INJECTION PUMP SPECIFICATION

FULL LOAD RPM: 2500 CUSTOMER PART #: RE-49360 MODEL NO.: DB2435-4972
GOV. REGULATION: 6-10 % CUSTOMER'S NAME: SUPERSEDES:
ENGINE: 4039 DF001 JOHN DEERE DUBUQUE/SARAN EDITION NO.: 11
APPLICATION: OEM 60 kW DATED: 02-07-00

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

USE LATEST REVISION FOR ALL REFERENCED DOCUMENTS.
TEST STAND: ISO 4008: PUMP SETTINGS: FOLLOWING PUMP SERVICE
1. CALIBRATING HIGH PRESSURE PIPES...SAE J1418/ISO 4093: 1. ROLLER-TO-ROLLER DIMENSION: 1.961" .001"
.063" (1.6 mm) I.D. X 25" (635 mm) LONG. (49.81 0.025 mm)
2. CALIBRATING INJECTORS... S.A.E. J968/ISO 7440: MAXIMUM ECCENTRICITY: .004" T.I.R.
0.5 mm ORIFICE PLATE NOP: 3000 PSI (207 BAR). 2. GOVERNOR LINKAGE GAP: .125" TO .165" (3.2-4.2 mm)
3. CALIBRATION FLUID...SAE J967/ISO 4113 (REF. S.B. 201): (USE KIT #23093 S.B. 95).
a. TEMPERATURE AT INLET: 110-115F (43-46C) 3. 1000 RPM (WOT): OPERATE PUMP FOR 10 MINUTES TO BRING TO
b. SUPPLY PRESSURE (S.B. 334): 2.0 0.5 PSI OPERATING TEMPERATURE AND CLEAR AIR FROM SYSTEM.
(14 3 kPa) AT PUMP INLET. 4. 400 RPM (WOT):
4. CAM MOVEMENT READOUT DEVICE: #23745. a. CHECK SHUT-OFF: 4 mm/STROKE, MAX.
b. CHECK FOR MINIMUM TRANSFER PUMP LIFT OF 18" HG,
PUMP INSTALLATION: IT-007 (60 kPa)
ROTATION-C-* LEVER ANGLES (REF.) 5. 2500 RPM (WOT):
NAME PLATE-L-SIDE** THOT MIN.(B )N/A a. ADJUST RETURN OIL TO 225-475 CC/MIN.
#1 CYL.-5-O'CLOCK** THOT MAX.(C) N/A (SUPPLY SET PER TEST STAND NOTE 3B)
THROTTLE-L-SIDE** S.O. ( E) N/A b. CHECK HOUSING PRESSURE FOR 8.5-13.5 PSI, (59-93 kPa).
TIMING MARK 131.5 S.O. ( F) N/A 6. 1700 RPM (WOT): ADJUST TRANSFER PUMP PRESSURE TO
E.S.O. (12V E.T.R.) 69-71 PSI, (476-489 kPa).
7. 1700 RPM (WOT): SET ADVANCE TRIMMER SCREW FOR
* VIEWED FROM DRIVE END ** VIEWED FROM TRANSFER PUMP END 5.25-6.25.
8. 1300 RPM (WOT): SET ROLLER-TO-ROLLER FUEL DELIVERY: 73.5-
PUMP OPERATING SPEED...HALF...ENGINE SPEED 74.5 mm/STROKE.
AIR TIMED TO HOUSING FLANGE (SEE SPECIAL NOTES) 9. 2500 RPM (WOT): SET TORQUE 58-59 mm/STROKE.
OR MECHANICALLY TIMED TO CAM (S.B. 177) 10. 2700 RPM (WOT): ADJUST HIGH IDLE SCREW TO OBTAIN
10-12 mm/STROKE.
PUMP CALIBRATION CHECKS: AS RECEIVED FOR SERVICE 11. 850 RPM (L.I.): SET LOW IDLE SCREW FOR 13-15 mm/STROKE.
(REF. SL-222) 12. CHECK POINTS:
1. 1000 RPM WOT: OPERATE PUMP FOR 10 MIN. TO BRING TO
OPERATING TEMPERATURE AND CLEAR AIR FROM SYSTEM. THROTTLE T.P.
2. 2700 RPM (WOT): RESET HIGH IDLE SCREW TO OBTAIN RPM POSITION mm/STROKE ADVANCE PRESSURE
10-12 mm/STROKE (IF NECESSARY). a. 150 WOT 25 MIN. --- **10 MIN.
3. CHECK POINTS: (SEQUENCE MUST BE FOLLOWED AS LISTED) b. 400 WOT* 4 MAX. --- ---
c. 850 L.I. 13-15 --- ---
THROTTLE d. 1000 WOT --- 2.25-4.25 ---
RPM POSITION mm/STROKE ADVANCE e. 1300 WOT 73.5-74.5 --- ---
a. 150 WOT 23 MIN. --- f. 1700 WOT --- 5.25-6.25 69-71***
b. 400 WOT* 4 MAX. --- g. 2500 WOT 58-59 7.0-8.0 ---
c. 850 L.I.** 13-15 --- h. 2500 WOT* 4 MAX. --- ---
d. 1000 WOT --- 2.25-4.25 i. 2700 WOT 10-12 --- ---
e. 1300 WOT 72-76 --- j. 2750 WOT 5 MAX. --- ---
f. 1700 WOT --- 4.75-6.75
g. 2500 WOT 55.5-61.5 7.0-8.0 * E.S.O. DE-ENERGIZED ** (69 kPa) *** (476-489 kPa)
h. 2500 WOT* 4 MAX. ---
i. 2700 WOT 10-12 --- 13. SPECIAL NOTES:
j. 2750 WOT 5 MAX. --- a. TORQUE ALL FASTENERS PER S.B. 106.
b. SEAL FASTENERS PER S.B. 134R.
* E.S.O. DE-ENERGIZED c. ASSEMBLE THROTTLE LEVER SPACER AND ARM IN B4-L
** RESET USING LOW IDLE SCREW POSITION PER S.B. 164.
d. ELECTRIC SHUT-OFF TO BE CHECKED PER S.B. 108.
14. FOR SERVICE ONLY:
AIR TIME PUMP USING HARTRIDGE BASIC AIR TIMING TOOL
7244-27 WITH INSERT 7244-30 AND PILOT RING 7244-26E. CONNECT
AIR SUPPLY WITH 60-100 PSI (4.1-6.9 BAR) TO #1 CYLINDER OUTLET.
SET TOOL TO 218 AND INSTALL TO DRIVE SHAFT. SLOWLY
ROTATE TOOL CLOCKWISE UNTIL ROLLERS STRIKE CAM RING AND
TOOL STOPS, SCRIBE LINE ON HOUSING FLANGE. REPEAT
PROCEDURE TO ENSURE ACCURACY. IF INTERFERENCE
BETWEEN STRAIGHT EDGE AND HOUSING FLANGE 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
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DB2435-4972 EDITION 11 DATED 02/07/2000 PAGE 2 OF 4
DESCRIPTION QTY P/N HOUSING & DRIVE GROUP P/N QTY DESCRIPTION
(60411)
21660 1 SCREW ASSY, VENT
OR 21661-21665
SEAL, O-RING 1 23367
11331 2 SCREW, HEX HEAD

SEAL, DRIVESHAFT 2 10453

DRIVESHAFT 1 30500 29677 1 CAP, TORQUE SCREW

KEY, WOODRUFF 1 30387 29671 1 NUT, TORQUE SCREW
17438 1 SEAL, O-RING
WASHER, DRIVESHAFT 1 32787 33922 1 SCREW, TORQUE

NUT, HEX 1 26346

26180 1 BEARING, THRUST
SCREW, RIVET 2 24419
21522 1 WASHER, DRSFT SPRING
NAMEPLATE 1 10394
GASKET, TMG WDO COVER 1 27603 10443 1 RING, RETAINING
21521 1 WASHER, THRUST
SCREW, HEX HEAD 2 21194
33050 1 HOUSING ASSY, PUMP
COVER, TIMING WINDOW 1 23107

NOTES:

DESCRIPTION QTY P/N HEAD & ROTOR GROUP P/N QTY DESCRIPTION
(60805)
32100 1 H&R ASSY, HYD 4 CYL
11086 2 PLUNGER, ROTOR
ROLLER, CAM 2 11141 USE 11087-11090 (STD)
OR 11097-11100 (O/S)
SHOE, CAM ROLLER 2 24569 AS IND. ON ROTOR SB 60R
11438 1 SCREW, SET
12216 1 SCREW, HEAD PLUG
RING, CAM 1 21687 20727 4 CONNECTOR, FUEL LINE

29710 1 SCREW, SKT HEAD CAP

29384 1 PLATE, SINTERED LOCK

SEAL, O-RING 1 27245 27601 1 SEAL, O-RING
13823 1 VALVE, DELIVERY
SPRING, LEAF 1 11197 OR 13824 O.S. AS REQ'D
REF. S.B. 143B
SCREW, LEAF SPR ADJ 1 11175 13837 1 SCREW, DLVY VALVE RET

SPRING, DLVY VALVE 1 16441

STOP, DELIVERY VALVE 1 16440

NOTES:

DESCRIPTION QTY P/N TRANSFER PUMP GROUP P/N QTY DESCRIPTION

(60126)
20530 2 RETAINER, ROTOR
SEAL, TRANSFER PUMP 1 27608
21232 1 LINER, TRANSFER PUMP
20511 4 BLADE, TRANSFER PUMP
OR 20512 REF. S.B. 304
20528 1 RING, ROTOR RETAINER

28987 1 REGULATOR ASSY, TP

SPRING, TP BLADE 2 15699
ROLL PIN 1 19837
SEAL, TP RGLTR SLEEVE 1 19844

19855 1 SPRING, REGULATING

PISTON, REGULATING 1 19895

PLUG ASSY, END PL ADJ 1 15228

FILTER, INLET 1 28986 28980 1 CAP, TP END

NOTES: REF. S.B. 444

INDENTED ITEMS INCLUDED

DB2435-4972 EDITION 11 DATED 02/07/2000 PAGE 3 OF 4
DESCRIPTION QTY P/N GOVERNOR GROUP P/N QTY DESCRIPTION
(60287)
SPRING, GOV CONTROL 1 17997
12210 1 RETAINER, SPRING
ARM, GOVERNOR 1 14482
11966 1 SPRING, IDLE
YELLOW-YELLOW
11969 1 GUIDE, IDLE SPRING

27606 1 WASHER, SEALING

SHAFT, GOVERNOR ARM 1 12214
SEAL, O-RING 2 31332 24726 1 STUD, GUIDE
NUT, PIVOT SFT RTNR 2 12288 22134 1 ARM ASSY, MTR VALVE
SPACER, GOV SPRING 1 15284 11563 1 VALVE, METERING
* SEE NOTE
26427 1 SHIM, MTR VALVE SPRG
20359 1 SPRING, MTR VALVE
SLEEVE, GOV THRUST 1 21312
WEIGHT, GOVERNOR 6 21201

WASHER, THRUST 1 23272

RING, RETAINING 1 12285 28370 1 RETAINER ASSY, GOV WT

NOTES: * O.S. METERING VALVE AND ARM ASSEMBLY 22248 REFERENCE S.B.336

DESCRIPTION QTY P/N LINKAGE GROUP P/N QTY DESCRIPTION

(60288)
SEAL, O-RING 2 17438
WASHER, SPACER 2 14408
SHAFT ASSY, THROTTLE 1 12019 16279 1 SHAFT, SHUTOFF

SCREW, HEX HEAD 1 12972

12253 1 CLIP, SHAFT RETAINER
NUT, HEX 1 12174
12221 1 LEVER, THROTTLE FORK

12169 1 SCREW, HEX HEAD

SPACER, THROT LVR ADJ 1 16135
12174 1 NUT, HEX
SCREW, SOCKET CAP 1 12051
ARM, ADJUSTING SPACER 1 16136 17605 1 HOOK ASSY, GOV LKGE
LEVER ASSY, THROTTLE 1 16392 12360 1 SCREW, HEX HEAD
12362 1 LOCK WASHER, SHPRF
SPRING, THROT LEVER 1 13003 17604 1 HOOK, GOV LINKAGE

12358 1 LINK ASSY, ADJUSTING

11919 1 SPRING, GOVERNOR LINK
SCREW, SKT HEAD CAP 1 15668
RNTR, THROT LVR SPR 1 13010

NOTES: THROTTLE LEVER BUSHING OUT

DESCRIPTION QTY P/N AUTOMATIC ADVANCE GROUP P/N QTY DESCRIPTION

(60143)
22658 1 PISTON, POWER
WASHER, ADVANCE SLIDE 2 12622 5 DEG. RETARD
22655 1 PLUG, PISTON HOLE
PISTON, SPRING 1 22328
2 DEG. ADVANCE
SPRING, INNER ADVANCE 1 12679
RED-YELLOW
18967 1 RING, PISTON SEAL
SPRING, ADVANCE 1 20276
WHITE-BLUE 29281 1 SEAL, RECT SECTION
GUIDE, ADV ADJ SPRING 1 14940 27602 2 SEAL, O-RING
SEAL, O-RING 2 29280
SEAL, O-RING 2 29282
22238 1 SCREW, HEAD LOCATING
PLUG, PISTON HOLE 1 14941 0.02

SCREW, ADV ADJUSTING 1 14544 33627 1 SCREW, CAM ADVANCE

SEAL, O-RING 1 17438
27610 1 SEAL, O-RING
NUT, HEX LOCK 1 13807 23056 1 PLUG, HEX SOCKET

NOTES: ASSEMBLE 22658 PISTON WITH PART NO. TOWARDS PISTON HOLE PLUG

INDENTED ITEMS INCLUDED

DB2435-4972 EDITION 11 DATED 02/07/2000 PAGE 4 OF 4
DESCRIPTION QTY P/N COVER GROUP P/N QTY DESCRIPTION
(60493)
22109 1 RGLTR ASSY, HSG PRESS

27607 1 SEAL, O-RING

14760 2 NUT, HEX LOCK
SCREW, BUTTON HD CAP 3 22351 22985 1 TERMINAL, BLADE
21618 1 INSULATOR, TERMINAL
STRAP, TERM GROUNDING 1 20951 12049 2 WASHER, INTL TOOTH
WASHER, INTL TOOTH 1 18493 30789 1 CAP, COVER SCREW

NUT, HEX 2 12519

WASHER, PLAIN 2 18501
30788 1 CUP, COVER SCREW
12500 2 WASHER, FIBER
SEAL, RECT SECTION 1 27244 21898 1 COVER, GOV CONTROL

26214 1 SOLENOID, 12V ETR

2-23190 TUBE, INSULATE

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

FOR SERVICE USE ONLY FOR ENGINEERING USE ONLY

APPLICABLE SERVICE ASSEMBLIES DATE CHANGE NO. EDITION
THROTTLE SHAFT BUSHING REPLACEMENT 15093 03/12/1991 20670 1
PILOT TUBE REPLACEMENT (REF SB 171C) 32980 10/07/1991 21052 2
OVERHAUL GASKET KIT 33814 09/04/1992 21792 3
ESO MOUNTING AND GROUNDING KIT 26431 12/14/1992 22027 4
04/22/1993 22474M 5
12/07/1993 22903 6
01/09/1995 22903 7
03/30/1995 22902 8
06/16/1995 23803 9
04/10/1996 23803 10
02/07/2000 26664 11

INDENTED ITEMS INCLUDED