INJECTION PUMP SPECIFICATION

FULL LOAD RPM: 1500

GOV. REGULATION: 3-5 %
ENGINE: 1000.4TG
APPLICATION: GENERATOR

MODEL NO.: DB2435-5183

SUPERSEDES:
EDITION NO.: 11
DATED: 07-31-03

CUSTOMER PART #: U2643U216 NC

CUSTOMER'S NAME:
PERKINS ENGINES LIMITED

NOTE: ALL SPEEDS ARE IN ENGINE RPM UNLESS OTHERWISE NOTED.

USE LATEST REVISION FOR ALL REFERENCED DOCUMENTS.
TEST STAND:
1. CALIBRATING HIGH PRESSURE PIPES...SAE J1418/ISO 4093:
.063" (1.6 mm) I.D. X 25" (635 mm) LONG.
2. CALIBRATING INJECTORS... S.A.E. J968/ISO 7440:
0.5 mm ORIFICE PLATE NOP: 3000 PSI (207 bar) LONG.
3. CALIBRATING FLUID...SAE J967/ISO 4113 (REF. S.B. 201):
a. TEMPERATURE AT INLET: 100-108F (38-42C)
b. SUPPLY PRESSURE (S.B. 334): 5.0 0.5 PSI (34 3 kPa) AT
PUMP INLET.
4. CAM MOVEMENT READOUT DEVICE: # 23745
PUMP INSTALLATION: IT-004
ROTATION-C-*
NAME PLATE-L-SIDE**
#1 CYL.-8-O'CLOCK**
THROTTLE-L-SIDE**
E.S.O. (12V E.T.R.)
* VIEWED FROM DRIVE END ** VIEWED FROM TRANSFER PUMP END
PUMP OPERATING SPEED...HALF...ENGINE SPEED
AIR TIMED TO HOUSING FLANGE (S.B. 177)(SEE SPECIAL NOTES)
PUMP CALIBRATION CHECKS: AS RECEIVED FOR SERVICE
(REF. SL-222)(REF. S.B. 97R FOR SPEED DROOP)
1. 1000 RPM (WOT): OPERATE PUMP FOR 10 MIN. TO BRING TO
OPERATING TEMPERATURE AND CLEAR AIR FROM SYSTEM.
2. TURN SPEED DROOP TO MINIMUM POSITION (C'C DIRECTION).
3. 1625 RPM (WOT): RESET HIGH IDLE SCREW TO OBTAIN 4 MAX.,
mm/STROKE.
4. CHECK POINTS: (SEQUENCE MUST BE FOLLOWED AS LISTED)

a.
b.
c.
d.
e.

RPM
1625
1500
1500
400
200

THROTTLE
POSITION
WOT
WOT*
WOT
WOT*
WOT

* E.S.O. DE-ENERGIZED

mm/STROKE
5 MAX.
4 MAX.
87-92
4 MAX.
48 MIN.

PUMP SETTINGS: FOLLOWING PUMP SERVICE

1. ROLLER-TO-ROLLER DIMENSION: 1.976" .001"
(50.19 .025 mm)
MAXIMUM ECCENTRICITY: .004" (0.10 mm) T.I.R.
2. GOVERNOR LINKAGE GAP: .125"-.145" (3.2-3.7 mm)
(USE KIT #23093 S.B. 95)
3. SPEED DROOP SETTING: ASSEMBLE SPEED DROOP PER S.B. 97R.
ENSURE CONTROL SPRING IS INSTALLED WITH 3.5 TURN ON
CONTROL SPRING GUIDE
4. 1000 RPM (WOT): OPERATE PUMP FOR 10 MINUTES TO BRING TO
OPERATING TEMPERATURE AND CLEAR AIR FROM SYSTEM.
5. 400 RPM (WOT):
a. CHECK SHUT-OFF: 4 mm/STROKE, MAX.
b. CHECK FOR MINIMUM TRANSFER PUMP LIFT OF 18" HG.
(60 kPa).
6. 1500 RPM (WOT):
a. SET TRANSFER PUMP PRESSURE FOR 70-75 PSI,
(483-517 kPa)(SUPPLY SET PER TEST STAND NOTE 3B).
b. ADJUST RETURN OIL TO 225-475 CC/MIN. RECHECK TRANSFER
PUMP PRESSURE.
c. CHECK HOUSING PRESSURE FOR 4-10.5 PSI, (28-72 kPa).
7. 1500 RPM (WOT): SET ROLLER-TO-ROLLER FUEL DELIVERY:
90-91 mm/STROKE.
8. 1625 RPM (WOT): ADJUST HIGH IDLE SCREW TO OBTAIN
4 MAX., mm/STROKE.
9. TURN LI SCREW IN UNTIL THE SCREW JUST CONTACTS THE
THROTTLE BOSS WITH THE THROTTLE IN THE WOT POSITION.
LOCK LI SCREW NUT.
10. CHECK POINTS:

a.
b.
c.
d.
e.

RPM
1625
1500
1500
400
200

THROTTLE
POSITION
WOT
WOT*
WOT
WOT*
WOT

mm/STROKE
5 MAX.
4 MAX.
90-91
4 MAX.
50 MIN.

* E.S.O. DE-ENERGIZED ** (69 kPa)

T.P.
PRESSURE
----70-75***
--10 MIN.**

*** (483-517 kPa)

11. SPECIAL NOTES:

a. TORQUE ALL FASTENERS PER S.B. 106.
b. TURN SPEED DROOP ADJUSTING CAP 1 1/4 TURN FROM FULL
COUNTERCLOCKWISE POSITION.
c. CHECK PUMP FOR MODIFICATION PLATES PER S.B. 490.
d. SEAL FASTENERS PER S.B. 134R AND 365R1.
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 292 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.
12. IF LETTER "U" APPEARS IN FRONT OF CUSTOMER PART NUMBER,
PUMP IS PRELIMINARY VERSION AND MAY NOT MEET THE AS
RECEIVED SPECIFICATION. IN SUCH CASES, ALL PERFORMANCE
RELATED ADJUSTMENTS ARE CHARGEABLE TO THE CUSTOMER.

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.

DB2435-5183
DESCRIPTION

EDITION 11
QTY

P/N

DATED 07/31/2003

HOUSING & DRIVE GROUP

PAGE 2 OF 4

P/N

QTY

DESCRIPTION

21660

SCREW ASSY, VENT

OR 21661-21665

11331

SCREW, HEX HEAD

12259
10464

1
1

SCREW, PAN HEAD

WASHER, SEALING

26180
21522

1
2

BEARING, THRUST
WASHER, DRSFT SPRING

10443

RING, RETAINING

21521

WASHER, THRUST

11354

WASHER, PLAIN

1
1

SEAL, O-RING
SCREW, SCKT HEAD CAP
SCREW, SOCKET HD CAP

(60566)

SEAL, DRIVESHAFT

10453

DRIVESHAFT

30941

KEY, WOODRUFF

30387

SEAL, O-RING

16371

HOUSING ASSY, PUMP

SLEEVE, THROTTLE STOP

1
1

33060
24364

SCREW, RIVET

24419

NAMEPLATE

28771

GASKET, TIMING WINDOW CVR

27603

SCREW, HEX HEAD

21194

27602
11363

COVER, TIMING WINDOW

23107

10393

QTY

P/N

P/N

QTY

32100
11086

1
2

11438
12216
20727

1
1
4

H&R ASSY, HYD 4 CYL

PLUNGER, ROTOR
USE 11087-11090 (STD)
OR 11097-11100 (O/S)
AS IND. ON ROTOR SB 60R
SCREW, SET
SCREW, HEAD PLUG
CONNECTOR, FUEL LINE

29710

SCREW, SKT HEAD CAP

29384
27601
13823

1
1
1

13837

PLATE, SINTERED LOCK

SEAL, O-RING
VALVE, DELIVERY
OR 13824 O.S. AS REQ'D
REF. S.B. 143B
SCREW, DLVY VALVE RET

P/N

QTY

20530

RETAINER, ROTOR

21232

LINER, TRANSFER PUMP

20511

BLADE, TRANSFER PUMP

OR 20512 REF. S.B. 304

20528

RING, ROTOR RETAINER

28987

REGULATOR ASSY, TP

19855

SPRING, REGULATING

33128

CAP, TP END

NOTES:

DESCRIPTION

HEAD & ROTOR GROUP

DESCRIPTION

(60050)

ROLLER, CAM

11141

SHOE, CAM ROLLER

20116

RING, CAM

21687

SEAL, O-RING

27245

SPRING, LEAF

11197

SCREW, LEAF SPR ADJ

11175

SPRING, DLVY VALVE

16441

STOP, DELIVERY VALVE

16440

QTY

P/N

NOTES:

DESCRIPTION

TRANSFER PUMP GROUP

DESCRIPTION

(60023)

SEAL, TRANSFER PUMP

27608

SPRING, TP BLADE

15699

ROLL PIN

19837

SEAL, TP RGLTR SLEEVE

19844

PISTON, REGULATING

19895

PLUG ASSY, END PL ADJ

15228

FILTER, INLET

28986

NOTES:

INDENTED ITEMS INCLUDED

DB2435-5183
DESCRIPTION

EDITION 11
QTY

P/N

DATED 07/31/2003

GOVERNOR GROUP
(63251)

PAGE 3 OF 4

P/N

QTY

DESCRIPTION

20240

ROD ASSY-CONTROL

SPRING, SPEED DROOP

BLACK STRIPE

29530

ARM ASSY, GOVERNOR

24929

13554

PIN, CONTROL SPRING

WASHER, SEALING

SHAFT, GOVERNOR ARM

12214

27606

SEAL, O-RING

31332

12966

SEAL, O-RING

NUT, PIVOT SFT RTNR

12288

36556

CAP, ADJUSTING

SPRING, DAMPER

20475

20355

CAP, DROOP CTRL LOCK

PISTON ASSY, DAMPER

16572
27599

GUIDE, CONTROL ROD

18121
22134
11563

1
1
1

26427
20359

1
1

BARREL ASSY, DAMPER

ARM ASSY, MTR VALVE
VALVE, METERING
* SEE NOTE
SHIM, MTR VALVE SPRG
SPRING, MTR VALVE

29111

RETAINER ASSY, GOV WT

P/N

QTY

SLEEVE, GOV THRUST

14483

WEIGHT, GOVERNOR

11658

WASHER, THRUST
RING, RETAINING

1
1

20222
12285

NOTES:

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

DESCRIPTION

QTY

P/N

LINKAGE GROUP

DESCRIPTION

(60779)

SPACER, THROT SHAFT

16587

SEAL, O-RING

17438

16279

SHAFT, SHUTOFF

WASHER, SPACER

14408

12253

CLIP, SHAFT RETAINER

12221

LEVER, THROTTLE FORK

SHAFT ASSY, THROTTLE

29366

NUT, HEX

12174

12972

SCREW, HEX HEAD

SCREW, HEX HEAD

12972

12174

NUT, HEX

17605
12360
12362
17604

1
1
1
1

HOOK ASSY, GOV LKGE

SCREW, HEX HEAD
LOCK WASHER, SHPRF
HOOK, GOV LINKAGE

12358

LINK ASSY, ADJUSTING

11919

SPRING, GOVERNOR LINK

P/N

QTY

26564

RGLTR ASSY, HSG PRESS

27607

SEAL, O-RING

14760

NUT, HEX LOCK

28388

TERMINAL, ESO

NOTES:

DESCRIPTION

QTY

P/N

COVER GROUP

DESCRIPTION

(60026)

SCREW, BUTTON HD CAP

22351

12049
12500

2
2

WASHER, INTL TOOTH

WASHER, FIBER

NUT, HEX

12519

30789

CAP, COVER SCREW

WASHER, PLAIN

18501
30788

CUP, COVER SCREW

21898

COVER, GOV CONTROL

26214

SOLENOID, 12V ETR

2-23190 TUBE, INSULATE

SEAL, RECT SECTION

NOTES:

27244

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

INDENTED ITEMS INCLUDED

DB2435-5183

EDITION 11

DATED 07/31/2003

FOR SERVICE USE ONLY

APPLICABLE SERVICE ASSEMBLIES
THROTTLE SHAFT BUSHING REPLACEMENT
OVERHAUL GASKET KIT
ESO MOUNTING AND GROUNDING KIT
PILOT TUBE REPLACEMENT (REF SB 171C)

PAGE 4 OF 4

FOR ENGINEERING USE ONLY

DATE
CHANGE NO.
EDITION
17776
33814
26431
32980

11/01/1994
11/14/1994
11/29/1994
05/12/1995
07/11/1995
10/31/1995
07/07/1998
01/05/1999
02/07/2000
06/30/2000
07/31/2003

23333
23333
23333
23333
23333
23333
25738
25738
26664
26934
27563

1
2
3
4
5
6
7
8
9
10
11

INDENTED ITEMS INCLUDED