INJECTION PUMP Mom.

DB2829ADE4368
SUfSRStDES MODEL
SPECIFICATION CUSTOMER PART NO. 18o7551cgl
1 I fERVICE/ASSEHBLY CUSlOMEt’S NAME 8 ADDRESS
EDITION NO.’ 10 DATED g/29/89 lwLmRxmmwIw6uqRp.
@NG’Nl 6.9L 19B4/85 165 HP full LOAD WH 3000 INDIANAPDLIS, INDIANA
A"L'c*T'ON l S" feri~?S ClrgOStW DOV. REDULAtlo,, 10 % ISSUED SY Ft. KapalcrynskI

NOTE: ALL SPEEDS ARE IN ENGINE RaPoH. UNLESS OTHERWISE NOTED

,--
USE LATESTREVISION FDR KL REFERENCED OOCLMENTS.
TEST STAND 7. b. UHENAIR BUBBLESCLEARFROMRETURNLINE. SET TRANSFER
1. INJECTION LINES.... .07Bto. x 25.LG.(REF. S.B.BO) PIMP PRESSUREAT 94-96 FS1.
2. NOZZLESPER SAL 5968 YITH AB O.Yn PLATEI AB F/N YSF C. .REDUCESPEEDTO 1400 RPM, ADJUST RETURNOIL TO m-500 CC/MIN.
2044 A 5X-SPRING 8. Al 4OD RF?4(UDT)
3. NOZZLEOPENIRGPRESSURE........l?OD t 25 PSI 6. DE-ENERGIZEE.5.D. CHECKFUEL DELIVERY 3W3/STR. Fax.
4. CALlBRATINGOIL-SAE 5967 b. MOVETMDTTLE TO (11) CHECKE.S.O. FOR PULL-IN UITH
TEMPERATURE llO'-115.F or (43.46.C) AT INLET. 10.0 -O+D.2 VOLTS. FUEL SHOULDBE 15 &/STR. UIN.
5. LOU PRESSUREPLUWBINGSYSTEM- PER S.B.334 FIG. 14. c. CHECKFOR MINIWH LIn UF 18' HG.
5.0 t 0.5 PSI AT FWP INLET 9. FOR THE REKAINDEROF THE SETTINGPROCEDURE, CONTROLTHRDT-~LE
6. CAn Fl0VEtlEN-lREAD-OUTDEVICE P/N 23745 SHAn ENDPLAY TO .004"-.006" AS MEASURED BETYEENSPACER
7. KL FUEL READINGSARE Al 1000 nRDKES AND HOUSINGON TKtDlTLE LEVER SIDE.
FURP OPERATINGSPEED: HALF ENGINESPEED 10. AT 3000 RFH (ROT) (RDLLER-RDLLERSET POINT)
FWF ROTATION: CLOCKUISE &. ROTATETHE FACE CAMTO ITS MXIMlJH LIFT POSITION IN
PUMPACCESSORIES: CORTACTUITH CM ROLLER.
1. ELECTRIC SHIT-OFF (12V ETR) b. ADJUSTTRIWER SCREUFOR 4.25' CAR ADVANCE
2. WLL ADVANCE 6. NDUSINGPRESSURECOLDADV. c. SET FUEL DELIVERY 54.0-55.0 N43/ ROW.
3. DELIVERY VALVE 7. TRAILlNG PORTROTOR d. DE-ENERGIZEE,S.D. CHECKFUEL 4.@94 53/STROKE cw(.
4. MN-FlAX.GOVERNDR IV 8. TEHPERATURE COHPENSATOR RE-ENERGIZEE.S.P.
5. AtCUMULATDRS 11. AT 3150 Rp14(UDT)
a. SET 6UIDE STUD FOR 52.0-53.0~3'STROKE.
PUMPCALIBRATIONCHECKS:- AS RECEIVEDFOR SERVICE. b. AnER SETTING IS UBTAINED, TORDUENUT P/N 23585 TO 80_
(REF. S.L. 222) 90 LBS.-IN.
i. OPERATEPUMPAT 2ODORPn (UDT) FOR 10 IINLflES TO c. CHECKDIHENSION BETNEENTOP OF NUT fl TOP OF BUIDE
BRING TO OPERATINGTEWERATUREAND CLEARAIR FRON STUD FOR .400" FWX.
SYSTEM. 12. AT
2. YITH THROTTLELEVER IN LOU IDLE FOSITlON AT 4OD RR( a. :&!FiIROTTLE LEVER FOR 27-29 FR&STROKE, AND ROTATE
CHECKE.S.O. FOR FULL-IN YITH 10.0 -0-0.2 VOLTS. FUEL FACE CAMTO OBTAIN 3.0. CAMADVANCE.
DELIVERY SHOULDBE 15 Flh3/STROKE,FlINIHlM. b. AFTER SmING IS OBTAINED, TORQUESCREUP/N 22398 TO
3. CHECKPOINTS: (SEWENCE MIST BE FOLLOUED AS LISTED) 28-30 LBS. - IN.
c. UITH THROTTLEAT 28 FBf3/STRDKEPOSITION ALIGN 0’ ON
TWTL.
PROTRACTOR P/N 22089 UITH CENTERRIB ON ROCKERLEVER.
lM3/STROKE JAR WZWECIENT RELEASETHROTTLEAND ROTATE44. TOUARDUDT POSITION.
a. ~.;-&5 3.25'-5.25'
_w_ ADJ. CIAX. TRAVELSCREWTO THIS 44. SETTING.
b.
d. CHECKFACE CAMTDRDUERnENIION PER 5.8.361.
C. 3000 L.I. *--- * 9'-10'
d.
NOTE: ANY CHANGES
AFIER THIS POINT UILL REDUIRERETESTINGOF
c. w-e PUMP- STARTINGUITW STEP 10.
f.
L. 9.
h.
(7b)
1.5*-4.5.
_--
13. CHECKPOINYS:

3.rs;;.75* IB!3/(17iI CAM PRESSURE

i: !!%. 'ZL- STROKE MOVEMENT u HDUSING
150 MDT 33 MIN. w-w a. 3000 WT Sri0 4.0* - 4.5' _w- _--
b. 3000 1.1. --- B.O.-10.0" w-m -mm
4. TOTALTHROTTLETRAVELFRW LOU IDLE TO BIDE OPEN c. 3150 UDT w-- ..-
SHOULDBE 60'.70'. 125 MAX. ---
5. CHECKAIR TIHING USING SAUGEP/N 24205(PERS.B.375) w-s -we
SET TO -5.5. to -3.5' ..57.0-60.0 --- _-- ---
6. TIRED TO THIS CYLINDERVIEWEDFRDHT.P. END CAP 27-29 2.75'.3.25' w-w w-e
_w- a-12
_w- o-1
7. NOTES: 35 WIN. -.- 12 MN. ---
4. E.S.O. DE-ENERGIZED 6
b. READINGTO BE 6.25. '. 2.25.LESS THAN REA!WG OB- 14. CHECKTOTALTMDlTLE TRAVEL60' - 70.
TAINED IN STEP 34. 15. g ;I~E~FI~ USING GAGEP/N 24205 (PER s.B.3751
c. READINGTO BE B-16 ml/STROKE. MY DE RESO USING
LOU IOLC SCREU. 16. TIFIED To iHIS CYLINDERVIEUED FROWT.P. END CAP.@
6. READING TO BE 1.0. - 2.5' 6REATERTHAN READINGOB- 17. SPECIAL NOTES:
TAINED IN STEP 31. WITH HWSING PRESSURECOLDAD- a. T;R$ECKL FASTENERSPER S.B.106
VANCESOLENOIDENERGIZED. b. .
PUtIP SETTINGS: FOLLOWINGPVIP SERVICE
-c ER TO RO ER DIME $10 1.974" f -601
r.'kAX. ECCEhiR1C1TYNO04~'iiR
b. WITH (O/S) CAMRINi R-R DI,r~NsIon:d~:.oso~s.B.3la t. UDUSINGPRESSURECOLDADVANCE$DLENOIDIS DE-ENERGIZED
LINKAGEGAP . . . .145" TO .165"(S.B.95) EXCEPTAS REQUIREDIN STEPS 6c rnd 13i.
:* GUIDE STUD BOTTCVfED TO ONE TURNOUT OF HOUSING. d. SEAL PLW FASTENERSPER S.B. 365
6' 4. SET THROTTLEAT 49. AS MEASURED BETWEEN THROTTLE l . SEAL GUIDE STUD TO REARCOVERSCREUUITH P/N 1WOB
LEVERRETURNSPRING STUDc AND VERTICALG SEALING UIRE ASSEMBLY.
OF THROTTLESHAFTUITH GAGEP/N 24135. f. READINGTO BE 12-14 FBl3/STR. IF ADJUSTHEKIIS REWIRED,
b. ADJUSTLOU IDLE SCREWUNTIL CONTACTIS h4DE WITH USE 1.1. SCREW.MAX. ADJU5THENTIS t 1 TURN FROMPOINT
IDLE STOP BOSS. SET IN SYEP 4r.
5. ;TA& TEST STANDAND RUN FOR 10 MINUTESB 2000 RFH 9. READINGTO BE 1.25*-2.25. %EATER THAN READING OBTAINED
IN STEP 13h. WITH UDUSINGPRESSURECOLDADVANCE
6. AT-650 RPM SOLENDIDENERGIZED.
4. WITH THROTTLESHAFT IN LOU IDLE POSITION, ADJUST h. READINGTO BE 0.75.e1.75'LESf THAN READINGOBTAINED
TRANSFERFUHP PRESSURE TO 58-60 PSI. IN STEP 138.
b* UlTB tOYERRORCOVERF&MOVED,ADJUSTMW4X. 6OV. I. M6xlnum cylfnder to cylhdrr varlatlon snwI0 De = Q
ASSERBLYFOR 12-14 FW/STR. (FUEL READINGUITH IQ43 frm the rYerAge f;Q* Cf aF! CYy\39-5.
COVERIN5TALLED. CHECKHOUSINGFOR 8-12 PSI)
f. UITH HOUSING'PRESSURECOLDADVANCESOLENOIDENER-
GIZED. CHECKHOUSINGPRESSUREFOR 1 PSI &4X.
7. AT 3000 (UOT)
4. CHECKTEST STANDBOOSTPRESSURE 6.0 PSI tD.5
 ItRISING AND DRlVt Bk@Jf’ ,‘,I Il. ;y Bc:LoIPIIoI
9ISCII~lIDY ;:; WI1 II.
Pg. 2 of 3.
IQDEL ND. ~@2629ADE~~~ 1
22351 r

I
pP 12202 1 SCREY, cover lold down
SCREU,cover hold down *
LOCKN4SHER.Cover SCrW f 115Bt*-1, P
- ’ 13521 J MWIER. cww rem
-w

cw~. ~ssy..return line

SGAL, return lfnr connector
&SW, Governor cover
LOVER, )ovtrnot control
SCRCuASSEMBLY,vent or
SEAL, pilot tube 21661 thw 21665
$; d;;;:,s~ft SCREY,bad loctlng
l

*APPLY A LIBERALCOATINGOF SYN-KU BASE1241 COMPWND

'10 SFALS6 HOUSINGBEFOREAS3
INTO HOUSING.
SCM;, mu plate f.p.165
RING, shaft retalnlng
GASI&, tMn9 line cover
XREY. tlmln9 line cover 1 WASHER,spring
COVER,tImin line 23107 }z:w- 1 HCUSIWG
ASSEMBLV(2755g0.S.)
w
c
HEADAHDROTORbRDUP 24884 blEAD6RMORASSY.*
'11056 RUNGER. rotor (Basic)
/

RKLER, tern
SnDE. cwn roller
- 11438'
i 11062 TWU 11065 (O'SIZE)
S INDICATE0 ON ROTORSB6DR
hydrrullc herd plu9
CM RING (OR OVERSIZE2312D) 3119 12216 hydrrullc bead plup
zp\ -
aR 27833
COMNECTOR.fuel Pine
StAL, hydrtullt herd RN, lcokinp plate
SPRING. lcrf ME. locttn9
SCREY,lcrt spring rdj. SHER. locktn9 plrte
SPRING,dcllverywlve LVE, dellvery SB143R

:1
STOP. deltvery vtlve 23727 (O'SIZE)rd REVD.
REY, delivery vrlve
17049 PISTON, eccumuletor
SCREY, eccucplstun nt.
::c SPRlNG, etcuwlrtor piston
. . *IKDEKlED IfMS INCLUDED
TRANSFER
PLW CROW

I ny ZAINER. rotor
- :I% [NER. trrnrfcr pump
SEAL, ttrnsfer pap
-6 - 20511 4
i!%i?iL,~
SPRINt,trrns. pap blade : &ATKl ASSY..trms. punp
ROLLPIN

DRING,rrguletfn9
: AlE,trens. pmp pressure
PISTON, rrpuletln
PLUGASSY.. rrrg DPrte cdl.
1 \P, trmsfer pID end
SCREEN,inlet filter

1 DRIffi, governor Inner

SPRING, ldllnp
GOV. ARt4AND TMPERATURE
CDRPENSATDR ASSMBLY
! 1 MER, YX> sped sprtn9
1 PRING, pov. outer

EK::yV
i MD: 9ulde
ItIN - WJI ASSEHBLY 1 23610 1-1 JT, 9ulde stud
M ASSY., meterln velve
i ,PRINC,metertn9 ve?ve enn
SLEEVE,thrust 1 1 'W.VE. rtertng or 24441
IUSHER, thrust sleeve 1 lElAlNER ASSEWLY. 9~. uct9h.
: RETAINERASSY.@v. rcl@t
UE!GwT. Bovernor IBJBASSY..*ctght retainer
RING, 90~. crge retelnlnp : l2293! alfIG. flexible reteinlno
c. i
I LINKAGEGROUP I

l Lubrlcete
Per XL-984 RETAINER.throttle lev. SPr.
or SB.38: : SCREW.throttle spring
SHAFTASSEHgLY. throttle 1 24170 1 sm~ffi.
throttle lever
SPRING, low Idle 1 21358 1 LEVERASSEMBLY,throttle
SCREU, low Idle rdj. 1 21646 1 SCREW.uxtum travel.
)uT, Iqvcr l dj.
SPACER, throttle shaft . 1 14408 : noor AssmLY. gov. linte9c
h SCREW.gav. llnk.hook rdJ-
SEAL, thmttle shaf!. 1
2 17438 WSHER.Bov. llnt. ha& rdj
SPRING, 9ov. thrust 1 24870

WASHER,throttle shaft 1 144DB

:

:
K is
-&ernor llnkege
SY., 9ov.llnk.rd.l
SPRING; pvemor llnkegt
SCREU. fete cem 1 22398

FACECAH 1 27180
 hgr 3 of 3
MODEL~2. DBZB29ADE4368

AUTWATIC ADVANCE
6RUJp
I
light 101d rdwcc 1 4885
SPRIIJG,

SUL, Ptrton hole Plug

PLUGASSEMBLY.sPyin sfdc
1 II 1fALVE, servo
PISTON. servo odv.
br 27616O'rlrc
ICAL. Plunger 1
PIN, rKk(r lewr 1 I PLUB. rdvrncc pow sIdt

RING, retalnlng 2 i ItAL. plrton ho'lt ~1~9

LEVER'AS!rEtlBLY,
rocker l 1 i
* Lubr+rtc Per XL-984 Or 8.3'87 PIN. cm rdvtncc
ICREw. servo rdv. rdj. 1
PLUNGER,wvo WW0Z 1 SEAL. rdvrncc saw hole
SEAL, head bcatfnp WC* PLUG, rdvrncc screw hole
SCREH.htrd locct~n9 1

INSTALL GROUNDING STRAP

ON RIGHT SIDE VIEYING
I fLtnRlC WY-OFF OROW
I
INSUUTDR, termtnrl
TRANS. PUMPS.B.108 LOCUIUT, termin contrct
TERJmw, rlcctrlc shut-off
STRAP, tenn$nal grounding 20951 LOCKdASHER, tmminrl eontrct
LOCWASWER,cover screw 18493
WASHER,temhl contrct
NUT, terminal contact MAStlm, twalM1 lnsulrtlng
WSHER. tcnniM1 contxt :::::

SOLEKIlOASSY., cold rdvrnce

TUBE. lntulatlno
SOLENOIDFRAHE6 ARMASSY.
TUBE. insulating TcikL. l lcctrlc-ihut-off
l NDTf:'Apply a 11berl MSHER, termirul contrct
brsc 1241 cwnpound UASHER, tmiml conwt
23190 on Y.P.C.A. $1 WIT, ttmbul contact
before rsrc&l(ng tf I LOCXNUT. tcrrhn81 contact
,I 1204! 1 LOWASHER. tmnlnrl contact

FORSERVICEUSE O(LY FOR ENGIN! ING USE o(LY

APPLICABLE
SERVICE ASSEMBLIES NO tDITSON
~~EVISED 4

I, BASKETKIT
PILOT TUBEREPLACEaNT
#266X
I
w-14-h
9-4-80
11-12-84
!
::
i7D
f
%XT%T~B~~~~PL~~E~~ ;
'25
(FOR LEFT SIDE ONLYVlEUlNt f.p. Ml' l23BSO !3B-5 9
YKROTTLE WAFT BUSHINGREPLACEHENT
9/29/89 19513 l!
(FOR RIGHT SIDE ONLYVlEUlNG T.P. EN61
.OOEY D'SIZE ADVANCEPlSTON(SB393)