INJECTION PUMP SPECIFICATION ©

FULL LOAD RPM: 2500 CUSTOMER PART #: RE-502716 MODEL NO.: DB2435-5593
GOV. REGULATION: 7-10 % CUSTOMER'S NAME: SUPERSEDES:
ENGINE: 4045DF150 JOHN DEERE DUBUQUE/SARAN EDITION NO.: 10
APPLICATION: O.E.M. 60 kW DATED: 01/30/2014
NOTE: THIS SPECIFICATION DEVELOPED WITH ISO LONG INLET STUD.
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: 1.9565" ± .0015"
.063" ( 1.6mm) ID X 25" (635 mm) LONG. (49.70 mm ± 0.04 mm)
2. CALIBRATING INJECTORS........SAE J968/ISO 7440: MAXIMUM ECCENTRICITY: .004" (0.10 mm) 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 110-115F (43-46C) AT INLET. 3. 1000 RPM (WOT.): OPERATE PUMP FOR 10 MINUTES TO BRING TO
b. SUPPLY PRESSURE (S.B. 334): 5.0 ± 0.5 PSI OPERATING TEMPERATURE AND CLEAR AIR FROM SYSTEM.
(34 ± 3 kPa) AT PUMP INLET. 4. 300 RPM (WOT): WITH SUPPLY PUMP ON, UNSCREW ADVANCE
4. CAM MOVEMENT READ-OUT DEVICE: #23745. CAP 4 TURNS AND ALLOW FUEL TO BLEED FOR 30 SECONDS.
RETORQUE CAP TO 200-225 LBS/IN.
PUMP INSTALLATION: IT-082 5. 400 RPM (WOT):
ROTATION-C-* LEVER ANGLES (REF.) a. CHECK SHUT-OFF: 4 mm³/STROKE MAX.
NAME PLATE-L-SIDE** THOT MIN.(B) N/A b. CHECK FOR MINIMUM TRANSFER PUMP LIFT OF 18" HG.
#1 CYL.-5-O'CLOCK** THOT MAX.(C) N/A (60 kPa).
THROTTLE-L-SIDE** S.O. ( E) N/A 6. 2500 RPM (WOT):
TIMING MARK N/A S.O. ( F) N/A a. SET TRANSFER PUMP PRESSURE FOR 89-91 PSI,
E.S.O. (12V E.T.R.) (614-628 kPa)(SUPPLY SET PER TEST STAND NOTE 3B)
b. ADJUST RETURN OIL TO 400-700 CC/MIN. RECHECK TRANSFER
PUMP PRESURE.
* VIEWED FROM DRIVE END ** VIEWED FROM TRANSFER PUMP END c. CHECK HOUSING PRESSURE FOR 8.5-13.5 PSI, (59-93 kPa)
7. 1700 RPM (WOT): SET ADVANCE TRIMMER PLUG FOR 1.0.
PUMP OPERATING SPEED...HALF...ENGINE SPEED 8. 300 RPM (WOT): WITH SUPPLY PUMP ON, UNSCREW ADVANCE
AIR TIME TO HOUSING FLANGE (S.B. 177)(SEE SPECIAL NOTES) CAP 4 TURNS AND ALLOW FUEL TO BLEED FOR 30 SECONDS.
RETORQUE CAP TO 200-225 LBS/IN.
PUMP CALIBRATION CHECKS: AS RECEIVED FOR SERVICE 9. 2500 RPM (WOT): SET ROLLER-TO-ROLLER FUEL DELIVERY 61-62
(REF. SL-222) mm³/STROKE.
1. 1000 RPM (WOT.): OPERATE PUMP FOR 10 MINUTES TO BRING TO 10. 2700 RPM (WOT): SET HIGH IDLE SCREW 10-12 mm³/STROKE
OPERATING TEMPERATURE AND CLEAR AIR FROM SYSTEM. 11. 850 RPM (L.I.): SET LOW IDLE SCREW 13-15 mm³/STROKE
2. 2700 RPM (WOT): RESET HIGH IDLE SCREW IF NECESSARY TO 12. 1500 RPM (ADJ. 25 mm³/STROKE): SET LIGHT LOAD ADVANCE
OBTAIN 10-12 mm³/STROKE. ADJUSTING SCREW FOR 3.0.
3. CHECK POINTS: (SEQUENCE MUST BE FOLLOWED AS LISTED) 13. 300 RPM (WOT): WITH SUPPLY PUMP ON, UNSCREW ADVANCE
CAP 4 TURNS AND ALLOW FUEL TO BLEED FOR 30 SECONDS.
THROTTLE RETORQUE CAP TO 200-225 LBS/IN.
RPM POSITION mm³/STROKE ADVANCE 14. CHECK POINTS:
a. 150 WOT 21 MIN. ---
b. 400 WOT* 4 MAX. --- THROTTLE T.P.
c. 850 L.I.** 13-15 --- RPM POSITION mm³/STROKE ADVANCE PRESSURE
d. 1700 WOT --- 0-2.0 a. 150 WOT 23 MIN. --- 10 MIN.**
e. 1500 WOT 64.5-70.5 --- b. 400 WOT* 4 MAX. --- ---
f. 2500 WOT 59.5-63.5 2-4 c. 850 L.I. 13-15 --- ---
g. 2500 WOT* 4 MAX. --- d. 1700 WOT --- 0.5-1.5 ---
h 1500 ADJ. 23-27 2.-4. e. 1500 WOT 65.5-69.5 0 ---
i. 2500 ADJ. 45.5-51.5 3.75MAX f. 2500 WOT 61-62 2.5-3.5 89-91***
j. 2700 WOT 10-12 8-9 g. 2500 WOT* 4 MAX. --- ---
k. 2750 WOT 5 MAX. --- h 1500 ADJ. 24.5-25.5 2.5-3.5 ---
i. 2500 ADJ. 45.5-51.5 3.75MAX ---
* E.S.O. DE-ENERGIZED j. 2700 WOT 10-12 8-9 ---
** RESET USING LOW IDLE SCREW, IF NECESSARY k. 2750 WOT 5 MAX. --- ---
* E.S.O. DE-ENERGIZED ** (69 kPa) *** (614-628 kPa)
15. SPECIAL NOTES:
a. TORQUE ALL FASTENERS PER S.B. 106.
b. ASSEMBLE THROTTLE LEVER SPACER AND ARM IN B4-L
POSITION PER S.B. 164.
c. SEAL FASTENER PER S.B. 134R.
d. ASSEMBLE DRIVE COMPONENTS PER S.B. 438.
e. 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 196 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 INTERFERANCE 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 ASSY 32966 REF S.B.336

Note: THROTTLE LEVER BUSHING OUT

ASSEMBLE THROTTLE LEVER SPACER AND ARM IN B4-L POSITION

Note:
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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
17776 THROTTLE SHAFT BUSHING REPLACEMENT 11/17/1998 25956 1
26431 ESO MOUNTING AND GROUNDING KIT 01/19/1999 25956 2
32980 PILOT TUBE REPLACEMENT (REF SB 171C) 09/09/1999 26352 3
33814 GASKET KIT 11/01/1999 26413 4
03/09/2000 26735 5
03/13/2001 27003 6
09/25/2002 26109 7
09/06/2005 29070 8
07/11/2008 31486 9
01/30/2014 36592 10