LUBPJCATION.

Same

as for

type

Same as for type 30E16-1-A.

Same as for type 30E16-1-A

REASSEMBLY.
except
as follows:
a. Two washers
are used with screws (45,figure 2-1)
to hold clamp (47).
b. A round drive end head (1, figure 4-3) is used in
place of the back head.
type housing (2)is used.
c. A different

TEST PROCEDURES.

Same as for type 30E16-1-A.

25/26

Direct

DIRECT

Current

CURRENT GENERATOR

TYPE

THE INSTRUCTIONS
APPLY EXCEPT

Generators

30E16-1

CONTAINED
IN PRECEDING SECTIONS OF THIS HANDBOOK
FOR THE DIFFERENCES
LISTED IN THIS DATA SHEET.

DISASSEMBLY.

Same

as for type 30E16-1-A

except

as follows:

-3

areused
with screws(45,
a. Twowashers
hold clamp (47).
b. See figure 4-4 for parts different from

"

figure 2-1)

to

1-A.

type 30E16-

The drive
shaft assembly
(20, figure 2-1) and
lining (22)have been changed
slightly to probetween
vide additional
clearance
the drive
shaft and the front plate (21).
2

CLEANING.

Same

as for

type 30E16-1-A.

INSPECTION.

1 Drive end head

2 Housing
Figure
Direct

3 Terminal

block

cover

Type 30E16-13-C
4-4. Exploded View
Current Generator Showing Differences
-

Same as for type 30E16-1-A

except
check the drive end of the drive shaft spline over two
pins 0.0864 0 dia. The minimum
permissible
diameter is 0.908 inch.
TESTING.

Same

REPAIR
OR
30E16-1-A.

LEADING PARTICULARS.
Same as for type 30E161-A except as follows:
drive spline,
a. The drive shaft has a 16-tooth
(See figure
b. The housing
.has a different
shape.
4-4.)
round mounting
c. The drive end head has a six-inch,
flange with six button-type mounting holes to facilitate
installation.
(See figure 4-4.)
d. A terminal block cover is used.
SPECIAL

TOOLS.
Same as for type 30E16-1-A
except
16-spline shaft holder QB80063-1
is used in place of
6-spline shaft holder QB80063-2.

LUBRICATION.

as for

type

30E16-1-A.

REPLACEMENT.

Same

as for

Same

type

as or

type

30E16-1-A.

REASSEMBLY.
Same as for type 30E16-1-A
except
as follows:
are used with screws (45, figure 2-1)
a. Two washers
to hold clamp (47).
b. A round drive
end head (1, figure 4-4) is used in
place of the back head.
type housing (2) is used.
c. A different
d. A terminal block cover (3) is used.

TEST PROCEDURES.

Same

as for type 30E16--1-A.

27/28

Electric
File Catalog: Aircraft
Section: o-c conoratora

Power

'

Equipment

30E16-15

types

3OE16-17

DESCRIPTION
Bendix Red Bank Types 30E16-15 and
The generators,
17, are designed for use as an engine-driven
source of d-c
and are nominally
rated
at 30 Volts, 150 Amperes,
power,
continuous duty over a speed range of 2800 to 4500 RPM.
The- 15 unit has a 6-tooth spline and square
flange.
The- 17 unit has a 16-tooth spline and round flange. The
spline drive rotates in a counter-clockwise
direction when
viewed
from the mounting flange end. Interpole
and compenskting windings
circuit to
are provided in the negative
prevent field distortion and provide fayorable commutation
conditions.
The units incorporate
a filter condenser to minimize radio interference.
These generators
for use in 28-volt,
are recommended
with
d-c electrical syste2ps, and can be used in conjunction
In most
the Bendix Red Bank Type 1588 voltage regulator.
equipment
produced
cases they can be used with generating
by other manufacturers.
However, it is recommended
that
any such anticipated
use be submitted
to this company for
analysis
prior to service
operation.

rating
150

Amperes, 30 Volts
RPM

2800-4500
DESIGN

Only

FEATURES
inorganic

construction

o
o
o
o
e

insulating
of

this

materials

are

used

in the

unit.

New design provides an improved method

of compensating for wear in the bearing bore in the head and
of a service
yoke assembly-instead
liner, a removable
bearing head support
that can be replaced during overhaul is used. Provision is made for the use of a service
liner in the commutator
end head when bearing surfaces of the original liner become worn
Reinforced
construction
of the mounting
head minimizes the possibility of failure due to fatigue stressesThe stainless steel brush boxes are accurately
broached
and fit of the brushes.
positioning
for the required
Brush pressure is adjustable.
Radial type brushes provide highly efficient commutation.
and
Ample space for air flow exists between shunt
coils, thus providing
interpole
thermal
an excellent

CIFICATIONS

SPE

The values listed below and the curves

PERFORMANCE
of actual,
following are representative
installed performand take into account field circuit and
ance in the airplane,
regulator
resistances.
Speed-RPM.
Min. Speed for Regulation-RPM.....
Max. Speed for Regulation-RPM.....
Current-AMPS
D-C
30
Volts
...............2800-4500

..............................

................2800

....

..,.....

................150

.............

..............

Power-Watts

Armature

Min. Air Blast Pressure

Time

G-6162.

Publication

No. R 89-22

..

..................5500

characteristic.

is statically
and dynamically
balanced.
construction
Wedge type armature
ensures safe overspeed operation.
and stator connoctions
All armature
are silver brazed.
Can be used as a replacement
for the P-f generator
where 150 Amperes is the maximum
load,
Designed to comply with basic requirements
of MIL-

............

.....4500

...........

....

.............

...............6.0

..........

..

PARALLELama

the drop through

negative
1s

circuit

.....

in.Water........
.

,.

..

The paralleling
the series winding
of

the

generator.

.....

..

.......

circuit

....

Continuous
by
in the
voltage drop

is energized

that is connected
No external

required.

wasoHT

39.5 lbs.

Printed

in U.S.A.

100
2800 R.P.M.
3500 R.P.M.
4500 R.P.M.

DO
80
70
60

650
210

i30
20
10

LOAD

16

18

20

160

l40

120

100

80

60

40

20

CURRENT-AMPERES

24

22
R.P.M.

26

100

" 6.0 INCHES WATER (STATIC AND VELOCITY) BLAST

COOLING l.25 OHMS RESlTANCE
SHUNT F LD.

IN EXTERNAL

28

30

.ova

IAULULY

TifillLIQ
l
CalIJUALIBULD1A

IRL

L&t--72
M

g DATA

==
-800

JEI

.LDJA9J1Mt.

TOP VIEW OF TERMINAL

RifikL
fg!TIONED

attac1L3ul1TJLARR2w
AREMXJKRE-M
AN&ROLT T9 ILALE

OLOOK

IBAt1A
IRULMALM
IM INCREME ITS OF 90

-+

ELG9_EII.G.li.

ELMA

NLARGED VIEW

2
4
4
+

I
3

4
412

AIR SPOU7

AtR

SP

UT NAY BE

MWIT1115LlJUL

L
INgREMJENTS OF

L.

##

32

INSTALLATEON

OFRA

liNG

30E16-17

45

TOP VIEW OF TERMlNALBLOCK

23

INTERNALWIRING DIAGRAM

ENLARGEDVIEW OF SPLINE

24 CAP SCREW
A

10-32 STUD
5
oD

os

STENCILWHITEARROW
APPROX. I Xy AS SHOWN
ADJACENT TO NAMEPLATE

32
WINDOW STRAP FASTENINGMAYBE
POSITIONED IN INCREMENTSOF 90

.343 DIA

3
4

ROTATr0 N

'

4 U 007

Gp

3.249

16

-4T2 SQUARE16

5000

AIR SPOUT MAY BE POSITIONED

IN INCREMENTS OF 30

oa2
BOLT CIRCLE*
*

6.000

INSTALLATION

sente-15

'