INJECTION PUMP SPECIFICATION ©

FULL LOAD RPM: 1500 CUSTOMER PART #: 2643U207 AC MODEL NO.: DB2435-5117
GOV. REGULATION: 3-5 % CUSTOMER'S NAME: SUPERSEDES:
ENGINE: 1004.4 PERKINS ENGINES LIMITED EDITION NO.: 18
APPLICATION: GENERATOR DATED: 11/17/2017
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: 1.968" ± .001"
.063" (1.6 mm) I.D. X 25" (635 mm) LONG. (49.99 ± .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). 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: 110°-115°F (43°-46°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 +1 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: IT-004 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 76.5-77.5 mm³/STROKE.
(REF. SL-222)(REF. S.B. 97R FOR SPEED DROOP) 8. 1575 RPM (WOT): ADJUST HIGH IDLE SCREW TO OBTAIN 4 MAX.,
1. 1000 RPM (WOT): OPERATE PUMP FOR 10 MIN. TO BRING TO 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 4 MAX., 10. CHECK POINTS:
mm³/STROKE.
4. CHECK POINTS: (SEQUENCE MUST BE FOLLOWED AS LISTED) THROTTLE T.P.
RPM POSITION mm³/STROKE PRESSURE
THROTTLE a. 1575 WOT 4 MAX. ---
RPM POSITION mm³/STROKE b. 1500 WOT* 4 MAX. ---
a. 1625 WOT 4 MAX. c. 1450 WOT 76.5-77.5 64-69***
b. 1500 WOT* 4 MAX. d. 400 WOT* 4 MAX. ---
c. 1500 WOT 75.5-78.5 e. 200 WOT 35 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 2 ± 1/4 TURNS FROM
FULL COUNTERCLOCKWISE POSITION AFTER TEST.
c. SEAL FASTENERS PER S.B. 134R AND 365R1.
d. CHECK PUMP FOR MODIFICATION NAME PLATES PER S.B. 490.
e. AIR TIME PUMP USING STANADYNE AIR TIMING FIXTURE 42973
WITH HUB ADAPTER 29711. CONNECT AIR SUPPLY WITH 60-100
PSI (4.1-6.9 BAR) TO #1 CYLINDER OUTLET. SET TOOL TO 291°
AND INSTALL TO DRIVE SHAFT. SLOWLY ROTATE TOOL
CLOCKWISE 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.

© STANADYNE Corporation, all rights reserved. Unless otherwise specified, no part of this publication may be reproduced or utilized in any
form or by any means, electronic or mechanical, including photocopying and microfilm, without permission in writing from the publisher.
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Note:

Note:

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

Note:

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

 DB2435-5117 EDITION 18 DATED 11/17/2017 Page 4 of 4

FOR SERVICE USE ONLY

APPLICABLE SERVICE ASSEMBLIES FOR ENGINEERING USE ONLY
Assembly Description DATE ECN NO EDITION
17776 THROTTLE SHAFT BUSHING REPLACEMENT 03/19/1993 22193 1
26431 ESO MOUNTING AND GROUNDING KIT 04/30/1993 22452 2
32980 PILOT TUBE REPLACEMENT (REF SB 171C) 05/26/1993 22527 3
33814 GASKET KIT 06/08/1993 22571-M 4
11/03/1993 22813 5
12/22/1993 22970 6
01/20/1994 22970 7
06/17/1994 22964 8
10/07/1994 23463 9
05/01/1996 22970 10
05/15/1996 22970 11
05/30/1997 24969 12
07/20/2000 26953 13
07/31/2003 27563 14
07/11/2008 31501 15
01/30/2014 36592 16
09/24/2014 37305 17
11/17/2017 39745 18