STANADYNE DB2

FUEL INJECTION PUMP SYSTEM

FOR THE MILITARY
M998A2 SERIES VEHICLES

Pump
Pump Operation,
Operation, Inspection/Diagnosis
Inspection/Diagnosis and
and Fuel
Fuel Injection
Injection Nozzle
Nozzle Description
Description
 Model Number System
a b c d e
DB2 8 33 JN 3000
a. DB2= D-Series pump, B- Rotor, 2- 2nd. Generation pump
b. 8= Number of cylinder (available in 2,3,4,6 & 8 cylinders).
c. 33= Abbreviation of plunger diameter.
25= .250” (6.35mm) 31= .310” (7.87mm)
27= .270” (6.86mm) 33= .330” (8.38mm)
29= .290” (7.37mm) 35= .350” (8.89mm)
d. JN= Accessory code: This code pertains to combinations of
special accessories such as electrical shutoff, automatic advance, etc.
e. 3000= Specification Number. Determines selection of parts and
adjustments for a given application.
Components and Functions
2 3
Housing Metering
Metering
Housing
Valve
Valve
4
1
Drive Hydraulic
Hydraulic Head
Head
Drive Shaft
Shaft
Assembly
Assembly
5
Transfer
Transfer Pump
Pump
Blades
Blades
11
Governor
Governor
6
Pressure
Pressure Regulator
Regulator
10 Assembly
Assembly
Pumping
Pumping 7
Plungers
Plungers 9 8 Distributor
Distributor
Automatic
Automatic Internal
Internal Rotor
Rotor
Advance
Advance Cam
Cam Ring
Ring
Mounting Flanges

HMMWV
Fuel Schematic 24 FUEL
SHUTOFF
SOLENOID
26
25 24VDC GOVERNOR
SPRING
GOVERNOR LINKAGE
22
28
11 HOUSING
AUTOMATIC
METERING ADVANCE PRESSURE
LEVER REGULLTOR
ALVE 21
20
CAM RING 19
AUTOMATIC
ADVANCE GOVERNOR
MECHANISM 23
INTERNAL PASSAGE

HOUSING

FUEL RETURN
PRESSURE
COLD
ADDANCE
10 SOLENOID
9 VENT WIRE 4
HYDRAULIC ASSEMBLY FUEL
HEAD ASSY. PUMP 27
GOVERNOR
HOUSING
14 12
PLUNGER CHARGING
PRESSURE 8 PRES.REG. 3 FUEL
13 5 1
LOW TANK
ROTOR FUEL/WATER PRESSURE

N
SEPARATOR LINEE

R
2

ETU
IN TANK
6 INLET

LR
7 FILTER
FILTER

FUE
TRANSFER PUMP
ROTOR AND RETAINERS
15 16
PUMPING DELIVERY
CHAMBER VALVE 17 (8EA.) HIGH PRESSURE FUEL INJECTION LINES
18
INLET PRESSURE (4-7 PSI) NOZZLE
TRANSFER PUMP PRESSURE CIRCUIT (12-130 PSI) 8 EA.
HIGH PRESSURE DISCHARGE CIRCUIT (up to 3500 PSI) 1500-1960
HOUSING PRESSURE CIRCUIT (5 to15 PSI) PSI
RETURN OIL CIRCUIT (5 to 15 PSI)
Rotor Operation
Cam Ring
Cam Roller
Lobe
Shoe
Rotor

Leaf Spring

Leaf Spring
Screw
Transfer Pump
A B C
Inlet
Slot Blade
Liner

Rotor

Outlet Groove
Inlet
Transfer Pump Pressure
 Regulator Assembly
Operation/Viscosity Compensation
A B
Regulating
Regulating Slot
Slot
Inlet
Inlet
Regulating
Regulating Piston
Piston Regulating
Regulating Spring
Spring
Regulator
Regulator Transfer
Transfer Pump
Pump Pressure
Pressure
Inlet
Inlet Side
Side
Thin
Thin Plate
Plate
Orifice
Orifice

Discharge
Discharge Side
Side Spring
Spring Adjusting
Adjusting
Plug
Plug
Charging Cycle
Metering
Valve
Plunger Circular
Roller Between
Cam Lobes Fuel Passage

Distributor
Leaf Rotor
Spring

Cam Transfer
Shoe Charging Pump
Inlet Passage
Passage
Transfer Pump Pressure
Discharge Cycle
Cam
Roller Contacts Distrubutor Rotor
Cam Lobe
Discharge
Fitting
Pumping
Chamber

Discharge Discharge
Passage Port
Delivery
Valve
Injector Pressure
Delivery Valve

A
Fuel Return Circuit
Ballcheck Return Air Vent Passage to
Fuel Fitting Governor Compartment

Housing Pressure
Transfer Pressure
Mechanical Governor
Linkage Hook Governor Spring
Governor Arm
Low Idle
Weight Spring Capsule
Pivot Shaft
Metering Valve

Thrust sleeve
and Washer

Weight
Retainer
Automatic Advance
Rotor Advance Direction
Rotation

Passage Cam
Piston Hole
Plug Groove
Advance Piston
Head
Piston Hole
Bleed Orifice Plug
Head Locating
Screw Groove Transfer Pump Pressure
Detailed
Inspection
Fuel Shutoff Solenoid
Plunger

“NO FUEL”
Electric Position
Shutoff (De-Energized)
Solenoid

Running Metering Valve

Position (Rotates to
(Energized) Arm Stop Fuel Flow)
H.P.C.A. Housing Pressure
Cold Advance Solenoid

Solenoid

Plunger
Defective Nozzle Check
(Engine
(Engine knocking
knocking due
due to
to nozzle
nozzle stuck
stuck open)
open)

Loosen
1 to 1-1/2 Turns
Mechanical Light Load Advance Check
Fuel Injectors
Main Purpose of Injector Nozzle
Types of Needle Valves
Purpose of Nozzle Holder Assembly
Body, Cap-Nut & Intermediate Plate
Additional Parts of Nozzle Holder
HMMWV Pintle Nozzle
Internal Head Shield
Nozzle Operation
Nozzle Operation
Stages of Operation
Precombustion Chamber
 Stanadyne DB2 Fuel Injection
Pump Specifications

(Service/Assembly)
(Service/Assembly)

Full
Full Load
Load RPM:
RPM: 3400
3400 AM
AM General
General Part
Part ## 05743796
05743796 Model
Model ## DB28331-5149
DB28331-5149

Gov.
Gov. Regulation:%
Regulation:% MFG.
MFG. Part
Part ## 125504396
125504396

Engine:
Engine: 6.5L-170
6.5L-170 BHP
BHP

Application:
Application: Heavy
Heavy duty–Military
duty–Military (1.2
(1.2 CST
CST Min.)
Min.)
Exploded View
Injection Pump Mounting and Drive

VIEW A Timing
Marks

VIEW B Driven
Gear

Alignment
Mounting Dowel
Stud and Nut
Timing
Marks Drive
Gear
Injection Pump Mounting and Drive
Plunger Spring
Drive Shaft

Dowel

Access to Bolts
Injection Pump External Linkage
VIEW A VIEW B

Throttle Return
Spring

Cable Pivots Idle Speed

Screw
Electrical Pump Electrical
Connections
HPCA Solenoid

Fuel Shutoff
Solenoid
TPS
Throttle Position
Sensor
Injection Pump Fuel System
Connections
VIEW A VIEW B
Return
Fitting
Cyl #8 Cyl #7

Cyl #1 Cyl #2

Cyl #3 Cyl #6
Connector for Hose
From Fuel Filter Cyl #4 Cyl #5
Injection Pump Construction

Housing/Cover
Housing/Cover
Drive
Drive Shaft
Shaft
Rotor
Rotor
Head
Head
Injection Pump Operation

B
A
Transfer
Transfer Governor
Governor
Pump
Pump Housing
Housing
Pressure
Pressure Pressure
Pressure

C
Supply
Supply Pressure
Pressure Note:
Note: Circled
Circled
Letters
Letters Indicate
Indicate
Lift
Lift Pump
Pump Pressure
Pressure Injection
Injection Pressure
Pressure Pressure
Pressure
Transfer
Transfer Pump
Pump Pressure
Pressure Lift
Lift Pump
Pump Suction
Suction Check
Check Points.
Points.
Housing
Housing Pressure
Pressure Return
Return Pressure
Pressure
Transfer Pump Flow

Circular
Circular
Passage
Passage
Fuel
Fuel
Filter
Filter

Lift
Lift
Inlet to
Inlet to Pump
Pump
Transfer Pump
Transfer Pump
Regulator
Regulator Transfer
Transfer Lift
Lift Pump
Pump Pressure
Pressure
Valve
Valve Pump
Pump Transfer
Transfer Pump
Pump Pressure
Pressure
(Increases
(Increases With
With Engine
Engine Speed)
Speed)
Transfer Pump Operation

Lift Pump Pressure

Transfer Pump Pressure
Metering Valve Flow
Metering
Metering Valve
Valve

Charging
Charging
Passage
Passage

Circular
Circular
Passage
Passage

Transfer
Transfer Pump
Pump Pressure
Pressure
Metering Valve Operation
Less Fuel

More Fuel

Metering Open
Edge
Governor Mechanism Parts
Min-Max Throttle
Governor
Assembly Shaft

Governor Guide Stud

Arm

Pivot Metering
(In-Housing) Valve

Governor Rotor
Weights Drive Shaft
Governor Governor Weight
Sleeve Retainer
 Min-Max Governor Assembly
VIEW A VIEW B
Governor
Governor Throttle
Throttle
Throttle
Throttle Arm/Linkage
Arm/Linkage Shaft
Shaft
Washer
Washer Spring
Spring Housing
Housing Min-Max
Min-Max Metering
Metering
Low
Low Idle
Idle Outer
Outer Bushing
Bushing Governor
Governor Valve
Valve
Spring
Spring Governor
Governor Assembly
Assembly
Spring
Spring
Seal
Seal
Rod
Rod Nut
Nut
Assembly
Assembly
Throttle
Throttle
Housing Block
Housing Block Inner
Inner
Bushing
Bushing Governor
Governor Guide
Guide
Throttle
Throttle Spring
Spring Stud
Stud
Shaft
Shaft
 Governor Mechanism Operation Min-Max
Min-Max
Governor
Governor
Metering
Metering Governor
Governor Linkage
Linkage Fuel
Fuel Shut-off
Shut-off Assembly
Assembly
Valve
Valve Solenoid
Solenoid
Governor
Governor
Arm
Arm
Governor
Governor
Throttle
Throttle Weight
Weight Pivot
Pivot
Shaft
Shaft Retainer
Retainer

Drive
Drive Shaft
Shaft
Rotor
Rotor Governor
Governor
Sleeve
Sleeve
 Governor Mechanism Operation
Throttle
Throttle Shaft
Shaft
Outer
Outer Spring
Spring
(Half
(Half Throttle
Throttle Position)
Position)

Throttle
Throttle Shaft
Shaft Throttle
Throttle Shaft
Shaft
(Low
(Low Idle
Idle Throttle
Throttle Position)
Position) (Full
(Full Throttle
Throttle Position)
Position)
Low
Low Idle
Idle
Spring
Spring Inner
Inner
Spring
Spring
 Pressurizing and Distributing
Metering
Valve

Rotor

Pumping
Plungers Charging Passage
 Charge Cycle
Roller Plunger Metering
Between Valve
Circular
Cam Lobes
Fuel Passage

Distributor
Leaf
Rotor
Spring

Plunger
Cam Movement
Ring
Transfer
Shoe Inlet Charging Pump
Passage Passage
 Discharge Cycle

Rotor
Rotor

Pumping
Pumping
Plungers
Plungers Fuel
Fuel Under
Under Pressure
Pressure Wave
Wave

Delivery
Delivery Valve
Valve Transfer
Transfer Pump
Pump Pressure
Pressure
Injection
Injection Pressure
Pressure
 Valve Retracts
Discharge Cycle Before Fuel Moves

Distributor
Cam Rotor
Roller Contacts Discharge
Cam Lobe Fittings
Pumping
Chamber

Discharge
Passage
Delivery Valve Discharge Port
Lubrication Flow Housing
Housing
Pressure
Pressure
Regulator
Regulator

Circular
Circular Housing
Housing
Passage
Passage Pressure
Pressure
Vent
Vent Wire
Wire Cold
Cold
Assembly
Assembly Advance
Advance
Solenoid
Solenoid

Transfer
Transfer Pump
Pump Pressure
Pressure
Housing
Housing Pressure
Pressure
Return
Return Pressure
Pressure
Lubrication
Timing

Automatic
Automatic
Advance
Advance Cam
Cam Ring
Ring
Mechanism
Mechanism Piston
Piston
Pin
Pin

Circular
Circular
Passage
Passage

Transfer
Transfer Pump
Pump

Transfer
Transfer Pump
Pump Pressure
Pressure
Timing
Timing
Timing at
at Timing
Timing at
at
Idle
Idle Speed
Speed Full
Full Speed
Speed

Piston
Piston Moves
Moves
Light Load Advance
Face
Face Throttle
Throttle
Cam
Cam Shaft
Shaft

Piston
Piston
Rocker
Rocker
Lever
Lever Servo
Servo
Valve
Valve

Plunger Spring
Spring
Plunger

Transfer
Transfer Pump
Pump Pressure
Pressure
Light Load Advance
Throttle
Throttle Shaft
Shaft
Face
Face Cam
Cam
Cam
Cam Ring
Ring
Rocker
Rocker Lever
Lever
Rotor
Rotor
Plunger
Plunger

Plug
Plug With
With Plug
Plug
Plunger
Plunger Seal
Seal
AT
AT LIGHTER
LIGHTER LOADS
LOADS AT
AT HEAVIER
HEAVIER LOADS
LOADS
(NO
(NO RESTRICTIONS)
RESTRICTIONS) (RESTRICTIONS)
(RESTRICTIONS)
Servo
Servo Cam
Cam Advance
Advance
Valve
Valve Advance
Advance Piston
Piston
PIN
PIN Pin
Pin PIN
PIN

From
From From
From
Transfer
Transfer Pump
Pump Transfer
Transfer Pump
Pump
HPCA (Warm Engine)
Housing
Housing
Pressure
Pressure
Regulator
Regulator

HPCA
HPCA
Solenoid
Solenoid
(Off)
(Off)

Transfer
Transfer Pump
Pump Pressure
Pressure
Housing
Housing Pressure
Pressure
Return
Return Pressure
Pressure
HPCA (Cold Engine)
Housing
Housing
Pressure
Pressure
Regulator
Regulator

Timing
Timing
Advance
Advance

HPCA
HPCA
Solenoid
Solenoid
(On)
(On)

Transfer
Transfer Pump
Pump Pressure
Pressure
Return
Return Pressure
Pressure
Fuel Supply Checks
Fuel Return Pressure Checks
Advance Mechanism Checks
Injection Line & Nozzle Checks
Injection Pump Governor
Cover & Parts Terminal
Terminal
Ground
Ground Strap
Strap
Governor
Governor Terminal
Terminal
Cover
Cover Screw
Screw Contact
Contact Nut
Nut
Lockwasher
Lockwasher Lockwasher
Lockwasher
Nut
Nut
Plain
Plain Washer
Washer Plain
Plain Washer
Washer
Lockwasher
Lockwasher Terminal
Terminal
Insulating
Insulating Washer
Washer
Plain
Plain Washer
Washer

HPCA
HPCA
Fuel
Fuel
Solenoid
Solenoid
Shut-Off
Shut-Off
Solenoid
Solenoid Governor
Governor
Cover
Cover Gasket
Gasket
Injection Lines
Cyl
Cyl #2
#2 Cyl
Cyl #4
#4 Cyl
Cyl #6
#6 Cyl
Cyl #8
#8

Cyl
Cyl #1
#1 Cyl
Cyl #3
#3 Cyl
Cyl #5
#5 Cyl
Cyl #7
#7
Injection Lines
INJECTION
INJECTION LINE
LINE FITTING
FITTING
TORQUE
TORQUE
•• At
At Pump:
Pump: 24
24 to
to 36
36 N•m
N•m
(18to 27 lb-ft)
(18to 27 lb-ft)
•• At
At Pump:
Pump: 27
27 to
to 39
39 N•m
N•m
(19to 29 lb-ft)
(19to 29 lb-ft)

#8
#8 Right
Right Left
Left #7
#7
Bank
Bank Bank
Bank
#6
#6
#5
#5
#4
#4
#3
#3
#2
#2 #1
#1
Construction and Operation
High-Pressure
High-Pressure Inlet
Inlet High-Pressure
High-Pressure Inlet
Inlet

Leak-off
Leak-off
Leak-off
Leak-off Port
Port
Shim
Shim Shim
Shim
Nozzle
Nozzle
Pressure
Pressure Spring
Spring Nut Presure
Presure
Nut
Spring
Spring
Pressure
Pressure Spindle
Spindle
Pressure
Pressure
Intermediate
Intermediate Plate
Plate Spindle
Spindle Color
Color
Ring
Ring
Pintle
Pintle Nozzle
Nozzle Intermediate
Intermediate
Plate
Plate
Heat Shield
Heat Shield Needle
Needle
Pintle
Pintle Vavle
Vavle
Nozzle
Nozzle
Nozzle
Nozzle Nut
Nut
Heat
Heat Shield
Shield
Wave
Wave Washer
Washer
Injection Nozzle Operation

Residual
Residual Pressure
Pressure
Injection
Injection Pressure
Pressure
Return
Return Pressure
Pressure
Injection Nozzle Testing
Fuel Return System
VIEW A

#8
#6
#4
VIEW B #2 VIEW C

#5 #7
#1 #3