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 TM 55-1905-217-34
rear cover (25) with washers (23 and 2A), lockwasher (18), and hex nut (21).
(5) Secure the rear cover (25) and cover gasket (26) to the rear housing (43) with two tapping screws (22).
(6) Place pulley spacer (7) on shaft, then the felt washer (6) and flat washer (5).
(7) Place woodruff key (14) into key slot in rotor shaft. Position fan (4) on rotor shaft.
(8) Press pulley (3) over key onto rotor shaft. Install flat washer (2) on shaft and secure with self-locking nut (1).
(9) Check assembly of all parts, particularly electrical connections. Examine rotor assembly for freedom of
movement; there should be no binding or contact between internal components.
(10) Perform in-vessel tests to determine that alternator is functioning properly (TM 55-1905-217-12, para 4-48).
o. Reassembly of Rotor and Front Housing Assembly (Hulls 8540-8560 and 8580-8618).
(1) Press rear bearing (16, fig. 4-2) to shoulder on rotor shaft applying pressure to bearing inner race only.
(2) Thread rotor winding leads through square hole in slip ring hub. Align square hole with slot on rotor shaft and
press slip ring assembly in place.
(3) Secure assembly with cap screw (19) and lockwasher (18).
(4) Using ohmmeter, check resistance between each slip ring and rotor shaft. The meter should indicate open
circuit or very high resistance.
(5) Solder rotor leads to slip ring terminals using resin core solder. The leads are interchangeable.
(6) Apply small amount of cement where rotor lead wires emerge from the slip ring hub.
(7) Using ohmmeter, measure resistance between slip rings. The meter should read 15.0 to 16.0 ohms resistance.
(8) Using ohmmeter, check for open circuit between each slip ring and the rotor shaft.
(9) Place front section housing, exterior side down on bed of arbor press. Press new seal (10) in housing with
grease cavity up.
CAUTION
Press on outer edge only until seal bottoms in the housing.
(10) Install new seal (10) in the bearing retainer (13) with the grease cavity away from the retainer.
(11) Pack each seal cavity 2/3 full of bearing grease.
CAUTION
Do not overpack grease seals.
(12) Press the front bearing (11) into front housing (9).
CAUTION
Apply pressure to the bearing outer metal ring only.
(13) Put retainer gasket (12) and bearing retainer (13) in place and secure with retaining screws (8).
(14) Press front section housing with bearing in place onto the rotor shaft using arbor press.
CAUTION
Apply pressure on inner bearing race only. Insure that rotor leads will not interfere.
p. Reassembly of Rear Housing Assembly (Hulls 8540-8560 and 8580-8618 ).
NOTE
Refer to figure 4-7 for proper location and arrangement of rectifier components.
(1) Install replacement diodes as follows:
(a) Fit new diode (24) or (33, figure 4 2) into round diode hole.
(b) Rotate diode until serrations on the diode are not lined up with existing serrations in the hole.
(c) Press diode into hole with a 1/2 inch tubular tool making sure diode is completely seated.
(d) Solder diode connecting leads using resin core solder.
CAUTION
When soldering diodes, grasp the diode connector terminal with long nose pliers
(2) Install carriage bolt (21) in field diode assembly (22) and place square insulator (23) on bolt.
(3) Assemble field diode assembly to the positive heat sink (25) ensuring that the square indicator separates the
assembly and the heat sink.
(4) Assemble negative heat sink (31) to positive heat sink insuring that the molded washer (26) separates the two
heat sinks.
(5) Place molded washers (26), with shoulder facing away from diode assembly, on bolts (21) and (32). Place
diode assembly into rear housing.
(6) Place insulator washers (38), flat washers (39), lockwashers (40), and hex nuts (41) on protruding carriage
bolts (21) and (32). Tighten nuts evenly to avoid breaking insulator washers.
(7) Install negative brush lead to negative diode plate. Position lead so it does not strike rotor.
(8) Install flat washers (28), square insulators (29), and diode harness (30) on bolts (27) and insert through rear
housing.
4-13
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