- Industrial & lab equipment
- Electrical equipment & supplies
- Power generators
- Leece-Neville
- AMA 5102UT
- Technical manual
- 263 Pages
Leece-Neville 2184 AC, 5300 GP, 5504 AA, AB, AMA 5102UT, 3002AC, 3002AD, 3002AE generator Technical manual
Below you will find brief information for generator AMA-5102UT, generator 3002AC, generator 3002AD, generator 3002AE, generator 5504AA, generator 5504AB, generator 2184AC, generator 5300GP. The manual guides you on how to disassemble, clean, inspect, repair, assemble, test, and adjust these generators. It is divided into chapters and sections for each model, providing step-by-step maintenance procedures.
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I
T.O. 38X6-7-22
TECHNICAL MANUAL
MAINTENANCE
DIRECT AND GENERAL SUPPORT LEVEL
GENERATOR ASSEMBLY
PRESTOLITE MODEL AMA-5102UT,
NSN 2920-00-909-2483
LEECE-NEVILLE MODEL 3002AC,
NSN 2920-00-909-2483
LEECE-NEVILLE MODEL 3002AD,
NSN 2920-00-909-2483
LEECE-NEVILLE MODEL 3002AE,
NSN 2920-00-909-2483
LEECE-NEVILLE MODEL 5504AA,
NSN 2920-00-475-1446
LEECE-NEVILLE MODEL 5504AB,
NSN 2920-00-475-1446
LEECE-NEVILLE MODEL 2184AC,
NSN 2920-00-782-1955
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LEECE-NEVILLE MODEL 5300GP,
NSN 2920-00-818-8635
- - - - - - - -- - - --- ----
NOTE:
THE STYLE OF THIS TM IS
EXPERIMENTAL. IT IS BEING TRIED
BY THE ARMY ONLY ON
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A LIMITED BASIS
- - - - - - - - — - - - - - - - - - -
DEPARTMENTS OF THE ARMY AND THE AIR FORCE
20 FEBRUARY 1981
WARNING
Dry cleaning solvent is flammable.
Do not use near an open flame. Keep a fire extinguisher nearby when solvent is used.
Use only in well-ventilated places.
Failure to do this may result in injury to personnel and damage to equipment.
Eye shields must be worn when using compressed air. Eye injury can occur if eye shields are not used.
Do not open high voltage compartment door unless main circuit breaker is turned off.
Electrical current can cause injury to personnel and damage to equipment.
TECHNICAL MANUAL
N O . 9 - 2 9 2 0 - 2 2 5 - 3 4
TECHNICAL ORDER
NO. 38X6-7-22
TM 9-2920-225-34
T.O. 38X67-22
DEPARTMENTS OF THE ARMY
AND
THE AIR FORCE
Washington, DC,20 February 1981
TECHNICAL MANUAL
MAINTENANCE
DIRECT AND GENERAL SUPPORT LEVEL
GENERATOR ASSEMBLY
PRESTOLITE MODEL AMA-5102UT, NSN 2920-00-909-2483
LEECE-NEVILLE MODEL 3002AC, NSN 2920-00-909-2483
LEECE-NEVILLE MODEL 3002AD, NSN 2920-00-909-2483
LEECE-NEVILLE MODEL 3002AE, NSN 2920-00-909-2483
LEECE-NEVILLE MODEL 5504AA, NSN 2920-00-475-1446
LEECE-NEVILLE MODEL 5504AB, NSN 2920-00-475-1446
LEECE-NEVILLE MODEL 2184AC, NSN 2920-00-782-1955
LEECE-NEVILLE MODEL 5300GP, NSN 2920-00-818-8635
REPORTING OF ERRORS AND RECOMMENDING IMPROVEMENTS
You can help improve this manual. If you find any mistakes or if you know of a way to improve the procedure, please let us know. Mail your letter, DA Form 2028 (Recommended Changes to
Publications and Blank Forms), or DA Form 2028-2 located in the back of this manual direct to:
Commander, US Army Tank-Automotive Command, ATTN: DRSTA-MB, Warren, Michigan
48090. A reply will be furnished to you.
I
TABLE OF CONTENTS
,
Paragraph
G E N E R A L M A I N T E N A N C E I N F O R M A T I O N
Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
G e n e r a l M a i n t e n a n c e . . . . . . . . .
* T h i s m a n u a l
~ supersedes TM 9-2920-225-34 dated 2 November 1973.
Page
TM 9-2920-225-34
TABLE OF CONTENTS -CONT
Cleaning
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Painting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools and Equipment
. . . . . . . . . . . . . . . . .
Repair
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Forms and Records . . . . . . . . . . . . . . . . . . . . . . . . . . .
Equipment Improvement Report and
Maintenance Digest (EIR MD) and
Equipment Improvement Report and
Maintenance Summary (EIR MS)
. . . . . . . . . . . . .
Reporting Improvement Recommendations . . . . . .
Metric System
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Differences Between Models . . . . . . . . . . . . . .
Description and Data . . . . . . . . . . . . . . . . . . . .
EQUIPMENT GROUP MAINTENANCE
Section 1.
Scope
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Equipment Items Covered
. . . . . . . . . . . . . . . . . . . .
Equipment Items Not Covered
. . . . . . . . . . . . . . .
Section 11.
Prestolite Model Generator AMA-5102UT . . . . . . . . .
Regulator Assembly . . . . . . . . . . . . . . . . . . . . . . . . .
Preliminary Procedure . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
End Housing and Insulator . . . . . . . . . . . . . . . . . . .
Preliminary Procedures . . . . . . . . . . . . . . . . . . . .
Removal
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning . . . . . . . .
●
. . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair . . . . . . . . . . . . . . . . . . . . . .
Assembly
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Intermediate Housing Assembly
. . . . . . . . . . . . . .
Preliminary Procedures . . . . . . . . . . . . . . . . . . . .
Removal
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rotor, Stator, and Drive End Bell
Assembly
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preliminary Procedures . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair . . . . . . . . . . . . . . . . . . . . . .
Assembly
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Paragraph
Page
ii
TM 9-2920-225-34
TABLE OF CONTENTS-CONT
Section III.
Leece-Neville Model Generator 3002AC
. . . . . . . . . . . .
Fan and Hub Assembly . . . . . . . . . . . . . . . .
Preliminary Procedure
. . . . . . . . . . . . . . . . . . . . .
Removal
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive End Bell and Regulator Assembly
. . . . . . .
Preliminary Procedure .. . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair
. . . . . . . . . . . . . . . . . . . . .
Assembly
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
End Housing and Rotor Assembly . . . . . . . . . . . . .
Preliminary Procedures . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Housing and Stator Assembly . . . . . . . . . . . . . . . . .
Preliminary Procedures . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair . . . . . . . . . . . . . . . . . . . . . .
Assembly
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section IV.
Leece-Neville Model Generator 3002AD . . . . . . . . . . .
End Cover and Regulator Assembly . . . . . . . . . . .
Preliminary Procedure . . . . . . . . . . . . . . . . . .
Removal
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive End Bell and Rotor Assembly
. . . . . . . . . . .
Preliminary Procedures . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Paragraph
Page
iii
TM 9-2920-225-34
TABLE OF CONTENTS-CONT
Housing and Stator Assembly . . . . . . . . . . . . . . .
Preliminary Procedures . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair
. . . . . . . . . . . . . . . . . . . . .
Assembly
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section V.
Leece-Neville
Model
Generator 3002AE . . . . . . . . . . .
End Cover and Regulator Assembly . . . . . . . . . . .
Preliminary Procedure . . . . . . . . . . . . . . . . . . . . .
Removal
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive End Bell and Rotor Assembly
. . . . . . . . . . .
Preliminary Procedures . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair . . . . . . . . . . . . . . . . . . . . . .
Assembly
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Housing and Stator Assembly
. . . . . . . . . . . . . . . . .
Preliminary Procedures . . . . . . . . . . . . . . . . . . . . .
Disassembly
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair . . . . . . . . . . . . . . . . .
Assembly .. . . . . . . . . . . . . . . . . . . . . . . .
Section VI.
Leece-Neville Model Generators 5504AA,
5504AB , and 5300GP. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fan and Hub Assembly
. . . . . . . . . . . . . . . . . . . . . . .
Preliminary Procedure . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair
. . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Slipring End Housing . . . . . . . . . . . . . . . . . . . . . . . . .
Preliminary Procedures . . . . . . . . . . . . . . . . . . . . .
Removal
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . .
Paragraph
Page
iv
TM 9-2920-225-34
TABLE OF CONTENTS -CONT
Drive End Bell and Rotor Assembly . . . . . . . . . . . .
Preliminary Procedures
. . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stator and Connector Assembly . . . . . . . . . . . . . . . .
Preliminary Procedures . . . . . . . . . . . . . . . . . . . . . .
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section VII.
Leece-NeviHe Model Generator 2184AC . . . . . . . . . . . .
Fan, End Bell, and Rotor Assembly . . . . . . . . . . . .
Preliminary Procedure . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive End Housing and Stator Assembly
. . . . . . .
Preliminary Procedure . . . . . . . . . . . . . . . . . . . . . . .
Disassembly
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and-Repair . . . . . . . . . . . . . . . . . . . . . . .
Assembly
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section VIII.
Tests and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . .
Test Setup Using Sun Model
(NSN 4190-00-767-0218) Test Stand
. . . . . . . . . . .
Mounting Generator on Test Stand . . . . . . . . . . .
Test Stand Base Setting
. . . . . . . . . . . . . . . . . . . .
Harness Connections
. . . . . . . . . . . . . . . . . . . . . . . .
Tachometer Calibration Information
. . . . . . . . . .
Preliminary Test Setting . . . . . . . . . . . . . . . . . . . .
Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
60-Ampere Generator . . . . . . . . . . . . . . . . . . . . . . .
100-Ampere Generator . . . . . . . . . . . . . . . . . . . . . . .
Test Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Switch Positioning (60 Amperes) . . . . . . . . . . . . .
Switch Positioning (100 Amperes). . . . . . . . . . . . .
Removalof Generator from Test Stand . . . . . . . .
Paragraph
Page
TM 9-2920-225-34
TABLE OF CONTENTS -CONT
Number
Number
LIST OF ILLUSTRATIONS
Title
Alternating Current Engine Generator . . . . . . . . . . .
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Slipring (Model AMA-5102UT) Allowable
Wear Limits
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rotor Assembly (Model AMA-5102UT) Tool
Fabrication Instructions . . . . . . . . . . . . . . . . . .
Slipring (Model 3002AC) Machining
Allowable Wear Limits .. . . . . . . . . . . . . . . . . . . . .
Rotor Assembly (Model 3002AC) Installing
Tool Fabrication Instructions . . . . . . . . . . . . . . . .
Slipring (Model 3002AD) Wear Limits . . . . . . . . . . .
Installing Tool Fabrication Instructions . . . . . . . .
Pilot Tool Fabrication Instructions . . . . . . . . . . .
Bearing Driver Fabrication Instructions . . . . . . . . .
Sliprings (Models 5504AA, 5504AB, and
5300GP) Allowable Wear Limits . . . . . . . . . . . . . . .
Sliprings (Model 2184AC ) Wear Limits. . . . . . . . . .
Rectifier Installing Tool Fabrication Instructions .
LIST OF TABLES
Title
Standard Torque Specifications . . . . . . . . . . . . . . . . . .
Special Tools and Equipment . . . . . . . . . . . . . . . . .
Tabulated Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Differences Between Models . . . . . . . . . . . . . . . . . . . . .
Rotor, Stator, and Drive End Bell Assembly
Wear Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive End Bell Assembly Wear Limits . . . . . . . . . . .
End Housing and Rotor Assembly Wear Limits. . . . .
Drive End Bell and Rotor Wear Limits . . . . . . . . . . . .
End Housing Assembly Wear Limits
. . . . . . . . . . . . . .
Paragraph Page
Page
Page
vi
Number
LIST OF TABLES - CONT
Title
Drive End Bell and Rotor Assembly (Models
5504AA and 5504AB ) Wear Limits . . . . . . . . . . . . . . . . .
Drive End Bell and Rotor Assembly (Model
5300GP) Wear Limits
. . . . . . . . . . . . . . . . . . . . . . . . . . .
End Bell Housing (Models 5504AA and 5504AB)
Wear Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
End Bell Housing (Model 5300GP) Wear Limits . . . . . .
Fan, End Bell, and Rotor Assembly (Model
2184AC ) Wear Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TM 9-2920-225-34
Page
vii /(viii blank)
TM 9-2920-225-34
CHAPTER 1
GENERAL MAINTENANCE INFORMATION
1-1.
SCOPE .
This technical manual gives instructions for direct support and general support maintenance of Leece-Neville generator models 3002AC, 3002AD , 3002AE ,
5504AA, 5004AB, 2184AC and 5300GP and Prestolite generator model AMA-5102UT.
This manual gives procedures for disassembly, cleaning, inspection, repair, assembly, testing and adjustment as directed by the maintenance allocation chart.
Figure 1-1 shows the different models of generators that you will be working on.
b.
Appendix A gives a list of current and applicable references covered in
this manual.
c.
Refer to TM 9-2920-225-34P for a listing of parts and special tools for the models of generators covered in this manual.
1-2.
GENERAL MAINTENANCE a.
Chapter 2 gives instructions for disassembly of the generator. However, the generator should not be taken apart beyond the point needed to repair or replace parts found damaged during inspection.
You must use your judgment in following the disassembly procedures so you do only those operations that are necessary.
b.
Troubleshooting a fault within a generator is done as part of the repair procedures; therefore, it should be noted that a component which is damaged or not working will be found as part of inspection, in this manual.
Corrective action will be repair this level of maintenance.
.
repair, and test procedures given or replacement as authorized at
1-3.
CLEANING .
WARNING
Dry cleaning solvent is flammable. Do not use near an open flame.
Keep a fire extinguisher nearby when solvent is used. Use only in wellventilated places.
Failure to do this may result in injury to personnel and damage to equipment.
Eye shields must be worn when using compressed air. Eye injury can occur if eye shields are not used.
a.
Before taking generator apart, clean exterior with dry cleaning solvent.
Dry thoroughly with compressed air.
b. Except where special cleaning procedures are given for a component or part, clean all components and parts with dry cleaning solvent. Dry thoroughly with compressed air.
1-1
TM 9-2920-225-34
MODEL AMA-5102UT
MODEL 3002AC
MODE L 3002AD AND 3002AE
MODELS 5504AA AND 5504AB
1-2
MODEL 5300GP
MODEL 2184AC
TA 118949
Figure 1-1.
Alternating Current Engine Generator Identification
TM 9-2920-225-34
1-4. PAINTING. Refer to TM 43-0139 for painting instructions for field use of equipment covered in this manual.
1-5.
TORQUE VALUES .
Critical torque values for a particular component are given in the maintenance procedures in chapter 2.
When torque values are not
given, bolts, screws, and nuts are to be tightened as given in table 1-1.
1-6.
SPECIAL TOOLS AND EQUIPMENT .
Special tools and equipment are provided to make it easier to do particular maintenance tasks and to keep the equipment in good repair.
Table 1-2 lists the special tools and equipment and gives a reference
to the maintenance paragraph where they are used and what they are used for.
1-7.
REPAIR .
Generator repair is limited only to removal, replacement, and repair of items covered in this manual.
Whenever the armature, field coil or housing is damaged, the generator is non-repairable.
1-8.
FORMS AND RECORDS. Maintenance forms, records, and reports which are to be used by maintenance personnel
at
all levels are listed in and prescribed by
TM 38-750.
1-9.
EQUIPMENT IMPROVEMENT REPORT AND MAINTENANCE DIGEST (EIR MD)
AND EQUIPMENT IMPROVEMENT REPORT AND MAINTENANCE SUMMARY (EIR MS).
The quarterly Equipment Improvement Report and Maintenance Digest, TB 43-0001-39 series, contains valuable field information on the equipment covered in this manual.
The information in the TB 43-0001-39 series is compiled from some of the Equipment
Improvement Reports that you prepared on the equipment covered in this manual.
Many of these articles result from comments, suggestions, and improvement recommendations that you submitted to the EIR program.
The TB 43-0001-39 series contains information on equipment improvements, minor alterations, proposed
Modification Work Orders (MWO’s) , warranties (if applicable) , actions taken on some of your DA Form 2028’s (Recommended Changes to Publications) , and advance information on proposed changes that may affect this manual. In addition, the more maintenance significant articles, including minor alterations, field-fixes, etc, that have a more permanent and continuing need in the field are republished in the
Equipment Improvement Report and Maintenance Summary (EIR MS) for TACOM
Equipment (TM 43-0143).
Refer to both of these publications ( TB 43-0001-39 series and TM 43-0143) periodically, especially the TB 43-0001-39 series, for the most current and authoritative information on your equipment.
The information will help you in doing your job better and will help in keeping you advised of the latest changes to this manual.
Also refer to DA Pam 310-4, Index of Technical Publica-
tions, and Appendix A, References, of this manual.
1-10.
REPORTING IMPROVEMENT RECOMMENDATIONS .
If your equipment 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 why you don’t like the design.
Tell us why a procedure is hard to perform. Put it on an
SF 368 (Quality Deficiency Report). Mail it to us at: Commander, U.S. Army
Tank-Automotive
Command,
ATTN: DRSTA-MT,
Warren, Michigan 48090. We’ll send you a reply.
1-11.
METRIC SYSTEM.
The equipment/system described herein is nonmetric and does not require metric common or special tools. Therefore, metric units are not supplied.
Tactical instructions, for sake of clarity, will also remain nonmetric.
1-3
TM 9-2920-225-34
Table 1-1.
Standard Torque Specifications
USAGE
CAPSCREW DIAMETER AND
MINIMUM TENSILE STRENGTH
PSI [KG/SQ CM]
MUCH USED
To 1/2-69.000
(4850.7000)
To 3/4–64,000
(4499.2000)
To 1 –55.000
[3866.5000]
QUALITY OF MATERIAL INDETERMINATE
MUCH USED
To 3/4-120,000
(8436.0000)
To 1 – 115,000
(8084.5000)
MINIMUM
COMMERCIAL
USED AT TIMES
To 5/8– 140,000
(9842.0000)
To 3/4-133.000
(9349.9000)
MEDIUM
COMMERCIAL
USED AT TIMES
150,000
(10545-0000)
BEST
COMMERCIAL
1-4
CAPSCREW BODY SIZE
( l N C H E S ) - ( T H R E A D )
1 / 4 – 2 0
- 2 8
5 / 1 6 – 1 8
- 2 4
3 / 8 – 1 6
– 2 4
7 / 1 6 – 1 4
– 2 0
1 / 2 - 1 3
– 2 0
9 / 1 6 – 1 2
- 1 8
5 / 8 - 1 1
- 1 8
3 / 4 – 1 0
- 1 6
7 / 8 - 9
– 1 4
TORQUE
FT-LB [KG M ]
5
6
11
13
18
20
[0.6915]
[0.8298]
[1.5213]
28
30
39
41
51
[1.7979]
[2 48941]
[2.7660]
[3.8132]
[4.1490]
[5.3937]
[5.6703]
[7,0533]
55
83
95
[7.6065]
[11.4789]
[13.1385]
1 0 5 [ 1 4 . 5 2 1 5 ]
1 1 5 [ 1 5 . 9 0 4 5 ]
1 6 0 [ 2 2 . 1 2 8 0 ]
[24.2025]
[32.5005]
2 5 0 [ 3 4 . 5 7 5 0 ]
TORQUE
FT-LB [KG M]
8
10
17
19
31
35
49
55
75
[1,1064]
[1.3830]
[2.3511]
[2.6277]
[4 2873]
[4.8405]
85
110
[11.7555]
[15.2130]
1 2 0 [ 1 6 . 5 9 6 0 ]
150
170
270
295
395
[20.7450]
[23.5110]
[37.3410]
[40.7985]
[54.6285]
4 3 5 [ 6 0 . 1 6 0 5 ]
5 9 0 [ 8 1 . 5 9 7 0 ]
6 6 0 [ 9 1 . 2 7 8 0 )
TORQUE
FT-LB [KG M]
10
19
34
[6.7767]
[7.6065]
55
[10.3725] 85
120
167
[1.3830]
[2.6277]
[4.7022]
[7.6065]
[11.7555]
[16.5960]
[23.0961]
2 8 0 [ 3 8 . 7 2 4 0 ]
4 4 0 [ 6 0 . 8 5 2 0 ]
6 6 0 [ 9 1 . 2 7 8 0 ]
T O R Q U E
FT-LB [KG M]
12
14
24
27
44
49
70
78
[1 .6596]
[1.9362]
[3.3192]
[3.7341]
[6.0852]
[6.7767]
[9.6810]
[10.7874]
1 0 5 [ 1 4 . 5 2 1 5 ]
1 2 0 [ 1 6 . 5 9 6 0 ]
1 5 5 [ 2 1 . 4 3 6 5 ]
1 7 0 [ 2 3 . 5 1 1 0 ]
2 1 0 [ 2 9 . 0 4 3 0 ]
2 4 0 [ 3 3 . 1 9 2 0 ]
3 7 5 [ 5 1 . 8 6 2 5 ]
4 2 0 [ 5 8 . 0 8 6 0 1 ]
6 0 5 [ 8 3 . 6 7 1 5 1 ]
6 7 5 [ 9 3 . 3 5 2 5 ]
9 1 0 [ 1 2 5 . 8 5 3 0 ]
9 9 0 [ 1 3 6 . 9 1 7 0 ]
1.
Always use
the torque values listed above when specific specifications are not available
Note:
Do not use
above values in place
of those specified in the engine groups of this
manual, special attention
should be
observed in case
of
SAE Grade 6, 7 and 8 capscrews.
2 The above iS based on use of clean and dry threads
3 Reduce torque
by
10%
when engine 0il is used
as a lubricant
4.
Reduce torque by 20% if new plated capscrews are used
Caution: Capscrews threaded into aluminum may require reductions in torque of 30% or more, unless inserts are used.
TA 113439
L
TM 9-2920-225-34
Item
Part
No.
Table 1-2.
Special Tools and Equipment
National
Stock No.
Reference
Paragraph
Use
TEST STAND : AGT-9 4910-00-767-0218
(Automotive
Generator,
Alternator and Starter)
Used to check the operation and output of the generator after it has been repaired.
1-12.
DIFFERENCES BETWEEN MODELS .
Refer to table 1-4 for differences between
generator models covered in this manual.
1-13.
DESCRIPTION AND DATA.
a.
Basic Generator.
The engine generators you will read about in this manual produce 28-volt, 3-phase alternating current.
These generators are self-cooled with rotor shafts on either ball or roller bearings. Some models are belt driven. Other models have a flexible direct drive coupling.
b.
Internally Rectified Generators.
Generator models AMA-5102UT, 3002AC,
3002AD, 3002AE and 2184AC have internal rectifiers.
These rectifiers change the alternating current to direct current before it leaves the generator.
c .
Internally Regulated Generators.
Generator models AMA-5102UT, 3002AC,
3002AD, and 3002AE besides having internal rectification, also have an internally mounted voltage regulator.
This device controls the output of the generator and does away with the need for an external reguator.
d.
Tabulated Data.
Refer to table 1-3 for tabulated data on each model generator
and regulator covered in this manual.
1-5
L
TM 9-2920-225-34
CHAPTER 2
EQUIPMENT GROUP MAINTENANCE
Section I. SCOPE
2-1.
EQUIPMENT ITEMS COVERED.
Maintenance procedures for generator models
AMA- 5102UT, 3002AC, 3002AD, 3002AE, 5504AA, 5504AB, 5300GP, and 2184AC, as authorized by the maintenance allocation chart are given in this chapter.
2-2. EQUIPMENT ITEMS NOT COVERED.
All equipment items are covered regulator model 3392R12P.
except for
Section II.
PRESTOLITE MODEL GENERATOR AMA5102UT
2-3. REGULATOR ASSEMBLY .
TOOLS: No special tools required
SUPPLIES : Regulator-to-housing preformed packing
PERSONNEL: One
2-1
TM 9-2920-225-34 b.
Removal.
FRAME 1
I
1.
Take out output switch access plug (1) from regulator (2).
2.
Take out six screws (3) and lockwashers (4).
3.
Take off regulator (2) and preformed packing (5).
NOTE
Do not take apart regulator (2).
END OF TASK
TA 103500
2-2
TM 9-2920-225-34 c. Replacement.
FRAME 1
I
1.
Put on regulator (1) and preformed packing (2), with three Pins on regulator in three holes in socket assembly ( 3).
2.
Put in six screws (4) and lockwashers (5) and tighten screws to 15 to 20 pound-inches.
2.
Put in access plug (6) and tighten plug to 30 to 35 pound-inches.
END OF TASK
T A 1 0 3 5 0 1
2-3
TM 9-2920-225-34
2-4. END HOUSING AND INSULATOR.
TOOLS: No special tools required
SUPPLIES :
Packing
Tags
Lead assembly preformed packing
Solder
Sealant MIL-A-46106
PERSONNEL: One
EQUIPMENT CONDITION :
Generator removed from vehicle, pulley removed from generator.
a.
Preliminary Procedures.
(1)
Clean generator before disassembly. Refer to para 1-3.
(2) Remove regulator assembly. Refer to para 2-3.
b.
Removal.
FRAME 1
I
1.
Take out two screws (1) and take off cover (2).
2.
Scrape away sealant.
Tag and unsolder three stator lead connections (3).
GO TO FRAME 2
T A 1 0 3 5 0 2
2-4
.
TM 9-2920-225-34
FRAME 2
1.
Take out six screws (1) and lockwashers (2).
2.
Scribe a mark across end housing (3) , insulator (4) , and intermediate housing (5).
3.
Take end housing (3) and insulator (4) from intermediate housing (5)
●
NOTE
Brush springs (6) will fall out. Do not lose them.
END OF TASK
T A 1 0 3 5 0 3
2-5
2-6
TM 9-2920-225-34 c .
Disassemble.
NOTE
Test rectifiers before starting disassembly.
Refer to para 2-4e.
FRAME 1
1.
Take out three screws (1) and lockwashers (2).
2.
Take out brush holder (3) and springs (4).
3.
Take out two screws (5),lockwashers (6), and brushes (7).
GO TO FRAME 2 w
T A 1 0 3 5 0 4
FRAME 2
1.
Tag all leads (1) so they will be put back the same way.
2.
Unsolder leads (1) and take them out.
3.
Take off nut (2) and screw (3). Take off output strap (4).
4.
Take out two lockclips (5).
5.
Take out socket terminal (6).
GO TO FRAME 3
TM 9-2920-225-34
T A 1 0 3 5 0 5
2-7
TM 9-2920-225-34
1.
Take out six screws (1) and lockwashers (2) ,
2.
Take negative rectifier mount (3) , positive rectifier mount (4) , and insulator
(5) from end housing ( 6).
GO TO FRAME 4
T A 1 0 3 5 0 6
2-8
TM 9-2920-225-34
FRAME 4
1.
Take out four screws ( 1).
2.
Take out terminal and lead assembly (2) and preformed packing ( 3). Throw away packing.
END OF TASK
T A 1 0 3 5 0 7
2-9
NOTE:
2-10
TM 9-2920-225-34 d.
Cleaning.
There are no special cleaning procedures needed. Refer to cleaning procedures given in para 1-3.
e. Inspection and Repair.
FRAME 1
N O T E
Generator is nonrepairable if any part is damaged.
1.
Check that housing (1) is not cracked or broken and that it has no stripped threads.
2.
Check that insulator (2) is not cracked or damaged.
3.
Check that brush holder (3) is not cracked or damaged.
4.
Check that connector (4) is not broken or damaged and that it has no loose pins.
5.
Check that all screws (5) and washers (6) are not bent, broken or worn and that they have no stripped threads or damaged heads.
6.
Check that insulator (7) is not cracked or broken.
7.
Check that output strap (8) has no loose or broken leads.
8.
Check that terminal cover (9) is not bent, Hammer out dents.
GO TO FRAME 2
T A 1 0 3 5 0 8
TM 9-2920-225-34
1.
2.
3.
4.
5.
Check that brushes (1) are not cracked or oil soaked, and that they have no loose leads.
If brushes are damaged, get new ones.
Measure distance A on brushes (1).
Brush length must be at least 1/4 inch.
If brushes are less than l/4-inch, get new ones.
Check that brush springs (2) are not overheated. Brush springs will turn blue if overheated.
If springs are damaged, get new ones.
Using spring pressure checker, load brush springs (2) with 8.6 ounces.
Spring length must be 7/8 inch.
If springs are not 7/8 inch when loaded, get new ones.
Check that terminal and lead assembly (3) has no burned, frayed or broken wiring.
If lead assembly is damaged, get a new one.
GO TO FRAME 3
2-11
TM 9-2920-225-34
FRAME 3
I
1
0
Check rectifier (1) using multimeter as follows.
N O T E
On ohmmeters that use one 1 1/2-volt dry cell, low resistance readings will be approximately 20 to 30 ohms.
On ohmmeters that use a 3-volt dry cell, low resistance readings will be approximately 10 to 15 ohms.
2.
3.
Touch negative test probe of multimeter to output terminal (2). Multimeter must show low resistance when positive test probe is touched to rectifier terminals (3, 4, 5, and 6).
Get a new rectifier (1) if it does not show correct reading.
Touch positive test probe of multimeter to output terminal (2). Multimeter must show infinite resistance when negative test probe is touched to rectifier terminals (3, 4, 5, and 6).
Get a new rectifier (1) if it does not show correct reading.
GO TO FRAME 4
T A 1 0 3 5 1 0
2-12
TM 9-2920-225-34
FRAME 4
1.
Check rectifier (1) using multimeter as follows.
N O T E
2.
3.
On ohmmeters that use one 1 1/2-volt dry cell, low resistance readings will be approximately 20 to 30 ohms. On ohmmeters that use a 3–volt dry cell, low resistance readings will be approximately 10 to 15 ohms.
Touch positive test probe of multimeter to screw hole
(2).
Multimeter must show low resistance when negative test probe is touched to rectifier terminals (3, 4, and 5).
Get a new rectifier (1) if it does not show correct reading.
Touch negative test probe of multimeter to screw hole (2). Multimeter must show infinite resistance when positive test probe is touched to rectifier terminals (3, 4, and 5).
Get a new rectifier (1) if it does not show correct reading.
END OF TASK
T A 1 0 3 5 1 1
2-13
TM 9-2920-225-34 f.
Assembly.
FRAME 1
1.
Place terminal and lead assembly (1) with preformed packing (2) into housing (3) .
2.
Put in four screws (4).
GO TO FRAME 2
T A 1 0 3 5 1 3
2-14
TM 9-2920-225-34
FRAME 2
I
N O T E
Insulator (1) must be put back with positive rectifier
(2) .
1.
Place insulator ( 1), positive rectifier ( 2), and negative rectifier mounting surface in end housing (4) .
(3) on
2.
Put in six screws (5) and lockwashers (6).
3.
Put in socket terminal (7) and put on two lockclips (8).
GO TO FRAME 3
T A 1 0 3 5 1 2
2-15
TM 9-2920-225-34
1.
Solder all leads (1) as tagged. Take off tags.
2.
Put in output strap (2) and put on nut (3) and screw (4).
G O
TO FRAME 4
T A 1 0 3 5 1 4
TM 9-2920-225-34
FRAME 4
1.
Put brush holder (1) into housing (2) .
2.
Put in three screws (3) and lockwashers (4) .
3.
Put in two screws (5) and lockwashers (6) to hold brush lead (7) in place.
END OF TASK
T A 1 0 3 5 1 5
2-17
TM 9-2920-225-34 g.
Replacement.
FRAME 1
I
1.
Put end housing (1) and insulator (2) onto intermediate housing (3) .
2.
3.
Aline scribe marks and put in six screws (4) and lockwashers (5). Tighten screws to 30 to 35 pound-inches.
Take out three screws (6) and lockwashers (7) .
Put brush springs (8) and brushes (9) into brush holder (10).
Put back three screws and lockwashers.
GO
TO FRAME 2
T A 1 0 3 5 1 6
2-18
L
TM 9-2920-225-34
1.
Solder three stator leads (1) to terminal and lead assembly (2).
2.
Coat rectifier mounts (3), connections on terminal and lead assembly (2), and solder connections (4) with sealant.
3.
Put on cover (5) and put in two screws (6).
NOTE
Follow-on Maintenance Action Required:
Replace regulator assembly. Refer to para 2-3.
END OF TASK
T A 1 0 3 5 1 7
2-19
TM 9-2920-225-34
2-5. INTERMEDIATE HOUSING ASSEMBLY .
TOOLS : No special tools required
SUPPLIES : Artillery and automotive grease, type GAA, MIL-G-10924
PERSONNEL: One
EQUIPMENT CONDITION :
Generator removed from vehicle, pulley removed from generator.
a.
Preliminary Procedures.
(1) Remove regulator assembly. Refer to para 2-3.
(2) Remove end housing and insulator. Refer to para 2-4.
.
Removal.
1.
Take off preformed packing (1) and retaining ring (2).
2.
Scribe a mark across intermediate housing ( 3), stator (4) , and drive end housing (5) .
3.
Take out six long screws (6) and lockwashers ( 7).
4.
Take off intermediate housing (3) .
END OF TASK
2-20
TM 9-2920-225-34 c .
Disassembly.
FRAME 1
I
CAUTION
Be careful when taking apart intermediate housing (5) .
If parts get damaged, generator is nonrepairable.
1.
Take lip seal ( 1), felt retainer (2), felt washer ( 3), and felt retainer (4) from intermediate housing (5) .
END OF TASK
T A 1 0 3 5 2 0
2-21
e. Inspection and Repair.
FRAME 1
N O T E
Generator is nonrepairable if any part is damaged.
1.
Check that intermediate housing (1) is not cracked or broken.
2.
Measure intermediate housing bearing bore (2). Bore must be 1.2489 to
1.2495 inches.
3.
Check that retaining ring (3), felt retainer (4), felt washer (5), felt retainer (6) , and rotor shaft bearing lip seal (7) are not damaged or worn.
END OF TASK
T A 1 0 3 5 2 1
2-22
TM 9-2920-225-34 f.
Assembly .
FRAME 1
1.
Coat inside and outside diameter of lip seal (1) with grease.
2.
Put felt retainer (2), felt washer ( 3), felt retainer (4), and lip seal (1) into bore of intermediate housing (5).
END OF TASK
T A 1 0 3 5 2 2
2-23
TM 9-2920-225-34 g.
Replacement.
FRAME 1
I
1.
2.
Slide intermediate housing (1) over rotor and fan assembly (2) with leads of stator (3) alined with slot in intermediate housing.
Aline scribe marks on intermediate housing ( 1), stator ( 3), and drive end housing (4) .
Put in six long screws (5) and lockwashers (6).
3.
4.
Put retaining ring (7) in place and put preformed packing (8) around outer bore of intermediate housing ( 1).
N O T E
Follow-on Maintenance Action Required:
END OF TASK
1.
Replace end housing assembly and insulator. Refer to para 2-4g.
2.
Replace regulator assembly. Refer to para 2- 3
C
.
T A 1 0 3 5 2 3
2-24
TM 9-2920-225-34
2-6. ROTOR, STATOR, AND DRIVE END BELL ASSEMBLY.
TOOLS : No special tools required
SUPPLIES : Artillery and automotive grease, type GAA, MIL-G-10924
Solvent, dry cleaning, type II (SD-2) Fed. Spec P-D-680
Felt, 1/8-inch thick
Masking tape, PPP-T-42C
PERSONNEL: One
EQUIPMENT CONDITION : Generator removed from vehicle, pulley removed from generator.
a. Preliminary Procedures.
(1) Remove regulator assembly. Refer to para 2-3.
(2) Remove end housing and insulator. Refer to para 2-4.
(3) Remove intermediate housing. Refer to para 2-5.
b.
Disassembly.
CAUTION
Be careful when taking apart rotor, stator, and drive end bell assembly. If any part is damaged, generator is nonrepairable.
FRAME 1
1.
Take off nut (1), washer (2), and woodruff key (3) from shaft (4) of fan and rotor assembly.
GO TO FRAME 2
I
2-25
TM 9-2920-225-34
1.
Take out six screws ( 1) .
2.
Take bearing retainer (2) off drive end housing (3) .
3.
Take preformed packing (4) , sleeve spacer seal (5) , preformed packing (6) , and sleeve spacer (7) from bearing retainer (2) .
GO TO FRAME 3
T A 1 0 3 5 2 5
TM 9-2920-225-34
1.
Using puller, drive shaft of rotor and fan assembly (1) from drive end housing (2) .
2.
Take stator (3) from drive end housing (2). Tap lightly with soft-faced hammer if needed.
3.
Press bearing (4) and seal (5) from drive end housing (2).
4.
Pull roller bearing (6) and inner race (7) from shaft of rotor and fan assembly ( 1).
END OF TASK
T A 1 0 3 5 2 6
2-27
TM 9-2920-225-34 d.
Inspection and Repair.
NOTE
If parts are not within limits given in table 2-1,
generator is nonrepairable.
Measure roller bearing outside diameter (1) and inside diameter (2).
1.
2.
3.
Measure roller bearing inner race outside diameter (3) and inside diameter (4).
Measure outside diameter of sliprings (5).
4.
5.
6.
Measure outside diameter of rotor shaft at roller bearing seat (6).
Measure outside diameter of rotor shaft at drive end bearing seat (7).
Measure drive end bearing inside diameter (8) and outside diameter (9).
GO TO FRAME 2
Index
Number
Table 2-1.
Rotor, Stator, and Drive End Bell Assembly Wear Limits
Item /Point of Measurement
Size and Fit of
New Parts
(inches)
Wear Limits
(inches)
8
6
5
4
2
1
9
7
3
Roller bearing outside diameter
Roller bearing inside diameter
Roller bearing inner race outside diameter
Roller bearing inner race inside diameter
Outside diameter of sliprings
Outside diameter of rotor shaft at roller bearing inner race seat
Outside diameter of rotor shaft of drive end bearing seat
Drive end bearing inside diameter
Drive end bearing outside diameter
1.2495 to 1.2500
0.7508 to 0.7519
0.7482 to 0.7487
0.4995 to 0.5000
0.715 to 0.725
0.5003 to 0.5006
0.7874 to 0.7877
0.7870 to 0.7874
2.0470 to 2.0475
None
None
None
None
0.680
None
None
None
None
2-28
TM 9-2920-225-34
FRAME 2
1.
Using multimeter, check rotor (1) for grounds by touching on test probe of multimeter to rotor shaft (2) and other test probe to sliprings (3). Ohmmeter must read over 10,000 ohms.
If it does not, generator is nonrepairable.
2.
Using multimeter, check sliprings (3) resistance. Resistance must be between
8.8 and 10.2 at 77°F.
If resistance is not within given limits, generator is non repairable.
3.
Check roller bearing (4) and drive end bearing (5) for serviceability. Refer to TM 9-214.
If bearings are damaged, generator is nonrepairable.
4.
Check that woodruff key (6) and key seat (7) are not damaged or worn. If woodruff key is damaged, get a new one.
If key seat is damaged, generator is nonrepairable.
5.
Check that seal (8) is not worn or damaged. If seal is damaged, generator is nonrepairable.
GO TO FRAME 3
T A 1 0 3 5 2 9
2-29
TM 9-2920-225-34
1.
Check that preformed packings (1 and 2) and seal (3) are not damaged or worn. If packings or seal are damaged, generator is nonrepairable.
2.
Check that drive end housing (4), bearing retainer (5), and sleeve spacer
(6) are not cracked, warped or damaged.
If parts are damaged, generator is nonrepairable.
3.
Measure inside diameter of drive housing bearing bore (7). Bore must be
2.0471 to 2.0477 inches.
If bore is not within given limits, generator is non-repairable.
GO TO FRAME 4
2-30
NOTE
CHECK ONLY THOSE PARTS WHICH
ARE CALLED OUT IN THIS FRAME.
PARTS WITHOUT CALLOUTS ARE
SHOWN FOR REFERENCE PURPOSES
OR ARE CHECKED IN ANOTHER FRAME.
T A 1 0 3 5 3 0
TM 9-2920-225-34
FRAME 4
I
1.
Check that stator (1) is not cracked or broken. If stator is damaged, generator is nonrepairable.
2.
Using multimeter, check stator (1) for continuity.
Touch test probes of multimeter to each pair of stator leads
(
2). Multimeter must show low resistance.
If it does not, generator is nonrepairable.
3.
Using multimeter, check stator (1) for grounds. Touch one test probe to stator and other test probe to each stator lead (2) . If stator is grounded, generator is nonrepairable.
GO
TO
FRAME 5
T A 1 0 3 5 3 1
2-31
TM 9-2920-225-34
FRAME 5
I
1.
N O T E
If sliprings (1) are out-of-round, they must be turned down.
Measure runout of sliprings (1) using dial indicator (2) and V-blocks as shown in view A.
Set dial indicator on one slipring, turn rotor (3), and note reading on dial indicator as rotor turns.
Runout cannot be more than
0.001 inches.
Do step 1 again for other slipring (1).
2.
3.
Check that rotor shaft (4) is straight by using a dial indicator (2) as shown in view b.
Set dial indicator on rotor shaft, turn rotor (3), and note reading on dial indicator.
END OF TASK
N O T E
If reading on dial indicator changes as rotor turns, rotor shaft (4) is bent and generator is nonrepairable.
VIEW B
T A 1 0 3 5 3 2
2-32
TM 9-2920-225-34
(2) Repair.
FRAME 1
1.
If slipring (1) runout is more than 0.001 inches, send rotor (2) to machine shop to have sliprings turned down.
Figure 2-1 gives slipring allowable
wear limits for machine shop use.
END OF TASK
T A 1 0 3 5 3 3
T A 1 0 3 5 3 4
Index
A
Item /Point of Measurement
Outside diameter of sliprings
Size and Fit of New Parts
(inches)
0.715 to 0.725
Wear Limits
(inches)
0.680
Figure 2-1.
Slipring (Model AMA-5102UT) Allowable Wear Limits
2-33
TM 9-2920-225-34
1.
Press roller bearing inner race (1) and roller bearing (2) onto shaft of fan and rotor assembly (3).
GO TO FRAME 2
T A 1 0 3 5 3 5
TM 9-2920-225-34
FRAME 2
I
1.
2.
3*
Place a piece of l/8-inch thick felt over fan of rotor and fan assembly (1).
Place stator (2) over rotor and fan assembly (1) with stator leads facing fan.
Place drive end housing (3) up to stator (2).
NOTE
4.
5.
Have machine shop make fabricated tool. Refer to
Put rotor assembly tool over threaded end of shaft so that large end of tool is against shaft shoulder.
Coat shaft journal and inside diameter of lip seal (4) with grease.
Place lip seal over tool and onto shaft and take off tool
●
With sharp edge of inner race of bearing (5) facing away from rotor (1), press bearing onto shaft of rotor and fan assembly.
GO TO FRAME 3
T A 1 0 3 5 3 7
2-35
TM 9-2920-225-34
NOTE: ALL DIMENSIONS SHOWN ARE IN INCHES
T A 1 0 3 5 3 6
2-36
Figure 2-2.
Rotor Assembly (Model AMA-5102UT) Tool
Fabrication Instructions
TM 9-2920-225-34
T A 1 0 3 5 3 8
2-37
TM 9-2920-225-34
FRAME 4
1.
2.
3.
Take tape off shaft (1).
Put nut (2), washer (3), and woodruff key (4) on shaft (l).
Wrap one turn of tape around woodruff key (4).
NOTE
Follow-on Maintenance Action Required:
1.
Replace intermediate housing. Refer to para 2-5.
2.
Replace end housing and insulator. Refer to para 2-4.
3.
Replace regulator assembly. Refer to para 2-3.
END OF TASK
T A 1 0 3 5 3 9
2-38
TM 9-2920-225-34
Section III.
LEECE-NEVILLE MODEL GENERATOR 3002AC
NOTE
The following procedures are the same for both early and late model 3002AC generators except where noted.
2-7. FAN AND HUB ASSEMBLY.
TOOLS: No special tools required
SUPPLIES: None
PERSONNEL: One
EQUIPMENT CONDITION: Generator removed from vehicle, pulley removed from generator.
a. Preliminary Procedure.
Clean outside of generator before disassembly.
Refer to para 1-3.
b.
Removal.
FRAME 1
1.
Take out screw (1) and washer (2).
2.
Take fan and hub assembly (3) off rotor shaft (4).
3.
Take out woodruff key (5).
END OF TASK
T A 1 0 3 5 4 0
2-39
TM 9-2920-225-34 d.
Inspection and Repair.
1.
Check that fan and hub assembly (1) is not cracked or damaged. Straighten any bent fins on fan.
If fan is bent, generator is, nonrepairable.
2.
Check that screw (2) is not bent or broken and that it has no stripped threads.
Fix minor thread damage by chasing threads with right size die-nut.
If threads cannot be fixed, generator is nonrepairable.
3.
Check that washer (3) and woodruff key (4) are not broken or cracked. If parts are damaged, get new ones.
END OF TASK
T A 1 0 3 5 4 1
2-40
e. Replacement.
FRAME 1
1.
Put woodruff key (1) in shaft of rotor (2).
2.
Put fan (3) on shaft of rotor (2) with smooth side out.
3.
Put washer (4) and screw (5) in end of shaft of rotor (2) .
END OF TASK
TM 9-2920-225-34
T A 1 0 3 5 4 2
TM 9-2920-225-34
2-8. DRIVE END BELL AND REGULATOR ASSEMBLY.
TOOLS: No special tools required
SUPPLIES : Drive end bell preformed packing (large)
Drive end bell seal
PERSONNEL: One
EQUIPMENT CONDITION:
Generator removed from vehicle, pulley removed from generator.
a.
Preliminary Procedure.
Clean outside of generator before disassembly.
Refer to para 1-3.
1.
Take off shaft nut (1), guard washer (2), and spacer (3) from rotor shaft (4).
2.
Take out six screws (5).
3.
Pull drive end bell (6) and preformed packing (7) off housing (8). Throw away packing.
END OF TASK
T A 1 0 3 5 4 3
TM 9-2920-225-34 c. Disassembly.
FRAME 1
1.
2.
Take out four screws (1), and take regulator (2) off end bell (3).
N O T E
Do not take apart voltage regulator (2). No repair can be made.
Press bearing (4) from drive end bell (3) by pressing on pulley side of bearing.
N O T E
Do not take out oil seal (6) unless it is damaged.
3.
Take spacer (5) and oil seal (6) from drive end bell (3). Throw away oil seal.
GO TO FRAME 2
T A 1 0 3 5 4 4
2-43
TM 9-2920-225-34
FRAME 2
1.
Take out two screws (1) .
2.
Take cover (2) and gasket (3) off drive end bell (4).
3.
Take out pipe plug (5).
END OF TASK
T A 1 0 3 5 4 5
TM 9-2920-225-34 e. Inspection and Repair.
FRAME 1
1.
Check that screws (1), washer (2), pipe plug (3) and nut (4) are not bent or broken and that they have no damaged threads. If parts are damaged, get new ones.
NOTE
Readings must be within limits given in table 2-2. If
bearing is not within given limits, throw away bearing and get a new one.
If drive end bell is not within given limits, generator is nonrepairable.
2.
3.
4.
Check that drive end bell (5) is not cracked, warped or damaged in any way.
Measure bearing bore (6) in drive end bell.
If drive end bell is damaged or worn, generator is nonrepairable.
Measure bearing (7) inner and outer diameters (8 and 9).
Refer to TM 9-214 to service bearing (7).
END OF TASK
Get a new bearing if it is damaged.
NOTE
CHECK ONLY THOSE PARTS WHICH
ARE CALLED OUT. PARTS WITHOUT
CALLOUTS ARE SHOWN ONLY FOR
REFERENCE PURPOSES.
T A 1 0 3 5 4 6
Table 2-2. Drive End Bell Assembly Wear Limits
Item /Point of Measurement
End bell bearing bore
Inside diameter of drive end bearing
Outside diameter of drive end bearing
2.0470 to 2.0475
0.7874 to 0.7870
2.0472 to 2.0467
None
None
None
2-45
TM 9-2920-225-34
1.
Put pipe plug (1), gasket (2), and cover plate (3) into drive end housing (4).
2.
Put in two screws (5).
GO TO FRAME 2
T A 1 0 3 5 4 7
L
L f
FRAME 2
1.
Press bearing (1) into drive end bell (2).
2.
Press oil seal (3) into spacer (4).
3.
Put spacer (4) into drive end bell (2).
N O T E
Make sure voltage adjusting screw on regulator (5) lines up with pipe plug (6).
4.
Put on voltage regulator (5) and put in four screws (7).
END OF TASK
TM 9-2920-225-34
T A 1 0 3 5 4 8
“ -
TM 9-2920-225-34 g.Replacement.
F R A M E 1
1.
Hold rotor (1) and housing (2).
2.
Press drive end bell (3) and preformed packing (4) onto rotor shaft (1).
3.
Put in six screws (5).
4.
Put on spacer (6), guard washer (7) and nut (8).
5.
Turn rotor shaft (1) and check that there is no binding or scraping.
6.
If there is any binding or scraping, do steps 1 through
5 again.
END OF TASK
TM 9-2920-225-34
2-9. END HOUSING AND ROTOR ASSEMBLY .
TOOLS: No special tools required
SUPPLIES : End housing preformed packing
Lip seal (2)
Sleeve seal
Ball bearing and roller bearing grease, MIL-G-18709
PERSONNEL: One
EQUIPMENT CONDITION :
Generator removed from vehicle, pulley removed from generator.
a.
Preliminary Procedures.
(1) Clean generator before disassembly. Refer to para 1-3.
(2) Remove drive end bell and regulator assembly. Refer to para 2-8.
(3) Remove fan and hub assembly. Refer to para 2-7.
.
Removal.
FRAME 1
1.
Take out six screws (1) .
N O T E
Scribe a mark from end housing (2) to intermediate housing (3) so that housings can be put back the same way.
2.
Take end housing (2) and rotor (4) assembly out of intermediate housing ( 3).
N O T E
END OF TASK
When rotor (4) is taken out, brushes will fall out at drive end of intermediate housing (3). Take out brushes.
T A 1 0 3 5 5 0
2-49
TM 9-2920-225-34 c. Disassembly.
FRAME 1
1.
Pull rotor (1) from end housing (2).
2.
Take out seal (3) and bearing (4). Throw away seal.
3.
Take out seal sleeve (5) and seal (6). Throw away seal.
END OF TASK
T A 1 0 3 5 5 1
2-50
TM 9-2920-225-34 d. Cleaning There are no special cleaning procedures needed. Refer to e. Inspection and Repair.
(1) Inspection.
FRAME 1
N O T E
If bearing is not within limits given in table 2-3, get
a new bearing.
If rotor is not within limits given in
table 2-3, generator is nonrepairable.
1.
Measure bearing outside diameter ( 1).
2.
Measure bearing inside diameter (2).
3.
Measure rotor shaft outside diameter (3) at far end.
4.
Measure bearing seat outside diameter (4) at far end of rotor shaft.
5.
Measure rotor shaft outside diameter (5) at drive end.
6.
Measure bearing seat outside diameter (6) at drive end of rotor shaft.
7.
Measure slipring outside diameters ( 7).
GO TO FRAME 2
TA103552
2-51
6
5
7
Index
Number
1
4
3
2
TM 9-2920-225-34
Table 2-3.
End Housing and Rotor Assembly Wear Limits
Item /Point of Measurement
Size and Fit of New Parts
(inches)
Wear Limits
(inches)
2.0470 to 2.0475
None
Outside diameter of drive end bearing
Inside diameter of drive end bearing
Outside diameter of far end of shaft
Outside diameter of bearing seat at far end
Outside diameter of drive end of shaft
Outside diameter of bearing seat at drive end
Outside diameter of sliprings
0.7874 to 0.7870
0.6255 to 0.6250
0.7878 to 0.7875
0.6690 to 0.6684
0.7874 to 0.7871
1.317 to 1.307
None
None
None
None
None
1.267
2-52
TM 9-2920-225-34
FRAME 2
1.
2.
3.
4.
Check that drive end bell (1) has no cracks, warping or other damage. If drive end bell is damaged, generator is nonrepairable.
Check drive end bell bearing (2). Refer to TM 9-214. Get a new bearing if it is damaged or worn.
Check that screws (3) are not bent or broken and that they have no damaged threads.
If screws are damaged, get new ones.
Check that rotor (4) has no grounds by using a multimeter and touching one test probe to rotor shaft (5) and the other to one slipring (6). Ohmmeter readings must be more than 10,000 ohms.
If reading is not more than 10,000 ohms, generator is nonrepairable.
5.
6.
Do step 4 again for other slipring (6).
Check resistance of sliprings (6) by using a multimeter and touching ohmmeter probes on each slipring (6). Resistance must be between 7.0 and
7.8 ohms.
If not within given limits, generator is nonrepairable.
GO TO FRAME 3
T A 1 0 3 5 5 3
2-53
TM 9-2920-225-34
FRAME 3
I
1.
2.
3.
N O T E
Runout of two sliprings (1) cannot be more than
0.001 inch.
Measure slipring (1) runout using a dial indicator (2) and V-blocks (3) as shown in view A.
Set dial indicator on one slipring, turn rotor (4) and note reading on dial indicator as rotor turns.
Do step 1 again for other slipring ( 1).
Check rotor (4) shaft for straightness using a dial indicator (2) as shown in view B.
Set the dial indicator on rotor shaft, turn rotor, and note reading on dial indicator.
N O T E
END OF TASK
If reading on dial indicator (2) varies as rotor (4) turns, shaft is bent and generator is nonrepairable.
2-54
VIEW A
VIEW B
T A 1 0 3 5 5 4
TM 9-2920-225-34
FRAME 1
I
1.
If runout of sliprings (1) was more than 0.001 inch, send rotor (2) to machine
shop to have sliprings turned down. See figure 2-3.
END OF TASK
T A 1 0 3 5 5 5
T A 1 0 3 5 5 6
Index
A
Item /Point of Measurement
Outside diameter of sliprings
Size and Fit of New Parts
(inches)
0.920 to 0.930
Wear Limits
(inches)
0.880
Figure 2-3.
Slipring (Model 3002AC ) Machining Allowable Wear Limits
2-55
TM 9-2920-225-34 f.
Assembly.
FRAME 1
1.
Put seal (1) into bore of end housing (2) with smooth side of seal toward drive end of generator.
Put grease in cavity behind seal.
2.
Slide end housing (2) onto short side of shaft of rotor (3).
3.
Hold rotor (3) and press bearing (4) into bore of end housing (2) and onto shaft of rotor ( 3).
Put grease around bearing.
4.
Put seal (5) and sleeve seal (6) into end housing (2).
END OF TASK
T A 1 0 3 5 5 7
2-56
-
TM 9-2920-225-34 g .
Replacement.
FRAME 1
N O T E
Have machine shop make fabricated installing tool ( 1).
1.
Using installing tool ( 1), place tapered end of tool into lip seals (2) through drive end of housing.
Be sure that tool surface has no nicks or burrs.
2.
Put rotor (3) and end housing (4) assembly into housing (5) and stator (6) assembly so that sliprings (7) enter recess in end of installing tool (1).
3.
Carefully slide in rotor ( 3), forcing out installing tool (1) as rotor shaft goes in.
4.
Aline scribe marks and put in six screws (8).
GO TO FRAME 2
T A 1 0 3 5 5 8
2-57
TM 9-2920-225-34
Figure 2-4.
Rotor Assembly (Model 3002AC ) Installing Tool Fabrication Instructions
2-58
TM 9-2920-225-34
FRAME 2
I
1.
Take out two screws ( 1), lockwashers (2), and guard washers (3) from brush holder (4).
2.
Put two brushes (5) into brush holder (4) and put in two lockwashers (2), and screws ( 1).
guard washers ( 3),
NOTE
Follow-on Maintenance Action Required:
1.
Replace fan and hub assembly. Refer to para 2-7.
2.
Replace drive end housing. Refer to para 2-8.
END OF TASK
NOTE : PARTS WITHOUT CALLOUTS ARE SHOWN
ONLY FOR REFERENCE PURPOSES.
T A 1 0 3 5 6 0
2-59
TM 9-2920-225-34
2-10. HOUSING AND STATOR ASSEMBLY.
TOOLS : No special tools required
SUPPLIES : Electrical tape, MIL-T-50886
Housing seal
Housing lip seal
Tags
PERSONNEL: One
EQUIPMENT CONDITION :
Generator removed from vehicle, pulley removed from generator.
a. Preliminary Procedures.
(1) Clean outside of generator before disassembly. Refer to para 1-3.
(2) Remove drive end bell. Refer to para 2-8.
(3) Remove fan and hub assembly. Refer to para 2-7.
(4) Remove end housing. Refer to para 2-9.
.
Disassembly.
N O T E
If working on early model generator, do frame 1.
If working on late model generator, go to frame 2.
1.
Tag all leads (1) so that they can be put back the same way.
2.
Unsolder three splice connections (2).
3.
Take out two screws (3) and take stator (4) away from housing (5).
GO TO FRAME 3
T A 1 0 3 5 6 1
2-60
TM 9-2920-225-34
FRAME 2
1.
Take off three nuts (1).
2.
Take out capacitor panel (2).
3.
Tag all leads in housing (3).
4.
Take off five nuts (4), six flat washers (5), and two lockwashers (6).
5.
Take all leads off stator terminal (7) and take stator (8) away from housing
(3).
GO TO FRAME 3
T A 1 0 3 5 6 2
2-61
TM 9-2920-225-34
FRAME 3
1.
Take out two screws ( 1), lockwashers ( 2), and guard washers (3) from brush holder (4).
2.
Take out two screws (5) from connector socket (6).
3.
Unsolder leads from brush holder (4) at connector socket (6) and take out brush holder.
4.
Unsolder capacitor lead (7) at connector socket (6).
5.
Take off nut and lockwasher (8).
6.
Take connector socket (6) out of housing (9).
GO TO FRAME 4
2-62
NOTE
PARTS WITHOUT CALLOUTS ARE SHOWN
ONLY FOR REFERENCE PURPOSES.
T A 1 0 3 5 6 3
FRAME 4
I
1.
Take out two screws (1) and lockwashers (2).
2.
Take cover (3) off housing (4).
3.
Take out four screws (5) and lockwashers (6) and clamp (7).
GO TO FRAME 5
TM 9-2920-225-34
L
T A 1 0 3 5 6 4
2-63
TM 9-2920-225-34
FRAME 5
I
1.
Take off nut and lockwasher (1) and capacitor lead (2).
2.
Take off nut ( 3).
3.
Take capacitor assembly (4) and gasket (5) from housing (6).
GO TO FRAME 6
T A 1 0 3 5 6 5
2-64
TM 9-2920-225-34
FRAME 6
I
1.
Take out
(3).
four screws (1) and guard washers (2), and three insulator washers
N O T E
Early model generator has two insulator mounts (5).
2.
Take two rectifiers (4) and insulator mount (5) from housing (6).
3.
Take out three bushings (7) from housing (6).
GO TO FRAME 7
T A 1 0 3 5 6 6
2-65
TM 9-2920-225-34
F R A M E 7
1.
Take seal (1) and lip seal (2) out of housing (3). Throwaway seals.
END OF TASK
T A 1 0 3 5 6 7
L
L
TM9-2920-225-34 c. Cleaning.
There are no special cleaning procedures needed. Refer to
cleaning procedures given in para 1-3.
d. Inspection and Repair.
.
FRAME 1
1.
2.
3.
Check that capacitor assembly ( 1), brush holder (2), and connector socket (3) are not cracked and that they have no loose leads or corroded terminals.
Throw away damaged parts and get new parts.
Check that brushes (4) are not cracked or oil soaked and that they have no loose leads.
Throw away brushes if they are damaged.
Measure distance A on brushes (4).
Brush length must be at least 1/4 inch.
Throw away brushes if they are worn past limit.
4.
Check that housing (5) is not cracked or warped. If housing is cracked or warped, generator is nonrepairable.
GO TO FRAME 2
T A 1 0 3 5 6 8
2-67
TM 9-2920-225-34
FRAME 2
1.
2.
Check that stator windings (1) has no loose or frayed insulation.
Check that connector (2) has no loose or damaged pins.
3.
Check that stator (3) is not grounded by using a multimeter and touching one test probe to housing and the other test probe to each pin or connector
(2). Each connection must indicate an open circuit. If circuit is closed, generator is nonrepairable.
G O TO FRAME 3
T A 1 0 3 5 6 9
2-68
TM9-2920-225-34
FRAME 3
CAUTION
Do not use a battery or test lamp to make a continuity test.
Reverse battey connection will burn out diodes instantly .
N O T E
On ohmmeters that use one 1 1/2-volt dry cell, low resistance readings will be approximately 20 to 30 ohms. On ohmmeters that use a 3-volt dry cell, low resistance readings will be approximately 10 to 15 ohms.
Positive rectifier has a coating of epoxy for insulation.
1.
2.
Check positive rectifier (1) for resistance using a multimeter. Touch positive test probe to checkpoint one (2) and negative test probe to each of three rectifiers (3, 4, and 5), ohmmeter must show low resistance when negative test probe is touched to each rectifier.
Check negative rectifier (6) for resistance using a multimeter. Touch negative test probe to checkpoint two (7) and positive test probe to each of three rectifiers (8, 9, and 10).
Ohmmeter must show low resistance when positive test probe is touched to each rectifier.
3.
Get new parts for those which do not show low resistance.
END OF TASK
T A 1 0 3 5 7 0
2-69
TM 9-2920-225-34 e. Assembly.
F R A M E 1
1.
Put lip seal (1) and seal (2) into bore of housing (3) with smooth face of seal facing drive end of housing.
GO TO FRAME 2
T A 1 0 3 5 7 1
TM 9-2920-225-34
FRAME 2
I
1.
N O T E
Early model generator has two insulator mounts (1).
Positive rectifier (3) has an epoxy coating for insulation.
Put insulator mount (1) and two rectifiers (2 and 3) into housing (4) as marked.
2.
3.
Put two screws (5) and nut (6) into negative rectifier (2).
Put two screws (5) and guard washers (7) and three insulator washers (8) into positive rectifier (3).
G O TO FRAME 3
T A 1 0 3 5 7 2
2-71
TM 9-2920-225-34
FRAME 3
I
1.
Put capacitor assembly (1) with gasket (2) in housing (3).
2.
Put capacitor lead (4) with nut and lockwasher (5) on positive rectifier stud
(6).
GO TO FRAME 4
T A 1 0 3 5 7 3
TM 9-2920-225-34
FRAME 4
I
1.
Put in four screws (1) and lockwashers (2), and clamp ( 3).
2.
Put on cover (4) and put in two screws (5) and lockwashers (6).
GO TO FRAME 5
T A 1 0 3 7 1 5
2-73
TM 9-2920-225-34
I
1.
Put lead from connector socket (1) on negative rectifier stud (2) with nut and lockwasher ( 3).
2.
Solder capacitor lead (4) to connector socket ( 1).
3.
Solder leads from brush holder (5) to connector socket (1).
4.
Put connector socket (1) in place with two screws (6).
5.
Put brush holders (5) in place with two screws ( 7), lockwashers (8), and guard washers (9).
IF WORKING ON EARLY MODEL GENERATOR, GO TO FRAME 6.
IF WORKING ON LATE MODEL GENERATOR, GO TO FRAME 7
T A 1 0 3 5 7 4
2-74
FRAME 6
1.
Aline stator (1) to housing (2) and put in two screws (3).
2.
Solder three splice connections (4) and tape over solder.
N O T E
Follow-on Maintenance Action Required:
1.
Replace end housing and rotor assembly. Refer to
2.
Replace fan and hub assembly. Refer to para 2-7.
3.
Replace drive end bell. Refer to para 2-8.
END OF TASK
TM 9-2920-225-34
T A 1 0 3 5 7 5
2-75
TM 9-2920-225-34
1.
2.
3.
Aline stator (1) with housing (2) and put on two nuts (3) and lockwashers
(4).
Put on three flat washers (5), as tagged, and three flat washers and nuts
(6) on stator terminal (7). Take off tags.
Put capacitor panel (8) onto stator terminal (7) and put on three nuts (9),
N O T E
Follow-on Maintenance Action Required:
1.
Replace end housing and rotor assembly. Refer to
2.
Replace fan and hub assembly. Refer to para 2-7.
3.
Replace drive end bell. Refer to para 2-8.
END OF TASK
T A 1 0 3 5 7 6
TM 9-2920-225-34
Section IV.
LEECE-NEVILLE MODEL GENERATOR 3002AD
2-11. END COVER AND REGULATOR ASSEMBLY.
TOOLS: No special tools required
SUPPLIES: End cover preformed packing
Artillery and automotive grease, type GAA, MIL-G-10924
PERSONNEL: One
EQUIPMENT CONDITION:
Generator removed from vehicle, pulley removed from generator.
a. Preliminary Procedure.
Clean outside of generator before disassembly. Refer
b.Removal.
FRAME 1
1.
Take out six screws (1) from slipring end cover (2).
CAUTION
Be careful not to damage leads (3) going to regulator
(4) when lifting end cover (2) away from housing (5).
2.
Lift slipring end cover (2) away from housing (5).
GO TO FRAME 2
TA103577
2-77
TM 9-2920-225-34
FRAME 2
1.
Tag five leads (1) going to regulator (2).
2.
Unplug leads (1).
3.
Take out screw and lockwasher (3) and clamp (4).
4.
Take off end cover (5) and regulator (2) assembly from housing (6).
5.
Take off and throw away preformed packing (7).
END OF TASK
T A 1 0 3 5 7 8
L
TM 9-2920-225-34 c. Disassembly.
F R A M E 1
1.
Take out three screws ( 1), lockwashers ( 2), and flat washers ( 3).
2.
Take regulator
(4) off end cover (5).
N O T E
Do not take apart regulator (4).
END OF TASK
T A 1 0 3 5 7 9
2-79
TM 9-2920-225-34 cleaning procedures given in para 1-3.
e. Inspection and Repair.
FRAME 1
1.
Check that all screws (1) are not bent or broken and that threads are not damaged.
Get new screws for all damaged ones.
2.
Check that regulator (2) is not cracked or damaged and that it has no loose leads.
If regulator is damaged, get a new one.
N O T E
Regulator (2) will be tested later.
3.
Check that end cover (3) is not cracked, warped or broken and that it has no damaged studs.
If end cover is damaged, get a new generator.
END OF TASK
T A 1 0 3 5 8 0
2-80
TM 9-2920-225-34 f.
Assembly.
1.
Put three flat washers (1) on standoffs (2) of end cover (3).
2.
With components of regulator (4) facing away from end cover holes and place regulator on standoffs (2).
(3), aline three
3.
Put in three screws (5) and lockwashers (6).
END OF TASK
TA 103581
2-81
TM 9-2920-225-34 g.
Replacement.
FRAME 1
1.
If brushes must be replaced, take out two screws, lockwashers, and flat washers ( 1).
Lift brush holder (2) and put brushes into brush holder.
Put brush holder back and put in two screws, lockwashers, and flat washers.
2* Put a coat of grease on preformed packing (3). Place packing in groove in housing (4) .
3.
Plug five leads (5) onto regulator (6) as tagged. Take off tags.
4.
Put clamp (7) around leads (5) and put in screw and lockwasher (8).
GO TO FRAME 2
.
TA 103582
.
2-82
FRAME 2
I
1.
Place slipring cover (1) onto housing (2).
NOTE
Make sure that pin (4) is alined ring cover (1).
with pin hole in slip-
2.
Put in six screws (3).
END OF TASK
TM 9-2920-225-34
TA 103583
TM 9-2920-225-34
2-12. DRIVE END BELL AND ROTOR ASSEMBLY.
TOOLS: No special tools required
SUPPLIES: Drive end preformed packing
Bearing retainer preformed packing
Drive end bell seal
Bearing retainer seal
Artillery and automotive grease, type GAA, MIL-G-10924
PERSONNEL: One
EQUIPMENT CONDITION :
Generator removed from vehicle, pulley removed from generator.
a. Preliminary Procedures.
(1) Clean outside of generator before disassembly. Refer to para 1-3.
(2) Remove end cover and regulator assembly, Refer to para 2-11.
b.
Removal.
FRAME 1
1.
Slide fan (1) off rotor shaft (2).
2.
Take out woodruff key (3) from rotor shaft (2).
3.
Scribe a line across end bell (4) and housing (5).
GO TO FRAME 2
2-84
—
—
TA 103584
TM 9-2920-225-34
FRAME 2
1.
Take out six screws (1) and washer (2).
NOTE
When end bell (3) and rotor (4) assembly are taken out of housing (5), brushes will fall out of brush holders at slipring end of housing. Take out brushes.
2.
Take end bell (3) and rotor (4) assembly out of housing (5). Tap lightly with a soft mallet if needed.
END OF TASK
2-85
TM 9-2920-225-34 c. Disassembly.
FRAME 1
1.
Press rotor shaft (1) out of end bell (2).
2.
Take out drive end spacer (3) packing.
and preformed packing (4). Throw away
3.
Take out four screws (5).
4.
Take bearing retainer (6) and
Throw away packing.
preformed packing (7) off end bell (2).
5.
Press bearing (8) and seal (9) out of end bell (2). Throw away seal.
6.
Punch seal (10) out of bearing retainer (6). Throw away seal.
END OF TASK
.
TA 103586
2-86
TM 9-2920-225-34 d.
Cleaning.
There are no special cleaning procedures needed. Refer to cleaning procedures given in para 1-3.
e. Inspection and Repair.
(1) Inspection.
1.
2.
3.
4.
5.
Measure
Measure
Measure
N O T E
Readings for rotor (1) and drive end bell (2) must be
within limits given in table 2-4. If readings are not
within given limits, generator is nonrepairable.
outside diameter of sliprings (3).
outside diameter of slipring end of shaft (4).
outside diameter of drive end of shaft bearing seat (5).
Measure outside diameter of drive end of shaft (6).
Measure inside diameter of drive end bell bearing bore (7).
N O T E
If bearing (8) is not within limits given in table 2-4,
get a new bearing.
6.
7.
Measure outside diameter (9) of drive end bearing (8).
Measure inside diameter (10) of drive end bearing (8).
GO TO FRAME 2
TA 103587
2-87
TM 9-2920-225-34
Index
Number
4
3
5
9
6
7
10
Table 2-4.
Drive End Bell and Rotor Wear Limits
Item /Point of Measurement
Sliprings outside diameter
Slipring end of shaft outside diameter
Drive end of shaft bearing seat outside diameter
Drive end of shaft outside diameter
Drive end bell bearing bore inside diameter
Drive end bearing outside diameter
Drive end bearing inside diameter
Size and Fit of New Parts
(inches)
0.920 to 0.930
1.000 to 0.9987
0.7878 to 0.7875
0.6690 to 0.6684
2.0470 to 2.0475
2.0472 to 2.0467
0.7874 to 0.7870
Wear Limits
(inches)
0.880
None
None
None
None
None
None
2-88
TM 9-2920-225-34
1.
2.
3.
4.
Check that end bell (1) and bearing retainer (2) have no cracks, damage or warping.
If damage is found, generator is nonrepairable.
Check that drive end bearing (3) is not damaged. Refer to TM 9-214.
Check that screws (4) are not bent or broken and that they have no damaged threads. If screws are damaged, get new ones.
Using multimeter, check that rotor (5) has no grounds. Touch one test probe to rotor shaft (6) and touch other test probe to one slipring (7) and check that ohmmeter reading is over 10, 000 ohms. If readings is not over 10,000 ohms, get a new generator.
Do step 4 again for other slipring (7).
5*
6.
Using multimeter, check resistance of two sliprings (7). Touch ohmmeter test probes to two sliprings at same time and check that resistance is between 7.0 and 7.8 ohms.
If resistance is not within given limits, generator is nonrepairable.
GO TO FRAME 3
TA 103588
2-89
TM 9-2920-225-34
1.
Check that runout of slipring (1) is less than 0.001 inch. Using dial indicator (2) and V–blocks (3) as shown in view A, set dial indicator on slipring, turn rotor (4), and note reading as rotor turns.
2.
Do step 1 again for other slipring (1).
3.
Check that shaft of rotor (4) is straight.
Using a dial indicator (2) as shown in view B, set dial indicator on shaft of rotor, turn rotor and check that reading does not change.
If reading changes, generator is nonrepairable.
END OF TASK
VIEW B
VIEW A
TA 103589
(2) Repair.
TM 9-2920-225-34
TA 103591
Index
Number
A
Item /Point of Measurement
Outside diameter of slipring
Size and Fit of New Parts
(inches)
0.920 to 0.930
Figure 2-5.
Slipring (Model 3002AD) Wear Limits
Wear Limits
(inches)
0.880
2-91
TM 9-2920-225-34 f.
Assembly.
1.
Using hammer and brass punch, put seal (1) into bore of bearing retainer (2) with part number facing out.
2.
Using hammer and brass punch, put seal (3) into bore of drive end bell (4) with part number facing in.
Slip housing (4) with seal (3) onto rotor shaft (5).
3.
4.
5.
6.
Press bearing (6) onto rotor shaft (5) into bore of end bell (4) with part number facing out.
Lightly grease preformed packing (7).
Put packing in groove of end bell (4).
Put bearing retainer (2) on end bell (4) and put in four screws (8).
7.
Lightly grease preformed packing (9).
Slide packing and spacer ( 10) onto rotor shaft (5).
END OF TASK
TA 103592
2-92
I
TM 9-2920-225-34 g .
Replacement.
FRAME 1
1.
Place end bell (1) and rotor (2) assembly in housing (3) and aline scribe marks.
2.
Put in six screws and washers (4).
,
GO TO FRAME 2
TA 103593
TM 9-2920-225-34
FRAME 2
I
1.
Put woodruff key (1) in slot of shaft (2).
2.
Put fan (3) onto shaft (2) over woodruff key (1).
NOTE
Follow-on Maintenance Action Required:
END OF TASK
Replace end cover and regulator assembly. Refer to
TA 103594
2-94
TM 9-2920-225-34
2-13. HOUSING AND STATOR ASSEMBLY.
TOOLS: No special tools required
SUPPLIES: Teflon seats (2)
Capacitor and terminal assembly gasket
Artillery and automotive grease, type GAA, MIL-G-10924
Tags
PERSONNEL: One
EQUIPMENT CONDITION : Generator removed from vehicle, pulley removed from generator.
a.
Preliminary Procedures.
(1) Clean outside of generator before disassembly. Refer to para 1-3.
(2) Remove end cover and regulator assembly. Refer to para 2-11.
(3) Remove drive end bell and rotor assembly. Refer to para 2-12.
b.
Disassemble.
FRAME 1
1.
Take off three tenz nuts (1).
2.
Take out capacitor panel (2).
GO TO FRAME 2
TA 103595
2-95
●
2-96
TM 9-2920-225-34
FRAME 2
I
1.
Tag nine leads (1).
2.
Take off three nuts (2).
3.
Take off nine leads (1).
4.
Take three flat washers (3) off stator terminal (4).
GO TO FRAME 3
TA 103596
FRAME 3
1.
Take off two nuts, lockwashers, and flat washers ( 1).
CAUTION
Be careful not to damage stator terminal when lifting off housing (2).
Terminal can be damaged and generator will not work correctly.
2.
Lift housing (2) off stator assembly (3).
GO TO FRAME 4
TM 9-2920-225-34
TA 103597
2-97
TM 9-2920-225-34
1.
Take out screw and lockwasher (1) and clamp (2).
2.
Take out lead (3).
3.
Scribe a mark on top of brush holder (4).
4.
Take out two screws, lockwashers, and flat washers (5).
GO TO FRAME 5
2-98
1.
Tag two leads (1) on negative heat sink stud (2).
2.
Take off nut, lockwasher, and flat washer (3).
3.
Take off two leads (1) from negative heat sink stud (2).
4.
Take brush holder (4) out of housing (5).
GO TO FRAME 6
TM 9-2920-225-34
TA 103599
2-99
TM 9-2920-225-34
1.
Take off nut, lockwasher, and flat washer (1).
2.
Tag lead (2) and take it off.
GO TO FRAME 7
TA 103600
TM 9-2920-225-34
1.
2.
3.
4.
5.
Take out two screws (1) and lockwashers (2).
Take off cover ( 3).
Take out four screws (4) and lockwashers (5) and one clamp (6).
Take capacitor and terminal assembly (7) and gasket (8) out of housing (9).
Throw away gasket.
Take pipe plug (10) out of housing (9).
GO TO FRAME 8
,
TA 103601
TM 9-2920-225-34
FRAME 8
Take off nut (1) .
Take out two screws (2).
Pull negative rectifier (3) out of drive end of housing (4).
TO FRAME 9
TA 103602
F R A M E 9
1.
Take off two insulating washers (1).
NOTE
One of the positive rectifier mounting screws is longer than the other.
Note positions of screws.
2.
Take out two screws, flat washers, and insulating washers (2).
3.
Pull positive rectifier (3) out of drive end of housing (4).
4.
Take out insulator mount (5).
5.
Take out three insulating bushings (6) from housing (4).
GO TO FRAME 10
TM 9-2920-225-34
TA 103603
2-103
TM 9-2920-225-34
FRAME
1 0
1.
Take out two teflon seals (1). Throw away seals.
2.
Take roller bearing (2) out of housing (3).
END OF TASK
2-104
TM 9-2920-225-34
1.
2.
Check that housing (1) is not cracked or damaged. If housing is damaged, generator is nonrepairable.
Measure inside diameter of bearing bore (2).
Inside diameter of bearing bore
3.
4.
generator is nonrepairable.
NOTE
If bearing (3) is not within given limits, get a new bearing.
Measure inside diameter (4) of bearing (3). Inside diameter must be go gage to 1.0015 inches no-go gage when held in 1.3120 ring gage.
1.0005
Measure bearing (3) outside diameter (5). Outside diameter must be inches nominal when pushed into 1.3120 inches ring gage.
1.3120
5.
Check that bearing (3) is not damaged. Refer to TM 9-214.
GO TO FRAME 2
TA 103605
2-105
TM 9-2920-225-34
FRAME 2
I
1.
2.
3.
Check that stator (1) and stator terminal (2) are not cracked and that there are no stripped threads or loose pins. If stator or terminal is damaged, generator is nonrepairable.
Check that stator (1) has no broken windings or loose connections. Resolder any loose or broken connections.
Check that stator (1) has no grounds between three pins (3, 4 and 5) on terminal (2) and outer case of stator.
Touch one test probe of multimeter to outer case and other test probe to each pin. If ground is present, generator is nonrepairable.
CAUTION
Do not use a battery or test lamp test.
Reverse battery connection instantly . to make a continuity will burn out diodes
4.
Check that stator (1) has continuity between three pins (3, 4 and 5) on terminal (2).
Touch test probes of multimeter to pins ( 3 and 4), pins
(3 and 5) and pins (4 and 5).
If continuity is not made between three pins, generator is nonrepairable.
GO TO FRAME 3
TA 103606
2-106
TM 9-2920-225-34
FRAME 3
I
1.
2.
3.
Check that brush holder (1) and capacitor assembly (2) has no cracks, frayed or broken leads or any other damage. Throw away damaged parts and get new ones.
Check that brushes (3) are not cracked or oil soaked and that they have no loose or frayed leads.
Check that distance A is 1/4 inch or more. If brushes are worn or damaged, get new ones.
Check that all screws (4) are not bent or broken and that they have no stripped threads or damaged heads.
Throw away damaged screws and get new ones.
4.
Check that capacitor panel (5) is not warped, cracked or damaged in any other way.
Throw away damaged capacitor panel and get a new one.
GO
TO FRAME 4
TA 103607
2-107
TM 9-2920-225-34
FRAME 4
CAUTION
Do not use a battery or test lamp test.
Reverse battery connection instantly .
to make a continuity will burn out diodes
NOTE
On ohmmeters that use one 1 1/2-volt dry cell, low resistance readings will be approximately 20 to 30 ohms.
On ohmmeters that use a 3-volt dry cell, low resistance readings will be approximately 10 to 15 ohms.
Positive rectifier (1) has a coating of epoxy for insulation.
1.
2.
3.
Check resistance of positive rectifier (1). Touch positive test probe of multimeter to checkpoint one (2) and negative test probe to each of three rectifiers (3, 4, and 5).
Ohmmeter must show low resistance when negative test probe is touched to each rectifier.
Check resistance of negative rectifier (6). Touch negative test probe of multimeter to checkpoint two (7) and positive test probe to each of three rectifiers (8, 9, and 10).
Ohmmeter must show low resistance when positive test probe is touched to each rectifier.
If rectifiers (3, 4, 5, 8, 9, and 10) do not have low resistance, get new ones.
END OF TASK
TA 103608
2-108
e. Assembly.
1.
Press bearing (1) into bore of housing (2).
2.
Lightly coat bearing (1) with grease.
3.
Press two new teflon seals (3) into bore of housing (2).
GO TO FRAME 2
TM 9-2920-225-34
Q
2
TA 103609
2-109
TM 9-2920-225-34
FRAME 2
I
1.
Place insulator mount (1) in housing (2) through drive end. Aline all holes in insulator mount.
2.
3.
NOTE
Positive rectifier (3) has an insulating coat of epoxy.
Put positive rectifier (3) on insulator mount (1) with one lead through each hole of housing (2).
Put in two screws (4), flat washers (5), insulating washers (6), and insulating bushings (7).
4.
Put insulating bushing (8) and two insulating washers (9) on positive rectifier stud (10).
GO TO FRAME 3
TA 103610
2-110
TM 9-2920-225-34
Q
3
TA 103611
2-111
TM 9-2920-225-34
FRAME 4
I
1.
Put capacitor and terminal assembly (1) and gasket (2) in housing (3) as shown.
2.
Put in four screws (4), lockwasher (5), and clamps (6).
3.
Slice capacitor assembly cover (7) onto pin on housing (3) and put in two screws (8) and lockwashers (9).
4.
Put in pipe plug (10).
GO TO FRAME 5
TA 103612
2-112
I
TM 9-2920-225-34
FRAME 5
1.
Put lead (1) from capacitor assembly (2) on positive heat sink stud (3).
2.
Put on nut, lockwasher, and flat washer (4).
GO TO FRAME 6
TA 103613
TM 9-2920-225-34
FRAME 6
I
CAUTION
Be careful not to damage stator and terminal assembly
(1) when putting in stator. If stator is damaged, generator will not work correctly.
1.
Aline stator terminal (1) with hole in housing (2) and put in stator and terminal assembly.
2.
Put on two nuts, lockwashers, and flat washers (3).
GO TO FRAME 7
TA 103614
2-114
TM 9-2920-225-34
FRAME 7
I
1.
2.
Put brush holder lead (1) and regulator lead (2) on negative heat sink stud
(3) as tagged and put on nut, lockwasher, and flat washer (4). Take off tags.
With scribe mark on brush holder ( 5 ) facing up, put brush holder in place and put in two screws, lockwashers, and flat washers (6).
GO TO FRAME 8
TA 103615
2-115
TM 9-2920-225-34
1.
Place three flat washers (1) on stator terminal (2).
2.
Place nine leads (3) on stator terminal (2) as tagged. Take off tags.
3.
Put three nuts (4) on stator terminal (2).
4.
Put clamp (5) around five leads (6) and put in screw and lockwasher (7).
GO TO FRAME 9
TA 103616
2-116
I
FRAME 9
1.
Put capacitor panel (1) in place.
2.
Put on three tenz nuts (2).
1.
2.
NOTE
Follow-on Maintenance Action Required:
Replace drive end bell and rotor assembly. Refer
Replace end cover and regulator assembly. Refer
END OF TASK
TM 9-2920-225-34
TA 103617
2-117
TM 9-2920-225-34
Section V.
LEECE-NEVILLE MODEL GENERATOR 3002AE
2-14. END COVER AND REGULATOR ASSEMBLY.
TOOLS: No special tools required
SUPPLIES:
Housing preformed packing
Artillery and automotive grease, type GAA, MIL-G-10924
Tags
PERSONNEL: One
EQUIPMENT CONDITION:
Generator removed from vehicle, pulley removed from generator.
a. Preliminary Procedure.
Clean outside of generator before disassembly. Refer
b.
Removal.
1.
Take out six screws (1).
CAUTION
Be careful when lifting end cover (2) and regulator (3) assembly.
Regulator leads (4) may be damaged and generator will not work correctly.
2.
Lift end cover (2) and regulator (3) assembly clear of housing (5).
3.
Tag five regulator leads (4) so that they can be put back in the same place.
4.
Slip off five regulator leads (4) from terminal strip (6).
5.
Take preformed packing (7) from groove in housing (5). Throw away packing.
END OF TASK
.
2-118
c .
Disassembly.
FRAME 1
1.
Take out nine screws with washers (1).
2.
Take off nut and washer (2).
3.
Take regulator (3) off cover (4).
4.
Tag and unsolder three wires (5).
END OF TASK
TM 9-2920-225-34
TA 103619
2-119
e. Inspection and Repair. Refer to para 2-11e.
f.
Assembly.
FRAME 1
1.
Solder three wires (1) as tagged.
2.
Put regulator (2) on cover
(
3).
3.
Put in nine screws with washers (4).
4.
Put on nut and washer (5).
END OF TASK
TA 103620
g.
Replacement.
TM 9-2920-225-34
2-121
TM 9-2920-225-34
2-15. DRIVE END BELL AND ROTOR ASSEMBLY .
TOOLS: No special tools required
SUPPLIES : Bearing retainer preformed packing
PERSONNEL: One
EQUIPMENT CONDITION :
Generator removed from vehicle, pulley removed from generator.
a. Preliminary Procedures.
(1) Clean outside of generator before disassembly. Refer to para 1-3.
(2) Remove end cover and regulator assembly. Refer to para 2-14.
b.
Removal.
FRAME 1
1.
2.
Take nut ( 1), washer (2), spacer ( 3), fan (4), and shaft (6).
woodruff key (5) off
Scribe a mark across drive end bell (7), stator (8), and housing (9).
GO TO FRAME 2
TM 9-2920-225-34
1.
Take out six screws and flat washers (1) from drive end bell (2).
CAUTION
When drive end bell (2) has been taken off, stator windings will show.
Be careful not to nick or cause other damage to stator windings. Do not rest generator on windings.
NOTE
Brushes will fall out of brush holders when drive end bell (2) is taken out.
Take out brushes and check that they are not worn.
Refer to para 2- 13d for inspection procedures.
2.
Pull drive end bell (2) and rotor (3) assembly from housing (4).
END OF TASK
TA 103623
I
2-123
TM 9-2920-225-34
c.
Disassembly.
1.
Take seal sleeve (1) and packing (2) off shaft of rotor (3).
2.
Take out four screws (4) and take off bearing retainer (5) and preformed packing (6).
Throw away packing.
3.
Press seal (7) out of bearing retainer (5).
4.
Pull drive end bell (8) from shaft of rotor (3).
5.
Press bearing (9) and seal ( 10) out of drive end bell (8) through front of drive end bell.
END OF TASK
TA 103624
.
2-124
TM 9-2920-225-34
e. Inspection and Repair. Refer to para 2-12e.
f.
Assembly.
1.
2.
Put seal (1) into bearing bore in housing (2) with smooth side of seal facing away from bearing ( 3).
Make sure that seal is flush with rear edge of bearing bore.
Fill cavity behind seal (1) with grease.
N O T E
3.
Have machine shop make installing tool. See figure
2-6.
Place installing tool into seal (1) seal face rear of end bell.
from front of drive end bell (2) so lips of
4.
Place drive end bell (2) on shaft drive end bell.
of rotor (4) so shaft forces tool out of
GO TO FRAME 2 w
TA 103625
2-125
TM 9-2920-225-34
r
60 DEGREE DIAMOND KNURL AROUND
MATERIAL: T.S. HDN 48-50RC
NOTE: ALL DIMENSIONS SHOWN ARE IN INCHES
TA 103626
2-126
Figure 2-6.
Installing Tool Fabrication Instructions
TM 9-2920-225-34
FRAME 2
1.
Press bearing (1) onto shaft of rotor (2) and into drive end bell (3).
2.
Put seal (4) into bearing retainer (5) with smooth side of seal facing outside of retainer.
3.
Put large packing (6) around outer edge of bearing (1) and put bearing retainer (5) in place.
4.
Put in four screws (7).
5.
Put small packing (8) around shaft and put seal sleeve (9) onto shaft with counterbore of sleeve facing toward bearing (1).
END OF TASK
TA 103627
2-127
TM 9-2920-225-34 g.
Replacement.
NOTE
Have machine shop make pilot tool. See figure 2-7.
1.
Place pilot tool (1) into bearing bore of housing (2) through slipring end of housing as shown.
GO TO FRAME 2
TA 103628
TM 9-2920-225-34
t
NOTE: ALL DIMENSIONS SHOWN ARE
IN INCHES
TA 103629
Figure 2-7.
Pilot Tool Fabrication Instructions
2-129
TM 9-2920-225-34
FRAME 2
I
1.
Put drive end bell (1) and rotor (2) assembly in housing and stator assembly
(3) so that sliprings (4) go into pilot tool.
2.
Push rotor (2) into place and push pilot tool out of housing and stator assembly ( 3).
3.
Aline scribe marks and put in six screws and washers (5).
4.
Fill cavity around shaft (6) in front of bearing retainer (7) with grease.
GO TO FRAME 3
TA 103630
2-130
TM 9-2920-225-34
TA 103631
2-131
TM 9-2920-225-34
FRAME 4
1.
Put woodruff shaft (6).
key (l), fan (2), spacer (3), washer (4), and nut (5) on
NOTE
Follow-on Maintenance Action Required:
END OF TASK
Replace regulator and end cover assembly. Refer to
TA 103632
TM 9-2920-225-34
2-16. HOUSING AND STATOR ASSEMBLY
●
TOOLS: No special tools required
SUPPLIES: Housing seal (2)
Sealer compound, type II, MIL-S-45180
Tags
PERSONNEL: One
EQUIPMENT CONDITION :
Generator removed from vehicle, pulley removed from generator.
a.
Preliminary Procedures.
(1) Clean outside of generator before disassembly. Refer to para 1-3.
(2) Remove end cover and regulator assembly. Refer to para 2-14.
(3) Remove drive end bell and rotor assembly. Refer to para 2-15.
b.
Disassembly.
1.
Tag all leads joined to stator terminal (1) so that they can be put back in the same place.
2.
Take off three nuts (2) and take off capacitor panel ( 3). Take off three nuts (4), all leads, and flat washers ( 5).
3.
Take off two nuts (6), lockwashers ( 7), and flat washers (8) that join stator terminal (1) to housing (9).
Carefully lift stator from housing.
GO TO FRAME 2
TA 103633
2-133
TM 9-2920-225-34
FRAME 2
I
1.
Take three screws (1), lockwashers (2), and flat washers (3) from brush holders (4 and 5).
2.
Take leads of brush holders (4 and 5) off terminal board (6) and take out brush holders.
GO TO FRAME 3
TA 103634
TM 9-2920-225-34
FRAME 3
1.
2.
3.
Take off nut (1), lockwasher (2), and flat washer (3) from positive rectifier stud (4) .
Take two leads from capacitor and lead assembly (5) off positive rectifier stud (4) .
Take off two flat insulating washers (6) from positive rectifier stud (4) in housing (7).
GO TO FRAME 4
TA 103635
TM 9-2920-225-34
1.
2.
3.
Tag and take off leads on terminal board (1).
Take out two screws (2) and lockwashers (3), and take out terminal board
(1) and capacitor (4),
Take out screw (5), lockwasher (6), flat washer (7) and two insulating washers (8) from positive rectifier (9).
NOTE
4.
Positive rectifier mounting screws and stud are insulated by three insulating bushings (10). Be careful not to lose these bushings when taking out positive rectifier (9).
Take out positive rectifier (9) and three insulating bushings (10).
GO TO FRAME 5
TM 9-2920-225-34
1.
2.
3.
Take two nuts (1), flat washer (2), and two ground leads off negative rectifier stud ( 3).
Take out two screws (4) and take negative rectifier (5) and insulator mount (6) out of housing (7).
Take off nut (8) and lockwasher (9). Take out capacitor (10).
GO TO FRAME 6
TA 103637
2-137
TM 9-2920-225-34
FRAME 6
1.
Take out two screws (1) and lockwashers (2) and take off cover (3).
2.
Take out four screws (4), lockwashers (5), and clamp (6).
3.
Take capacitor and lead assembly (7) and gasket (8) out of housing (9).
4.
Take out pipe plug (10).
GO TO FRAME 7
TA 103638
TM 9-2920-225-34
FRAME 7
I
1.
Take out and throw away two seals (1) from bore in housing (2).
2.
Pull bearing (3) out of bore in housing (2).
END OF TASK
TA 103639
2-139
1.
Press bearing (1) into bore in housing (2).
2.
Coat bore of bearing (1) with grease.
3.
Press two seals (3) into bore in housing (2) with flat side of seal away from bearing (1).
3.
Put sealer compound around outer edge of two seals (3).
GO TO FRAME 2 .
TA 103640
2-140
TM 9-2920-225-34
FRAME 2
I
1.
Put in pipe plug (1).
2.
3.
Put gasket (2) and capacitor and lead assembly (3) into housing (4). Put in four screws (5), lockwashers (6), and one clamp (7) to hold down ignition lead.
Put cover (8) on housing (4) and put in two screws (9) and lockwashers (10).
GO TO FRAME 3
TA 103641
2-141
TM 9-2920-225-34
FRAME 3
I
1.
2.
3.
Coat insulator mount (1) with sealer compound on both sides. Place insulator mount in housing (2), alining holes.
NOTE
Housing (2) is marked POS. and NEG. so rectifiers will be put back the right way. Positive rectifier has an epoxy coating for insulation and negative rectifier
(3) has no coating.
Place negative rectifier (3) in housing (2). Put in two screws (4) and capacitor (5).
Put two nuts (6), flat stud (8) .
washers ( 7), and ground leads on negative rectifier
4.
Put capacitor (5) lead
GO TO FRAME 4 on with nut (8) and lockwasher (10).
TA 103642
2-142
TM 9-2920-225-34
FRAME 4
1.
Put positive rectifier (1) in place.
2.
Put in three insulating bushings (2).
3.
Put in screw (3), lockwasher (4), flat washer (5), and one insulating washer (6).
4.
Put in terminal board (7) and capacitor (8) and put in two screws (9), lockwashers (10), and other insulating washer (6).
GO TO FRAME 5
●
TA 103643
2-143
TM 9-2920-225-34
FRAME 5
1.
Put two insulating washers (1) on positive rectifier stud (2) in housing
(3).
2.
Put two leads from capacitor and lead assembly (4) on positive rectifier stud (2) .
3.
Put on nut (5), lockwasher (6), and flat washer (7).
GO TO FRAME 6
TA 103644
2-144
TM 9-2920-225-34
1.
Slip leads from brush holders (1 and 2) onto terminal board (3).
2.
Put brush holders (1 and 2) in place with three screws (4), lockwashers (5), and flat washers (6).
GO TO FRAME 7
TA 103645
2-145
TM 9-2920-225-34
FRAME 7
I
1.
2.
3.
4.
Aline stator (1) with housing (2) and put them together.
Put on two nuts (3), lockwashers (4), and flat washers (5) that hold stator
(1) and housing (2) together.
Put on three flat washers (5), leads as tagged, and nuts (6). Take off tags.
Put on capacitor panel (7) with three nuts (8).
NOTE
Follow-on Maintenance Action Required:
1.
Replace drive end bell and rotor assembly. Refer to para 2-15.
2.
Replace end cover and regulator assembly. Refer to para 2-14.
END OF TASK
TA 103646
2-146
TM 9-2920-225-34
Section VI.
LEECE-NEVILLE MODEL GENERATORS 5504AA,
5504AB , AND 5300GP
2-17. FAN AND HUB ASSEMBLY.
TOOLS: No special tools required
SUPPLIES: None
PERSONNEL: One
EQUIPMENT CONDITION: Generator generator.
removed from vehicle, pulley removed from
Preliminary Procedure.
Clean generator
before disassembly. Refer to b.
Removal.
1.
Take off nut (1) and flat washer (2).
2.
Slide fan (3) off shaft (4).
3.
Take out woodruff key (5).
END OF TASK
TA 103650
2-147
TM 9-2920-225-34 c.
Disassembly.
(1) Models 5504AA and 5504AB.
FRAME 1
I
1.
Take out four screws (1) and lockwashers (2).
2.
Take off clutch disk ( 3), fan hub (4), and fan spring (5) from fan (6).
END OF TASK
TA 103651
I t
(2) Model 5300GP.
FRAME 1
1.
Take out four screws (1) and lockwashers (2).
2.
Take fan hub (3) off fan (4).
END OF TASK
TM 9-2920-225-34
TA 103652
e.
Inspection and Repair.
FRAME 1
NOTE
If any part is damaged, generator is nonrepairable.
1.
Check that fan (1), hub cracked, bent or broken
(2), clutch disk (3), and fan spring (4) are not and that they have no stripped threads.
2.
Check that screws (5), washers (6), woodruff key (7), and nut (8) are not bent or broken and that they have no damaged threads or heads.
END OF TASK
2-150
MODELS 5504AA AND 5504AB
MODEL 5300 GP
TA 103653
1
1.
TM 9-2920-225-34 f.
Assembly.
(1) Models
5504AA and 5504AB.
FRAME 1
1.
Put fan spring (1), fan hub (2), and clutch disk (3) on flat side of fan (4).
Put in four screws (5) and lockwashers (6).
END OF TASK
TA 103654
2-151
TM 9-2920-225-34
(2) Model 5300GP.
2-152
TA 103655
g.
Replacement.
TM 9-2920-225-34
TA 103656
2-153
TM 9-2920-225-34
2-18. SLIPRING END HOUSING.
TOOLS: No special tools required
SUPPLIES: Cotter pin (4)
PERSONNEL: One
EQUIPMENT CONDITION:
Generator removed from vehicle, pulley removed from generator.
a.
Preliminary Procedures.
(1) Clean outside of generator before disassembly. Refer to para 1-3.
(2) Remove fan and hub assembly. Refer to para 2-17.
b.
Removal.
FRAME 1
1.
Straighten tabs on two key washers (1).
Take off two nuts (2), lockwashers
(3), and two terminal leads (4).
2.
Take off four brush leads (5) and two key washers (1).
3.
Pull four brushes (6) out halfway in brush holder (7). Place four brush levers (8) so they hold brushes in the halfway position.
IF WORKING ON MODEL 5504AA OR MODEL 5504AB , GO TO FRAME 2.
IF WORKING ON MODEL 5500GP, GO TO FRAME 4
2-154
1
TM 9-2920-225-34
FRAME 2
1.
Take out two screws (1), two screws (2), and four lockwashers (3).
2.
Take off connector cover (4).
3.
Break seal between connector elbow (5) and slipring end housing (6).
GO TO FRAME 3
)
TA 103658
2-155
TM 9-2920-225-34
FRAME 3
1.
Scribe a mark across slipring end housing (1) and stator shroud (2).
2.
Straighten tabs on washers (3) and take out six screws (4), lockwashers
(5), and tabbed washers.
3.
Using soft-faced hammer, hit drive end of shaft (6) enough to fit puller on slipring end housing (1).
4.
Pull off slipring end housing ( 1).
END OF TASK
TA 103659
2-156
TM 9-2920-225-34
1.
Take out four screws (1) and four lockwashers (2) and take off cover plate ( 3).
GO TO FRAME 5
TA 104253
TM 9-2920-225-34
FRAME 5
1.
Scribe mark across slipring end housing (1) and shroud (2).
2.
Take out seven screws (3) and seven lockwashers (4).
3.
Pull off slipring end housing ( 1).
END OF TASK
TA 104254
2-158
TM 9-2920-225-34
1.
Take out three screws (1) and take off bearing retainer (2).
2.
Take out four screws (3).
Take off brush holder (4) and bearing retainer (5).
NOTE
Have machine shop
make fabricated tool.
3.
Using fabricated tool, drive housing (7) .
bearing (6) from bore in slipring end
GO TO FRAME 2
TA 103660
I
2-159
TM 9-2920-225-34
1.
Lift four brushes (1) from brush holder (2) .
2.
Take out four cotter pins ( 3), four brush levers (4), and four springs (5) from post of brush holder (2). Throw away cotter brush pins.
END OF TASK
TA 103662
2-160
TM 9-2920-225-34 d. Cleaning.
There are no special cleaning procedures needed. Refer to
cleaning procedures given in para 1–3.
e. Inspection and Repair.
NOTE
Readings must be within limits given in table 2-5. If
readings are not within given limits, generator is nonrepairable.
1.
Check that end housing (1) and bearing retainers (2 and 3) have no cracks or breaks.
If parts are damaged, generator is nonrepairable.
Measure end housing bearing bore (4).
2.
3.
4.
Check that screws (5) are not bent or broken and that they have no stripped threads or damaged heads.
If screws are damaged, get new ones.
Measure bearing (6) inside diameter (7) and outside diameter (8). If inside
and outside diameters are not within limits given in table 2-5, get new
bearing.
5.
Check that bearing (6) is not damaged. Refer to TM 9-214.
GO TO FRAME 2
Index
Number
4
7
8
Table 2-5. End Housing Assembly Wear Limits
Item /Point of Measurement
Size and Fit of New Parts
(inches)
1.8497 to 1.8501
Inside diameter of end housing bearing bore
Inside diameter of end housing bearing
Outside diameter of end housing bearing
0.7870 to 0.7874
1.8499 to 1.8504
Wear Limits
(inches)
None
None
None
2-161
TM 9-2920-225-34
FRAME 2
1
I
1.
NOTE
If parts are damaged, get new ones.
Check that brush holder (1) is not cracked or broken and that it does not have bent or loose studs.
2.
Check that brush springs (2) are not burned or overheated. If spring is overheated, get a new one.
3.
4.
Check that leads on brushes (3) are not loose, broken or frayed.
Measure distance A on brushes ( 3).
Brush length must be at least 5/8 inch.
5,
Check brush levers (4) to see that they are not bent, broken or cracked.
END OF TASK
TA 103664
2-162
TM 9-2920-225-34 f.
Assembly.
FRAME 1
1.
Put four brush springs (1), four brush levers (2), and four cotter pins
(3) on post of brush holder (4).
2.
Put four brushes (5) halfway in brush holders (6).
GO TO FRAME 2
T A 1 0 3 6 6 5
TM 9-2920-225-34
FRAME 2
1.
Press bearing (1) into base of slipring end housing (2).
2.
Place bearing retainer (3) and brush holder (4) on slipring end housing
(2) and put in four screws (5).
3.
Put bearing retainer (6) on slipring end bell (2). Put in three screws (7).
END
OF TASK
T A 1 0 3 6 6 6
.-.
2-164
TM 9-2920-225-34 g.
Replacement.
(1) Models 5504AA and 5504AB.
FRAME 1
NOTE
1.
Make sure that connector leads (1) do not get damaged when pressing slipring end housing (2) onto rotor shaft (3).
Check that connector leads (1) are out of the way. Press slipring end housing (2) onto rotor shaft ( 3).
2.
Align scribe marks on slipring end housing (2) and stator (4). Put in six screws (5) with six lockwashers (6) and six tabbed washers (7).
GO TO FRAME 2
T A 1 0 3 6 6 7
2-165
TM 9-2920-225-34
FRAME 2
1.
Place connector elbow (1) on slipring end housing (2).
2.
Place connector cover (3) on elbow (1) so that cover seals slipring end housing (2).
Put in two screws (4), two screws ( 5), and four lockwashers (6).
GO TO FRAME 3
T A 1 0 3 6 6 8
TM 9-2920-225-34
FRAME 3
1.
Put two key washers (1) on terminals (2).
2.
Place leads (3) on two terminals (2) as tagged. Take off tags.
3.
Put two nuts (4) and lockwashers (5) on two terminals (2). Lock nuts.
by bending tabs on washers (1).
4.
Push four brushes (6) all the way into brush holders (7).
NOTE
END OF TASK
Follow-on Maintenance Action Required:
Replace fan and hub assembly. Refer to para 2-17.
T
2-167
TM 9-2920-225-34
(2) Model 5300GP.
FRAME 1
NOTE
Make sure that connector leads (1) do not get damaged when pressing slipring end housing (2) onto rotor shaft (3).
1.
Check connector leads (1) and press slipring end housing (2) into rotor shaft ( 3).
2.
Align scribe marks on slipring end housing (2) and stator (4). Put in seven screws (5) and seven lockwashers (6).
GO TO FRAME 2
T A 1 0 4 2 5 5
I
2-168
TM 9-2920-225-34
FRAME 2
1,
Put on cover plate (1).
Put in four screws (2) with four lockwashers ( 3).
GO TO FRAME 3
TA 104256
2-169
`TM 9-2920-225-34
FRAME 3
1.
2.
3.
Push four brushes (1) and four brush levers (2) in place.
Put two key washers (3) and four brush leads (4) on two terminals (5).
Put two terminal leads (6), two nuts (7), and lockwashers (8) on two terminals (5).
Bend up tabs on two key washers (3).
N O T E
Follow-on Maintenance Action Required:
Replace fan and hub assembly. Refer to para
END OF TASK
TA 104257
2-170
TM 9-2920-225-34
2-19. DRIVE END BELL AND ROTOR ASSEMBLY.
TOOLS: No special tools required
SUPPLIES: None
PERSONNEL: One
EQUIPMENT CONDITION :
Generator removed from vehicle, pulley removed from generator.
a. Preliminary Procedures.
(1) Clean outside of generator before disassembly. Refer to para 1-3.
(2) Remove fan and hub assembly. Refer to para 2-17.
(3) Remove slipring end housing. Refer to para 2-18.
b.
Removal.
(1) Models 5504AA and 5504AB.
FRAME 1
I
1.
Straighten tabs on six locking plates (1). Take out 12 screws (2) and lockwashers (3) and six locking plates.
2.
Take off coupling cover (4).
Pull out driveshaft (5) and take two drive blocks (6) from block holder (7).
3.
Take retaining ring (8) from rotor shaft (9) and take off block holder (7).
GO TO FRAME 2
TA 103670
2-171
I
TM 9-2920-225-34
FRAME 2
1.
Scribe a mark across drive end bell (1) and stator (2).
2.
Take out seven screws (3) and lockwashers (4).
3.
Take drive end bell (1) and rotor (5) assembly out of stator (2).
4.
Using puller, press rotor (5) out of drive end bell ( 1).
5* Take out machine key (6).
END OF TASK
TA 103671
2-172
TM 9-2920-225-34
(2) Model 5300GP.
FRAME 1
I
1.
Scribe a mark across stator (1) and drive end bell (2).
2.
Take out seven screws (3) and lockwashers (4).
3.
Take drive end bell (2) and rotor (5) assembly out of stator (l).
4.
Take woodruff key (6) out of shaft of rotor (5).
5.
Using puller, drive shaft of rotor (5) from drive end bell (2).
END OF TASK
TA 103672
2-173
TM 9-2920-225-34 c .
Disassemble.
FRAME 1
NOTE
If
1.
Using arbor press, take drive end housing bearing (1) off
(2) as shown.
On model 5300GP, take washer (3) off shaft shaft of rotor of rotor (2).
END OF TASK
Bearing (1) may come off with drive end housing.
so, press out bearing from drive end housing.
TA 103673
2-174
TM 9-2920-225-34 d.
Cleaning.
There are no special cleaning procedures needed. Refer to
cleaning procedures given in para 1-3.
e .
Inspection and Repair.
(1) Inspection.
1.
2.
3.
4.
5.
NOTE
If rotor (1) is not within limits given in tables 2-6 and
2-7, generator is nonrepairable.
Measure outside diameter of sliprings (2).
Measure outside diameter of shaft at fan end bearing seat (3).
Measure outside diameter of shaft at fan hub seat (4).
Measure outside diameter of shaft at drive end bearing seat (5).
Measure outside diameter of shaft at drive end (6).
NOTE
If bearing (7) is not within limits given in tables
6.
7.
Measure drive end bearing (7) inside diameter (8).
Measure drive end bearing (7) outside diameter (9).
GO TO FRAME 2
2-175
TM 9-2920-225-34
Table 2-6. Drive End Bell and Rotor Assembly (Models 5504AA and 5504AB)
Wear Limits
Index
Number Item /Point of Measurement
Size and Fit of New Parts
(inches)
Wear Limits
(inches)
2
3
4
6
5
8
9
Outside diameter of slipring
Outside diameter of shaft at fan bearing seat
Outside diameter of shaft at fan hub seat
Outside diameter of shaft at drive end bearing seat
Outside diameter of shaft at drive end
Inside diameter of drive end bearing
Outside diameter of drive end bearing
1.8430 to 1.8530
0.7874 to 0.7878
0.6250 to 0.6255
0.9842 to 0.9846
0.6245 to 0.6250
0.9839 to 0.9843
2.0467 to 2.0472
1.7500
None
None
None
None
None
None
Table 2-7. Drive End Bell and Rotor Assembly (Model 5300GP) Wear Limits
Index
Number Item /Point of Measurement
Size and Fit of New Parts
(inches)
Wear Limits
(inches)
6
2
3
4
5
8
9
Outside diameter of slipring
Outside diameter of shaft at fan end bearing seat
Outside diameter of shaft at fan hub seat
1.8480 to 1.8530
0.7874 to 0.7878
0.6250 to 0.6255
Outside diameter of shaft at drive end bearing seat
0.9843 to 0.9847
Outside diameter of shaft at drive end
0.8740 to 0.8745
Inside diameter of drive end bearing
0.9839 to 0.9843
Outside diameter of drive end bearing
2.4404 to 2.4409
1.7500
None
None
None
None
None
None
2-176
TM 9-2920-225-34
NOTE
If end bell is damaged or is not within limits given in
tables 2-8 and 2-9, generator is nonrepairable.
1.
Check that drive end bell (1) is not cracked, bent or warped.
2.
Measure inside diameter of drive end bell (1) bearing bore ( 2).
NOTE
When working on models 5504AA and 5504AB, if any part of drive assembly is damaged, generator is nonrepairable.
3.
Check that block holder ( 3), retaining ring (4), drive blocks (5), drive shaft (6), and coupling cover ( 7) are not bent, broken cracked or warped.
GO TO FRAME 3
MODELS 5504AA AND 5504AB MODEL 5300GP
TA 103675
Index
Number
Table 2-8. End Bell Housing (Models 5504AA and 5504AB) Wear Limits
Item /Point of Measurement
Size and Fit of New Parts
(inches)
Wear Limits
(inches)
2
Inside diameter of drive end bell bearing bore
2.0465 to 2.0468
None
Index
Number
2
Table 2-9.
End Bell Housing (Model 5300GP) Wear Limits
Item /Point of Measurement
Size
and Fit of New Parts
(inches)
Wear Limits
(inches)
Inside diameter of drive end bell bearing bore
2.4407 to 2.4412
None
2-177
TM 9-2920-225-34
1.
2.
Check that bearing (1) is not damaged.
Refer to TM 9-214. If bearing is damaged, get a new one.
Using multimeter, check rotor (2) for grounds by touching one test probe of multimeter to rotor shaft (3) and other test probe to one slipring (4).
Ohmmeter reading must be over 10,000 ohms. If it is not, generator is nonrepairable.
Do step 2 again for other slipring (4).
3.
4.
5.
6.
Using multimeter, check resistance of sliprings (4) by touching ohmmeter probes to each slipring.
Resistance must be between 1.5 and 2.5 ohms.
If it is not, generator is nonrepairable.
test
Check slipring (4) runout. Refer to para 2-9e.
Check that rotor shaft (3) is straight. Refer to para 2-9e.
END OF TASK
TA 103676
2-178
TM 9-2920-225-34
(2) Repair.
1.
If runout of sliprings (1) is more than 0.001 inch, send rotor (2) to machine shop to have sliprings turned down.
END OF TASK
Index
Number
A
Item/Point of Measurement
Outside diameter of sliprings
Size and Fit of New Parts
(inches)
1.8430 to 1.8530
Wear Limits
(inches)
1.7500
Figure 2-9. Sliprings (Models 5504AA, 5504AB , and 5300GP) Allowable Wear Limits
2-179
TM 9-2920-225-34 f.
Assembly.
FRAME 1
1.
Using arbor press, press drive end bearing (1) (models 5504AA and 5504AB) or drive end bearing and washer (2) (model 5300GP) onto rotor shaft (3).
END OF TASK
TA 103679
TM 9-2920-225-34
1.
Put woodruff key (1) in shaft of rotor (2).
2.
Press rotor (2) and drive end bell (3) together.
3.
Place rotor (2) and drive end bell (3) assembly into stator (4).
4.
Aline scribe marks, and put in seven screws (5) and lockwashers (6).
GO TO FRAME 2
TA 103680
2-181
TM 9-2920-225-34
FRAME 2
1.
Put block holder (1) on rotor shaft (2) with retaining ring (3).
2.
3.
4.
Put two drive blocks (4) and drive shaft (5) in block holder (l).
Put coupling cover (6) in place.
Put in six locking plates (7),
12 lockwashers (8), and 12 screws (9).
Bend tabs on six locking plates (7).
NOTE
END OF TASK
Follow-on Maintenance Action Required:
1.
Replace slipring end housing. Refer to para
2.
Replace fan and hub assembly. Refer to para
TA 103681
2-182
TM 9-2920-225-34
(2) Model 5300GP.
1.
Press drive end bell (1) and rotor (2) together.
2.
Put woodruff key (3) in keyway of rotor (2) shaft.
3.
Put drive end bell (1) and rotor (2) assembly into stator (4).
4.
Aline scribe marks and put in seven screws (5) and lockwashers (6).
NOTE
END OF TASK
Follow-on Maintenance Action Required:
1.
Replace slipring end housing. Refer to para
2.
Replace fan and hub assembly. Refer to para
TA 103682
2-183
TM 9-2920-225-34
2-20.
STATOR AND CONNECTOR ASSEMBLY.
TOOLS : No special tools required
SUPPLIES:
None
PERSONNEL: One
EQUIPMENT CONDITION: a. Preliminary Procedures.
Generator removed from vehicle, pulley removed from generator.
(1) Clean outside of generator before disassembly. Refer to para l-3.
(2) Remove fan and hub assembly. Refer to para 2-17.
(3) Remove slipring end housing. Refer to para 2-18.
(4) Remove drive end bell and rotor assembly. Refer to para 2-19.
—
2-184
TM 9-2920-225-34 c.
Inspection.
FRAME 1
1.
2.
Check that stator (1) and connector (2) have no cracks or breaks. If cracks or breaks are found, generator is nonrepairable,
Check that connector (2) has no loose rims or stripped threads. If connector is damaged, generator is nonrepairable.
CAUTION
3.
Do not use a battery or test lamp test.
Reverse battery connection instantly.
to make a continuity will burn out diodes
Using multimeter, check stator (1) for continuity. Touch test probes of multimeter to pins (3, 4, and 5, and 3 and 5). Multimeter must show continuity between each set of pins.
NOTE
4.
Pins (6, 7, and 8) are not tested for continuity. Make sure that they are not touching stator (1).
Using multimeter, check stator (1) for open circuits.
Touch one test probe of multimeter to stator housing, and the other test probe to each pin (3 through 8) on connector (2).
Each check must show an open circuit.
END OF TASK
TA 103683
2-185
TM 9-2920-225-34 d.
Repair.
FRAME 1
1.
2.
Solder loose or broken connections on stator (1) and connector (2).
Retest stator (l) and connector (2) assembly after soldering. Refer to
2-20c.
If continuity is not made between pins (3, 4, and 5), generator nonrepairable.
If there is ground between any pins (3 through 8) and housing (1), generator is nonrepairable.
para is
NOTE
Follow-on Maintenance Action Required:
1.
Replace drive end bell and rotor assembly. Refer
2.
Replace slipring end housing. Refer to para
3.
Replace fan and hub assembly. Refer to para
END OF TASK
TA 103683
2-186
TM 9-2920-225-34
Section VII.
LEECE-NEVILLE GENERATOR MODEL 2184AC
2-21. FAN, END BELL, AND ROTOR ASSEMBLY.
TOOLS: No special tools required
SUPPLIES :
Brush holder preformed packing
Lip seal (2)
End housing preformed packing (2)
Sealant, MIL-S-45180
Ball bearing and roller bearing grease, MIL-G-18709
Masking tape, PPP-T-42C
PERSONNEL: One
EQUIPMENT CONDITION : Generator removed from vehicle, pulley removed from generator.
a. Preliminary Procedure.
Clean generator before disassembly. Refer to
2-187
TM 9-2920-225-34
1.
Take rubber sealant off brush holder terminals (1).
2* Take off nut (2) and lockwasher (3).
Tag and take off terminal (1).
3.
Take off nut (4), lockwasher (5), and spacer (6).
4.
Take out brush holder ( 7), brush (8), preformed packings (9), and screw with washer ( 10). Throw packings away.
5.
Do steps 2 through 4 again for other brush assembly.
GO TO FRAME 2
2-188
TA 103684
TM 9-2920-225-34
1.
Take screw ( 1), washer (2), fan ( 3), and woodruff key (4) off rotor shaft ( 5).
2.
Take nut (6), washer (7), and woodruff key (8) off drive end of rotor shaft (9).
GO TO FRAME 3
TA 103685
2-189
TM 9-2920-225-34
FRAME 3
I
1.
Scribe a line across end bell (1) and shroud (2).
2.
Take out four screws ( 3).
3.
Using puller, take out end bell (1) and rotor (4) assembly from drive end bell (5) and stator (6) assembly.
END OF TASK
TA 103686
2-190
TM 9-2920-225-34 c .
Disassembly.
1.
Using puller, drive rotor (1) from end bell (2).
2.
Take out two lip seals (3), two spacers (4), two preformed packings (5), packing (6), and bearing (7) from end housing (2). Throw away seals and packings.
END OF TASK
TA 103687
2-191
1.
2.
3.
4.
5.
NOTE
If rotor (1) is not within limits given in table 2-10,
generator is nonrepairable.
Measure outside diameter of shaft (2) at end housing.
Measure outside diameter of sliprings (3).
Measure outside diameter of drive end bearing seat (4).
Measure outside diameter of drive end of shaft (5),
NOTE
If end housing (6) is not within limits given in table
2-10, generator is nonrepairable.
Measure inside diameter of end housing bearing bore ( 7).
NOTE
If bearing (8) is not within limits given in table 2-10,
get a new bearing.
Measure bearing (8) inside diameter (9).
6.
7.
Measure bearing (8) outside diameter ( 10).
GO TO FRAME 2
NOTE: CHECK ONLY THOSE PARTS WHICH
ARE CALLED OUT IN THIS FRAME.
PARTS WITHOUT CALLOUTS ARE
SHOWN ONLY FOR REFERENCE
PURPOSES OR ARE CHECKED IN
ANOTHER FRAME.
2-192 o
10
TA 103688
TM 9-2920-225-34
Table 2-10. Fan, End Bell, and Rotor Assembly (Model 2184AC ) Wear Limits
Index
Number
2
4
5
3
7
9
10
Item /Point of “Measurement
Outside diameter of shaft at end housing
Outside diameter of sliprings
Outside diameter of drive end bearing seat of shaft
Outside diameter of drive end of shaft
Inside diameter of end housing bore
Inside diameter of end housing bearing
Outside diameter of end housing bearing
Size and Fit of New Parts
(inches)
0.6695 to 0.6693
1.6350 to 1.620
0.9847 to 0.9844
0.8745 to 0.8740
1.5746 to 1.5751
0.693 to 0.6690
1.5748 to 1.5743
Wear Limits
(inches)
None
1.580
None
None
None
None
None
2-193
TM 9-2920-225-34
FRAME 2
I
1.
2.
3.
4.
5.
6.
7.
Check that fan (1) is not cracked or broken.
If fan is damaged, generator is nonrepairable.
Check that end bell (2) has no cracks, breaks or warping. If end bell is damaged, generator is nonrepairable.
Check that all screws (3) are not bent or broken and that they have no damaged heads or stripped threads.
If screws are damaged, get new ones.
Check that spacers (4) and washers (5) are not cracked or worn. If parts are damaged, get new ones.
Check that woodruff keys (6) are not bent or broken. If keys are damaged, get new ones.
Check that nut (7) and washer (8) are not worn, stripped or damaged. If parts are damaged, get new ones.
Check that bearing (9) is not damaged. Refer to TM 9-214. If bearing is damaged, get a new one.
GO TO FRAME 3
NOTE: CHECK ONLY THOSE PARTS WHICH
ARE CALLED OUT IN THIS FRAME.
PARTS WITHOUT CALLOUTS ARE
SHOWN ONLY FOR REFERENCE
PURPOSES OR ARE CHECKED IN
ANOTHER FRAME.
2-194
TA 103689
TM 9-2920-225-34
1.
Check that nuts (1), washers (2), and screw (3) are not worn, stripped, bent or broken and that they have no damaged threads. If parts are damaged, get new ones.
2.
Check that brush holder (4) is not cracked or broken. If brush holder is damaged, get a new one.
3.
Check that brushes (5) are not oil soaked, that they have no loose leads, and that they are not less than 1/4 inch long. If brushes are worn or damaged, get new ones.
GO TO FRAME 4
NOTE: CHECK ONLY THOSE PARTS WHICH
ARE CALLED OUT IN THIS FRAME.
PARTS WITHOUT CALLOUTS ARE
SHOWN ONLY FOR REFERENCE
PURPOSES OR ARE CHECKED IN
ANOTHER FRAME.
TA 103690
2-195
TM 9-2920-225-34
FRAME 4
I
Check that rotor shaft (1) has no burred or stripped threads.
1.
2.
Check that rotor (2) has no grounds using multimeter by touching one test probe of multimeter to rotor shaft (1) and other test probe to one slipring
(3). Ohmmeter reading must be more than 10,000 ohms. If ohmmeter reading is not more than 10,000 ohms, generator is nonrepairable.
Do step 2 again for other slipring (3).
3.
4.
5.
6.
Check sliprings (3) resistance using multimeter by touching test probes of multimeter to each slipring.
Resistance must be between 1.8 to 2.0 ohms.
If resistance is not within limits, generator is not repairable.
Check sliprings (3) runout. Refer to para 2-9e.
Check that rotor shaft (1) is straight. Refer to para 2-9e.
END OF TASK
TA 103691
2-196
TM 9-2920-225-34
1.
If shaft threads (1) are damaged, clean up threads with a die.
cannot be fixed, generator is not repairable.
If threads
2.
If runout of sliprings (2) is over 0.001 inch, send rotor (3) to
to have sliprings turned. See figure 2-10.
machine shop
END OF TASK
TA 103692
TA 103693
Item
Number
A
Item /Point of Measurement
Outside diameter of sliprings
Size and Fit of New Parts
(inches)
1.635 to 1.620
Figure 2-10.
Sliprings (Model 2184AC ) Wear Limits
Wear Limits
(inches)
1.580
2-197
TM 9-2920-225-34 g.
Assembly.
FRAME 1
1.
2.
3.
4.
Put preformed packing (1) in bearing bore of end housing (2).
Press lip seal (3) into rotor side of end housing (2) with smooth side of seal facing away from housing.
Coat outer edge of seal with sealant.
Place end housing (2) on short end of rotor shaft (4).
Slide spacer (5) over shaft (4) with counterbore facing away from rotor (6).
Put a light coating of grease around spacer and seal (3).
Put preforming packing (7) over shaft (4) into spacer (5).
5.
6.
7.
8.
9.
Press bearing (8) onto shaft (4) into end housing (2). Make sure to hold up both rotor (6) and end housing.
Fill cavity behind bearing (8) with grease.
Put preformed packing (7) into spacer (5) and slide spacer onto shaft (4) with counterbore facing rotor (6).
Put lip seal (3) into end housing (2) with smooth side of seal facing outward.
Coat outer edge of seal with sealant.
END OF TASK
TA 103694
2-198
I
I
1 i
TM 9-2920-225-34 h.
Replacement.
FRAME 1
1.
Slide end bell (1) and rotor (2) assembly into stator (3) and drive end bell (4) assembly.
2.
Aline scribe marks on end bell (1) and stator shroud (3) and put in four screws (5).
GO TO FRAME 2
TA 103695
2-199
TM 9-2920-225-34
FRAME 2
I
1.
Put woodruff key (1) into rotor shaft (2).
2.
Slide fan (3) onto rotor shaft (2) and put in screw (4) and washer (5).
Tighten screw (4) to 115 to 130 pound-inches.
3.
Put nut (6), washer (7), and woodruff key (8) onto rotor shaft (9).
Put tape around key.
GO TO FRAME 3
TA 103696
..-.
TM 9-2920-225-34
1.
Put preformed packing (l), preformed packing (2), guard washer (3), and screw (4) into brush holders (5).
Put brushes (6) into brush holders.
2.
Put leads (7)onto brush holders (5) as tagged. Takeoff tags. Put on guard washer (8), two lockwashers (9), and two nuts (10).
3.
Put brush holders (5) into place.
Put sealant over brush holders.
END OF TASK
TA 103697
2-201
TM 9-2920-225-34
2-22. DRIVE END HOUSING AND STATOR ASSEMBLY.
TOOLS : No special tools required
SUPPLIES :
Rivet (3)
End housing lip seal
End housing preformed packing
PERSONNEL: One
EQUIPMENT CONDITION : Generator removed from vehicle, pulley removed from generator.
a.
Remove fan, end bell, and rotor assembly. Refer
b.
Disassembly.
FRAME 1
I
1.
Take out three rivets (1) and take off shroud (2) .
2.
Scribe a mark across stator (2) and drive end bell (4).
3.
Tag three stator leads (5).
4.
Take out three screws (6) with lockwashers (7) and take stator leads (5) off rectifier mounts (8). Take off stator ( 3).
GO TO FRAME 2
TA 10369S
2-202
I
I
I
I
TM 9-2920-225-34
1.
Take out four screws (1) with lockwashers (2). Lift cover (3) away to reach connector (4) wiring.
2.
Unsolder diode leads (5) from connector (4) and take connector (4) off housing (6) .
GO TO FRAME 3
TA 103699
2-203
TM 9-2920-225-34
FRAME 3
1.
Take out six screws (l), guard washers (2), spring tension washer (3), insulation washers (4), sleeves (5), and guard washers (6). Take rectifier mounts (7) out of housing (8).
2.
NOTE
Rectifier (9) must be kept apart from rectifiers (10).
Take out three rectifiers (9) and three rectifiers ( 10) from rectifier mounts (7).
GO TO FRAME 4
TA 103700
I
TM 9-2920-225-34
FRAME 4
I
1.
Take out four screws (1) and take bearing retainer (2) from drive end housing ( 3).
2.
Press bearing (4), preformed packing (5), spacer (6), washer (7), and lip seal (8) from bore of end housing ( 3). Throw away preformed packing and seal.
END OF TASK
TA 103701
I
2-206 d.
Inspection and Repair.
FRAME 1
I
1.
2.
3.
4.
5.
6.
Check that drive end housing (1) has no cracks or breaks. If end housing is damaged, generator is nonrepairable.
Measure bearing bore (2) of drive end housing (1). Bore must be 2.4412 to
2.4407 inches.
If bore is not within given limits, generator is nonrepairable.
Check that rectifier mounts (3) are not cracked or broken and no damaged threads.
that they have
Check that connector (4) has no damage, stripped threads, or wiring.
If connector is damaged, generator is nonrepairable.
loose or frayed
Check that screws (5) and washers (6) do not have damaged heads and that they are not broken.
If parts are damaged, get new ones.
Check that terminal cover (7) is not cracked or broken. If terminal cover is damaged, get a new one.
GO TO FRAME 2
TA 103702
I
I
TM 9-2920-225-34
FRAME 2
CAUTION
1.
2.
Do not use a battery or test lamp to make a continuity test.
Reverse battery connection will burn out diodes instantly.
Check stator (1) for continuity using multimeter. Touch test probe of multimeter to each pair of stator leads (2).
If there is not continuity between all three stator leads, generator is not repairable.
Check that stator shroud (3) is not cracked or broken.
If shroud is damaged, generator is not repairable.
NOTE
3.
On ohmmeters that use one 1 l/2-volt dry cell, low resistance readings will be approximately 20 to 30 ohms. On ohmmeters that use a 3-volt dry cell, low resistance readings will be approximately 10 to
15 ohms.
Using multimeter, check three positive rectifiers (4) by touching positive test probe of multimeter to base of rectifier and negative test probe to top of rectifier. Multimeter must show low resistance. If multimeter does not show low resistance, get a new rectifier.
4.
Using multimeter, check three negative rectifiers (5) by touching positive test probe of multimeter to base of rectifier and negative test probe to the top of rectifier.
Multimeter must show low resistance. If multimeter does not show low resistance, get a new rectifier.
GO TO FRAME 3
TA 103703
2-207
TM 9-2920-225-34
FRAME 3
NOTE
If any part is damaged, generator is nonrepairable.
1.
Check that all screws insulating sleeves (4)
(1), washers (2), insulating washers (3), and are not broken or worn and that they have no damaged-heads or stripped threads.
2.
Check that bearing retainer (5), washer (6), and spacer (7) are not cracked or broken.
GO TO FRAME 4
2-208
NOTE: CHECK ONLY THOSE PARTS WHICH
ARE CALLED OUT IN THIS FRAME.
PARTS WITHOUT CALLOUTS ARE
SHOWN ONLY FOR REFERENCE
PURPOSES OR ARE CHECKED IN
ANOTHER FRAME.
TA 103704
TM 9-2920-225-34
1.
Measure inside diameter of bearing (1).
Inside diameter (2) must be 0.9847
to 0.9844 inches.
If bearing is not within given limits, get a new bearing.
2.
Measure outside diameter of bearing (1).
Outside diameter (3) must be 2.4412
to 2.4407 inches.
If bearing is not within given limits, get a new bearing.
3.
Check that bearing (1) is not damaged. Refer to TM 9-214.
4.
Check that nut (4) and washer (5) are not stripped, worn or damaged.
If parts are damaged, get new ones.
END OF TASK
NOTE: CHECK ONLY THOSE PARTS WHICH
ARE CALLED OUT IN THIS FRAME.
PARTS WITHOUT CALLOUTS ARE
SHOWN ONLY FOR REFERENCE
PURPOSES OR ARE CHECKED IN
ANOTHER FRAME.
TA 103705
2-209
TM 9-2920-225-34 e. Assembly.
FRAME 1
1.
Press seal (1) and bearing (2) into bore of drive end housing ( 3).
2.
Place preformed packing (4) in spacer (5) and put spacer to bearing (2).
3.
Put washer (6) and bearing retainer (7) on drive end housing (3) and put in four screws (8).
GO TO FRAME 2
T A 1 0 3 7 0 6
TM 9-2920-225-34
FRAME 2
I
NOTE
Have machine shop make rectifier
installing tool.
1.
Using rectifier installing tool, put in three rectifiers (2).
rectifiers (1) and three
2.
Put rectifier mounts (3) into housing (4).
Put in six screws (5), guard
(9) and guard washers (10).
GO TO FRAME 3
I
I
I
TA 103708
Figure 2-11.
Rectifier Installing Tool Fabrication Instructions
2-211
TM 9-2920-225-34
FRAME 3
I
1.
2.
3.
Place connector (1) on housing (2).
Solder diode leads (3) to connector (1).
Put on cover (4) and put in four screws (5) with four lockwashers (6).
GO TO FRAME 4
-TA 103709
2-212
.
TM 9-2920-225-34
1.
Put stator (1) to drive end housing (2).
2, Put stator (1) leads to rectifier mounts as tagged. Put in three screws (4) and lockwashers (5).
Take off tags.
3.
Place shroud (6) over stator (1) and put in three rivets (7).
NOTE
END OF TASK
Follow-on Maintenance Action Required:
Replace fan, end bell, and rotor assembly. Refer to
TA 103710
2-213
TM 9-2920-225-34
Section VIII.
TESTS AND ADJUSTMENTS
2-23. TEST SETUP USING SUN MODEL (NSN 4910-00-767-0218) TEST STAND.
1.
Place woodruff key (1) in shaft (2).
2.
Aline pulley keyway (3) with key (1).
Push pulley (4) onto shaft (2).
3.
Put washer (5) on shaft (2) and put on nut (6).
4.
Place pulley (4) in vise with soft-jaw caps.
Using torque wrench, tighten nut (6) to 40 to 50 pound-feet.
5.
Take pulley (4) out of vise.
GO TO FRAME 2
TA 103527
2-214
TM 9-2920-225-34
1.
Swing pivot arm (1) to the right and aline three studs (2) with stud holes in pivot arm.
Let studs go into stud holes in pivot arm.
2.
Put mounting flange adapter (3) over studs in pivot arm (1). Put on 12 nuts
(4).
3.
Put key (5) in keyway (6) of pulley shaft (7).
Slide pulley shaft onto driving head (8).
Slide pulley adapter (9) onto studs of adapter flange (3).
4.
Put on six nuts ( 10).
GO TO FRAME 3
TA 118943
2-215
TM 9-2920-225-34
1.
Choose the right size pulley (1) to match pulley on generator to
Refer to TM 9-4910-485-12.
be mounted.
2.
Put key (2) in keyway (3) of pulley shaft (4). Slide pulley (1) over shaft.
3.
Put on retaining washer (5) and retainer (6).
GO TO FRAME 4
TA 088545
2-216
I
TM 9-2920-225-34
FRAME 4
CAUTION
1.
2.
3.
When putting generator (1) in chain vise, do not clamp vise over nameplates and raised surfaces.
Generator can come loose and damage equipment.
Put generator (1) on mounting bracket (2) and tighten chain vise (3).
Loosen four nuts (4) and aline generator pulley (5) with test stand pulley (6).
Tighten four nuts.
Loosen four nuts (7) behind generator mounting bracket (2). Lift mounting bracket and place belts (8) on test stand pulley (6) and generator pulley (5).
4.
Take up slack on belts (8) and tighten four nuts (7).
END OF TASK
TA 118944
2-217
TM 9-2920-225-34 b.
Test Stand Base Setting.
FRAME 1 I
1.
Set MAIN POWER switch (1) to OFF position.
2.
Set DC AMMETER LOAD AND STARTER selector (2) to 500 amperes.
3.
Set DC AMMETER FIELD AND BATTERY selector (3) to 30 amperes.
4.
Set MILLIVOLT METER RANGE selector (4) to 9 volts.
5.
Set DC VOLTMETER RANGE selector (5) to 50 volts.
6.
Set DC VOLTMETER CIRCUIT selector (6) to RECT /GEN position.
7.
Turn TACHOMETER PULLEY CALIBRATION control (7) to the left.
8.
Set TACHOMETER CIRCUIT selector (8) to DIRECT DRIVE position.
GO TO FRAME 2
TA 103727
TM 9-2920-225-34
FRAME 2
I
1.
2.
Set AC AMMETER RANGE selector (1) to highest range.
Set AC AMMETER PHASE selector (2) to PHASE A position.
3.
4.
5.
6.
Set AC VOLTMETER RANGE selector (3) to 50V position.
Set AC VOLTMETER CIRCUIT selector (4) to OFF position.
Set EQUALIZER COIL switch (5) to OFF position.
Set IGNITION switch (6) to OFF position.
7.
Hook up bus bar from B+ (7) to G+ (8) terminals of REGULATOR binding post.
8.
Hook up a bar bar from B- (9) to G- ( 10) terminals of REGULATOR binding post.
GO TO FRAME 3
T A 0 8 8 5 2 7
2-219
TM 9-2920-225-34 m
1.
Set POWER SUPPLY switch (1) to OFF position.
2.
Set BATTERY CHARGER switch (2) to OFF position.
3.
Set EXTERNAL FIELD switch (3) to OFF position.
4.
Set
FIELD COMMON switch (4) to NEGATIVE position.
5.
Set FIELD CIRCUIT switch (5) to REGULATOR position.
6.
Set RELAY LAMP switch (6) to OFF position.
7.
Set REGULATOR LOAD RESISTOR selector (7) to OFF position.
8.
Set
GROUND POLARITY switch (8) to negative
(-) position.
9.
Set BATTERY selector (9) to OFF position.
GO TO FRAME 4
●
TA 088534
2-220
I
TM 9-2920-225-34
FRAME 4
I
1.
2.
3.
4.
5.
Set STARTER TEST switch (1) to OFF position.
Turn STARTER VOLTAGE knob (2) to the left.
Set all LOAD BANK switch (3) to OFF position.
Set MASTER LOAD switch (4) to OFF position.
Turn FIELD CURRENT RHEOSTAT (5) to the left.
6.
7.
Turn VARIABLE LOAD (6) to the left.
Turn POWER SUPPLY (7) to the left.
8.
Set CHARGE TIMER (8) to OFF position.
9.
Turn BATTERY CHARGER control (9) to the left.
10. Turn 400A CONTROL BOX VOLTAGE ADJUST knob (10) to the left.
END OF TASK
TA 103716
2-221
TM 9-2920-225-34 c. Harness Connections.
(1) 60-ampere generator.
FRAME 1
1.
Hook up test lead (1) from generator B+ terminal (2) to G+ terminal (3) of generator binding post on test stand.
2.
Hook up test lead (4) from generator ground (5) to G- terminal (6) of generator binding post on test stand.
3.
Hook up test lead (7) from generator ignition lead (8) to F terminal (9) of generator binding post on test stand.
4.
Hook up test lead (10) between F-B terminal and IGN-SW terminal as shown.
END OF TASK
REGULATOR
B + B -
STARTER o
ALTERNATOR o
0 0 I
0
0 0
TA 103648
2 - 2 2 2
TM 9-2920-225-34
1.
Hook up special purpose cable (1) to generator connector (2) and hook up each lead of special purpose cable to alternator terminal and binding post on test stand as labeled.
2.
Hook up a bus bar (3) to GND terminal (4) and D terminal (5).
GO TO FRAME 2
STARTER
0
0
0 0
ALTERNATOR
GENERATOR
T A 1 0 3 7 1 7
2-223
TM 9-2920-225-34
FRAME 2
1.
Hookup rectifier (1)using two special purpose cables (2 and 3). Put leads onto rectifier terminals (4) on test stand as labeled.
2.
Put other ends of special purpose cables (2 and 3) into receptacles in rectifier (1).
END OF TASK
TA 103718
TM 9-2920-225-34 d.
Tachometer Calibration Information.
Find the speed of generator using the following formula:
(Y) = Diameter of test stand drive pulley.
generator.
I
1 .
Place DC AMMETER LOAD AND STARTER selector (1) in 150A position.
2.
Set DC AMMETER FIELD AND BATTERY CHARGER selector (2) in 5A position.
3.
Make sure that DC VOLTMETER RANGE selector (3) is in 50V position.
4.
Make sure that DC VOLTMETER CIRCUIT selector (4) is in RECT /GEN position.
5.
Set FIELD CIRCUIT switch (5) to REGULATOR position.
GO TO FRAME 2
/
●
TA 103719
2-225
TM 9-2920-225-34
●
FRAME 2
1.
Make sure that all LOAD BANK switches (1) are in OFF position.
2.
Make sure that GROUND POLARITY switch (2) is in negative (-) position.
3.
Make sure that IGNITION switch (3) is in OFF position.
4.
Turn FIELD CURRENT control (4) all the way to the left.
5.
Set BATTERY SELECTOR (5) to OFF position.
END OF TASK
TA 103720
. .
I
I
TM 9-2920-225-34
(2) 100-ampere generator.
1.
Place DC AMMETER LOAD AND STARTER selector (1) in 150A position.
2.
Set DC AMMETER FIELD AND BATTERY CHARGER selector (2) in 15A position.
3.
Make sure that DC VOLTMETER RANGE selector (3) is in 50V position.
4.
Make sure that DC VOLTMETER RANGE selector (2) is in RECT /GEN position.
5.
Set FIELD CIRCUIT switch (5) to MANUAL position.
GO TO FRAME 2
TA 103719
2-227
TM 9-2920-225-34
FRAME 2
I
1.
Make sure that all LOAD BANK switches (1) are in OFF position.
2.
Make sure that GROUND POLARITY switch (2) is in negative (-) position.
3.
Place AC AMMETER RANGE selector (3) in 100A position.
4.
Make sure that AC VOLTMETER RANGE selector (4) is in 50V position.
5.
Make sure that FIELD CURRENT control (5) is turned all the way to the left.
6.
Make sure that BATTERY selector (6) is in OFF position.
END OF TASK
2-228
TM 9-2920-225-34
2-24. TEST PROCEDURE.
a. 60-Ampere Generator.
1.
Set MAIN POWER switch (1) to ON position.
2.
Press START button (2) and hold it for three seconds. Turn DRIVE SPEED control (3) to the left until TACHOMETER (4) reads 2000 RPM.
3.
Turn TACHOMETER SELECTOR switch (5) to CAL position and turn CAL control (6) to right until TACHOMETER (4) reads generator speed. Refer
4.
Turn DRIVE SPEED control (3) until TACHOMETER (4) reads 2000 RPM.
5.
Turn FIELD CURRENT control (6) to the right.
6.
Turn BATTERY selector (7) to 24V position.
GO TO FRAME 2
TA 103722
2-229
TM 9-2920-225-34
1.
2.
3.
4.
5.
Turn on IGNITION switch (1) and note reading on DC LOAD AND STARTER
AMMETER (2) .
NOTE
DC LOAD AND STARTER AMMETER will read according to the state of charge of test stand batteries. As batteries become charged, reading will drop. Let test stand run for about 5 minutes before going on with test.
If DC LOAD AND STARTER AMMETER (2) reads over 10 amperes, turn on
25A and 0-25A switches on LOAD BANK (3).
If DC LOAD AND STARTER AMMETER (2) reads under 10 amperes, turn on
50A and 0-25A switches on LOAD BANK ( 3).
Set MASTER LOAD switch (4) to ON position.
Turn LOAD CURRENT CONTROL (5) slowly to the right until DC LOAD AND
STARTER AMMETER (2) reads 60 amperes.
At this point, DC VOLTMETER
(6) must read about 28 volts and DC FIELD AND STARTER AMMETER (7) must read one ampere or less.
6.
generator is nonrepairable.
END OF TASK
TA 103723
2-230
TM 9-2920-225-34
1.
Set MAIN POWER switch (1) to ON position.
2.
Press START button (2) and hold it for three seconds. Turn DRIVE SPEED control (3) to right until TACHOMETER (4) reads 2000 RPM.
3.
Turn TACHOMETER SELECTOR switch (5) to CAL position and turn
TACHOMETER CONTROL (6) to right until TACHOMETER (4) reads generator speed.
Refer to para 2-23d.
4, Turn DRIVE SPEED control (3) until TACHOMETER (4) reads 2000 RPM.
5.
Place BATTERY selector (7) in 24V position.
6.
Set 100A LOAD switch (8) and MASTER LOAD (9) to ON position.
GO TO FRAME 2
I
[
TA 103724
2-231
TM 9-2920-225-34
FRAME 2
CAUTION
1.
2.
3.
4.
Never let voltage on DC VOLTMETER (3) be more than 32 volts or ampere reading on DC FIELD AND
BATTERY CHARGER AMMETER (4) be more than
15 amperes or rectifier may be damaged.
Turn FIELD CURRENT control (1) to the right until DC LOAD AND STARTER
AMMETER (2) reads 100 amperes and DC VOLTMETER (3) reads 68 volts.
DC FIELD AND BATTERY CHARGER AMMETER (4) should read 9 to 11 amperes.
Turn AC AMMETER PHASE selector (5) through A, B, and C positions. AC
AMMETER should read about the same in all three positions.
Turn AC VOLTMETER selector (6) through T1-T2, T1-T3, and T2-T3 positions.
AC VOLTMETER (7) should read about the same in all three positions.
If DC FIELD AND BATTERY AMMETER (4) reads less than 9 amperes or more than 12 amperes, get a new regulator.
END OF TASK
TA 103725
.-
2-232
TM 9-2920-225-34
2-25. TEST SHUTDOWN.
1.
Turn FIELD CURRENT rheostat (1) all the way to the left.
2.
Turn MASTER LOAD switch (2) to OFF position.
3.
Turn IGNITION switch (3) to OFF position.
4.
Turn BATTERY selector (4) to OFF position.
5.
Turn TACHOMETER CIRCUIT selector (5) to DIRECT DRIVE position.
6.
Turn DRIVE SPEED control (6) to the right until TACHOMETER (7) reads
1,000 RPM.
7.
Press STOP button (8) and turn MAIN POWER switch (9) to OFF position.
8.
Set all switches and controls to their base settings. Refer to para 2-23b.
9.
Take off test cables (10).
END OF TASK
Q
9
TA 103726
2-233
TM 9-2920-225-34
FRAME 1
1.
2.
Turn FIELD CURRENT rheostat (1) fully to the left.
Turn MASTER LOAD switch (2) to OFF position.
3.
4.
Turn BATTERY selector (3) to OFF position.
Turn TACHOMETER SELECTOR switch (4) to DIRECT DRIVE position.
5.
Turn DRIVE SPEED CONTROL (5) to the right until TACHOMETER (6) reads 1,000 RPM.
Press STOP button (7) .
6.
7.
8.
9*
Set MAIN POWER switch (8) to OFF position.
Set all switches and controls to their base settings. Refer to para 2-23b.
Take off test cables (9).
END OF TASK
TA 118945
2-234
t
TM 9-2920-225-34
1.
Loosen four nuts (1).
Lift mounting bracket (2) and take off belts (3).
Tighten four nuts.
2.
Loosen chain vise grip (4) and take chain (5) off generator (6).
3.
Take off generator (6).
GO TO FRAME 2
TA 118946
2-235
TM 9-2920-225-34
.
FRAME 2
1.
Take out pulley retainer (1) and washer (2).
2.
Slide pulley (3) off pulley shaft (4).
3.
Take key (5) out of keyway (6) in pulley shaft (4).
GO TO FRAME 3
,,
TA 102024
TM 9-2920-225-34
1
0
Take off six nuts (1) from pulley shaft adapter (2). Pull out pulley shaft and pulley assembly (3). Take out key (4).
2.
Take off 12 nuts (5) from mounting flange adapter (6). Take off mounting flange adapter.
GO TO FRAME 4
TA 118947
TM 9-2920-225-34
FRAME 4 m
1.
Place generator pulley (1) in vise with soft jaw caps as shown.
2.
Take off nut (2) and flat washer (3) from shaft (4).
3.
Take pulley (1) out of vise.
4.
Pull pulley (1) off shaft (4) using puller (5),
END OF TASK
.
TA 049083
.
2-238
TM 9-2920-225-34
APPENDIX A
REFERENCES
A-1. GENERAL.
This appendix contains a list of references which appear in this technical manual.
A-2. PUBLICATION INDEXES .
Index of Technical Publications . . . . . . . . . . . . . . .
DA Pam 310-4
A-3. FORMS.
Quality Deficiency Report . . . . . . . . . . . . . . . . . . . . . . . . . . .
SF 368
Recommended Changes to Equipment
Publications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DA Form 2028-2
A-4. TECHNICAL MANUALS.
Inspection, Care and Maintenance of
Antifriction Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TM 9-214
Direct Support and General Support
Maintenance Repair Parts and Special Tools
Lists (Including Depot Maintenance Repair Parts and Special Tools): Generator, Engine Accessory
(Alternating Current) Prestolite Model AMA-5102UT
(FSN 2920-90$2483) Leece-Neville Models 3002AC and 3002AD (FSN 2920-909-2483) , 5504AA and
5504AB (FSN 2920-475-1446), 2184AC (FSN
2920-782-1955) 5300GP (FSN 2920-818- 8635). . . . .
TM 9-2920-225-34P
Operator and Organizational Maintenance
Manual (Including Repair Parts and Special
Tools List): Test Stand, Automotive Generator,
Alternator and Starter, Floor Mounted, 10 to 50V
500 Amp, DC and 25 to 50V, 100 to 400 Amp, AC,
Testing Ranges W/8000 to 12000 RPM, 22 1/2 HP,
220/440V, 60 Cycle, 3 Phase, Dual Head Vari-
Drive Assembly (Sun Electric Corporation Model
AGT-9 and AGT-9A (FSN 4910-767-0218) . . . . . . . . . . . .
TM 9-4910-485-12
The Army Maintenance Management
System (TAMMS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TM 38-750
Painting Instructions for Field Use . . . . . . . . . . . . . . . . . TM 43-0139
Equipment Improvement Report and Maintenance
Summary for TARCOM Equipment . . . . . . . . . . . . . . . . . . .
TM 43-0143
A-5. TECHNICAL BULLETINS.
Equipment Improvement Report and
Maintenance Digest: Tank and Automotive
Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TB 43-000139-1, -2,
-3, -4
A-1 (A-2 blank)
TM 9-2920-225-34
By Order of the Secretaries of the Army and the Air Force:
E. C. MEYER
General, United States Army
Chief of Staff
Official:
J. C. PENNINGTON
Major General, United States
The Adjutant General
Army
LEW ALLEN, JR., General, USAF
Chief of Staff
Official:
VAN L. CRAWFORD, JR., Colonel, USAF
Director of Administration
Distribution:
To be distributed in accordance with DA Form 12-38, Direct and General Support Maintenance requirements for 1/4 Ton Truck, Utility, and 1/4 Ton Truck, Ambulance: Ml51.
P U B L I C A T I O N N U M B E R
TM 9-2920-225-34
BE EXACT PIN-POINT WHERE IT
IS
RECOMMENDED CHANGES TO EQUIPMENT TECHNICAL PUBLICATIONS
PHONE NUMBER
PUBLICATION NUMBER
TM 9-2920-225-34
BE
E X A C T
PAGE
NO
P I N - P O I N T W H E R E I T I S
.
—
PARA-
GRAPH
F I G U R E
NO
TABLE
NO
P U B L I C A T I O N D A T E
20 Feb 81
P U B L I C A T I O N T I T L E
ENGINE ACCESSORY GENERATOR,
DIR. & GEN. SUPPORT MAINTENANCE
IN
THIS
SPACE
TELL WHAT IS WRONG
AND WHAT SHOULD
BE
DONE ABOUT IT:
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I t
I i
I
.
—.,
THE
METRIC
SYSTEM AND
EQUIVALENTS
LINEAR MEASURE
1 . C e n t i m e t e r = 1 0 M i l l i m e t e r s = 0 . 0 1 m e t e r s 0 . 3 9 3 7 I n c h
1 Meter= 100 Centimeters= 1000 Millimeters =39.37 Inches
1 Kilometer= 1000 Meters= 0.621 Miles
WEIGHTS
1 Gram 0.001 Kilograms 1OOO Milligrams =0.035 Ounces
1
Kilogram =1000 Gains =2.2 Lb
1 Metric Ton 1000 Kilograms =1 Megagram =1.1 Short Tons
LIQUID MEASURE
1 Milliliter 0.001 Liters = 0.0338 Fluid Ounces
1 Liter
=
1000 Milliliters
=
33.82 Fluid Ounces
SQUARE MEASURE
1 Sq Centimeter = 100 Sq Millimeters
=
0.155
Sq
I n c h e s
1 Sq Meter= 10,000 Sq Centimeters
=
10.76 Sq Feet
1 Sq Kilometer= 1,020,000 Sq Meters= 0.386 Sq Miles
CUBIC MEASURE
1 Cu
Centimeter =1000 Cu Millimeters
=0.06 Cu
Inches
1 Cu Meter =1,000,000 C. Centimeters =35.31 C. Feet
T E M P E R A T U R E
5 / 9 ( ° F - 3 2 ) = ° C
212° Fahrenheit is equivalent to 100 Celsius
90 Fahreheit is equivalent to 32.2° Celsius
32° Fahrenheit is equivalent to 0 Celsius
9 / 5 C + 3 2 = F
O
APPROXIMATE CONVERSlON FACTORS
TO CHANGE
Inches. . . . . . . . . .
Feet. . . . . . . . . . .
Yards . . . . . . . . . .
Miles . . . . . . . . . .
Square Inches . . . . .
Square Feet . . . . .
Square Yards . . . . .
Square Miles . . . . . .
Acres . . . . . . . . . .
Cubic Feet. . . . . .
Cubic Yards . . . . . .
Fluid Ounces. . . . .
Pints . . . . . .
Quarts. . . . . . . .
Gal ions . . . . . . .
Ounces. . . . . . . .
Pounds . . . . . . . . .
Short Tons. . . . . . . .
Pound-Feet. . . . . .
P o u n d s p e r S q u a r e I n c h . .
Miles per Gallon. . . . .
Miles per Hour. . . . . .
T O M U L T I P L Y B Y
Centimeters. . . . . . . 2.540
Meters . . . . . . . . . 0.305
Meters . . . . . . . . . 0.914
Kilometers . . . . . .
1 . 6 0 9
S q u a r e C e n t i m e t e r s . . . 6 . 4 5 1
Square Meters. . . . . . 0.093
Square Meters. . . . . . 0.836
S q u a r e K i l o m e t e r s . . . . 2 . 5 9 0
S q u a r e H e c t o m e t e r s . . . 0 . 4 0 5
Cubic Meters . . . . . 0.028
Cubic Meters . . . . . . 0.765
Milliliters. . . . . . 29.573
Liters . . . . . . . . 0.473
L i t e r s 0 . 9 4 6
L i t e r s . . . . . . . . .
3 . 7 8 5
Grams. . . . . . . . . . 28.349
Kilograms. . . . . . . .
0 . 4 5 4
Metric Tons. . . . .
0 . 9 0 7
Newton-Meters. . . . .
1 . 3 5 6
Kilopascals. . . .
6 . 8 9 5
K i l o m e t e r s p e r L i t e r . .
0 . 4 2 5
K i l o m e t e r s p e r H o u r . . .
1 . 6 0 9
TO CHANGE
Centimeters . . . . . .
Meters. . . . . . . . .
Meters. . . . . . . . .
Kilometers. . . . . . .
S q u a r e C e n t i m e t e r s . . . .
Square Meters . . . . .
Square Meters . . . . .
S q u a r e K i l o m e t e r s . . . .
S q u a r e H e c t o m e t e r s . . . .
Cubic Meters. . . . . . .
Cubic Meters. . . . . . .
Milliliters . . . . . . .
Liters. . . . . . . . . .
Liters. . . . . . . . . .
Liters. . . . . . . . . .
Grams . . . . . . . . . .
Kilograms . . . . . . . .
Metric Tons . . . . . . .
Newton-Meters . . . . .
Kilopascals . . . . . .
K i l o m e t e r s p e r L i t e r . .
Kilometers per Hour . . .
TO
M U L T I P L Y B Y
Inches . . . . . . . . 0.394
Feet . . . . . . . .
3 . 2 8 0
Yards. . . . . . . . .
1 . 0 9 4
Miles. . . . . . . . .
0 . 6 2 1
Square Inches. . . . . . 0.155
Square Feet. . . . . . . 10.764
Square Yards . . . . . 1.196
Square Miles . . . . . . 0.386
Acres. . . . . . . . .
2 . 4 7 1
Cubic Feet . . . . . . . 35.315
Cubic Yards. . . . . .
1 . 3 0 8
Fluid Ounces . . . . . . 0.034
Pints. . . . . . . . . .
2 . 1 1 3
Quarts . . . . . . . . . 1.057
G a l l o n s .
. . . . . . . .
0 . 2 6 4
Ounces . . . . . . . . . 0.035
Pounds . . . . . . . . .
2 . 2 0 5
Short Tons . . . . . . .
1 . 1 0 2
Pound-Feet . . . . . . .
0 . 7 3 8
P o u n d s p e r S q u a r e I n c h .
0 . 1 4 5
Miles per Gallon . . . .
2 . 3 5 4
Miles per Hour . . . . .
0.621
T A 0 8 9 9 9 1
PIN: 018444-000
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Key Features
- Disassembly instructions
- Cleaning procedures
- Inspection guidelines
- Repair techniques
- Assembly steps
- Testing methods
- Adjustment procedures