Leece-Neville 2184 AC, 5300 GP, 5504 AA, AB, AMA 5102UT, 3002AC, 3002AD, 3002AE generator Technical manual

I

TM 9-2920-225-34

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

I

I

I

I

I

I

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

I

i

I

I

A LIMITED BASIS

- - - - - - - - — - - - - - - - - - -

DEPARTMENTS OF THE ARMY AND THE AIR FORCE

20 FEBRUARY 1981

C h a p t e r 2

Equipment

G r o u p

M a i n t e n a n c e

A p p e n d i x A

R e f e r e n c e s

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

CHAPTER 1.

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 . . . . . . . . .

1-1

1 - 2

* T h i s m a n u a l

~ supersedes TM 9-2920-225-34 dated 2 November 1973.

Page

1-1

1 - 1

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


Maintenance Summary (EIR MS)

. . . . . . . . . . . . .

Reporting Improvement Recommendations . . . . . .

Metric System

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Differences Between Models . . . . . . . . . . . . . .

Description and Data . . . . . . . . . . . . . . . . . . . .

CHAPTER 2.

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

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rotor, Stator, and Drive End Bell

Assembly

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Preliminary Procedures . . . . . . . . . . . . . . . . . . . . .

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Assembly

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Paragraph

1-3

1-4

1-5

1-6

1-7

1-8

1-9

1-10

1-11

1-12

1-13

2-1

2-2

2-6

2-6a

2-6b

2-6c

2-6d

2-6e

2-3

2-4e

2-4f

2-4g

2-5

2-5a

2-5b

2-5c

2-5d

2-3a

2-3b

2- 3c

2-4

2-4a

2-4b

2-4c

2-4d

2-5e

2-5f

2-5g

1-3

1-3

1-3

1-5

1-5

2-1

2-1

2-1

2-1

2-1

2-1

2-2

2-3

2-4

2-4

2-4

2-6

2-10

2-10

2-14

2-18

2-20

2-20

2-20

2-21

2-22

2-22

2-23

2-24

2-25

2-25

2-25

2-28

2-28

2-34

Page

1-1

1-3

1-3

1-3

1-3

1-3

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


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

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Housing and Stator Assembly . . . . . . . . . . . . . . . . .

Preliminary Procedures . . . . . . . . . . . . . . . . .

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Assembly

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section IV.

Leece-Neville Model Generator 3002AD . . . . . . . . . . .

End Cover and Regulator Assembly . . . . . . . . . . .

Preliminary Procedure . . . . . . . . . . . . . . . . . .

Removal

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Disassembly

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacement

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drive End Bell and Rotor Assembly

. . . . . . . . . . .

Preliminary Procedures . . . . . . . . . . . . . . . .

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacement

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Paragraph

2-7

2-7a

2-7b

2-7c

2-7d

2-7e

2-8

2-8a

2-8b

2-8c

2-8d

2-8e

2-8f

2-8g

2-9

2-9a

2-9b

2-9c

2-9d

2-9e

2-9f

2-9g

2-10

2-10a

2-10b

2-10C

2-10d

2-10e

2-11

2-11a

2-llb

2-11c

2-11d

2-11e

2-11f

2- 11g

2-12

2-12a

2-12b

2-12c

2-12d

2-12e

2-12f

2-12g

Page

2-56

2-57

2-60

2-60

2-60

2-67

2-67

2-70

2-77

2-43

2-45

2-45

2-46

2-48

2-49

2-49

2-49

2-50

2-51

2-51

2-39

2-39

2-39

2-39

2-40

2-40

2-41

2-42

2-42

2-42

2-77

2-77

2-77

2-79

2-80

2-80

2-81

2-82

2-84

2-84

2-84

2-86

2-87

2-87

2-92

2-93

iii

TM 9-2920-225-34

TABLE OF CONTENTS-CONT

Housing and Stator Assembly . . . . . . . . . . . . . . .

Preliminary Procedures . . . . . . . . . . . . . . . . . .

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


. . . . . . . . . . . . . . . . . . . . .

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

. . . . . . . . . . .


Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Disassembly

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Assembly

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Housing and Stator Assembly

. . . . . . . . . . . . . . . . .


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

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


. . . . . . . . . . . . . . . . . . . . . .

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Slipring End Housing . . . . . . . . . . . . . . . . . . . . . . . . .


Removal

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Disassembly

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inspection and Repair . . . . . . . . . . . . . . . . . . . .

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacement . . . . . . . . . . . . . . . . . . . .

Paragraph

2-13

2-13a

2-13b

2-13c

2-13d

2-13e

2-17

2-17a

2-17b

2-17c

2-17d

2-17e

2-17f

2-17g

2-18

2-18a

2-18b

2-18c

2-18d

2-18e

2-18f

2-18g

2-14

2-14a

2-14b

2-14c

2-14d

2-14e

2-14f

2-14g

2-15

2-15a

2-15b

2-15c

2-15d

2-15e

2-15f

2-15g

2-16

2-16a

2-16b

2-16c

2-16d

2-16e

Page

2-147

2-147

2-147

2-147

2-148

2-150

2-150

2-151

2-153

2-154

2-154

2-154

2-159

2-161

2-161

2-163

2-165

2-95

2-95

2-95

2-105

2-105

2-109

2-118

2-118

2-118

2-118

2-119

2-120

2-120

2-120

2-121

2-122

2-122

2-122

2-124

2-125

2-125

2-125

2-128

2-133

2-133

2-133

2-140

2-140

2-140

iv

TM 9-2920-225-34


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

2-19

2-19a

2-19b

2-19c

2-19d

2-19e

2-19f

2-19g

2-20

2-20a

2-20b

2-20C

2-20d

2-23

2-23a

2-23b

2-23c

2-23d

2-23e

2-24

2-24a

2-24b

2-25

2-25a

2-25b

2-25c

2-21

2-21a

2-21b

2-21C

2-21d

2-21e

2-21f

2-21g

2-21h

2-22

2-22a

2-22b

2-22C

2-22d

2-22e

Page

2-187

2-187

2-188

2-191

2-192

2-192

2-197

2-198

2-199

2-202

2-202

2-202

2-206

2-206

2-210

2-214

2-171

2-171

2-171

2-174

2-175

2-175

2-180

2-181

2-184

2-184

2-184

2-185

2-186

2-187

2-214

2-214

2-218

2-222

2-225

2-225

2-229

2-229

2-231

2-233

2-233

2-234

2-235

TM 9-2920-225-34


Number

1-1

1-2

1-3

1-4

2-1

2-2

2-3

2-4

2-5

Number

1-1.

2-1.

2-2.

2-3.

2-4.

2-5.

2-6.

2-7.

2-8.

2-9.

2-10.

2-11.

APPENDIX A. REFERENCES

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

A-1

Page

1-4

1-5

1-6

1-6

2-28

2-45

2-52

2-88

2-161

Page

1-2

2-33

2-36

2-55

2-58

2-91

2-126

2-129

2-159

2-179

2-197

2-211

vi

Number

2-6

2-7

2-8

2-9

2-10

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

2-176

2-176

2-177

2-177

2-193

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)

2-23

2-24

2-25

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.


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).


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).


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).


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



a.



(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


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


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.


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.


(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



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

figure 2-2.

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


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.


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.


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.


SUPPLIES : Drive end bell preformed packing (large)

Drive end bell seal

PERSONNEL: One

EQUIPMENT CONDITION:


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


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 .


SUPPLIES : End housing preformed packing

Lip seal (2)

Sleeve seal

Ball bearing and roller bearing grease, MIL-G-18709

PERSONNEL: One



a.


(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


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



(inches)

Wear Limits

(inches)

2.0470 to 2.0475

None



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


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.


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




(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).

Refer to figure 2-4.

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


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.


SUPPLIES : Electrical tape, MIL-T-50886

Housing seal

Housing lip seal

Tags

PERSONNEL: One




(1) Clean outside of generator before disassembly. Refer to para 1-3.

(2) Remove drive end bell. Refer to para 2-8.


(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).


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


1.

Replace end housing and rotor assembly. Refer to

para 2-9.

2.


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


1.

Replace end housing and rotor assembly. Refer to

para 2-9.

2.


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.


SUPPLIES: End cover preformed packing

Artillery and automotive grease, type GAA, MIL-G-10924

PERSONNEL: One




Clean outside of generator before disassembly. Refer

to para 1-3.

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


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.


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.


SUPPLIES: Drive end preformed packing

Bearing retainer preformed packing

Drive end bell seal

Bearing retainer seal


PERSONNEL: One





(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


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.


(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


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


(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.


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.


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


Outside diameter of slipring


(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


END OF TASK

Replace end cover and regulator assembly. Refer to

para 2-11.

TA 103594

2-94

TM 9-2920-225-34

2-13. HOUSING AND STATOR ASSEMBLY.


SUPPLIES: Teflon seats (2)

Capacitor and terminal assembly gasket


Tags

PERSONNEL: One


a.



(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.


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


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


Replace drive end bell and rotor assembly. Refer

to para 2-12.

Replace end cover and regulator assembly. Refer

to para 2-11.

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.


SUPPLIES:

Housing preformed packing


Tags

PERSONNEL: One




Clean outside of generator before disassembly. Refer

to para 1-3.

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 .


SUPPLIES : Bearing retainer preformed packing

PERSONNEL: One






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


END OF TASK

Replace regulator and end cover assembly. Refer to

para 2-11.

TA 103632

TM 9-2920-225-34

2-16. HOUSING AND STATOR ASSEMBLY

●


SUPPLIES: Housing seal (2)

Sealer compound, type II, MIL-S-45180

Tags

PERSONNEL: One



a.





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


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.


SUPPLIES: None

PERSONNEL: One

EQUIPMENT CONDITION: Generator generator.

removed from vehicle, pulley removed from


Clean generator

para 1-3.

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.


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.


SUPPLIES: Cotter pin (4)

PERSONNEL: One



a.




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

2-8.

make fabricated tool.

See figure

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.


cleaning procedures given in para 1–3.


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.


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.


GO TO FRAME 2

Index

Number

4

7

8

Table 2-5. End Housing Assembly Wear Limits



(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).


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.


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



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


Replace fan and hub assembly. Refer to para

2-17.

END OF TASK

TA 104257

2-170

TM 9-2920-225-34

2-19. DRIVE END BELL AND ROTOR ASSEMBLY.


SUPPLIES: None

PERSONNEL: One






(3) Remove slipring end housing. Refer to para 2-18.

b.

Removal.


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.


cleaning procedures given in para 1-3.

e .


(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 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

2-6 and 2-7, get new bearing.

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


(inches)

Wear Limits

(inches)

2

3

4

6

5

8

9


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



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


(inches)

Wear Limits

(inches)

6

2

3

4

5

8

9


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


0.9839 to 0.9843


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



(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


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.


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.

See figure 2-9.

END OF TASK

Index

Number

A

Item/Point of Measurement



(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


1.

Replace slipring end housing. Refer to para

2-18.

2.


2-17.

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


1.


2-18.

2.


2-17.

TA 103682

2-183

TM 9-2920-225-34

2-20.

STATOR AND CONNECTOR ASSEMBLY.


SUPPLIES:

None

PERSONNEL: One

EQUIPMENT CONDITION: a. Preliminary Procedures.


(1) Clean outside of generator before disassembly. Refer to para l-3.


(3) Remove slipring end housing. Refer to para 2-18.


—

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.


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


1.

Replace drive end bell and rotor assembly. Refer

to para 2-19.

2.


2-18.

3.


2-17.

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.


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



Clean generator before disassembly. Refer to

para 1-3.

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,


Measure outside diameter of shaft (2) at end housing.


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 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


(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.


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



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






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.


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




(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.


SUPPLIES :

Rivet (3)

End housing lip seal

End housing preformed packing

PERSONNEL: One


a.


Remove fan, end bell, and rotor assembly. Refer

to para 2-21.

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.


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.


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






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.


4.

Check that nut (4) and washer (5) are not stripped, worn or damaged.


END OF TASK






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

See figure 2-11.

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


Replace fan, end bell, and rotor assembly. Refer to

para 2-21.

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

to para 2-23d.

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.


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.


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

This fine document...

Was brought to you by me:

Liberated Manuals -- free army and government manuals

Why do I do it? I am tired of sleazy CD-ROM sellers, who take publicly available information, slap “watermarks” and other junk on it, and sell it.

Those masters of search engine manipulation make sure that their sites that sell free information, come up first in search engines. They did not create it...

They did not even scan it... Why should they get your money? Why are not letting you give those free manuals to your friends?

I am setting this document FREE. This document was made by the US

Government and is NOT protected by Copyright. Feel free to share, republish, sell and so on.

I am not asking you for donations, fees or handouts. If you can, please provide a link to liberatedmanuals.com, so that free manuals come up first in search engines:

<A HREF= http://www.liberatedmanuals.com/ >Free Military and Government Manuals</A>

–

Sincerely

–

Igor Chudov

http://igor.chudov.com/

Chicago Machinery Movers

Leece-Neville 2184 AC, 5300 GP, 5504 AA, AB, AMA 5102UT, 3002AC, 3002AD, 3002AE generator Technical manual

Assistant Bot

MAINTENANCE

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

- - - - - - - -- - - --- ----

DEPARTMENTS OF THE ARMY AND THE AIR FORCE

20 FEBRUARY 1981

MAINTENANCE

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

TABLE OF CONTENTS

,

TABLE OF CONTENTS -CONT

TABLE OF CONTENTS-CONT

TABLE OF CONTENTS-CONT

TABLE OF CONTENTS -CONT

TABLE OF CONTENTS -CONT

LIST OF ILLUSTRATIONS

LIST OF TABLES

LIST OF TABLES - CONT

CHAPTER 1

GENERAL MAINTENANCE INFORMATION

CHAPTER 2

EQUIPMENT GROUP MAINTENANCE

I

APPENDIX A

REFERENCES

This fine document...

Was brought to you by me:

Liberated Manuals -- free army and government manuals

Why do I do it? I am tired of sleazy CD-ROM sellers, who take publicly available information, slap “watermarks” and other junk on it, and sell it.

Those masters of search engine manipulation make sure that their sites that sell free information, come up first in search engines. They did not create it...

They did not even scan it... Why should they get your money? Why are not letting you give those free manuals to your friends?

I am setting this document FREE. This document was made by the US

Government and is NOT protected by Copyright. Feel free to share, republish, sell and so on.

I am not asking you for donations, fees or handouts. If you can, please provide a link to liberatedmanuals.com, so that free manuals come up first in search engines:

–

Sincerely

Igor Chudov

http://igor.chudov.com/

Chicago Machinery Movers

Key Features

Frequently Answers and Questions

What models of generators are covered in this manual?

What are the maintenance procedures for generator AMA-5102UT?

What types of generators are described?

Related manuals

Prestolite

5504 AA

RHUB

M109 A2

United Manufacturing Company

AGARTS, Type II 7336-3

Bendix Corporation

30B95-3-C

CUMMINS

V8 300