INJECTION PUMP SPECIFICATION

FULL LOAD RPM: 1800

GOV. REGULATION: 3-5 %
ENGINE: 4039DF
APPLICATION: GEN. SET 49KW
AVIATION FUEL ( 1.2 CST MIN.)

MODEL NO.: DB2435-5000

SUPERSEDES:
EDITION NO.: 8
DATED: 02-07-00

CUSTOMER PART NO.: RE-47176

CUSTOMER NAME:
JOHN DEERE DUBUQUE/SARAN

NOTE: ALL SPEEDS ARE IN ENGINE RPM UNLESS OTHERWISE NOTED

USE LATEST REVISION FOR ALL REFERENCED DOCUMENTS
TEST STAND: ISO 4008:
1. CALIBRATING HIGH PRESSURE PIPES...SAE J1418/ISO 4093:
.063" (1.6 mm) ID X 25" (635 mm) LONG.
2. CALIBRATING INJECTORS........SAE J968/ISO 7440:
0.5 mm ORIFICE PLATE NOP: 3000 PSI (207 BAR)
3. CALIBRATION FLUID: SAE J967/ISO 4113 (REF. S.B. 201)
a. TEMPERATURE 110-115F (43-46C) AT INLET.
b. SUPPLY PRESSURE (S.B. 334): 2.0 0.5 PSI
(14 3 kPa) AT PUMP INLET.
4. CAM MOVEMENT READ-OUT DEVICE: #23745.
PUMP INSTALLATION: IT-010
ROTATION-C-*
NAME PLATE-L-SIDE**
#1 CYL.-5-O'CLOCK**
THROTTLE-L-SIDE**
TIMING MARK 131.5
E.S.O. (24V E.T.R.)

LEVER ANGLES (REF.)

THOT MIN.(B) N/A
THOT MAX.(C) N/A
S.O. ( E)
N/A
S.O. ( F)
N/A

* VIEWED FROM DRIVE END ** VIEWED FROM TRANSFER PUMP END

PUMP OPERATING SPEED...HALF...ENGINE SPEED
AIR TIME TO HOUSING FLANGE (SEE SPECIAL NOTES)
MECHANICALLY TIMED TO CAM (PER S.B. 177)
PUMP CALIBRATION CHECKS: AS RECEIVED FOR SERVICE
(REF. SL-222)(REF. S.B. 97R FOR SPEED DROOP)
1. 1000 RPM (WOT): OPERATE PUMP FOR 10 MINUTES TO BRING TO
OPERATING TEMPERATURE AND CLEAR AIR FROM SYSTEM.
2. TURN SPEED DROOP TO MINIMUM (C'C DIRECTION).
3. 1920 RPM: PRIOR TO CHECKING PUMP PERFORMANCE, RESET
HIGH IDLE SCREW TO OBTAIN 5 MAX mm/STROKE.
4. CHECK POINTS:

a.
b.
c.
d.
e.
f.
g.

RPM
150
400
525
1300
1750
1750
1920

THROTTLE
POSITION
WOT
WOT*
WOT
WOT
WOT
WOT*
WOT

* E.S.O. DE-ENERGIZED

mm/STROKE
22 MIN.
4 MAX.
----76-80
4 MAX.
5 MAX.

ADVANCE
----1.0-3.0
5.0-6.0
-------

PUMP SETTINGS: FOLLOWING PUMP SERVICE

1. ROLLER-TO-ROLLER DIMENSION: 1.966 .001"
(49.94 mm .025 mm)
MAXIMUM ECCENTRICITY: .004" (0.10 mm) T.I.R.
2. GOVERNOR LINKAGE GAP: .125" TO .145" (3.2-3.7 mm)
(USE KIT #23093 S.B. 95).
3. 1000 RPM (WOT): OPERATE PUMP FOR 10 MINUTES TO BRING TO
OPERATING TEMPERATURE AND CLEAR AIR FROM SYSTEM.
4. 400 RPM (WOT):
a. CHECK SHUT-OFF: 4 mm/STROKE, MAX.
b. CHECK FOR MINIMUM TRANSFER PUMP LIFT OF 18" HG.
(60 kPa).
5. 1750 RPM (WOT):
a. SET TRANSFER PUMP PRESSURE FOR 78-80 PSI,
(538-552 kPa)(SUPPLY SET PER TEST STAND NOTE 3B)
b. ADJUST RETURN OIL TO 225-475 CC/MIN. RECHECK TRANSFER
PUMP PRESSURE.
c. CHECK HOUSING PRESSURE FOR 4-8.5 PSI, (28-59 kPa).
6. 525 RPM (WOT): SET ADVANCE TRIMMER SCREW FOR 2.0
7. 1750 RPM (WOT): SET ROLLER-TO-ROLLER FUEL DELIVERY
77.5-78.5 mm/STROKE.
8. TURN SPEED DROOP ADJUSTING CAP IN 2 FULL TURNS
CLOCKWISE.
9. 1920 RPM (WOT): ADJUST HIGH IDLE SCREW TO OBTAIN
5 MAX mm/STROKE.
10. 1400 RPM (L.I.): SET LOW IDLE SCREW FOR 10-20 mm/STROKE. DO
NOT BACK OUT SCREW FROM INITIAL SETTING.
11. CHECK POINTS:

a.
b.
c.
d.
e.
f.
g.

RPM
150
400
525
1300
1750
1750
1920

THROTTLE
POSITION
WOT
WOT*
WOT
WOT
WOT
WOT*
WOT

mm/STROKE
24 MIN.
4 MAX.
----77.5-78.5
4 MAX.
5-MAX.

* E.S.O. DE-ENERGIZED ** (69 kPa)

12.

ADVANCE
----1.0-3.0
5.0-6.0
-------

T.P.
PRESSURE
10 MIN.
------78-80
-----

*** (538-552 kPa)

SPECIAL NOTES:
a. TORQUE ALL FASTENERS PER S.B. 106.
b. ADJUST SPEED DROOP PER S.B. 97R.
c. SEAL FASTENERS PER S.B. 134.
d. ASSEMBLE THROTTLE LEVER SPACER AND ARM IN B4L POSTION PER S.B. 164.
e. ELECTRIC SHUT-OFF TO BE CHECKED PER S.B. 108.
f. 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 217 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 Automotive Corp. All rights reserved. Unless otherwise specified, no part of this publication may be reproduced or utilized in any
form or by any means, electronic or mechanical, including photocopying and microfilm, without permission in writing from the publisher.

DB2435-5000
DESCRIPTION

EDITION 8
QTY

P/N

DATED 02/07/2000

HOUSING & DRIVE GROUP

(60648)

SLEEVE, THROTTLE STOP

24364

SEAL, DRIVE SHAFT BLK

10453

SHAFT, DRIVE

27639

KEY, WOODRUFF

30387

SEAL, O-RING

23367

WASHER, DRIVE SHAFT

32787

NUT, HEX

26346

SCREW, NAME PLATE

24419

NAME PLATE
GASKET, TIMING COVER

1
1

10394
27603

SCREW,HEX WASH HD M

21194

COVER, TIMING WINDOW

23107

QTY

P/N

PAGE 2 OF 4

P/N

QTY

DESCRIPTION

21660

SCREW ASSY-VENT
OR 21661-21665

12259
10464

1
1

SCREW, PAN HEAD

WASHER, SEALING

11331

SCREW, HEAD LOCKING

26180
24691

1
1

BEARING, THRUST
WASHER, SPRING

10443

RING, RETAINING

21521

WASHER, THRUST

33057

HOUSING ASSY, PUMP

P/N

QTY

32100
11086

1
2

11438
12216
20727

1
1
4

HEAD & ROTOR ASSY

PLUNGER, BASIC
USE 11087-11090 (STD)
OR 11097-11100 (O/S)
AS IND. ON ROTOR SB 60R
SCREW, SOCKET SET
SCREW, HEAD PLUG
CONNECTOR, FUEL LINE

29710

SCREW, TX DR SOC HD

29384
27601
13821

1
1
1

13837

PLATE-LOCK
SEAL, O-RING
VALVE, DELIVERY 15MM
OR 13822 (O/S) AS REQD
REF. S.B. 143B
SCREW, DEL VALV

P/N

QTY

20530

RETAINER, ROTOR

22988

LINER,T.P.(THIN FUEL)

20803

BLADE, TRANS PUMP

OR 20804 REF. S.B. 304

20528

RING, LINER LOCATING

28987

REG. ASSY, TRANS.PUMP

19855

SPRING, REGULATING

28980

CAP, TRANS. PUMP END

NOTES:

DESCRIPTION

HEAD & ROTOR GROUP

DESCRIPTION

(60407)

ROLLER, CAM

11141

SHOE, CAM ROLLER -10

24569

CAM RING

SEAL, O-RING

21687

27245

SPRING, LEAF

11197

SCREW, LEAF SPRING

11175

SPRING, DLVY VALVE

16441

STOP, DELIVERY VALVE

16440

QTY

P/N

NOTES:

DESCRIPTION

TRANSFER PUMP GROUP

DESCRIPTION

(60133)

SEAL, TRANSFER PUMP

SPRING, T.P. BLADE

27608

15699

ROLL PIN

19837

SEAL, REG. SLEEVE

19844

PISTON, REGULATOR

19895

PLUG ASSY, TP REG

15228

FILTER, INLET

28986

NOTES:

INDENTED ITEMS INCLUDED

DB2435-5000
DESCRIPTION

EDITION 8
QTY

P/N

SPRING, SPEED DROOP

RED STRIPE

13558

ARM ASSY, GOVERNOR

20219

SHAFT, GOV ARM

20224

DATED 02/07/2000
GOVERNOR GROUP
(60649)

PAGE 3 OF 4

P/N

QTY

DESCRIPTION

20240

ROD ASSY-CONTROL

13554

PIN, CONTROL SPRING

27606

WASHER, SEALING

12966

SEAL, O-RING

20243

CAP ASSY, ADJUSTING

SEAL, O-RING

31332

20355

CAP, DROOP CONT. LOCK

NUT, PIVOT SHAFT RET.

12288

27599
22134
11563

1
1
1

SLEEVE, GOV. THRUST

14483

26427
20359

1
1

GUIDE, CONTROL ROD

ARM ASSY-MET.VALVE
VALVE, METERING
* SEE NOTE
SHIM, MET.VALVE SPRG
SPRING, MTR VALVE

WEIGHT, GOV-PLATED

20214

WASHER, THRUST

20222

28681

RETAIN ASSY, GOV WT

RING, RETAINING

12285

P/N

QTY

16279

SHAFT, SHUT-OFF

12253

CLIP, SHAFT RETAINER

12221

LEVER, THROTTLE FORK

12169

SCREW, LEVER ADJUST

12174

NUT, HEX

HOOK ASSY-GOV.LINK.

NOTES:

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

DESCRIPTION

QTY

P/N

SEAL, O-RING
WASHER, SPACER

2
2

17438
14408

SHAFT ASSY, THROTTLE

12015

SCREW, LEVER ADJUST

21646

NUT, HEX

12173

SPACER, THR.LEVER ADJ

16135

SCREW, SOCKET CAP

12051

LINKAGE GROUP

DESCRIPTION

(61824)

ARM, ADJUSTING SPACER

16136

20226

LEVER ASSY, THROTTLE

16392

SPRING, THROT. LEVER

13003

12360
12362
17604

1
1
1

20225

LINK ASSY, HOOK ADJ.

11919

SPRING, GOVERNOR LINK

P/N

QTY

22655

PLUG, PISTON HOLE

18967

RING, PISTON SEAL

27602

SEAL, O-RING

22238

SCREW, HEAD LOCATING

0.02

SCREW, SOCKET HD CAP

RETAINER, TH.LEV.SPRG
NOTES:

1
1

SCREW, HEX HEAD MACH.

LOCKWASHER,SHAKEPROOF
HOOK, GOV LINK

15668
13010

THROTTLE LEVER BUSHING OUT

DESCRIPTION

QTY

P/N

AUTOMATIC ADVANCE GROUP

DESCRIPTION

(60410)

SEAL, PISTON RING

29281

PISTON, POWER
5 DEG. RETARD
WASHER, ADVANCE SLIDE

22658

12622

23611

18959

PISTON, SPRING SIDE

0 DEG. ADVANCE
SPRING, ADVANCE
BLACK-BROWN
GUIDE, ADV.ADJ.SPRING

14940

SEAL, O-RING
SEAL, O-RING

2
2

29280
29282

PLUG, PISTON HOLE

14941

SCREW, ADVANCE
SEAL, O-RING

1
1

14544
17438

33627

SCREW, CAM ADVANCE

27610

SEAL, O-RING

NUT, LOCK

13807

23056

PLUG, ADV. SCREW HOLE

NOTES:

ASSEMBLE 22658 PISTON WITH PART NO. TOWARDS PISTON HOLE PLUG

INDENTED ITEMS INCLUDED

DB2435-5000

EDITION 8

DESCRIPTION

QTY

P/N

DATED 02/07/2000
COVER GROUP

PAGE 4 OF 4

P/N

QTY

DESCRIPTION

22109

REG ASSY, HSG PRESS

27607

SEAL, O-RING

14760

NUT, LOCK

22351

22985

TERMINAL, BLADE

1
2

INSULATOR, TERMINAL
LOCK WASHER, TOOTH

(60500)

SCREW, BUTTON HD CAP

STRAP, TERM GROUNDING

20951

21618
12049

LOCK WASHER, TOOTH

18493

30789

CAP, COVER SCREW

NUT, HEX

12519

WASHER, PLAIN

18501

30788

CUP, COVER SCREW

12500

WASHER, TERM INSUL

21898

COVER, GOV CONTROL

26387

SOLENOID, 24V ETR

2-23190 TUBE, INSULATE

SEAL, RECT SECTION

NOTES:

27244

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

FOR SERVICE USE ONLY

APPLICABLE SERVICE ASSEMBLIES
THROTTLE SHAFT BUSHING REPLACEMENT
GASKET KIT
ESO MOUNTING AND GROUNDING KIT
PILOT TUBE REPLACEMENT (REF SB 171C)

FOR ENGINEERING USE ONLY

DATE
CHANGE NO.
EDITION
17776
24373
26431
32980

05/15/1991
12/04/1991
11/30/1992
04/11/1994
01/27/1999
03/24/1999
04/05/1999
02/07/2000

20845
21234
22027
23162
26099
26208
26208
26664

1
2
3
4
5
6
7
8

INDENTED ITEMS INCLUDED