Thermo King KD-II SR, Manual

Page: 88 / 182

Engine Maintenance (Rev. 04/03)
74
2. Remove the injection line from the number 1 injector
and the injection pump. Remove the delivery valve
holder, delivery valve and spring. Care must be taken to
prevent dirt from entering the fuel injection system.
Replace the delivery valve holder and delivery valve.
3. Install a drip valve on the nozzle holder.
4. Activate the run solenoid and the fuel pump by turning
the unit switch ON. Make sure the Diesel-Electric
switch is in the DIESEL position.
CAUTION: The 8S wire on the starter motor
should be disconnected.
CAUTION: Loosen the injection lines on the
injection nozzles of the number 2 and 3 cylin-
ders to prevent any possibility of the engine firing.
5. The engine should be close to the top dead center posi-
tion with the plunger port in the pump closed. No fuel
should flow from the drip tube.
6. Turn the engine backwards past the injection timing
mark until fuel flows from the drip tube.
7. Slowly rotate the engine in the direction of rotation
while watching the drip tube. When the fuel flow slows
to approximately one drip every 10 to 15 seconds,
check the timing marks. They should be lined up.
8. If the timing marks did not line up, a shim or shims
will have to be added or subtracted from the injection
pump. Adding shims will retard the injection timing,
subtracting shims will advance the timing. Increasing
or decreasing shim thickness by 0.004 in. (0.1 mm)
will change the timing by 1
o
.
9. After shims have been added or subtracted, recheck the
timing.
10. When the injection pump has been correctly timed to
the engine, remove the pump and put a light coat of sil-
icone gasket sealer on the shim pack and the pump, or
dip the new shims in lacquer thinner to activate the
sealer.
11. Reinstall the pump, and torque the nuts to 18 to 20 ft-lb
(24 to 27 N•m).
12. Reinstall the delivery valve and spring. Torque the
delivery valve holder to 30 ft-lb (41 N•m).
13. Reinstall the injector lines, bleed the air from the
nozzles, and test run the engine.