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INJECTION LINES REPLACEMENT - TM-5-4210-229-14P_193
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TM-5-4210-229-14P Truck Firefiighting 1000 GPM Multipurpose Model 2500L Manual
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FUEL INJECTION PUMP REPLACEMENT (cont) - TM-5-4210-229-14P_195
TM5-4210-229-14&P 4-76.  FUEL INJECTION PUMP REPLACEMENT (Continued). REMOVAL a. Disconnect accelerator cable or linkage from outer injection pump control lever (1). b. Remove injection pump timing pointer plug (2) and gasket from left side of pump mounting adapter. c. Rotate  engine  in  normal  operating  direction  until engine  front  cover  timing  pointer  is  approximately 90 degrees from top dead center dot on crankshaft pulley.  (The  injection  pump  is  driven  at  one-half engine  speed.    Therefore,  each  time  the  injection pump  hub  mark  (3)  is  aligned  with  injection  pump timing pointer (4), engine should be on number one cylinder compression stroke. d. Turn  engine  slowly  in  normal  direction  of  rotation until  timing  mark  (3)  on  hub  is  aligned  with  injec- tion   pump   timing   pointer   (4)   (observe   through mounting adapter timing plug hole (2)).  If engine is turned   past   timing   mark,   rotate   engine   counter- clockwise at least 90 degrees to remove gear train backlash.  Rotate  engine  until  timing  mark  (3)  and pump timing pointer (4) are aligned. e. Observe   engine   front   cover   timing   pointer   and crankshaft  pulley  degree  alignment.  To  ensure  an accurate  reading,  view  pointer  straight  on  the  en- gine  should  now  be  positioned  at  specified  static pump to engine timing. If timing is not within speci- fications,  rotate  engine  to  correct  crankshaft  posi- tion   (specified   degrees   before   top   dead   center) before  removing  injection  pump.  If  necessary  to rotate  engine  in  opposite  direction  of  normal  rota- tion to achieve specified timing, rotate engine to 90 degrees  before  top  dead  center  and  then  rotate engine to specified timing. This procedure takes up gear backlash. f. Remove   high   pressure   injection   lines   as   an   as- sembly   of   six   lines   from   injection   nozzles   and pump.  Cap  all  openings  to  keep  dirt  out  of  fuel system. g. Remove  or  disconnect  all  other  necessary  lines, hoses, and wires from pump. h. Cap all openings to keep dirt out of fuel system. i. Remove  injection  pump  drive  gear  access  cover capscrews and washers (5). 4-88

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