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INJECTION PUMP SPECIFICATION

FULL LOAD RPM: 1500 / 1800 GOV. REGULATION: 1-3 % ENGINE: 4BTA3.9G4 APPLICATION: GENERATOR 130/145 HP CUSTOMER PART #:3977327 CUSTOMER'S NAME: CUMMINS ENGINE COMPANY MODEL NO.: DB4429-5968 SUPERSEDES: EDITION NO.: 2 DATED: 10/05/2007

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: ISO 4008: 1. CALIBRATING HIGH PRESSURE PIPES...SAE J1418/ISO 4093: .063" (1.6 mm) I.D. X 25" (635 mm) LONG. 2. CALIBRATING INJECTORS... STANADYNE P/N 37392 (LOW DEAD VOLUME). 0.6 mm ORIFICE PLATE NOP: 3000 PSI (207 bar). 3. CALIBRATION FLUID...SAE J967/ISO 4113 (REF. S.B. 201): a. TEMPERATURE AT INLET 110-115F (43-46C) b. SUPPLY PRESSURE (S.B. 334): 4.5-5.5 PSI. (31-38 kPa) AT PUMP INLET. 4. CAM MOVEMENT READ-OUT DEVICE: #23745. PUMP INSTALLATION: IT-108 ROTATION-C-* NAME PLATE-L-SIDE** #1 CYL. -2-O'CLOCK** THROTTLE-L-SIDE** ELECTRONIC ACTUATOR (12V) LEVER ANGLES (REF.) LOW IDLE (B) 23 HIGH IDLE (C) 10 RUN ( E) 21 S.O. ( F) 38 PUMP SETTINGS: FOLLOWING PUMP SERVICE 6. 400 RPM (WOT): a. CHECK E.S.O. 4 mm/STROKE MAX. b. CHECK FOR MINIMUM TRANSFER PUMP LIFT OF 18" HG. (60 kPa) 7. 1500 RPM (WOT): a. SET TRANSFER PUMP PRESSURE FOR 90-92 PSI. (621-635 kPa) (SUPPLY SET PER TEST STAND NOTE 3B). b. ADJUST RETURN OIL TO 400-750 CC/MIN. RECHECK TRANSFER PUMP PRESSURE. c. CHECK HOUSING PRESSURE FOR 5.5-10 PSI, (38-69 kPa). 8. 1500 RPM (WOT): SET ROLLER-TO-ROLLER FUEL DELIVERY: 156-157 mm/STROKE. 9. 1800 RPM (WOT): SET TORQUE SCREW FOR 142.5-143.5 mm/STROKE. 10. 1500 RPM (ADJ.): ADJUST THROTTLE FOR 69.5-70.5 mm/STROKE. SET LIGHT LOAD ADJUSTING SCREW FOR 5.25. 11. 2070 RPM (WOT): ADJUST HIGH IDLE SCREW TO OBTAIN 4 MAX. mm/STROKE. 12. CHECK POINTS: RPM 150 1500 1500 1500 1500 1500 1800 2000 2070 THROTTLE POSITION WOT WOT ADJ. ADJ. WOT * WOT ** WOT WOT WOT mm/STROKE 70 MIN. 156-157 132-136 69.5-70.5 4 MAX. 4 MAX. 142.5-143.5 110 MIN. 4 MAX. ADVANCE 0.5 MAX. 0-0.3 0-0.3 4.75-5.75 ----0-0.3 --11-12 T.P PRESSURE 10 MIN. 90-92 ---------------

* VIEWED FROM DRIVE END ** VIEWED FROM TRANSFER PUMP END PUMP OPERATING SPEED...HALF...ENGINE SPEED MECHANICALLY TIMED TO CAM (PER S.B. 177) 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 MINUTES TO BRING TO OPERATING TEMPERATURE AND CLEAR AIR FROM SYSTEM. 2. TURN SPEED DROOP ADJUSTING CAP ASSEMBLY COUNTERCLOCKWISE UNTIL IT STOPS, THEN TURN IT 2 TURNS CLOCKWISE. 3. 2070 RPM (WOT): RESET HIGH IDLE SCREW IF NECESSARY TO OBTAIN 4 MAX. mm/STROKE. 4. CHECK POINTS: (SEQUENCE MUST BE FOLLOWED AS LISTED) RPM 150 1500 1500 1500 1500 1800 2000 2070 THROTTLE POSITION WOT WOT ADJ. ADJ. WOT * WOT WOT WOT mm/STROKE 68 MIN. 154.5-158.5 132-136 68-72 4 MAX. 140-146 110 MIN. 4 MAX. ADVANCE 0.5 MAX. 0-0.3 0-0.3 4.25-6.25 --0-0.3 --11-12

a. b. c. d. e. f. g. h. i. * ** 13.

E.S.O. DE-ENERGIZED E.S.O. ENERGIZED AND SHUT-OFF LEVER IN OFF POSITION SPECIAL NOTES: a. TORQUE ALL FASTENERS PER S.B. 106 b. LOCK DRIVE SHAFT PER S.B. 460 c. ASSEMBLE DRIVE COMPONENTS PER S.B. 438. d. SEAL FASTENERS PER S.B. 134R. FOR SERVICE USE ONLY:

a. b. c. d. e. f. g. h.

14.

* E.S.O. DE-ENERGIZED PUMP SETTINGS: FOLLOWING PUMP SERVICE 1. ROLLER-TO-ROLLER DIMENSION: 1.992" .0015" (50.60 mm 0.04 mm) MAXIMUM ECCENTRICITY: .004" (0.10 mm) T.I.R. 2. ADJUST SPEED DROOP PER S.B. 97R, THEN TURN SPEED DROOP ADJUSTING CAP ASSEMBLY 2 TURNS CLOCKWISE. 3. GOVERNOR LINKAGE GAP: .125" TO .145" (3.2-3.7 mm) (USE KIT #23093 S.B. 95). 4. SET L.I. SCREW PER LEVER ANGLE SPECIFIED UNDER PUMP INSTALLATION B WITH ACTUATOR REMOVED. 5. 1000 RPM (WOT): OPERATE PUMP FOR 10 MINUTES TO BRING TO OPERATING TEMPERATURE AND CLEAR AIR FROM SYSTEM.

AIR TIME PUMP USING HARTRIDGE BASIC AIR TIMING TOOL 7244-27 WITH INSERT 7244-30 AND PILOT RING 7244-26E. INSTALL TOOL TO DRIVE SHAFT AND TIGHTEN LOCKING NUT TO 50-60 lbf-inches (5.7-6.8 NM). CONNECT AIR SUPPLY WITH 60-100 PSI (4.1-6.9 BAR) TO #1 CYLINDER OUTLET. SLOWLY ROTATE TOOL IN DIRECTION OF ROTATION UNTIL ROLLERS STRIKE CAM RING AND TOOL STOPS. LOOSEN THE TIMING FIXTURE THUMBSCREW AND ROTATE THE FIXTURES OUTER PORTION UNTIL POINTER IS CENTERED OVER ONE OF THE PUMP HOUSING FLANGE EARS. USING THE POINTER AS A GUIDE, PLACE A THIN REFERENCE LINE ON THE FLANGE WITH A LEAD PENCIL. NEXT, LOOSEN THE FIXTURES THUMBSCREW AND ROTATE OUTER PORTION IN THE OPPOSITE DIRECTION OF ROTATION A TOTAL OF 7.0. TIGHTEN THUMBSCREW TO LOCK THE INNER AND OUTER PORTIONS OF THE FIXTURE TOGETHER. WITH COMPRESSED AIR OFF, ROTATE AIR TIMING FIXTURE AND PUMP DRIVE SHAFT IN DIRECTION OF ROTATION UNTIL TIMING POINTER IS REALIGNED WITH PREVIOUS REFERENCE LINE. TIGHTEN DRIVE SHAFT LOCKING SCREW TO 105-110 lbf-inches (11.9-12.4 NM). IF INTERFERENCE BETWEEN STRAIGHT EDGE AND HOUSING 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.

DB4429-5968

EDITION 2

DATED 10/05/2007

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DB4429-5968

EDITION 2

DATED 10/05/2007

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Note: * O.S. METERING VALVE AND ARM ASSEMBLY 35865 REFERENCE S.B. 336

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DB4429-5968

EDITION 2

DATED 10/05/2007

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FOR SERVICE USE ONLY APPLICABLE SERVICE ASSEMBLIES Assembly Description 17776 THROTTLE SHAFT BUSHING REPLACEMENT 26431 ESO MOUNTING AND GROUNDING KIT 33702 GASKET KIT

FOR ENGINEERING USE ONLY DATE ECN NO EDITION 02/14/2006 29904 1 10/05/2007 31007 2