INJECTION PUMP SPECIFICATION

FULL LOAD RPM: 2400 CUSTOMER PART #: RE-504061 MODEL NO.: DB2435-5686
GOV. REGULATION: 7-10 % CUSTOMER'S NAME: SUPERSEDES:
ENGINE: 4045D JOHN DEERE TORREON EDITION NO.: 7
APPLICATION: 5415 TRACTOR (57.7 kW XM1) DATED: 09-08-03

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: 1.9605" .0015"
.063" ( 1.6mm) ID X 25" (635 mm) LONG. (49.79 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 110-115F (43-46C) 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. 400 RPM (WOT):
4. CAM MOVEMENT READ-OUT DEVICE: #23745. a. CHECK SHUT-OFF: 4 mm/STROKE MAX.
b. CHECK FOR MINIMUM TRANSFER PUMP LIFT OF 18" HG.
PUMP INSTALLATION: IT-008 (60 kPa).
ROTATION-C-* LEVER ANGLES (REF.) 5. 2400 RPM (WOT):
NAME PLATE-L-SIDE** THOT MIN.(B) 17 a. SET TRANSFER PUMP PRESSURE FOR 89-91 PSI,
#1 CYL.-5-O'CLOCK** THOT MAX.(C) 13 (614-628 kPa)(SUPPLY SET PER TEST STAND NOTE 3B)
THROTTLE-L-SIDE** S.O. ( E) N/A b. ADJUST RETURN OIL TO 225-475 CC/MIN. RECHECK TRANSFER
TIMING MARK N/A S.O. ( F) N/A PUMP PRESURE.
E.S.O. (12V E.T.R.) c. CHECK HOUSING PRESSURE FOR 8.5-13.5 PSI, (59-93 kPa)
6. 1400 RPM (WOT): SET ADVANCE TRIMMER SCREW FOR 3.
* VIEWED FROM DRIVE END ** VIEWED FROM TRANSFER PUMP END 7. 1400 RPM (WOT): SET ROLLER-TO-ROLLER FUEL DELIVERY
74.5-75.5 mm/STROKE.
PUMP OPERATING SPEED...HALF...ENGINE SPEED 8. 2400 (WOT): SET TORQUE SCREW FUEL DELIVERY 61.5-62.5
AIR TIME TO HOUSING FLANGE (S.B. 177)(SEE SPECIAL NOTES) mm\STROKE.
9. 2600 RPM (WOT): SET HIGH IDLE SCREW 10-12 mm/STROKE
PUMP CALIBRATION CHECKS: AS RECEIVED FOR SERVICE 10. 850 RPM (L.I.): SET LOW IDLE SCREW 13-15 mm/STROKE
(REF. SL-222) 11. CHECK POINTS:
1. 1000 RPM (WOT): OPERATE PUMP FOR 10 MINUTES TO BRING TO
OPERATING TEMPERATURE AND CLEAR AIR FROM SYSTEM. THROTTLE T.P.
2. 2600 RPM (WOT): RESET HIGH IDLE SCREW IF NECESSARY TO RPM POSITION mm/STROKE ADVANCE PRESSURE
OBTAIN 10-12 mm/STROKE. 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. 1400 WOT 74.5-75.5 2.5-3.5 ---
RPM POSITION mm/STROKE ADVANCE e. 2400 WOT 61.5-62.5 6.0-7.0 89-91***
a. 150 WOT 23 MIN. --- f. 2400 WOT* 4 MAX. --- ---
b. 400 WOT* 4 MAX. --- g. 2600 WOT 10-12 --- ---
c. 850 L.I.** 13-15 --- h. 2650 WOT 5 MAX. --- ---
d. 1400 WOT 73-77 2-4
e. 2400 WOT 59-65 6-7 * E.S.O. DE-ENERGIZED ** (69 kPa) *** (614-628 kPa)
f. 2400 WOT* 4 MAX. ---
g. 2600 WOT 10-12 --- 12. SPECIAL NOTES:
h. 2650 WOT 5 MAX. --- a. TORQUE ALL FASTENERS PER S.B. 106.
b. ASSEMBLE THROTTLE LEVER SPACER AND ARM IN B4-L
* E.S.O. DE-ENERGIZED POSITION PER S.B. 164.
** RESET USING LOW IDLE SCREW, IF NECESSARY 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 197.5 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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DB2435-5686 EDITION 7 DATED 09/08/2003 PAGE 2 OF 4
DESCRIPTION QTY P/N HOUSING & DRIVE GROUP P/N QTY DESCRIPTION
(61880)
21660 1 SCREW ASSY, VENT
OR 21661-21665
SEAL, O-RING 1 23367
11331 2 SCREW, HEX HEAD

SEAL, DRIVESHAFT 2 10453

DRIVESHAFT 1 32901 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, TIMING WINDOW CVR 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
(62187)
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 32164 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
13821 1 VALVE, DELIVERY
SPRING, LEAF 1 11197 OR 13822 (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

(61333)
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 32636 1 CAP, TP END

NOTES:

INDENTED ITEMS INCLUDED

DB2435-5686 EDITION 7 DATED 09/08/2003 PAGE 3 OF 4
DESCRIPTION QTY P/N GOVERNOR GROUP P/N QTY DESCRIPTION
(63126)
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 24726 1 STUD, GUIDE
SEAL, O-RING 2 31332
NUT, PIVOT SFT RTNR 2 12288
SPACER, GOV SPRING 1 15284 22134 1 ARM ASSY, MTR VALVE
21917 1 SPRING, MTR VALVE
11563 1 VALVE, METERING
* SEE NOTE
SLEEVE, GOV THRUST 1 21312
WEIGHT, GOVERNOR 6 11643

WASHER, THRUST 1 23272

RING, RETAINING 1 12285 29111 1 RETAINER ASSY, GOV WT

NOTES: * O.S. METERING VALVE AND ARM ASSEMBLY 27130 REFERENCE S.B.336

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

(61143)
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

12972 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

(63054)
22658 1 PISTON, POWER
WASHER, ADVANCE SLIDE 2 12622 5 DEG. RETARD
22655 1 PLUG, PISTON HOLE
PISTON, SPRING 1 22515
1 DEG. ADVANCE
SPRING, INNER ADVANCE 1 14258
RED
18967 1 RING, PISTON SEAL
SPRING, ADVANCE 1 18959
BLACK-BROWN 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

DB2435-5686 EDITION 7 DATED 09/08/2003 PAGE 4 OF 4
DESCRIPTION QTY P/N COVER GROUP P/N QTY DESCRIPTION
(60082)

14760 2 NUT, HEX LOCK

SCREW, BUTTON HD CAP 3 22351
20951 1 STRAP, TERM GROUNDING
WASHER, INTL TOOTH 1 18493 12049 1 WASHER, INTL TOOTH

WASHER, PLAIN 2 18501 12519 2 NUT, HEX

WASHER, FIBER 2 12500 22109 1 RGLTR ASSY, HSG PRESS
30789 1 CAP, COVER SCREW

30788 1 CUP, COVER SCREW

27607 1 SEAL, O-RING

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 17776 12/14/1999 26549 1
OVERHAUL GASKET KIT 33814 03/17/2000 26549 2
ESO MOUNTING AND GROUNDING KIT 26431 08/13/2002 26549 3
PILOT TUBE REPLACEMENT (REF SB 171C) 32980 11/01/2002 27960 4
12/03/2002 28008 5
04/10/2003 28173 6
09/08/2003 28361 7

INDENTED ITEMS INCLUDED