TM 9-2320-387-24-2
18-3. 200~AMPERE DUAL VOLTAGE ALTERNATOR TESTING AND REPAIR
This task covers:
a. Alternator Output Testing
b. Disassembly
c. Static Testing
d. Cleaning
e. Assembly
INITIAL SETUP:
Test Equipment
Multimeter (Appendix B, Item 155)
Test stand (Appendix B, Item 56)
Tools
General mechanic’s tool kit:
automotive (Appendix B, Item 1)
Puller (Appendix B, Item 54)
Materials/Parts
Silicone compound (Appendix C, Item 75)
RTV sealant (Appendix C, Item 74)
Locknut (Appendix G, Item 175)
Eighteen locknuts (Appendix G, Item 176)
Three lockwashers (Appendix G, Item 191)
Welve locknuts (Appendix G, Item 177)
Locknut (Appendix G, Item 172)
Lockwasher (Appendix G, Item 239)
Lockwasher (Appendix G, Item 205)
Locknut (Appendix G, Item 112)
Personnel Required
One mechanic
One assistant
Manual References
TM 9-2320-387-24P
TM 9-4910-663-12
TM 9-4910-485-12
Equipment Condition
Alternator removed (para. 4-5).
General Safety Instructions
Always support alternator core and shaft assembly
during removal and installation.
Maintenance Level
Direct support
a. Alternator Output Testing
1.
2.
3.
4.
5.
6.
Mount pivot arm of 500-amp test stand to high-speed side and install mounting flange adapter on
pivot arm. Connect pulley driveshaft to high-speed head. Install pulley driveshaft on mounting
flange adapter.
Mount alternator to starter/alternator mounting bracket on 500-amp test stand. Connect belt from
500~amp test stand pulley to alternator pulley. Adjust belt tension.
Connect cable from alternator ground terminal to 500-amp test stand G- terminal. Connect cable
from alternator battery terminal to 500-amp test stand G+ terminal. Connect cable from alternator
regulator IGN to 500-amp test stand F terminal.
Install voltage regulator (para. 4-8).
Connect 28VDC output and 14VDC output to test stand. Auxiliary voltage and current meters may
be required to measure 14VDC output.
Fabricate a jumper wire with a ring terminal at both ends. Connect jumper wire on 500~amp test
stand from IGNITION SWITCH terminal to F-B terminal.
18-2
