Quantcast (6.5L)  FUEL  INJECTION  PUMP  (DB2831-5149)  CALIBRATION  (Contd)

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TM 9-2815-237-34 2-35.  (6.5L)  FUEL  INJECTION  PUMP  (DB2831-5149)  CALIBRATION  (Cont’d) 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20- 21. Set  the  throttle  lever  in  correct  low  idle  position  prior  to  calibration  using  throttle  lever  gauge.  The low idle screw must beat 34 ± 2 degrees as measured between vertical centerline of throttle shaft bushing  bore  and  throttle  connection  stud. Flush  the  pump  with  calibrating  oil  to  remove  metal  chips  and  possible  contamination. Before  mounting  the  pump  on  the  test  stand,  check  the  drive  shaft  for  freedom  of  rotation  in  the housing.  Pump  should  be  mounted  securely  in  the  appropriate  adapter,  and  the  intermediate coupling  checked  for  freedom  of  movement. Connect supply and return lines securely. Install  high  pressure  injection  lines.  Use  copper  gaskets  or  steel  washers  where  required.  Leave  fuel line  connections  at  the  pump  and  nozzles  loose. Apply 17.6 V to electric shutoff solenoid and operate pump at 1000 rpm (WOT) for 10 minutes to bring  to  operating  temperature  and  clear  air  from  system. Tighten  all  connections  securely.  Check  connections  for  leaks  while  operating. Set  transfer  pump  pressure  at  2000  rpm  (WOT)  for  60-62  psi  (414-427  kPa);  test  stand  boost  should be set at 5 ± 0.5 psi (34.5 ± 3.4 kPa). Set  return  oil  flow  to  225-375  cc/minute  at  2000  rpm  (WOT). Measure housing pressure: (a) Check housing pressure at 650 rpm, with throttle shaft in low idle position, pressure should be  8-12  psi  (55-83  kPa). (b)  Energize  housing  pressure  cold  advance  solenoid  with  17.6  V.  Housing  pressure  should  be 0-1  psi  (0-7  kPa). With governor cover removed and throttle shaft in low idle position, set min-max governor assembly for  7-9  mm3/stroke  at  650  rpm  (fuel  reading  with  cover  installed). NOTE If  low  idle  screw  adjustment  is  required,  refer  to  step  3.  Adjust- ment is ± 1 turn from the point in step 3. At 650 rpm, adjust low idle screw for 13-15 mm3/stroke for the remainder of the setting and checking procedures. During  and  at  the  completion  of  all  settings,  ensure  face  cam  to  throttle  shaft  end  play  measures 0.004-0.006-in.  (0.10-0.15  mm)  between  throttle  shaft  spacer  and  housing. At  3400  rpm  (WOT),  rotate  face  cam  to  its  maximum  lift  position  in  contact  with  the  cam  roller. Adjust  trimmer  screw  at  3400  rpm  (WOT),  for  4.0  degrees  cam  advance  and  set  fuel  delivery  to 50-51 mm3/troke. Set  guide  stud  for  35.5-37.5  mm3/stroke  at  3650  rpm  (WOT).  Tighten  guide  stud  nut  to  80-90  lb-in. (9-10  N•m)  and  check  dimension  from  top  of  nut  to  top  of  guide  stud  for  0.400-in.  (10.2  mm) maximum. Set  throttle  for  21.5-23.5  mm3/stroke  at  3200  rpm  and  rotate  face  cam  to  obtain  5.10  degrees  cam advance. Tighten  face  cam  screw  to  28-30  lb-in.  (3  N•m)  and  check  face  cam  retention. (a)  Put  0.005-in.  (0.127  mm)  feeler  gauge  between  throttle  shaft  mylar  washer  and  housing  boss. (b) Put throttle shaft in idle position. Squeeze throttle shaft and face cam tightly toward each other  and  rotate  face  cam  as  lower  roller  rests  approximately  in  middle  at  low  idle  step. Tighten  screw  to  30  lb-in.  (3  N•m)  with  torx  bit  and  remove  feeler  gauge. Set  total  throttle  travel.  With  throttle  in  low  idle  position,  align  zero  degree  mark  on  protractor with  center  of  rib  on  rocker  lever.  Move  throttle  to  WOT  and  adjust  maximum  travel  screw  to 75-84  degrees. NOTE Any changes to pump or settings after this point will require retesting  of  pump,  starting  with  step  12. 2-139


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