9-34. FLYWHEEL ASSEMBLY MAINTENANCE

Figure 9-62. Exploded View of Rear Housing, Flywheel Housing, and Flywheel

Figure 9-63. Flywheel Capscrew Tightening Procedure

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-8-6334 (14) Position the large diameter of the assembly sleeve over the crankshaft. Using ST-1093, push the seal off the assembly sleeve and onto the crankshaft (Figure 9-61). Remove and discard the assembly sleeve. (15) Complete the seal installation using ST-1093 to drive the seal (28, Figure 9-62) into the retainer (26). (16) Install the flywheel housing (9) in accordance with paragraph 9-35. 9-34. FLYWHEEL ASSEMBLY MAINTENANCE a. Inspect Installed Flywheel Assembly. (1) Remove the flange cover (14, Figure 9-62) by removing the capscrews (12) and lockwashers (13). (2) Use the barring device to rotate the engine slowly while observing the flywheel (3) for indications of cracks, and the ring gear (5) for chipped, cracked, or worn teeth. (3) Replace the flywheel assembly if it is cracked. If the ring gear is worn or cracked, replace it in accordance with step d, below. If cracks are suspected, remove the flywheel and inspect it in accordance with step c, below. (4) Replace the flange cover (14) using lockwashers (13) and capscrews (12). Tighten the capscrews in accordance with Table 1-3. b. Remove. (1) Remove the generator in accordance with paragraph 2-16. (2) Remove two capscrews and washer assemblies (1, Figure 9-62) and washers (2) from opposite sides of the flywheel (3). (3) Refer to Table 2-2. Fabricate two guide studs and install them in the capscrew holes to support the crankshaft during removal. (4) Bolt a sling to the outer diameter of the flywheel at the 10 and 2 O'clock positions, and attach to an overhead hoist. (5) Remove the remaining capscrews and washer assemblies (1, Figure 9-62) and washers (2). Remove the flywheel (3) using the overhead hoist. (6) If damaged, remove roll pins (4). c. Inspect. (1) Visually inspect the flywheel assembly in accordance with step a, above. (2) Inspect the capscrew holes and roll pin holes for elongation. Replace the flywheel if the holes are elongated. (3) Inspect the mating surfaces of the flywheel and crankshaft for burrs that could cause misalignment. Remove buns using a flat mill file. (4) Inspect the flywheel and ring gear for cracks using magnetic particle inspection in accordance with MIL-1- 6868. (5) Replace the flywheel if it is cracked. If the ring gear is worn or cracked, replace it in accordance with step d, below. d. Replace Ring Gear. (1) Using a blunt chisel, drive the ring gear (5) from the flywheel (3). WARNING To avoid bum Injury when handling heated parts, Insulated gloves and protective clothing are required. CAUTION To avoid damaging the gear through overheating, do not heat the gear above 660-F (349°C). (2) Place the new ring gear in a controlled-heat oven set at 600F (316C) for 1 hour. (3) Remove the heated ring gear from the oven. Working quickly to avoid heating and expanding the flywheel, position the ring gear on the flywheel, and use a soft hammer to drive it in place until it is firmly seated. Be sure the ring gear remains seated until the assembly is cool. 9-111

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