TM-9-2320-387-24 HMMWV Direct Support & General Support Maintenance Manual Volume 1 Download
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4-8.3. 400-AMPERE DUAL VOLTAGE ALTERNATOR REPLACEMENT This task covers: a. Removal b. Installation a. Removal NOTE Prior to removal, tag leads for installation. 1. Position 3/8-in. breaker bar or, as appropriate, a 1/2-in. ratchet wrench on belt tensioner (4), move tensioner (4) clockwise, and remove drivebelt (1) from power steering pump pulley (3) and alternator pulley (2). 2. Remove nut (5), lockwasher (6), washer (7), ground strap (8), and washer (10) from stud (9). Discard lockwasher (6). .WARNING. Alternator must be support during removal and installation. Failure to do so may cause injury to personnel or damage to equipment. 3. Remove nut (19), lockwasher (20), washer (21), screw (12), lockwasher (13), and washer (14) from alternator bracket (15) and alternator mounting bracket (11). Discard lockwashers (13) and (20). 4. Remove screw (18), lockwasher (17), washer (16), and bracket (15) from alternator (22). Discard lockwasher (17). 5. Remove nut (28), lockwasher (27), washer (26), screw (23), washer (24), and alternator (22) from alternator support bracket (25) and alternator mounting bracket (11). Discard lockwasher (27). 6. Remove alternator pulley (2) (para. 4-2). 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 Five lockwashers (Appendix G, Item 190) Personnel Required One mechanic One assistant Manual References TM 9-2320-387-10 TM 9-2320-387-24P Equipment Condition • Hood raised and secured (TM 9-2320-387-10). • Battery ground cables disconnected (para. 4-68). • Alternator cables removed (para. 4-8.2). General Safety Instructions Alternator must be supported during removal and installation. 4-18.12 Change 1 TM 9-2320-387-24-1 1. Install alternator pulley (2) (para. 4-3). 2. Position alternator (22) on alternator mounting bracket (11). 3. Install alternator (22) on alternator mounting bracket (11) and alternator support bracket (25) with washer (24), screw (23), washer (26), lockwasher (27), and nut (28). Do not tighten nut (28). 4. Install alternator bracket (15) on alternator (22) with washer (16), lockwasher (17), and screw (18). Do not tighten screw (18). 5. Install washer (14), lockwasher (13), screw (12), washer (21), lockwasher (20), and nut (19) on alternator mounting bracket (11) and alternator bracket (15). 6. Tighten screw (18) to 40 lb-ft (54 N•m). 7. Tighten nut (28) to 155 lb-ft (210 N•m). b. Installation