NMWR_9-2920-331_200_Amp_Alternator_aug_2008.pdf

NMWR 9-2815-274

5-274

NATIONAL MAINTENANCE WORK REQUIREMENT

CONTAINING NATIONAL OVERHAUL STANDARDS

FOR

200-AMP ALTERNATOR

HMMWV FOV

NSN 2920-01-420-9968

MODEL N76761-N1225-1

P/N 12447109

AVAILABILITY STATEMENT: This publication is not available through the AG publication centers. This publication is available through TACOM Life Cycle Management Command, Warren, MI 48397-5000

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

*NMWR 9-2920-331

TACOM LIFE CYCLE MANAGEMENT COMMAND, WARREN, MI

31 AUGUST 2008

This supersedes NMWR 9-2920-331, dated 6 May 2005.

NMWR 9-2920-331

a/b blank

WARNING SUMMARY

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

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.). Failure to comply may result in injury to personnel.

Use extreme care when handling heavy parts. Provide adequate support and use assistance during procedure. Failure to do so may result in death or injury to personnel.

A/B blank

LIST OF EFFECTIVE PAGES/WORK PACKAGES

The date of issue for original pages/work pages for this NMWR is:

Original 31 August 2008

TOTAL NUMBER OF PAGES IN THIS PUBLICATION IS 108

TOTAL NUMBER OF WORK PACKAGES IS 18.

THE PAGES/WORK PACKAGES CONSISTS OF THE FOLLOWING:

Page No. . . . . . . . . . . . . .Change No. * Warning a Warning b blank A B blank i ii blank iii iv blank v–vii viii blank

WP 0001 00–WP 0018 00

Index 1–Index 2

*Zero in this column indicates original page.

NATIONAL MAINTENANCE WORK REQUIREMENTS NATIONAL MAINTENANCE WORK REQUIREMENTS

CONTAINING NATIONAL OVERHAUL STANDARDS

REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS

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

This supersedes NMWR 9-2920-331, dated 6 May 2005.

i/ii blank

You can help improve this publication. If you find any mistakes or if you know of a way to improve the procedures, please let us know. Submit your DA Form 2028 (Recommended Changes to Equipment Technical Publications), 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 quicker to your comments and better manage the DA Form 2028 program. You may also mail, fax, or E-mail your letter or DA Form 2028 direct to: 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 ROCK-TACOM-TECH-PUBS@conus.army.mil The fax number is DSN 793-0726 or Commercial (309)782-0726.

NATIONAL MAINTENANCE WORK REQUIREMENTS HEADQUARTERS,

WARREN, MI, 31 August 2008

-1

FOR

NSN 2920-01-420-9968

P/N 12447109

MODEL N76761-N1225-1

TACOM LIFE CYCLE MANAGEMENT COMMAND,

http://aeps.ria.army.mil/ mailto:TACOM-TECH-PUBS@ria.army.mil

TABLE OF CONTENTS

Work Package/Page No.

How to Use This NMWR ......................................................................... v

CHAPTER 1 GENERAL INFORMATION AND DATA

List of Acronyms/Abbreviations............................................................... WP 0001 00-1 General Information.................................................................................. WP 0002 00-1 Equipment Description and Data .............................................................. WP 0003 00-1 Component Checklist................................................................................ WP 0004 00-1 General Maintenance Information ............................................................ WP 0005 00-1

CHAPTER 2 OVERHAUL INSTRUCTIONS

Removing Alternator from Container....................................................... WP 0006 00-1 200-Amp Alternator Overhaul.................................................................. WP 0007 00-1 200-Amp Alternator Testing and Painting Procedures.............................. WP 0008 00-1

CHAPTER 3 SUPPLEMENTAL INFORMATION

Preparing Alternator for Storage............................................................... WP 0009 00-1 Torque Limits............................................................................................ WP 0010 00-1 Test Limits ................................................................................................ WP 0011 00-1 Expendable and Durable Items List.......................................................... WP 0012 00-1 Illustrated List of Manufactured Items ..................................................... WP 0013 00-1 Mandatory Replacement Parts .................................................................. WP 0014 00-1 Tools and Special Tools............................................................................ WP 0015 00-1 Parts Required for Testing ........................................................................ WP 0016 00-1 Repair Parts Introduction and Repair Parts............................................... WP 0017 00-1 References................................................................................................. WP 0018 00-1

Index.......................................................................................................... INDEX-1 iii/iv blank v

HOW TO USE THIS

NATIONAL MAINTENANCE WORK REQUIREMENT (NMWR)

INTRODUCTION

This section explains the basic organization, contents, format, and special features of this NMWR. After reading this section, spend some time reviewing the NMWR to familiarize yourself with the contents and layout. This will enable you to locate information easily and reduce the time needed to complete required procedures.

ORGANIZATION AND CONTENTS

This NMWR is divided into three main chapters. Chapter 1 presents general information and preliminary data; Chapter 2 contains detailed overhaul procedures; and Chapter 3 provides supplemental tool, equipment, and parts information. The following table provides an overview of the material contained in each chapter of this NMWR.

Chapter 1 • Definition of acronyms/abbreviations used throughout the NMWR

• Basic information about the component, along with general guidelines and criteria for inspection and repair or replacement

• Detailed equipment description and data

• Component Checklist

• General maintenance information

Chapter 2 • Detailed overhaul procedures for disassembly, inspection, repair or replacement, Chapter 3 • Preparing alternator for storage, supplementary information covering torque limits, test

You can locate specific information in the NMWR by using either the Table of Contents located at the front of the NMWR or the alphabetical subject Index located at the back of the NMWR.

Table 1. NMWR Contents.

and assembly.

NMWR 9-2920-331

limits, expendable and durable items, manufactured items (if required), mandatory replacement parts, tools and special tools, repair parts, and reference publications.

vi

HOW TO USE THIS NATIONAL MAINTENANCE WORK REQUIREMENT (NMWR) (Cont'd)

NMWR 9-2920-331

FORMAT

Work Package (WP) Format

Each chapter in this NMWR is divided into WPs, which group data into stand-alone informational or task-oriented units. Here are some important things to know about the WP format:

• Each WP has its own identification number, which appears in the upper right corner of each page. WPs are numbered sequentially throughout the manual.

• Each WP starts with page number 1. Page numbers appear at the bottom of the pages, following the WP number.

• Informational WPs begin with a listing of the specific topics covered, in the order in which they appear in the WP. This listing provides a quick overview of each WP and enables you to locate specific information easily.

• Each task-oriented WP begins with an Initial Setup list that identifies all tools, mandatory replacement parts, personnel, and other materials needed to complete the procedure in the WP.

The Initial Setup list also identifies the equipment condition required before the procedure can be started. Before you begin a procedure, review the Initial Setup information to ensure that all requirements have been met.

• Task-oriented WPs (overhaul procedures) appear in the manual in the order of logical work sequence. This format makes the NMWR easy to follow and helps improve efficiency as you progress through the procedures.

Text and Illustration Modular Layout

Throughout this NMWR, overhaul procedures are set up in two-page modular layouts. This means that illustrations appear either on the same page as, or on the page facing, the step you are performing.

This feature eliminates the need to search for illustrations that correlate with each procedural step.

In addition, procedural text is cross-referenced to numerical callouts in the illustrations, helping you immediately identify and locate specific parts mentioned. Callout numbers referencing the illustrations appear in parentheses in the text.

vii/viii blank

HOW TO USE THIS NATIONAL MAINTENANCE WORK REQUIREMENT (NMWR) (Cont'd)

NMWR 9-2920-331

SPECIAL FEATURES

Illustration Features

This NMWR utilizes a variety of illustration methods, such as locator views and exploded views, to help you locate and identify parts easily. Each illustration is identified by a title printed below it.

The illustrations contain numerical callouts to identify parts, components, etc. mentioned in the text.

Numerical callouts generally appear in clockwise order in the illustrations, beginning at the 11 o’clock position.

A special feature of this NMWR is that callout numbers for mandatory replacement parts are circled in the illustrations. This visually distinguishes mandatory replacement parts from those that may be repairable or otherwise reusable.

Supplemental Information

The WPs at the end of this NMWR contain supplemental information that supports the procedures in the NMWR. This information is cross-referenced in the Initial Setup list of each maintenance WP. The following supplemental information is included in this NMWR:

• Torque Limits—Torque specifications for all fasteners used to assemble the component being overhauled in this NMWR

• Test Limits—Location/description and wear limits for parts used in this NMWR.

• Expendable and Durable Items—National Stock Number (NSN), description, Commercial and

Governments Entity Code (CAGEC), Part Number (P/N), and description for all expendable and durable items necessary to operate or maintain the equipment used in this NMWR

• Illustrated List of Manufactured Items—Complete instructions for making items authorized to be fabricated for this NMWR

• Mandatory Replacement Parts—Name, P/N, and NSN for all parts that must be replaced during overhaul of the component; also includes cross-references to figures and item numbers in the Repair Parts WP.

• Tools and Special Tools—Name, P/N, and NSN for common and special tools required for the procedures in this NMWR

• Repair Parts—Source, Maintenance, and Recoverability (SMR) code, NSN, CAGEC, P/N, and quantity for all parts required for the procedures in this NMWR

• References—All publications referenced in this NMWR.

CHAPTER 1

GENERAL INFORMATION AND DATA

FOR

NMWR 9-2920-331 0001 00

0001 00-1

NATIONAL MAINTENANCE WORK REQUIREMENT (NMWR)

200-AMP ALTERNATOR

HMMWV FOV

NSN 2920-01-420-9968 P/N 12447109 MODEL 76761-N1225-1

LIST OF ACRONYMS/ABBREVIATIONS

SCOPE

This Work Package (WP) lists acronyms and abbreviations that appear in this NMWR.

NMWR 9-2920-331 0001 00

0001 00-2

LIST OF ACRONYMS/ABBREVIATIONS (Cont'd)

ACRONYM/ DEFINITION

ABBREVIATION

AEPS Army Electronic Product Support

CAGEC Commercial and Government Entity Code

CPC Corrosion Prevention and Control

ECP Engineering Change Proposal

EDRS Electronic Deficiency Reporting System

EIR Equipment Improvement Recommendations

FIR Final Inspection Report

FOV Family of Vehicles

MAC Maintenance Allocation Chart

MEL Maintenance Expenditure Limit

NMWR National Maintenance Work Requirement

NSN National Stock Number

P/N Part Number

PQDR Product Quality Deficiency Report

QDR Quality Deficiency Report

SMR Source, Maintenance, and Recoverability

SRA Specialized Repair Activity

TAMMS The Army Maintenance Management System

UOC Usable On Code

WP Work Package

E END OF WORK PACKAGE

NMWR 9-2920-331 0002 00

0002 00-1

NATIONAL MAINTENANCE WORK REQUIREMENT (NMWR)

200-AMP ALTERNATOR

HMMWV FOV

NSN 2920-01-420-9968 P/N 12447109 MODEL 76761-N1225-1

GENERAL INFORMATION

THIS WORK PACKAGE (WP) COVERS:

Scope; Maintenance Forms, Records, and Reports; Reporting Equipment Improvement Recommendations (EIRs); Corrosion Prevention and Control (CPC); Preparation for Storage; Warranty Information;

Quality of Material; Safety, Care, and Handling; Engineering Change Proposals (ECPs); Deviations and Exceptions; and Cost Considerations.

SCOPE

This NMWR is for use by maintenance technicians at certified repair sites. The instructions in this NMWR apply to the 200-amp alternator. In case of conflict with other information, the data contained in this NMWR shall take precedence. The condition of the 200-amp alternator after overhaul shall be that utility and performance are returned to a near-zero-time/near-zero-miles or like-new condition.

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.

Before performing any overhaul activity, the maintenance technician shall become familiar with all procedures in this NMWR.

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 738-750, Functional Users Manual for The Army Maintenance Management System (TAMMS).

REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIR’S)

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 don’t like about your equipment. Let us know what you don’t like about the design or performance. The preferred method for submitting Quality Deficiency Reports (QDRs) is through the Army Electronic Product Support (AEPS) website under the Electronic Deficiency Reporting System (EDRS). The web address is: https://aeps.ria.army.mil. This is a secured site requiring a password that can be applied for on the front page of the website. If the above method is not available to you, put it on an SF 368, Product Quality Deficiency Report (PDQR), and mail it to us at:

Department of the Army, United States Army TACOM Life Cycle Management Command, 6501 East 11 Mile Road, Mail Stop 420, ATTN: AMSTA-LC-CHLD, Mr. William S. Bayes, william.s.bayes@us.army.mil Warren, MI 48397-5000

0002 00-2

GENERAL INFORMATION (Cont'd)

CORROSION PREVENTION AND CONTROL (CPC)

Corrosion Prevention and Control (CPC) of Army materiel is a continuing concern. It is important that any corrosion problem with this item be reported so that the problem can be corrected and improvements made to prevent the problem in the future.

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 corrosion problem.

If a corrosion problem is identified, it can be reported using an SF 368, Quality Deficiency Report. Use of key words, such as corrosion, rust, deterioration, or cracking, will ensure that the information is identified as a CPC problem.

The form should be submitted to the address specified in DA PAM 738-750, Functional Users Manual for the Army Maintenance Management Systems (TAMMS).

PREPARATION FOR STORAGE

To prepare the 200-amp alternator for storage, refer to WP 0009 00. Additional information can be found in TM 746-10, General Packaging Instructions for Field Use, Marking, Packing, and Shipment of Supplies and Equipment.

WARRANTY INFORMATION

The 200-amp alternator will be covered by warranty. For warranty information, contact Department of the Army, United States Army TACOM Life Cycle Management Command, 6501 East 11 Mile Road, Mail Stop 420, ATTN: AMSTA-LC-CHLD, Mr. William S. Bayes, william.s.bayes@us.army.mil

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 this 200-amp alternator.

SAFETY, CARE, AND HANDLING

1. Adequate safety precautions will be provided for the performance of overhaul operations. These precautions will include safety in work environment, selection and usage of equipment, and procedures provided for performing all operations. Inspection, which follows completion of overhaul procedures, will ensure equipment compliance with applicable safety standards.

2. Supplies and materials such as solvents, cleaning fluids, sealers, adhesives, oils, and other products used in this NMWR may be dangerous or harmful if safety precautions are not observed. Read manufacturers’ warnings and cautions on product labels before using and observe all recommended safety precautions.

3. Ensure proper procedures are followed during lifting of heavy items. Follow all warnings and cautions identified in this NMWR.

Warren, MI 48397-5000

0002 00-3/4 blank

GENERAL INFORMATION (Cont'd)

ENGINEERING CHANGE PROPOSALS (ECP’S)

ECPs will be submitted using DD Form 1693, Engineering Change Proposal (Short Form). (Refer to MIL-STD-973, Configuration Management, for instructions.) Completed forms should be mailed directly to Department of the Army, United States Army TACOM Life Cycle Management Command, 6501 East 11 Mile Road, Mail Stop 420, ATTN: AMSTA-LC-CHLD, Mr. William S. Bayes, DEVIATIONS AND EXCEPTIONS

Requests for deviations or exceptions to this NMWR will be processed in accordance with ISO 9000 Series standards or equivalent. Deviations and exceptions may include certain parts that are no longer available from suppliers and will have to be repaired.

COST CONSIDERATIONS

This work requirement shall be the basis for establishing the extent of the overhaul while considering cost factors. A determination shall be made on all subassemblies/assemblies to replace a worn or damaged component that is available in supply if acquisition cost is less than the cost to repair/restore it to the NMWR standard. The cost to repair/restore any individual item shall not exceed the standard Maintenance Expenditure Limit (MEL) of 80% (percent). For parts/components that are not available or that exceed the MEL, a request for deviation or exception to this MEL will be processed in accordance with ISO 9000 Series standards or equivalent on a case-by-case basis. Submit a request for deviation or exception to the Department of the Army, United States Army TACOM Life Cycle Management Command, 6501 East 11 Mile Road, Mail Stop 420, ATTN: AMSTA-LC-CHLD, Mr. William S. Bayes william.s.bayes@us.army.mil Warren, MI 48397-5000.

END OF WORK PACKAGE

william.s.bayes@us.army.mil Warren, MI 48397-5000. A reply will be furnished to you.

NMWR 9-2920-331 0003 00

0003 00-1

NATIONAL MAINTENANCE WORK REQUIREMENT (NMWR)

200-AMP ALTERNATOR

HMMWV FOV

NSN 2920-01-420-9968 P/N 12447109 MODEL 76761-N1225-1

EQUIPMENT DESCRIPTION AND DATA

THIS WORK PACKAGE (WP) COVERS

Description, Equipment Data Plate, and Overhaul Data Plate.

DESCRIPTION

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 Equipment Data Plate Location.

EQUIPMENT DATA PLATE

REGULATOR

FAN SHROUD

OUTPUT STUDGROUND TERMINAL

0003 00-2

EQUIPMENT DESCRIPTION AND DATA (Contd)

EQUIPMENT DATA PLATE

The equipment data plate is located on the side of the alternator. See Figure 1 for location of equipment data plate. The data plate shows the alternator serial number, part number, and model number. See Figure 2 for identification of equipment data plate. If the data plate has been damaged or is illegible, it must be replaced. Copy the pertinent data from damaged data plate to a new data plate.

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)

Stamping Information Required:

1. Serial number

2. Part number

3. Model number

Installation/Replacement:

1. Remove damaged or illegible data plate.

2. After overhaul, testing, and final inspection are complete, install new stamped equipment data plate in location shown in Figure 1.

Figure 2. Equipment Data Plate.

MFR: C. E. Niehoff

Generator, Engine Accessory

Part No. XXXX

NSN: XXXX

Contract: XXXX

U.S.A. XXXX

Dual Volt 14V and 28V 200A DC

Date: XXXX

Ser. No. XXXX

U.S.

1.625 in.

(41.27 mm)

5.625 in.

(142.87 mm)

0003 00-3

EQUIPMENT DESCRIPTION AND DATA (Contd)

OVERHAUL DATA PLATE

Location:

An overhaul data plate will be attached to the alternator after overhaul is complete. See Figure 3, Overhaul Data Plate, for identification of the overhaul data plate.

Replacement Data:

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

New Plate:

New overhaul data may be fabricated in accordance with Figure 3, Overhaul Data Plate.

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

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 Required:

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

2. Overhauled at: Name or initials of overhaul facility

3. Date:

Month — Three-letter abbreviation

Year — Last two digits

Example — October 02 for October 2002

0003 00-4

EQUIPMENT DESCRIPTION AND DATA (Contd)

Figure 3. Overhaul Data Plate.

Figure 4. Overhaul Data Plate Installation.

4 5

END OF WORK PACKAGE

0.750 in.

(19 mm)

0.250 in.

(6 mm)

1.00 in.

(50.8 mm)

3.00 in.

(63.5 mm)

0.250-in.

(6-mm)

OVERHAUL DATA PLATE (Contd)

Installation/Replacement:

1. Remove existing overhaul data plate, if installed.

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

NMWR 9-2920-331 0004 00

0004 00-1

NATIONAL MAINTENANCE WORK REQUIREMENT (NMWR)

200-AMP ALTERNATOR

HMMWV FOV

NSN 2920-01-420-9968 P/N 12447109 MODEL 76761-N1225-1

COMPONENT CHECKLIST

THIS WORK PACKAGE (WP) COVERS:

Scope; Component Checklist Instructions.

SCOPE

The purpose of the Component Checklist is to identify the component and the condition as received.

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

COMPONENT CHECKLIST INSTRUCTIONS

1. Make a copy of the Component Checklist (Table 1) and fill in the information as requested.

Identifying information: Fill in the required information at top of the Component Checklist.

Item 1. Records check Review accompanying shipping and maintenance tags and documents. These tags and documents may supply information helpful to the maintenance technician. Record any significant information.

NOTE

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

Item 2. Container, crate, box, pallet, check, etc.

Visually check container for evidence of damaged or missing parts. Note any damaged or missing parts.

Item 3. Component check

Visually check component for evidence of damage or missing parts. Note any damage or missing parts.

2. Upon completion of the Component Checklist, remove all tags and documents from component.

Develop a record file for the component. Include the tags and documents, completed Component Checklist, Test Report, and Final Inspection Report (FIR) in the record file. The Test Report will be completed during final testing of the overhauled component. The FIR will be completed when preparing component for storage.

NMWR 9-2920-331 0004 00

0004 00-2

COMPONENT CHECKLIST (Cont'd)

ITEM TEST/ CONDITION RECOMMENDED MAINTENANCE

NO. INSPECTION ACTION

Table 1. Component Checklist.

COMPONENT CHECKLIST

DATE RECEIVED: INSPECTOR:

NOMENCLATURE/PART NAME: NSN:

SERIAL #: MODEL #:

1.

2.

3.

Records check

Container, crate, box, pallet, check, etc.

Component check

NMWR 9-2920-331 0005 00

NATIONAL MAINTENANCE WORK REQUIREMENT (NMWR)

NSN 2920-01-420-9968 P/N 12447109 MODEL 76761-N1225-1

GENERAL MAINTENANCE INFORMATION

THIS WORK PACKAGE (WP) COVERS:

Scope; Precautions; Special Processes; Tools and Equipment; Disassembly; Cleaning;

Inspection—Acceptance and Rejection Criteria; Repair or Replacement; and Assembly.

SCOPE

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

Maximum overhaul of parts to like-new condition will be 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. In instances where 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.

0005 00-1

GENERAL MAINTENANCE INFORMATION (Cont'd)

PRECAUTIONS

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

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.

TOOLS AND EQUIPMENT

Tools and equipment required to overhaul this component can be found in the Tools and Special Tools, WP 0015 00.

Torque wrench specifications are given in text, as applicable. Metric equivalents are in parentheses following the U.S. standard measurement. (Example: Tighten mounting bolts to 33–40 lb-ft (45–54 N•m).) Standard capscrew markings and torque specifications are found in Torque Limits, WP 0010 00. Tolerances, torque values, and adjustments are provided in each WP as necessary.

DISASSEMBLY

Each appropriate WP will contain specific instructions for disassembly of the components.

Take care in 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.

0005 00-2

CLEANING

WARNING

Compressed air source must not exceed 30 psi (207 kPa).

Eyeshields must be worn when cleaning with compressed air.

Failure to comply may result in injury to personnel.

Cleaning compound is very flammable and must be kept away from open flame. Failure to comply may result in injury or death to personnel.

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. Refer to DISASSEMBLY on page 0005 00-2.

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

Table 1. Cleaning Guidelines

NO. #

ITEM

CLEANING

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.

Electrical assemblies

Use lint-free cloth dampened with PD680 cleaning solvent. Use compressed air to dry electrical components.

Castings

Clean inner and outer surfaces of castings and all areas subject to grease and oil with PD680 cleaning solvent.

Nonmetallic parts & hoses

Soap and water.

Bearing

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

0005 00-3

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

Threads (internal and external)

Inspect threads for minor irregularities and for damaged threads.

Refer to Table 3, Repairable Defects.

Rotating inner parts

Inspect 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.

Gears

Inspect for cracked, chipped, nicks, ridge, or pits.

Keyways

Inspect for cracked or split keyways.

Snapring grooves

Inspect for cracked, chipped, and worn snapring grooves.

Stator and field windings, wiring, and voltage regulator

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

Oil channels

Inspect oil channels for cracked walls or chipped edges.

Machined surfaces

Inspect for damage that could cause oil leakage or malfunction of the part.

Antifriction bearings

Inspect all bearings and matching cones or races per TM 9-214.

Spline and shafts

Inspect for nicks, burrs, or scoring.

Rotating or lockup inner parts

Inspect for cracked rotating or lockup inner parts.

Sealing areas

Inspect for chipped edges, burred sealing ridges, and longitudinal scratches on sealing surfaces.

Rust and surface scale

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

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.

Pins

Inspect for cracked, worn, or bent pins.

Castings

Inspect for cracks.

0005 00-4

REPAIR OR REPLACEMENT

Parts that are beyond wear limit tolerances, broken, cracked, or otherwise damaged may be considered for repair by special processes listed below by requesting approval from TACOM and/or the Contracting Officer. In requesting approval, the overhaul 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 listed below:

a. Cast aluminum parts may be welded in approved areas before machining to add sufficient finish stock to repair cracks, fill sand holes, etc. Weld in accordance with AM-STD-2219, Process and Performance of Welding Fusion: Aluminum Alloys.

b. Steel parts may be welded in approved areas before machining to add sufficient finish stock to repair cracks, flaws, etc. Weld in accordance with A 488/A 488M, Standard Practice for Steel Castings, Weldings, Qualifications for Procedures and Personnel.

c. 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.

d. It is permissible to impregnate structurally sound castings (containing some porosity, including microporosity) that weep or sweat during hydrostatic or pneumatic pressure testing.

Use MIL-STD-276A, Impregnation of Porous Nonferrous Metal Castings.

e. A film 0.002–0.015-in. (0.05–0.38-mm) thick after finish-machining to print dimensions and surface finished specified may be used to repair damaged surfaces in accordance with Chrome plate, Class 2, AMS QQ-C-320, Chromium Plating (Electrodeposited).

f. Electroless nickel plating, per AMS-C-26074, Requirements for Coatings, Electroless Nickel, may be used to correct undersized or oversized condition. After plating, parts must meet print dimensions and surface finish specified.

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

0005 00-5

REPAIR OR REPLACEMENT (Cont'd)

Repairable Defects

Table 3. Repairable Defects.

REPAIRABLE PART/AREA

Shaft journals

Shaft load surfaces

Flat surfaces

Casting buildup of bores

Casting crack

Machined surfaces

Damaged external threads

Damaged internal threads

Housing; castings;

and shaped, machined surfaces

Splines and shafts

Surface rust and corrosion

REPAIR PROCESS

Chrome plate

Spray metalize

Hard-facing arc weld

Weld

Weld

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.

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.

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 components not repairable.

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

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

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

Mechanical and/or chemical methods may be used. Use fine 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.

0005 00-6

ASSEMBLY

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 or that is outside specified test limits listed in the maintenance WPs or in WP 0011 00.

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 0010 00.

For parts identification, refer to WP 0017 00.

0005 00-7/8 blank

CHAPTER 2

OVERHAUL INSTRUCTIONS

FOR

NMWR 9-2920-331 0006 00

0006 00-1

NATIONAL MAINTENANCE WORK REQUIREMENT (NMWR)

200-AMP ALTERNATOR

HMMWV FOV

NSN 2920-01-420-9968 P/N 12447109 MODEL 76761-N1225-1

REMOVING ALTERNATOR FROM CONTAINER

INITIAL SETUP:

Tools and Special Tools General mechanics’s tool kit:

automotive (Item 1, Table 1, WP 0015 00)

0006 00-2

REMOVING ALTERNATOR FROM CONTAINER (Contd)

NOTE

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

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

Discard gasket (4).

2. Remove cushioning panels (6), (7), and (8) from top of alternator (9) and inside container (5).

3. Remove alternator (9) from container (5).

4. Remove four dessicant packages from bottom of container (5). Discard dessicant packages.

5. Remove cushioning panels (10) and (11) from bottom of container (5).

6. Remove paper wrap and closure tape from alternator (9). Discard paper wrap and closure tape.

Figure 1. Opening Container.

0006 00-3/4 blank

REMOVING ALTERNATOR FROM CONTAINER (Contd)

Figure 2. Removing Alternator from Container.

NMWR 9-2920-331 0007 00

0007 00-1

NATIONAL MAINTENANCE WORK REQUIREMENT (NMWR)

200-AMP ALTERNATOR

HMMWV FOV

NSN 2920-01-420-9968 P/N 12447109 MODEL 76761-N1225-1

200-AMP ALTERNATOR OVERHAUL

DISASSEMBLY, CLEANING AND INSPECTION, ASSEMBLY

INITIAL SETUP:

Tools and Special Tools General mechanic’s tool kit: automotive

(Item 1, Table 1, WP 0015 00) Maintenance and repair shop equipment:

automotive (Item 2, Table 1, WP 0015 00) Multimeter (Item 3, Table 1, WP 0015 00) Press

Materials/Parts Cleaning compound (Item 6, Table 1, WP 0012 00) Sealing compound (Item 11, Table 1, WP 0012 00) Thread locking compound

(Item 1, Table 1, WP 0012 00) Lockwasher (Front)

(Item 1, Table 1, WP 0014 00) Two lockwashers (Rear)

(Item 2, Table 1, WP 0014 00) Locknut (Item 3, Table 1, WP 0014 00) Nut, Selflocking

(Item 4, Table 1, WP 0014 00) Bearing (Item 5, Table 1, WP 0014 00) Bearing (Item 6, Table 1, WP 0014 00) Bushing (Item 7, Table 1, WP 0014 00) Eighteen locknuts

(Item 8, Table 1, WP 0014 00)

Personnel Required One assistant

200-AMP ALTERNATOR OVERHAUL (Cont'd)

DISASSEMBLY

Use extreme care when handling heavy parts. Provide adequate support and use assistance during procedure.

Failure to do so may result in death or injury to personnel.

NOTE

Clean any sealing compound from alternator assembly prior to disassembly.

1. Disconnect two electrical connectors (8) from regulator (4).

2. Remove two rear screws (1), lockwashers (2), and washers (3) securing regulator (4) to front housing (14). Discard lockwashers (2).

If regulator (P/N N3119 or N3117) is found on generator, replace with regulator (P/N N3135) during assembly.

3. Remove front screw (5), lockwasher (6), washer (7), and regulator (4) from stator shell (13).

Discard lockwasher (6).

Scribe alignment marks on front housing (14) and stator shell (13).

4. Remove three bolts (9), washers (10), and fan shroud (11) from end housing (12).

5. Remove locknut (17), washer (16), and fan (15) from rear of core and shaft assembly (19). Discard locknut (17).

For ease of disassembly, file any burrs off shaft assembly.

6. Remove woodruff key (22) and bearing cover plate (29) from front of core and shaft assembly (19).

7. Remove four screws (20) and front housing cover plate (21) from front housing (14).

8. Remove nine locknuts (23) from stator shell (13). Discard locknuts (23).

9. Remove eight nuts (28), stator leads (24), flat washers (27), and insulator washers (26) from stator studs (25).

10. Remove snapring (30) from front of core and shaft assembly (19).

Insert a screw into hole adjacent to the negative terminal.

11. Using a press, remove front housing (14) from stator shell (13).

12. Remove nine locknuts (18) securing end housing (12) to stator shell (13). Discard locknuts (18).

13. Using three-jaw puller, remove end housing (12) from stator shell (13).

14. Remove three screws (31) securing front rotor (32) from front of core and shaft assembly (19).

15. Using a soft-face hammer, lightly tap front rotor (32) to remove front rotor (32) from front of core and shaft assembly (19).

16. Remove three screws (33) securing rear rotor (39) from rear of core and shaft assembly (19).

0007 00-2

DISASSEMBLY (Cont'd)

17. Using a soft-face hammer, lightly tap rear rotor (39) to remove rear rotor from rear of core and shaft assembly (19).

18. Remove two snaprings (34) and (38) retaining bearing (35) in front housing (14).

19. Using press, remove bearing (35) from front housing (14). Discard bearing (35).

20. Using press, remove bearing (36) from rear of core and shaft assembly (19). Discard bearing (36).

21. Remove bushing (37) from end housing (12). Discard bushing (37).

0007 00-3

15 16

Figure 1. Regulator and Fan Shroud Disassembly. Figure 2. Fan and End Housing Disassembly.

Juanita.C.Orr Oval

Juanita.C.Orr Oval

Juanita.C.Orr Oval

Juanita.C.Orr Oval

0007 00-4

DISASSEMBLY (Cont'd)

Oval

Juanita.C.Orr Oval

Juanita.C.Orr Oval

Juanita.C.Orr Oval

Line

CLEANING AND INSPECTION

CAUTION

All parts must be thoroughly cleaned. Do not allow dirt or other contaminants to enter alternator components. Failure to comply may result in damage to components.

1. For general parts cleaning information, refer to CLEANING, WP 0005 00.

2. For general parts inspection information, refer to INSPECTION, WP 0005 00.

3. Using multimeter set to ohmmeter scale, check resistance between each successive pair of stator phase leads (6)-(5), (5)-(12), and (6)-(12). Maximum resistance should read less than 1 ohm. If multimeter reads infinity (∞ ), stator is open. Replace stator and field coil assembly (13).

4. Using multimeter set to ohmmeter scale, check resistance between each stator phase lead (6), (5), (12), (11), (10), (9) and ground terminal (1) on front housing (3). Multimeter should read infinity (∞ ). If multimeter reads 0, stator is grounded. Replace stator and field coil assembly (13).

5. Using multimeter set to ohmmeter scale, check resistance between field positive lead (7) and field negative lead (8). Maximum resistance should read less than 3 ohms. If multimeter reads more than 3 ohms, field coil is open. Replace stator and field coil assembly (13).

6. Using multimeter set to ohmmeter scale, check resistance between both field positive lead (7) and field negative lead (8) and ground terminal (1) on front housing (3). Multimeter should read infinity (∞ ). If multimeter reads less than 100K ohms, field coil is grounded. Replace stator and field coil assembly (13).

7. Using multimeter set to ohmmeter scale, check resistance between B positive output stud (2) and six S-studs (4). Maximum resistance should read less than 600 ohms or infinity (∞ ) for all six S-studs (4). Reverse multimeter leads. Multimeter should read nearly alike for all six S-studs (4) but opposite the first set of readings. If readings are not opposite, rectifier diodes in front housing (3) are open or shorted. Replace front housing (3).

8. Using multimeter set to ohmmeter scale, check resistance between ground terminal (1) and six

S-studs (4). Multimeter should read either less than 600 ohms or infinity (∞ ) for all six S-studs (4).

Reverse multimeter leads. Multimeter should read nearly alike for all six S-studs (4) but opposite the first set of readings. If readings are not opposite, rectifier diodes in front housing (3) are open or shorted. Replace front housing (3).

0007 00-5

0007 00-6

200-AMP ALTERNATOR OVERHAUL (Contd)

Figure 8. Alternator Testing.

2 3

Figure 9. Stator and Field Coil Assembly.

0007 00-7

200-AMP ALTERNATOR OVERHAUL (Cont'd)

ASSEMBLY

WARNING

Use extreme care when handling heavy parts. Provide adequate support and use assistance during procedure.

Failure to do so may result in death or injury to personnel.

1. Install new bushing (2) in end housing (1).

2. Using press, install new bearing (4) for end housing (1) on rear of core and shaft assembly (3) until fully seated.

3. Using press, install new bearing (7) in front housing (6). Ensure new bearing (7) is seated between snapring grooves (8).

4. Install tapered snapring (5) in snapring groove (8) in forward side of front housing (6).

5. Install snapring (12) in snapring groove (8) in backside of front housing (6)

6. Apply thread locking compound to three front rotor screws (11).

7. Install front rotor (10) on front of core and shaft assembly (3) with three front rotor screws (11). Tighten front rotor screws (11) to 45 lb-in (5 N•m).

8. Install front of core and shaft assembly (3) in vise with front rotor (10) facing up.

9. Using press, install front housing (6) and new bearing (7) on front of core and shaft assembly (3) until fully seated.

10. Install snapring (9) on front of core and shaft assembly (3).

Tapered snapring must be installed with flat surface facing bearing to ensure snapring locks properly into snapring groove (8).

Figure 10. End Housing Bushing Assembly

0007 00-8

200-AMP ALTERNATOR OVERHAUL (Cont'd)

Figure 11. End Housing Bearing Assembly.

Figure 13. Rear Rotor, Core and Shaft Assembly, and Front Housing Assembly.

Figure 12. Front Housing Bearing Assembly.

NOTE:

Flat Surface Facing Bearing

Juanita.C.Orr Oval

Juanita.C.Orr Oval

ASSEMBLY (Cont’d)

11. Align scribe mark (24) on front housing (6) with scribe mark (24) on stator shell (23).

12. Install front housing (6) on stator shell (23) and route stator leads (22) through openings in front housing (6). Ensure stator leads (22) are not pinched between front of core and shaft assembly (3) and front housing (6).

13. Apply thread locking compound to stator shell studs (25) and install nine new locknuts (21) on stator shell studs (25). Tighten new locknuts (21) to 18 lb-in (2 N•m).

The RED stator leads terminal studs are course threaded. Use course threaded nuts only.

The BLACK stator leads terminal studs are fine threaded. Use fine thread nuts only.

14. Install eight insulating washers (27), flat washers (13), six each BLACK stator leads (22) and two each RED stator leads (22) and nuts (14) on stator studs (26). Tighten nuts (14) to 18 lb-in (2 N•m).

15. Apply sealing compound to all nuts (14) and stator leads (22).

16. Install front housing cover plate (19) on front housing (6) with four screws (18). Tighten screws (18) to

45 lb-in (5 N•m).

17. Install front housing bearing cover (15) on front of core and shaft assembly (3).

18. Install woodruff key (20) in front of core and shaft assembly (3).

19. Apply thread locking compound to six front rotor screws (17).

20. Install rear rotor (16) on rear of core and shaft assembly (3) with six rear rotor screws (17). Tighten rear rotor screws (17) to 45 lb-in (5 N•m).

0007 00-9

0007 00-10

200-AMP ALTERNATOR OVERHAUL (Cont'd)

Figure 14. Front Housing Assembly.

14 13 27

Figure 15. Front Rotor Assembly.

0007 00-11

200-AMP ALTERNATOR OVERHAUL (Cont'd)

28 30 31

Figure 16. Fan and End Housing Assembly.

ASSEMBLY (Contd)

21. Align scribe mark (24) on end housing (1) with scribe mark (24) on stator shell (23).

22. Using press, install end housing (1) on stator shell (23).

23. Apply thread locking compound to stator shell studs (25).

24. Install nine new locknuts (29) on stator shell studs (25) securing end housing (1) on stator shell (23).

Tighten new locknuts (29) to 18 lb-in (2 N•m).

25. Install fan (28), washer (30), and new locknut (31) on rear of core and shaft assembly (3). Tighten new locknut (31) to 50 lb-ft (68 N•m).

Juanita.C.Orr Oval

0007 00-12

200-AMP ALTERNATOR OVERHAUL (Cont'd)

ASSEMBLY (Contd)

26. Apply thread locking compound to three fan shroud bolts (33).

27. Install fan shroud (35) on end housing (1) with three washers (34) and fan shroud bolts (33). Tighten fan shroud bolts (33) to 50 lb-in (6 N•m).

28. Apply thread locking compound to front screw (40) and two rear screws (36).

29. Install overhaul plate (32) and regulator (39) on stator shell (23) with front screw (40), new lockwasher (41), and washer (42). Do not tighten front screw (40).

30. Install regulator (39) on front housing (6) with two rear screws (36), new lockwashers (37), and washers

(38). Tighten two rear screws (36) and front screw (40) to 18 lb-in (2 N•m).

31. Connect two electrical connectors (43) to regulator (38).

Figure 17. Regulator and Fan Shroud Assembly.

37 39

END OF WORK PACKAGE

6 1

Juanita.C.Orr Oval

NMWR 9-2920-331 0008 00

0008 00-1

NATIONAL MAINTENANCE WORK REQUIREMENT (NMWR)

200-AMP ALTERNATOR

NSN 2920-01-420-9968 P/N 12447109 MODEL 76761-N1225-1

INITIAL SETUP:

Tools and Special Tools General mechanic's tool kit:

automotive (Item 1, Table 1, WP 0015 00) Maintenance and repair shop equipment:

automotive (Item 2, Table 1, WP 0015 00) Test bench

Materials/Parts Pulley Grooved (Item 1, Table 1, WP 0016 00) Pulley Serpentine (Item 2, Table 1, WP 0016 00) Locknut (Item 3, Table 1, WP 0016 00) Washer (Item 4, Table 1, WP 0016 00)

200-AMP ALTERNATOR TESTING AND PAINTING PROCEDURES

Table 1. No-Load Tests.

0008 00-2

200-AMP ALTERNATOR TESTING AND PAINTING PROCEDURES (Contd)

NOTE

Test bench must be capable of driving alternator up 7000 rpms, or inaccurate test results may occur.

Normal voltage range is 13-15 volts for 14V system and 26-30 volts for 28V system. High amperage is +/- 10 percent of rated alternator output of 200 amps at 5000 rpm at ambient temperature.

Alternator can be driven by a V-belt or serpentine belt pulley.

Instal…