Assembly.

ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 NOTE The brushes are excessively worn if 3/16 inch or less extends beyond the bottom of the holder. (14) Check brush spring tension. A force of 4 to 6 ounces should move brush against spring. (15) Using an ohmmeter, test brushholder assembly as follows: (a) Attach one test lead to brushholder and touch other lead to each terminal and each brush. There should be no indication of continuity between brushholder and any terminal or brush. (b) Check for continuity between each terminal and its respective brush. (16) Replace brushholder assembly if inspection and test requirements are not met. (17) Inspect pulley for excessive wear at pulley groove, cracks, corrosion. and other damage. (18) Inspect fan for cracks, corrosion, bent blades and other damage. (19) Inspect bearings for pitting, excessive wear, and other damage. (20) Inspect head assemblies (11 and 49) for cracks, breaks, and corrosion. (21) Inspect all threads for crossing, stripping, and peening. d. Assembly. (1) (2) (3) (4) (5) (6) (7) (8) (9) Install positive diode rectifier assembly (42, figure3-5) and negative diode rectifier assembly (41) onto stator assembly (43) and solder diode leads. Using a driver which exerts pressure on the outer race only, install front bearing (52) into front head (49) and secure with snap ring (51). Install cover (54) and support rear bearing area of rotor assembly (50) on a suitable press and fit assembled front head and bearing over rotor shaft. Using a driver which exerts pressure on the inner race only, press front head down until front bearing contacts cover (54) on rotor shaft. Support front of rotor assembly shaft on a suitable press. Using a driver which contacts the inner race only, press rear bearing (53) onto rotor shaft until it contacts shoulder on shaft. Remove rotor assembly from press. Install spacer (48), woodruff key (47), fan (46), pulley (45), and nut (44). Torque nut to 35 to 50 ft-lbs. Fit front part of insulating bushings (36, 37,38, and 39) over rectifier studs. Position stator and rectifier assembly (40) into rear head assembly (11). Install rear part of insulating bushings (36, 37,38 and 39) and washers (31, 32,33, and 34). Install brushholder (19), insulating plate (18), Iockwashers (17) and screws (16). NOTE Insure that the contour of the brushes correspond to the contour of the commutator when installing brushes in the brushholder. (10) Install brush and spring assemblies (20) in brushholder (19). (11) Insert a wire of sufficient stiffness in the access hole provided (point A, figure 3-5), to hold the brushes (20) depressed into the brushholder (19). (12) Install the rotor (50) with assembled front head (49) into rear head (11), assembled together with rectifier and stator assembly (40). (13) Install thru bolts (10). 3-20