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 TM 55-1905-217-34
Test the negative rectifier diodes in a similar manner. Defective diodes in either the positive or negative heat sink can be
removed as follows:
CAUTION
When applying soldering iron to a diode lead connection, grasp the diode connection
terminal with long nose pliers (between diode and soldering iron) to prevent
overheating and damage to the diode:
(a) Unsolder the connection wires to the diode.
(b) Set the diode plate on a 3/4 inch to 1 inch diameter tubular tool or jig with the terminal facing down.
(c) Use a small round tool and arbor press to press the diode from the heat sink.
CAUTION
Do not hammer diode to remove it.
l. Reassembly of Rotor and Front Housing Assembly (Hulls 8500-8519 and 8520-8539).
(1) Place the slip ring connecting wires in the groove of the rotor shaft.
(2) Press the rear ball bearings (16, fig. 4-1) onto the shaft applying pressure on the INNER race only.
(3) Place the slip rings (17) on the rotor shaft and draw them into place with the hex socket screw (19) using a new
lock washer (18).
(4) Solder the two leads using resin core solder (Federal Specification QQ-S-571). Do not use excessive amounts
of solder. (Leads are interchangeable).
(5) With an acceptable material such as red glyptal, cement the wires to the slip rings to prevent them from
loosening.
(6) Press the seals (10) into front housing (9) and bearing retainer (13).
CAUTION
Apply pressure to the outer metal ring only. Otherwise permanent damage may
result.
(7) Press the ball bearing (11) into the front housing (9).
CAUTION
Apply pressure on outer race only.
(8) With retainer gasket (12) in place, secure front bearing retainer (13) with three retainer screws (8).
(9) Press this front housing assembly onto the rotor shaft using an arbor press and suitable jig.
m. Reassembly of Rear Housing Assembly (Hulls 8500-8519 and 8520-8539).
(1) Install replacement diodes as follows: Fit new diode into round diode hole. Slowly rotate the diode in the hole
until the serrations on the diode are not lined up with the serrations made in the hole by the original diode. This procedure
insures good heat conduction and a secure mounting.
(2) Press diode into the hole with a 1/2 inch tubular tool making sure diode is completely seated. (Federal
Specification QQ-S-571).
CAUTION
When soldering diodes, grasp the diode connection terminal with long nose pliers
(between soldering iron and diode) to prevent overheating and possible damage to
diode.
(3) Install diodes as necessary using procedures in (1) and (2) above. Be certain diode lead wires and harness are
connected properly.
(4) Assemble carriage bolts (50 and 52, fig. 4-1), insulators (48 and 51) and terminal lug (49) on isolation diode
assembly (46) and rectifier diode assemblies.
(5) Place the isolation diode assembly onto the two rectifier diode heat sink assemblies. Install washers (40, 41
and 42) on protruding carriage bolts and secure with acorn nuts (47).
(6) Place the entire diode assembly into rear housing (43). Secure the assemblies with the proper insulating
washers (42), flat washers (41), lock washers (40) and hex nuts (39). Install the self-tapping screw to secure the ground
lead to the negative diode plate.
(7) Place the stator assembly (20) into rear housing (43) and insert the carriage bolts (45), lock washers (38), and
insulators (27). Secure the stator winding leads with the insulating washers (36), washers (23), lock washers (18) hex nuts
(21) and stud caps (35).
n. Reassembly of Alternator (Hulls 8500-8519 and 8520-8539).
(1) Install bearing retainer (44, fig. 4-1). Carefully align front housing assembly with rotor and rear housing
assembly. Press the housings together and install thru bolts (37) and lock washers (38). Tighten thru bolts to secure.
CAUTION
When replacing brush assembly, observe that the replacement is identical to the
original since an error could cause serious damage to alternator.
(2) Place brush assembly (33) into rear housing (43) being certain brushes are set properly onto slip rings without
chipping. Secure assembly and insulator (32) with two tapping screws (31).
(3) Secure internal field wire (29) and auxiliary wire to brush assembly terminals with two tapping screws (34).
(4) Assemble carriage bolt (30), internal field wire (29), washer (28), terminal insulator (27), to
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