REPLACING BREAKER PLUNGER AND BUSHING

ADJUST ARMATURE TIMING

MAGNA-MATIC SYSTEM

TM-5-4240-501-14P Special Diver Air Support System (SDASS) NSN 4220-01-292-3708 Manual
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TM 5-4240-501-14P IGNITION Flywheel Type - External Breaker REPLACING BREAKER PLUNGER AND BUSHING Model Series 19D, 23D, 193000, 200000, 230000, 243000, 300000, 320000 Two styles of plunger bushing have been used. Removal and installation is as follows. Fig. 37 Remove breaker box cover, condenser and breaker assembly, Fig. 38, Illus. 1. Place a thick 3/8" inside diameter washer, such as P/N 22238, over the end of bushing and screw on a 3/8-24 nut, as shown in Fig. 38, Illus. 2. Tighten the nut to pull the bushing. After the bushing has moved about 1/8", remove the nut and put on a second thick washer, as shown in Fig. 38, Illus. 3. A total stack of 3/8" of washers (2-22238) will be required to completely remove the bushing. Be sure the plunger does not fall out of the bushing as it is removed. Fig. 38 - Removing Plunger and Threaded Bushing Installing Threaded Bushing and Plunger Place the new plunger in the bushing with the large end of the plunger opposite the threads on the bushing. Screw the 3/8-24 nut onto the threads to protect them. See Fig. 39. Fig. 39 - Plunger and Bushing Fig. 40 - Inserting Bushing Insert bushing into cylinder. Place a piece of tubing such as P/N 295840 piston pin against the nut, as shown in Fig. 40. Use a hammer to drive the bushing into the cylinder until the square shoulder on the bushing is flush with the face of the cylinder. Check to be sure plunger operates freely. Alternate Design Fig. 41 - To Remove Bushing and Plunger Pull plunger outward as far as possible. Use a pliers to break plunger off as close to bushing as possible. See Illus. A, Fig. 42. Use a 1/4-20 tap ora 93029 self- threading screw to thread the hole in the bushing to a depth of approximately 1/2 to 5/8" deep, as shown in Illus. B. Use 1/4-20 x 1/2" hex head screw and two spacer washers as shown in Illus. C, to pull the bushing out of the cylinder. The bushing will be free when it has been extracted 5/16". CAREFULLY remove the bushing and the remainder of the broken plunger. Do not allow the plunger or chips to drop into the crankcase. 2 11

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