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