TM-9-2320-387-24 HMMWV Direct Support & General Support Maintenance Manual Volume 1 Download
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4-8. 200-AMPERE DUAL VOLTAGE REGULATOR REPLACEMENT This task covers: a. Removal b. Installation a. Removal 1. Disconnect regulator plug (13) from voltage regulator (11). 2. Slide back rubber boot (3) and remove nut (2), lead 5A (1) and washer (22.1) from IGN terminal (22). 3. Slide back rubber boot (4) and remove nut (5), lead 2A (6) and washer (6.1) from yellow (AC) terminal (7). 4. Remove nut (20) and ground wire (12) from 14-volt stud (21). 5. Remove screw (8), lockwasher (9), washer (10), and ground wire (12) from voltage regulator (11). Discard lockwasher (9). 6. Disconnect alternator connector (15) from connector (16) on voltage regulator (11). 7. Remove three screws (19), lockwashers (18), washers (17), and voltage regulator (11) from alternator (14). Discard lockwashers (18). INITIAL SETUP: Tools General mechanic’s tool kit: automotive (Appendix B, Item 1) Maintenance and repair shop equipment: automotive (Appendix B, Item 2) Materials/Parts Three lockwashers (Appendix G, Item 231) Lockwasher (Appendix G, Item 232) Grease (Appendix C, Item 25) Manual References TM 9-2320-387-10 TM 9-2320-387-24P Equipment Condition • Battery ground cables disconnected (para. 4-68). • Hood raised and secured (TM 9-2320-387-10). Maintenance Level Unit 1. Install voltage regulator (11) on alternator (14) with three washers (17), lockwashers (18), and screws (19). Tighten screws (19) to 30-34 lb-in. (3-4 N•m). 2. Connect alternator connector (15) to connector (16) on voltage regulator (11). 3. Install washer (22.1), lead 5A (1) and nut (2) on IGN terminal (22). Tighten nut (2) to 23-27 lb-in. (2.6-3.0 N•m). 4. Apply grease to IGN terminal (22), lead 5A (1), and inside of boot (3), and slide boot (3) over IGN terminal (22). 5. Install washer (6.1), lead 2A (6) and nut (5) on yellow (AC) terminal (7). Tighten nut (5) to 18-22 lb-in. (2.0-2.5 N•m). 6. Apply grease to yellow (AC) terminal (7), lead 2A (6), and inside of boot (4), and slide boot (4) over yellow (AC) terminal (7). 7. Connect regulator plug (13) to voltage regulator (11). 8. Install one end of ground wire (12) on 14-volt stud (21) on voltage regulator (11) with nut (20). Tighten nut (20) to 45-55 lb-in. (5-6 N•m). 9. Install other end of ground wire (12) on voltage regulator (11) with washer (10), lockwasher (9), and screw (8). Tighten screw (8) to 88-94 lb-in. (10-11 N•m). 4-18 Change 1 b. Installation NOTE Prior to removal, tag leads for installation. TM 9-2320-387-24-1