INJECTION PUMP MODEL JDB635MD2803

diesel systems SPECIFICATION SUPERSEDES MODEL JDB635AL2446

CUSTOMER PART NO. AR 5,568
EDITION NO. 14 DATED l-28-86 CUSTOMERS NAME 6 ADDRESS:
ENGINE 6329T 6 6329D John Deere Dubuque Tractor Works
FULL LOAD RPM 2500
APPLICATION JD540A:JD544: I ,
Dubuque, Iowa
6600 and 699 Gob'. REGULATION 5-7 96 ISSUED BY: J. McMahon

NOTE: ALL SPEEDS ARE IN ENGINE RPM UNLESS OTHERWISE NOTED

TFST STAND
1. INJECTION LINES (12SO12 NOZZLES) 93 2 I.D. BY 20 LON G x:E,LE;;;;;; ,:,
(HOLDER BK850smI & 0.5 MM PLATE) /IS 1.0. BY 25 LON G
2. TEST OIL TEMPERATURE llO-115'F. 10. CHECK POINT.
3. NOZZLE OPENING PRESSURE (12SO12 NOZZLES)Z5W F?il I 11. SET TORQUE SCREW
(HOLDER BKB50S533B & 0.5~~ PLATE)JOOO PCil 12. CHECKSHUT-OFF (WOT) ..2500
4. CALIBRATING OIL (s.B.201) 3 MAx. :0-y.
13. HIGH IDLE (WOT). 2650 lo-12 4
PUMP OPERATING SPEED HALF ENGINE SPEED 14. GOVERNOR CUT.OFF 2700 5 MAX. 5Hax.
ENGINE FUEL CGNSUYlPTlON 41.5. {//Hr. @ 2500 RPM 800 lo-12 10-12
15. LOW IDLE 4
PUMP ACCE55GRIE5
16. TRANS. PUMPPRESS. g&T; .
1. Delivery Valve
17.CHECK SHUT-OFF .(WOT). 400 3 MAX. 3 MAX.
2. Speed Advance
13. MIN.CRANK.SPEED DEL.. 150 27MIFj. 22MIN. 12 MIN.
3. Electric Shut-off (12V. E.T.R.)
4. Close Flow 1"CTR: Return Oil 150-500 CC/da. et rated epeea.
I
PUMP SETTINGS (t . . . ITEMS APPLY TO SERVICE ONLY) IS. NAME PLATE. LEFT SIDE VIEWING END PLATE
1. ROLLER TO ROLLER DIMENSION 1.957 * 0015 20. TIMED.. LEFT. SIDE VIEWING END PLATE w
2. GOVERNOR LINKAGE GAP.. .125 TO .165 U. TlMED TO CAM.(FOr rel+tiVq,q"d ,Of injection)*
(USE KIT NO. 23093 SB95/XL662) 22. GOVERNOR CONTROL COVER TO BE STAMPED 1?.VOLTS.
13. OPERATE PUMP AT loo0 RPM WOT (WIDE OPEN THROTTLE) 23. NUMBER ONE CYLINDER (FROM END PLATE) _________
FOR 10 MINUTES TO BRING TO OPERATING TEMPERATURE AN D 24 SPECIAL NOTES:
CLEAR AIR FROM SYSTEM. a. Torque all Fasteners perXL784 or S.B.106 a

4. CHECK FOR MINIMUM 18 HG TRANSFER PUMP LIFT AT 400 RPL b.

IF EQUIPPED WITH THE BY PASS SYSTEM, PINCH BY PASS HOSI c. Install Throttle Lever Spacer and Arm in B4-L position per XL528
5. ADJUST TRANSFER PUMP PRESSURE (WOT)
f6. CHECK FOR MINIMUM CRANKING SPEED DELIVERY (SEE STEP15 d. True End of Injection is 2' (Pump) before Timing Mark on Retainer
7. AUTO ADVANCE SPEED RESPONSIVE Assembly and 4' BTDC on Engine
. . ADVANCE MOVEMENT 6 - O0 + 1 e.
-. The use of Shims m"st limit the Roller-to-Roller dimension to
.005" above the specified dimension
- &% f. Before setting Low Idle in Cover, set Throttle Lever Stop
b. 700-11011 I 14 Screw for Low Idle RPM and Delivery - then back out 1 full turn.
NOTE PUMPROTATION CLOCKWISE
By 2200 25. SEALING WIRES: PART NO. 10408 1 . . REQUIRED
FOR SE& USE ON (REFERENCE DRAWINGXL-1067 OR SERVICE BULLETIN 134R)
1. At 1500 RPM FULL LOAD2 SET 4" (Check 4" + 1' NOTE: HIGH IDLE SCREWTO BE SEALED BY JOHN DEERE INSPECTOR
2. Adv. must FI 6 1% 5-l/2 Min. Movement by 2300 b M F.L.
3. No Load Advance is 4' Movement
-- @ 1200 RPH
C#ESCI)PTIClPI :z;. P*R,(10. "c."S1*CIO*I"EOIO"P
I

SCREW, low idle adjusting 1 15442

12337 1 ASHER, low idle adj. screw
NUT, low idle adj. screw 1 12174
SEAL, low idle screw 1 11588

SCREW, cover hold down

1
A
22351 12202 1 S CREW, cover hold dew"
LOCKWASHER,cover screw 11582
i
NUT, drive shaft : 10529 15830 1 CONNECTORASSY., return line
WASHER, drive shaft 1 10534 13521 3 WASHER, cover hold down screv
121oe 1 COVER, governor control

GASKET, governor cover 1 27244

16371 11331 2 S CREW, head locking
SEAL, pilot tube 1
SEAL, drive shaft 2 10453
SHAFT, drive 1 10213
SICREW, torq. ec~ew hole plug
KEY, drive shaft 1 to274 W.ASHER, torq. screw hole plug.
BUTTON, thrust 1 16365
SPRING, thrust button 1 10541

tiOUSING ASSEMBLY
SCREW, name plate S.B.165 2 10401
; STOP, adjusting screw
PLATE, name 1 10394
1 SCREW, adjusting stop
GASKET, timing line cover I 10574
SCREW, timing line cover 10584
COVER, timing line 1 10567 -Ll I
I Ii..L.L Qv- R
A HEAD AND ROTORGROUP rm*o. DCSCIl?TlON
II
PAW 110. 3
18846 1 1IYD. HRAD 6 ROTORASSY. *
2 PLUNGER, rotor (basic)

ROLLER, cam
7 I _ll 1
I eel1087
,r 11097
4~8 indicated
thro 11090 (standard,
thru 11100 (0wrsize)

I JALVE, delivery
on rotor S.B. 6OR
S.B.143R
13823
SHOE, cam roller ,,r 13824 (oversize) as req'd.
13839 1 SxaHG, delivery valve
h CAY, ring 16440 1 STOP, delivery valve
13837 1 SCREW,delivery valve ret.
.11437 1 WIRE, vent or 14565 (Blk)
SEAL, hydraulic head 11438 2 SCREW, hydraulic head plug
SPRING, leaf 11439 1 WIRE, vent wire ret.
SCREW, leaf spring adj. 12216 1 SCREW, hydraulic head plug
SIIIM, spring leaf
(See Special Notes 24) 11208 1 RING, rotor retainer
11212 2 RETAINER, rotor
WASHER, fuel line co""eCto
SCREW, fuel line connector * INDENTED ITEMS INCLUDED

I
 Page 2 of 3
m *o
z? DucRWllOM
y%
JDB635MD2803 5228 LUG ASSY., end plate adj.
17917 1 LEEM, end plate

2406 1 EAL, end plate sleeve

;225 1 LEMENT, filter

5627 EAL, element
flOLLPIN, end plate lot. : ING, sleeve seal
SPRING, trans. pump blade 'E PRING, regulating
1
&LADE, transfer pump
1508 1 ISTON, regulating
or 20512 Per SB30
LINER, transfer pump
.5877 LATE, end
SEAL, transfer pump .7616 : 'LIP, end plate screw
Bend Tab.-
CRATE, thrust .7504 2 TRAP, end plate
JEAL, end plate plug .7506 4 ,CREW, end plate
J/& L 'LUG. end "late

GOVERNORGROUP
SPRING, governor control 1 20859 2210 1 RETAINER, spring
ARM, governor 1 14482 1966 1 SPRING, idling
SHAFT, gov. arm pivot 1 12214 1969 1 GUIDE, idling spring
SEAL, pivot shaft I 11588 1
!7606 WASHER, guide stud
NL'T, pivot shaft retaining 2 12288 !4726 1 STUD, guide
SP.ACER, governor spring 1 1610 1 SHIM, metering valve
ARM ASSY., metering valve 1 ::%
0849 1 VALVE, metering
SLEEVE, governor thrust 1 21312
"r 22250 Ref. to S.B. 336
WEIGHT, governor 6 11643 0359 1 SPRING, metering valve
9534 1 RETAINER ASSY., gov. weight
WASHER, go". thrust sleeve 1 23272 9528 1 RET. ASSY., gov.wt.(Basic)
RING, gov. cage retaining 1 12205. 3267 1 RETAINER, gov. weight
8986 1 HUB ASSY., gov. weight
!2935 1 RING,, flexible ret.
= -.--.-~-T_~
-
6392 1 EVER ASSY.. throttle
3003 1 PRING, throttle lever
3010 1 ETAINER. throttle IeVer SPg.
.5668 1 CREW, throttle ret. Spring

- ,V!JT, thr. lev. stop

12175
SCREW, thr. lev. StOU
12167
6136 1 RH, adjusting spacer
LEVER, throttle shaft i 12221 2051 1 CREW, throttle lever pOS.
<LIP, shaft retaining L 12253 6135 1 PACER, throttle lever adj.
JEAL, throttle shaft ! 17438 .7602 :AP, adjusting screw
IJASHER, throttle shaft Seal ! 14408 .7992 : CREW, high idle adjusting
-2174 1 IUT, S. o. arm adj. screw
JHAFT, shut-off 1 16279 1 HAFT_ASSY., throttle
::A; 1 OOK ASSEMBLY, gov. linkage
2360 SCREW, gov. link. hook adj.
2362 : WASHER, gov. link. hook adj
17604 1 HOOK, governor linkage
2358 1 LINK ASSY., gov. link. adj.
1919 1 PRING, Rovernor linka'e
Z =

*Assemble with Part No. 22655 1 ?LUG, piston hole (power)

towards piston hole plug
SEAL, piston ring 1 1575c 18967 1 ?.INC, piston
*PISTON, power 1 16241
WASHER, slide 1 1262;

WASHER, slide 1 1262:

2760: 2 j&u,, head lot. acre"
PISTON, spring 1 22181 6 Adv.
SPRING, outer advance 1 18955 22231 1 SCREWASSY.. had locating
SPRING, 1""er advance 1 14251
GUIDE, adv. adj. spring 1 1494(
SEAL, piston hole plug 12761
SEAL, piston hole plug : 2011:
PLUG, piston hole (sprlnl 1 1494:
SCREW, advance adj. 1 14541 15431 1 SCREW, cam advance
NUT, trimmer screw 1 1380:
27611 1 SEAL, adv. screw hole plug
SEAL, adv. adj. screw 1 1743; 2305 1 PLUG, adv. [icrew hole
 Page 3 of 3
- -_.
- ELECTRIC SHUT-OFFGROUP(E.T.R.)

2 LOCKEiuT,terminal contact

- 20951 1 STRAP, temhal grounding

_ 12049 1 LOCKWASHER, term. Contact
LOCKWASHER,cover screw 1 18493 .
. 12519 2 Nm, terminal COntaCt
WASHER,terminal contact 2 18501 WASHER,terminal insulating
2

SOLENOIDFRAME6 ARMASSEMBLY 22315 -

TUBE, insulating 23190

-
FOR SERVICE USE ONLY FOR ENGINEERINGUSE ONLY
APPLICABLESERVICEASSEMBLIES DATE CHG. NO
k- EDITION
THROTTLESHAFTBUSHINGRBPtiC~~ 1115093
GASKETKIT t/24371 09-14-81 14316 10
PILOT TUBE REPLACEMENT 1116320 12-15-82 15011 11
SOLENOIDFRAXEASSE;Z+LYKIT (122146 10-12-83 15801 12
9-18-84 16438 13
I-28-86 17315-s 14