Bluewin ACB225 Manuale utente

Function – Installation

Electronic Speed Governor

D E

2(0)

Electronic Speed Governor

Function – Installation – Fault-tracing

This booklet only covers the ACB225, ACB275 and

ACD175-24 actuators and the ESD5500E control unit.

Genset applications:

Note. If the GAC system is to be used for a genset application, please contact

Hügli Tech Ltd. (Switzerland) for application assistance.

– telephone: INT +41-62 9165030

– telefax: INT +41-62 9165035

– e-mail: [email protected]

Contents

Safety precautions ......................................................................... 2

General information ....................................................................... 5

General description........................................................................ 7

Function ......................................................................................... 8

Installation...................................................................................... 11

Electromagnetic compatibility ........................................................ 12

Setting and Adjusting..................................................................... 13

Running ......................................................................................... 15

Fault-tracing................................................................................... 17

As a general rule all service operations must be

carried out with the engine stopped. Some work,

e.g. certain adjustments, require the engine to be

running. Approaching an engine which is running

is a safety risk. Remember that loose clothes or

long hair can fasten in rotating parts and cause

severe personal injuries. If working in proximity of

an engine which is operating, careless move-

ments or a dropped tool can result in personal in-

jury. Take care to avoid contact with hot surfaces

(exhaust pipes, Turbocharger (TC), air intake

pipe, start element etc.) and hot liquids in lines

and hoses on an engine which is running or which

has just been stopped. Reinstall all protective

parts removed during service operations before

starting the engine.

Check that the warning or information decals on

the engine are always clearly visible. Replace de-

cals that have been damaged or painted over.

Never start the engine without installing the air

cleaner (ACL). The rotating compressor in the

Turbo can cause serious personal injury. Foreign

objects entering the intake ducts can also cause

mechanical damage.

Never use start spray or similar to start the en-

gine. The start spray may cause an explosion in

the inlet manifold. Danger of personal injury.

Avoid opening the coolant filler cap when the en-

gine is hot. Steam or hot coolant can spray out as

system pressure is lost. Open the filler cap slowly

and release coolant system pressure, if the filler

cap or a drain cock/venting cock must be opened,

or if a plug or engine coolant line must be re-

moved on a hot engine. It is difficult to anticipate

in which direction steam or hot coolant can spray

out.

Hot oil can cause burns. Avoid skin contact with

hot oil. Ensure that the lubrication system is not

under pressure before commencing work on it.

Never start or operate the engine with the oil filler

cap removed, otherwise oil could be ejected.

Stop the engine and close the sea cock before

carrying out operations on the engine cooling sys-

tem.

Introduction

This Service Manual contains technical specifications,

installation instructions and wiring diagrams for the

Electronic Speed Governor.

If you do not understand or are uncertain about any op-

eration or information in this Manual, please contact

your Volvo Penta dealer for assistance.

Read the “Safety Precautions” and the “General In-

formation” carefully before starting work.

Important!

In this book and on the engine you will find the following

special warning symbols.

WARNING! Possible danger of personal injury,

damage to property or mechanical malfunction if

the instructions are not followed.

IMPORTANT! Used to attract attention to what

can cause injury, malfunction, or damage to

property.

NOTE! Used to attract attention to important informa-

tion for the simplification of work processes or

handling.

To provide a general understanding of the risks and

precautions to which attention should always be

given we have made the following list.

Plan work in advance to ensure that there is suffi-

cient space to remove components without dan-

ger of injury or damage. Plan the engine compart-

ment (and other compartments such as the bat-

tery compartment) so that all service points are

accessible. Take precautions so that you do not

come into contact with rotating components, hot

surfaces or sharp edges when servicing or in-

specting the engine. Ensure that all equipment

(pump or compressor drives for example) are

equipped with suitable safety guards.

Immobilize the engine by turning off the power

supply to the engine at the main switches so it is

impossible to start, and lock them in the OFF po-

sition before starting work. Set up a warning no-

tice at the engine control point or helm.

Safety Precautions

Only start the engine in a well-ventilated area. If

operating the engine in a closed area ensure that

there is exhaust ventilation leading out of the

work area to remove exhaust gases and crank-

case ventilation emissions.

Always use protective goggles where there is a

danger of pieces of metal, sparks from grinding,

acid or other chemicals being thrown into your

eyes. Your eyes are very sensitive, injury can

lead to loss of sight!

Avoid skin contact with oil. Long-term or repeated

contact with oil can remove the natural oils from

your skin. The result can be irritation, dry skin, ec-

zema and other skin problems.

Used oil is more dangerous to health than new oil.

Use protective gloves and avoid oil-soaked

clothes and rags.

Wash regularly, especially before meals. Use the

correct barrier cream to prevent dry skin and to

make cleaning your skin easier.

Most chemicals used in products (engine and

transmission oils, glycol, petrol and diesel oil) and

workshop chemicals (solvents and paints) are

hazardous to health Read the instructions on the

product packaging carefully! Always follow safety

instructions (using breathing apparatus, protective

goggles and gloves for example). Ensure that oth-

er personnel are not unwittingly exposed to haz-

ardous substances (by breathing them in for ex-

ample). Ensure that ventilation is good. Handle

used and excess chemicals according to instruc-

tions.

Be extremely careful when tracing leaks in the

fuel system and testing fuel injection nozzles. Use

protective goggles! The jet ejected from a fuel in-

jection nozzle is under very high pressure. It can

penetrate body tissue and cause serious injury

There is a danger of blood poisoning.

WARNING! Delivery pipes must not be bent,

twisted or subjected to other stress. Replace

damaged delivery pipes.

All fuels and many chemicals are inflammable.

Ensure that a naked flame or sparks cannot ignite

fuel or chemicals. Combined with air in certain ra-

tios, petrol, some solvents and hydrogen from

batteries are easily inflammable and explosive.

Smoking is prohibited! Ensure that ventilation is

good and that the necessary safety precautions

have been taken before carrying out welding or

grinding work. Always have a fire extinguisher to

hand in the workplace.

Store oil and fuel-soaked rags and fuel and oil fil-

ters safely. In certain conditions oil-soaked rags

can spontaneously ignite. Used fuel and oil filters

are environmentally dangerous waste and must

be deposited at an approved site for destruction

together with used lubricating oil, contaminated

fuel, paint remnants, solvent, degreasing agents

and waste from washing parts.

Ensure that the battery compartment is construct-

ed according to applicable safety regulations.

Never allow a naked flame or electric sparks near

the batteries. Never smoke in proximity to the bat-

teries. The batteries give off hydrogen gas during

charging which when mixed with air can form an

explosive gas - oxyhydrogen. This gas is easily

ignited and highly volatile. Incorrect connection of

the battery can cause a spark which is sufficient

to cause an explosion with resulting damage. Do

not disturb battery connections when starting the

engine (spark risk) and do not lean over batteries.

Never mix up the positive and negative battery

terminals when installing. Incorrect installation

can result in serious damage to electrical equip-

ment. Refer to wiring diagrams.

Always use protective goggles when charging and

handling batteries. The battery electrolyte con-

tains extremely corrosive sulfuric acid. If this

should come in contact with the skin, immediately

wash with soap and plenty of water. If battery acid

comes in contact with the eyes, immediately flush

with plenty of water and obtain medical assist-

ance without delay.

Turn the engine off and switch off power at the

main switches before carrying out work on the

electrical system.

Clutch adjustments, where a clutch is fitted, must

be carried out with the engine turned off.

Use the lifting eyes mounted on the engine/re-

verse gear when lifting the drive unit. Always

check that the lifting equipment used is in good

condition and has the load capacity to lift the en-

gine (engine weight including reverse gear and

any extra equipment installed).

To ensure safe handling and to avoid damaging

engine components on top of the engine, use a

lifting beam to raise the engine. All chains and ca-

bles should run parallel to each other and as per-

pendicular as possible in relation to the top of the

engine.

If extra equipment is installed on the engine alter-

ing its center of gravity, a special lifting device is

required to achieve the correct balance for safe

handling.

Never carry out work on an engine suspended on

a hoist.

Never handle heavy components alone, even

where secure lifting equipment such as secured

blocks are being used. Even where lifting equip-

ment is being used it is best to carry out the work

with two people; one to operate the lifting equip-

ment and the other to ensure that components

are not trapped and damaged when being lifted.

When working on-board ensure that there is suffi-

cient space to remove components without dan-

ger of injury or damage.

WARNING! The components in the electrical sys-

tem and in the fuel system on Volvo Penta prod-

ucts are designed and manufactured to minimize

the risk of fire and explosion.

The engine must not be run in areas where there

are explosive materials.

Always use fuels recommended by Volvo Penta.

Refer to the Instruction Book. The use of lower

quality fuels can damage the engine. On a diesel

engine poor quality fuel can cause the control rod

to seize and the engine to overrev with the result-

ing risk of damage to the engine and personal in-

jury. Poor fuel quality can also lead to higher

maintenance costs.

Observe the following rules when cleaning with

high-pressure water jets. Never direct the water

jet at seals, rubber hoses or electrical compo-

nents. Never use a high pressure jet when wash-

ing the engine.

Certificated engines

For service and repair of an engine certificated for

any area where exhaust emissions are regulated by

law, the following is important:

Certification means that an engine type is inspected and

approved by the authorities. The engine manufacturer

guarantees that all engines manufactured of that type

correspond to the certified engine.

This places special requirements on maintenance

and service as follows:

●The maintenance and service intervals recommend-

ed by Volvo Penta must be observed.

●Only genuine Volvo Penta replacement parts may be

used.

●The service of injection pumps and injectors or pump

settings must always be carried out by an authorized

Volvo Penta workshop.

●The engine must not be modified in any way except

with accessories and service kits approved by Volvo

Penta.

●No modifications to the exhaust pipes and air supply

ducts for the engine may be undertaken.

●Seals may only be broken by authorized personnel.

Otherwise the general instructions contained in the In-

struction Manual concerning operation, service and

maintenance must be followed.

IMPORTANT! Late or inadequate maintenance/

service or the use of spare parts other than genu-

ine Volvo Penta original spare parts will invalidate

AB Volvo Penta’s responsibility for the engine

specification being in accordance with the certifi-

cated variant.

Volvo Penta accepts no responsibility or liability

for any damage or costs arising due to the above.

General Information

General

This Manual is primarily intended for use by expert pro-

fessionals. Persons using this book are assumed to

have a basic knowledge and be able to carry out related

mechanical and electrical work.

The mechanic is responsible for ensuring that installa-

tion is carried out correctly, that only approved materials

and equipment is used, that function tests are carried

out after installation, and that the installation meets all

applicable regulations.

Volvo Penta is continuously developing their products.

We therefore reserve the right to make changes. All the

information contained in this book is based on product

data available at the time of going to print. Any impor-

tant modifications to the product or changes to installa-

tion methods after the date of going to press will be noti-

fied in Service Bulletins.

Plan installation carefully

Plan the installation of the engine and its components

carefully in advance. Always ensure that the correct

drawings, Wiring Diagrams and data are used, and that

all installation drawings, templates, technical and other

necessary data are available before starting work. This

will prevent problems in the planning phase and during

installation.

Plan the engine compartment so that regular service

and maintenance can be carried out and so that compo-

nents can be replaced easily. Compare the service liter-

ature for the engine with the drawings so that there is

enough room to service the engine.

It is of the greatest importance that no dirt or foreign

particles get into the fuel system, cooling system or in-

take system when installing the engine. This could lead

to malfunction or serious damage. Blow clean all pipes

and hoses with compressed air before connecting them

to the engine. Remove the engine plugs only when con-

necting the engine to external systems.

Joint responsibility

Each engine consists of many connected systems and

components. If one component deviates from the tech-

nical specifications this can have dramatic consequenc-

es on the environmental impact of the engine. It is

therefore vital that systems that can be adjusted are ad-

justed properly and that Volvo Penta Genuine Parts are

used.

Certain systems (components in the fuel system for ex-

ample) may require specialist expertise and test equip-

ment. Some components are sealed at the factory for

environmental reasons. No work should be carried out

on sealed components except by authorized personnel.

Bear in mind that most chemicals are harmful to the en-

vironment if used incorrectly. Volvo Penta recommends

the use of biodegradable degreasing agents for clean-

ing engine components, unless otherwise stated in a

workshop manual. Take special care that oil and waste

is taken for destruction and is not accidentally pumped

into the environment.

All rights to changes or modifications reserved.

Printed on environmentally-friendly paper

General description

The difference value is converted into a signal to an

electro-magnet (actuator) which adjusts the injection

pump’s control rod to increase or decrease the injected

fuel amount.

The following text describes the components making up

the system, and their function, separately.

Certain engines have injection pumps with RQ gover-

nors fitted as speed limiters. In these cases the actuator

is fitted on a separate bracket. The sender and the elec-

tronic overspeed protection is omitted in these cases,

and the stop solenoid/fuel shut off valve is only used to

stop the engine normally.

The electronic governor system is a control unit which

governs the engine speed. Its task is to:

– maintain the idling speed at an adjustable set point

– maintain the engine’s operating speed at an adjusta-

ble set point despite varying loads.

Unlike the mechanical governor, the electronic governor

does not have governor weights. The speed is control-

led by the control unit (1, fig 1) “sensing” the difference

between the set speed and the actual speed.

WARNING!

An overspeed protection MUST always be fitted besides

the electronic governor to prevent bodily injury or material

damage if the engine should run out of control.

Fig. 1. Engine fitted with an electronic governor (system diagram)

1. Control unit 5.1 Stop solenoid

2. Engine speed pickup 5.2 Fuel shut-off valve

3. Actuator 6. Batteries

4. Engine speed pickup for overspeed protection

Engine speed pickup

The engine speed pickup is a variable reluctance sen-

sor fitted in the flywheel housing directly above the fly-

wheel ring gear. As the teeth of the ring gear pass un-

der the electromagnet an alternating current is in-

duced (one cycle per tooth).

The pulse's voltage is between 1V AC to 30V (AC.

RMS.)

The pickup's threads is 5/8"–18 UNF-2A.

Function

Control unit

The electronic control Unit (fig 3) compares the incom-

ing signals with the pre-set values, and a correcting sig-

nal or an unchanged signal is transmitted to the actua-

tor.

The control unit has a number of adjustment possibili-

ties which are described below. Adjustments can be

made after first removing the round rubber plugs from

the control unit.

1. Adjusting the idling speed (marked “IDLE”), (4, fig.

3) is done with a single turn potentiometer. The

idling speed can be adjusted with a jumper between

the terminals “G” and “M” installed.

The adjustment range is 1200–4100 Hz below the

frequency for the set engine speed. Turning the po-

tentiometer clockwise will increase the idling

speed.

2. Adjusting the operating speed (“SPEED”), (1, fig.

3) is done with a 22 turn potentiometer.

The frequency range is 1000–7500 Hz. Turning the

potentiometer clockwise will increase the engine

speed.

The frequency from the magnetic pickup (engine

speed pickup) is dependent on the number of teeth

on the flywheel ring gear and the desired engine

speed, i.e. the engine speed in r/s (revs per second)

multiplied by the number of teeth on the ring gear.

Engine No. of teeth

6 Ltr. engines .............................................. 140

7 Ltr. engines (standard/optional*) ............. 140/153*

10/12 Ltr. engines ....................................... 156

16 Ltr. engines ............................................ 153

*Flywheel housing with connection acc. to SAE 1.

Fig. 2. Location of engine speed

pickup

1. Engine speed pickup

2. Flywheel ring gear

Example: Engine TWD1630 set on 1500 rpm.

(25 r/s): 25 x 153 = 3825 Hz.

3. Governor sensitivity. The governor’s sensitivity is

adjusted by a single turn potentiometer (“GAIN”), (1,

fig. 3). A small change of frequency can be noticed

when adjusting the “GAIN” control. This can be ad-

justed by the “SPEED” potentiometer (3).

4. Stability control. The governor’s time constant is

adjusted by the single turn potentiometer (“STABILI-

TY”), (7, fig. 3).

The time constant is the time required by the engine

to return to the set operating speed after there has

been a change in load.

5. Droop. The droop control (4, fig. 3), marked

“DROOP” is working when terminals “K” and ”L” are

connected. The adjustment range is 1–5%. Turning

clockwise will increase the value.

With a jumper between terminals “G” and “H”, an in-

creased droop can be obtained.

6. Starting fuel adjustment. Turning the

“STARTING FUEL” adjustment clockwise will in-

crease the amount of fuel delivered to the engine

during cranking. With the adjustment full counter-

clockwise, the fuel amount will be very low or zero

depending on the actuator linkage. With the adjust-

ment full clockwise, starting fuel is unlimited and

the actuator will move to 100% fuel during cranking.

7. Speed Ramping Adjustment. Turning the

“SPEED RAMPING” adjustment clockwise will slow

the acceleration of the engine speed. With the ad-

justment full clockwise, the acceleration can be as

long as 20 seconds depending on the speed range

selected. With the adjustment full counter-clock-

wise, the ramping will be effectively eliminated.

Fig. 3. Control unit ESD5500E with the rubber plugs removed.

1. Gain control 5. Starting fuel adjustment

2. Idle adjustment 6. Speed ramping adjust-

3. Operating speed, setting ment

4. Droop control 7. Stability control

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