TM-9-2320-280-20 HMMWV Technical Manual Unit Maintenance Volume 2 Download
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4-112. 200 AMPERE ALTERNATOR CABLE (12339317) REPLACEMENT This task covers: a. Removal b. Installation INITIAL SETUP: NOTE Prior to removal, tag leads for installation. 1. Remove tiedown strap (30), screw (31), clip (32), and 200 ampere cable (8) from starter (33). Discard tiedown strap (30). NOTE Step 2 applies to M997 and M997A1 vehicles only. Step 3 applies to M996, M996A1, M1097, and M1097A1 vehicles only. 2. Remove assembled locknut (9), bolt (24), cable (8), and clamps (28), (25), and (27) from oil pan bracket (26). Discard assembled locknut (9). 3. Remove assembled locknut (9), bolt (24), cable (8), and clamp (28) from oil pan bracket (26). Discard assembled locknut (29). 4. Remove nut (19), washer (20), clamps (21), and (22), and cable (8) from compressor (18). 5. Remove nut (15), lockwasher (16), cable (8), and clamp (17) from engine lift bracket (1). Discard lockwasher (16). 6. Remove nut (11), lockwasher (12), cable (8), and clamp (13) from water crossover stud (14). Discard lockwasher (12). 7. Slide back rubber boot (2) and remove nut (4), lockwasher (5), washer (6), fuse (3), insulator (7), cable (8), and bushing (9) from positive stud (10). Discard lockwasher (5). 8. Remove cable (8) from vehicle. NOTE Ensure terminals are clean before connections are made. 1. Install bushing (9), cable (8), fuse (3), and insulator (7) on positive stud (10) with washer (6), lockwasher (5), and nut (4). Tighten nut (4) to 10-15 lb-ft (14-20 N • m). Slide rubber boot (2) over nut (4). NOTE For vehicles equipped with deep water fording kits, perform step 2. 2. Apply sealant to positive stud (10) and cable (8) so all exposed metallic surfaces are coated. The sealant should be evenly applied with a minimum thickness of .06 in. (1.5 mm). 3. Install clamp (13) and cable (8) on water crossover stud (14) with lockwasher (12) and nut (11). 4. Install clamp (17) on cable (8) and engine lift bracket (1) with lockwasher (16) and nut (15). b. Installation a. Removal Applicable Models M996, M996A1, M997, M997A1, M1097, M1097A1 Tools General mechanic’s tool kit: automotive (Appendix B, Item 1) Materials/Parts Two lockwashers (Appendix G, Item 191) Assembled locknut (Appendix G, Item 131) Lockwasher (Appendix G, Item 186) Materials/Parts (Cont’d) Tiedown strap (Appendix G, Item 308) Adhesive sealant (Appendix C, Item 9) Manual References TM 9-2320-280-10 TM 9-2320-280-24P Equipment Condition • Battery ground cable disconnected (para. 4-73). • Hood raised and secured (TM 9-2320-280-10). TM 9-2320-280-20-2 4-264 Change 3