TM 9-2330-356-14
(4) Remove lead from diode trio (42) to terminal
(b) Position the new brush lead next to the
on regulator housing (37). Loosen the inner nut (34) and
tinned sections of the original brush lead. Install and
pull blue wire (35) from under head of terminal screw.
crimp the brass strip connectors (included) around both
Remove the regulator (43).
leads to hold the new brushes in place (fig. 7-63).
(5) Lift the brush and spring assemblies (44) from
the regulator housing (37).
the brush leads so they do not contact the frame or
interfere with through bolt installation.
(6) Remove three nuts and lift diode trio (42)
from AC terminal studs (fig. 7-65).
(4) Install brush assembly (15, fig. 7-62) and
brush washers (13) in frame assembly (19), and install
(7) Remove three self-locking nuts (32,
previously removed lockwasher and nut on stud of brush
assembly (15).
separate the rotor (12) and drive end housing (7) from the
stator (14) and slip ring end housing (31). See figure 7-66
(5) Install brushes (15 and 20) in brush holder
for typical disassembly. If drive end housing binds on
(18). Attach brush holder (18) to frame assembly (19) with
stator, loosen by tapping with a soft hammer. Ensure that
screws (16) and lockwashers (17).
drive end housing separates from stator and that stator
remains attached to slip ring end housing to avoid damage
(6) Assemble armature (27), drive assembly (29),
to stator leads.
and pinion housing (22) with frame assembly (19).
(8) Remove three nuts (fig. 7-67) which secure
(7) Install brush springs (14).
stator leads to terminals and remove stator from slip ring
end housing.
(8) Install thrust washers (21) on the end of the
armature shaft (27) and install backplate assembly (12) on
(9) Remove two nuts (40), washers (39), and nuts
the frame assembly (19) with through bolts (10) and
(38) from positive and negative output terminal bolts (19
lockwashers (11).
and 20). Remove terminal bolts (19 and 20). Tag the
location of the red and black regulator leads on the heat
(9) Install solenoid switch (9) on frame assembly
sinks.
(19) with screws (7) and lockwashers (8) so that bottom
terminal of solenoid (9) goes through connector (4).
(10) Remove regulator housing (37). Note the
Attach terminal to connector with hardware on the
location of gasket (36) which seals the brush
solenoid switch (9). Connect plunger of solenoid (9) and
compartment.
yoke (26) with pin (6). Retain pin (6) with cotter pin (5).
Install boot (24) and retainer (23) over yoke (26). Check
(11) Remove three screws (23, fig. 7-64), clamp
that plunger and yoke move freely when solenoid switch is
(24), and capacitor (25) connected between the heat sinks
securely fastened to starting motor.
(21 and 22).
(10) Connect tagged lead (3) between solenoid
(12) Remove two capscrews (15), lockwashers
switch (9) and brush assembly (15). Install nut (1) and
(16), and guard washers (17) which retain lower end of
lockwasher (2). Remove tags.
heat sinks (21 and 22). Remove heat sinks, and remove
insulating bushings (26) from heat sinks.
(13) Remove terminal stud insulating bushings
Disassembly.
a.
(27, 28,29, and 30) from slip ring end housing (31). There
are two bushings in each terminal hole.
(1) Hold the pulley of the alternator in a vise with
soft jaws and remove pulley nut (1, fig. 7-64). Use a
(14) Remove slip ring end bearing (13) only if
suitable puller and remove pulley (2) and fan (3).
replacement is necessary. Pry flanged dust cap (33) out of
slip ring end housing (31). Press bearing from the inside of
(2) Using a brass drift and hammer, remove
the housing outward.
woodruff key (11) from keyway in rotor shaft. Remove
spacer (4).
(15) If bearing (8) must be replaced, use a puller to
remove the drive end housing (7) and bearing assembly (8,
(3) Remove four screws which fasten regulator
9, and 10) from the rotor shaft.
(43) in housing (37). Lift regulator from housing and
(16) Remove four screws (10) and bearing retainer
disconnect red and black leads from regulator. Tag the
position of the leads for correct assembly.
(9), and press bearing (8) out of drive end housing.
