INSTALLATION INSTRUCTIONS. Starter / Alternator Bracket Installation. PA 18 series REVISION HISTORY

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1 Phone: (907) * Fax: (907) atleedodge@acsalaska.net ~ INSTALLATION INSTRUCTIONS Starter / Alternator Bracket Installation PA 18 series Document Number: II-1002 REVISION HISTORY Revision Description Date Original Issue 20.August.09 For updated revisions of this document it is the owner/operators responsibility to contact F. Atlee Dodge Aircraft through our website or directly at the numbers given above.

2 1 References B&C STC No. SE00939WI, Installation of B&C Specialty Products Model BD 315-() Starter on Lycoming Engines B&C STC No. SA01343WI, Installation of B&C Specialty Products BC400 Alternator on PA-18 Aircraft.. FAA AC B/2A 2 Introduction This document will aide in the installation of F. Atlee Dodge Aircraft Service, LLC (FAD) starter and alternator mounts for Lycoming engines. This STC supplies three (3) mounting brackets for the B&C Starter (P/N 315-()) and/or Alternator (P/N BC400). This STC for the mounting brackets requires that the installer also have B&C Specialty Products STC No s SE00939WI and/or SA01343WI and all associated hardware. NOTE These brackets will NOT work with other Starter/Alternators. Use only the B&C products referenced. The mounting brackets allow for an integration of the chin mounted oil cooler. This mounting bracket STC will supply only the mounting brackets. It is possible to install either the starter or alternator with the corresponding bracket as shown in this installation guide. Page 2 of 10

3 2.1 Model Applicability This Installation Instruction is intended to guide the installer when modifying the applicable aircraft listed. Additional information on recommended best practices and acceptable methods, techniques can be obtained from FAA AC B/2A. This document is applicable to the following Make and Model aircraft once the STC is installed. Applicable Make / Model Piper Aircraft, Inc. - Models: PA-18, PA-18S, PA-18 "105" (Special) PA-18S "105" (Special), PA-18A PA-18 "125" (Army L-21A), PA-18S "125" PA-18AS "125", PA-18 "135" (Army L-21B), PA-18A "135", PA-18S "135" PA-18AS "135", PA-18 "150" PA-18A "150", PA-18S "150" PA-18AS "150", PA-19 (Army L-18C) PA-19S TCDS 1A2 2.2 Parts List Weldment, B&C Alternator Mount Weldment, Chin Oil Cooler and B&C Starter, Mount Weldment, Chin Oil Cooler with B&C Alternator, Mount Starter / Alternator Brackets Starter / Alternator Mount Parts List All additional hardware depicted and used in the installation is the responsibility of the installer to procure. Page 3 of 10

4 2.3 Configuration It is not possible to cover every possible configuration of PA-18. The table below summarizes part needed for the Chin mounted Oil Cooler. Part Required Configuration Starter Alternator FAD Mount Brackets Chin Mount Oil Cooler Starter Only BC 315-() 6018 Alternator Only BC Starter & Alternator BC 315-() BC Page 4 of 10

5 3 Initial Installation NOTE: PRIOR TO STARTING WORK -Read through the entire sequence of installation steps prior to starting work. -It is assumed that the cowl nose bowl has been removed allowing access to the complete front of the engine and engine compartment. -It will be necessary to remove the chin mounted oil cooler fitting and secured nuts, and drain the oil cooler prior to starting work. -It will be necessary to remove the propeller and starter / pulley ring on the engine. -The existing alternator, and mounting bracket should be removed. -The existing starter and any oil cooler mounting brackets should be removed. Retain all hardware removed for the above preparation. Most hardware will be reused at installation. If installing the starter and/or alternator on the aircraft for the first time it is required to follow the installation instructions provided with these components. This installation instruction ONLY defines the installation and security of the mounting brackets for the oil cooler. Mount 6020 FAD Mount, 6018 See Fig 3.4 See Fig 3.2 Mount 6003 Oil Cooler Figure 3.1: Front View of Installation Page 5 of 10

6 3.1 Starter / Oil Cooler Mount FAD Mount, 6018 B&C Starter315-() Chin mounted oil cooler Locking Plate Or safety wire. Figure 3.2: LH Side View of Installation Upper Engine bolts with star washers; ¼ Lycoming supplied bolts for case MS PLCS Starter bolt with star washers; 5/16 bolt supplied with starter MS PLCS Figure 3.3: LH Side View of Installation Page 6 of 10

7 Instructions: F. Atlee Dodge Aircraft 1. Mount the B&C 315 series starter per manufacturer installation instructions. 2. Align the 6018 mount attach the two upper arm bolts to engine block (ref. fig 3.3). Each of the upper engine bolts should have a star washer under them. 3. Verify that the 6018 mount does not contact the starter in any location 4. Attach the single center arm bolt to the starter. NOTE: It may be necessary to trim the baffling material to accommodate the new mount. OR If there is gap in the baffling material, greater then ½ inch, it is required to fill this in with appropriate material. 5. Align the oil cooler and attach the LH oil cooler nut. It may be required to temporarily support the oil cooler during these steps. 6. Hand tighten bolts and continue with Alternator / Oil Cooler bracket installation. Page 7 of 10

8 3.2 Alternator / Oil Cooler Mount Case Bolts & Lock rings 3 places Alternator Mount 6020 Chin Oil Cooler Mount 6003 Chin mounted oil cooler Figure 3.4: RH Side View of Installation Alternator tensioning bracket supplied with alternator. Alternator BC400 Mount 6020 Mount 6003 Oil Cooler Page 8 of 10

9 Figure 3.5: Front RH Side View of Installation Figure 3.6: RH Side View of Installation Page 9 of 10

10 Instructions: 1. Align and secure 6020 mount with the three (3) case bolts (ref. fig 3.4). Do not tighten bolts. Include the lock ring (if removed) under the bolt heads. 2. Align and secure 6003 mount with two (temporary) bolts as shown (ref fig 3.4). Secure the mount boss to the oil cooler. 3. Install the alternator and secure. 4. Install the alternator tensioning bracket. It may be required to trim the baffle material to allow correct positioning of tensioning bracket. 5. With the starter pulley ring mounted determine the correct alignment of the alternator pulley and start ring pulley. Adjust the 6020 bracket as required. (ref. fig 3.6). It is important to align the alternator and starter ring pulleys so that the alternator belt rides smoothly. NOTE: Lycoming engine cases vary. Accordingly there is a.25 slot in the mount bracket 6020 which should be adequate to adjust for pulley alignment. 6. Attach the alternator belt and secure the starter ring. 7. Adjust the oil cooler so that it is symmetrically aligned on the center line of the engine. Fit the nose bowl temporarily to determine the side to side and fore/aft fit of the oil cooler. Adjust accordingly. Larger misalignment will result in premature alternator belt ware. 8. Verify adequate movement of alternator and the ability to properly tighten alternator belt. 9. Tighten all bolts and nuts on mounts, and oil cooler. Safety wire or bend all locking plates as required. Tighten all bolts and secure with appropriate method (tabs or safety wire). 4 Weight & Balance Mount weights as follows: lbs lbs lbs The CG is the same for the parts removed and for the alternator and starter locations. Update weight and balance of aircraft accordingly. Do not forget to weight all parts removed E N D Page 10 of 10