MODEL DB2 8 2 9 ADE 4 2 3 7

INJECTION PUMP WPERSEDES MODEL

SPECIFICATION CUSTOMER PART NO. 18031401392
diesel systems
CUSTOMER’S NWf L ADDRLSS

EDITION 1 9_ _
NO.
____ __ DATED g/29/89 N4vlsm xmmtanctw a!w.

ENGINE 1983 b.YL til ALI. Indianapolis, Indiana

FULL LOAC'RPM3300
APCLICATION FORE TRUCK sov. IEGULATION 10 % USUED BY G. DuPont
NOTE: ALL SCEfDS ARf IN ENGINE R?M UNLESS 07nfuWlsf NOTfD
TEST STAND
1. INJEkON LINES..... .078"l.O.X ZS"LG.(REF.S.B.80)
2. NOZZLES PER SAE J968c WITH AB D.hn PLATE 6 A8 9. FOR THE REN4INOER OF THE SETTING AND CHECKING PROCEDURES,
WSF 2044 A 5X SPRING CONTROLFACE CAM AND THROTTLE SHAfT END PLAY YO .OD4- - .006'
3. NOZZLE OPENING PRESSURE....... 1700 t 25 PSI As f!EASUREDBETWEENSPACER (122900) AND THE HOUSING.
4. CALIBRATING OIL-SAE 5967 (Latest Rcvtslon) 0. A7 3300 RPM (HOT) (Roller-Roller Set Point)
TEMPERATUREllO"-115°F or 43-46-C (at Inlet) a. ROTATE THE fACE_CAM TO 17s WiWlM ~I~T'PDSITION IN CONTACT
5. LOU PRESSUREPLUMBING SYSTEM - PER 5.8.334 FIG. 14 WITH CAM ROLLER.
(5.0t0.5 PSI At Pump Inlet) b. ADJUST TRImER SCREY FOR 4.25' CAM ADVANCE.
6. CAMMOVEMENTREAD-OUT DEVICE P/N 23745 C. SET FUEL DELIVERY .46.5 - 47.5 f&i3 STROKE
d. DE-ENERGIZE ESO. CHECK FUEi 4.OP9l/ /STR. MAX. RE-ENERGIZE ESO.
7. ALL FUEL READINGS ARE AT 1000 STROKES
PUMP OPERATING SPEED...HALF...ENGINE SPEED
1. Al 3450 RPM (WDT)
PUMP ACCESSORIES:
4. SET GUIDE STUD FOR 44.5 - 45.5 m3/STROKE
1. ELECTRIC SHUT-OFF (12V ETR)
b. AFTER SETTING IS OBTAINED. TORQUEBUT (123!s85) TO
2. M/LL ADVANCE 6. HOUSING PRESSURECDL0 ADV.
3. DELIVERY VALVE 7. TRAILING PORT ROTOR 80-90 lbf-in.
C. CHECKDIMENSIONBETWEEN TDP OF NUT TO TOP OF GUIDE STUD AT
4. MIN-MAX.GOVERNOEIV 8. TEMPERATURECOMPENSATOR
5. ACClPiULATORS .400" PtAx
PUMPCALIBRATION CHECKS:-ASRECEIVEDFOR SERVICE. .__ RPE! '
2. Al 1400
IREF. S.L.222) a. ADJUST THROTTLE LEVER FOR 27-29 P943/SlROKE,, AND ROTATE FACE
i. OPERATEPUMP AT 2000 RPM (HOT) FOR 1D MINUTES TO CAM TO OBTAIN 3.0. CAH ADVANCE.
b. AFTER SE'I-TING IS OBTAINED, TORQUESCREWP/N 22398 TO
TO BRING TO OPERATINGTEMPERATUREAND CLEAR AIR
FROMSYSTEM. __ __ lfb.-in.
28-30 _. . ...
2. WITH THROTTLE LEVER IN LOU IDLE POSITION AT 4D0 RP c. WITH THROTTLE AT 28 m3/STROKE POSITION ALIGN 0. ON
CHECK E.S.O. FOR PULL-IN WITH10.0 -0tD.2 VOLTS. FL PROTRACTORP/N 22089 WITH CENTER RI8 ON ROCKERLEVER.
DELIVERY SHOULDBE 15mn3/STRDKE. MIN. RELEASE THROlTLE AND ROTATE 44' TOYARDNOT PDSITIOA. ADJ
3. CHECKPOINTS: (SEQUENCEMUST BE FOLLDUEOAS LISTED RAX. TRAVEL SCREWTO THIS 44a SETTING.
d. CHECK FACE CAM TDRQUERETENTIONPER S.B.361.
THRTL. IOTE: ANY CHANGESAnER THIS POINT YILL REQUIRE RETESTING OF PonP
RPM POS. PB43/STRDKE CAM MOVEMENT - STARTING WITH STEP 10.
a. 33oci- YDT 45-49 3.25'-5.2Sc
r_- 3. CHECK POINTS: .
b. 3302 WOT(6d) 4.0 WiX.
3300 L.I. __- 8.0°;9.00
--- THRTL. m3/ PRESSURE
::
e. 375c UO? 16 MAX. ___ RPM pas. STROKE F'IO%ENT ;- TP HOUSING
f. 253" UOT --- ;.$-:.t!: (6b) a. 3300 UOT 46.5-47.5 4.D*-4.5' ---
9. 14DC
h. 14x
ADJ.
WCT
27-29
47.5-55.0
. -.
___
b.
c.
3300
3450
iof. ___
44.0;47.(!
8.0*-9.0'
___
---
___
8-16 (6a) 0.5'-3.5' (6b) d. 3750 WDT 15 WIX. se_
125 PAX. _-a

3;: ::z k:f: --- c. 2500 UDT r*_ 1.5*-2.5*n?%).- ___

0.75'-2.2S"(6c)
_-- f. 1400 UDT 50-53 -we ___ ___

:: T%L THR%LE TRAVE:6F%'LOW IDLE TO WIDE OPEN 1' 1:;; ADJ. 27-29 2.75"-3.25' --- MS_

SHOULDBE 60"-70". i2;ip (18f) 8-12

4. CHECKAIR TIMING USING GAUGEP/N 24205(PERS.B.375 1: 650 :*:* me-
o-1
j. 150 ULiT' 28 MIN. --- 12 MIN. --_
SET TO -3.5' to -5.5*
5. TIMED TO THIS CYLINDER@ 4. CHECK TOTAL THROTTLE TRAVEL 60° - 70°
5. NAME PLATE....RIGHT....VIEWING END PLATE
6. :; :;HEPI$P USING GAGE P/N 24205 (PER S.B.375)
6. _ __
N0TES:
a. RESET USING LOW IDLE SCREW 7. TIMED To'iHIS CYLINDER (FROM END PLATE)@
b. LESS THAN READING OBTAINED IN STEP 38. 8. SPECIAL NOTES:
c. GREATERTHAN READING OBTAINED IN STEP 3i. WITH a. TOROUEALL FASTENERSPER 5.8.106.
HOUSING PRESSURECOLD ADVANCESOLENOID ENERGIZE b. GO TO C.
d. E.S.D. DE-ENERGIZED.
PUMP SETTINGS:(fOLLOWING PUMPSERVICE)
1. ROLLER TO ROLLER DIMENSION... 1.967" t .OOl.
WIX. ECCENTRICITY .DDR" TIR. SEE 18i. C. HOUSINGPRESSURECOLD ADVANCESOLENOID IS DE-ENERGIZED
2. LINKAGE GAP... .145" TO .165"(PER S.B.95) EXCEPT AS REQUIRED IN STEPS 6c and 131.
3. GUIDE STUD BOTTOMEDTO ONE TURN OUT OF HOUSING. d. SEAL PLBIP fASTERNERS PER 70030 or 58134.
4 a. SET THROTTLE AT 2" AS MEASUREDBETWEENTHROTTL
LEVER BALL STUD c AND VERTICAL COF THROTTLE
SHAFT WITH GAGE P/N 24135. e. If ADJUSTMENTIS REDUIRED. USE L.I. SCREW. MAX. ADJUSTMENT
b. ADJUST LOW IDLE SCREWUNTIL CONTACTIS CtADEWIT IS f 1 TURN
___.___ _ FROMPOINT SET IN STEP la.
IDLE STOP BOSS. f. GREATERTtL4N READING OBTAINED IN STEP 13h WITH HOUSING
5. STA;cT TEST STAN0 AND RUN FOR 10 MINUTES 9 2000 RPM PRESSURECOLDADVANCESOLENOIDENERGIZED.
(UOTI (r. LESS THAN READING OBTAINED IN STEP 13a.
6. AT 650 RPM h. WITH O.S. CAM RING, R-R TO BE 1.973' t .ool. S.B.33@
a. WIT!! THROTTLE SHAFT IN LDW IDLE POSITION. ADJU! KITE: PWP MOUNTING - HORIZONTAL PUIP ROTATION - CLOCKWISE
TRANSFERPUMP PRESSURETO 58-60 PSI.
b. WITH GOVERNORCOVER REMOVED, ADJUST MIN/M~x.
GOVERNDRASSEMBLYFOR 12-14MM3/STR. (FUEL
READING WITH COVER INSTALLED. CHECK HOUSING Ft
8-12 PSI)
C. WITH HOUSING PRESSURECOLD ADVANCESOLENOID
ENERGIZED, CHECK HOUSING PRESSUREAT 1 PSI MAX.
7. A7 3300 (WOT)
a. CHECK TEST STAND BOOST PRESSUREAT 4.5-5.5 PSI.
b. UHENAIR BUBBLESCLEAR FR0M RETURN LINE. SET
TRANSFERPUMP PRESSUREAT 99-101 PSI.
C. REDUCESPEED TO 1400 RPM, ADJUST RETURNOIL
TO 200-500 CC/MIN.
8. At 4oO RPM (UOT)
a. DE-ENERGIZE E.S.O. CHECK FUELDELIVERY 3m3/
STROKEMAX.
b. MOVE EH~OTTLE To (LII.CHE~.S.O..F~R PULL-II
YITH 10.0 -0+0.2 VOLTS. FUEL SHOULDBE 15 M4
 CAR1
1
PAN E
DfSCNIIK)N NO. NDUSING I DNVf GROUP WCWTION
NO. E
r 0 I Pg. 2 of 3.
YODEL NO. DBZB29ADE4237
.SCREU. cover hold-down 2 2351 v
LOCKWASHER,cover screw 1
'562w* o = 0 113521 3 rlASHER. cover screw
ICDNh. ASS!., return line 3645
:SEAL. return line connector
GASKET. governor cover
1 iOVER, governor,control

ISHAFT. drive
SCREWASSENBLY,vent or21661
thru A and 22733 or 22734 as req'c
11331 2 SCREU, head locking

5EhL. drive shaft

!LEAL, pilot tube
HOUSING ASSEMBLY
1 !ING. shaft rctcrining
COVER. timing line
!;CREY, timing line cover
1 IASHER, spring
1 LASHER. thrust
IUTE, namE
GASKET. timing line cover
l APPLY A LIBERAL CDATlNG OF SYN-KU1 SE 121 :c BUND
!XREii, name plate 58165 i TO SEALS BEFORE ASSEMBLINGTO SHAFT AND SHi 17 PUMP
= --

I IlOUSING AND DRIVE GROUP

n
2

SCREIi. cover hold down

LOCWWER. cover screir
3
3
2
1 ::r
: 13521 3 rlASHER.cover screw
COllll.ASSY., return 1 ine 1 3615
SEAL, retvr: line comector 1 : 7GO7
GASKET, goverrlor cover 1 2 7244
23629 1 LOVER, governor control
drrve
SIIAFT, 1 '6179
BEARING, drive shaft ’ 1 3101

SCEEI! ASSEfIOLY( vent 1 SCREW,head locking

21661-21655 : COVER, timing line
SCREW.timing line cover
k SEAL, drive shaft*
SEAL, drive shaft
2
1
I
0453
: 1860 : GASKET, tjming line COVE
SEA:, oilot tube 2 3367
1 PLATE, nrme
IIOUSll~G ASSEIW:~ 1 2 j177 2 SCREW,name plate S.B.l(
1 RING, shaft retaining
BtARlNt. thrust 1 26 100
1 HASHER, spring
WASHER, thrust 1 21'521

l APW_Yh LlBEtAl COATIII~ or S'tll.KL 01hSE 1241 COl4POUIIO

TO SEALS
L IIOUSI% OErORE ASSEllBLIIlt L! SIIAFT INTO WUSING. I.
= I
HEAD AND ROTORGROUP i=
_ 23719 1 !YD. HEAD 6 ROTORASSEMBLY'
11056 2 PLUNGER, rotor (Basic)
ROLLER, car; ! 1141 ISE 11057 thru llD60 !STD.)
I@ 11~62 thru 11065 (O'SIzE:
SH3E. car: roller 7
IS indicated on rotor (SBE?i
CAF:RI&G 1 SCREW, hyd. head plus
SCREU, hyd. head plus
CONNECTOR,fuel line
,CREW, locking plate
SEAL, hydraulic head 'LATE, locking
SPRING. leaf 1 ;EAL. locking plate
SCREW, leaf spring 1 XREW. delivery valve
JOP, delivery valve
;PRING, delivery valve
IALVE, delviery
IR 23727 (OVERSIZE) 8s reo'o
Pi~T~N,‘accumulator
SCREY, eccum. piston ret.
SPRING, accumulator plstop
rINDE!:TED ITlEt'S INCLUDE?
I’
TRANSFER PIMP GROUP I

RETAINER. rotor
LINER, transfer pump
SEAL, transfer pump 1 27608 BLADE, transfer pump
or 20512 Per SE304
RING, liner locating
..A. f;;W;;, trans. pulp blade 2 REGULATORASSY.. trans. pump
1
23915 SPRXNG, regulating
20523 PLATE, trans. puep Pressure
W&DzSegulating 1 19895
.* end plate l dj 1 15228
20525 CAP, trmsfefr pump end
SCREEN, inlet filter 1 26617
-
 DE%829ADE-4237 3-iF3 **SEE SERVICE ASSEMBLIES
22325 WASHER,max. speed spring
23583 SPRING, gov. outer
;OVERNORARH L TEMP. COMP.
4SSEMBLY -et-- BLOCKASSEMBLY
SPRING, Idle
MIN.-MAX. ASSEMBLY
SPRTYG, governor inner
. r-x 23584 STUD, guide
5 guide
23585 NUT. guide stud
ARMASSEMBLY,meterlng valve
SPRING, metering vslve arm
VALVE, metering or 24441

SLEEVE. thrust 1 21312

WASHER,thrust sleeve 1 23272 RETAINERASSEMBLY,gov. wt.

UEIGHT, governor 6 21201 - i‘c)

RING. gov. cage retaining 1 12285

I

I I LINKAGEGROUP

"SEE SERVICE ASSEMBLIES

SCREW,low idle adj. 27660 SCREW,maximumtravel
SPRING, low idle load
SPACER, throttle !shaft 12173 NUT, lever adj.
jEAL, throttle shaft
'jPRING, igOV. thrust

ISEAL. throttle shaift 1 17438

WASHER.throttle s,haft seal i 14408 23588 SHAFTASSEMBLY,throttle
18021 HOOKASSEMBLY,gov. linkage
SCREW,face cam 1 22398 SCREW,gov. link. hook adj.
12360
12362 WASHER,gov. link. hookadj.
1 23595 18020 HOOK, governor linkage
FACECAM
12358 LINK. ASSY..gov. link.adj.
PIN, vacuum module drive 1 21284
11919 SPRING, governor llnkaae
.--
.--
a' t..b;;:;.e Per 70027 I
f
AUTOMATICADVANCEGROUP I 1
!;PRING, light load advance 423601 I 2236 VALVE, servo
!iEAL, pis,ton hole plug 276G9 .._- ~--
PLUGASSEMBLY,spring side
SEAL, plunger
t piStON,servo adv.

:':"- -.ker lever ,

PLUG, advance power side i
:!ING, retaining t23566 2760 SEAL, piston hole plug
-EVER ASSEHBiY_r a+ 28196
SCREW,rocker 't ever - 22-1
396
ROLLER. rocker lever
"CREW, servo adv. adj. ,1
22:(/$!
26L_.
2392 5 PIN, cam advance

L';:;tER* servo advance 0 SEAL, advance screw hole

SEAL, hea.d locating screw 22917
27602 I r
6 PLUG, advance screw :lole
i;CREW.head locating
- 2a87 v
- -

I
ELECTRIC SHUT-OFFGROUP

INSTALL GROUNDINGSTRAP . :
'IN RIGHT SIDE VIEWING
foy;;.,p,l;MP 58108 r 2 INSULATOR, terminal
i LOCKNUT.terminal co&
IDCKWASHER.cover screw 1 STRAP, terminal grounding
--
I1UT, terminal contact 22985 1 TERMINAL,electric sbut:oE_
12049 2 LOCKWASHER,term.contact:'&:
IIASHER, terminal contact 12049 2 WASHER,terminal contact
12500 i WASHER,termtnal contact
----

SDLENOUL.ASSY..~~~.~~~. S:
TUBE. insulatina
:iOLENOID.FRAME_&ARM ASSY. 21518 TERMINAL,el~ctrl~~f
TUBE, insulating WASHER,terminal contact
12500
18501 WASHER,terminal contact :
'%%?$pplyaeral coati %?- 12519: NUT, terminal contact
base 1241 compound to the t ) oi 14760 LOCKNUT,terminal contact i
23190 on H.P.C.A.. solenoid mir --1
LOCKWASHER,term%i contact,
before assemblin(1 t0 cover. 1204g1

FOR SERVICE USE ONLY FOR ENGINEERINGUSE ONLY

.rr, EPLICABLE SERVICE ASSEMBLIES m 'tHGDITION
d
.ET KIT g/29/89 19513 19
r.a.0. MDUNTIING & GROUNDINGKIT f%
.OD.8' O’SIZE #ADVANCE
PISTON (5.8.393) #26383
HOUSINGb DRIVE GROUP2
123633 THROTTLEsw\FT BUSHINGS 115093
THR~ITTLEsHf0 BUSHINGS UIN. k4X. BLOCK 124880
LE.FT SIDE VIEWING T.P. END . rt60V. THRUSTSPRING /261Bl
RIGHT SIDE VIEWING
‘ T.P. END %5!
+t V. THRUSTSPRING& IIIN.WAX. BLOCKKIT f 27060 HOUSINGAND DRIVE KIT (28467
‘ REF. S.B.383A)
io
NOTE: NO EXISTING PILOT TUBE REPLACEMENT
FOR THIS APPLICATION.