The document provides information about the 103 Series Integral Electric Actuator from Governors America Corp. for mounting directly on Delphi DPG/DP210 fuel pumps. The actuator provides proportional fuel control for diesel engines in a sealed, reliable design. It installs easily in place of the fuel shutoff solenoid with minimal setup. The actuator integrates into the engine's speed control system to regulate fuel flow based on engine speed sensor input.
The document provides information about the 103 Series Integral Electric Actuator from Governors America Corp. for mounting directly on Delphi DPG/DP210 fuel pumps. The actuator provides proportional fuel control for diesel engines in a sealed, reliable design. It installs easily in place of the fuel shutoff solenoid with minimal setup. The actuator integrates into the engine's speed control system to regulate fuel flow based on engine speed sensor input.
The document provides information about the 103 Series Integral Electric Actuator from Governors America Corp. for mounting directly on Delphi DPG/DP210 fuel pumps. The actuator provides proportional fuel control for diesel engines in a sealed, reliable design. It installs easily in place of the fuel shutoff solenoid with minimal setup. The actuator integrates into the engine's speed control system to regulate fuel flow based on engine speed sensor input.
The document provides information about the 103 Series Integral Electric Actuator from Governors America Corp. for mounting directly on Delphi DPG/DP210 fuel pumps. The actuator provides proportional fuel control for diesel engines in a sealed, reliable design. It installs easily in place of the fuel shutoff solenoid with minimal setup. The actuator integrates into the engine's speed control system to regulate fuel flow based on engine speed sensor input.
103 Series Integral Electric Actuator for the Delphi DPG / DP210G Pumps
A Low Cost Integral Actuator.
Proven Electromechanical Design with High Reliability. Easy Installation with Minimal Setup Time.
Fast Response (< 45msec).
Environmentally Sealed, All Metal Design. Increased Operational Integrity and Security.
Introduction The 103 Series Integral Actuator is a field-proven proportional actuator designed to mount directly to the Delphi DPG/DP210 Pump. No external linkage or brackets are required to install this actuator. When de-energized the 103 Series electric actuator provides the function of the fuelshutoff solenoid. This is accomplished by an internal spring that returns the fuel-metering valve linkage to the no fuel position when the actuator is de-energized. Installing the 103 Series actuator does not defeat the engines mechanical governor operation. During the installation process, the mechanical governor must be set to a higher speed than the electric governors operating speed. In this configuration the mechanical governor acts as a speed limiter, but does not interfere with the operation of the actuator. System Description This integral actuator is an electromagnetic servo device which, when installed becomes part of a closed loop fuel control system. This system can be described as follows: Electrical pulses, generated by the magnetic speed sensor, are directly proportional to the engine speed. These pulses are transmitted to the speed control unit, which will compare the real-time pulses to the preset engine speed setting. If the real-time pulses differ from the preset speed setting, the speed control unit will deviate the current to the electric actuator in an amount proportional to the difference. This deviation in current will cause the actuator shaft to rotate thus adjusting engine speed to match the preset engine speed setting. Since there are no sliding parts in the 103 Series electric actuator and the unit is sealed, outstanding reliability and no maintenance are the resulting qualities. Wiring
An actuator cable harness is used to connect the 103 Series
actuator to the selected GAC speed control unit. There are no polarity connections from the speed control unit to the actuator which need to be observed. For more information on additional wiring, see literature specific to the speed control unit being used. Chart A Actuator Model #
12 Volt
ADD103-12
24 Volt
ADD103-24 ADE103-12
X X
Compatible GAC Controls
Analog
Digital
ESD2244 Series
SDG Series
ESD5120
IGC Series
ESD5520E ESD5522E
The 103 Series Electric Actuator is designed in either a
12Vdc or 24Vdc version. These actuator models are identified in Chart A. You must be sure that the actuator voltage matches the battery supply voltage when ordering.
w/ Cable Harness
X X
ADE103-24
w/ Mating Connector
The 103 Series actuator
is designed to operate with a wide selection of GAC analog and digital controls.
ESD5570
Warning: An Overspeed shutdown device, independent of
the governor system, should be provided to prevent loss of engine control, which may cause personal injury or equipment damage.
Governors America Corp. 720 Silver St. Agawam, MA 01001
Governor Actuator Speed Set Screw and Trunnion Droop Control
(4) Screw Mountings for
Electronic Governor Conversion
Four Bolt Control Cover
Preparing the Fuel Pump
Note: Before starting this procedure, make sure that the upper surface of the pump is clean of all dirt and grime. The following procedure will then assist you with installing your new GAC 103 Series electric actuator. approximately nine turns clockwise. Once you have the engine running at 1950 RPM, shut the engine down and disconnect the starter-motor from the battery.
Step 1 The Overshoot Protection Screw may have to be replaced with a shorter screw. A 10mm M6 screw is recommended. This will provide the adequate clearance needed to install the 103 Series actuator.
Installation Note: Before installing the actuator to the fuel pump, make sure that the engine can NOT be started. Remove the battery connection from the starter-motor and depress the emergency STOP button.
Step 2 To adjust the Droop Control, loosen the locking-bolt and turn the Droop Control Allen Screw clockwise, but do not force or over-tighten, until it cannot be turned any further. Then adjust the Allen Screw in a counter-clockwise direction the number of turns as specified in Table 1.
Step 4 Remove the Access Port Plug Cover (not Pictured) from the top of the fuel injector pump. Then remove the Access Port Plug.
Step 3 Set the no-load engine speed to 1950 RPM by loosening the Trunnion (Locknut) and adjusting the Speed Set Screw. This adjustment requires turning the Speed Set Screw
Caution: Once the Access Port Plug is removed, make
sure no contamination or fragments can get in to the fuel pump!!
Step 5 Liberally apply clean diesel fuel to the ORing on the actuator. This will allow the actuator to slide easily into position on the pump. It will also protect the O-ring. Temporarily connect the actuators leads to the Battery terminals on the speed control unit. This will energize the actuator and place the actuators lever at the full-fuel position. This is done so that the lever on the actuator will properly engage the pumps fuelmetering valve linkage. See Figure 2 (before energizing actuator) and Figure 3 (actuator is energized) and notice the positional difference of the lever located on the bottom of the actuator. Battery polarity does not have to be observed with respect to the actuator coil.
Step 6 With the engine stopped, the fuel-metering valve linkage in the fuel pump will be in full fuel position. Rotate the actuator slightly CCW (looking down from the top of the actuator) while inserting it into the Fuel Pump housing. Slowly push the actuator into the Access Port of the pump. See Figure 4, notice the actuator is turned slightly CCW and that bolt-holes are slightly misaligned. This is done to make sure that the actuator lever makes proper contact with the fuel mechanism inside the pump. Figure 2
Caution: Do not force the actuator into position. If you
feel any obstruction, simply rotate the actuator further counter-clockwise while inserting it into the pump. Step 7 Once the actuator is fully inserted into the Access Port, align the Screw Mounting holes, insert and hand-tighten the four Mounting Screws. Tighten all four mounting bolts to approx. 5-6Nm. See Figure 5.
Figure 3
Figure 5 Step 8 You can now check that the actuator is functioning properly by turning the DC power off and on. You should hear a clicking sound, which is the coil armature inside the actuator striking its zero-fuel position stop. Step 9 Connect the 103 Series actuator to the proper terminals on the speed control unit as described in the speed control units literature.
Figure 4
Note: You must keep the actuator energized with the battery voltage until the installation is completed.
Step 10 Reconnect the starter-motor to the battery.
Troubleshooting Measure Coil Isolation If the electronic governor system fails to operate and the actuator is suspected, you can perform the following tests to check the integrity of the 103 Series actuator.
Check the resistance from one wire to the housing of the
actuator, then from the remaining wire to the housing. In both cases you should get a reading: >1M ohm
Measure Coil Resistance (Room Temp.)
Checking for Physical Obstruction Check the resistance of the coil by disconnecting the actuator from the control unit and connecting your meter to the ends of the wires coming from the actuator. This resistance should be approximately: 1.6 ohms 12Vdc 7.2 ohms 24Vdc
Remove the actuator from the pump. Hold the actuator with the lever side down. Manually move the actuators shaft through its entire range of motion by depressing the actuator lever. You should NOT feel any binding or sticking.
Energize the actuator to full fuel (follow steps in speed control
publication) while observing the movement of the lever. The actuator should operate smoothly throughout its entire stroke without any interruptions in motion.
If the 103 Series actuator passes these tests, the problem is
likely elsewhere in the speed control unit, speed sensor or fuel system. Refer to the speed control unit troubleshooting publication or fuel pump information.
Specifications Power Input Operating Voltage (Dedicated Coil) 12 or 24Vdc Available Nominal Operating Current 1.9A @ 12Vdc or 1.5A @ 24Vdc Maximum Current (Continuous) 2.7A @ 12Vdc or 1.9A @ 24Vdc
Physical Dimensions See Diagram 1 Weight2 lbs. Mounting Directly to Delphi Type DPG / DP210G
Reliability Testing All Units 100% Tested
Environmental Operating Temperature Range -40 to 180F (-40 to 85C) Relative Humidity Up to 100%
Mating Hardware All models come with mounting hardware and O-ring. ADD models come with mating connector. ADE models come with cable harness already installed to mating connector.
Hou-Cheng Huang PHD, BSC, MSC, Asif S. Usmani PHD, BE, MS (Auth.) - Finite Element Analysis For Heat Transfer - Theory and Software-Springer-Verlag London (1994) PDF
Hou-Cheng Huang PHD, BSC, MSC, Asif S. Usmani PHD, BE, MS (Auth.) - Finite Element Analysis For Heat Transfer - Theory and Software-Springer-Verlag London (1994) PDF
