Figure 7-4. Timing Port and Port Closing Mark

Figure 7-3. Engine Flywheel and Ring Gear Assembly

TM-5-6115-584-34 Generator Set Diesel Engine Driven Tactical Skid Mtd. 30 Kw 3 Phase 4 Wire 120/208 and 240/416 Volts Manual
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e. Replace. Using screws (13, figure 7-2), lock- washers (14), and nuts (15), attach governor control bracket (12) to engine back plate. Attach speed control cable (11) to governor arm (3) with pin (6) and cotter pin (5). Attach governor arm (3) and governor linkage (1) between governor and fuel injection pump (2). If new ball joints are used on linkage, position the new joints to obtain the same length or 1/32 inch more (1 turn = 1/32 inch) than the old linkage. If old linkage length is not available, position new ball joints about midway on each end linkage, then lengthen 1/8 inch. Do not overspeed engine for more than a moment. Start engine and adjust speed control for 61.5 Hz output at no load. It should then be possible to move the entire linkage down 1/2 inch with a light finger pressure. If not, adjust linkage 1 turn at a time until 1/2 inch downward travel is obtained. It should then be possible to momentarily lift the linkage 1/2 inch with unit operating at rated load. Balance up and down travel by adjusting length of the linkage. On ASK equipped generators, refer to Operator and Organizational Maintenance Manual and replace right panel assembly. 7-4. FLYWHEEL AND RING GEAR ASSEMBLY. a. Removal (see figure 7-3). (1) Remove engine from set per paragraph 2-9. (2) Remove timing pointer (10, figure 7-3) by re- moving screws (11). (3) The flywheel (1) is a tapered fit on the crankshaft (2). Remove flywheel mounting screw (3) and washer (4). Support and remove flywheel and ring gear assembly by using a two pronged wheel puller inserted through the slots provided in the flywheel. b. Clean and Inspect. Clean the flywheel and ring gear assembly (1) using solvent. Check the ring gear for broken or worn teeth. c. Install. Replacement flywheels are supplied with timing marks already stamped in place. The engine must still be timed properly to this timing mark. The only accurate method of determining the port closing point is to measure piston travel. This is a critical measurement and should be done only with accurate, dependable equipment. Mount flywheel keying properly and tighten in place using screw (3) and washer (4), (figure 7-3). With the flywheel mounted, rotate flywheel counterclockwise until Number 1 cylinder is on its compression stroke, which follows the closing of its intake valve. Remove the exhaust rocker arm (3, figure 7-9), exhaust valve rotator (1, figure 7-11), valve looks (2), spring retainer (3) and spring (5). using fabricated tool (see figure 7-10). Allow exhaust valve to drop down onto top of piston. Rotate flywheel counterclockwise until piston is at TM 5-6115-584-34 NAVFAC P-8-622-34 TO-35C2-3-456-2 TM-0568C-34 NOTE As the piston comes up to Top Dead Center there is very little change in the dial indicator reading and extreme care should be used to establish the exact Top Dead Center. Zero the dial indicator. Rotate flywheel in opposite direction (clockwise) to a point where the dial indica- tor will indicate approximately 0.200 inch. Rotate fly- wheel counterclockwise slowly until dial indicator shows 0.128 inch before Top Dead Center. Care must be taken to insure that the valve is following the piston, and that reading is accurate. This procedure must be followed to insure that all slack is taken out of the piston and connecting rod fits. At 0.128 inch before Top Dead Center position, check timing pointer in timing port on side of flywheel housing (5, figure 7-3). The timing pointer (10) should be in exact alignment with P.C. mark on flywheel. If pointer is not in align- ment, move pointer, and remark generator adapter as shown in figure 7-4. Destroy old alignment mark. Figure 7-4. Timing Port and Port Closing Mark Top Dead Center. This can be measured on top of exhaust valve stem with a dial indicator (see figure 7- 5). Change 6 7 -5

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