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REPAIR (cont) - TM-5-4210-220-34_182
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TM-5-4210-220-34 Truck Firefiighting 1000 GPM Multipurpose Model 2500L Manual
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Assembly After Repair
TM 5-4210-220-34 2-19. ENGINE - Continued (10)  Be very careful with the plunger (5).  After cleaning do not touch the plunger surfaces with your fingers Check for sharp edges on that portion that rides In the gear Remove edges with 500 grit stone. (11)  Check bushing (13) bleed hole (on side) is not plugged.  Keep the bushing (13) and plunger (5) together as   these   are   mated   parts.      Slip   plunger   into   bushing   Check   for   free   movement.   Replace   both components If required (12)  Inspect teeth on the control rack (10) and control rack gear (9).  Check for excessive wear or damage to the teeth (13)  Check for excessive wear of the bore of the gear (9) and the gear retainer (12).  Both should be a snug fit on the flats of the plunger. (14)  Inspect the injector follower (4) for wear.  If the face requires refinishing, this must be flat ground.  The distance between face and plunger slot must never be less than 1.645 in. otherwise injector timing will be incorrect.  New followers are 1.647 + 0.002 in.  (41.83 + 0.05 mm). (15)  Inspect both ends of spill deflector (21) for burrs.  Remove with 500 grit stone. (16)  Inspect follower spring (6) for usual defects.  Check spring with tester J22738-02.  Spring free length is 1.504 in.  (38.20 mm).  Spring wire diameter is 0 142 in.  (3.61 mm).  A load of 70 lb (31.8 kg) should compress spring to 1.028 in.  (26.11 mm) or greater.  Replace spring if any specification is not satisfied or spring is cracked, broken, or badly corroded. (17)  Check  the  seal  ring  area  on  the  Injector  body  for  burrs  or  scratches.    Discard  injector  body  (8)  if evidence of damage is found.  Check surface which contacts the injector bushing similarly.  Replace any loose injector body plugs or dowel pin. (18)  Examine  the  spray  tip  seating  surface  of  the  injector  nut  and  spray  tip  for  nicks,  burrs,  erosion  or brinelling, Reseat the surface or replace the nut or tip If severely damaged. (19)  Inspect valve spring (16) and replace if worn or broken. (20)  Inspect   the   sealing   surfaces   shown   with   a magnifying   glass.      Check   for   burrs,   nicks, erosion,  cracks,  chipping  or  excessive  wear. Replace any component failing inspection. (21)  Examine needle valve seating area in the spray tip   for   wear   or   damage   or   foreign   material. Polish    the    seat    area    with    polishing    stick J22964.      Coat   the   taper   end   of   stick   with compound    J23038    and    insert    directly    into center of spray tip until it bottoms.  Rotate the stick 6 to 12 times applying light pressure. Ensure the tapered surfaces higher up in the spray tip are not contaminated with the 2-187 compound. After lapping, wash seat with dry cleaning solvent (item 10, Appendix B).  Carry out the needle valve tip test detailed in TEST preceding. 2-187

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