INJECTION PUMP SPECIFICATION ©

FULL LOAD RPM: 3400 CUSTOMER PART NO.: GEP 18000515 MODEL NO.: DB2831-5966
GOV. REGULATION: % CUSTOMER NAME: AM GENERAL SUPERSEDES:
ENGINE: 6.5L-170 B.H.P. EDITION NO.: 1
APPLICATION: N.A. HEAVY DUTY-MILITARY (1.2 CST MIN. FUEL) DATED: 04-25-05

NOTE: ALL SPEEDS ARE IN ENGINE RPM UNLESS OTHERWISE NOTED

USE LATEST REVISION FOR ALL REFERENCED DOCUMENTS
TEST STAND: ISO 4008: PUMP SETTINGS: (CON'T)
1. CALIBRATING HIGH PRESSURE PIPES...SAE J1418/ISO 4093: 675 RPM (L.I.): (CON'T)
.098" (2.5 mm) ID X 25" (635 mm) LONG. b. WITH HOUSING PRESSURE COLD ADVANCE SOLENOID
2. CALIBRATING INJECTORS..... SAE J968/ISO 7440: ENERGIZED WITH 17.6 VOLTS, HOUSING PRESSURE SHOULD
0.5 mm ORIFICE PLATE.....1700 PSI (117 BAR) OPENING BE 0-1 PSI, (0-7 kPa).
PRESSURE. c. WITH GOVERNOR COVER REMOVED AND THROTTLE IN LOW
NOTE: INJECTORS SPECIFIED AT 1700 PSI OPENING PRESSURE MUST IDLE POSITION, SET MIN.-MAX. GOVERNOR ASSEMBLY FOR 7-9
USE SPRING P/N WSF 2044 A 5X OR EQUIVALENT. mm³/STROKE.(FUEL READING WITH COVER INSTALLED)
3. CALIBRATION FLUID...SAE J967/ISO 4113 (REF. S.B. 201): d. ADJUST LOW IDLE SCREW FOR 13-15 mm³/STROKE,
a. TEMPERATURE AT INLET: 110°-115°F (43°-46°C) (NOTE 14c) FOR THE REMAINDER OF THE SETTING AND
b. SUPPLY PRESSURE (S.B. 334): 5.0 ± 0.5 PSI CHECKING PROCEDURES, CONTROL FACE CAM AND
(34 ± 3 kPa) AT PUMP INLET. THROTTLE SHAFT END PLAY TO .004"-.006" AS MEASURED
4. CAM MOVEMENT READ OUT DEVICE: #23745. BETWEEN SPACER #22900 AND HOUSING.
8. 3400 RPM (WOT):
PUMP INSTALLATION: IT -044 a. ROTATE FACE CAM TO ITS MAXIMUM LIFT POSITION IN
ROTATION-C'C-* CONTACT WITH THE CAM ROLLER.
NAME PLATE-L-SIDE** b. SET TRIMMER SCREW FOR 3.5° ADVANCE.
#1 CYL.-10-O'CLOCK** c. SET FUEL DELIVERY TO 61-63 mm³/STROKE.
THROTTLE-L-SIDE** 9. 3650 RPM (WOT):
TIMING MARK N/A a. SET GUIDE STUD FOR 35.5-37.5 mm³/STROKE.
* VIEWED FROM DRIVE END ** VIEWED FROM TRANSFER PUMP END b. AFTER SETTING IS OBTAINED, TORQUE NUT #23585 TO
80-90 IN-LBS.
AIR TIMED TO HOUSING FLANGE (PER S.B. 177) c. CHECK DIMENSION FROM TOP OF NUT TO TOP OF GUIDE STUD
PUMP OPERATING SPEED...HALF...ENGINE SPEED FOR .425" MAX.
10. 3200 RPM:
PUMP ACCESSORIES: a. ADJUST THROTTLE TO 21.5-23.5 mm³/STROKE.
1. E.S.O. (24V E.T.R.) 5. TRAILING PORT ROTOR b. ROTATE FACE CAM TO OBTAIN 5.75° ADVANCE.
2. MIN.-MAX. GOVERNOR IV 6. ACCUMULATORS
3. HOUSING PRESSURE COLD ADV. 7. M/LL ADVANCE c. AFTER SETTING IS OBTAINED, TORQUE SCREW #22398 TO
4. THIN FUEL COMPONENTS 28-30 IN-LBS.
d. CHECK FACE CAM RETENTION PER S.B. 361.
PUMP CALIBRATION CHECKS: AS RECEIVED FOR SERVICE 11. SET TOTAL THROTTLE TRAVEL:
(REF. SL-222) a. 1500 RPM: SET THROTTLE FOR 22.5 ± 3 mm³/STROKE.
1. 1000 RPM (WOT): OPERATE PUMP FOR 10 MINUTES TO BRING TO b. LOCK THROTTLE LEVER IN POSITION AND INSTALL THROTTLE
OPERATING TEMPERATURE AND CLEAR AIR FROM SYSTEM. LEVER PROTRACTOR #22089 ONTO SHAFT.
2. 400 RPM: CHECK E.S.O. FOR PULL-IN WITH 17.6 VOLTS MAX., WITH c. ALIGN 0° ON PROTRACTOR WITH CENTER OF RIB ON ROCKER
THROTTLE IN LOW IDLE POSITION. LEVER #28937. UNLOCK THROTTLE LEVER AND ROTATE TO
3. CHECK POINTS: WOT POSITION. ADJUST MAX. TRAVEL SCREW TO 60°.
d. CHECK TOTAL THROTTLE TRAVEL: WITH THROTTLE IN LOW
THROTTLE CAM HOUSING IDLE POSITION, ALIGN 0° ON PROTRACTOR WITH CENTER OF
RPM POSITION mm³/STROKE MOVEMENT PRESSURE RIB ON ROCKER LEVER. MOVE THROTTLE TO WOT READING
a. 150 L.I. 27 MIN. --- 0-12 SHOULD BE BETWEEN 75° AND 84°.
b. 400 WOT 43 MIN. --- --- NOTE: ANY CHANGES AFTER THIS POINT WILL REQUIRE RE-TESTING
c. 400 WOT * 4 MAX. --- --- OF PUMP, STARTING WITH STEP 7.
d. 675 L.I. *** 12-16 0.5° MIN. 8-12 12. CHECK POINTS:
e. 675 L.I. --- **** 0-1 ** a. 1500 RPM (WOT): DE-ENERGIZE ELECTRIC SHUT-OFF. FUEL
f. 2000 WOT 68 MAX. --- --- SHOULD BE 4 mm³/STROKE, MAX. RE-ENERGIZE E.S.O.
g. 3200 ADJ. 21.5-23.5 4.5°-7.0° ---
h. 3400 WOT 59.5-64.5 2.5°-4.5° --- THROTTLE CAM T.P. HOUSING
i. 3500 WOT 55 MIN. --- --- RPM POSITION mm³/STROKE MOVEMENT PRESS PRESS
j. 3650 WOT 30 MIN. --- --- b. 150 L.I. 28 MIN. --- 16 MIN. 0-12
k. 3900 WOT 15 MAX. --- --- c. 400 WOT 43 MIN. --- --- ---
d. 400 WOT * 4 MAX. --- --- ---
* E.S.O. DE-ENERGIZED ** HPCA ENERGIZED e. 400 L.I. ** --- --- --- ---
*** RESET USING LOW IDLE SCREW **** MIN. OF 1.25° MORE f. 675 L.I. 12-16 1.0° MIN. --- 8-12
THAN READING OBTAINED IN STEP 3d. g. 675 L.I. ---- **** --- 0-1
4. CHECK AIR TIMING USING GAUGE #23715, h. 2000 WOT 68 MAX. --- 60-62 ---
(PER S.B. 334 & 375) SET TO -2.0° TO 0°. i. 3200 ADJ. 21.5°-23.5° 4.75°-6.75° --- ---
5. TOTAL THROTTLE TRAVEL FROM LOW IDLE TO WIDE OPEN j. 3400 WOT 60.5-63.5 3°-4° --- ---
SHOULD BE 75°-84°. k. 3500 WOT 55 MIN. --- --- ---
PUMP SETTINGS: (FOLLOWING PUMP SERVICE) l. 3650 WOT 31.5 MIN. --- --- ---
1. ROLLER-TO-ROLLER DIMENSION: 1.975" ± .001" m. 3900 WOT 15 MAX. --- 125 MAX. ---
(50.16 ± .026 mm)
MAXIMUM ECCENTRICITY: .008" (0.2 mm) T.I.R. * E.S.O. DE-ENERGIZED ** CHECK E.S.O. FOR PULL-IN WITH 8.8
2. WITH OVERSIZE CAM RING ROLLER-TO-ROLLER DIMENSION TO BE VOLTS MAX. WITH THROTTLE IN LOW IDLE POSITION, CHECK
1.981" ± .001 (50.31 ± .026 mm)(REF. S.B. 338). E.S.O. 4 mm³/STROKE, MAX. **** MIN. OF 1.25° MORE THAN
3. LINKAGE GAP: .130" TO .175" (3.3 TO 4.4 mm) READING OBTAINED IN STEP 13f.
(PER S.B. 95 & 342.) 13. AIR-TIME PUMP USING GAGE #23715 SET TO -1.0° ± 0.5°.
4. a. USE GAGE #23716, SET THROTTLE WITH LOW IDLE SCREW TO (PER S.B. 334 & 375).
34° ± 2° AS MEASURED BETWEEN VERTICAL CENTERLINE OF 14. SPECIAL NOTES:
THROTTLE SHAFT BUSHING BORE AND THROTTLE a. TORQUE ALL FASTENERS PER S.B. 106.
CONNECTION STUD. b. SECURE MAXIMUM TRAVEL ADJUSTING SCREW, ADVANCE
b. ADJUST LOW IDLE SCREW UNTIL THROTTLE CONNECTION STUD TRIMMER SCREW, AND FACE CAM SCREW WITH RETAINING
MAKES CONTACT WITH GAGE. COMPOUND #21915.
5. 1000 RPM (WOT): OPERATE PUMP FOR 10 MINUTES TO BRING TO c. IF ADJUSTMENT IS REQUIRED, USE L.I. SCREW. CHECK
OPERATING TEMPERATURE AND CLEAR AIR FROM SYSTEM. CENTERLINE OF THROTTLE STUD TO VERTICAL CENTERLINE
a. CHECK FOR MINIMUM LIFT OF 18"HG. AT 400 RPM. OF SHAFT AT 32°-36°. ADJUSTMENT IS ± 1 TURN FROM POINT
6. 2000 RPM (WOT): SET TRANSFER PUMP PRESSURE FOR 60-62 PSI, IN STEP 4a.
(414-427 kPa)(SUPPLY SET PER TEST STAND NOTE 3B) d. INSTALL GUIDE STUD TAMPER PROOFING CAP #26961 (FIELD
a. SET RETURN OIL 225-375 CC/MIN. SERVICE P/N) ON GUIDE STUD #26495 (REF. S.B. 365A).
7. 675 RPM (L.I.): e. SEAL PUMP FASTENERS PER S.B. 365.
a. CHECK HOUSING PRESSURE FOR 8-12 PSI, (55-83 kPa). 15. FURTHER INFORMATION SUPPLEMENTING THE ABOVE
PROCEDURES SHOULD BE OBTAINED FROM S.B. 375.

© STANADYNE Corporation, 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.
DB2831-5966 EDITION 1 DATED 04/25/2005 PAGE 2 OF 4
DESCRIPTION QTY P/N HOUSING & DRIVE GROUP P/N QTY DESCRIPTION
(61268)

BUTTON, THRUST 1 22064

SPRING, THRUST BTN 1 10541
DRIVESHAFT ASSEMBLY 1 33925
PIN, DOWEL 1 23100

SEAL, DRIVESHAFT 2 10453 21660 1 SCREW ASSY, VENT

OR 21661-21665
SEAL, DRIVESHAFT RED 1 21860
11331 2 SCREW, HEX HEAD
BEARING, NEEDLE 1 23101
10445 1 RING, RETAINING
COVER, TIMING WINDOW 1 23107

SCREW, HEX HEAD 2 21194

28861 1 HOUSING ASSY, PUMP

NAMEPLATE 1 10394 27603 1 GASKET, TIMING WINDOW CVR

SCREW, RIVET 2 24419

NOTES: APPLY SYN-KUT P/N 22204 TO DRIVE SHAFT SEALS BEFORE ASSEMBLING TO SHAFT AND SHAFT TO PUMP

DESCRIPTION QTY P/N HEAD & ROTOR GROUP P/N QTY DESCRIPTION
(60312)
31506 1 H&R ASSY, HYD 8 CYL
11066 2 PLUNGER, ROTOR
ROLLER, CAM 2 11141 USE 11067-11070 (STD)
OR 11072-11075 (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 27833 20727 8 CONNECTOR, FUEL LINE
OR 23120 O.S.:INCREASE
SPECIFIED R-R BY .006 " 29710 1 SCREW, SKT HEAD CAP

29384 1 PLATE, SINTERED LOCK

SEAL, O-RING 1 27245 27601 1 SEAL, O-RING
23124 1 SCREW, RETAINING
SPRING, LEAF 1 23238

SCREW, LEAF SPR ADJ 1 11175 26070 1 STOP, DELIVERY VALVE

26071 1 SPRING, DLVY VALVE
28012 1 VALVE, DELIVERY
OR 28013 O.S. AS REQ'D

17049 2 PISTON, ACCUMULATOR

17050 2 SCREW, ACC PSTN RET
17188 2 SPRING, ACCUMULATOR
NOTES:

DESCRIPTION QTY P/N TRANSFER PUMP GROUP P/N QTY DESCRIPTION

(63866)
20530 2 RETAINER, ROTOR
SEAL, TRANSFER PUMP 1 27608
37447 1 LINER, TRANSFER PUMP
37268 4 BLADE, TRANSFER PUMP
OR 37449 REF. S.B. 304
20528 1 RING, ROTOR RETAINER

SPRING, TP BLADE 2 15699

28988 1 REGULATOR ASSY, TP
ROLL PIN 1 19837

23915 1 SPRING, REGULATING

PISTON, REGULATING 1 19895

PLUG ASSY, END PL ADJ 1 15228

FILTER, INLET 1 28986 28981 1 CAP, TP END

NOTES: REFERENCE S.B. 444

INDENTED ITEMS INCLUDED

DB2831-5966 EDITION 1 DATED 04/25/2005 PAGE 3 OF 4
DESCRIPTION QTY P/N GOVERNOR GROUP P/N QTY DESCRIPTION
(62861)
22325 1 WASHER, MAX SPEED SPR
ARM ASSY, TEMP COMPEN 1 23461
28397 1 SPRING, MIN MAX GOV
BLUE STRIPE

SPRING, IDLE 1 30777 24880 1 BLOCK ASSY, GOVERNOR

ROD&SLV ASSY, MM GOV 1 23610

26495 1 STUD, GUIDE
SPRING, GOV INNER 1 23744 26923 1 CAP, TAMPER PROOF
RED
23585 1 NUT, GUIDE STUD
SEAL, O-RING 1 11507
21895 1 ARM ASSY, MTR VALVE
21917 1 SPRING, MTR VALVE
SLEEVE, GOV THRUST 1 21312 36021 1 VALVE, METERING
* SEE NOTE
WASHER, THRUST 1 20222
28370 1 RETAINER ASSY, GOV WT
WEIGHT, GOVERNOR 6 21201
30251 1 BALL, PRECISION STEEL
OR 11430 OR 30322
RING, RETAINING 1 12285 REF. S.B. 426

NOTES: * O.S. METERING VALVE AND ARM ASSEMBLY 36106 REFERENCE S.B.336
OUTER GOVERNOR SPRING 29864 MAY BE USED TO LIMIT GUIDE STUD PROTRUSION
IDLE SPRINGS 22125, 30776 & 30778 MAY BE USED

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

(60780)

NUT, HEX 1 12173 26181 1 SPRING, GOV THRUST

SCREW, LEVER ADJUST 1 21646 22398 1 SCREW, SKT HD CAP TX

SPRING, IDLE SCREW 1 21358 29122 1 CAM, ROCKER LVR FACE

14408 1 WASHER, SPACER
24585 2 SEAL, O-RING
SHAFT ASSY, THROTTLE 1 31843
18021 1 HOOK ASSY, GOV LKGE
SCREW, MAX TRAVEL 1 27660
12358 1 LINK ASSY, ADJUSTING
12360 1 SCREW, HEX HEAD
WASHER, THROT SHAFT 1 22900 12362 1 LOCK WASHER, SHPRF
18020 1 HOOK, GOV LINKAGE
11919 1 SPRING, GOVERNOR LINK

NOTES: LUBRICATE PER S.B. 387

DESCRIPTION QTY P/N AUTOMATIC ADVANCE GROUP P/N QTY DESCRIPTION

(60316)
28937 1 LEVER ASSY, ROCKER
RING, RETAINING 2 23566 22720 1 ROLLER, ROCKER LEVER
22396 1 SCREW, RCR LEVER RLR
RING, RETAINING 2 30844
28197 1 WASHER, PLAIN
SPRING, MECH LLA 1 28463 22397 1 PIN, RKR LEVER PIVOT
GOLD
VALVE, SERVO ADVANCE 1 22367 26087 1 SCREW, SERVO ADV ADJ
22917 1 PLUNGER, SERVO ADV
PISTON, SERVO ADVANCE 1 29043
28474 1 PLUG ASSY, SPR SIDE
27163 1 SEAL, ADV PLUNGER
27609 1 SEAL, O-RING
PLUG, POWER SIDE 1 22505
27602 1 SEAL, O-RING
26787 1 SCREW ASSY, HD LCTING

SEAL, O-RING 1 27609

PIN, ADVANCE CAM 1 23925
SEAL, O-RING 1 27610
PLUG, HEX SOCKET 1 23056
NOTES: LUBRICATE LEVER ASSEMBLY PER S.B. 387

INDENTED ITEMS INCLUDED

DB2831-5966 EDITION 1 DATED 04/25/2005 PAGE 4 OF 4
DESCRIPTION QTY P/N COVER GROUP P/N QTY DESCRIPTION
(63792)

33096 1 TAG, IDENTIFICATION

SCREW, BUTTON HD CAP 3 22351
27008 1 TERMINAL, ESO HPCA
27009 1 WASHER, TERM CONT
27010 1 SHELL, ESO TERMINAL
NUT, HEX LOCK 1 14760
STRAP, TERM GROUNDING 1 20951 27008 1 TERMINAL, ESO HPCA
WASHER, INTL TOOTH 1 18493 27009 1 WASHER, TERM CONT
WASHER, INTL TOOTH 1 12049
27065 1 SHELL, HPCA TERMINAL
12519 3 NUT, HEX
RGLTR ASSY, HSG PRESS 1 23183 12049 3 WASHER, INTL TOOTH
18501 3 WASHER, PLAIN
12500 3 WASHER, FIBER
SEAL, O-RING 1 27607
COVER, GOV CONTROL 1 27014
14760 1 NUT, HEX LOCK
SEAL, RECTANGULAR SECTION 1 27244 12519 1 NUT, HEX
12049 1 WASHER, INTL TOOTH
18501 1 WASHER, PLAIN
12500 1 WASHER, FIBER
SOLENOID, 24V ETR 1 26387 27007 1 SOL ASSY, COLD ADV
2-23190 TUBE, INSULATE 2-23190 TUBE, INSULATE

NOTES: INSTALL GROUNDING STRAP ON LEFT SIDE VIEWING TRANSFER PUMP REF S.B. 108

FOR SERVICE USE ONLY FOR ENGINEERING USE ONLY

APPLICABLE SERVICE ASSEMBLIES DATE CHANGE NO. EDITION
.002 OVERSIZE ADVANCE PISTON 29042 04/25/2005 29206 1
PILOT TUBE REPLACEMENT 26890
ESO MOUNTING AND GROUNDING KIT 26431
GASKET KIT 24370
THROTTLE SHAFT BUSHING REPLACEMENT 15093

INDENTED ITEMS INCLUDED