NO: 483AR7 SERVICE BULLETIN DATE: October 29, 2004 Supersedes: S.B. 483AR6 dated 6/21/2004 LIMITED DISTRIBUTION SISU DIESEL LIMITED DISTRIBUTION PUMP MODELS AFFECTED: DB4629-5711 and DB4629-5712 SUBJECT: FULL AUTHORITY INTEGRATED ACTUATOR FOR STANADYNE INJECTION PUMPS Sisu Diesel and the Woodward Governor Company (formerly the Barber-Colman Company) jointly developed an integrated electronic governing actuator which is capable of providing full governor authority throughout the engine speed and load range. This actuator is controlled by an electronic control unit (ECU), and is fitted on Stanadyne s DB4629-5711 and DB4629-5712 pump models. These pump models are being used on Sisu Diesel 6.6 Liter six cylinder 620 series engines found in Steyr CVT series and Case CVX series tractors. Full Authority Integrated Actuator Figure 1 The full authority integrated electronic actuator consists of a rotary actuator with internal feedback sensor, as shown in Figure 1. The actuator is currently available only in a 12 volt DC configuration as Stanadyne part number 35007 and Woodward Governor Company part number DYNC 70025-102-*-12 (previously Barber Colman part number DYNC 70025-101-*-12). The ECU, which sends commands to the actuator, is unique to Sisu Diesel and is not available from Stanadyne. *This number may vary from 0 thru 9. Stanadyne Corporation 92 Deerfield Road, Windsor, CT 06095, U.S.A. Tel: (860) 525-0821; Fax: (860) 683-4581; www.stanadyne.com
- 2 - S.B. 483AR7 Operation Desired changes in engine speeds and loads are transmitted by the equipment operator through the throttle position sensor of the vehicle to the ECU. Other engine operating parameters are also supplied to the ECU through various engine sensors. Responding to these input commands, the ECU sends an electrical signal to the actuator. The actuator then repositions the pump s metering valve, by means of the actuator yoke which is engaged to the governor linkage hook, thereby controlling fuel delivery. Being a closed loop system, a feedback signal is returned to the ECU indicating the new position of the actuator yoke. Maximum fuel delivery is set during pump calibration by adjusting the mechanical stop screw located on the side of the actuator housing, as shown in Figure 2. Input Voltage Manually Check Actuator Arm Travel By Applying Force In This Direction ECU Actuator Yoke Actuator Arm Mechanical Stop Screw Figure 2 Service Should a pump equipped with a full authority integrated actuator be received for service, refer to Service Bulletin 483 for removal and installation procedures. Pump calibration and testing is performed as follows: Test As Received For Service 1. With the pump mounted on the test bench, connect a 9 volt DC power supply, capable of providing a minimum of 5 Amps, to the input voltage connector (two pin connector) shown in Figure 2 (polarity is unimportant). This will rotate the actuator out of contact with the linkage hook and allow for full fuel delivery. CAUTION: Damage to the integrated actuator may occur if more than 9 volts is applied to the actuator. Because fuel flow through the pump serves to cool the actuator, damage may also occur if the actuator is energized for extended periods of time without the pump running. 2. With the throttle in the wide open position, operate the pump for 10 minutes as indicated on the specification to remove any air from the system.
- 3 - S.B. 483AR7 3. Check the pump performance per the individual service specification. To perform shutoff checks, de-energize the actuator. Note: It may be necessary to reset the high idle and mechanical stop screw settings to specification prior to checking pump performance. As stated in Service Letter 298, adjustment to high idle, low idle, and torque screws are not warrantable items. This policy also applies to the mechanical stop screw. 4. The operation of the actuator sensor is checked as follows: (Note: Service tool 35360, the Actuator Output Voltage Kit, as shown in Figure 3, is required to perform this test) Actuator Output Voltage Harness Actuator Output Voltage Power Supply Actuator Output Voltage Kit P/N 35360 Figure 3 Install the actuator output voltage kit and perform the test as follows (Reference Figure 4): a. Connect the power supply to the wiring harness and plug the power supply into an AC outlet (suitable for 120V-240V operation). b. Connect actuator output voltage harness connector to the ECU connector on the top of the actuator. c. Plug the two pin connector into a digital voltmeter (not included) and set the scale to VDC. Power Supply Actuator ECU Power Supply 120-240V AC Two Pin Figure 4 Digital Voltmeter (Set to VDC) Figure 4
- 4 - S.B. 483AR7 d. Adjust the mechanical stop screw (Reference Figures 5 and 6) to the fuel delivery listed on the specification and record the output voltage. Repeat this procedure for the other fuel delivery point listed. The difference between the two recorded voltage values is to be as stated on the service specification. NOTE: The mechanical stop screw supplied on current actuators is smaller in diameter, shorter in length, and has a different screw head than those supplied on earlier actuators. In addition, the lock-nut was also changed (Reference Figure 5). When performing the output voltage checks on actuators with the current mechanical stop screw configuration, the lock-nut and washer may need to be removed and then re-installed once the checks have been performed. A slight amount of calibration oil may leak from the screw hole during this procedure. Any leakage should be eliminated once the washer and nut have been re-installed. Mechanical Stop Screw Configurations 3/8 inch Hex Nut 25-30 lbf-in (2.8-3.4 N m) Two Wrench Flats Long Screw 50-60 lbf-in 15 IPR Short Screw (5.6-6.8 N m) 3/32 inch Internal Hex Early Design Current Design e. Readjust the mechanical stop screw to the fuel delivery stated in the appropriate step of the Test Following Pump Service calibration. f. Following adjustment, hold the mechanical stop screw stationary and tighten the locknut to the torque value specified in Figures 5 and 6. 5. The mechanical operation of the actuator is checked by removing the electronic actuator from the pump and manually moving the actuator arm. Hold the actuator arm and move the arm through its range of motion to feel for internal binding of the actuator shaft (Reference Figure 2). If the shaft is binding, replace the actuator. Figure 5 If the actuator arm shaft rotates freely, install the electronic actuator onto the pump and recheck its operation by performing the appropriate steps of the service specification.
- 5 - S.B. 483AR7 Test Following Pump Service Following pump service and prior to installing the electronic actuator on the pump, the actuator arm motion should be manually inspected for freedom of travel as described in Step 5. The actuator output voltage is also checked during the Test Following Pump Service calibration routine. Therefore, the 35360 Actuator Output Voltage Kit must be installed as described in the Test As Received For Service section of this bulletin. The sensor output voltage is checked with the test bench speed at 0 R.P.M. and the electronic actuator de-energized (9 volt input voltage removed). If the voltage reading is less than 0.3 volts, loosen the three (3) actuator hold down screws and move the actuator towards the transfer pump end. While holding the actuator in this position, tighten the screws to 35-45 lbf-in (4.0-5.5 N m). Re-check the sensor output voltage and readjust the actuator position if required. 3/32 inch Hex or 15 IPR Bit P/N 33036 Current Lock-nut (Hex): 25-30 lbf-in (2.8-3.4 N m) Early Lock-nut (Flats): 50-60 lbf-in (5.6-6.8 N m) Figure 6 Check the sensor differential voltage and adjust the maximum fuel delivery as described in the Test as Received for Service section of this bulletin. The low idle screw is adjusted during calibration to ensure that the pump can meet this operating parameter. Following pump calibration, the low idle screw is then turned in until the throttle is locked in the wide open throttle (W.O.T.) position. Warranty The original integrated actuator (Stanadyne P/N 35007) fitted to DB4-5711 and DB4-5712 pumps is covered under the same warranty and conditions as our fuel injection pumps sold to Sisu Diesel. Therefore, the warranty coverage for the original factory installed 35007 actuator is 12 months parts and labor and 18 months parts only (Refer to Section 4.3.20 of your 99666 Service Policies and Procedures Manual for the specific conditions of warranty).
- 6 - S.B. 483AR7 Note: The previously offered extended warranty coverage of 18 months for both parts and labor (as outlined in SB 483AR5) was discontinued as of January 1, 2004. In addition, the service parts warranty for the 35007 actuator is the same as all other service parts, 12 months or 500 hours (whichever occurs first). As a reminder, all service parts warranty claims must be submitted with supporting documentation (reference Service Letter 301R3). The supporting documentation must consist of the parts bill of sale, repair invoice, and the current hours on the equipment, plus the number of hours on the equipment when the service part was installed. Important: To receive warranty consideration, all service dealers (except North America) must submit a warranty claim and return the 35007 Integrated Actuator to: Stanadyne Corporation 26-30 Avenue des Feres Lumiere 78190 Trappes, France Attn: Warranty Returns In addition, the 35007 Actuators Serial Number and the Manufacturing Code, which are on the nameplate located on the side of the actuators housing, must be recorded in the comments section of your warranty claim. Figure 7 depicts the nameplates used on both early and current actuators. Note: Some 35007 actuators may not have a Manufacturing Code. Early Nameplate BARBER-COLMAN CO. 1354 CLIFFORD AVE. LOVES PARK, IL USA SER. NO. : VOLTS 0801 P 1805 12 MGR. CODE: R-1401-C PART NO. DYNC70025-101-1-12 Current Nameplate SER. NO. 2804 C 123 PART NO. DYNC70025-102-1-12 VOLTS 12 www.woodward.com Figure 7 Technical Support Group Product Support Department Revision Date Changes 6 6/04 Revised warranty section 7 10/04 Changes to mechanical stop screw