INJECTION PUMP SPECIFICATION ©

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FULL LOAD RPM: 2300 (SEE NOTE 16) CUSTOMER PART NO.: 3502 2028F MODEL NO.: DB4427-5015GOV. REGULATION: 8-10 % CUSTOMER NAME : VM SUPERSEDES:ENGINE: SUN 4 T EDITION NO.: 19APPLICATION: OEM DATED: 08-29-00

NOTE: ALL SPEEDS ARE IN ENGINE RPM UNLESS OTHERWISE NOTEDUSE LATEST REVISION FOR ALL REFERENCED DOCUMENTS

TEST STAND: ISO 4008:1. CALIBRATING HIGH PRESSURE PIPES...SAE J1418/ISO 4093:

.063" (1.6 mm) ID X 25" (635 mm) LONG.2. CALIBRATING INJECTORS........SAE J968/ISO 7440:

0.5 mm ORIFICE PLATE NOP: 3000 PSI (207 BAR)3. CALIBRATION FLUID: SAE J967/ISO 4113 (REF. S.B. 201)

a. TEMPERATURE 110°-115°F (43°-46°C) AT INLET.b. SUPPLY PRESSURE (S.B. 334): 5.0 ± 0.5 PSI

(34 ± 3 kPa) AT PUMP INLET.4. CAM MOVEMENT READ-OUT DEVICE: #23745.

PUMP INSTALLATION: IT-032ROTATION-C-* LEVER ANGLES (REF.)NAME PLATE-L-SIDE** THOT MIN.(∠B) N/A#1 CYL.-4-O'CLOCK** THOT MAX.(∠C) N/ATHROTTLE-L-SIDE** S.O. (∠ E) N/ATIMING MARK N/A S.O. (∠ F) N/AE.S.O. (12V E.T.R.)

* VIEWED FROM DRIVE END ** VIEWED FROM TRANSFER PUMP END

PUMP OPERATING SPEED...HALF...ENGINE SPEEDAIR TIMED TO HOUSING FLANGE (S.B. 177)(SEE SPECIAL NOTES)MARK WEIGHT CAGE TO CAM

PUMP CALIBRATION CHECKS: AS RECEIVED FOR SERVICE(REF. SL-222)1. 1000 RPM (WOT): OPERATE PUMP FOR 10 MINUTES TO BRING TO

OPERATING TEMPERATURE AND CLEAR AIR FROM SYSTEM.2. DISCONNECT ANEROID OPERATING ROD FROM SHUT-OFF LEVER

AND PLACE SHUT-OFF LEVER IN "RUN" POSITION BEFORECHECKING PUMP PERFORMANCE. S.B. 225R.

3. 2590 RPM (WOT): RESET HIGH IDLE SCREW IF NECESSARY TOOBTAIN 12-14 mm³/STROKE.

4. CHECK POINTS: (SEQUENCE MUST BE FOLLOWED AS LISTED)

THROTTLERPM POSITION mm³/STROKE ADVANCE

a. 150 WOT 48 MIN. ---b. 400 WOT* 4 MIN. ---c. 800 L.I.** 12-14 ---d. 800 WOT --- 0°e. 1150 WOT --- 2.5°-4.5°f. 1500 WOT 81-84 5.75°-6.25°g. 2300 WOT 69.5-75.5 ---h. 2300 WOT* 4 MAX. ---i. 2590 WOT 12-14 ---j. 2640 WOT 5 MAX. ---

* E.S.O. DE-ENERGIZED** RESET USING LOW IDLE SCREW, IF NECESSARY

PUMP SETTINGS: FOLLOWING PUMP SERVICE1. ROLLER-TO-ROLLER DIMENSION: 1.9635" ± .0015"

(49.87 mm ± 0.04 mm)MAXIMUM ECCENTRICITY: .004" (0.10 mm) T.I.R.

2. GOVERNOR LINKAGE GAP: .125" TO .165" (3.2-4.2 mm)(USE KIT #23093 S.B. 95).

3. 1000 RPM (WOT): OPERATE PUMP FOR 10 MINUTES TO BRING TOOPERATING TEMPERATURE AND CLEAR AIR FROM SYSTEM.

4. DISCONNECT ANEROID OPERATING ROD FROM SHUT-OFF LEVERAND PLACE SHUT-OFF LEVER IN "RUN" POSITION BEFORECHECKING PUMP PERFORMANCE. S.B. 225R.

5. 400 RPM (WOT):a. CHECK SHUT-OFF: 4 mm³/STROKE, MAX.b. CHECK FOR MINIMUM TRANSFER PUMP LIFT OF 18" HG.

(60 kPa)

PUMP SETTINGS: (CON'T) 6. 2300 RPM (WOT):

a. SET TRANSFER PUMP PRESSURE FOR 90-93 PSI,(620-641 kPa)(SUPPLY SET PER TEST STAND NOTE 3B).

b. ADJUST RETURN OIL TO 200-500 CC/MIN. RECHECK TRANSFERPUMP PRESSURE.

c. CHECK HOUSING PRESSURE FOR 4-10.5 PSI, (28-72 kPa). 7. 2300 RPM (WOT): BACK-OUT TRIMMER SCREW TO MEASURE 0.5O"

(1.27 mm) FROM FACE OF ADVANCE END PLUG. USING THE SPRINGSIDE ADVANCE PLUG, ADJUST FOR TOTAL ADVANCE TRAVEL OF 6°.

8. 1150 RPM (WOT): SET ADVANCE TRIMMER SCREW FOR 3.5°. 9. 1500 RPM (WOT): SET ROLLER-TO-ROLLER FUEL DELIVERY:

82.5-83.5 mm³/STROKE.10. 2590 RPM (WOT): ADJUST HIGH IDLE SCREW FOR 12-14

mm³/STROKE.11. 800 RPM (L.I.): SET LOW IDLE SCREW FOR 12-14 mm³/STROKE.12. CHECK POINTS:

THROTTLE T.P.RPM POSITION mm³/STROKE ADVANCE PRESSURE

a. 150 WOT 50 MIN. --- 10 MIN.**b. 400 WOT* 4 MAX. --- ---c. 800 L.I. 12-14 --- ---d. 800 WOT --- 0° ---e. 1150 WOT --- 2.5°-4.5° ---f. 1500 WOT 82.5-83.5 5.75°-6.25° ---g. 2300 WOT 71-74 --- 90-93***h. 2300 WOT* 4 MAX. --- ---i. 2590 WOT 12-14 --- ---j. 2640 WOT 5 MAX. --- ---

* E.S.O. DE-ENERGIZED ** (69 kPa) *** (620-641 kPa)

13. ANEROID SETTING (OFF TEST STAND) S.B. 225R.1. SET ANEROID TRAVEL TO .630" ± 0.025" BY USING REAR SHUT-

OFF ADJUSTING SCREW.2. CONNECT ANEROID ROD TO LEVER. LEVER SHOULD LIFT OFF

FRONT SCREW AT 3" TO 4" HG. (1.5-2.0 PSI). FULL TRAVEL OFLEVER SHOULD BE OBTAINED AT 13" TO 15" HG. (6.4 TO 7.4 PSI). IF LEVER MOTION REQUIRES MORE THAN 4" HG. (2.0 PSI),LENGTHEN ROD. IF LESS THAN 3" HG. (1.5 PSI) IS REQUIREDSHORTEN ROD.

3. RE-CHECK RESPONSE AND REPEATABILITY.4. POSITION ANEROID INLET AT 12 O’CLOCK, VIEWING END CAP.

14. SPECIAL NOTES:a. TORQUE ALL FASTENERS PER S.B. 106.b. ASSEMBLE THROTTLE LEVER SPACER AND ARM IN B4-L

POSITION PER S.B. 164.c. ASSEMBLE SHUT-OFF ARM ASSEMBLY IN R4-R POSITION PER

S.B. 164.d. SET FORWARD SHUT-OFF ADJUSTING SCREW AT 1500 RPM

FOR 60 mm³/STROKE.e. SEAL FASTENERS PER S.B. 134R AND 365R1.f. AIR TIME PUMP USING HARTRIDGE BASIC AIR TIMING TOOL

7244-27 WITH ADAPTER,P/N 29711 CONNECT AIR SUPPLY WITH60-100 PSI (4.1-6.9 BAR) TO #1 CYLINDER OUTLET. SET TOOL TO110° AND INSTALL TO DRIVE SHAFT. SLOWLY ROTATE TOOLCLOCKWISE UNTIL ROLLERS STRIKE CAM RING AND TOOLSTOPS, SCRIBE LINE ON HOUSING FLANGE. REPEATPROCEDURE TO ENSURE ACCURACY. IF INTERFERENCEBETWEEN STRAIGHT EDGE AND HOUSING FLANGE OCCURS,PLACE WASHER (i.e. 13521) BETWEEN STRAIGHT EDGE ANDTOOL.

15. FACTORY USE ONLY: TIME PER T-5015.16. FOR OPERATION AT OTHER RATED SPEEDS SET 12-14

mm³/STROKE 290 R.P.M. ABOVE RATED SPEED AND RESTAMPNAMEPLATE ACCORDINGLY.

17. PUMP TO BE TESTED PER S.B. 478.18. PUMP MAY BE CONVERTED TO 24V. E.T.R. WITH PART NUMBER

26387 SOLENOID FRAME ASSY WITHOUT CHANGE IN IN THE PUMPMODEL. THE GOVERNOR COVER AND PUMP NAMEPLATE MUST BESTAMPED 24V.

DB4427-5015 EDITION 19 DATED 08/29/2000 PAGE 2 OF 4

INDENTED ITEMS INCLUDED

(60372)

NOTES:

DESCRIPTION QTY P/N P/N QTY DESCRIPTIONHOUSING & DRIVE GROUP

28381 1 WASHER, DR SH SPRING

26469 1 RING, RETAINING

26468 1 WASHER, THRUST28749 1 BEARING, THRUST

11331 2 SCREW, HEAD LOCKING

10464 1 WASHER, SEALING

12259 1 SCREW, PAN HEAD

OR 21661-2166521660 1 SCREW ASSY-VENT

30804 1 SEAL, TEFLON LIP

26355 1 SEAL, VITON LIP

211942SCREW,HEX WASH HD M

231071COVER, TIMING WINDOW

276031GASKET, TIMING COVER

103941NAME PLATE

244192SCREW, NAME PLATE

198401SEAL, RECT SECTION

344041HOUSING ASSY, PUMP

303871KEY, WOODRUFF

263461NUT, HEX

327871WASHER, DRIVE SHAFT

303861SHAFT, DRIVE

(60363)

NOTES:

DESCRIPTION QTY P/N P/N QTY DESCRIPTIONHEAD & ROTOR GROUP

20127 1 SCREW, RETAINING

REF. S.B. 143BOR 21220 (O/S) AS REQ’D

21219 1 VALVE, DELIVERY 30MM29384 1 PLATE-LOCK29710 1 SCREW, TX DR SOC HD27601 1 SEAL, O-RING

20727 4 CONNECTOR, FUEL LINE

12216 1 SCREW, HEAD PLUG11438 1 SCREW, SOCKET SET

AS IND. ON ROTOR S.B.60ROR 15960-15963 (O/S)USE 15710-15713 (STD)

15709 2 PLUNGER, BASIC

OR 11052-11055 (O/S)USE 11047-11050 (STD)

11046 2 PLUNGER, BASIC

31832 1 HEAD & ROTOR ASSY

201281STOP, DELIVERY VALVE

201291SPRING, DLVY VALVE

272451SEAL, O-RING

216871CAM RING

111414ROLLER, CAM

299322SPRING, LEAF

REF S.B. 332(-.010) AS REQ’D.OR 20123 (STD) OR 20119

201244SHOE, CAM ROLLER -5

156192SCREW, LEAF SPRING

(60054)

NOTES:

DESCRIPTION QTY P/N P/N QTY DESCRIPTIONTRANSFER PUMP GROUP

33128 1 CAP, TRANS PUMP END

28135 1 SPRING, REGULATING

28987 1 REG. ASSY, TRANS.PUMP

20528 1 RING, LINER LOCATING

OR 20512 REF. S.B. 30420511 4 BLADE, TRANS PUMP

21232 1 LINER, TRANS. PUMP

20530 2 RETAINER, ROTOR

289861FILTER, INLET

152281PLUG ASSY, TP REG

198951PISTON, REGULATOR

198441SEAL, REG. SLEEVE

198371ROLL PIN

156992SPRING, T.P. BLADE

276081SEAL, TRANSFER PUMP

DB4427-5015 EDITION 19 DATED 08/29/2000 PAGE 3 OF 4

INDENTED ITEMS INCLUDED

(60300)

NOTES: * O.S. METERING VALVE AND ARM ASSEMBLY 22249 REFERENCE S.B.336

DESCRIPTION QTY P/N P/N QTY DESCRIPTIONGOVERNOR GROUP

19873 6 CUSHION, WEIGHT RET.19894 3 RETAINER, CUSHION

REF. S.B. 37029136 3 CLIP, RETAINING

20359 1 SPRING, MTR VALVE26427 1 SHIM, MET.VALVE SPRG

* SEE NOTE11563 1 VALVE, METERING

21895 1 ARM ASSY-MET.VALVE

24726 1 STUD, GUIDE

27606 1 WASHER, SEALING

11969 1 GUIDE, IDLE SPRINGYELLOW-YELLOW

11966 1 SPRING, IDLE

12210 1 RETAINER, SPRING

198931RETAINER ASSY, WEIGHT

198586WEIGHT, GOVERNOR

198601WASHER, THRUST

217091SLEEVE, GOV. THRUST

122882NUT, PIVOT SHAFT RET.

313322SEAL, O-RING122141SHAFT, GOV ARM

198661ARM, GOVERNOR

BLUE-GREEN208591SPRING, GOV CONTROL

(60373)

NOTES: THROTTLE LEVER BUSHING OUT

DESCRIPTION QTY P/N P/N QTY DESCRIPTIONLINKAGE GROUP

11919 1 SPRING, GOVERNOR LINK

12358 1 LINK ASSY, ADJUSTING

18020 1 HOOK, GOV LINK12362 1 LOCKWASHER,SHAKEPROOF12360 1 SCREW, HEX HEAD MACH.

18021 1 HOOK ASSY, GOV.LINK.

12174 1 NUT, HEX12167 1 SCREW, LEVER ADJUST

12249 1 CAM, SHUT-OFF

12237 1 SHAFT ASSY, SHUT-OFF

12165 1 SCREW, ADJUSTING

12174 1 NUT, HEX11582 1 LOCK WASHER, TOOTH

12998 1 SCREW, SOCKET CAP

12049 1 LOCK WASHER, TOOTH

12051 1 SCREW, SOCKET CAP

19778 1 LEVER ASY,ADJ SHUTOFF

130101RETAINER, TH.LEV.SPRG156681SCREW, SOCKET HD CAP

130031SPRING, THROT. LEVER

150261LEVER ASSY, THROTTLE

161361ARM, ADJUSTING SPACER

120511SCREW, SOCKET CAP

161351SPACER, THR.LEVER ADJ

121741NUT, HEX

121671SCREW, LEVER ADJUST

120191SHAFT ASSY, THROTTLE

144082WASHER, SPACER174382SEAL, O-RING

122211LEVER, THROTTLE FORK

121751LOCKNUT, ADJ. SCREW

121691SCREW, LEVER ADJUST

(60381)

NOTES:

DESCRIPTION QTY P/N P/N QTY DESCRIPTIONAUTOMATIC ADVANCE GROUP

0.01522237 1 SCREW ASSY, HD LOCAT.

27602 2 SEAL, O-RING

22080 1 LOCKNUT, ADV.END PLUG

22293 1 SEAL, O-RING

21146 1 VALVE, REED

19834 1 SCREW, REED VALVE

26126 1 SEAL, O-RING

21161 1 PLUG, POWER SIDE END

230561PLUG, ADV. SCREW HOLE

276101SEAL, O-RING

220811LOCKNUT, TRIMMER SCRW

219551SEAL, O-RING

217291SCREW, ADV. TRIMMER

211501PLUG, SPRING SIDE END

211471PIN, CAM ADVANCE

211521SPRING, SERVO ADVANCE

217311SEAT,PILOT VALVE SPRG

221561VALVE, PILOT

211491PISTON, SERVO ADVANCE

DB4427-5015 EDITION 19 DATED 08/29/2000 PAGE 4 OF 4

INDENTED ITEMS INCLUDED

(60382)

NOTES: INSTALL GROUNDING STRAP ON LEFT SIDE VIEWING TRANSFER PUMP REFERENCE S.B. 108

DESCRIPTION QTY P/N P/N QTY DESCRIPTIONCOVER GROUP

2-23190 TUBE, INSULATE26214 1 SOLENOID, 12V ETR

22567 1 COVER, GOV CONTROL

30788 1 CUP, COVER SCREW

30789 1 CAP, COVER SCREW

27607 1 SEAL, O-RING

26564 1 REG ASSY, HSG PRESS

12500 2 WASHER, TERM INSUL12519 2 NUT, HEX14760 2 NUT, LOCK

272441SEAL, RECT SECTION

185012WASHER, PLAIN

184931LOCK WASHER, TOOTH

120491LOCK WASHER, TOOTH209511STRAP, TERM GROUNDING223513SCREW, BUTTON HD CAP

(62282)

NOTES:

DESCRIPTION QTY P/N P/N QTY DESCRIPTIONANEROID GROUP

17429 2 RING, RETAINING

19776 1 ROD, ANEROID

16809 1 BOOT, ANEROID

34303 1 NUT, BODY ASSY RET

19780 1 BRACKET, ANEROID

34995 1 ANEROID ASSEMBLY

115824LOCK WASHER, TOOTH

197794SCREW, HEX HEAD MACH.

GASKET KIT 33702DRIVE SHAFT SUPPORT TUBE 30586ESO MOUNTING AND GROUNDING KIT 26431THROTTLE SHAFT BUSHING REPLACEMENT 17776

APPLICABLE SERVICE ASSEMBLIESFOR SERVICE USE ONLY

08/29/2000 26594 1908/07/2000 26752 1803/20/2000 26752 1708/25/1999 26224 1611/07/1998 25814 1505/03/1996 24058 1401/03/1996 24058 1304/24/1995 23825 1209/20/1994 23279 1108/19/1994 23279 1007/19/1994 23279 906/23/1994 23279 804/02/1993 22416 702/08/1993 22298 601/08/1993 22207 501/08/1993 21485 511/16/1992 22098M 410/06/1992 21908 308/31/1992 21803 210/23/1991 21110 110/23/1991 20439 1

DATE CHANGE NO. EDITIONFOR ENGINEERING USE ONLY