INTEGRATED FUEL SYSTEM SPECIFICATION ©

FULL LOAD RPM: 1800 CUSTOMER PART #: RE-530802 IFS SYSTEM PART NO.: 38239
ENGINE: 4024T CUSTOMER'S NAME: SUPERSEDES:
APPLICATION: GEN-SET JOHN DEERE EDITION NO.: 3
DATED: 07/23/2007

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

ALL TIMING REFERENCES ARE IN PUMP DEGREES UNLESS OTHERWISE NOTED.
USE LATEST REVISION FOR ALL REFERENCED DOCUMENTS.

TEST STAND ISO 8984 SYSTEM SETTINGS: FOLLOWING SYSTEM SERVICE

1. CALIBRATION FLUID: SAE J967 / ISO 4113 1. 0000 RPM: SET-UP TEST BENCH PER 99976 IFS SERVICE EQUIPMENT KIT
a. INLET TEMPERATURE: 38˚-42˚C (100.4˚-107.6˚F) OPERATION AND INSTRUCTION MANUAL
b. SUPPLY PRESSURE: 0.5 ± 0.06 BAR (7.5 ± 1.0 PSI)
2. 1800 RPM: (MICROMETER POSITION: 9.58mm)
c. RETURN FUEL FLOW: 800 cc/min MINIMUM
a. STABILIZE INLET FUEL TEMPERATURE AT 38.0˚-42.0˚C (100.4˚-107.6˚F)
2. LUBE OIL: SAE 15W-40
b. RECORD RETURN FUEL FLOW (800 cc/min MINIMUM)
a. LUBE OIL SUPPLY AND COLD ADVANCE ACTUATION PRESSURE:
3.38-3.52 BAR (49-51 PSI) 3. 1300 RPM: (MICROMETER POSITION: 15.38mm) CHECK FUEL DELIVERY
3
(9.0-11.5 mm /STROKE). IF ADJUSTMENT IS REQUIRED GO TO STEP 3a.
SYSTEM INSTALLATION: IT-120 IF FUEL DELIVERY IS ACCEPTABLE GO TO STEP 3d.
ROTATION – CCW AS VIEWED FROM THE DRIVE END a. 0000 RPM. ROTATE UNIT PUMP CW TO INCREASE FUEL AND CCW TO
SYSTEM OPERATING SPEED…HALF…ENGINE SPEED DECREASE FUEL
b. 1300 RPM: (MICROMETER POSITION: 15.38mm) CHECK FUEL DELIVERY
SERVICE COMPACT PENCIL NOZZLE (CPN) PER THE INDIVIDUAL 3
(9.5-10.5 mm /STROKE). IF FUEL DELIVERY IS INCORRECT REPEAT STEP
SPECIFICATION AND S.B. 557 3a
c. 0000 RPM. USE SPRING SEAT TORQUE TOOL (P/N 39152). LOOSEN
TEST BENCH SET-UP: IFS SERVICE EQUIPMENT KIT P/N 39105. UPPER SPRING SEAT SCREW. MAINTAIN PRESSURE ON UPPER SPRING
SEAT, ADJUST MICROMETER TO 2.63mm. TIGHTEN SCREW TO 2.0-2.5
IMPORTANT: UNIT PUMP MUST BE CLOCKED IN THE CAM BOX. CPN MUST BE N•m (18-22 LBF-IN). CHECK MICROMETER SETTING FOR 2.63-2.81mm.
HYDRAULICALLY LOCKED. REPEAT IF NECESSARY
d. 1300 RPM (MICROMETER POSITION: 15.38mm) RECORD FUEL DELIVERY
SYSTEM CALIBRATION CHECKS: AS RECEIVED FOR SERVICE: 3
(9.0-11.5 mm /STROKE). IF FUEL DELIVERY IS INCORRECT RETURN TO
1. 0000 RPM: SET-UP TEST BENCH PER 99976 IFS SERVICE EQUIPMENT STEP 3a
OPERATION AND INSTRUCTION MANUAL
4. 1800 RPM: (MICROMETER POSITION: 8.58mm) RECORD FUEL DELIVERY
2. 1800 RPM: (MICROMETER POSITION: 9.58mm) 3
(48.0-58.0 mm /STROKE)
a. STABILIZE INLET FUEL TEMPERATURE AT 38.0˚-42.0˚C (100.4˚-107.6˚F)
a. CHECK TIMING (-0.125˚- 0.125˚). PRESS “CHECK SHIM” AND FOLLOW
b. RETURN FUEL FLOW (800 cc/min MINIMUM)
INSTRUCTIONS.
3. 0200 RPM: (MICROMETER POSITION: 2.88mm)
3 5. 1800 RPM: (MICROMETER POSITION: 8.58mm) ENERGIZE COLD START
a. RECORD FUEL DELIVERY (41-63 mm /STROKE)
ADVANCE. RECORD TIMING (4.50˚- 5.50˚)
b. RECORD TIMING (3.00˚-5.00˚)
6. 1800 RPM: DE-ENERGIZE COLD START ADVANCE. TURN MICROMETER OUT
4. 1300 RPM: (MICROMETER POSITION: 15.38mm) RECORD FUEL DELIVERY 3
3 FOR A FUEL DELIVERY OF 25.5-27.5 mm /STROKE. RECORD FUEL DELIVERY
(7.0-14.0 mm /STROKE)
a. RECORD TIMING (MAXIMUM OF 0.06˚ GREATER THAN THE TIMING VALUE
5. 1800 RPM: (MICROMETER POSITION: 8.58mm) OBTAINED IN STEP 4a)
3
a. RECORD FUEL DELIVERY (47.0-59.0 mm /STROKE)
7. 1800 RPM: TURN MICROMETER OUT FOR A FUEL DELIVERY OF 4.0-6.0
b. RECORD TIMING (-0.40˚- 0.40˚) 3
mm /STROKE. RECORD FUEL DELIVERY.
6. 1800 RPM: (MICROMETER POSITION 8.58mm) ENERGIZE COLD START a. RECORD TIMING (MINIMUM OF 1.40˚ GREATER THAN THE TIMING VALUE
ADVANCE. RECORD TIMING (4.00˚- 6.00˚) OBTAINED IN STEP 4a)
7. 1800 RPM: DE-ENERGIZE COLD START ADVANCE. TURN MICROMETER OUT 8. 200 RPM: (MICROMETER POSITION: 2.88mm) RECORD FUEL DELIVERY
3 3
FOR A FUEL DELIVERY OF 25.5-27.5 mm /STROKE. RECORD FUEL DELIVERY (42-62 mm /STROKE)
a. RECORD TIMING (MAXIMUM OF 0.06˚ GREATER THAN THE TIMING VALUE a. RECORD TIMING (3.00˚-5.00˚)
OBTAINED IN STEP 5b)
9. 4200 RPM: (MICROMETER POSITION: 22.88mm) RECORD FUEL DELIVERY
3
8. 1800 RPM: TURN MICROMETER OUT FOR A FUEL DELIVERY OF (MAXIMUM OF 2.5 mm /STROKE)
3
4.0-6.0 mm /STROKE. RECORD FUEL DELIVERY
a. RECORD TIMING (MINIMUM OF 1.40˚ GREATER THAN THE TIMING VALUE SPECIAL NOTES:
OBTAINED IN STEP 5b) TIMING VALUE IS NOT A CONSIDERATION FOR WARRANTY
9. 4200 RPM: (MICROMETER POSITION: 22.88mm) RECORD FUEL DELIVERY
3
(MAXIMUM OF 2.5 mm /STROKE)

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 38239 EDITION 3 DATED 07/23/2007 Page 2 of 3

Note: USE INDIVIDUAL CPN SPECIFICATION AND SB 557 FOR NOZZLE TESTING.

Note:

Note:
 38239 EDITION 3 DATED 07/23/2007 Page 3 of 3

UNIT PUMP TIMING SHIMS

SIZE SIZE SIZE SIZE

PART NO. (mm) PART NO. (mm) PART NO. (mm) PART NO. (mm)
35991 1.300 36184 1.575 36001 1.850 36195 2.125
36179 1.325 35997 1.600 36190 1.875 36007 2.150
35992 1.350 36185 1.625 36002 1.900 36196 2.175
36180 1.375 35998 1.650 36191 1.925 36008 2.200
35993 1.400 36186 1.675 36003 1.950 36197 2.225
36181 1.425 35999 1.700 36192 1.975 36009 2.250
35994 1.450 36187 1.725 36004 2.000 36845 2.275
36182 1.475 35716 1.750 36193 2.025 36846 2.300
35995 1.500 36188 1.775 36005 2.050
36183 1.525 36000 1.800 36194 2.075
35996 1.550 36189 1.825 36006 2.100

FOR SERVICE USE ONLY

APPLICABLE SERVICE ASSEMBLIES FOR ENGINEERING USE ONLY
Assembly Description DATE ECN NO EDITION
36529 KIT, IFS PARTS 10/20/2005 29678 1
06/22/2007 30802 2
07/23/2007 30887 3