4-6. 200-AMPERE DUAL VOLTAGE ALTERNATOR CABLE REPLACEMENT
This task covers:
a. Removal
b. Installation
INITIAL SETUP:
Tools
General mechanic’s tool kit:
automotive (Appendix B, Item 1)
Maintenance and repair shop equipment:
automotive (Appendix B, Item 2)
Materials/Parts
Four lockwashers (Appendix G, Item 205)
Four tiedown straps (Appendix G, Item 464)
Lockwasher (Appendix G, Item 233)
Manual References
TM 9-2320-387-10
TM 9-2320-387-24P
Equipment Condition
• Hood raised and secured (TM 9-2320-387-10).
• Battery ground cables disconnected (para. 4-68).
• Engine access cover removed (para. 10-22).
Maintenance Level
Unit
TM 9-2320-387-24-1
4-12
Change 1
a. Removal
b. Installation
NOTE
Prior to removal, tag leads for installation.
NOTE
Ensure terminals are clean before connections are made.
1.
Install cable (4) through grommet (28) in battery box (23).
1.1 Install cable (4) on buss bar (24) with washer (25), lockwasher (26), and nut (27).
2.
Route cable (4) through clamp (19) and install clamp (19) to bracket (20) with lockwasher (18),
screw (17), lockwasher (21), and nut (22).
3.
Route cable (4) through clamp (15) and install clamp (15) on stud (12) with lockwasher (13) and
nut (14).
4.
Route cable (4) through clamp (10) and install clamp (10) on water crossover bracket (11) with
capscrew (9).
5.
Install washer (2), nut (3), and cable (4) on positive stud (1) with washer (6), lockwasher (7), and nut (8).
Tighten nut (8) to 10-15 lb-ft (14-20 N•m) and slide rubber boot (5) over nut (8).
6.
Install four tiedown straps (16) on cable (4).
1.
Slide back rubber boot (5) and remove nut (8), lockwasher (7), washer (6), cable (4), nut (3), and
washer (2) from positive stud (1). Discard lockwasher (7).
2.
Remove capscrew (9) and clamp (10) from water crossover bracket (11) and separate cable (4) from
cables and clamp (10).
3.
Remove nut (14), lockwasher (13), and clamp (15) from stud (12) and separate cable (4) from cables
and clamp (15). Discard lockwasher (13).
4.
Remove four tiedown straps (16). Discard tiedown straps (16).
5.
Remove nut (22), lockwasher (21), screw (17), lockwasher (18), and clamp (19) from bracket (20) and
remove cable (4) from clamp (19). Discard lockwashers (21) and (18).
6.
Remove nut (27), lockwasher (26), washer (25), and cable (4) from buss bar (24) on battery box (23).
Discard lockwasher (26).
7.
Remove cable (4) from grommet (28) and vehicle.
