NMWR 9-2920-331 (200amp Alternator May 2013).pdf

NATIONAL MAINTENANCE WORK REQUIREMENT

CONTAINING

NATIONAL MAINTENANCE OVERHAUL STANDARDS

FOR

200-AMP ALTERNATOR

HMMWV FOV

(MODEL N1225-1)

(NSN 2920-01-420-9968) P/N 12447109

This publication is not available through the St. Louis Media Distribution Division. This publication is available through U.S. Army TACOM Life Cycle Management Command, ATTN: AMSTA-LCL-

MPP/TECH PUBS, 6501 E. 11 Mile Rd., Warren, MI 48397-5000.

*NMWR 9-2920-331, dated 22 May 2013 supersedes NMWR 9-2920-331, dated 31 August 2008, including all changes.

DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited.

U.S. ARMY TACOM LIFE CYCLE MANAGEMENT COMMAND

22 MAY 2013

*NMWR 9-2920-331

WARNING SUMMARY

• This warning summary contains general safety warnings and hazardous materials warnings that must be understood and applied during operation and maintenance of this equipment. Failure to comply may result in death or injury to personnel. Refer to FM 4-25.11 for first aid instructions.

• Improper cleaning methods and use of unauthorized cleaning solutions may result in injury to personnel and/or damage to equipment.

• Compressed air used for cleaning purposes must not exceed 30 psi (207 kPa). Use only with effective chip guarding and personal protective equipment (goggles/shield, gloves, etc.).

• Do not use compressed air to dry bearings.

• Direct all personnel to stand clear during hoisting operations. A heavy swinging load can be extremely dangerous.

• When steam cleaning, protective clothing must be worn.

• Degreaser solvent is very flammable and must not be used near an open flame. A fire extinguisher must be kept nearby when solvent is used. Use only in well-ventilated places. Failure to comply may result in death or injury to personnel.

• Use caution when handling heavy parts. Provide adequate support and use assistance during procedure.

• Wear adequate protective goggles/shields to prevent injury from possible airborne fragments.

• Always support alternator core and shaft assembly during removal. Failure to comply may result in injury to personnel or damage to equipment. Seek medical attention in the event of an injury.

• Cleaning compound solvent MIL-PRF-680 is flammable and must not be used near an open flame. A fire extinguisher must be kept nearby when cleaning solvent is used. Use only in well-ventilated areas. Failure to comply may result in injury to personnel. Seek medical attention in the event of an injury.

• Cleaning compound solvent MIL-PRF-680 is an environmentally compliant and low toxic material. However, it may be irritating to the eyes and skin. Always use protective goggles or face shield and avoid repeated and prolonged skin contact by wearing rubber or solvent resistant gloves. If contact with eyes occurs, flush eyes with water and seek medical attention. Wash hands and skin immediately after exposure with soap and water and use a lanolin-based skin cream to prevent skin drying. Remove contaminated clothing and store, handle, and dispose of contaminated cloths and clothing according to local procedures and plans.

• Ensure cleaning solvent container is sealed when not in use. Store, handle, and dispose of unused and spent solvents in accordance with local procedures and plans. Failure to comply may result in damage to environment and health of personnel. Seek medical attention in the event of an injury.

• Appropriate eye protection must be worn when cleaning with a wire brush, sandblast, grit blast, or other effective methods. Failure to comply may result in injury to personnel. Seek medical attention in the event of an injury.

• Paints, cleaning solvents, and primers may cause burns, skin irritation, and emit harmful vapors. Inhalation may cause irritation to upper respiratory passages. Keep paints, cleaning solvents, and primers away from fire or heat sources and use only in well-ventilated areas. Keep paints, cleaning solvents, and primers closed when not in use. Always wear protective equipment such as goggles, face mask, gloves, and a proper respirator. If paints, cleaning solvents, and primers contact skin, wash immediately with soap and water. Failure to comply may result in injury to personnel. Seek medical attention in the event of an injury.

• Prolonged contact with lubricating oil may cause a skin rash. Skin and clothing that come in contact with lubricating oil should be thoroughly washed. Saturated clothing should be removed immediately. Areas in which lubricating oil is used should be well ventilated to keep fumes to a minimum. Failure to comply may result in injury to personnel. Seek medical attention in the event of an injury.

NMWR 9-2920-331

a/b blank

LIST OF EFFECTIVE PAGES/WORK PACKAGES

NOTE: This manual supersedes NMWR 9-2920-331, dated 31 August 2008, including all changes. Zero in the ″Change No.″ column indicates an original page or work package.

Date of issue for the original NMWR is:

Original: 22 MAY 2013

TOTAL NUMBER OF PAGES FOR FRONT AND REAR MATTER IS 22 AND

TOTAL NUMBER OF WORK PACKAGES IS 24,

CONSISTING OF THE FOLLOWING:

Page/WP No. Change No.

Front cover

Blank

Warning Summary (2 pgs) i–iv (4 pgs)

Chapter 1 title page (2 pgs)

WP 0001 (4 pgs)

WP 0002 (6 pgs)

Chapter 2 title page (2 pgs)

WP 0003 (8 pgs)

WP 0004 (4 pgs)

WP 0005 (4 pgs)

WP 0006 (8 pgs)

WP 0007 (4 pgs)

WP 0008 (8 pgs)

WP 0009 (4 pgs)

WP 0010 (2 pgs)

WP 0011 (2 pgs)

Page/WP No. Change No.

WP 0012 (8 pgs)

WP 0013 (2 pgs)

WP 0014 (2 pgs)

WP 0015 (8 pgs)

Chapter 3 title page (2 pgs)

WP 0016 (8 pgs)

WP 0017 (4 pgs)

WP 0018 (4 pgs)

WP 0019 (2 pgs)

WP 0020 (2 pgs)

Chapter 4 title page (2 pgs)

WP 0021 (2 pgs)

WP 0022 (2 pgs)

WP 0023 (2 pgs)

WP 0024 (2 pgs)

Back cover

A/B blank

U.S. ARMY TACOM LIFE CYCLE

MANAGEMENT COMMAND

22 MAY 2013

NATIONAL MAINTENANCE WORK REQUIREMENT

CONTAINING

NATIONAL MAINTENANCE OVERHAUL STANDARDS

FOR

200-AMP ALTERNATOR

HMMWV FOV

(MODEL N1225-1)

(NSN 2920-01-420-9968) P/N 12447109

REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS

You can help improve this publication. If you find any errors, or if you would like to recommend any improvements to the procedures in this publication, please let us know. The preferred method is to submit your DA Form 2028 (Recommended Changes to Publications and blank forms) through the Internet, on the TACOM Unique Logistics Support Applications (TULSA) Web site. The Internet address is https://tulsa.tacom.army.mil. Access to all applications requires CAC authentication, and you must complete the Access Request form the first time you use it. The DA Form 2028 is located under the

TULSA Applications on the left-hand navigation bar. Fill out the form and click on SUBMIT. Using this form on the TULSA Web site will enable us to respond more quickly to your comments and better manage the DA Form 2028 program. You may also mail, email, or fax your comments or DA Form 2028 directly to the Army TACOM Life Cycle Management Command, ATTN: AMSTA-LCL-MPP/TECH

PUBS, MS 727,6501 E. 11 Mile Road, Warren, MI 48397-5000. The e-mail address is tacomlcmc.daform2028@us.army.mil. The fax number is DSN 786-1856 or commercial (586) 282-1856. A reply will be furnished to you.

This publication is not available through the St. Louis Media Distribution Division. This publication is available through U.S. Army TACOM Life Cycle Management Command, ATTN: AMSTA-LCL-MPP/TECH PUBS, 6501 E. 11 Mile Rd., Warren, MI 48397-5000.

*NMWR 9-2920-331, dated 22 May 2013 supersedes NMWR 9-2920-331, dated 31 August 2008, including all changes.

DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited.

*NMWR 9-2920-331

i

TABLE OF CONTENTS

WP Sequence No./Page No.

Chapter 1 - General Information and Equipment Description and Data

General Information ......................................................................................................................... WP 0001

Equipment Description and Data .................................................................................................... WP 0002

Figure 1. 200 - Amp Alternator. ................................................................................................. WP 0002-1

Table 1. 200 - Amp Alternator. .................................................................................................. WP 0002-2

Figure 2. Equipment Data Plate. ................................................................................................. WP 0002-3

Figure 3. Rebuild Data Plate. ..................................................................................................... WP 0002-4

Figure 4. Rebuild Data Plate Installation. .................................................................................. WP 0002-5

Chapter 2 - Maintenance Instructions

General Maintenance Instructions ................................................................................................... WP 0003

Table 1. Cleaning Guidlines. ...................................................................................................... WP 0003-3

Table 2. General Inspection Guidelines. .................................................................................... WP 0003-3

Table 3. Repairable Defects. ....................................................................................................... WP 0003-6

Removing 200 - Amp Alternator from Shipping Container .......................................................... WP 0004

Figure 1. Opening Container. ..................................................................................................... WP 0004-2

Figure 2. Removing 200 - Amp Alternator from Shipping Container. ..................................... WP 0004-3

Preshop Analysis .............................................................................................................................. WP 0005

Table 1. Preshop Analysis Cover Sheet. .................................................................................... WP 0005-2

Table 2. Preshop Analysis Checklist. ......................................................................................... WP 0005-3

Figure 1. 200-Amp Alternator Preshop Analysis. ...................................................................... WP 0005-3

Table 3. Component Checklist. ................................................................................................... WP 0005-4

200-Amp Alternator Disassembly ................................................................................................... WP 0006

Figure 1. Regulator and Fan Shroud Disassembly. ................................................................... WP 0006-2

Figure 2. Fan and End Housing Removal. ................................................................................. WP 0006-3

Figure 3. Front Housing Disassembly. ....................................................................................... WP 0006-4

Figure 4. Front Rotor and Core and Shaft Assembly Disassembly. ......................................... WP 0006-5

Figure 5. Front Housing Bearing Disassembly. ......................................................................... WP 0006-6

Figure 6. End Housing Bearing Disassembly. ........................................................................... WP 0006-6

Figure 7. End Housing Bushing Disassembly. ........................................................................... WP 0006-7

Static Testing, Cleaning, and Inspection ........................................................................................ WP 0007

Figure 1. Alternator Testing and Stator and Field Coil Assembly. .......................................... WP 0007-3

200-Amp Alternator Assembly ....................................................................................................... WP 0008

Figure 1. End Housing Bushing Assembly. ............................................................................... WP 0008-2

Figure 2. End Housing Bearing Assembly. ................................................................................ WP 0008-3

Figure 3. Front Housing Bearing Assembly. ............................................................................. WP 0008-3

Figure 4. Front Rotor, Core and Shaft Assembly, and Front Housing Assembly. ................... WP 0008-4

Figure 5. Front Housing Assembly. ........................................................................................... WP 0008-5

Figure 6. Rear Rotor Assembly. ................................................................................................. WP 0008-6

Figure 7. Fan and End Housing Assembly. ............................................................................... WP 0008-6

Figure 8. Regulator and Fan Shroud Assembly. ........................................................................ WP 0008-7

Alternator Testing ............................................................................................................................ WP 0009

Figure 1. Alternator Pulley Installation. ..................................................................................... WP 0009-1

Figure 2. Alternator Pulley Removal. ......................................................................................... WP 0009-2

Table 1. No-Load Tests. ............................................................................................................. WP 0009-3

Table 2. Full-Load Tests. ............................................................................................................ WP 0009-3 ii

TABLE OF CONTENTS - CONTINUED

WP Sequence No./Page No.

Chapter 2 - Maintenance Instructions - Continued

Test Limits .........................................................................................................................................WP 0010

Table 1. Resistance Values. ........................................................................................................ WP 0010-1

Preservation, Packaging, and Marking ............................................................................................ WP 0011

Preparation for Storage or Shipment .............................................................................................. WP 0012

Figure 1. Painting 200-Amp Alternator. ..................................................................................... WP 0012-3

Figure 2. 200-Amp Container. .................................................................................................... WP 0012-5

Figure 3. Installing Container Cover. ......................................................................................... WP 0012-6

Table 1. Final Inspection Report (FIR). ..................................................................................... WP 0012-7

Quality Assurance Requirements .................................................................................................... WP 0013

Illustrated List of Manufactured Items ........................................................................................... WP 0014

Figure 1. Cushioning Panels. ...................................................................................................... WP 0014-1

Table 1. Materials. ....................................................................................................................... WP 0014-1

Torque Limits .................................................................................................................................. WP 0015

Figure 1. Measuring Screw Diameter. ........................................................................................ WP 0015-1

Figure 2. Capscrew Head Markings. .......................................................................................... WP 0015-1

Figure 3. Measuring Screw Length. ........................................................................................... WP 0015-2

Table 1. Torque Limits for Dry Fasteners. ................................................................................ WP 0015-3

Table 2. Torque Limits for Wet Fasteners. ................................................................................ WP 0015-4

Table 3. Torque Limits for Dry Metric Fasteners. .................................................................... WP 0015-5

Table 4. Torque Limits for Wet Metric Fasteners. .................................................................... WP 0015-6

Table 5. Torque Specifications for 200-Amp Alternator. .......................................................... WP 0015-8

Chapter 3 - Parts Information

Repair Parts and Special Tools List (RPSTL) Introduction ........................................................... WP 0016

Table 1. SMR Code Explanation. ............................................................................................... WP 0016-1

Table 2. Source Code Explanation. ............................................................................................ WP 0016-2

Table 3. Maintenance Code Explanation. ................................................................................... WP 0016-4

Table 4. Maintenance Code Explanation. ................................................................................... WP 0016-4

Table 5. Recoverability Code Explanation. ................................................................................ WP 0016-5

Alternator Container ........................................................................................................................ WP 0017

Figure 1. Alternator Container. ................................................................................................... WP 0017-2

200-Amp Alternator ......................................................................................................................... WP 0018

Figure 2. 200-Amp Alternator. ................................................................................................... WP 0018-2

National Stock Number Index ......................................................................................................... WP 0019

Part Number Index .......................................................................................................................... WP 0020

Chapter 4 - Supporting Information

References ........................................................................................................................................ WP 0021

Expendable and Durable Items List ................................................................................................ WP 0022

Table 1. Expendable and Durable Items List. ............................................................................ WP 0022-2

Tool Identification List .................................................................................................................... WP 0023

Table 1. Tool Identification List. ................................................................................................ WP 0023-2

Mandatory Replacement Part List ................................................................................................... WP 0024

Table 1. Mandatory Replacement Part List. ............................................................................... WP 0024-2 iii/iv blank

CHAPTER 1

GENERAL INFORMATION AND EQUIPMENT

DESCRIPTION AND DATA

FOR

200-AMP ALTERNATOR

HMMWV FOV

(MODEL N1225-1)

SUSTAINMENT MAINTENANCE

GENERAL INFORMATION

SCOPE

This NMWR covers the repair of the 200-Amp alternator, NSN 2920-01-420-9968, P/N 12447109, Model N1225-1. This alternator is used in the High Mobility Multi-purpose Wheeled Vehicle (HMMWV). The procedures contained in this NMWR describe disassembly, inspection, component repair, and assembly to ensure a product that is serviceable and issuable to all customers without limitation or restriction, Condition Code A.

Tolerances and wear limits established by this NMWR are the minimum acceptable standards. Parts, components, assemblies, or subassemblies not meeting these requirements will be disposed of in accordance with the appropriate directive.

Test requirements stated or referenced in this NMWR are the minimum acceptable standards. Components that are found to be worn or defective beyond the repair limits established by this NMWR shall be disposed of in accordance with current directives.

Each repair activity shall, in accordance with the terms and conditions set forth herein, furnish equipment, facilities, and services required to perform inspections and complete repair of the 200-Amp alternator.

MAINTENANCE FORMS, RECORDS, AND REPORTS

Department of the Army forms and procedures used for equipment maintenance will be those prescribed by (as applicable) DA PAM 750-8, The Army Maintenance Management System (TAMMS) Users Manual.

REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIR)

If your 200-Amp alternator needs improvement, let us know. Send us an EIR. You, the user, are the only one who can tell us what you do not like about your equipment. Let us know why you do not like the design or performance.

All non-Aviation/Missile EIRs and PQDRs must be submitted through the Product Data Reporting and Evaluation Program (PDREP) Web site. The PDREP site is: https://www.pdrep.csd.disa.mil/.

If you do not have Internet access, you may submit your information using an SF 368 (Product Quality Deficiency Report). You can send your SF 368 using email, regular mail, or fax using the addresses/fax numbers specified in DA PAM 750-8, The Army Maintenance Management System (TAMMS) Users Manual.

We will send you a reply.

NMWR 9-2920-331 0001

0001-1

CORROSION PREVENTION AND CONTROL (CPC)

Corrosion prevention and control of Army materiel is a continuing concern. It is important that any corrosion problems with this item be reported so that the problem can be corrected and improvements can be made to prevent the problem in future items.

Corrosion specifically occurs with metals. It is an electrochemical process that causes the degradation of metals. It is commonly caused by exposure to moisture, acids, bases, or salts. An example is the rusting of iron. Corrosion damage in metals can be seen, depending on the metal, as tarnishing, pitting, fogging, surface residue, and/or cracking.

Plastics, composites, and rubbers can also degrade. Degradation is caused by thermal (heat), oxidation (oxygen), solvation (solvents), or photolytic (light, typically ultraviolet) processes. The most common exposures are excessive heat or light. Damage from these processes will appear as cracking, softening, swelling, and/or breaking.

SF 368, Product Quality Deficiency Report should be submitted to the address specified in DA PAM 750-8, The Army Maintenance Management System (TAMMS) Users Manual.

DESTRUCTION OF ARMY MATERIEL TO PREVENT ENEMY USE

Procedures for destruction of Army materiel to prevent enemy use can be found in TM 750-244-6, Procedures for Destruction of Tank-Automotive Equipment to Prevent Enemy Use.

PREPARATION FOR STORAGE OR SHIPMENT

To prepare the 200-Amp alternator for storage or shipment, refer to WP 0012. Additional information can be found in TM 746-10, General Packaging Instructions for Field Use, Marking, Packing, and Shipment of Supplies and Equipment.

Perform packing, packaging, preservation, and marking requirements in accordance with Special Packaging Instructions (SPI).

The applicable SPI can be found at https://www.ilsc.army.mil/tdps/index.asp by searching for 200-Amp alternator NSN or NIIN.

An NSN or part number must be entered at the query screen. An image reviewer will be needed to view images. The viewer can be downloaded from the website by going to Help and following the directions.

0001-2

LIST OF ABBREVIATIONS/ACRONYMS

Abbreviations and acronyms appearing in this manual are defined in the paragraph from where they first appear, after which only the abbreviation or acronym is used. The following is a quick-reference list of all abbreviations and acronyms and their corresponding word or compound term used in this NMWR.

AMP–Amperage

CAGEC–Commercial and Government Entity Code

CATT MSL/IRRD–Computer Automated Transportation Tool Military Shipment Label/Issue Receipt Release Document

CPC–Corrosion Prevention and Control

ECP–Engineering Change Proposal

EIR–Equipment Improvement Recommendations

FIR–Final Inspection Report

FOV–Family of Vehicles

HMMWV–High Mobility Multi-Purpose Wheeled Vehicle

MEL–Maintenancee Expenditure Limit

MAC–Maintenance Allocation Chart

NIIN–National Item Identification Number

NMWR–National Maintenance Work Requirement

NSN–National Stock Number

P/N–Part Number

PQDR–Product Quality Deficiency Report

QA–Quality Assurance

QTY–Quantity

PDREP–Product Data Reporting and Evaluation Program

RPSTL–Repair Parts and Special Tools List

SMR–Source, Maintenance, and Recoverability

SPI–Special Packaging Instructions

TACOM–Tank-automotive and Armaments Command

TAMMS–The Army Maintenance Management System

TAMMS-A–The Army Maintenance Management System-Aviation

TB–Technical Bulletin

TM–Technical Manual

TMDE–Test, Measurement, and Diagnostic Equipment

U/I–Unit of Issue

UOC–Usable On Code

WP–Work Package

WPM–Wood Packaging Materials

V–Volt

QUALITY OF MATERIAL

Material used for replacement, repair, or modification must meet the requirements of this NMWR. If quality of material requirements are not stated in this NMWR, the material must meet the requirements of the drawings, standards, specifications, or approved engineering change proposals applicable to the subject equipment.

ENGINEERING CHANGE PROPOSALS (ECPs)

Engineering Change Proposals (ECPs) are submitted in accordance with AR 70-1, Army Acquisition Policy, directly to Commander, U.S. Army TACOM Life Cycle Management Command, ATTN: AMSTA-LCC-HHM, Mail Stop 420, 6501 E. 11 Mile Road, Warren, Michigan 48397-5000. A reply will be furnished to you.

DEVIATIONS AND EXCEPTIONS

Requests for deviations or exceptions to this NMWR will be processed in accordance with ISO 9000 Series standards or equivalent.

MOBILIZATION REQUIREMENTS

All rebuild/repair procedures contained within this NMWR are required to return the 200-Amp alternator to a serviceable condition.

0001-3

COST CONSIDERATIONS

This work requirement shall be the basis for establishing the extent of rebuild while taking into consideration cost factors. A determination shall be made on all subassemblies/assemblies to replace worn or damaged components which are available in supply, if acquisition cost is less than the cost to repair and restore to the NMWR standard. The cost to repair/restore any individual item with an established Maintenance Expenditure Limit (MEL) to the NMWR standard shall not exceed the MEL, unless a waiver has been approved in accordance with AMC-R 750-51. This requirement does not apply to items exempted from MEL in accordance with AMC-R 750-51.

END OF WORK PACKAGE

0001-4

EQUIPMENT DESCRIPTION AND DATA

EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES

The 200-Amp alternator is a belt-driven, air-cooled, waterproof, fungus and corrosion resistant, heavy duty piece of equipment capable of providing dual-voltage (14V and 28V).

Figure 1. 200-Amp Alternator.

PULLEY

HOUSING

REGULATOR

GROUND TERMINAL

OUTPUT TERMINAL

FAN SHROUD

DATA PLATE

NMWR 9-2920-331 0002

0002-1

EQUIPMENT DATA

Refer to table 1 for equipment data.

Table 1. 200-Amp Alternator.

Manufacturer C. E. Niehoff

Type 200-Amp alternator

Rated Output 200 amps, 14 volts and 28 volts

EQUIPMENT DATA PLATE

Equipment data plates: Each 200-Amp alternator shall display an equipment data plate listing the manufacturer name, serial number, model number.

If original equipment data plate is missing, damaged, or illegible, a new plate must be installed in the original location. If information on original plate is legible, copy it to the new plate using 1/4-in. (6.35-mm) stamps. If information on original equipment data plate is not legible or is incomplete, contact the TACOM equipment specialist.

CAUTION

Stamping of data plate shall be accomplished prior to placing on alternator to reduce chance of error, ensure clarity, and prevent damage to alternator housing.

A new equipment data plate may be fabricated as follows:

1. Material: Photosensitive aluminum in accordance with GG-P-455, Type II, Class 1

2. Overall size: 5.625 x 1.625 in. (142.87 x 41.27 mm)

3. Thickness: 0.0312–0.0625 in. (0.7925–1.5875 mm)

4. Height of metal stamps: 0.125 in. (3.175 mm)

CAUTION

When drilling holes to mount data plate, do not drill through housing, as damage may result. Failure to comply may result in damage to equipment.

NOTE

The serial numbers must match from old equipment data plate to new equipment data plate. Contact TACOM and/or Contracting Officer if the numbers are illegible.

0002-2

Stamping Information Required:

1. Designation of rebuild activity

2. Completion date (month and year)

3. Serial number

4. Part number

5. Model number

Installation/Replacement:

1. Remove damaged or illegible data plate.

2. After rebuild, testing, and final inspection are complete, install new stamped equipment data plate.

Figure 2. Equipment Data Plate.

MFR: C. E. NIEHOFF

GENERATOR ENGINE ACCESSORY DUAL VOLT 14V AND 24V 200A DC

USA XXXX

XXXX

XXXX

XXXX

XXXX

XXXXPART NO

NSN

CONTRACT

DATE

SER NO

1.625 IN

(41.27 MM)

5.625 IN

(142.87 MM)

0002-3

REBUILD DATA PLATE

After the 200-Amp alternator has been rebuilt, tested, and documented to be serviceable, a rebuild data plate is attached to the alternator. The rebuild data plate provides the serial number, date of rebuild, and a code identifying the rebuild facility.

Replacement Data:

When sufficient space is not available to add information on existing rebuild data plate or alternator does not have a rebuild data plate, the plate shall be replaced and pertinent data transferred to the new plate. Data shall not be stamped directly on any part, assembly, or item of equipment except when approved by TACOM.

Equipment:

Manufacture of Data Plates, color as specified. Install as required by TB Ord 1030.

1. Material: Photosensitive aluminum in accordance with A-A-50271, Plate, Identification

2. Overall size: 2.50 x 2.0 in. (63.5 x 50.8 mm)

3. Thickness: 0.0312–0.0625 in. (0.7925–1.5875 mm)

4. Height of metal stamps: 0.125 in. (3.175 mm)

5. Mounting hole outside diameter: 0.250 in (6 mm)

6. Mounting hole locations: 0.250 in. (6 mm) from side of overplate

7. Mounting hole spacing: 0.750 in. (19 mm)

Stamping Information:

1. Serial Number: Must agree with number stamped on equipment data plate.

2. Rebuilt at: Name or initials of rebuild facility

3. Date:

Month – Three-letter abbreviation Year – Last two digits Example – OCT 02 for October 2002

Figure 3. Rebuild Data Plate.

0.750 in.

(19 mm)

0.250 in. (6 mm)

2 in.

(50.8 mm)

2.50 in.

(63.5 mm)

0.250 in. (6 mm)

0002-4

Installation/Replacement:

1. Remove existing rebuild data plate, if installed.

2. After rebuild, testing, and final inspections are complete, install new stamped rebuild inspection plate (Figure 4, Item 5) under regulator (Figure 4, Item 1) and spacer (Figure 4, Item 4) with new lockwasher (Figure 4, Item 3), and bolt (Figure 4, Item 2). Tighten bolt (Figure 4, Item 2) to 18 lb-in. (2 N·m).

END OF WORK PACKAGE

Figure 4. Rebuild Data Plate Installation.

4 5

0002-5/6 blank

CHAPTER 2

MAINTENANCE INSTRUCTIONS

FOR

200-AMP ALTERNATOR

HMMWV FOV

GENERAL MAINTENANCE INSTRUCTIONS

INITIAL SETUP:

Materials/Parts

Cleaning compound (WP 0022, Item 1)

Cloth, cleaning (WP 0022, Item 2)

References

NASM 33537

TB 43-0213

TM 9-214

WP 0015

WP 0016

WP 0023

SCOPE

This WP contains general maintenance information pertaining to disassembly, cleaning, inspection, repair, and assembly of the 200-Amp alternator. Detailed information is found in specific WPs.

Maximum rebuild of parts to like-new condition is mandatory. Parts, components, assemblies, or subassemblies found to be worn or defective beyond limits established by this NMWR will be disposed of in accordance with appropriate directives and, in the case of commercial contracts, as specified in the contract. When new or rebuilt parts, components, assemblies, or subassemblies are unavailable, items will be reviewed on a case-by-case basis. Tolerances and wear limits set forth herein are the minimum acceptable standards.

PRECAUTIONS

All material-handling equipment shall be adequate to ensure safe working conditions for personnel and efficient processing of items.

The component shall be properly mounted on a fixture for disassembly and assembly to ensure safe working conditions.

Follow all WARNINGS, CAUTIONS, and NOTES included in specific WPs to ensure personnel safety and prevent damage to equipment.

SPECIAL PROCESSES

Special processes and equipment required for overhaul operations, as specified in this NMWR, are defined or referenced at the point of their application. When a special process is required, the overhaul activity (when requested) shall provide evidence of compliance with controlling specifications. Following is a summary of some of the special processes that may be required for this NMWR.

END OF TASK

TOOLS AND EQUIPMENT

Tools and equipment required to rebuild this component are found in the Tool Identification List, WP 0023.

Torque specifications are given within the text, as applicable. U.S. standard measurements are listed first, followed by metric equivalents in parentheses. For example: Tighten oil pump mounting bolts to 33–40 lb-ft (45–54 N•m). Standard capscrew markings and torque specifications are found in Torque Limits, WP 0015. Tolerances, torque values, and adjustments are provided in each WP where necessary.

END OF TASK

NMWR 9-2920-331 0003

0003-1

DISASSEMBLY

Each appropriate WP contains specific instructions for disassembly of the components.

Use caution when handling parts during disassembly. Nicks, scratches, or other damage caused by careless handling may cause premature failure of equipment. Matched, married, or mated items (examples: bearings and races, covers and housings, and some gear sets) should be fastened together or otherwise identified as parts being processed together. If one part fails inspection, both parts must be replaced as a set.

END OF TASK

CLEANING

WARNING

• Cleaning compound solvent MIL-PRF-680 is flammable and must not be used near an open flame. A fire extinguisher must be kept nearby when cleaning solvent is used. Use only in well-ventilated areas. Failure to comply may result in injury to personnel. Seek medical attention in the event of an injury.

• Cleaning compound solvent MIL-PRF-680 is an environmentally compliant and low toxic material. However, it may be irritating to the eyes and skin. Always use protective goggles or face shield and avoid repeated and prolonged skin contact by wearing rubber or solvent resistant gloves. If contact with eyes occurs, flush eyes with water and seek medical attention. Wash hands and skin immediately after exposure with soap and water and use a lanolin-based skin cream to prevent skin drying. Remove contaminated clothing and store, handle, and dispose of contaminated cloths and clothing according to local procedures and plans.

• Ensure cleaning solvent container is sealed when not in use. Store, handle, and dispose of unused and spent solvents in accordance with local procedures and plans. Failure to comply may result in damage to environment and health of personnel. Seek medical attention in the event of an injury.

• Appropriate eye protection must be worn when cleaning with a wire brush, sandblast, grit blast, or other effective methods. Failure to comply may result in injury to personnel. Seek medical attention in the event of an injury.

• Paints, cleaning solvents, and primers may cause burns, skin irritation, and emit harmful vapors. Inhalation may cause irritation to upper respiratory passages. Keep paints, cleaning solvents, and primers away from fire or heat sources and use only in well-ventilated areas. Keep paints, cleaning solvents, and primers closed when not in use. Always wear protective equipment such as goggles, face mask, gloves, and a proper respirator. If paints, cleaning solvents, and primers contact skin, wash immediately with soap and water. Failure to comply may result in injury to personnel.

Seek medical attention in the event of an injury.

• Prolonged contact with lubricating oil may cause a skin rash. Skin and clothing that come in contact with lubricating oil should be thoroughly washed. Saturated clothing should be removed immediately. Areas in which lubricating oil is used should be well ventilated to keep fumes to a minimum. Failure to comply may result in injury to personnel. Seek medical attention in the event of an injury.

0003-2

CLEANING - CONTINUED

CAUTION

• Block all ports and mask machined surfaces of aluminum castings before using the following cleaning procedures. Failure to comply may result in damage to equipment.

• Do not separate or intermix matched, married, or mated parts during cleaning operations.

For authorized cleaning materials, refer to TB 43-0213, Corrosion Prevention and Control (CPC) for Tactical Vehicles.

Table 1. Cleaning Guidelines.

NO. # ITEM CLEANING

1 Oil passages Remove all obstructions with compressed air or by working a soft wire back and forth through oil passage and flushing it with dry cleaning solvent.

2 Electrical assemblies Use lint-free cloth dampened with cleaning solvent. Use compressed air to dry electrical components.

3 Castings Clean inner and outer surfaces of castings and all areas subject to grease and oil with cleaning solvent.

Nonmetallic parts & hoses Soap and water

5 Bearing After removing surface oil and gum deposits, wipe bearing with a lint-free cloth. Do not use compressed air.

END OF TASK

INSPECTION—ACCEPTANCE AND REJECTION CRITERIA

Throughout this NMWR, measurements are used to confirm serviceability of items after a visual inspection.

Measurements will be performed as required by quality assurance, in-process inspection, overhaul procedures, test report, and Final Inspection Report (FIR). Used components and refinished parts, recovered as products of disassembly, will be examined 100 percent to determine serviceability by contractor. Refer to the maintenance WPs, work directive, or contract for more detail. Parts showing evidence of overheating are unrepairable by any process. Discard these parts.

Table 2. General Inspection Guidelines.

NO. # INSPECT ACTION CORRECTIVE ACTION

1 Threads (internal) Inspect threads for minor irregularities and for damaged threads.

Refer to Table 3, Repairable Defects.

2 Rotating inner parts Check for cracked rotating inner parts.

No repair authorized. Replace parts.

Through-bore or high-stress areas

Inspect casting for crack at through-bore or high stress areas.

No repair authorized. Replace parts.

4 Keyways Inspect for cracked or split keyways.

No repair authorized. Replace parts.

5 Snapring grooves Inspect for cracked, chipped, and worn snapring grooves.

No repair authorized. Replace parts.

Stator and field windings, wiring, and voltage regulator

Inspect parts for evidence of overheating, delamination, and wear.

No repair authorized. Replace parts.

7 Machined surfaces Check for damage that may cause oil leakage or malfunction of the part.

Refer to Table 3, Repairable Defects.

0003-3

Table 2. General Inspection Guidelines - Continued.

NO. # INSPECT ACTION CORRECTIVE ACTION

8 Spline and shafts Inspect for nicks, burrs, or scoring.

Refer to Table 3, Repairable Defects.

Rotating or lockup inner parts

Inspect for cracked rotating or lockup inner parts.

No repair authorized. Replace parts.

10 Rust and surface scale

Use wire brush, sand blast, grit blast, or other effective methods in accordance with standard procedures.

Refer to Table 3, Repairable Defects.

Bushing & bushing-type bearings

Check for secure fit, evidence of heating, wear, burrs, nicks, and out-of-round conditions. Insure holes and grooves are free from damage.

No repair authorized. Replace parts.

Pins, connectors, wire cable, and insulation

Inspect for cracked, worn, bent pins, dirt, evidence of overheating, cuts, and chaffing.

Repair/replace parts IAW TM 9-8000, Chapter 17, Section 5.

13 Castings Inspect for cracks.

Refer to Table 3, Repairable Defects.

14 Capscrews and plugs

Inspect capscrews and plugs for damage.

Replace capscrews and plugs that are damaged and cannot be repaired. Inspect heads for rounding, cracks, or fractures.

Replace capscrews or plugs with damaged heads. Inspect capscrews and plugs for minor irregularities. If major thread damage is found, replace fastener.

Refer to Table 3, Repairable Defects.

END OF TASK

0003-4

REPAIR OR REPLACEMENT

Parts that are beyond wear limit tolerances, broken, cracked, or otherwise damaged may be considered for repair by special processes by requesting approval from TACOM Equipment Specialists. In requesting approval, the rebuild activity will furnish:

1. Written repair procedure

2. Specifications covering the procedure

3. Reference drawing

4. Samples (when requested) of parts repaired by the applicable process

a. Damaged internal threads may be repaired using threaded inserts, per NASM 33537, Standard

Dimensions for Insert Screw Thread, Helical Coil, Coarse and Fine Thread, as stated in salvage rework drawings.

b. Peening, rolling, etc. may be used in accordance with drawings.

END OF TASK

UNREPAIRABLE DEFECTS

Do not repair any of the following:

1. Casting cracks at through-bores, threaded holes, or high-stress areas

2. Cracked, chipped, ridged, or pitted spline or gear teeth

3. Cracked or split keyways

4. Cracked or chipped snapring grooves

5. Oil channels with cracked walls or chipped edges

6. Pitted or grooved gear teeth and splines, unless otherwise indicated in this NMWR

7. Parts showing evidence of overheating

8. Cracked rotating or lockup inner parts

END OF TASK

0003-5

REPAIRABLE DEFECTS

Table 3. Repairable Defects.

REPAIRABLE PART/AREA REPAIR PROCESS

Machined surfaces Small burrs and scratches may be removed with a fine-mill file or fine-grit emery cloth. Discard components that have burrs or scratches too large to repair.

Damaged external threads Repair threads having slight irregularities. Remove burrs with a soft stone, fine mill file, or emery cloth. Clean up slight irregularities by running thread die of correct size over thread. Discard components not repairable.

Damaged internal threads Repair threads in tapped holes having minor irregularities by re-tapping with correct size previously used hole tap. Drill out tapped holes having badly damaged threads and install a threaded insert.

Follow kit manufacturer’s and NASM 33537 instructions. When drilling, the land width (space between holes, or between edge of hole and edge of material) must measure no less than three-fourths of the hole diameter. Discard any component with damaged internal threads that are not repairable.

Housing, castings, and shaped, machined surfaces

Unless otherwise indicated, use fine-grit emery cloth, crocus cloth, or soft stone to repair minor nicks, burrs, and scoring. Minor surface irregularities on non-contact surfaces do not need repair. Discard components not repairable.

Gears, splines, and shafts Use crocus cloth, fine-mill file, or soft stone to remove minor nicks, burrs, and scoring. Welding, grinding, machining, plating, etc. of gear or splined teeth to correct defects is not authorized. Discard components not repairable.

Surface rust and corrosion Remove surface rust and corrosion from all internal parts and surfaces.

Mechanical and/or chemical methods may be used. Use fine-grit emery cloth, crocus cloth, or soft stone to remove minor surface rust and corrosion. Do not assemble components having rusted or corroded parts. Corrosion or rust may flake off and cause damage to component while circulating in oil during operation. Discard components not repairable.

Pins, connectors, wire cable, and insulation Label wires before any repair procedures are implemented to identify correct wires and/or pins for reconnection. Clean wires, pins, connectors, and wire insulation. Use care to avoid damage when removing the connector nut. Suggested method: With no power applied, temporarily connect the connector to its mated male/female end. With the connector stationary to avoid movement, remove the connector nut to access this area for repair or replacement of connector and/or pins. Evidence of overheating can be caused by components against a high temperature heat source and/or internal component failure. Cuts in wire strands are not acceptable. Evidence of chaffing is generally an indication the wire cable and connector was rubbing against another component or hardware and should be evaluated for possible repair.

END OF TASK

0003-6

ASSEMBLY

Seals may be contaminated with dirt, debris, or moisture when the seal packets are opened. Do not open seal packets until seals are ready to be installed. Failure to comply may result in equipment damage.

Cleanliness is essential in all component assembly operations. Dust and dirt, even in minute quantities, are abrasive. Parts must be kept clean.

See individual WPs for specific assembly instructions.

Replace any part that does not pass visual inspection.

Follow WP instructions for coating bearings, bushings, shafts, seals, friction parts, and other contact surfaces with operating oil to ensure lubrication of parts during initial operation after overhaul. For additional information on bearing lubrication and installation, refer to TM 9-214.

Seal handling:

1. Do not open seal packets until ready to install seal. Seals may become contaminated with dust or dirt and some types of seals can absorb moisture, which may cause damage during installation and/or shorten the lifespan of the seals.

2. Ensure lip-type seals are installed so spring-loaded lip faces toward lubricant.

3. Tighten all capscrews, screws, bolts, nuts, and fittings to torque values as specified in maintenance WPs and in torque specifications in WP 0015.

For parts identification, refer to WP 0016.

END OF TASK

END OF WORK PACKAGE

0003-7/8 blank

REMOVING 200-AMP ALTERNATOR FROM SHIPPING CONTAINER

INITIAL SETUP:

Tools and Special Tools

Tool kit, general mechanic’s: automotive (WP 0023, Item 4)

NMWR 9-2920-331 0004

0004-1

REMOVAL FROM CONTAINER

NOTE

Container and cushioning panels are reusable. Do not discard or replace unless damaged.

1. Loosen seal ring bolt (Figure 1, Item 5) and remove seal ring (Figure 1, Item 1), cover (Figure 1, Item 2), and gasket (Figure 1, Item 3) from container (Figure 1, Item 4). Discard gasket (Figure 1, Item 3).

Figure 1. Opening Container.

0004-2

REMOVAL FROM CONTAINER - CONTINUED

2. Remove cushioning panels (Figure 2, Items 1, 2, and 3) from top of alternator (Figure 2, Item 4) and inside container (Figure 2, Item 7).

3. Remove alternator (Figure 2, Item 4) from container (Figure 2, Item 7).

4. Remove four desiccant packages from bottom of container (Figure 2, Item 7). Discard desiccant packages.

5. Remove cushioning panels (Figure 2, Items 5 and 6) from bottom of container (Figure 2, Item 7).

6. Remove paper wrap and closure tape from alternator (Figure 2, Item 4). Discard paper wrap and closure tape.

END OF TASK

END OF WORK PACKAGE

Figure 2. Removing 200-Amp Alternator from Shipping Container.

0004-3/4 blank

PRESHOP ANALYSIS

INITIAL SETUP:

References

WP 0004

SCOPE

The purpose of the Component Checklist (table 3) is to identify the component and the condition as received.

This information comes from shipping labels, attached tags, and visual inspection.

PRESHOP ANALYSIS INSTRUCTIONS

1. Remove 200-Amp alternator from container. Refer to WP 0004.

2. Copy Preshop Analysis Cover Sheet (table 1), Preshop Analysis Checklist (table 2), and Component Checklist (table 3) and fill in the information as requested.

3. Fill in the required information on the Preshop Analysis Cover Sheet.

NOTE

If there is damage to the container, component, or any parts are missing from the component, refer to the work directive/contract for instructions.

4. Visually check components on Preshop Analysis Checklist for evidence of damage or missing parts. Note any damage or missing parts on Preshop Analysis Checklist.

5. Fill out a Component Checklist for each component when required to support the Preshop Analysis Checklists. Additional copies of Component Checklist may be needed.

6. Upon completion of the Preshop Analysis Checklist and Component Checklist, remove all tags and documents from component. Develop a record file for the component. Include tags and documents, completed Component Checklist, Test Report, and Final Inspection Report (FIR) in the record file. Test Report will be completed during final testing of the rebuilt component. FIR will be completed when preparing component for storage.

NMWR 9-2920-331 0005

0005-1

Table 1. Preshop Analysis Cover Sheet.

PRESHOP ANALYSIS

FOR

P/N: ________________________

SERIAL #:_______________________________ NSN:________________________________________

MWO’S REQUIRED:______________________________

REASON FOR REBUILD/REPAIR:

UNPACKING SECONDARY ITEMS REQUIRED:______________?

REVIEWED TAGS:______________?

NAME (PLEASE PRINT):_________________________________________________

SIGNATURE:_________________________________________________

DATE:______________________________

0005-2

Table 2. Preshop Analysis Checklist.

INSPECTION

POINT

CONDITION ACTION REMARKS DATE

CHECKED

CHECKED

BY

Pulley

Inspect for obvious damage. Check pulley rotation by turning pulley.

External Visual Inspection

Regulator Inspect for obvious signs of wear and looseness.

External Visual Inspection

Housing Inspect for obvious damage or missing parts.

External Visual Inspection

Fan Shroud Inspect for obvious damage to fan shroud missing parts.

External Visual Inspection

Figure 1. 200-Amp Alternator Preshop Analysis.

PULLEY

HOUSING

REGULATOR

GROUND TERMINAL

OUTPUT TERMINAL

FAN SHROUD

DATA PLATE

0005-3

Table 3. Component Checklist.

END OF WORK PACKAGE

0005-4

200-AMP ALTERNATOR DISASSEMBLY

INITIAL SETUP:

Tools and Special Tools

Digital multimeter (WP 0023, Item 1)

Standard automotive tool set (WP 0023, Item 2)

Tool kit, general mechanic’s: automotive (WP 0023, Item 4)

NMWR 9-2920-331 0006

0006-1

DISASSEMBLY

WARNING

Use caution when handling heavy parts. Provide adequate support and use assistance during procedure. Failure to comply may result in death or injury to personnel. Seek medical attention in the event of an injury.

NOTE

• Work area must be clean, well ventilated, and dirt and dust free.

• Clean any sealing compound from alternator assembly prior to disassembly.

1. Disconnect two electrical connectors (Figure 1, Items 6 and 16)…