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    GAC - Application Note Cummins PT Fuel Systems PIB1006

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    gilizanini
    The document provides installation instructions and parts list for installing a GAC electromechanical actuator on Cummins NT and KT series engines with a PT fuel pump system that uses either an Electronic Fuel Control (EFC) system or a mechanical or hydraulic governor to control fuel delivery. The GAC actuator replaces the existing actuator integrated into the PT pump. For engines with an EFC system, the GAC actuator can be installed to work with either the normally open or normally closed EFC actuator. The instructions describe identifying the type of EFC system and replacing the PT pump actuator, connecting the GAC actuator to the fuel pump and fuel rail, and selecting the appropriate GAC speed controller based on the EFC system type. Optional mounting

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    GAC - Application Note Cummins PT Fuel Systems PIB1006

    Uploaded by

    gilizanini
    200 views12 pages
    The document provides installation instructions and parts list for installing a GAC electromechanical actuator on Cummins NT and KT series engines with a PT fuel pump system that uses either an Electronic Fuel Control (EFC) system or a mechanical or hydraulic governor to control fuel delivery. The GAC actuator replaces the existing actuator integrated into the PT pump. For engines with an EFC system, the GAC actuator can be installed to work with either the normally open or normally closed EFC actuator. The instructions describe identifying the type of EFC system and replacing the PT pump actuator, connecting the GAC actuator to the fuel pump and fuel rail, and selecting the appropriate GAC speed controller based on the EFC system type. Optional mounting

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    Original Title

    GAC_Application Note Cummins PT Fuel Systems PIB1006

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    The document provides installation instructions and parts list for installing a GAC electromechanical actuator on Cummins NT and KT series engines with a PT fuel pump system that uses either an Electronic Fuel Control (EFC) system or a mechanical or hydraulic governor to control fuel delivery. The GAC actuator replaces the existing actuator integrated into the PT pump. For engines with an EFC system, the GAC actuator can be installed to work with either the normally open or normally closed EFC actuator. The instructions describe identifying the type of EFC system and replacing the PT pump actuator, connecting the GAC actuator to the fuel pump and fuel rail, and selecting the appropriate GAC speed controller based on the EFC system type. Optional mounting

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    200 views12 pages

    GAC - Application Note Cummins PT Fuel Systems PIB1006

    Uploaded by

    gilizanini
    The document provides installation instructions and parts list for installing a GAC electromechanical actuator on Cummins NT and KT series engines with a PT fuel pump system that uses either an Electronic Fuel Control (EFC) system or a mechanical or hydraulic governor to control fuel delivery. The GAC actuator replaces the existing actuator integrated into the PT pump. For engines with an EFC system, the GAC actuator can be installed to work with either the normally open or normally closed EFC actuator. The instructions describe identifying the type of EFC system and replacing the PT pump actuator, connecting the GAC actuator to the fuel pump and fuel rail, and selecting the appropriate GAC speed controller based on the EFC system type. Optional mounting

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    GAC ACTUATOR INSTALLATION INSTRUCTIONS FOR CUMMINS ENGINES WITH PT

    PUMP AND EFC FUEL SYSTEM OR PT PUMP WITH MECHANICAL OR HYDRAULIC


    GOVERNOR.

    GAC APPLICATION NOTE (all of the components specified are sold separately).

    CUSTOMER / OEM: CUMMINS


    APPLICATIONS: Diesel Engine Generators, Compressors, Marine, others
    ENGINE MAKE, MODEL, Cummins NT and KT Series engines with PT pump with EFC system
    DISPLACEMENT: or mechanical or hydraulic governor.
    EQUIPMENT MAKE & MODEL: Various
    FUEL SYSTEM: PT Pump (normally closed or normally open integrated actuators or
    mechanical or hydraulic governor).
    OPERATING SPEED(S): Full RPM range
    BATTERY VOLTAGE: 12 or 24 V DC
    INSTALLED OR • Actuator: ADB120E4-GAC (EFC system) or ADC225JS-12/24
    RECOMMENDED (mechanical or hydraulic governor).
    PRODUCTS: o Optional Mounting Bracket for ADB120E4-GAC: BK114
    o Optional Mounting Bracket for ADC225JS-12/24: BK267
    • Speed Control Options:
    o EFC (normally closed): EEG6500, ESD5522E, ESD5120
    o EFC (normally open): ESD5119, ESD5160
    o Mechanical and Hydraulic Governor- EEG6500, EDG6000,
    ESD2210, ESD5111, ESD5500E, ESD5500-II, ESD5550
    • Optional EAM Module: EAM100 (interface module for Cummins EFC to
    GAC load sharing and synchronizing modules).
    • Optional Load Sharing Modules: LSM100, 201 and 672
    • Optional Auto Synchronizers: SYC6714
    • Optional Throttle Linkage components for mechanical governor systems:
    • Bearing Rod Ends: BR200 (1/4”-28 thread), BR300 (M5 thread), BR400
    (M6 thread).
    • Threaded Rod: RD102- Zinc coated ¼”-28 thread precut to 1.0 ft. (0.3 m).
    RD233- Zinc coated M6 thread precut to 8.75 in. (222 mm)

    SUMMARY: ATB120E4-GAC and 225 Series Installation Instructions and Parts List for Cummins NT
    and KT engines provide an electromechanical actuator used for engine fuel control
    positioning.

    The Cummins P.T. fuel system is controlled with either a Normally Open or Normally
    Closed Electronic Fuel Control (EFC) system with its actuator integrated in the P.T. pump
    or a mechanical or hydraulic governor externally linked to the PT pump. GAC has actuator
    and governor solutions for each control system offering Isochronous, Droop and Variable
    Speed operation.
    Rev A1_2021-03 CUMMINS PT FUEL ACTUATOR INSTALLATION PROCEDURE PIB1006 Page 1 of 12
    Cummins P.T. Governor System Options:
    • EFC - Internal P.T. pump actuator with GAC Governor (Normally Open or
    Normally Closed)
    • GAC integrated metering valve / actuator with GAC Governor, replacing Cummins
    control system.
    • Mechanical Governor with 225 Series GAC actuator
    The Electronic Fuel Control (EFC) system controls fuel delivery by metering the amount of
    fuel fed to the mechanical unit injectors through a common distribution rail. The actuator,
    in the EFC pump, controls the amount of fuel going into the rail, controlling the rail
    pressure. The quantity of fuel delivered to the combustion chamber is the result of the rail
    pressure level and the speed dependent time for that pressure to fill the injectors pumping
    chamber. This means of control is also known as the Cummins PT (Pressure/Time) fuel
    system.

    HOW TO CORRECTLY IDENTIFY YOUR PT PUMP AND EFC FUEL SYSTEM

    PT PUMP WITH AMBAC AGD130E4 ACTUATOR (NON-EFC SYSTEM)


    – REPLACE WITH ADB120E4-GAC ACTUATOR

    Rev A1_2021-03 CUMMINS PT FUEL ACTUATOR INSTALLATION PROCEDURE PIB1006 Page 2 of 12


    PT PUMP WITH EFC (NOTE WIRING TO EFC ACTUATOR MOUNTED ON ENGINE BLOCK
    SIDE)-FOLLOW ADB120E4-GAC INSTALLATION INSTRUCTIONS

    PT PUMP WITH MECHANICAL AND HYDRAULIC GOVERNOR - REPLACE WITH GAC 225
    SERIES ACTUATOR

    Rev A1_2021-03 CUMMINS PT FUEL ACTUATOR INSTALLATION PROCEDURE PIB1006 Page 3 of 12


    EFC SYSTEM REPLACEMENT USING ADB120E4-GAC ACTUATOR

    The ADB120E4-GAC actuator performance has been improved from the previous design. These improvements
    include:
    1. The piston pin and lever apparatus are fully enclosed so eliminate external fuel leakage.
    2. The piston pin to bore clearance has been increased eliminating any sticking caused by debris.
    3. The check valve in the actuator outlet circuit has been upgraded to improve forward flow and reverse
    flow check characteristics in the circuit.

    HOW TO IDENTIFY A NORMALLY CLOSED VS. NORMALLY OPEN EFC ACTUATOR

    PT fuel systems use both NORMALLY OPEN and NORMALLY CLOSED integrated actuators. You
    must identify the type of actuator you have to pick the correct speed controller. PT pump actuators often
    have the letter ‘C’, for NORMALLY CLOSED (N.C.), stamped between its terminals or the letter ‘O’ for
    NORMALLY OPEN (N.O.). Referring to table 1, select the appropriate speed controller for either type
    actuator.

    TABLE 1: SELECT THE COMPATIBLE SPEED CONTROLLERS FOR THE N.O. AND N.C.
    ACTUATORS
    Speed Controller PN Normally Closed / Forward Normally Open / Reverse
    Acting EFC Actuator Acting EFC Actuator
    EEG7000 X
    EEG6500 X
    ESD5522E X
    ESD5120 X
    ESD5119 X
    ESD5160 X

    Rev A1_2021-03 CUMMINS PT FUEL ACTUATOR INSTALLATION PROCEDURE PIB1006 Page 4 of 12


    Referencing Photo 1, if the actuator is not externally identified, you can momentarily disconnect one terminal
    while the engine is idling, if the engine stalls the actuator is a normally closed, forward acting valve. If the
    engine accelerates it is a normally open, reverse acting valve. PT pump actuator terminals are connected directly
    to the governor.

    PHOTO 1

    REPLACING THE PT PUMP ACTUATOR


    GAC part number ADB120E4-GAC is an integrated metering valve / actuator assembly that replaces the PT
    pump actuator and can be installed on any Cummins engine with the optional BK114 mounting bracket. The
    discharge fitting of the PT fuel pump is connected to the inlet of the ADB120E4-GAC valve. The outlet from
    the valve is connected to the fuel rail that leads to the injectors, inlet and outlet fittings are both 1/4” NPT
    threads. The drain from the valve must be connected to the injector return line through the check valve, sup-
    plied with the assembly. A maximum of 1 PSI (7kPa) back pressure is acceptable. A system schematic is shown
    in figure 1.

    Rev A1_2021-03 CUMMINS PT FUEL ACTUATOR INSTALLATION PROCEDURE PIB1006 Page 5 of 12


    ADB120E4-GAC

    FIGURE 1

    Rev A1_2021-03 CUMMINS PT FUEL ACTUATOR INSTALLATION PROCEDURE PIB1006 Page 6 of 12


    The ADB120E4-GAC metering valve / actuator assembly can be installed on a Normally Open PT
    actuator with no fuel pump modifications beyond routing the external plumbing as shown. Use the
    following rebuild procedure for a Normally Closed PT actuator:

    REMOVING N.C. PT ACTUATOR (REFERENCE PHOTOS 2 THROUGH 10)

    1. Disconnect the engine starter battery and shut off the fuel supply before the filters.
    2. Disconnect the electrical lines from the stop solenoid. Note the solenoid is polarized and the top screw is
    battery positive.
    3. Once the fuel supply line is closed, remove the fuel inlet and return from the pump.

    PHOTO 2

    4. Remove the four flange mounting screws. Note, the pump has no timing device so clocking its radial
    position to the crank is not necessary. The pump is fuel lubricated so there should be very little engine
    oil to spill.

    PHOTO 3

    Rev A1_2021-03 CUMMINS PT FUEL ACTUATOR INSTALLATION PROCEDURE PIB1006 Page 7 of 12


    5. Clamp the pump into a vise and remove the three mounting screws from the EFC actuator.

    PHOTO 4

    6. Pull the EFC actuator out from the PT pump turning it slightly to overcome any resistance from the O-
    ring adhering to its bore. Ensure O-ring seal did not fall out and is still in pump gland.

    PHOTO 5

    7. Clean the pump’s sealing surface making sure no debris particles or contaminates get into the pump.

    PHOTO 6

    Rev A1_2021-03 CUMMINS PT FUEL ACTUATOR INSTALLATION PROCEDURE PIB1006 Page 8 of 12


    PREPARING THE PUMP FOR AN ADB120E4-GAC ACTUATOR

    8. Lift the gasket off the EFC actuator, it can be reused for the replacement cover.

    PHOTO 7

    TO ENSURE THE PT PUMP IS IN THE OPEN MODE, INSERT ACTUATOR


    PLUG PART NUMBER PG112 INTO THE ACTUATOR BORE.

    PHOTO 8

    Rev A1_2021-03 CUMMINS PT FUEL ACTUATOR INSTALLATION PROCEDURE PIB1006 Page 9 of 12


    9. Insert an M5 x 0.8 hex head screw with a lock nut into hole plug part number PG112. Select and adjust
    its length so the end of the hex head is flush with the cover mounting surface. The screw should just
    contact the cover plate to retain the hole plug in its position. Place the gasket onto the pump.

    PHOTO 9

    10. Place the cover on the pump and torque the three screws to 2.8 N·m (25 lbf·in).

    PHOTO 10

    11. Once the pump, actuator bracket and actuator are installed, connect the fuel line from the pump to the
    actuator and the line from the actuator to the rail, and connect the drain from the check valve to the
    return fuel circuit.
    12. Connect the fuel shut-off solenoid, the top terminal on the solenoid is positive. Open the fuel supply to
    the filters.

    Rev A1_2021-03 CUMMINS PT FUEL ACTUATOR INSTALLATION PROCEDURE PIB1006 Page 10 of 12


    13. Purge air from the fuel system, cranking may take longer for the first start as the pump, metering valve
    and fuel lines have to be refilled with a solid column of pressurized fuel. Ensure the RPM setting on the
    speed control is properly set for an initial start, refer to specific literature for the speed controller being
    used.

    PT PUMP WITH MECHANICAL OR HYDRAULIC GOVERNOR REPLACEMENT USING THE


    GAC ADC225JS-12/24 ACTUATOR ASSEMBLY AND OPTIONAL BK267 BRACKET

    FINISHED INSTALLATION

    225 Series Actuator

    Rev A1_2021-03 CUMMINS PT FUEL ACTUATOR INSTALLATION PROCEDURE PIB1006 Page 11 of 12


    SELECT THE DESIRED SPEED CONTROLLERS FOR ADC225JS-12/ 24 ACTUATORS
    SPEED CONTROLLER PN DIGITAL TYPE ANALOG TYPE
    EEG7500 X
    EEG7000 X
    EEG6500 X
    EDG6000 X
    ESD5111 X
    ESD5131 X
    ESD5221 X
    ESD5500-II X
    ESD5500E X

    FOR ADDITIONAL INSTALLATION INSTRUCTIONS REFER TO INDIVIDUAL PRODUCT


    LITERATURE AT WWW.GOVERNORS-AMERICA.COM.

    Rev A1_2021-03 CUMMINS PT FUEL ACTUATOR INSTALLATION PROCEDURE PIB1006 Page 12 of 12

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