Flywheel Alternator.

TM 5-4320-273-14

crankcase (37).

NOTE

(2) Install gasket (28) and cover (27) on crank-

Use a standard gear puller to remove the camshaft

gear.

case; secure cover to crankcase with lockwasher (26)

(4) Remove screws (2) and lockwashers (3) that

and nut (25).

secure gear (4) to the camshaft. Remove thrust

(3) Install oil level gage rod tube (24), strainer

plunger (5) and spring (6) from the camshaft.

element (23), and oil fill tube (22) in crankcase. In-

(5) Remove oil level gage rod (7), oil line assem-

stall bracket (21) and secure with lockwasher (20) and

bly (8), adapter (9), tee (10), and nipple (11) from

screw (19).

crankcase (37).

(4) Install clamps (18 and 16) and secure with

(6) Remove oil fill cap (12). Remove nut (13), lock-

screw (17), flat washer (15), lockwasher (14), and nut

washer (14), flat washer (15), and clamp (16). Remove

(13). Install oil fill cap (12).

screw (17) and clamp (18).

(5) Install nipple (11), tee (10), adapter (9), and

(7) Remove screw (19), lockwasher (20), and

connect oil line assembly (8). Install oil level gage rod

bracket (21). Remove oil fill tube (22), strainer

(7) in tube.

element (23), and oil level gage rod tube (24) from the

NOTE

The timing gear has offset mounting holes and can only

crankcase (37).

be installed with the timing mark matching that of the

(8) Remove nut (25), lockwasher (26), cover (27),

crankshaft gear.

and gasket (2$) from the crankcase (37).

(6) Press gear (4) onto the camshaft and secure

(9) Remove stud (29), pipe plugs (30 and 31), studs

with lockwashers (3) and screws (2). Install spring (6)

(32, 34, and 36) and expansion plugs (33 and 35) from

and thrust plunger (5) in camshaft (l).

the crankcase (37).

(7) Lubricate the camshaft journals with engine

b. Cleaning and Inspection.

oil and insert the camshaft into the crankcase (37),

WARNING

making sure you do not ram the camshaft against the

DRY CLEANING SOLVENT, P-D-680

expansion plug (35).

or P - S - 6 6 1 , w e d t o c l e a n p a r t s i s

(8) Install all valve tappets, cylinder block

potentially dangerous to personnel

assembly, piston and connecting rods, alternator and

a n d property. Avoid repeated and

flywheel.

prolonged skin contact. DO NOT use

(9) Install oil pump, oil pan, gear cover, cylinder

n e a r open flame or excessive heat.

head, magneto, governor, carburetor, manifolds, and

Flash point of solvent is 100 to 138F

air shrouding.

(38 to 60C).

(1) Clean all parts with cleaning solvent (fed.

6-11. Flywheel Alternator.

spec. P-D-680); dry thoroughly.

Before you test the alternator and its components,

(2) Inspect the camshaft plunger and spring for

check the operation of the battery charging system

wear, scoring, and distortion; inspect the spring for

by observing the ammeter. The ammeter should in-

resiliency. Replace if worn or damaged,

dicate a high charging rate immediately after start-

(3) Inspect the cam gear for cracked, chipped, or

ing. After a few minutes the ammeter should return

broken gear teeth or a damaged shaft bore. Replace

to near zero. If the ammeter does not operate in this

the cam gear if damaged or worn.

manner or if it indicates a discharge rate, perform

(4) Inspect the camshaft for cracks, worn or

checks and tests as indicated in the following sub-

scored cams, worn or scored bearing surfaces, and

paragraphs.

clogged oil passages. Replace a damaged or worn

a. Testing.

camshaft.

(1) Test the alternator and components while the

(5) You can clean the oil passages in the crank-

parts are mounted on the engine. The rectifier and

case using compressed air.

regulator modules and the isolation diode are ground-

(6) Clean all other parts with cleaning solvent;

ed to the engine and therefore cannot be tested while

dry thoroughly.

mounted at a remote location. Check to ensure that

you have good continuity between the modules and

(7) Discard all gaskets.

the engines. These are static tests which do not

(8) Inspect the block for cracks, damaged sealing

require that you run the engine, Disconnect battery

surfaces, damaged threads, loose or damaged studs,

leads and uncouple the connectors that connect the

or other defects. Replace the block if defects cannot

modules to the stator leads.

be repaired or if it is cracked. Replace loose or

(2) To check for stator continuity, use an ohm-

damaged studs, Retap damaged threads.

c Reassembly.

meter with R X 1 scale (minimum sensitivity of

20,000 ohm/volts). If the ohmmeter indicates a short

(1) Install expansion plugs (33 and 35, fig. 6-12),

(no resistance) or open (infinite resistance) circuit,

studs (29, 32,34, and 36), and pipe plugs (30 and 31) in

6-16