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INJECTION

PUMP SPECIFICATION

(SERVICE/ASSEMBLY)

I-

STANADYNE
FULL LOAD RPN: 3000
GOV. REGULATICN:

ENGINE: 7.3L 155 HP


APPLICATION:NATO/RUNWAY SWEEPER

NOTE:

CUSTDNERPART #:1816625C91
CUSTDNERS NAME:

llODEL NO.:DB2831-5009
SUPERSEDES:

NAVISTAR INTERNATIONAL CORP.

EDITION NO.:1
DATED:lD-15-91

ALL SPEEDS ARE IN ENGINE RPH VNLESS OTHERWISE NOTED.


USE LATEST RSVISION FOR ALL REFERSNCED DOCUMENTS.

TEST STAND:
1. CALImTING
HIGH PRESSURE PIPES...SAE
J1418/ISO 4093:
.078" (2.OOm) I.D. X 25" (635 mn) LONG.
2. CALIBRATING INJECTORS... S.A.E. J968/ISO 7440:
0.5 mn ORIFICE PLATE NOP: 1700 PSI (116 BAR).
NOTE: INJECTORS SPECIFIED AT 1700 PSI OPENING
PRESSURE MUST USE SPRING P/N 780104 OR EQUIVALENT.
3. CALIBRATING FLUID . ..SAE J967/ISO 4113 (REF. S.B.201):
A. TEMPERATUREAT INLET: IlO"-115F
(43"-46C)
B. SUPPLY PRESSURE CS.B.334):
5.0 * 0.5 PSI
(34 f 3 kpa) AT PUMP INLET.
4. CAM MOVEMENTREADOUT DEVICE: #23745.
PLHP INSTALLATIW:
#I CYL.- 8- O'CLOCK**
THROTTLE-R-SIDE**
TIMING MARK (AG) N/A
*VIEWED FROM DRIVE END

LEVER ANGLES (REF.)


) 22"
:,T$C,
57":;:'
N/A
**VIEWED

AIR TINED TO HDUSING (PER S-B.1


aPtRATING SPttD . . . HALF-.. t

F$I:-T:AbN?

PUMPN:;D

NE SPEED.

pulp ACCESSORIES:
2V t.T.R.)
5. HOUSING PRESSURE COLD ADV.
2: M;L~ ADVANCE
6. TRAILING PORT ROTOR
3. MIN.-MAX. GOVERNORIV
7. LOW VISCOSITY FUEL PARTS
4. ACCUMULATORS
WnP CALIBRATIOll CHECKS: AS RECEIVED FOR SERVICE:
RtF SL 222)
1. loo0 &I
(UOT): OPERATE PUMP FOR IO MINUTES TO BRING
TO OPERATING TEMPERATUREAND CLEAR AIR FROM SYSTEM.
2. 400 RPN: (L.I.):CHECK
E.S.O.
FOR PULL-IN WITH 10.0
-0+0.2 VOLTS.
FUEL SHOULD BE I~I~I/STROKE,MIN.
3.

CHECK POIN;;~~~EQUENCE MUST BE FOLLOWEDASL&STED).


RPll

a.

3000

::

%%

::

%81
2000

f.
9.
h1.

J.

5.

I$;;

Pus.'

K- *
ii.
ADJ:
WOT
1-b

m/STROKE

"'ioil:;:"
-__
16 MAX.
___
9-11
5285;;:;:
-__

NDVENENT

l.OO"-4.50"
-_7.50"-8.50"
___
****
4.25"-7.25"
-__
2.25li6.25"

___
WOT:
26 MIN.
*E.S.O.
DE-ENERGIZED.
*READING TO BE 1-O"-2.75" GREATER THAN READING
OBTAINED IN STEP 3H W/HPCA ENERGIZED.
HWAY BE RESET USING LOU IDLE SCREW.
-*READING
TO BE O-25-2.75
LESS THAN READING
OBTAINED IN 3A.
;;~";,~"A""
FROM LOW IDLE TO WIDE OPEN SHOULD BE

PU4P SETTINGS: (CONT'D.)


6 /oD RPN (L I). a. ADJUST TRANSFER PUMP PRESSURE FOR 58-60 PSI
b. WITH GOVERNORCOVER REMOVED,ADJUST MIN.- MA)'. GOV.
ASSEMBLY FOR 12-14 I&/STROKE.
(FUEL READING WITH
COVER INSTALLED.) CHECK HOUSING FOR 8-12 PSI.
c. ;;;HM;;CA
ENGERIZED, CHECK HOUSING PRESSURE FOR 1

7.3000 RPN (WiT.1:


a. SET TRANSFER PUMP PRESSURE FOR 94-96 PSI.
(SUPPLY SET PER TEST STAND NOTE 38).
b. REDUCE SPEED TO 1400 RPM ADJUST RETURN OIL TO 200500 cc/min.
8. 400 RPN (UDT):
a. DE-ENERGIZE E.S.O. CHECK FUEL FOR 4 mn3/STR.MAX.
b. MOVE THROTTLE TO (L.1.).
CHECK E.S.O.
FOR PULL-IN
WITH 10.0-0+0.2
VOLTS.
FUEL SHOULD BE
15 a&/STROKE,MIN.
c. CHECK FOR MIN. T.P. LIFT OF 18" Hg.
NOTE: FOR RENAINER OF THE SETTINGS AND CHECKING
PROCEDURESCONTROL FACE CAN AND THROTTLE SHAFT END
PLAY TO .DD4-.DD6
AS MEASUREDBETWEENSPACER
#229DO AND THE HOUSING.
9. 3000 RPN (WOT):
a. ROTATE FACE CAM TO ITS MAXAMUMLIFT POSITION IN
CONTACT WI TH THE CAM ROLLE
b. SET TRIMME
W Fun r.>d"'ADVANCE.
c
SET FUEL DEL:;;;.- Y TO
-nn 51.5-52.5
1 ="
mn'/STROKE.
d: DE-ENERGIZE E-S...0. CHECK FUEL FOR 4 mnl/STR.MAX.
RF-ENERGIZE
..._
E.S.O.
10. 3125 liLPM (UOT):
a. SET GUIID-F STUD
____ FOR
._.. 43-44 mn'/STROKE AND
TORQUE NUT #2358 5 TO 80-90 I N-LBS.
b. CHECK DIMENSION FROM TOP OF NUT TO TOP OF GUIDE
STUD FOR -425" MAX.
11. 21DO0RPN:
a. ADJUSlr THROTTLE TO 9-11 mnS/STROKE AND ROTATE
FACE CAM TO OBTAIN 5.75" ADVANCE.
b. TORQUE SCREW #22398 TO 28-30 IN-LBS.
12. 14P"
p-I
nrn.
a. WITH THROTTLE AT 28 nnn/STROKE, ALIGN 0 ON LEVER
PROTRACTOR#22089 WITH CENTER OF RIB ON
LEVER. RELEASE THROTTLE LEVER AND ROTATE%S4 0
..,..,
IIIIP/STROKE TOWARDWOT POSITION.
ADJUST MAX.

__.
.. . . __ !ZrREW

TRAVFI

d. CHECK FACE
:

O
w

TORQUE RETENTION PER S.B.361.

NOTE:
13.

7::

PU4P-SETTINGS: (FOLLOWING PUMP SER


ROLLER TO ROLLtR DIHi?t&ION
1
(49.80 f .025 mn)(OVERSIZE'CAI;I
MAXIMUM ECCENTRICITY:
.004" (T.1 R )
2. LINKAGE GAP: -145" TO .165" (3.7 iO'4.2 mn).
(USE KIT #23093 S.B.95).
GUIDE STUD BOTTOMEDTO ONE TURN OUT OF HOUSING_
Z: a. SET THROTTLE AT 49" AS MEASUREDBETWEEN THROTTLE
LEVER BALL STUD CENTERLINE AND VERTICAL CENTERLINE
OF THROTTLE SHAFT WITH GAGE #24135.
b. ADJUST
LOW IDLE
SCREW UNTIL
CONTACT
IS MADE WITH
IDLE STOP BOSS.
c. ADJUST MAX TRAVEL SCREW TO OBTAIN 62'-'TOTAL
THROTTLE TRAVEL.
5. 1000 RPM (UOT):OPERATE PUMP FOR 10 MINUTES TO BRING
TO OPERATING TEMPERATUREAND CLEAR AIR FROM SYSTEM.

Tn
I

ci 4M

ANY CHANGESAFTER THIS POINT WILL REQUIRE RETESTING OF PUNP, STARTING WITH STEP 7.
CHECK POINTS:
THRTL.
(PST 1
RFN FOS. mn3/STROKE NOiiENT
PkkURE
HSG
-_
-I

a.
b.
c.
e.
d.

3000
3000
3125
3400
2500

f. 2000
g.
h- I$;;

WOT.
L.I.
WOT.
WOT.

51.5-52.5
--42-45
15--- MAX.

2.25"-2.75"
7.50"-8.50"
___
-;-

ADJ.

9-11

5.250-6.25"
--2.75;;:.75'

10;.

__~
___,
--~

1:::
:::
--------80:1,2
--12 MIN.
LESS THAN READTUG---

:;::661.5
--j.
28.5 MIN.
150 WOT.
* READING TO BE .75"-2.75"
OBTAINED IN STEP 13A.
ee NAY BE RESET USING L-1. SCREW.
n*READING TO BE l-25-2.50
GREATER THAN READING
OBTAINED IN STEP 13H W/HPCA ENERGIZED.
CHECK TOTAL TRAVEL: 57"-67'.
1.

700 L:I:

1::

AIR

TIME

16.

-6.5".
NOTES:

17.

---'
-__
___
125 MAX.

PUMP

USING

GAGE

#24205

(S.B.375)SET

TO

IF ADJUSTMENT IS REQUIRED, USE L.I.


SCREW. MAX.
ADJUSTMENT IS +I TURN FROM POINT SET IN STEP 4a.
SPECIAL NOTES:
a. TORQUE ALL FASTENERS PER S.B.106.
b. SEAL PUMP FASTENERS PER S.B.365.
c. INSTALL GUIDE STUD TAMPER PROOFING CAP # 26961
(FIELD SERVICE P/N) ON GUIDE STUD # 26495.
(REF. S.B.365a).

DB2831-5009

SHAFT, drive
BEARING, drive

____,

1
shaft

SCRENASSElIDLY, vent
21661-21665

660

2
1
1.

1453
BGO
1367

Sl77

SEAL, drive
SEAL, drive
SEAL, pilot

PAGE 2 OF 3

shaft*
shaft
tube

IIOUSIIIG ASSEMBLY

;101

BEARING, thrust
NASIIER, thrust

1
1

100
521

*APPLY A LIOERAL COATIDG OF


- L-.IIOUSIIIG BEFOREASSEf~OLIIIG

-KU
&S
-

#ASE1241 COMPOUND
TO SEALS
SIIAFT INTO HOUSING,
BEAD AND ROTORGROUP

I
ROLLER, cam

SIIOE, cam roller

CA8 RIIIG

SEAL, hydraulic
head
SPRIIIG, leaf
SCREW, leaf spring 8d.t.

- SEAL, transfer

xi=

SPRlllG, trans.
ROLLPIN

pump

pump blade

2
1

:RECl, head locking


IVER, timing line
:REW, timing line cover
\SKET, timing line cover

10394
24419

ATE, name
:REW, name, plate

10443

ING, shaft

24691

\SIIER, spring

,28369

4565

CD

OlSCRlPllOH

11331
23107
21194
27603

II

x0.

5699
?837

TRANSFER PUMP GROUP

!----

123949
28947

flli

x0

S.D.165

retaining

ID. DEAD b RDTORASSEIIDLY*


PLUBGER, rotor (Oaslc)
;E 11067 thr(J 11070 STAND.
r 11072 thrlJ ii075 I 0,s.)
j indicated on rotor (SO600
SCREW, hyd. head plug
SCREW, hyd. head plug
CONNECTOR,fuel line
;REW, locking plate
ATE, locking
:AL, locking plate
JREW, dellvelry valve
IOP, delivery
valve
'RING, de1iwr.y valve
ILYE, delivery valve
i 28948 (OVERSIZE) as req'd
PISTON, accumulator
SCREW, accum. piston ret.
SPRING, accumulator pjston
'INDENTED ITEMS INCLUDE0
DlSCRlPllON
-:TAINER, rotor
'NER, transfer
pump
.ADE, transfer
pump
r20804
per SO304
ING, liner lociiting
IGULATORASSY., trans. pump

'RING, regulating

PISTOR, regulating
PLUG ASSY,, end plate
SCREEN, inlet

1
1

adj.

filter

GOVERROR
ARII b TEMP. COMP.
ASSEEIULY
SPRING, idle
MIN.-MAX. ASSEIHBLY
SPRING, governor inner
SEAL, guide

I,
1

\p,

transfer

pump end

232f
84%

ASlIER, max. speed spring


PRING, gov. outer

GOVERNORGROUP

LOCK ASSEMBLY

i
;

64915
Jo?
35B!

IUD, guide
Ap, guide stud

1215
!I91
156
!I89

IETERING VALVE & ARM ASSY:


IR (O/S) 24441
SPRING, metering valve ar;
VALVE METIERINGVALVE
ARM ASSY., metering valve

8371

{ETAINER ASSEElBLY,gov,

1431

IALL, steel

IUT, guide stud

SLEEVE, thrust
WASHER, thrust

I980

sleeve

WEIGHT, governor

RING, gov, cage retaining

I.

*SEE

SPECIALNOTE

Wt.

DB2831- DB2831-5009
*Lubricate

=
I

per

LINKJGE GROUP

S.B.387

29493

IOLLER, spring

1
SCREW, low idle adjusting

21646

SPRltlG, low Idle

21350

screw

1
1

SPRING, governor thrust


SEAL, throttle shaft
WASHER, throttle
spacer

FACECAM

28465

SCREW,face cam

22398

qUT, max, travel


screw
jllAFT ASSEi%LY, throttle
IOOK ASSEFIOLY,gov. llnkaiy
LINK, ASSY..,gov. link. a J
WASIIER,gov. 1 Ink, hook adj
SCREW,gov. link,hook adj.
HOOK, governor linkage

26181
17438
14408

.EVER ASSEMBLY, throttle


;CREW, max. travel

27660 1

i
1
,!

SPRING, governor linkage

=.

=
*Lubricate
or 50,307

AUTOMATICADVANCEGROUP

SPRIIIG, light

load advance

24085

SEAL, piston hole plug


PLUG ASSEHOLY, spring side
SEAL, plunger

1
1
i

27609
24931
27163
22397

RING, retaintng

23566

LEVER ASSEIIOLY, rocker

28196

scnw, servo adv. adj,


KUIIGER, servo advance
SEAL, head locating screw

26037

SCREW, head locating

22917
27602
26787

PIN,

rocker

level

Q-

2761(

+-

23051

3
3

NUT, termtnal COntaCt


WASHER, terminal contact

Cover

SOLEllOIO FRAIIE 6 ARM ASSY.


TUBE,insulating

PLUG, advance power side

SEAL, piston

SEAL, advance screw hole

WASHER, cover

,Qf

2161;
14761

--

PLUG, advance screw hole

COVER, governor

I
1
23621

21511
1250(
1102%
,476;
1204!

of

, o!

FOR SERVICF. USE ONLY


'1
APPLICAULE SERVICE ASSEWJES
GASKETKIT
ES0 MOUNTING,&+GRO~NDINGKIT

'*.

./24370

$26431

1llllUTTl.E WAFT UUSIIING REPLhcEf4EN


,002" 0 .,S AOV. PISTON S I.B 393
,

u15093
126989

U/\TE

, g:lf:tj;

screw

INSULATOR, terminal
LOCKNUT, terminal contact
STRAP, termfnal grounding
TEPJIINAL, electric
shut-off
LOCKWASHER~
terminal contact
LOC~WASIIER,te~inal. contact
WASHER, Jerminal insulating

i
2

--.-__-~

PIN, cam advance

1
1

;
'I(OTE:"Apply a liberal
coat'
base 1241 compound to the (
.23190 on 1l.P.C.A. solenoid
before assembling to cover<

hole plug

screw

GASKET, governor

PlSTON ASSEtIDLY, servo

I
COl~li.ASSY
*, return 1ine
sEAI_, return line connector

VALVE, servo

ELECTRIC SHUT-OFFGROUP

TRAIIS, PUI4P PER SO108

lOCKWASHER,cover

per XL-904,

1
1

2392E 1

IllSTALL GROUflOIllCSTRAP
OH RIGlIT SIDE VIEWIHG

SCREW, cover hold down


tOC#IIASIIER, cover screw

Iit&, retairring
IETAINXR, lii?;tl.
lcv, spl'lng
;CREW, throttle
spring
;PRlNG, throl.tle
lever

SOLENOIDASSY,, cold adv.'


TUBE, insulating
TEREIINAL, sol&old
CIASHER,terminal insulating

WASHER, terminal contact


NUT, terminal contact
LOCKNUT, terminal contact'
LOCKIIASIIER,I:enninal contact

---

FOR ENGIIIEERIIIG USE ONLY


EOITJOII
"U.
--

CIIC.

SE%

control

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