INJECTION PUMP SPECIFICATION ©

FULL LOAD RPM: 1500 CUSTOMER PART #: 2643U006 WT MODEL NO.: DB2435-4899
GOV. REGULATION: 3-5 % CUSTOMER'S NAME: SUPERSEDES:
ENGINE: 4.236 PERKINS ENGINES LIMITED EDITION NO.: 8
APPLICATION: GENERATOR DATED: 07-31-03
NOTE: THIS SPECIFICATION DEVELOPED WITH ISO LONG INLET STUD.
ALL SPEEDS ARE IN ENGINE RPM UNLESS OTHERWISE NOTED.
USE LATEST REVISION FOR ALL REFERENCED DOCUMENTS
TEST STAND: PUMP SETTINGS: FOLLOWING PUMP SERVICE
1. CALIBRATING HIGH PRESSURE PIPES...SAE J1418/ISO 4093: 1. ROLLER-TO-ROLLER DIMENSION: 1.966" ± .001"
.063" (1.6 mm) I.D. X 25" (635 mm) LONG. (49.94 ± .025 mm)
2. CALIBRATING INJECTORS... S.A.E. J968/ISO 7440: MAXIMUM ECCENTRICITY: .004" (0.10 mm) T.I.R.
0.5 mm ORIFICE PLATE NOP: 3000 PSI (207 bar) LONG. 2. GOVERNOR LINKAGE GAP: .125"-.145" (3.2-3.7 mm)
3. CALIBRATING FLUID...SAE J967/ISO 4113 (REF. S.B. 201): (USE KIT #23093 S.B. 95)
a. TEMPERATURE AT INLET: 100°-108°F (38°-42°C) 3. SPEED DROOP SETTING: ASSEMBLE SPEED DROOP PER S.B. 97R.
b. SUPPLY PRESSURE (S.B. 334): 5.0 ± 0.5 PSI ENSURE CONTROL SPRING IS INSTALLED WITH 3.5 ± ½ TURNS ON
(34 ± 3 kPa) AT PUMP INLET. CONTROL ROD SPRING GUIDE.
4. 1000 RPM (WOT): OPERATE PUMP FOR 10 MINUTES TO BRING TO
PUMP INSTALLATION: OPERATING TEMPERATURE AND CLEAR AIR FROM SYSTEM.
ROTATION-C-* 5. 400 RPM (WOT):
NAME PLATE-L-SIDE** a. CHECK SHUT-OFF: 4 mm³/STROKE, MAX.
#1 CYL.-8-O'CLOCK** b. CHECK FOR MINIMUM TRANSFER PUMP LIFT OF 18" HG.
THROTTLE-L-SIDE** (60 kPa).
E.S.O. (12V E.T.R.) 6. 1500 RPM (WOT):
a. SET TRANSFER PUMP PRESSURE FOR 65-70 PSI,
* VIEWED FROM DRIVE END ** VIEWED FROM TRANSFER PUMP END (448-483 kPa)(SUPPLY SET PER TEST STAND NOTE 3B).
b. ADJUST RETURN OIL TO 225-475 CC/MIN. RECHECK TRANSFER
PUMP OPERATING SPEED...HALF...ENGINE SPEED PUMP PRESSURE.
AIR TIMED TO HOUSING FLANGE (S.B. 177)(SEE SPECIAL NOTES) c. CHECK HOUSING PRESSURE FOR 4-10.5 PSI,(28-72 kPa).
7. 1500 RPM (WOT): SET ROLLER-TO-ROLLER FUEL DELIVERY:
PUMP CALIBRATION CHECKS: AS RECEIVED FOR SERVICE 71.5-72.5 mm³/STROKE.
(REF. SL-222)(REF. S.B. 97R FOR SPEED DROOP) 8. 1625 RPM (WOT): ADJUST HIGH IDLE SCREW TO OBTAIN
1. 1000 RPM (WOT): OPERATE PUMP FOR 10 MIN. TO BRING TO 4 MAX. mm³/STROKE.
OPERATING TEMPERATURE AND CLEAR AIR FROM SYSTEM. 9. TURN L.I. SCREW IN UNTIL THE SCREW JUST CONTACTS THE
2. TURN SPEED DROOP ADJUSTING CAP TO FULL THROTTLE BOSS WITH THE THROTTLE IN THE WOT POSITION.
COUNTERCLOCKWISE POSITION. LOCK L.I. SCREW NUT.
3. 1625 RPM (WOT): RESET HIGH IDLE SCREW TO OBTAIN 10. CHECK POINTS:
4 MAX. mm³/STROKE.
4. CHECK POINTS: (SEQUENCE MUST BE FOLLOWED AS LISTED) THROTTLE T.P.
RPM POSITION mm³/STROKE PRESSURE
THROTTLE a. 1625 WOT 4 MAX. ---
RPM POSITION mm³/STROKE b. 1500 WOT* 4 MAX. ---
a. 1625 WOT 4 MAX. c. 1500 WOT 71.5-72.5 65-70***
b. 1500 WOT* 4 MAX. d. 400 WOT* 4 MAX. ---
c. 1500 WOT 70.5-73.5 e. 200 WOT 25 MIN. 10 MIN.**
d. 400 WOT* 4 MAX.
e. 200 WOT 33 MIN. * E.S.O. DE-ENERGIZED ** (69 kPa) *** (448-483 kPa)
* E.S.O. DE-ENERGIZED 11. SPECIAL NOTES:
a. TORQUE ALL FASTENERS PER S.B. 106.
b. TURN SPEED DROOP ADJUSTING CAP 1 ± 1/4 TURNS FROM
FULL COUNTER CLOCKWISE POSITION AFTER TEST.
3. SEAL FASTENERS PER S.B. 134R & 365R
d. CHECK PUMP FOR MODIFICATION NAME PLATES PER S.B. 490.
e. AIR TIME PUMP USING HARTRIDGE BASIC AIR TIMING TOOL
7244-27 WITH INSERT 7244-28 AND PILOT RING 7244-26D
CONNECT AIR SUPPLY WITH 60-100 PSI (4.1-6.9 BAR) TO #1
CYLINDER OUTLET. SET TOOL TO 296° AND INSTALL TO DRIVE
SHAFT. SLOWLY ROTATE TOOL CLOCWISE UNTIL ROLLERS
STRIKE CAM RING AND TOOL STOPS, SCRIBE LINE ON
HOUSING FLANGE. REPEAT PROCEDURE TO ENSURE
ACCURACY. IF INTERFERENCE BETWEEN STRAIGHT EDGE
AND HOUSING FLANGE OCCURS, PLACE WASHER (i.e. 13521)
BETWEEN STRAIGHT EDGE AND TOOL.

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DB2435-4899 EDITION 8 DATED 07/31/2003 PAGE 2 OF 4
DESCRIPTION QTY P/N HOUSING & DRIVE GROUP P/N QTY DESCRIPTION
(60021)

21660 1 SCREW ASSY, VENT

SEAL, DRIVESHAFT 2 10453 OR 21661-21665

11331 2 SCREW, HEX HEAD

DRIVESHAFT 1 21519
REF. S.B. 378 12259 1 SCREW, PAN HEAD
10464 1 WASHER, SEALING
SEAL, O-RING 1 16371 26180 1 BEARING, THRUST
HOUSING ASSY, PUMP 1 33052 21521 1 WASHER, THRUST
SLEEVE, THROTTLE STOP 1 24364

SCREW, RIVET 2 24419

10443 1 RING, RETAINING
NAMEPLATE 1 28771 21522 2 WASHER, DRSFT SPRING
11354 1 WASHER, PLAIN
GASKET, TIMING WINDOW CVR 1 27603
27602 1 SEAL, O-RING
SCREW, HEX HEAD 2 21194 11363 1 SCREW, SCKT HEAD CAP
COVER, TIMING WINDOW 1 23107 10393 1 SCREW, SOCKET HD CAP

NOTES:

DESCRIPTION QTY P/N HEAD & ROTOR GROUP P/N QTY DESCRIPTION
(60065)
32100 1 H&R ASSY, HYD 4 CYL
11086 2 PLUNGER, ROTOR
ROLLER, CAM 2 11141 USE 11087-11090 (STD)
OR 11097-11100 (O/S)
SHOE, CAM ROLLER 2 20116 AS IND. ON ROTOR SB 60R
11438 1 SCREW, SET
12216 1 SCREW, HEAD PLUG
RING, CAM 1 21687 20727 4 CONNECTOR, FUEL LINE

29710 1 SCREW, SKT HEAD CAP

29384 1 PLATE, SINTERED LOCK

SEAL, O-RING 1 27245 27601 1 SEAL, O-RING
13827 1 VALVE, DELIVERY
SPRING, LEAF 1 11196 OR 13828 (O/S) AS REQ'D
REF. S.B. 143B
SCREW, LEAF SPR ADJ 1 11175 13837 1 SCREW, DLVY VALVE RET

SPRING, DLVY VALVE 1 16441

STOP, DELIVERY VALVE 1 16440

NOTES:

DESCRIPTION QTY P/N TRANSFER PUMP GROUP P/N QTY DESCRIPTION

(60023)
20530 2 RETAINER, ROTOR
SEAL, TRANSFER PUMP 1 27608
21232 1 LINER, TRANSFER PUMP
20511 4 BLADE, TRANSFER PUMP
OR 20512 REF. S.B. 304
20528 1 RING, ROTOR RETAINER
28987 1 REGULATOR ASSY, TP
SPRING, TP BLADE 2 15699
ROLL PIN 1 19837
SEAL, TP RGLTR SLEEVE 1 19844

19855 1 SPRING, REGULATING

PISTON, REGULATING 1 19895

PLUG ASSY, END PL ADJ 1 15228

FILTER, INLET 1 28986 33128 1 CAP, TP END

NOTES:

INDENTED ITEMS INCLUDED

DB2435-4899 EDITION 8 DATED 07/31/2003 PAGE 3 OF 4
DESCRIPTION QTY P/N GOVERNOR GROUP P/N QTY DESCRIPTION
(63250)
SPRING, SPEED DROOP 1 13558 20240 1 ROD ASSY-CONTROL
RED STRIPE
ARM ASSY, GOVERNOR 1 24929 13554 1 PIN, CONTROL SPRING

SHAFT, GOVERNOR ARM 1 12214 27606 1 WASHER, SEALING

SEAL, O-RING 2 31332 12966 1 SEAL, O-RING

NUT, PIVOT SFT RTNR 2 12288 36556 1 CAP, ADJUSTING

SPRING, DAMPER 1 20475 20355 1 CAP, DROOP CTRL LOCK

PISTON ASSY, DAMPER 1 16572

27599 1 GUIDE, CONTROL ROD
18121 1 BARREL ASSY, DAMPER
22134 1 ARM ASSY, MTR VALVE
SLEEVE, GOV THRUST 1 14483 11563 1 VALVE, METERING
* SEE NOTE
26427 1 SHIM, MTR VALVE SPRG
20359 1 SPRING, MTR VALVE
WEIGHT, GOVERNOR 6 11658
29111 1 RETAINER ASSY, GOV WT
WASHER, THRUST 1 20222
RING, RETAINING 1 12285

NOTES: * O.S. METERING VALVE AND ARM ASSEMBLY 22248 REFERENCE S.B.336

DESCRIPTION QTY P/N LINKAGE GROUP P/N QTY DESCRIPTION

(60052)

SPACER, THROT SHAFT 1 16587

SEAL, O-RING 2 17438 16279 1 SHAFT, SHUTOFF

WASHER, SPACER 2 14408 12253 1 CLIP, SHAFT RETAINER

12221 1 LEVER, THROTTLE FORK
SHAFT ASSY, THROTTLE 1 29366
NUT, HEX 1 12174 12169 1 SCREW, HEX HEAD
SCREW, HEX HEAD 1 12972 12174 1 NUT, HEX

17605 1 HOOK ASSY, GOV LKGE

12360 1 SCREW, HEX HEAD
12362 1 LOCK WASHER, SHPRF
17604 1 HOOK, GOV LINKAGE

12358 1 LINK ASSY, ADJUSTING

11919 1 SPRING, GOVERNOR LINK

NOTES:

DESCRIPTION QTY P/N COVER GROUP P/N QTY DESCRIPTION

(60026)

26564 1 RGLTR ASSY, HSG PRESS

27607 1 SEAL, O-RING
14760 2 NUT, HEX LOCK
28388 2 TERMINAL, ESO
SCREW, BUTTON HD CAP 3 22351 12049 2 WASHER, INTL TOOTH
12500 2 WASHER, FIBER

NUT, HEX 2 12519 30789 1 CAP, COVER SCREW

WASHER, PLAIN 2 18501

30788 1 CUP, COVER SCREW

SEAL, RECT SECTION 1 27244 21898 1 COVER, GOV CONTROL

26214 1 SOLENOID, 12V ETR

2-23190 TUBE, INSULATE

NOTES: E.S.O. TERMINAL ORIENTATION TO BE IN LINE WITH SIDES OF COVER

INDENTED ITEMS INCLUDED

DB2435-4899 EDITION 8 DATED 07/31/2003 PAGE 4 OF 4

FOR SERVICE USE ONLY FOR ENGINEERING USE ONLY

APPLICABLE SERVICE ASSEMBLIES DATE CHANGE NO. EDITION
THROTTLE SHAFT BUSHING REPLACEMENT 17776 05/26/1993 19975 1
PILOT TUBE REPLACEMENT (REF SB 171C) 32980 08/18/1993 22633M 2
OVERHAUL GASKET KIT 33814 06/20/1994 22964 3
ESO MOUNTING AND GROUNDING KIT 26431 11/28/1994 23564 4
07/07/1998 25738 5
01/05/1999 25738 6
02/07/2000 26664 7
07/31/2003 27563 8

INDENTED ITEMS INCLUDED