c. Inspect and Repair

9-18. TIMING GEARS AND COVER REPLACEMENT

TM-9-6115-604-34 Generator Set Diesel Engine Driven Tactical Skid Mtd 5 Kw. 1 Phase-2 Wire 1 Phase -3 Wire 3 Phase -4 Wire 120. 120/240 and 120/208 Volts Manual
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TM 9-6115-604-34 NAVFAC P-8-633-34 WARNING Dry cleaning solvent PD-0, Type III, or equivalent, Is flammable, and moderately toxic to the skin, eyes, and respiratory tract. Assure adequate ventilation. Skin, eye, and respiratory protection Is required to avoid Injury to personnel. b. Cleaning. Clean all parts thoroughly using dry cleaning solvent PD-680, Type III, or equivalent Remove all traces of old gaskets from the mating surfaces, and remove nicks or burrs from the gasket surfaces using a flat mill file. c. Inspect and Repair. (1) Visually inspect the camshaft and timing gears in accordance with paragraph 9-1 7. Discard any defective gears. (2) Inspect the camshaft and timing gears using fluorescent magnetic inspection in accordance with MIL-1- 6868. (3) Inspect the keys (31) for wear or distortion. Replace the keys if defective. (4) Inspect the thrust plates (32) for scoring and wear. Replace the plates if scored deeper than 0.0003 inch (0.008 mm), or if worn beyond the limits given in Table 1-4. (5) Check the idler shafts (35 and 41) for scoring and wear. Replace the shafts if they are scored deeper than 0.002 inch (0.05 mm), or if the minimum diameter is less than 1.872 inch (47.55 mm). (6) Check the idler gear bushings (42) for scoring and wear. Scoring shall not exceed 0.003 inch (0.08 mm) in depth, and maximum diameter shall be 1.8785 inch (47.714 mm). (7) Replace worn idler gear bushings (42) using standard bushing drivers. Hone or ream the new bushings for a free fit of 0.0015 to 0.0030 inch (0.038 to 0.076 mm) on the shafts (35 and 41). (8) Check the thrust washers (38) for wear. Replace the thrust washers if the minimum thickness is less than 0.088 inch (2.24 mm). (9) Check the shaft retainer center bolts (33 and 39) for worn or stripped threads. Repair minor thread damage by chasing. Replace the center bolts i more than three threads are damaged. (10) Inspect the housing (47) using fluorescent magnetic inspection in accordance with MIL-1-6868. Replace the housing if cracked. (11) Check the gasket surface of the housing (47) for nicks or burrs. Remove nicks or burrs with a flat mill file. (12) Check the threaded holes in the housing (47) for stripping. Repair stripped threads in accordance with paragraph 2-12. (13) Inspect the cover (5) using fluorescent magnetic inspection in accordance with MIL-1-6868. Replace the cover if cracked. (14) Check the gasket surface of the cover (5) for nicks or burrs. Remove nicks or burrs with a flat mill file. (15) Check the threaded holes in the cover(5) for stripping. Repair stripped threads in accordance with paragraph 2-12. (16) Check the bushings (57) in the cover (5) for scoring and wear. Scoring shall not exceed 0.003 inch (0.08 mm) in depth, and maximum diameter shall be 1.571 inch (39.90 mm). NOTE If the mating shafts are worm, bushings (57) are available in 0.010 inch (0.25 mm) and 0.020 inch (0.51 mm) undersize. These bushings may be used provided the correct running fit of 0.003 to 0.006 inch (0.08 to 0.15 mm) is maintained. (17) Replace worn bushings (57) using mandrel ST-598, and ream for a free fit of 0.003 to 0.006 inch (0.08 to 0.15 mm) on the mating shaft. (18) Check the bushing (58) for scoring and wear. Scoring shall not exceed 0.003 inch (0.08 mm) in depth, and ¾ maximum diameter shall be 1.506 inch (38.25 mm). (19) Install a new bushing (58) using mandrel ST-598. (20) Check the trunnion sleeve (59) for wear, scoring, or distortion. Remove the damaged sleeve by striking it around the outer diameter with a blunt chisel to relieve the press fit. (21) Install a new sleeve (59) using a soft drift and a hammer. 9-38

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