INJECTION PUMP SPECIFICATION ©
FULL LOAD RPM: 1500 CUSTOMER PART NO.: RE-503740 MODEL NO.: DB4629-5656
GOV. REGULATION: 3-5 % CUSTOMER NAME: SUPERSEDES:
ENGINE: 6068TF150 JOHN DEERE DUBUQUE/SARAN EDITION NO.: 7
APPLICATION: 105 kW GEN-SET DATED: 01-13-04
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... 1.966" ± .0015"
.063" (1.6 mm) ID X 25" (635 mm) LONG. (49.93 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"-.145" (3.2-3.7 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. 0 RPM (WOT):
b. SUPPLY PRESSURE (S.B. 334): 5.0 ± 0.5 PSI a. SPEED DROOP SETTING: ASSEMBLE SPEED DROOP PER S.B.
(34 ± 3 kPa) AT PUMP INLET. 97R. ENSURE CONTROL ROD SPRING IS INSTALLED WITH
4. CAM MOVEMENT READ-OUT DEVICE: #23745 5 ± ½ TURNS ON CONTROL ROD GUIDE.
b. TURN SPEED DROOP ADJUSTING CAP IN 5 TURNS FROM
PUMP INSTALLATION: IT-083 MINIMUM DROOP POSITION.
ROTATION-C-* LEVER ANGLES (REF.) c. BACK-OUT HIGH IDLE SCREW.
d. ADJUST SPEED ADVANCE PLUG TO PLACE END OF PLUG
NAME PLATE-L-SIDE** THOT MIN.(∠B) N/A FLUSH WITH END OF LLA PISTON
#1 CYL.-5-O'CLOCK** THOT MAX.(∠C) N/A 4. 1000 RPM (WOT): OPERATE PUMP FOR 10 MINUTES TO BRING TO
THROTTLE-L-SIDE** S.O. (∠ E) N/A OPERATING TEMPERATURE AND CLEAR AIR FROM SYSTEM.
E.S.0. (12V E.T.R.) S.O. (∠ F) N/A 5. 300 RPM (WOT): WITH SUPPLY PUMP ON, UNSCREW ADVANCE
CAP 4 TURNS AND ALLOW FUEL TO BLEED FOR 30 SECONDS.
* VIEWED FROM DRIVE END ** VIEWED FROM TRANSFER PUMP END RETORQUE CAP TO 200-225 LB/IN.
6. 400 RPM (WOT):
PUMP OPERATING SPEED...HALF...ENGINE SPEED a. CHECK SHUT-OFF: 4 mm³/STROKE, MAX.
AIR TIMED TO HOUSING FLANGE (S.B. 177)(SEE SPECIAL NOTES) b. CHECK FOR MINIMUM TRANSFER PUMP LIFT OF 18" HG.
(60 kPa)
PUMP CALIBRATION CHECKS: AS RECEIVED FOR SERVICE 7. 1500 RPM (WOT):
(REF. SL-222)(REF. S.B. 97R FOR SPEED DROOP) a. SET TRANSFER PUMP PRESSURE 87-89 PSI,
1. 1000 RPM WOT: OPERATE PUMP FOR 10 MINUTES TO BRING TO (600-614 kPa)(SUPPLY SET PER TEST STAND NOTE 3B)
OPERATING TEMPERATURE AND CLEAR AIR FROM SYSTEM. b. ADJUST RETURN OIL TO 400-700 CC/MIN. RECHECK TRANSFER
2. ADJUST SPEED DROOP TO MINIMUM DROOP POSITION PUMP PRESSURE.
(CCW DIRECTION) TURN SPEED DROOP CAP IN 5 FULL TURNS c. CHECK HOUSING PRESSURE FOR 8.5-13.5 PSI, (59-93 kPa)
CLOCKWISE. 8. 1500 RPM (WOT): CHECK ADVANCE FOR 0 °. IF NECESSARY
3. 1620 RPM (WOT): RESET HIGH IDLE SCREW IF NECESSARY TO ADJUST ADVANCE ADJUSTING SCREW FOR 0 °.
OBTAIN 10-20 mm³/STROKE. 9. 1500 RPM (WOT): SET ROLLER-TO-ROLLER FUEL DELIVERY
4. CHECK POINTS: (SEQUENCE MUST BE FOLLOWED AS LISTED) 106.5-107.5 mm³/STROKE.
10. 1500 RPM (ADJ. 40 mm³/STROKE): SET LIGHT LOAD ADVANCE
THROTTLE TRIMMER SCREW FOR 5.5 °.
RPM POSITION mm³/STROKE ADVANCE 11. 300 RPM (WOT): WITH SUPPLY PUMP ON, UNSCREW ADVANCE
a. 150 WOT 54 MIN. --- CAP 4 TURNS AND ALLOW FUEL TO BLEED FOR 30 SECONDS.
b. 400 WOT * 4 MAX. --- RETORQUE CAP TO 200-225 LB/IN.
c. 1500 WOT 105-109 0° 12. 1620 RPM (WOT): ADJUST HIGH IDLE SCREW TO OBTAIN
d. 1500 ADJ. 38-42 4.5°-6.5° 10-20 mm³/STROKE.
e. 1500 WOT * 4 MAX. --- 13. 1400 RPM (L.I.): SET LOW IDLE SCREW FOR 10-14 mm³/STROKE. DO
f. 1620 WOT 10-20 --- NOT BACK OUT SCREW FROM INITIAL SETTING.
g. 1670 WOT 5 MAX. 8.0°-9.0°
14. CHECK POINTS:
* E.S.O. DE-ENERGIZED
THROTTLE T.P.
RPM POSITION mm³/STROKE ADVANCE PRESSURE
a. 150 WOT 56 MIN. --- 10 MIN.**
b. 400 WOT* 4 MAX. --- ---
c. 1400 L.I. 10-14 --- ---
d. 1500 WOT 106.5-107.5 0° 87-89***
e. 1500 ADJ. 39.5-40.5 5.0°-6.0° ---
f. 1500 WOT* 4 MAX. --- ---
g. 1620 WOT 10-20 --- ---
h. 1670 WOT 5 MAX. 8.0°-9.0° ---
* E.S.O. DE-ENERGIZED ** (69 kPa) *** (600-614 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. ASSEMBLE DRIVE COMPONENTS PER S.B. 438.
d. SEAL FASTENERS PER S.B. 134R.
e. FOR SERVICE ONLY:
AIR TIME PUMP USING HARTRIDGE BASIC AIR TIMING TOOL
244-27 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 209° 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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DB4629-5656 EDITION 7 DATED 01/13/2004 PAGE 2 OF 4
DESCRIPTION QTY P/N HOUSING & DRIVE GROUP P/N QTY DESCRIPTION
(63548)
DRIVESHAFT 1 32880
26359 1 BEARING, NEEDLE
WASHER, DRIVESHAFT 1 32787
36534 1 SEAL, DRIVE SHAFT
NUT, HEX 1 26346
30804 1 SEAL, TEFLON LIP
KEY, WOODRUFF 1 30387
SCREW ASSY, VENT 1 21660
OR 21661-21665
HOUSING ASSY, PUMP 1 34222 22601 1 SCREW, BUTTON HD CAP
SLEEVE, THROTTLE STOP 1 24364 27606 1 WASHER, SEALING
21194 2 SCREW, HEX HEAD
SCREW, HEX HEAD 2 11331 23107 1 COVER, TIMING WINDOW
27603 1 GASKET, TIMING WINDOW CVR
SEAL, RECT SECTION 1 26470
12259 1 SCREW, PAN HEAD
SCREW, RIVET 2 24419 10464 1 WASHER, SEALING
NAMEPLATE 1 10394 28749 1 BEARING, THRUST
26468 1 WASHER, THRUST
28381 1 WASHER, DRSFT SPRING
SEAL, O-RING 1 17438
SEAL, O-RING 1 32884 26469 1 RING, RETAINING
SCREW, LLA ORIFICE 1 33985
NOTES:
DESCRIPTION QTY P/N HEAD & ROTOR GROUP P/N QTY DESCRIPTION
(61926)
34326 1 H&R ASSY, HYD 6 CYL
SCREW, LEAF SPR ADJ 2 15619
11056 2 PLUNGER, ROTOR
USE 11057-11060 (STD)
SHOE, CAM ROLLER 4 20120 OR 11062-11065 (O/S)
OR 20119 (-.010) OR AS IND. ON ROTOR S.B.60R
20118 (-.020) AS REQ'D
PER S.B.332 20101 2 PLUNGER, ROTOR
USE 20102-20105 (STD)
OR 20107-20110 (O/S)
AS IND. ON ROTOR S.B.60R
12216 1 SCREW, HEAD PLUG
SPRING, LEAF 2 29363 11438 1 SCREW, SET
ROLLER, CAM 4 11141 20727 6 CONNECTOR, FUEL LINE
RING, CAM 1 32163
27601 1 SEAL, O-RING
29384 1 PLATE, SINTERED LOCK
29710 1 SCREW, SKT HEAD CAP
21213 1 VALVE, DELIVERY
SEAL, O-RING 1 27245 OR 21214 (O/S) AS REQ'D
REF S.B. 143B
FILTER, HD LCTING SCR 1 24565 20127 1 SCREW, RETAINING
SPRING, DLVY VALVE 1 20129 17049 2 PISTON, ACCUMULATOR
17050 2 SCREW, ACC PSTN RET
STOP, DELIVERY VALVE 1 20128 17188 2 SPRING, ACCUMULATOR
NOTES:
DESCRIPTION QTY P/N TRANSFER PUMP GROUP P/N QTY DESCRIPTION
(61998)
32859 1 RETAINER, ROTOR
SEAL, TRANSFER PUMP 1 27608 21232 1 LINER, TRANSFER PUMP
20511 4 BLADE, TRANSFER PUMP
OR 20512 REF. S.B. 304
RETAINER, ROTOR 1 19870
19906 1 RING, LINER LOCATING
32548 1 RGLTR ASSY, PORTING
SPRING, TP BLADE 2 15699
ROLL PIN 1 19837
SEAL, TP RGLTR SLEEVE 1 19844
23915 1 SPRING, REGULATING
PISTON, REGULATING 1 31240
PLUG, END PLATE ADJ 1 32642
FILTER, INLET 1 28986 32636 1 CAP, TP END
NOTES: REFERENCE S.B. 444
INDENTED ITEMS INCLUDED
DB4629-5656 EDITION 7 DATED 01/13/2004 PAGE 3 OF 4
DESCRIPTION QTY P/N GOVERNOR GROUP P/N QTY DESCRIPTION
(63331)
SPRING, SPEED DROOP 1 13558 20240 1 ROD ASSY-CONTROL
RED STRIPE
ARM ASSY, GOVERNOR 1 29060 13554 1 PIN, CONTROL SPRING
SHAFT, GOVERNOR ARM 1 12214 27606 1 WASHER, SEALING
SEAL, O-RING 2 31332 12966 1 SEAL, O-RING
NUT, PIVOT SFT RTNR 2 12288 36556 1 CAP, ADJUSTING
SPRING, DAMPER 1 20475 20355 1 CAP, DROOP CTRL LOCK
PISTON ASSY, DAMPER 1 16572
27599 1 GUIDE, CONTROL ROD
16568 1 BARREL ASSY, DAMPER
22134 1 ARM ASSY, MTR VALVE
SLEEVE, GOVERNOR THRUST 1 36498 11563 1 VALVE, METERING
* SEE NOTE
26427 1 SHIM, MTR VALVE SPRG
WASHER, THRUST 1 19860 20359 1 SPRING, MTR VALVE
WEIGHT, GOVERNOR 6 29135 29136 3 CLIP, RETAINING
REF. S.B. 370
RETAINER ASSY, GOV WT 1 19893 19894 3 RETAINER, CUSHION
19873 6 CUSHION, GOV WT RNTR
NOTES: * O.S. METERING VALVE AND ARM ASSEMBLY 22248 REFERENCE S.B.336
DESCRIPTION QTY P/N LINKAGE GROUP P/N QTY DESCRIPTION
(61369)
SEAL, O-RING 2 17438
WASHER, SPACER 2 14408
SHAFT ASSY, THROTTLE 1 12015 16279 1 SHAFT, SHUTOFF
SCREW, HEX HEAD 1 12167
12253 1 CLIP, SHAFT RETAINER
NUT, HEX 1 12174
12221 1 LEVER, THROTTLE FORK
15306 1 SPACER, GOV SPRING
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
(62332)
SEAL, O RING 1 32948
PLUG ASSY, ADVANCE 1 34644 34633 1 SEAL, RECT SECTION
PISTON, LLA 1 34033
PLUG, SPEED ADV ADJ 1 34244
SPRING, LLA 1 34285
SEAL, O-RING 1 33613
SCREW, SPRING ADJ 1 33614
33012 4 SCREW, SOCKET HD CAP
SEAL, O RING 1 32948
CAP, LLA 1 35109 34805 1 COVER, POWER SIDE
VALVE, CHECK 1 21146 30206 1 SEAL, RECT SECTION
PISTON, ADVANCE 1 33586
19834 1 SCREW, REED VALVE
SEAT, SPRING 1 23197
SPRING, SERVO ADVANCE 1 33840
VALVE, SERVO ADVANCE 1 32818
27602 2 SEAL, O-RING
PIN, ADVANCE CAM 1 21147
SEAL, O-RING 1 27610
PLUG, HEX SOCKET 1 23056 22238 1 SCREW, HEAD LOCATING
0.02
NOTES:
INDENTED ITEMS INCLUDED
DB4629-5656 EDITION 7 DATED 01/13/2004 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, RECTANGULAR 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 01/25/2000 26249 1
ESO MOUNTING AND GROUNDING KIT 26431 08/18/2000 26221 2
GASKET KIT 33702 09/11/2000 27028 3
09/19/2000 27003 4
07/31/2003 27563 5
10/23/2003 26277 6
01/13/2004 28511 7
INDENTED ITEMS INCLUDED
