NMWR 9-2815-560 Draft.pdf

NMWR 9-2815-560 – DRAFT

NATIONAL MAINTENANCE WORK REQUIREMENT INCLUDING REPAIR

PARTS AND SPECIAL TOOLS LIST

FOR

PUMP, FUEL, METERING AND DISTRIBUTING

FOR 6.5 LITER ENGINES

DB2831-6282, DB2831-6364

NSN 2910-01-641-0042

DB2831-6277, DB2831-6365

NSN 2910-01-633-7271

DB2831-6278, DB2831-6361

NSN 2910-01-633-7261

USED ON

HMMWV FOV

AVAILABILITY STATEMENT - This publication is not available through the St. Louis Media Distribution Division. This publication is available through US Army Tank-automotive and Armaments Command, ATTN: AMSTA-LCC-HL/TECH PUBS, Warren, MI 48397-5000.

SUPERSEDURE NOTICE - NMWR 9-281 5-560, dated XXXX 2018, supersedes NMWR 9-2815-560, dated 16 December 2011 including all changes.

DISTRIBUTION STATEMENT C - Distribution authorized to U.S. Government Agencies and their contractors only for Administrative- Operational Use as determined on Xxxx 2018. Other requests for this document shall be referred to US Army Tank-automotive and Armaments Command, ATTN: AMSTA-LCC-HL, Mail Stop 420, 6501 East 11 Mile Road, Warren, MI 48397-5000.

WARNING – This document contains technical data whose export is restricted by the Arms Export Control Act (Title 22, U.S.C., Sec 2751, et.

seq.) or the Export Administration Act of 1979 (Title 50, U.S.C., App. 2401 et seq.), as amended. Violations of these export laws are subject to severe criminal penalties. Disseminate in accordance with provisions of DoD Directive 5230.25.

DESTRUCTION NOTICE – Destroy by any means possible to prevent disclosure of contents or reconstruction of the document.

US ARMY TANK-AUTOMOTIVE AND ARMAMENTS COMMAND, WARREN,

MI

OCTOBER 2018

WARNING SUMMARY

This warning summary contains general safety warnings and hazardous materials warnings which must be understood and applied during operation and maintenance of this equipment. Failure to comply may result in serious injury or death to personnel.

FIRST AID

For information on first aid, refer to TC 4-02.1, First Aid (WP 0030).

Warning description

WARNING

Improper cleaning methods and use of unauthorized cleaning solutions may result in injury to personnel. Only use approved cleaning solutions and methods IAW shop safety standards. Failure to comply may result in injury or death to personnel. Seek medical attention in the event of an injury.

WARNING

When cleaning, protective clothing must be used. Use approved Personal Protective Equipment (PPE) IAW shop safety standards. Failure to comply may result in injury to personnel. Seek medical attention in the event of an injury.

WARNING

Wear adequate protective goggles/shields to prevent injury from possible airborne fragments. Use approved Personal Protective Equipment (PPE) IAW shop safety standards. Failure to comply may result in injury to personnel. Seek medical attention in the event of an injury.

WARNING

Cleaning compound solvent MIL-PRF-680 is flammable and must not be used near an open flame. A fire extinguisher must be kept nearby when cleaning solvent is used. Use only in well-ventilated areas. Failure to comply may result in injury to personnel. Seek medical attention in the event of an injury.

a

WARNING SUMMARY - Continued

Warning description - Continued

WARNING

• Solvent cleaning compound MIL-PRF-680 may be irritating to the eyes and skin.

Wear protective gloves and eye protection. First aid for skin contact: remove contaminated clothing. Wash skin thoroughly with soap and water. First aid for eye contact: flush with water for 15 minutes or until irritation subsides. Seek medical attention in event of injury. Failure to comply may result in injury or death to personnel.

• Use solvent cleaning compound MIL-PRF-680 in a well-ventilated area. Use respirator as needed. Accidental ingestion can cause irritation of digestive tract and respiratory tract. May cause lung and central nervous system damage. Can be fatal if swallowed. Inhalation of high/massive concentrations can cause coma or be fatal. First aid for ingestion: DO NOT induce vomiting. Seek immediate medical attention. First aid for inhalation: move to fresh air. If not breathing, provide artificial respiration. Seek medical attention in event of injury. If symptoms persist, seek medical attention. Failure to comply may result in injury or death to personnel.

• MIL-PRF-680 solvent is combustible. DO NOT use or store near heat, sparks, flame, or other ignition sources. Use mechanical ventilation whenever product is used in a confined space, heated above ambient temperatures, or agitated. Keep container sealed when not in use. Seek medical attention in event of injury. Failure to comply may result in injury or death to personnel.

WARNING

Ensure cleaning solvent container is sealed when not in use. Store, handle, and dispose of unused and spent solvents in accordance with local procedures and plans. Failure to comply may result in damage to environment and health of personnel. Seek medical attention in the event of an injury.

WARNING

Appropriate eye protection must be worn when cleaning with a wire brush, sandblast, grit blast, or other effective methods. Always wear appropriate eye protection (i.e. goggles/ shield/safety glasses) when using wire brush, sandblast, or grit blast. Use approved Personal Protective Equipment (PPE) IAW shop safety standards. Failure to comply may result in injury to personnel. Seek medical attention in the event of an injury.

WARNING

Paints, cleaning solvents, and primers may cause burns, skin irritation, and emit harmful vapors. Inhalation may cause irritation to upper respiratory passages. Keep paints, cleaning solvents, and primers away from fire or heat sources and use only in well-ventilated areas. Keep paints, cleaning solvents, and primers closed when not in use.

Always wear protective equipment such as goggles, face mask, gloves, and a proper respirator. If paints, cleaning solvents, and primers contact skin, wash immediately with soap and water. Failure to comply may cause injury to personnel. Seek medical attention in the event of an injury.

b

WARNING SUMMARY - Continued

Warning description - Continued

WARNING

Prolonged contact with lubricating oil may cause a skin rash. Skin and clothing that come in contact with lubricating oil should be thoroughly washed. Saturated clothing should be removed immediately. Areas in which lubricating oil is used should be well ventilated to keep fumes to a minimum. Failure to comply may result in injury to personnel. Seek medical attention in the event of an injury.

WARNING

Steam-cleaning is concentrated and may cause serious injury when pointed directly at oneself or someone else. Never point directly at oneself or someone else under any circumstances. Always wear approved Personal Protective Equipment (PPE) IAW shop safety standards. Failure to comply may result in serious injury to personnel. Seek medical attention in the event of an injury.

WARNING

Do not use compressed air to dry bearings. Spinning a dry bearing with compressed air may cause bearings to explode. injury to personnel and/or damage to equipment. Failure to comply may result in injury or death to personnel. Seek medical attention in the event of an injury.

WARNING

Compressed air is concentrated and may cause serious injury when pointed directly at oneself or someone else. Never point directly at oneself or someone else under any circumstances. Always wear appropriate eye protection (i.e. goggles/shield/safety glasses) when using compressed air. Use approved Personal Protective Equipment (PPE) IAW shop safety standards. Failure to comply may result in injury or death to personnel. Seek medical attention in the event of an injury.

WARNING

Compressed air used for cleaning purposes must not exceed 30 psi (207 kPa). Use only with effective chip guarding and personal protective equipment (goggles/shield, gloves, etc.). Failure to comply may result in injury or death to personnel. Seek medical attention in the event of an injury.

WARNING

Adhesives, solvents, and sealing compounds can burn easily, can give off harmful vapors, and are harmful to skin and clothing. Keep away from open fire and use in well-ventilated area. If adhesive, solvent, or sealing compound gets on skin or clothing, wash immediately with soap and water. If injury occurs, seek medical attention immediately. Failure to comply may result in injury or death to personnel.

c/blank

NOTE: This manual supersedes NMWR 9-2815-560, dated 16 December 2011 including all changes. Zero in the "Change No." column indicates an original page or work package.

Date of issue for the original manual is:

Original XXXX 2018

TOTAL NUMBER OF PAGES FOR FRONT AND REAR MATTER IS 22 AND TOTAL NUMBER OF

WORK PACKAGES IS 20 CONSISTING OF THE FOLLOWING:

Page/WP No. Change No.

Front Cover 0 Blank 0 a-b 0 i-ii 0 Chapter 1 - Title Page 0 Blank 0 WP 0001 (0 pages) 0 WP 0002 (0 pages) 0 Chapter 2 - Title Page 0 Blank 0 WP 0003 (0 pages) 0 Chapter 3 - Title Page 0 Blank 0 WP 0004 (0 pages) 0 WP 0005 (0 pages) 0 WP 0006 (0 pages) 0 WP 0007 (0 pages) 0 WP 0008 (0 pages) 0 WP 0009 (0 pages) 0 WP 0010 (0 pages) 0 WP 0011 (0 pages) 0 WP 0012 (0 pages) 0 WP 0013 (0 pages) 0 WP 0014 (0 pages) 0 WP 0015 (0 pages) 0 WP 0016 (0 pages) 0 WP 0017 (0 pages) 0 WP 0018 (0 pages) 0 WP 0019 (0 pages) 0 WP 0020 (0 pages) 0 Chapter 4 - Title Page 0 Blank 0 WP 0021 (0 pages) 0 WP 0022 (0 pages) 0 WP 0023 (0 pages) 0 WP 0024 (0 pages) 0 WP 0025 (0 pages) 0 WP 0026 (0 pages) 0 WP 0027 (0 pages) 0

Page/WP No. Change No.

WP 0028 (0 pages) 0 WP 0029 (0 pages) 0 Chapter 5 - Title Page 0 Blank 0 WP 0030 (0 pages) 0 WP 0031 (0 pages) 0 WP 0032 (0 pages) 0 WP 0033 (0 pages) 0 Inside Back Cover 0 Back Cover 0

NMWR 9-2815-560 – DRAFT

LIST OF EFFECTIVE PAGES/WORK PACKAGES

A/blank

US ARMY TANK-AUTOMOTIVE AND ARMAMENTS COMMAND

WARREN, MI, XXXX 2018

NATIONAL MAINTENANCE WORK REQUIREMENT INCLUDING REPAIR PARTS AND SPECIAL TOOLS

LIST

FOR

PUMP, FUEL, METERING AND DISTRIBUTING FOR 6.5 LITER ENGINES

DB2831-6282, DB2831-6364

NSN 2910-01-641-0042

DB2831-6277, DB2831-6365

NSN 2910-01-633-7271

DB2831-6278, DB2831-6361

NSN 2910-01-633-7261

REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS

You can help improve this manual. If you find any mistakes, or if you know of a way to improve the procedures, please let us know. Reports, as applicable by the requiring service, should be submitted as follows:

The preferred method is to submit your DA Form 2028 (Recommended Changes to Publications and Blank Forms) through the Internet on the TACOM Unique Logistics Support Applications (TULSA) website. The Internet address is https://tulsa.tacom.army.mil. Access to all applications requires CAC authentication, and you must complete the Access Request form the first time you use it. The DA Form 2028 is located under the TULSA Applications on the left-hand navigation bar.

Fill out the form and click on SUBMIT. Using this form on the TULSA website will enable us to respond more quickly to your comments and better manage the DA Form 2028 program. You may also mail, e-mail, or fax your comments or DA Form 2028 directly to the US Army Tank-automotive and Armaments Command. The postal mail address is US Army Tank-automotive and Armaments Command, ATTN: AMSTA-LCC-HL/TECH PUBS, MS 727, 6501 E. 11 Mile Road, Warren, MI 48397-5000. The e-mail address is usarmy.detroit.tacom.mbx.ilsc-tech-pubs@mail.mil. The fax number is DSN 786-1856 or Commercial (586) 282-1856. A reply will be furnished to you.

AVAILABILITY STATEMENT - This publication is not available through the St. Louis Media Distribution Division. This publication is available through US Army Tank-automotive and Armaments Command, ATTN: AMSTA-LCC-HL/TECH PUBS, Warren, MI 48397-5000.

SUPERSEDURE NOTICE - NMWR 9-281 5-560, dated XXXX 2018, supersedes NMWR 9-2815-560, dated 16 December 2011 including all changes.

DISTRIBUTION STATEMENT C - Distribution authorized to U.S. Government Agencies and their contractors only for Administrative- Operational Use as determined on Xxxx 2018. Other requests for this document shall be referred to US Army Tank-automotive and Armaments Command, ATTN: AMSTA-LCC-HL, Mail Stop 420, 6501 East 11 Mile Road, Warren, MI 48397-5000.

WARNING – This document contains technical data whose export is restricted by the Arms Export Control Act (Title 22, U.S.C., Sec 2751, et.

seq.) or the Export Administration Act of 1979 (Title 50, U.S.C., App. 2401 et seq.), as amended. Violations of these export laws are subject to severe criminal penalties. Disseminate in accordance with provisions of DoD Directive 5230.25.

DESTRUCTION NOTICE – Destroy by any means possible to prevent disclosure of contents or reconstruction of the document.

i

TABLE OF CONTENTS

Page No.

WP Sequence No.

Chapter 1 - GENERAL INFORMATION AND EQUIPMENT DESCRIPTION AND DATA

GENERAL INFORMATION................................................................................................................ WP 0001

EQUIPMENT DESCRIPTION AND DATA......................................................................................... WP 0002

Chapter 2 - TROUBLESHOOTING PROCEDURES

PRESHOP ANALYSIS....................................................................................................................... WP 0003

Chapter 3 - SUSTAINMENT MAINTENANCE INSTRUCTIONS

PRESERVATION, PACKAGING, AND MARKING GENERAL INFORMATION................................ WP 0004

GENERAL MAINTENANCE INSTRUCTIONS................................................................................... WP 0005

DISASSEMBLY.................................................................................................................................. WP 0006

INSPECTION AND REPAIR.............................................................................................................. WP 0007

ASSEMBLY........................................................................................................................................ WP 0008

GENERAL CALIBRATION SETUP INSTRUCTIONS........................................................................ WP 0009

CALIBRATION EFFECTIVITY (NSN 2910-01-641-0042) P/N: DB2831-6282, DB2831-6364.......... WP 0010

CALIBRATION EFFECTIVITY (NSN 2910-01-633-7271) P/N: DB2831-6277, DB2831-6365.......... WP 0011

CALIBRATION EFFECTIVITY NOTICE: (NSN 2910-01-633-7261) P/N:

DB2831-6278, DB2831-6361............................................................................................................. WP 0012

REMOVAL OF FUEL INJECTION PUMP FROM TEST STAND (MODEL A2000)........................... WP 0013

AFTER REPAIR PERFORMANCE TEST REPORT.......................................................................... WP 0014

DEPOT MOBILIZATION REQUIREMENTS...................................................................................... WP 0015

PREPARATION FOR STORAGE...................................................................................................... WP 0016

PREPARATION FOR SHIPMENT..................................................................................................... WP 0017

TRANSPORT..................................................................................................................................... WP 0018

QUALITY ASSURANCE REQUIREMENTS...................................................................................... WP 0019

TORQUE LIMITS............................................................................................................................... WP 0020

Chapter 4 - REPAIR PARTS AND SPECIAL TOOLS LIST (RPSTL)

REPAIR PARTS AND SPECIAL TOOLS LIST (RPSTL) INTRODUCTION....................................... WP 0021

GROUP 0302 Fuel Injection Pump..................................................................................................... WP 0022

GROUP 0302 Fuel Injection Pump Cover Assembly, Governor Linkage, and Related Parts.............WP 0023 ii

TABLE OF CONTENTS - Continued

Page No.

WP Sequence No.

GROUP 0302 Fuel Injection Pump Throttle Shaft, Regulator, Transfer Pump, and Related Parts....................................................................................................................................................WP 0024

GROUP 0302 Fuel Injection Pump Housing, Head and Rotor, Drive Shaft, and Related Parts.........WP 0025

GROUP 0302 Data Plates.................................................................................................................. WP 0026

GROUP 9401 Kits...............................................................................................................................WP 0027

NATIONAL STOCK NUMBER INDEX............................................................................................... WP 0028

PART NUMBER INDEX..................................................................................................................... WP 0029

Chapter 5 - SUPPORTING INFORMATION

REFERENCES................................................................................................................................... WP 0030

EXPENDABLE AND DURABLE ITEMS LIST.................................................................................... WP 0031

TOOL IDENTIFICATION LIST........................................................................................................... WP 0032

MANDATORY REPLACEMENT PARTS........................................................................................... WP 0033 iii/blank

CHAPTER 1

GENERAL INFORMATION AND

EQUIPMENT DESCRIPTION AND DATA

FOR

PUMP, FUEL, METERING AND DISTRIBUTING

FOR 6.5 LITER ENGINES

HMMWV FOV

BELOW DEPOT

GENERAL INFORMATION

SCOPE

This NMWR is for use by maintenance technicians at certified repair sites. The instructions in this NMWR apply to fuel injection pumps NSN 2910-01-641-0042, P/Ns DB2831-6282 and DB2831-6364; NSN 2910-01-633-7271, P/Ns DB2831-6277 and DB2831-6365; NSN 2910-01-633-7261, PNs DB2831-6278 and DB2831-6361; NSN 2910-01-434-8597, P/N DB2831-5079; NSN 2910-01-414-1272, P/N DB2831-5149; and NSN 2910-01-467-9029, P/N DB2831-5209. These fuel injection pumps are used with 6.5L engines, HMMWV FOV. The procedures contained in this NMWR describe disassembly, inspection, repair, assembly, and calibration to ensure a product that is serviceable and issuable to all customers without limitation or restriction, Condition Code A. In case of conflict with other information, the data contained in this NMWR shall take precedence.

You will use this NMWR to convert (NSN 2910-01-434-8597) to P/N: DB2831-6282, DB2831-6364 (NSN 2910-01-641-0042), (NSN 2910-01-414-1272) to P/N: DB2831-6277, DB2831-6365 (NSN 2910-01-633-7271), and (NSN 2910-01-467-9029) to P/N: DB2831-6278, DB2831-6361 (NSN 2910-01-633-7261).

Fuel injection pumps may be received in various stages of disrepair. Confirm that component parts conform to established standards. Reject all non-conforming parts.

Fuel injection pump repair procedures are the same for all models except where noted. Refer to pump data plate before ordering replacement parts.

Tolerances and wear limits established by this NMWR are the minimum acceptable standards. Parts, components, assemblies, or subassemblies not meeting these requirements will be disposed of in accordance with the appropriate directive.

Test requirements stated or referenced in this NMWR are the minimum acceptable standards. Components found to be worn or defective beyond the repair limits established by this NMWR shall be disposed of in accordance with current directives.

A performance test report shall be prepared for each fuel injection pump repaired. Performance Test Reports must be maintained by the repair activity along with calibration test printouts for a minimum of two years. For more information in the required test report see After Repair Performance Test Report (WP 0014).

Each repair activity shall, in accordance with the terms and conditions set forth herein, furnish equipment, facilities, and services required to perform inspections and completely repair the fuel injection pumps.

Before performing any overhaul activity, the maintenance technician shall become familiar with all procedures in this NMWR.

MAINTENANCE FORMS, RECORDS, AND REPORTS

Department of the Army forms and procedures used for equipment maintenance will be those prescribed by (as applicable) DA PAM 750-8 (WP 0030), The Army Maintenance Management System (TAMMS) Users Manual;

DA PAM 738-751 (WP 0030), Functional Users Manual for the Army Maintenance Management Systems - Aviation (TAMMS-A); or AR 700-138 (WP 0030), Army Logistics Readiness and Sustainability.

REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIR)

If your fuel injector needs improvement, let us know. Send us an EIR. You, the user, are the only one who can tell us what you do not like about your equipment. Let us know why you do not like the design or performance.

All non-Aviation/Missile EIRs and PQDRs must be submitted through the Product Data Reporting and Evaluation Program (PDREP) Web site. The PDREP site is: https://www.pdrep.csd.disa.mil/.

NMWR 9-2815-560 – DRAFT 0001

0001-1

REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIR) - Continued

If you do not have Internet access, you may submit your information using an SF 368 (Product Quality Deficiency Report) (WP 0030). You can send your SF 368 (WP 0030) using email, regular mail, or fax using the addresses/fax numbers specified in DA PAM 750-8 (WP 0030), The Army Maintenance Management System (TAMMS) Users Manual. We will send you a reply.

CORROSION PREVENTION AND CONTROL (CPC)

Corrosion prevention and control of Army materiel is a continuing concern. It is important that any corrosion problems with this item be reported so that the problem can be corrected and improvements can be made to prevent the problem in future items. The term “corrosion” means the deterioration of a material or its properties due to a reaction of that material with its chemical environment. An example is the rusting of iron. Corrosion damage in metals can be seen, depending on the metal, as tarnishing, pitting, fogging, surface residue, and/or cracking. Plastics, composites, and rubbers can also degrade (also considered to be corrosion based on the above definition of corrosion). Degradation is caused by thermal (heat), oxidation (oxygen), solvation (solvents), or photolytic (light, typically ultraviolet) processes. The most common exposures are excessive heat or light.

Damage from these processes will appear as cracking, softening, swelling, and/or breaking. The US Army has defined the following nine (9) forms of corrosion used to evaluate the deterioration of metals. These shall be used when evaluating and documenting corrosion.

UNIFORM (or general attack): Affects a large area of exposed metal surface, like rust on steel or tarnish on silver.

It gradually reduces the thickness of the metal until it fails.

CREVICE: Occurs in crevices created by rubber seals, gaskets, bolt heads, lap joints, dirt or other surface deposits. It will develop anywhere moisture or other corrosive agents are trapped and unable to drain or evaporate.

SELECTIVE LEACHING: One element, usually the anodic element of an alloy, corrodes away, leaving the cathodic element. This can create holes in metal.

INTERGRANULAR: Metal deterioration caused by corrosion on the bonds between or across the grain boundaries of the metal. The metal will appear to be peeling off in sheets, flaking, or being pushed apart by layers. A particular type of intergranular corrosion is exfoliation.

PITTING: This can result from conditions similar to those for crevice corrosion. Pits can develop on various materials due to their composition. Rifle boxes are big victims of pitting.

EROSION: Results when a moving fluid (liquid or gas) flows across a metal surface, particularly when solid particles are present in the fluid. Corrosion actually occurs on the surface of the metal, but the moving fluid washes away the corrosion and exposes a new metal surface, which also corrodes.

FRETTING: Occurs as a result of small, repetitive movements (e.g., vibration) between two surfaces in contact with each other. It’s usually identified by a black powder corrosion product or pits on the surface.

GALVANIC: Occurs when two different types of metal come in contact with each other, like steel bolts on aluminum, for example. This is a common problem on aircraft because of their mix of metals.

STRESS: Term used to describe corrosion cracking and corrosion fatigue.

Refer to TB 43-0213 (Corrosion Prevention and Control (CPC) for Wheeled Vehicles) (WP 0030).

Where an item is not ready/available due to one of these forms of corrosion, it shall be recorded as a corrosion failure in the inspection record and the appropriate code (170) for corrosion shall be used when requesting/ performing maintenance.

If a corrosion problem is identified, it can be reported as an EIR or PQDR. Use of key words such as "corrosion," "rust," "deterioration," or "cracking" will ensure that the information is identified as a CPC problem. SF Form 368, Product Quality Deficiency Report (WP 0030) should be submitted to the address specified in DA PAM 750-8, The Army Maintenance Management System (TAMMS) Users Manual (WP 0030).

0001-2

DESTRUCTION OF ARMY MATERIEL TO PREVENT ENEMY USE

Procedures for the destruction of Army materiel to prevent enemy use are contained in TM 750-244-6 , Procedures for Destruction of Tank-Automotive Equipment To Prevent Enemy Use (U.S. Army Tank-Automotive Command).

PREPARATION FOR STORAGE OR SHIPMENT

Military preservation, Level A packing and marking shall be accomplished in accordance with the specific packaging instructions in this WP and Preservation, Packaging, and Marking General Information (WP 0004).

Overhauled and inspected components shall be preserved, packed, and marked to preclude damage during transit and storage and to properly identify contents. The repair activity must perform packing, packaging, preservation, and marking requirements in accordance with applicable Special Packaging Instructions (SPI).

Packaging information can be found at https://www.ilsc.army.mil/tdps/index.asp by searching by one of the fuel injection pump NSNs or PNs. The most recent revision shall be used. You can also reference Preparation for Storage (WP 0016) or Preparation for Shipment (WP 0017).

LIST OF ABBREVIATIONS/ACRONYMS

Table 1. List of Abbreviations/Acronyms.

ABBREVIATION/

ACRONYM OFFICIAL NOMENCLATURE

AR Army Regulation

ASTM American Society for Testing and Materials

ATTN: Attention

C Centigrade/Celsius

CAGEC Commercial And Government Entity Code

CARC Chemical Agent Resistant Coating

CATT MSL/IRRD Computer Automated Transportation Tool Military Shipment Label/Issue Receipt Release Document cm centimeter

CPC Corrosion Prevention Control

CTA Common Table of Allowances

DA Department of the Army

DoD Department of Defense

ECP Engineering Change Proposal

EID Elastomer Insert Drive

EIR Equipment Improvement Recommendations

0001-3

LIST OF ABBREVIATIONS/ACRONYMS - Continued

Table 1. List of Abbreviations/Acronyms - Continued.

ABBREVIATION/

ACRONYM OFFICIAL NOMENCLATURE

EMP Electromagnetic Pulse etc. and so forth (Et Cetera)

F Fahrenheit

FIG. Figure

FIR Final Inspection Report

FITS Fuel Injection Test Stand

FOV Family of Vehicles ft Feet

HCI Hardness Critical Item

HMMWV High Mobility Multipurpose Wheeled Vehicle

IAW In Accordance With

in. Inches

ISO International Standards Organization

ISPM International Standards for Phytosanitary Measures kg Kilograms kPa Kilopascals

L.I. Low Idle lb Pounds lb-ft pound foot lb-in pound inch m Meter

MAC Maintenance Allocation Chart

MEL Maintenance Expenditure Limit

MIL-HDBK Military Handbook

0001-4

ABBREVIATION/

ACRONYM OFFICIAL NOMENCLATURE

MIL-STD Military Standard mm Millimeter

MSL Military Shipping Label

NHA Next Higher Assembly

NIIN National Item Identification Number

N·m Newton Meter

NMWR National Maintenance Work Requirement

No. Number

NSN National Stock Number

PAM Pamphlet

PDREP Product Data Reporting and Evaluation Program

PMI Precious Metal Indicator

P/N Part Number

PQDR Product Quality Deficiency Report psi Pounds per Square Inch

PUB Publication

QA Quality Assurance qty Quantity

RC Recoverability Code

RPM Revolutions per Minute

RPSTL Repair Parts and Special Tools List

SB Supply Bulletin

SC/SM Supply Catalogs/Supply Manuals

SF Standard Form

0001-5

ABBREVIATION/

ACRONYM OFFICIAL NOMENCLATURE

SMR Source, Maintenance, and Recoverability

SPI Special Packing Instructions

SRA Specialized Repair Activity

TACOM Tank-Automotive and Armaments Command

TAMMS The Army Maintenance Management System

TAMMS-A The Army Maintenance Management System - Aviation

TB Technical Bulletin

TM Technical Manual

TMDE Test, Measurement, and Diagnostic Equipment

TULSA TACOM Unique Logistics Support Applications

U/I Unit of Issue

UOC Usable On Code

US United States

WOT Wide-Open Throttle

WP Work Package

WPM Wood Packaging Materials

QUALITY OF MATERIAL

Material used for replacement, repair, or modification must meet the requirements of this NMWR. If quality of material requirements are not stated in this NMWR, the material must meet the requirements of the drawings, standards, specifications, or approved engineering change proposals applicable to the subject equipment.

ENGINEERING CHANGE PROPOSALS (ECP)

Engineering Change Proposals (ECPs) will be submitted in accordance with AR 70-1, Army Acquisition Policy (WP 0030), directly to the Commander, U.S. Army TACOM Life Cycle Management Command, ATTN:

AMSTALCC- HHM, Mail Stop 420, 6501 E. 11 Mile Road, Warren, Michigan 48397-5000. A reply will be furnished to you.

0001-6

DEVIATIONS AND EXCEPTIONS

Requests for deviations or exceptions to this National Maintenance Work Requirement (NMWR) will be processed in accordance with International Standards Organization (ISO) 9000 Series standards (WP 0030), or equivalent.

MOBILIZATION REQUIREMENTS

All requirements of this NMWR will be exempted or revised in the event of mobilization. Only those procedures necessary to return the fuel injection pump to a serviceable condition will be performed. The exemptions and revisions are explained in Depot Mobilization Requirements (WP 0014).

COST CONSIDERATIONS

This work requirement shall be the basis for establishing the extent of overhaul while taking into consideration cost factors. A determination shall be made on all subassemblies/assemblies to replace worn or damaged components which are available in supply, if acquisition cost is less than the cost to repair and restore to the NMWR standard. The cost to repair/restore any individual item with an established Maintenance Expenditure Limit (MEL) to the NMWR standard shall not exceed the MEL, unless a waiver has been approved in accordance with AR 750-1 (WP 0030). This requirement does not apply to items exempted from MEL in accordance with AR

750-1 (WP 0030).

END OF WORK PACKAGE

0001-7/blank

BELOW DEPOT

EQUIPMENT DESCRIPTION AND DATA

EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES

DB2 series fuel injection pumps are used with 6.5 Liter engines in the HMMWV Family of Vehicles (FOV). DB2 series pumps are opposed plunger, inlet metered, positive displacement, distributor type pumps. DB2 series pumps incorporate a single pumping chamber which rotates to deliver high pressure fuel. The fuel injection pump meters and delivers fuel to each cylinder at precisely timed intervals.

LOCATION AND DESCRIPTION OF MAJOR COMPONENTS

The locations of components illustrated in Figure 1 are common to all DB2 series fuel injection pumps used with 6.5L engines in the HMMWV FOV.

Figure 1. DB2 Series Pump.

DIFFERENCES BETWEEN MODELS

NSNs 2910-01-641-0042, 2910-01-633-7271, and 2910-01-633-7261 are replacements for NSNs 2910-01-434-8597, 2910-01-414-1272, and 2910-01-467-9029. The major changes from the old models to the new are in the housing and advance piston. The new housing, P/N 42575, is sleeved. The new advance piston, P/N 42580, is not plated. This will improve long-term reliability of the components and eliminate the need for oversized advance pistons for the new models.

To convert NSN 2910-01-434-8597 to NSN 2910-01-641-0042 use kit 42978 to add P/N 42575 housing assembly, P/N 42580 advance piston, P/N 42578 power side plug, P/N 42908 spring side plug, and two P/N 32982 O-rings to the MRP list. A new drive shaft bearing (P/N 23101) must be installed in the new housing assembly before proceeding to pump assembly. Calibrate the pump in accordance with (WP 0010).

NMWR 9-2815-560 – DRAFT 0002

0002-1

DIFFERENCES BETWEEN MODELS - Continued

To convert NSN 2910-01-414-1272 to NSN 2910-01-633-7271 use kit 42979 to add P/N 42575 housing assembly, P/N 42580 advance piston, P/N 42578 power side plug, P/N 42577 spring side plug, and two P/N 32982 O-rings to the MRP list. A new drive shaft bearing (P/N 23101) must be installed in the new housing assembly before proceeding to pump assembly. Calibrate the pump in accordance with (WP 0011).

To convert NSN 2910-01-467-9029 to NSN 2910-01-633-7261 use kit 42979 to add P/N 42575 housing assembly, P/N 42580 advance piston, P/N 42578 power side plug, P/N 42577 spring side plug, and two P/N 32982 O-rings to the MRP list. A new drive shaft bearing (P/N 23101) must be installed in the new housing assembly before proceeding to pump assembly. Calibrate the pump in accordance with (WP 0012).

EQUIPMENT DATA

1. Injection pump operating speed is half of engine speed.

2. Injection pump rotation is counterclockwise.

3. Injection pump is timed to the outlet port in the 10 o’clock position, when viewed from the transfer pump end.

END OF WORK PACKAGE

NMWR 9-2815-560 – DRAFT 0002

0002-2

CHAPTER 2

TROUBLESHOOTING PROCEDURES

FOR

PUMP, FUEL, METERING AND DISTRIBUTING

FOR 6.5 LITER ENGINES

BELOW DEPOT TROUBLESHOOTING

PRESHOP ANALYSIS

INITIAL SETUP:

Tools and Special Tools General Mechanic’S Tool Kit: Automotive (WP

0032, Table 1, Item 13)

Materials/Parts Cleaning Compound, Solvent (WP 0031, Table 1, Item 2) Cloth, Cleaning (WP 0031, Table 1, Item 5)

SCOPE

The purpose of the Preshop Analysis Checklist is to identify the condition of the component as received. This information comes from shipping labels, attached tags, and visual inspection.

PRESHOP ANALYSIS INSTRUCTIONS

1. Make a copy of the Preshop Analysis cover sheet and Preshop Analysis Checklist (Table 1).

2. Fill in the required information at top of the cover sheet.

3. Review accompanying shipping and maintenance tags and documents. These tags and documents may supply information helpful to the maintenance technician. Record any significant information, such as “housing cracked.”

4. Remove fuel injection pump from shipping container

5. Clean fuel injection pump as necessary to conduct preshop analysis.

6. Inspect items identified on Preshop Analysis Checklist.

7. Remove all tags, other than pump data plate, and documents from fuel injection pump. Develop a record file for the fuel injection pump. Include the tags and documents, completed Preshop Analysis Checklist, Test Report, and Final Inspection Report (FIR) in the record file. The Test Report will be completed during final testing and calibration of the rebuilt fuel injection pump. The FIR will be completed when preparing the rebuilt fuel injection pump for storage or shipment.

NMWR 9-2815-560 – DRAFT 0003

0003-1

PRESHOP ANALYSIS

FOR

P/N

Serial No.

NSN

MWOs Required

Reason(s) for Overhaul/Repair

Unpacking Secondary Items Required?

Reviewed Tags?

Reviewed Forms?

Name (please print)

Signature Date

0003-2

PRESHOP ANALYSIS CHECKLIST

Before disassembling the item, the item must first be inspected to determine its overall condition, serviceability, and whether further overhaul of subcomponents is needed. The Preshop Analysis Checklist, Table 1, is provided as a means of recording the condition and presence of components, assemblies, and subassemblies.

The checklist contains the following columns:

Inspection Point. This column lists the location and the order inspection procedure should be performed.

Condition. This column identifies the condition of items to be inspected.

Action. This column lists the type of inspection needed.

Remarks. This column lists what is found after inspection.

Date Checked. This column identifies the date item was inspected.

Checked By. This column identifies the person who inspected the item.

Table 1. Preshop Analysis Checklist.

INSPECTION

POINT CONDITION ACTION REMARKS DATE

CHECKED

CHECKED

BY

Fuel Injection Pump

Inspect for missing components

External Visual Inspection

Housing Inspect for obvious damage

External Visual Inspection

Drive Shaft Inspect for obvious damage

Check drive shaft rotation by attempting to turn and external visual inspection

END OF WORK PACKAGE

0003-3/blank

CHAPTER 3

SUSTAINMENT MAINTENANCE INSTRUCTIONS

FOR

PUMP, FUEL, METERING AND DISTRIBUTING

FOR 6.5 LITER ENGINES

BELOW DEPOT MAINTENANCE

PRESERVATION, PACKAGING, AND MARKING GENERAL INFORMATION

PACKAGING

Military preservation, Level A packing, and marking shall be accomplished in accordance with the specific packaging instructions contained in this WP and Preservation, Packaging, and Marking General Information (WP 0001).

MARKING FOR SHIPMENT AND STORAGE

Storage: In addition to any special markings called out on the special packaging instruction (SPI) or in the packaging requirements code, all unit packages, intermediate packs, exterior shipping containers, and, as applicable, unitized loads shall be marked in accordance with MIL-STD-129 (WP 0030) including bar coding. The repair facility is responsible for application of special markings as required by MIL-STD-129 (WP 0030) regardless of whether specified in the contract/order or not. Special markings include, but are not limited to, Shelf-life markings, structural markings, and transportation special handling markings. The marking of pilferable and sensitive materiel will not identify the nature of the materiel.

Shipment: The repair facility shall apply identification and address markings with bar codes in accordance with MIL-STD-129 (WP 0030). A Military Shipment Label (MSL) is required for all shipments except contractor to contractor. The MSL will include both linear and 2D bar codes per the standard. Military Shipping Label: Military Shipment Labels may be created using the Computer Automated Transportation Tool Military Shipment Label/ Issue Receipt Release Document (CATT MSL/IRRD) (WP 0030).

HEAT TREATMENT AND MARKING OF WOOD PACKAGING MATERIALS

Wood Packaging Materials (WPM) (e.g., boxes, crates, skids, pallets, and any wood used as inner packaging made of non-manufactured wood) shall be constructed of lumber that has been heat-treated in accordance with the requirements of International Standard for Phytosanitary Measures (ISPM) –15 (WP 0030). The WPM manufacturer shall be affiliated with an inspection agency accredited by the board of review of the American Lumber Standard Committee. The WPM manufacturer shall ensure traceability to the original source of heat treatment. Each piece of WPM shall be marked to show the conformance to the International Plant Protection Convention Standard. Certification markings shall be indelible and permanent. They may be stamped, stenciled, or branded directly onto or into the WPM. Certification marks shall be applied in a visible location on at least two opposite sides of the wood packaging product but are not required on each individual component piece of a wood packaging product. On dunnage, the marking shall be applied every 2 feet to opposite surfaces of each piece. If possible, the mark shall be visible when the dunnage is placed in the load to enable inspectors to verify the WPM’s compliance without unloading or unstuffing the container. Foreign manufacturers shall have the heat treatment of WPM verified in accordance with their National Plant Protection Organization’s compliance program.

ALTERNATIVES

The packaging requirements have been validated and the method of preservation/packing has proven successful in meeting the needs of the military distribution system, including undefined storage and shipment throughout the world. Tailoring of the packaging instructions may only be authorized by the packaging requirements developer. If tailored, prototype package is required to validate the sizes and fit requirements. Minor dimensional and size changes are acceptable provided e-mail notification is provided to the packaging requirements developer. Any design changes or changes in the method of preservation that provide a cost savings without degrading the method of preservation or packing or affecting the serviceability of the item will be considered and responded to within 10 days of submission. The equipment proponent reserves the right to require testing to validate alternate preservation methods, materials, alternates, blocking, bracing, cushioning, and packing.

NMWR 9-2815-560 – DRAFT 0004

0004-1

REUSE OF PACKAGING MATERIALS

The cushioning material and the fiberboard boxes may be reused provided:

a. There is no visible damage to material.

b. The foam cushioning has not taken a permanent set.

c. The fiberboard has no punctures, delaminating, or crushed flutes

The water vapor proof barrier bag shall never be reused. Always use new barrier material, evacuate air from the barrier bag, and conduct a snap test after 2 hours on each bag to ensure seal is holding. All components of the wood box/crate must be present, properly secured in position, and not broken. Splits are acceptable provided the boards remain secured and not loose. When reapplying the lid, fasteners shall be placed 1/2 inch away from the previous fastener hole. Strapping shall be applied per MIL-HDBK-774 (WP 0030).

CONTAINER REPAIR

Each long life metal reusable container will be inspected and reconditioned in accordance with TB 9-289 (WP 0030), TB 55-8100-200-24 (WP 0030), or SB 725-92-1 (WP 0030) and the applicable container drawing package.

Container drawings are available upon request from the packaging requirements developer. This reconditioning effort includes mandatory replacement of breather valves, humidity indicators, data plates, sealing gaskets, and desiccant, plus all shear mounts with an age factor of 5 years or older. It also includes a leak test after reconditioning, inspection and replacement of unserviceable wood skids, and touch up or total stripping and refinishing of the container surfaces with CARC paint.

END OF WORK PACKAGE

NMWR 9-2815-560 – DRAFT 0004

0004-2

GENERAL MAINTENANCE INSTRUCTIONS

INITIAL SETUP:

Tools and Special Tools General Mechanic’s Tool Kit: Automotive (WP

0032, Table 1, Item 13)

Materials/Parts Cleaning Compound, Solvent (WP 0031, Table 1, Item 2)

Materials/Parts (cont.)

Cloth, Cleaning (WP 0031, Table 1, Item 5) Injector Test Oil (WP 0031, Table 1, Item 7)

References

TM 9-214 (WP 0030)

1. General Instructions.

a. Procedures for cleaning must be done in accordance with the best commercial and/or local practices.

Parts and/or components that require special or specific cleaning procedures are addressed within maintenance work packages.

b. Great care and effort are required in all cleaning operations. The presence of dirt, dust, and foreign matter are the greatest enemies of the fuel injection pump. It is essential that clean work space, tools, and hands be used. Clean all parts before inspection, after repair, and before assembly.

2. Disassembled parts cleaning.

a. Keep all related parts and components together. Do not mix parts.

b. Keep all disassembled parts in wire baskets for cleaning.

c. A clean pan should be available in which parts may be placed during disassembly and a pan of clean fuel injector test oil must be available in which parts may be flushed.

d. It is recommended that deep pans with rounded corners be used to lessen the chance of dirt pockets developing.

e. Parts being stored must be lightly coated with oil and covered or wrapped in plastic or paper to protect from dust and/or dirt.

3. Castings.

a. Clean inner and outer surfaces of castings and all areas subject to grease and oil with degreasing solvents. Pay particular attention to bores, grooves, and seal seats.

b. Use a stiff brush to remove sludge and gum deposits

WARNING

Compressed air used for cleaning purposes must not exceed 30 psi (207 kPa). Use only with effective chip guarding and personal protective equipment (goggles/shield, gloves, etc.). Failure to comply may result in injury or death to personnel. Seek medical attention in the event of an injury.

c. Use compressed air to blow out all cap screw holes and to dry castings after cleaning.

4. Passages. Particular attention must be given to all passages in castings and machined parts. Passages must be clean and free of any obstructions.

a. Clean passages with wire probes to break up sludge or gum deposits.

NMWR 9-2815-560 – DRAFT 0005

0005-1

b. Wash passages by flushing with degreasing solvents.

WARNING

Compressed air used for cleaning purposes must not exceed 30 psi (207 kPa). Use only with effective chip guarding and personal protective equipment (goggles/shield, gloves, etc.). Failure to comply may result in injury or death to personnel. Seek medical attention in the event of an injury.

c. Dry passages with compressed air.

CAUTION

Do not allow degreasing solvents to come in contact with seals or flexible hoses. These cleaners cause rubber and synthetic materials to dry out, rot, and lose pliability making them unserviceable. Failure to comply may result in damage to equipment.

5. Nonmetallic Parts. Clean hoses and other nonmetallic parts with soap and water.

6. Electrical Components.

a. Clean electrical components with a clean cloth dampened with degreasing solvent. Care must be taken to avoid damage to protective insulation.

WARNING

Compressed air used for cleaning purposes must not exceed 30 psi (207 kPa). Use only with effective chip guarding and personal protective equipment (goggles/shield, gloves, etc.). Failure to comply may result in injury or death to personnel. Seek medical attention in the event of an injury.

b. Use compressed air to dry electrical components.

WARNING

Do not use compressed air to dry bearings. Spinning a dry bearing with compressed air may cause bearings to explode. injury to personnel and/or damage to equipment.

Failure to comply may result in injury or death to personnel. Seek medical attention in the event of an injury.

c. Refer to Inspection, Care, and Maintenance of Antifriction Bearings, TM 9-214 (WP 0030) for cleaning bearings.

END OF TASK

INSPECTION

1. General Instructions. Procedures for inspection will be the same for many parts and components of the fuel injection pump. General inspection procedures are detailed in Steps 2 - 10 .

2. Castings.

a. Inspect all ferrous and nonferrous castings for cracks. Replace all cracked castings.

b. Inspect all machined surfaces for nicks, burrs, and raised metal. Replace damaged parts.

c. Inspect all cap screws and cap screw openings for damaged and stripped threads. Replace components with damaged or stripped threads that cannot be repaired.

d. Check all gasket mating surfaces, flanges on housings for warping with a straight edge or surface plate. Inspect mating flanges for discoloration which may indicate leakage. Replace all parts with warped gasket mating surfaces.

3. Bushings and Bushing-Type Bearings.

0005-2

INSPECTION - Continued

a. Check all bushings and bushing-type bearings for secure fit, evidence of heating, wear, burrs, nicks, and out-of-round conditions.

b. Check for dirt in lubrication holes and grooves. Holes and grooves must be clean and free from damage.

4. Machined Parts.

a. Check machined parts for cracks, distortion, and damage. Replace damaged components.

b. Check all surfaces for nicks, burrs, and raised metal. Replace components showing significant damage.

c. Inspect all threaded plugs for damage. Replace damaged components.

5. Bolts, Cap scews, and Nuts. Replace if threads are damaged.

6. Seals. All seals are mandatory replacement items.

7. Springs. Inspect for damaged, distorted, and collapsed coils. Replace springs which are damaged, distorted, or have collapsed coils.

8. Snap Rings, Retaining Rings, and Washers. Many of these parts are mandatory replacement items. Inspect all others for obvious damage.

9. Non-metallic Parts. Replace if obvious damage or general deterioration.

WARNING

Do not use compressed air to dry bearings. Spinning a dry bearing with compressed air may cause bearings to explode. injury to personnel and/or damage to equipment. Failure to comply may result in injury or death to personnel. Seek medical attention in the event of an injury.

10. Bearings. Refer to Inspection, Care, and Maintenance of Antifriction Bearings, TM 9-214 (WP 0030) for cleaning bearings.

END OF TASK

REPAIR

CAUTION

Repaired items must be thoroughly cleaned to remove metal chips and abrasives to prevent them from entering working parts of the machine. Failure to comply may result in damage to equipment.

1. General Instructions. Repair of most parts and components is limited to procedures outlined in applicable maintenance instructions and the following detailed procedures.

2. Castings.

a. All cracked castings must be replaced.

b. Only minor repairs to machined surfaces, flanges, and gasket mating surfaces are permitted. Remove minor nicks, burrs, and/or scratches with:

1. Fine mill file.

2. Abrasive crocus cloth dipped in cleaning solvent.

3. Lapping across a surface plate.

0005-3

REPAIR - Continued

4. Re-matching of machined surfaces to repair damage, warpage, or uneven surfaces is not permitted. Replace castings with any of these conditions.

WARNING

Do not use compressed air to dry bearings. Spinning a dry bearing with compressed air may cause bearings to explode. injury to personnel and/or damage to equipment. Failure to comply may result in injury or death to personnel. Seek medical attention in the event of an injury.

3. Bearings. Refer to Inspection, Care, and Maintenance of Antifriction Bearings, TM 9-214 (WP 0030) for cleaning bearings.

4. Bushings and Bushing Type Bearings. When bushings and bushing-type bearings seize to a shaft and spin in the bore the associated part must also be inspected and replaced as required.

5. Seals.

a. Remove seals, being careful not to damage casting or adapter bore.

b. Always install new seal in bore using proper seal replacing tool.

6. Threads. Repair damaged threaded holes with a thread tap. Threaded inserts are not permitted.

END…