NMWR_9-2920-333.pdf

NMWR 9--2920--333

TACOM LIFE CYCLE MANAGEMENT COMMAND, WARREN, MI JUNE 2008

NATIONAL MAINTENANCE WORK REQUIREMENT (NMWR)

CONTAINING

NATIONAL MAINTENANCE REPAIR STANDARDS

FOR

GENERATOR, AC--DC

650 AMP

(57K1788) (NSN 2920--01--442--8079)

AVAILABILITY STATEMENT: This publication is not available through the St. Louis Media Distribution Division publication centers. This publication is available through TACOM Life Cycle Management Command, Warren, MI 48397--5000.

SUPERSEDURE NOTICE: This manual supersedes DMWR 9--2920--259, dated 2 August 1993.

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

TACOM LIFE CYCLE MANAGEMENT COMMAND, WARREN, MI DRAFT

a

WARNING SUMMARY

This list summarizes critical WARNINGS in this manual. They are repeated here to let you know how important they are. Study these WARNINGS carefully; they can save your life and the lives of personnel with whom you work. Read and follow all general shop safety procedures.

First Aid

Refer to FM 4--25.11, First Aid for Soldiers for correct procedures if personnel are injured.

WARNING

Never crawl under equipment when performing maintenance unless equipment is securely blocked. Equipment may fall and cause serious injury or death to personnel.

Keep clear of equipment when it is being raised or lowered. Equipment may fall and cause serious injury or death to personnel.

Do not work on any item supported by only lift jacks or hoist. Always use blocks or proper stands to support the item prior to work. Equipment may fall and cause serious injury or death to personnel.

Do not allow heavy components to swing while suspended by lifting device.

Equipment may strike personnel and cause injury.

Exercise extreme caution when working near a cable or chain under tension. A snapped cable, shifting or swinging load may result in injury or death to personnel.

All personnel must stand clear during lifting operations. A swinging or shifting load may cause injury or death to personnel.

WARNING

Cleaning compound can cause skin rash and can give off harmful vapors. To avoid injury, use in a well--ventilated area. Wash immediately with soap and water if compound gets on skin or clothes.

WARNING

Fuel and oil are slippery and can cause falls. To avoid injury, wipe up spilled fuel or oil with rags.

b

WARNING

Wear safety glasses and steel--tipped shoes to avoid possible injury while handling equipment.

WARNING

Components of these generators are heavy and may be awkward to handle. Use correct lifting procedures, indicated lifting devices, and/or assistance from other personnel to avoid injury.

WARNING

Adhesive, primer, sealant compounds, and isopropyl alcohol are toxic and flammable.

These compounds are toxic to eyes, skin, and respiratory tract. Continued exposure can make you dizzy and irritate your eyes and throat.

WARNING

Air pressure in excess of 30 psi (207 kPa) can injure personnel. Do not direct pressurized air at yourself or others. Always wear goggles.

WARNING

Use caution when using a press. Improper tools or tools not properly aligned may cause injury to personnel or damage to parts or equipment.

c

WARNING

The electrical power used to test components can cause personal injury or even DEATH if adequate safety precautions are not followed. Remove jewelry such as rings, bracelets, wristwatches, and neck chains before testing. These items may catch on the equipment or cause electrical shorts and may result in severe burns or electrical shock.

c/d blank d

A/B blank

INSERT LATEST UPDATED PAGES/WORK PACKAGES. DESTROY SUPERSEDED DATA.

LIST OF EFFECTIVE PAGES/WORK PACKAGES

Note: Zero in the “Change No.” column indicates an original page or work package.

Date of issue for original manual is:

Original (12 June 2008)

TOTAL NUMBER OF PAGES FOR FRONT AND REAR MATTER IS 28 AND TOTAL

NUMBER OF WORK PACKAGES IS 21 CONSISTING OF THE FOLLOWING:

Page/WP *Change No. No.

Page/WP *Change No. No.

Cover 0 a -- c/d blank 0 A/B blank 0 i – ii 0

WP 0001 00 0

Chapter 1 title page 0

WP 0002 00 0

Chapter 2 title page 0

WP 0003 00 -- WP 0004 00 0

Chapter 3 title page 0

WP 0005 00 – WP 0017 00 0

Chapter 4 title page 0

WP 0018 00 – WP 0021 00 0

Glossary--1 – Glossary--3/4 blank 0 Index--1 – Index--2 0 DA Form 2028 Sample/Reverse 0 DA Form 2028/Reverse (3) 0 Metric Chart 0 Back Cover 0

*Zero in this column indicates an original page

NMWR 9--1025--216

ii i

HEADQUARTERS

TACOM LIFE CYCLE MANAGEMENT COMMAND

WARREN, MI 12 JUNE 2008

NATIONAL MAINTENANCE WORK REQUIREMENT (NMWR)

CONTAINING

NATIONAL MAINTENANCE REPAIR STANDARDS

FOR

GENERATOR, AC--DC

650 AMP

(57K1788) (NSN 2920--01--442--8079)

REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS

You can help improve this publication. If you find any errors, or if you would like to recommend any im-provements 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 Army Electronic Product Support (AEPS) website. The Internet address is https://aeps.ria.army.mil.

The DA Form 2028 is located under the Public Applications section in the AEPS Public Home Page. Fill out the form and click on SUBMIT. Using this form on the AEPS will enable us to respond quickly to your comments and better manage the DA Form 2028 program. You may also mail, e--mail, or fax your com-ments or DA Form 2028 directly to the U.S. Army TACOM Life Cycle Management Command. The post-al mail address is U.S. Army TACOM Life Cycle Management Command, ATTN: AMSTA--LC--LMPP / TECH PUBS, 1 Rock Island Arsenal, Rock Island, IL 61299--7630. The e--mail address is tacomlcmc.da-form2028@us.army.mil. The fax number is DSN 793--0726 or Commercial (309) 782--0726.

AVAILABILITY STATEMENT: This publication is not available through the St. Louis Media Distribution Division publication centers. This publication is available through TACOM Life Cycle Management Command, Warren, MI 48397--5000.

SUPERSEDURE NOTICE: This manual supersedes DMWR 9--2920--259, dated 2 August 1993.

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

ii

TABLE OF CONTENTS

WP Sequence No.

GENERAL INFORMATION 0001 00

CHAPTER 1. DESCRIPTION AND THEORY OF OPERATION

Description and Data 0002 00

CHAPTER 2. TROUBLESHOOTING PROCEDURES

Preshop Analysis 0003 00 Troubleshooting Procedures 0004 00

CHAPTER 3. OVERHAUL INSTRUCTIONS

Remove/Install Generator (57K1788) 0005 00 Overhaul Procedures for Oil Pump Assembly 0006 00 Overhaul Procedures for End Bell Assembly 0007 00 Overhaul Procedures for Stator Housing Assembly 0008 00 Overhaul Procedures for Heat Sinks 0009 00 Overhaul Procedures for Generator Rotor Assembly 0010 00 Overhaul Procedures for Stator Exciter Assembly 0011 00 Final Testing and Final Inspection Record (FIR) 0012 00 Preservation, Packaging, and Marking 0013 00 Facilities 0014 00 Quality Assurance Requirements 0015 00 Illustrated List of Manufactured Work Items 0016 00 First Article Inspection Requirements 0017 00

CHAPTER 4. SUPPORTING INFORMATION

References 0018 00 Expendable and Durable Items 0019 00 Tool Identification List 0020 00 Mandatory Replacement Parts 0021 00

GLOSSARY Glossary--1

INDEX Index--1

0001 00--1

GENERAL INFORMATION 0001 00

SCOPE

The instructions within this National Maintenance Work Requirement (NWMR) contain the information necessary, along with the referenced specifications, to establish the guidelines for the total disassembly, replacement, cleaning, component inspection, repair, assembly, final inspection, and testing, preserving/painting, and packaging of the 650 Amp Generator 57K1788 (NSN 2920--01--442--8079) used on the M109A6 155MM Medium Self--Propelled Howitzer.

These instructions are for use by contractor/repair activity personnel. They apply to the generator and in case of conflict take precedence over all other documents pertinent to depot/repair activity maintenance of the item.

Condition of the overhauled generator shall be that its utility and performance are equal to that of a condition code A, as defined in AR 725--50, Requisition, Receipt, and Issue System. The repair activity shall, in accordance with the terms and conditions set forth herein furnish all equipment, facilities, and services required to perform inspections and completely repair the generator.

The overhauling/repair activity may in many cases develop its own methods of performing the required inspection and overhaul. The requirements of this NMWR as to inspection limits, mandatory replacement items, and quality testing must be adhered to. Tolerances and wear limits are the minimum acceptable overhaul standards, and must be adhered to by the contractor/repair activity personnel. Parts not meeting these requirements shall be rejected and disposed of as directed by AR 750--1, Army Material Maintenance Policy, supply provisions of the contract, or as directed by the Director, TACOM.

Shipping containers are to be overhauled in accordance with DMWR 9--8145--211.

All instructions in this NMWR have been treated in the following manner:

1. References to applicable technical manuals are held to a minimum. The length of some technical manual instructions prohibited their reprint in this manual and they are referred to in the text.

2. Unusual or critical steps have been covered in Warnings, Cautions, and Notes and have been provided when injury to personnel, damage to equipment, or critical procedures are involved.

3. Instructions are not provided or referenced for routine tasks, such as cover removal. Instead the text merely states that the next step is cover removal.

4. If there is a question on how to accomplish a certain task or if a task has been omitted from this publication, refer to the proper technical manual (TM) for instructions, and contact the appropriate maintenance authority in accordance with the contract.

GOVERNMENT FURNISHED INFORMATION (GFI)

TACOM shall provide the following:

1. TM 9--2350--314--20--1; Unit Maintenance Manual for Hull Systems and Components, Howitzer, Medium, Self--Propelled, 155MM, M109A6 (NSN 2350--01--305--0028) (EIC: 3FC)

2. TM 9--2350--314--24P--1; Unit, Direct Support and General Support Maintenance Repair Parts and Special Tools List (Including Depot Maintenance Repair Parts) for Hull Associated Components of Howitzer, Medium, Self--Propelled: 155MM, M109A6 (NSN 2350--01--305--0028) (EIC: 3FC)

3. Drawing 12361436; Generator, 650 AMP DC

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) User’s Manual or AR 700--138, Army Logistics Readiness and Sustainability.

0001 00--2

GENERAL INFORMATION -- Continued 0001 00

REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIRs)

If your generator needs improvement, let us know. Send us an Equipment Improvement Recommendation (EIR).

You, the user, are the only one who can tell us what you don’t like about your equipment. Let us know why you don’t like the design or performance. EIRs can be submitted through the Army Electronic Product Support (AEPS) web site, http\\aeps2.ria.army.mil, under the Electronic Deficiency Report System (EDRS). This is a secured web site requiring a password, which can be applied for on the front page of the web site. You can also put it on an SF 368, Product Quality Deficiency Report (PQDR). Mail it to the address specified in DA PAM 750--8, The Army Maintenance Management System (TAMMS) User’s Manual or as specified by the acquiring activity. We will send you a reply.

CORROSION PREVENTION AND CONTROL

Corrosion Prevention and Control (CPC) of Army material is a continuing concern. It is important that any corrosion problems with these items be reported so that the problem can be corrected and improvements can be made in the future items.

While corrosion is typically associated with rusting of metals, it can also include deterioration of other materials, such as rubber and plastic. Unusual cracking, softening, swelling, or breaking of these materials may be a corrosive problem.

If a corrosion problem is identified it can be reported using SF 368, Product Quality Deficiency Report. Use of key words such as corrosion, rust, deterioration, or cracking will insure that the information is identified as a CPC problem. Submit the form to the address specified in the DA PAM 750--8, The Army Maintenance Management System (TAMMS) User’s Manual.

The preferred method for submitting PQDRs is through the Army Electronic Product Support (AEPS) website, under the Electronic Deficiency Report System (EDRS). The web address is https://aeps2.ria.army.mil. This is a secured web site requiring a password, which can be applied for on the front page of the web site. When sending PQDRs by mail, submit form to the address specified in the DA PAM 750--8, The Army Maintenance Management System (TAMMS) User’s Manual.

DESTRUCTION OF MATERIAL TO PREVENT ENEMY USE

Destruction of the vehicle, armament, and equipment when subject to capture or abandonment in a combat zone, will be undertaken by the using Army only when the unit commander decides such action is necessary in accordance with orders of, or policy established by, the Army commander.

Refer to TM 750--244--6 for information on destruction of all mechanical equipment. In general, destruction of essential parts, followed by burning, will usually be sufficient to render the vehicle, armament, and equipment useless.

Time is critical.

Material must be damaged so that it cannot be restored to usable condition by either repair or cannibalization. If a lack of time or personnel prevents destruction of all parts, give priority to destruction of parts hardest to replace. It is important the same parts be destroyed on all units to prevent construction of a complete unit from several damaged ones.

OZONE DEPLETING SUBSTANCES (ODS)

The continued use of ODS has been prohibited by executive order 12856 of 3 August 1993. The use of ODS in the Army for overhaul/remanufacturing of components is prohibited. A listing of these substances will be provided by the acquiring activity.

PREPARATION FOR STORAGE OR SHIPMENT

Refer to WP 0013 00, Preservation, Packaging, and Marking for information about storage and shipment.

0001 00--3

GENERAL INFORMATION -- Continued 0001 00

NOMENCLATURE CROSS REFERENCE LIST

Common Name Official Nomenclature

Generator Generator, AC--DC, 650 AMP

LIST OF ABBREVIATIONS/ACRONYMS

A Amperage

AEPS Army Electronic Product Support

AMC Army Materiel Command

AMDF Army Master Data File

Amp Amperage

ANSI American National Standards Institute

AQL Acceptable Quality Level

ASQC American Society for Quality Control

ASSY Assembly

CAGEC Commercial and Government Entity Code

CPC Corrosion Prevention Control

CT Certification Test

CT Current Transformer

DAC Days after Completion

DRMS Defense Revitalization Marketing Service

ECP Engineering Change Proposal

EDRS Electronic Deficiency Report System

EIR Equipment Improvement Recommendation

EMI Electro Magnetic Interference

ESD Electrostatic Discharge

FAI First Article Inspection

FAT First Article Test

FIR Final Inspection Record

GFE Government Furnished Equipment

GFI Government Furnished Information

GFM Government Furnished Material

GFP Government Furnished Property

HCP Hardness Critical Process

IAW In Accordance With

ISO International Standards Organization

LA Line Amps

MEL Maintenance Expenditure Limit

MRB Material Review Board

0001 00--4

GENERAL INFORMATION -- Continued 0001 00

LIST OF ABBREVIATIONS/ACRONYMS -- Continued

NDT Nondestructive Testing

NSN National Stock Number

ODS Ozone Depleting Substance

OEM Original Equipment Manufacturer

OIP Overhaul Inspection Procedure

PCO Procurement Contracting Officer

PQDR Product Quality Deficiency Report

PSA Preshop Analysis

QPL Qualified Products List

QMS Quality Management System

ISO International Organization for Standardization

RAM Reliability, Availability, Maintainability, and Durability

REF References

SOP Standard Operating Procedure

SOW Scope of Work

TACOM U.S. Tank--automotive and Armaments Command

TAMMS The Army Maintenance Management System

TMDE Test, Measurement, Diagnostic Equipment

WP Work Package

QUALITY ASSURANCE

1. The repair activity shall develop, implement, administer, and maintain a Quality Management System (QMS) acceptable to the Government for all supplies and services delivered under this NMWR and the contract/program work directive.

2. The repair activity may select one of the following three (3) methods for submittal and approval by the Procurement Contracting Officer (PCO) of their Quality Management System:

a. If the repair activity can demonstrate a successful completion of an ISO/ASQ Q9000:2000 or latest revision registration audit or re--audit within the six month period prior to contract award, the U.S. Government will accept the repair activity’s plan based on successful completion of the audit and issuance of a valid registration by a ISO 9000 qualified registrar. Submit the repair activity’s plan and current registration documents to the PCO not later than 60 Days After Completion (DAC). Any subsequent (re)certification or decertification must be provided to the PCO within 30 days after receipt from the International Organization for Standardization (ISO)/Registrar Accreditation Board (RAB) approved registering activity.

b. As an alternative to para 2a. above, the repair activity may submit for PCO approval a Quality Management System that has been previously approved by the Government for the same or similar items, or equivalent North Atlantic Treaty Organization (NATO) standards. The repair activity must demonstrate that this proposed Quality Management System has been reviewed and revised by the repair activity to reflect any new conditions that might have resulted from newer requirements within this contract, or the passage of time, from federal law, regulations, or changes to the repair activity’s organization or ownership.

3. Additional Quality Assurance requirements can be found in WP 0015 00.

0001 00--5

GENERAL INFORMATION -- Continued 0001 00

QUALITY OF MATERIAL

Material used for replacement, repair, or modification must meet the requirements of this NMWR. If the qualities 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.

SAFETY, CARE, AND HANDLING

Adequate safety precautions must be provided for the performance of maintenance, overhaul, and repair operations of these generators. These precautions shall include safety in the work environment and proper selection and use of equipment and procedures provided for performing operations.

Overhaul of these generators requires the use of lubricants, solvents and cleaning fluids, sealers, adhesives, and/or other products that may be dangerous or harmful if safety precautions are not observed. Read manufacturer’s warnings and cautions on product labels before using, and observe recommended safety precautions.

Be sure lifting devices are capable of handling the weight of components to be lifted. Attempts to handle heavy components by hand may result in injury to personnel.

Warnings and cautions found throughout the maintenance procedures must be observed. A list of vital warnings is provided at the front of this NMWR.

Safety equipment and clothing shall be used to prevent death and injury. As a minimum, safety shoes and glasses shall be used in all shop areas.

ENGINEERING CHANGE PROPOSALS

Engineering change proposals (ECPs) will be submitted using DD Form 1693 (Engineering Change Proposal (Short Form)). (See MIL--STD--973 for instructions.) Completed forms should be mailed direct to Commander, U.S. Army Armament Research Development and Engineering Center, ATTN: AMSTA--AR--FSA--R, Rock Island, IL 61299-- 7300. A reply will be furnished to you.

ELECTROMAGNETIC COMPATIBILITY STANDARDS

The generator, when assembled, shall meet electrostatic compatibility standard requirements specified in CE04 and RE02 of MIL--STD--461, Measurement of Electromagnetic Interference Characteristics.

ELECTROSTATIC DISCHARGE (ESD)

Electrostatic discharge control standards for protection of electrical and electronic parts, assemblies, and equipment are defined in DOD--STD--1686, Electrostatic Discharge Control Program and MIL--HDBK--163, Directory of Electronic Warfare Equipment.

NUCLEAR HARDNESS

The generators are designed and manufactured to meet nuclear hardness requirements. The nuclear hardness requirements will not be degraded if repaired or overhauled using authorized repair parts. Paragraphs and procedures highlighted by the symbol HCP indicates that those items, if requisitioned through authorized supply manuals, meet the nuclear hardness criteria.

DEVIATIONS AND EXCEPTIONS

Requests for deviations or exceptions to this National Work Requirement (NMWR) shall be sent to TACOM--RI--M109--SPH@ria.army.mil.

MOBILIZATION REQUIREMENTS

Mobilization requirements are not applicable to this NMWR.

0001 00--6

GENERAL INFORMATION -- Continued 0001 00

COST CONSIDERATIONS

This work requirement is the basis for establishing the extent of overhaul while taking into consideration cost factors.

Make a determination 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, use new parts. 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 AR 750--1. This requirement does not apply to items exempted from MEL in accordance with AR 750--1.

REPAIR PARTS SPECIAL TOOLS, TMDE, AND SUPPORT EQUIPMENT

1. For authorized common tools and equipment, refer to the Modified Table of Organization and Equipment (MTOE), CTA 50--970, Expendable/Durable Items (Except: Medical, Class V, Repair Parts, and Heraldic Items), or CTA 8--100, Army Medical Department Expendable/Durable Items as applicable to your unit.

2. Special Tools, TMDE, and Support Equipment are listed in WP 0019 00, Expendable and Durable Items List and WP 0020 00, Table 20--1, Tool Identification List.

3. Repair parts for this generator are listed and illustrated in the following Direct Support and General Support Maintenance Manuals (Including Repair Parts and Special Tools) for M109A6 Vehicles.

a. Refer to WP 0021 00, Table 21--1, Mandatory Replacement Parts List.

b. TM 9--2350--314--24P--1, Unit, Direct Support and General Support Maintenance Repair Parts and Special Tools (Including Depot Maintenance Repair Parts) for Hull Associated Components of Howitzer, Medium, Self Propelled: 155 MM, M109A6.

4. Reference Drawing.

12361436, Generator, 650 AMP DC

FACILITIES

Refer to Work Package 0014 00, Facilities, for detailed instructions on the facility requirements for overhauling the generator.

DISPOSAL

1. A part that does not meet minimum Overhaul Inspection Procedures (OIPs) as stated in this document, is faulty through testing provided, or is a mandatory replacement part and is either unserviceable or non--repairable.

2. Each repair facility is responsible for disposal of non--repairable, mandatory replaced parts, unused parts and/or assemblies.

3. Disposal of all non--repairable parts, components, and scrap is through the Defense Reutilization Marketing Service (DRMS).

INSPECTIONS

During the course of this contract, the repair activity may be supplied Government Furnished Equipment/Government Furnished Material/Government Furnished Property (GFE/GFM/GFP).

1. Inspection of equipment (GFP/GFM):

a. The repair activity is responsible to supply and maintain all inspection and test equipment necessary to assure that the end item and end item components conform to contract requirements. This will include all Government Furnished Property, except where specific relief from this requirement is provided for in the contract.

b. The repair activity’s inspection and test equipment calibration system shall be IAW ISO 10012--1, Quality Assurance Requirement for Measuring Equipment, and shall be addressed in the Government approved Quality Management System.

c. All repair activity furnished inspection and test equipment shall be available for use prior to start of production.

0001 00--7

GENERAL INFORMATION -- Continued 0001 00

INSPECTIONS -- Continued

d. Make all necessary inspection and test equipment, regardless of ownership, available to the Government for Government end item or component inspection upon request. In addition, the repair activity shall provide all test support equipment (i.e. repair parts, manuals, etc.) and technical assistance necessary to conduct FAT (First Article Test) and CT (Certification Test) until completion of all testing. Upon completion of the inspection or test by the Government, return the equipment to the repair activity.

2. Inspection of Drawings:

a. The repair activity shall make available to the Government inspector at the time of any Government inspection (in--process or end item), legible drawings and printed specifications to which the product was manufactured.

(1) Annotate these drawings and specifications to the latest revision incorporated therein.

(2) Upon completion of product inspection and acceptance by the Government inspector, return all drawings and specifications to the repair activity.

END OF WORK PACKAGE

0001 00--7/8 blank

0001 00--8

0001 00--1

CHAPTER 1

DESCRIPTION AND THEORY OF OPERATION

FOR

GENERATOR, AC--DC

650 AMP

(57K1788) (NSN 2920--01--442--8079)

0001 00--2

0002 00--1

DESCRIPTION AND DATA 0002 00

EQUIPMENT DESCRIPTION, CHARACTERISTICS, AND FUNCTION

GENERATOR, 650 AMP, AC--DC (57K1788): is heavy duty, oil cooled, and brushless. The generator converts me-chanical energy to an alternating current which is rectified within the generator to produce a direct current at the out-put terminals. Regulation is provided by an externally mounted voltage regulator that is controlled by the current transformer to prevent overcharging. Cooling is provided by an oil pump located on the antidrive end of the generator.

The oil pump circulates filtered oil through the interior of the generator for cooling purposes only. The oil pump does not lubricate the generator. The generator is completely enclosed, waterproof, and will function properly even if sub-merged in water.

Figure 2--1. Generator (57K1788) – Overall View

0002 00--2

DESCRIPTION AND DATA -- Continued 0002 00

EQUIPMENT CHARACTERISTICS, FUNCTION, AND LOCATION -- Continued

The generator consist of the following components: Drive shaft, stator exciter housing assembly, stator housing, rotor and rotor exciter assembly, end bell assembly, oil pump assembly, current transformer, and interference filter. The ex-ternal characteristics are illustrated in Figure 2--2.

Figure 2--2. Generator (57K1788) – External Characteristics and Location

0002 00--3

DESCRIPTION AND DATA -- Continued 0002 00

DATA PLATES

1. Ensure the data plates and decals shown in Figure 2--3 are installed on this generator. Data plates and decals that are damaged must be replaced. When sufficient space is not available on the existing data plate to add information, the plate shall be replaced and all 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 the government.

2. Refer to TM 9--2350--314--24P--1 for part number 57K1788 to obtain numbers to requisition new equipment data plates. Refer to Figure 2--3 for the identification and location of the equipment data plates. Install data plates in location indicated and attach with drive screws.

3. Overhaul data plates will be affixed at the time of overhaul at the contractor facility in accordance with the following instructions. The overhaul data plate will be manufactured or requisitioned in accordance with ORDNANCE DRAWING 7996979 (19207). Each plate shall have the name or initials of the overhaul activity using government abbreviations found in TB ORD 1030 and a three letter abbreviation for the month followed by the last two digits of the year. (i.e. JUN 06 for JUNE 2006). Refer to Figure 2--3 for the identification and location of the overhaul data plate.

4. Do not remove any equipment or overhaul data plate without replacement data plates available. They must be available to record the original configuration of the equipment and any modifications.

Figure 2--3. Data and Overhaul Plate – Identification and Location

0002 00--4

DESCRIPTION AND DATA -- Continued 0002 00

EQUIPMENT DATA

Generator (57K1788) (NSN) 2920--01--442--8079

Part Number 57K1788

Model 30B95--46

Supply Code (CAGEC) 19207

Manufacturer Bendix Corporation

Type Oil cooled

Rated output 28 volts dc, 650 amperes

Operating range 2400--8000 rpm

Ground polarity Negative

Rotation Clockwise viewed from drive end

Control of output Remote voltage regulator

Dimensions:

Length 17.47 inches (44.38 cm)

Height 9.77 inches (24.82 cm)

Weight 106 lb (48.1 kg)

CONFIGURATION DATA

There are other generators that have the same 650 amp electrical output as generator 57K1788, but there are physi-cal differences. The unique characteristics of 57K1788 are listed in Table 2--1:

Table 2--1.

GENERATOR CHARACTERISTIC

57K1788 Quick couple connectors.

Belt driven.

Drive shaft is longer and has a smaller spline outside diameter on the drive end.

Clockwise rotation viewed from end drive.

0002 00--1

CHAPTER 2

TROUBLESHOOTING PROCEDURES

FOR

GENERATOR, AC--DC

0002 00--2

0003 00--1

PRESHOP INSPECTION 0003 00

SCOPE

The purpose of the preshop analysis is to determine equipment completeness, condition, level of operation, and degree of overhaul required to return the generators to a serviceable condition as specified in this NMWR and/or by work directive.

0003 00--1/2 blank

0003 00--2

0004 00--1

TROUBLESHOOTING PROCEDURES 0004 00

SCOPE

This work package provides guidelines for diagnosing failures occurring during generator test operations. Before troubleshooting the generator, ensure that all test conditions and test hookup requirements are met. Refer to Figures 4--1 thru 4--6 when troubleshooting the generator.

Table 4--1. Troubleshooting for Generator Assembly

Malfunction Probable cause

Corrective action

Common Generator Malfunctions

1. Test stand circuit breaker trips.

Stator or rotor assembly shorted.

Replace/repair as necessary. Refer to WP 0008 00 for stator assembly, WP 0010 00 for rotor assembly.

2. Incorrect output voltage and current.

a. Stator assembly/stator exciter is defective if the voltage is low and current is high.

Replace/repair stator assembly/stator exciter. Refer to WP 0008 00 for stator assembly, WP 0011 00 for stator exciter.

b. Rotor assembly/rotor exciter is defective if the voltage and current are low.

Replace/repair rotor assembly. Refer to WP 0010 00.

3. Output voltage is high.

a. Defective voltage regulator.

Replace voltage regulator.

b. Faulty or improper connections between generator and voltage regulator.

Replace/repair as necessary.

0004 00--2

TROUBLESHOOTING PROCEDURES -- Continued 0004 00

Table 4--1. Troubleshooting for Generator Assembly -- Continued

Malfunction Probable cause

Corrective action

Common Generator Malfunctions -- Continued

4. Output voltage erratic or fluctuating.

a. Defective voltage regulator.

Replace voltage regulator.

b. High resistance connections, either internally or externally to stator/exciter.

Replace/repair as necessary. Refer to WP 0011 00.

c. Intermittent shorted, grounded, or open rotor and/or stator.

Test/replace/repair rotor or stator assemblies. Refer to WP 0008 00 for stator assembly, WP 0010 00 for rotor assembly.

5. Generator overheats.

a. Excessive output current.

Adjust output current.

b. Low or no oil flow thru generator.

Refer to lubricating troubleshooting.

6. Generator noisy. (Refer to notes on Figure 4--6 for flat wire type stator.)

a. Generator not securely mounted to test stand.

Secure to test stand as necessary.

b. Rotor assembly dragging against stator or stator exciter field windings.

Test/repair as necessary. Refer to WP 0010 00.

c. Loose connections or open circuits in stator assembly.

Replace/repair as necessary. Refer to WP 0008 00.

d. Defective bearing in rotor assembly.

Replace/repair as necessary. Refer to WP 0010 00.

e. Short between phases in stator field windings if current and voltage outputs are normal.

Replace/repair as necessary. Refer to WP 0008 00.

7. Output current high

a. Improperly adjusted load of regulator is defective.

Adjust or replace regulator as necessary.

b. Defective current transformer.

Replace current transformer. Refer to WP 0008 00.

0004 00--3

TROUBLESHOOTING PROCEDURES -- Continued 0004 00

Table 4--1. Troubleshooting for Generator Assembly -- Continued

Malfunction Probable cause

Corrective action

Lubrication Malfunctions

1. Leakage exceeds maximum rate.

a. Defective seals (preformed packing).

Disassemble and replace defective components. Refer to WP 0006 00 and WP 0007 00.

b. Improper assembly.

Replace/repair as necessary.

c. Cracked, bent, or deformed components.

Replace defective components as necessary.

2. Oil flow below specified minimum.

a. Defective pump or improperly adjusted.

Replace pump as required. Refer to WP 0006 00.

b. Input oil pressure below specified minimum.

Adjust input pressure.

c. Incorrect rpm.

Adjust rpm.

d. Oil temperature low.

Adjust temperature.

e. Restriction in generator oil passages.

Replace/repair as necessary.

3. Oil flow above specified maximum.

a. Incorrect pressure flow.

Adjust input pressure/flow.

b. Oil pump improperly adjusted.

Adjust pump as required.

c. Excessive leakage.

Locate and repair leakage.

d. Oil temperature high.

Adjust temperature.

e. Incorrect rpm.

Adjust rpm.

0004 00--4

TROUBLESHOOTING PROCEDURES -- Continued 0004 00

Table 4--1 Troubleshooting for Generator Assembly -- Continued

Malfunction Probable cause

Corrective action

Lubrication Malfunctions -- Continued

4. Oil pressure below specified minimum.

a. Defective pump or improperly adjusted.

Adjust pump as required. Refer to WP 0006 00.

b. Incorrect input pressure.

Adjust input pressure

c. Restriction in input side of oil pressure circuit.

Locate and remove restriction.

d. Oil temperature high.

Adjust temperature.

e. Incorrect rpm.

Adjust rpm.

5. Oil pressure above specified maximum.

a. Defective pump or improperly adjusted.

Replace pump as required. Refer to WP 0006 00.

b. Incorrect input pressure.

Adjust input pressure.

c. Restriction in output side of oil pressure circuit.

Locate and remove restriction.

d. Oil temperature low.

Adjust temperature.

e. Incorrect rpm.

Adjust rpm.

0004 00--5

TROUBLESHOOTING PROCEDURES -- Continued 0004 00

Table 4--1 Troubleshooting for Generator Assembly -- Continued

Malfunction Probable cause

Corrective action

Testing/Performance Checks

Bond and Ground Test

1. Resistance exceeds specified maximum.

High resistance path between J1 receptacle and case.

Replace/repair as necessary.

2. Resistance exceeds specified maximum.

High resistance path between J2 receptacle and case.

Replace/repair as necessary.

NOTE

Refer to the Common Generator Malfunctions for other troubles that can occur while performing the following tests in the Testing/Performance Checks section.

Field Current Test

Field current exceeds specified maximum.

Shorted or grounded stator/rotor assembly.

Replace/repair as necessary. Refer to WP 0008 00 for stator assembly, WP 0010 00 for rotor assembly.

Ripple Voltage Test

1. Ripple voltage exceeds specified maximum.

a. Capacitor assembly (EMI filter) is defective if the ripple voltage exceeds 4 vpp or ringing appears on the negative cycles as shown on Figure 4--2.

Replace capacitor assembly. Refer to WP 0008 00.

b. Stator assembly is defective if the ripple voltage waveform indicates a loss of one or more of the cycles as shown on Figure 4--3.

Replace/repair stator assembly. Refer to WP 0008 00.

c. Rotor assembly is defective if the ripple voltage waveform indicates a loss of one or more of the cycles as shown on Figure 4--4.

Replace/repair stator assembly. Refer to WP 0008 00.

0004 00--6

TROUBLESHOOTING PROCEDURES -- Continued 0004 00

Table 4--1 Troubleshooting for Generator Assembly -- Continued

Malfunction Probable cause

Corrective action

Testing/Performance Checks -- Continued

Ripple Voltage Test -- Continued

Current Transformer Signal Test

2. Incorrect current transformer voltage.

a. Current transformer defective.

Replace current transformer. Refer to WP 0008 00.

b. Faulty wiring or connections.

Replace/repair as necessary. Refer to WP 0008 00.

Output Power Verification Test

Field current above specified maximum.

Shorted or grounded stator or rotor assembly.

Replace/repair as necessary. Refer to WP 0008 00 for stator assembly, WP 0010 00 for rotor assembly.

Overspeed Test

Field current above specified maximum.

Shorted or grounded stator or rotor assembly.

Replace/repair as necessary. Refer to WP 0008 00 for stator assembly, WP 0010 00 for rotor assembly.

Output Power Verification Test

Voltage is below specified minimum.

Rotor assembly is defective if the field current waveform indicates a loss of one or more of the cycles as shown on Figure 4--5.

Replace/repair as necessary. Refer to WP 0010 00.

0004 00--7

TROUBLESHOOTING PROCEDURES -- Continued 0004 00

Table 4--1 Troubleshooting for Generator Assembly -- Continued

Malfunction Probable cause

Corrective action

Post Test Requirements

Dielectric Test

1. OTB terminals B and E leakage current exceeds specified maximum.

Shorted or grounded components in stator assembly.

Replace/repair stator assembly. Refer to WP 0008 00.

2. Leakage exceeds maximum rate.

a. Defective gaskets or preformed packing.

Replace defective parts as necessary. Refer to WP 0008 00.

b. Leaking past screws or through connectors.

Replace/repair as necessary. Refer to WP 0008 00.

c. Defective housings.

Replace/repair as necessary. Refer to WP 0008 00.

0004 00--8

TROUBLESHOOTING PROCEDURES -- Continued 0004 00

NOTES:

1. PHASE GROUP 2 IS ROTATED 30º FROM PHASE GROUP 1.

2. WHEN TESTING, EVERY OTHER LEAD (1--3--5 OR 2--4--6, ETC.) WILL APPEAR SHORTED, CHECK IN A

COUNTERCLOCKWISE DIRECTION STARTING AT THE CURRENT TRANSFORMER FIELD LEAD.

RESISTANCE BETWEEN ADJACENT LEADS (LEAD 1 TO LEAD 2, ETC.) SHALL BE INFINITY.

3. CURRENT TRANSFORMER SIGNAL WILL BE 4.5 TO 7.0 VRMS FOR THE 2.4 ± 0.3 OR 7.7 TO 20 VRMS FOR

THE 8.9 ± 0.3 OHM COIL USING THE BENDIX REGULATOR.

4. CURRENT TRANSFORMER SIGNAL WILL BE 3.5 TO 6.0 VRMS FOR THE 2.4 ± 0.3 OR 4.5 TO 7.0 VRMS FOR

THE 8.9 ± 0.3 OHM COIL USING THE WESTINGHOUSE REGULATOR.

Figure 4--1. Generator Schematic (Round Wire Type)

0004 00--9

TROUBLESHOOTING PROCEDURES -- Continued 0004 00

Figure 4--2. Oscilloscope Waveform of Ripple Voltage (Faulty EMI Filter Indicator)

Figure 4--3. Oscilloscope Waveform of Ripple Voltage (Faulty Stator Indicator)

0004 00--10

TROUBLESHOOTING PROCEDURES -- Continued 0004 00

Figure 4--4. Oscilloscope Waveform of Ripple Voltage (Faulty Rotor Assembly Indicator)

Figure 4--5. Oscilloscope Waveform of Field Current (Faulty Rotor Assembly Indicator)

0004 00--11

TROUBLESHOOTING PROCEDURES -- Continued 0004 00

NOTES:

1. THE FLAT WIRE TYPE STATOR IS EXTREMELY NOISY UNDER NORMAL LOAD CONDITIONS, GIVING FALSE INDICATIONS OF BEARING FAILURE, ETC. TO PREVENT UNNECESSARY REJECTION, OPERATE GENERATOR AT 8000 ± 100 RPM AND NO LOAD TO CHECK FOR BEARING NOISE AND ROTOR RUBBING AGAINST STATOR(S). IF THE NOISE TEST IS SATISFACTORY UNDER NO LOAD, DO NOT REJECT

GENERATOR STRICTLY BECAUSE OF NOISE UNDER NORMAL LOAD.

2. PHASE GROUP 2 IS ROTATED 30º FROM PHASE GROUP 1.

3. USE ONLY THE 8.9 ± 0.3 OHM COIL WITH THE FLAT WIRE TYPE STATOR.

4. WHEN TESTING, TEST IN GROUPS OF THREE (LEADS 1--2--3 OR 4--5--6, ETC.). LEADS WITHIN EACH

GROUP WILL APPEAR SHORTED. CHECK IN A COUNTERCLOCKWISE DIRECTION STARTING AT THE

CURRENT TRANSFORMER FIELD LEAD. RESISTANCE BETWEEN GROUPS (LEADS 1--2--3 TO 4--5--6, ETC.) SHALL BE INFINITY.

5. CURRENT TRANSFORMER SIGNAL WILL BE 7.7 TO 10.0 VRMS FOR THE 8.9 ± 0.3 OHM COIL USING THE

BENDIX REGULATOR.

6. CURRENT TRANSFORMER SIGNAL WILL BE 4.5 TO 7.0 VRMS FOR THE 8.9 ± 0.3 OHM COIL USING THE

WESTINGHOUSE REGULATOR.

Figure 4--6. Generator Schematic (Round Wire Type)

0004 00--12

TROUBLESHOOTING PROCEDURES -- Continued 0004 00

Table 4--2. Test Malfunction and Deficiency Sheet

650 Ampere Generator Assembly

Serial number: Date of test: Tested by:

Step or Para

Describe malfunction or discrepancy encountered

Corrective action taken Date Initials

0004 00--1

CHAPTER 3

OVERHAUL INSTRUCTIONS

FOR

GENERATOR, AC--DC

0004 00--2

0005 00--1

REMOVE/INSTALL GENERATOR (57K1788) 0005 00

THIS WORK PACKAGE COVERS:

Removal and Installation

INITIAL SETUP:

Tools and Special Tools Electronic system tool kit (WP 0020 00, Item 1)

References

TM 9--2350--314--20--1

Equipment Conditions Generator removed from vehicle

(TM 9--2350--314--20--1)

REMOVAL

WARNING

Wear safety glasses and steel--tipped shoes to avoid possible injury while handling equipment.

WARNING

Components of these generators are heavy and may be awkward to handle. Use cor-rect lifting procedures, indicated lifting devices, and/or assistance from other person-nel to avoid injury.

WARNING

Fuel and oil are slippery and can cause falls. To avoid injury, wipe up spilled fuel or oil with rags.

1. Refer to TM 9--2350--314--20--1 for removal of the generator from the major item.

2. Visually inspect components of the generator for obvious damage.

CAUTION

To prevent contamination of components and internal channels and cavities, the external surfaces of the generator must be thoroughly cleaned prior to disassembly.

0005 00--2

REMOVE/INSTALL GENERATOR (57K1788) -- Continued 0005 00

REMOVAL -- Continued

3. Refer to TM 9--2350--314--20--1 for removal of any components of the oil cooling system if these are present on the generator.

4. Refer to WP 0006 00 through WP 0011 00 for the overhaul procedures for all the generator subassemblies.

1. Oil pump

2. End bell

3. Stator housing

4. Stator exciter housing

5. Couple clamp

6. Generator rotor

Figure 5--1. Generator Subassemblies

0005 00--3

REMOVE/INSTALL GENERATOR (57K1788) -- Continued 0005 00

INSTALLATION

WARNING

Wear safety glasses and steel--tipped shoes to avoid possible injury while handling equipment.

WARNING

Components of these generators are heavy and may be awkward to handle. Use cor-rect lifting procedures, indicated lifting devices, and/or assistance from other person-nel to avoid injury.

CAUTION

To prevent contamination of components and internal channels and cavities, the external surfaces of the generator must be thoroughly cleaned prior to assembly.

1. If necessary, refer to TM 9--2350--314--20--1 for installation of any components of the generator oil cooling system.

2. Refer to TM 9--2350--314--20--1 for installation of the generator to the major item.

0005 00--3/4 blank

0005 00--4

0006 00--1

OVERHAUL PROCEDURES FOR OIL PUMP ASSEMBLY 0006 00

THIS WORK PACKAGE COVERS:

Removal, Disassembly, Cleaning, Inspection, OIPs, Repair, Assembly, and Installation

INITIAL SETUP:

Tools and Special Tools Electronic system tool kit (WP 0020 00, Item 1)

Materials Grease (WP 0019 00, Item 5) Lubricating compound (WP 0019 00, Item 7) Lubricating oil (WP 0019 00, Item 8) Nonelectrical wire (WP 0019 00, Item 11)

Parts Packing with retainer (4) (WP 0021 00, Item 20) Preformed packing (WP 0021 00, Item 26) Preformed packing (WP 0021 00, Item 22) Preformed packing (WP 0021 00, Item 42) Self--locking nut (WP 0021 00, Item 36)

References

TM 9--2350--314--20--1

TM 9--2350--314--24P--1

Equipment Conditions Generator removed from vehicle

(TM 9--2350--314--20--1)

REMOVAL

WARNING

Wear safety glasses and steel--tipped shoes to avoid possible injury while handling equipment.

WARNING

Components of these generators are heavy and may be awkward to handle. Use cor-rect lifting procedures, indicated lifting devices, and/or assistance from other person-nel to avoid injury.

WARNING

Fuel and oil are slippery and can cause falls. To avoid injury, wipe up spilled fuel or oil with rags.

0006 00--2

OVERHAUL PROCEDURES FOR OIL PUMP ASSEMBLY -- Continued 0006 00

REMOVAL -- Continued

CAUTION

To prevent contamination of components and internal channels and cavities, the external surfaces of the generator must be thoroughly cleaned prior to disassembly.

1. Remove pipe plug (1) from oil pump assembly (2). Discard pipe plug (1).

2. Remove safety wire (3) connected between screw (4) and oil pump nut (5). Discard safety wire.

3. Loosen nut (5) and remove setscrew (6) with nut (5).

4. Remove preformed packing (7) from set screw (6). Discard preformed packing.

5. Remove spring (8), plunger (9), and relief plunger (10) from oil pump (2).

6. Remove screw (4), three screws (11), and four packings with retainers (12) from oil pump assembly (2). Discard packings with retainers.

7. Remove oil pump assembly (2), splined shaft (13), preformed packing (14), key (15), and preformed packing (16) from generator assembly (17). Discard preformed packing.

0006 00--3

OVERHAUL PROCEDURES FOR OIL PUMP ASSEMBLY -- Continued 0006 00

DISASSEMBLY

NOTE

Do not disassemble pump when overhauling generator. If pump fails inspection requirements of OIP 1545567--1, page 0006 00--8, and functional test requirements of Final Testing, WP 0012 00, pump must be replaced.

Inspect oil pump in accordance with the Inspection and OIP paragraphs.

CLEANING

The primary objectives of cleaning are the removal of contaminants, dirt, grease, oil, other foreign material, and paint (if required) to permit adequate inspection of the item, to determine serviceability, and to permit components to oper-ate properly. All components must be cleaned to meet the minimum standards of these objectives. The methods of cleaning and types of equipment and materials used will differ according to the part material or according to a special-ized requirement for the part. Clean the components of the generator using appropriate cleaning materials, methods, equipment, and procedures prescribed in the Overhaul Inspection Procedures.

1. Cleaning materials are listed and identified in WP 0019 00, Expendable and Durable Items, and are listed by item number when used.

WARNING

Adhesive, primer, sealant compounds, and isopropyl alcohol are toxic and flammable.

These compounds are toxic to eyes, skin, and respiratory tract. Continued exposure can make you dizzy and irritate your eyes and throat.

2. Clean generator components using cleaning solvent (WP 0019 00, Item 9).

3. Reverse flush internal passages and oil ports. Repeat flushing and reverse flushing operations as necessary to remove trapped particles.

4. Drain cleaning solvent from all cavities and oil ports.

WARNING

Air pressure in excess of 30 psi (207 kPa) can injure personnel. Do not direct pressur-ized air at yourself or others. Always wear goggles.

5. Use compressed air and ensure the oil orifices are open and clear of foreign matter.

6. Use care when handling parts during cleaning and maintenance. Nicks, scratches, dents, and burrs can prevent proper assembly or cause malfunctions after assembly.

7. Except where specifically called for in a task, don’t use abrasives, files, wire brushes, or sharp tools. On some surfaces, finish is important to the operation of the close fitting parts.

8. Parts must be thoroughly cleaned and kept clean throughout the maintenance process.

0006 00--4

OVERHAUL PROCEDURES FOR OIL PUMP ASSEMBLY -- Continued 0006 00

INSPECTION

In--process inspections are provided in the Overhaul Inspection Procedures (OIPs) where applicable. Critical in--pro-cess inspections are identified by (QA) in the left margin at the paragraph which it applies. In--process inspections designated (QA) will be made by a quality control (QC) inspector in accordance with the quality plan during the over-haul process to verify that the work is being accomplished in accordance with this NMWR and reference documents.

DURING AND AFTER DISASSEMBLY

Inspections should be performed to evaluate the serviceability of components, assemblies, subassemblies, and piece parts as they are removed during disassembly of the item.

1. Inspect parts for cracks, distortions, overheating, corrosion, scoring of critical surfaces, and evidence of metal fatigue.

2. Inspect parts for damage resulting from improper clearance, lack of lubrication, undesired movement of parts, overload, uneven load distribution, heat shock, and extension of minor damage such as scratches, tool marks, grinding, cracks, and nicks. Inspect for the presence of foreign material such as grit, chips, moisture, and chemicals, and for damage resulting from improper assembly or disassembly.

3. Inspect surface finishes for wear through to parent metal and for chipping, scratching, or peeling of finished metal.

4. Inspect for damage that may have been caused by other parts or for damage that may reflect damage to mating or adjacent parts.

5. Inspect parts with critical fit and wear tolerances for compliance with wear limit, fit, and tolerance information. See Overhaul Inspection Procedures (OIPs).

6. Inspect ball and roller bearings as prescribed in TM 9--214.

7. Inspect gears for chips, scratches, cracks, nicks, and/or foreign material. Replace defective gears.

8. Inspect splines for bends, twists, cracks, nicks, and for damage resulting from improper assembly.

9. Replace defective shafts.

10. Inspect attaching hardware as it is removed. Once removed, locknuts, lockwashers, cotter pins, and spring pins should not be reused. Inspect hardware for wear and corrosion. Replace the part if signs of wear or corrosion exist.

11. Visually inspect castings and weldments for cracks. Inspect parts by magnetic particle or liquid penetrant inspection when specified by an OIP or when a crack or flaw is suspected.

12. Inspect machined surfaces for warpage, rough spots, scores, burrs, and gouges.

13. Inspect connectors and terminals for looseness, cracks, and broken parts. Inspect individual wires and cables for pinched, kinked, smashed, or otherwise damaged insulation resulting in bare, broken, or cut wire or strands.

Replace broken or damaged parts with new parts or replace the entire assembly.

14. Studs. Inspect all studs for stripped or damaged threads, a bent or lose condition, and signs of stretching.

15. Threaded Parts. Inspect all threaded parts for burrs, and stripped or damaged threads.

DURING ASSEMBLY

1. Assembly of an item must be accomplished in accordance with included or referenced procedures to…