INJECTION PUMP SPECIFICATION ©

FULL LOAD RPM: 1800 CUSTOMER PART #: T832210078 MODEL NO.: DB2635-6221
GOV. REGULATION: 3-5 % CUSTOMER'S NAME: SUPERSEDES:
ENGINE: 1006 TG1A TIANJIN LOVOL ENGINE CO., LTD EDITION NO.: 5
APPLICATION: 102 KW GENERATOR TIER 0 TIANJIN, CHINA DATED: 11/20/2017
NOTE: THIS SPECIFICATION DEVELOPED WITH STANADYNE LOW DEAD VOLUME CALIBRATION INJECTORS.
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: 1.991" ± .001"
.063" (1.6 mm) I.D. X 25" (635 mm) LONG. (50.57 ± .025 mm)
2. CALIBRATING INJECTORS... STANADYNE P/N 37392 MAXIMUM ECCENTRICITY: .004" (0.10 mm) T.I.R.
(LOW DEAD VOLUME). 2. GOVERNOR LINKAGE GAP: .125"-.145" (3.2-3.7 mm)
0.6 mm ORIFICE PLATE NOP: 3000 PSI (207 BAR). (USE KIT #23093 S.B. 95)
3. CALIBRATING FLUID...SAE J967/ISO 4113 (REF. S.B. 201): 3. 0 RPM (WOT):
a. TEMPERATURE AT INLET: 110°-115°F (43°-46°C) a. SPEED DROOP SETTING: ASSEMBLE SPEED DROOP PER S.B.
b. SUPPLY PRESSURE (S.B. 334): 5.0 ± 0.5 PSI (34 ± 3 kPa) AT PUMP 97R. ENSURE CONTROL SPRING IS INSTALLED WITH 5.0 -½ +1
INLET. TURN ON CONTROL SPRING GUIDE.
b. TURN SPEED DROOP ADJUSTING CAP IN 5.0 TURNS FROM THE
PUMP INSTALLATION: IT-192 MINIMUM POSITION.
ROTATION-C-* c. BACK OUT HIGH IDLE SCREW.
NAME PLATE-L-SIDE** 4. 1000 RPM (WOT): OPERATE PUMP FOR 10 MINUTES TO BRING TO
#1 CYL.-9-O'CLOCK** OPERATING TEMPERATURE AND CLEAR AIR FROM SYSTEM.
THROTTLE-L-SIDE** 5. 400 RPM (WOT):
E.S.O. (12V E.T.R.) a. CHECK ESO SHUT-OFF: 4 mm³/STROKE, MAX.
b. CHECK FOR MINIMUM TRANSFER PUMP LIFT OF 18" HG.
* VIEWED FROM DRIVE END ** VIEWED FROM TRANSFER PUMP END (60 kPa).
6. 1800 RPM (WOT):
PUMP OPERATING SPEED...HALF...ENGINE SPEED a. SET TRANSFER PUMP PRESSURE FOR 84-86 PSI,
AIR TIMED TO HOUSING FLANGE (S.B. 177) (SEE SPECIAL NOTES) (579-593 kPa) (SUPPLY SET PER TEST STAND NOTE 3B)
b. ADJUST RETURN OIL TO 200-500 CC/MIN. RECHECK TRANSFER
PUMP CALIBRATION CHECKS: AS RECEIVED FOR SERVICE PUMP PRESSURE.
(REF. SL-222)(REF. S.B. 97R FOR SPEED DROOP) c. CHECK HOUSING PRESSURE FOR 8.5-13.5 PSI, (59-93 kPa).
1. 1000 RPM (WOT): OPERATE PUMP FOR 10 MIN. TO BRING TO 7. 1800 RPM (WOT): SET ROLLER-TO-ROLLER FUEL DELIVERY:
OPERATING TEMPERATURE AND CLEAR AIR FROM SYSTEM. 106-107 mm³/STROKE.
2. CHECK POINTS: (SEQUENCE MUST BE FOLLOWED AS LISTED) 8. TURN SPEED DROOP ADJUSTING CAP IN 5.0 TURNS FROM MINIMUM
DROOP POSITION.
THROTTLE 9. 1925 RPM (WOT): ADJUST HIGH IDLE SCREW TO OBTAIN
RPM POSITION mm³/STROKE 10-22 MAX. mm³/STROKE.
a. 1975 WOT 5 MAX. 10. TURN THE L.I. SCREW IN UNTIL THE SCREW JUST CONTACTS THE
b. 1925 WOT 25 MAX. THROTTLE BOSS. WITH THE THROTTLE IN THE WOT POSITION
c. 1800 WOT * 4 MAX. LOCK THE L.I. SCREW NUT.
d. 1800 WOT 104.5-108.5 11. CHECK POINTS:
e. 400 WOT * 4 MAX.
f. 150 WOT 51 MIN. THROTTLE T.P.
RPM POSITION mm³/STROKE PRESSURE
* E.S.O. DE-ENERGIZED a. 1975 WOT 5 MAX. ---
b. 1925 WOT 25 MAX. ---
c. 1800 WOT * 4 MAX. ---
d. 1800 WOT 106-107 84-86 ***
e. 400 WOT * 4 MAX. ---
f. 150 WOT 53 MIN. 10 MIN. **
* E.S.O. DE-ENERGIZED ** (69 kPa) *** (579-593 kPa)
12. SPECIAL NOTES:
a. TORQUE ALL FASTENERS PER S.B. 106.
b. SEAL FASTENERS PER S.B. 134R AND 365–R1.
c. 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 336°
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.

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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

 DB2635-6221 EDITION 5 DATED 11/20/2017 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 04/23/2012 34174 1
26431 ESO MOUNTING AND GROUNDING KIT 09/19/2013 36100 2
32980 PILOT TUBE REPLACEMENT (REF SB 171C) 02/03/2014 36596 3
33814 GASKET KIT 10/01/2014 37305 4
11/20/2017 39745 5