service bulletin

NO: 483AR7
SERVICE BULLETIN
DATE: October 29, 2004
LIMITED
DISTRIBUTION
Supersedes: S.B. 483AR6 dated 6/21/2004
LIMITED DISTRIBUTION — SISU DIESEL
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
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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
Connector
Manually Check
Actuator Arm Travel
By Applying Force In
This Direction
Actuator
Yoke
ECU Connector
Mechanical
Stop Screw
Actuator
Arm
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.
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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
Connector
Actuator ECU
Connector
Power
Supply
Digital Voltmeter
(Set to VDC)
120-240V AC
Connector
Two Pin Connector
Figure 4
Figure 4
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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)
Long Screw
15 IPR
Two
Wrench Flats
50-60 lbf-in
(5.6-6.8 N•m)
Early Design
Short Screw
3/32 inch Internal Hex
Current Design
Figure 5
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.
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.
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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).
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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.
Current Nameplate
Early Nameplate
BARBER-COLMAN CO.
1354 CLIFFORD AVE.
LOVES PARK, IL USA
SER. NO. :
0801 P 1805
SER. NO.
2804 C 123
VOLTS
12
MGR. CODE:
R-1401-C
PART NO.
DYNC70025-102-1-12
PART NO.
DYNC70025-101-1-12
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