Figure 7-42. Injection Pump Installation

Figure 7-40. Checking Plunger Sleeve Alignment - TM-5-6115-584-34_142

Figure 7-43. Delivery Valve - TM-5-6115-584-34_144

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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TM 5-6115-584-34 NAVFAC P-8-622-34 TO-35C2-3-456-2 TM-05862C-34 NOTE A fuel inlet stud can be fabricated with a 1/4 “-18 NPT pipe die. High pressure tubing must be used between the Nozzle Test Stand and the pump assembly. NOTE Always check to make sure that all external con- nections are tight and that the Nozzle Test Stand is in good order. (8) Slowly operate the Nozzle Test Stand until a pressure of 400 psi is achieved. A rapid drop in pressure indicates that a leak is present. The pressure must remain above 250 psi for at least 30 seconds. DO NOT EXCEED A PRESSURE OF 400 PSI. (9) Visual inspection should be as follows: (a) Check for leakage by the head locating screw (13, figure 7-34). (b) Slight leakage by control unit shaft is normal and is necessary to lubricate shaft. Fuel leakage between the control unit body (4) and pump housing (6) indicates that either the “O” ring (33 ) is damaged or the mating surfaces are damaged. Replace the “O” ring (33 ) and re- test the pump. If fuel leakage is excessive at control unit shaft or continues past “O” ring (33) replace defective parts. (c) Check for leakage of fuel around the face gear (28 ). If leakage is evident, disassemble pump and inspect “O” ring (19). (d) Check for fuel leakage between top of housing and head flange. To correct, disassemble and replace upper hydraulic head “O” ring (18). f. Install (Method 1). (1) Turn engine flywheel to the port closing mark (PC) on the front cylinder (closest to blower wheel) com- pression stroke (see figure 7-44 ). (2) Remove timing hole screw located on pump mounting flange (figure 7-42). Insert a 1/8 inch diameter wire into the hole. (3) Rotate pump face gear until wire slips into place, locking the gear in position. (4) Mount pump on crankcase (see figure 7-32) (be sure shims (5) are in place) and secure in position using four hexagon nuts (2), flatwashers (4) and Iockwashers (3). If “O” ring seal between pump and crankcase is worn, cracked or otherwise defective, replace it. (5) Remove wire. Install timing hole screw and copper gasket. Figure 7-42. Injection Pump Installation g. Install (Alternate Method 2). (1) If pump was not timed by method 1, time now using alternate method 2 below. (2) Connect flexible fuel inlet line to pump inlet. Connect fuel return line. (3) Connect each fuel outlet line to the proper pump outlet (see paragraph 7-2). (4) Connect governor linkage to governor arm. (5) Start and run engine. Adjust governor linkage if required (see paragraph 7-3). A maximum trottle stop screw, located on the injection pump control assembly, limits the max- imum amount of fuel which can be injected into the engine. This screw should not be tampered with; it has been properly adjusted at the factory to protect the engine from over-fueling (see figure 7-33). h. Adjust/Time on Equipment. (1) Time the injection pump to the engine by using the proper thickness timing button between pump plunger and tappet (see figure 7-33). Use method 1 when replacing an old pump if the port closing dimensions and bottom number of the old pump were recorded. Use method 2 if the dimensions are lost, an old pump is being timed, or when replacing either the camshaft or crankshaft. 7 - 3 8 Change 5

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