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.: 14
APPLICATION: OEM 60 KW DATED: 01/30/2014
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-115F (43-46C) 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 mm³/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 mm³/STROKE.
AIR TIMED TO HOUSING FLANGE (SEE SPECIAL NOTES) 9. 2500 RPM (WOT): SET TORQUE 58-59 mm³/STROKE.
OR MECHANICALLY TIMED TO CAM (S.B. 177) 10. 2700 RPM (WOT): ADJUST HIGH IDLE SCREW TO OBTAIN
10-12 mm³/STROKE.
PUMP CALIBRATION CHECKS: AS RECEIVED FOR SERVICE 11. 850 RPM (L.I.): SET LOW IDLE SCREW FOR 13-15 mm³/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 mm³/STROKE ADVANCE PRESSURE
10-12 mm³/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 mm³/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.

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Note:

Note:

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

Note: THROTTLE LEVER BUSHING OUT

ASSEMBLE THROTTLE LEVER SPACER AND ARM IN B4-L POSITION

Note: ASSEMBLE 22658 PISTON WITH PART NO. TOWARDS PISTON HOLE PLUG
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Note: INSTALL GROUNDING STRAP ON LEFT SIDE VIEWING TRANSFER PUMP REF. S.B. 108

FOR SERVICE USE ONLY

APPLICABLE SERVICE ASSEMBLIES FOR ENGINEERING USE ONLY
Assembly Description DATE ECN NO EDITION
15093 THROTTLE SHAFT BUSHING REPLACEMENT 03/12/1991 20670 1
26431 ESO MOUNTING AND GROUNDING KIT 10/07/1991 21052 2
32980 PILOT TUBE REPLACEMENT (REF SB 171C) 09/04/1992 21792 3
33814 GASKET KIT 12/14/1992 22027 4
04/22/1993 22474-M 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
07/18/2008 31503 12
06/30/2011 33372 13
01/30/2014 36592 14