HEINZMAN GOVERNOR (3600 MARINE APPLICATION) Caterpillar

Initial Checks And Adjustments At Installation

Usage:

Introduction

This section is a guide to be used for the first installation of the engine or when a replacement of the equipment is made. The engine and the equipment can be damaged or destroyed before it is ever used because of incorrect wiring, lead shorts, wrong polarity, a mechanical problem, or overvoltage.

The information that follows contains a basic, step by step checklist to be followed. Before supply power is applied, all wiring and settings should be verified to be correct. The voltage level should be checked and verified. The governor is energized and the components are checked to make sure they function correctly. The last steps are to START the engine and check the complete system. The engine is checked and adjusted dynamically.

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NOTICE

The correct use of these initial checks will eliminate most of the early failures that can occur.

Static Checks And Adjustments Index

Static Checks

Visual Inspection

At Engine

1. Governor linkage checks:

Linkage moves freely (NOT binding).

Correct thread engagement of rod ends.

Full travel available to FUEL OFF position.

Full travel available to FUEL ON position.

2. Magnetic pickup to flywheel ring gear tooth clearance [0.5 to 0.8 mm (.02 to .03 in)]

3. Magnetic pickup resistance (approximately 200 ohms)

4. Shielded wire checks:

Only the KG30 Governor Control Unit end to be connected to the terminals indicated on the wiring diagrams.

NOT in same conduit with high current cables.

Power Supply Check

A battery with a charger (60A hour battery rating or larger), or a separate DC power supply (8A or larger) is recommended.

The following tests are performed to verify the power supply is in the correct voltage range, clean (no alternating current), and has sufficient amperage (little or no voltage drop).

KG30 Governor Control Unit
(1) 14 Pin receptacle. (2) 2 Pin receptacle (magnetic pickup). (3) 10 Pin receptacle (accessory connection).

1. Before turning ON the power to the KG30 Governor Control Unit, disconnect the large 14 pin plug from the 14 pin receptacle (1) and connect a multimeter in the DC VOLTS mode to the 14 pin plug in the wiring harness at pin E (+) and pin F (-). Turn ON the power to the KG30 Governor Control Unit. The voltage must be 20 to 35 VDC (preferably 24 VDC). With the multimeter still connected, put the multimeter in AC volts mode. If the multimeter reads more than approximately 1 VAC, the voltage supply must be inspected to find the source of the excessive AC voltage. Do NOT connect the 14 pin plug to the KG30 Governor Control Unit if any excessive AC voltage is present. The KG30 Governor Control System will NOT function properly, and could be damaged.

2. After the voltage is verified to be clean and in the correct range, connect the 14 pin plug to the KG30 Governor Control Unit and disconnect the 2 pin receptacle (magnetic pickup) (2) and the 10 pin receptacle (accessory connection) (3).

KG30 Governor Control Unit
(4) 10 Pin switch.

3. The 10 pin switch (4) comes with the 4C-6710 Governor Test Unit Group (PG 01 Heinzmann Tester). Put the MOT-STOP switch in the MOT position. Put the P-I switch in the I position. Insert the 10 pin switch in the 10 pin receptacle (3) on the KG30 Governor Control Unit.

KG30 Governor Control Unit
(5) Diode. (6) OV (-). (7) TP6 (+).

4. Connect the multimeter in DC volts mode to OV (-) (6) and to the diode (5). Turn ON the power supply and record the static voltage at the KG30 Governor Control Unit. The static voltage should be 20 to 35 VDC.

5. Connect the Heinzmann Tester according to the instructions. Put the switch in position 3 and turn ON the Heinzmann Tester. Adjust the Load potentiometer on the Heinzmann Tester until the actuator pointer is at 40 to 60 percent. Refer to Special Instruction, SEHS9222, "Using The 4C-6710 Governor Test Unit Group" for use of this tool group.

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When the Heinzmann Tester is turned ON, the actuator and linkage moves. The moving parts can result in personal injury.

6. Put the MOT-STOP switch in the STOP position to drive the actuator to SHUTOFF and record the voltage. There is an alternative to using the MOT-STOP switch in the STOP position. Jumper across terminals H3 and I3 in the 10 pin receptacle (3) on the KG30 Governor Control Unit. The jumper will drive the actuator to SHUTOFF.

When the actuator is at SHUTOFF, the KG30 Governor Control Unit is at Minimum Voltage and Maximum Current Draw of the actuator. The minimum voltage (voltage drop) can be no more than a maximum of 2 volts less than the static control voltage recorded earlier.

If the voltage drop is less than 2 volts (preferable less than 1 volt), the power supply and power cables are good.

If the voltage drop is more than 2 volts, the KG30 Governor Control Unit does NOT get sufficient amperage from the power supply for one of two reasons:

The power supply is less than the required amperage.

There is a voltage drop caused by high resistance in the supply cables from the power source to the KG30 Governor Control Unit.

7. Connect the DC voltmeter to the source of the DC power (battery or DC power supply) in order to determine the fault. Rerun the previous test with the Heinzmann Tester in order to determine the voltage drop at the power source.

If the voltage drop is less than 2 volts, there is high resistance in the power cables to the KG30 Governor Control Unit. Check all of the connections for resistance and check the wiring diagram for the proper wire sizes.

If the voltage drop at the power source is more than 2 volts, the battery or DC power supply has insufficient amperage and must be increased. Do NOT run the engine until the maximum voltage drop at the KG30 Governor Control Unit is 2 volts or less.

8. When finished with the previous tests, turn OFF the power to the KG30 Governor Control Unit and disconnect the multimeter and the Heinzmann Tester.

Initial Adjustments (Static)

Actuator

NOTE: No actuator adjustments are necessary or possible, and none should be attempted.

KG30 Governor Control Unit

Remove the cover from the KG30 Governor Control Unit and perform the following:

KG30 Governor Control Unit
(1) Gain potentiometer. (2) Stability potentiometer. (3) Derivative potentiometer. (4) Gas Diesel switch. (5) Fast Response potentiometer. (6) Damping potentiometer.

1. Set the Gain potentiometer (1) to 30 percent.

2. Set the Stability potentiometer (2) to 30 percent.

3. Set the Derivative potentiometer (3) to 0 percent.

4. Set the Gas Diesel switch (4) to DIESEL.

5. Set the Fast Response potentiometer (5) and the Damping potentiometer (6) by turning fully counterclockwise (CCW).

Wiring Schematics

Power Supply Connection (customer supplied)
(1) Charger (if battery is used). (2) Protective diode. (3) Fuse (15A). (4) Wire (to governor). (5) Governor ON/OFF switch (20A).

NOTE: Always connect the power cables directly to the battery (or power supply) with a fuse and a switch in the positive line.

Governor Connection Diagram [L1 and L2, 10 to 20 m (32.8 to 65.6 ft)]
(6) Droop potentiometer. (7) Droop switch. (8) ISOCHRONOUS mode. (9) DROOP mode. (10) Remote Speed Setpoint potentiometer. (11) Synchronizer. (12) Load Sharing (equal fuel). (13) Load Anticipation. (14) Load Sharing (kilowatt). (15) Engine STOP switch. (16) Magnetic pickup. (17) Gap between the pickup and the flywheel-0.5 to 0.8 mm (.02 to .03 in).

Cable Size

1. L1 (KG30 Governor Control Unit to battery):

a. Up to 7 m (23 ft) [2 × 1.5 mm² (14 AWG)]

b. 7 to 12 m (23 to 39 ft) [2 × 2.5 mm² (12 AWG)]

c. 12 to 20 m (39 to 65.6 ft) [2 × 4 mm² (10 AWG)]

2. L2 [KG30 Governor Control Unit to actuator, up to 20 m (65.6 ft)]:

a. Cable I [2 × 2.5 mm² (12 AWG)]

b. Cable II (with shielded cable) [3 × 0.75 mm² (18 AWG)]

3. L3 (KG30 Governor Control Unit to Remote Speed Setpoint potentiometer, with shielded cable):

a. 3 × 0.75 mm² (18 AWG)

4. L4 (KG30 Governor Control Unit to magnetic pickup with shielded cable):

a. 2 × 0.75 mm² (18 AWG)

5. L5 (KG30 Governor Control Unit to accessory unit with shielded cable):

a. 1 mm² (16 AWG)

Checking The Shield (Screen)

Terminals (D, F, G, K, B2, A3, and H3) are all a common connection inside the KG30 Governor Control Unit. When all connections are made, the terminals are all common (-) to the battery through the (F) terminal connection.

KG30 Governor Control Unit
(1) 14 Pin receptacle. (2) 2 Pin receptacle (magnetic pickup). (3) 10 Pin receptacle (accessory connection).

Check for poor shield connections:

1. Disconnect the plug from the 14 pin receptacle (1).

2. Check the D and K terminals in the plug against the battery ground (-). The ohmmeter should read Open Circuit or Infinite ohms.

3. Disconnect the plug from the 2 pin receptacle (2).

4. Check the B2 terminal in the plug to battery ground (-). The ohmmeter should read Open Circuit or Infinite ohms.

5. Disconnect the plug from the 10 pin receptacle (3).

6. Check the A3 terminal in the plug to battery ground (-). The ohmmeter should read Open Circuit or Infinite ohms.

NOTE: The purpose of the above tests is to make sure the shields are NOT tied to ground at a second point in the harness (cable) assembly. If they are, it is necessary to find the unwanted connection and remove it.

Check for the desired shield connections.

With all plugs (control harnesses) still disconnected from the KG30 Governor Control Unit check the following:

Check the continuity with an ohmmeter between the end of the cable shield and the terminal in the plug. In order to check the end of the cable shield, pierce the outer cable insulation with a needle type ohmmeter probe in order to contact the shield. The ohmmeter should read 0 ohms. Specific checks follow:

L2 (KG30 Governor Control Unit to actuator) between the shield at the actuator end of the cable and the K terminal in the plug.

L3 (KG30 Governor Control Unit to Remote Speed Setpoint potentiometer) between the shield at the potentiometer end of the cable and the D terminal in the plug.

L4 (KG30 Governor Control Unit to magnetic pickup) between the shield at the magnetic pickup end of the cable and the B2 terminal in the plug.

L5 (KG30 Governor Control Unit to accessory unit) between the shield at the accessory connection and the A3 terminal in the plug. A variation of the above may exist with the use of some accessories as shown on their wiring diagrams.

Static Checks/Adjustments

The following checks and adjustments are made statically before the engine is started:

Actuator Feedback Voltage

Rated Speed

Idle Speed

Droop

Start Fuel Limit

In order to make the above adjustments:

1. Turn OFF the power to the KG30 Governor Control Unit.

2. Connect the 14 pin plug of the wiring harness to the KG30 Governor Control Unit and the 5 pin plug of the wiring harness to the actuator.

3. Disconnect the magnetic pickup cable (L4) and the accessory cable (if used) at the KG30 Governor Control Unit.

4. Connect the Heinzmann Tester according to instructions. Refer to Special Instruction; SEHS9222, "Using The 4C-6710 Governor Test Unit Group" for use of this tool group.

Actuator Feedback Voltage

Actuator (with base)
(1) Position indicator plate. (2) Connector (from the KG30 Governor Control Unit). (3) Actuator output shaft. (4) Position indicator.

KG30 Governor Control Unit
(5) Stop 1.5V potentiometer. (6) Maximum Speed potentiometer. (7) Droop potentiometer. (8) Maximum Fuel 5V potentiometer. (9) Minimum Speed potentiometer. (10) Droop Isochronous switch.

1. Put the Heinzmann Tester in position 2 (FEEDBACK) and disconnect the linkage on the actuator.

2. Turn ON the power to the KG30 Governor Control Unit and turn ON the Heinzmann Tester.

3. With the actuator output shaft (3) at the 0 Percent position on the position indicator plate (1), the feedback voltage should read 1.5 ± 0.1 VDC. Adjust the potentiometer marked STOP 1.5V (5) if adjustment is needed.

4. Hold the actuator output shaft (3) in the 100 Percent position. The feedback voltage should read 5.0 ± 0.1 VDC. Adjust the potentiometer marked MAX FUEL 5V (8) if adjustment is needed.

NOTE: When using equal fuel load sharing the feedback voltage for the two KG30 Governor Control Units should be almost identical.

NOTE: The Heinzmann Tester in position 2 (FEEDBACK) reads in millivolts, NOT volts.

Rated Speed

1. With the power to the KG30 Governor Control Unit OFF, connect the linkage to the actuator.

2. Put the Heinzmann Tester in position 3 (ENGINE SIMULATION) and put the Load potentiometer on the Heinzmann Tester in the 12 O'clock position.

3. Turn the Remote Speed Setpoint potentiometer to MAXIMUM speed.

4. Put the Droop Isochronous switch (10) in ISOCHRONOUS position (right position).

NOTE: For Droop operation, read the above section (Rated Speed) and then read the section on (Droop Adjustment).

5. Turn ON the Heinzmann Tester and the power to the KG30 Governor Control Unit. Read the frequency in Hertz.

NOTE: If at any point the Heinzmann Tester digital display reads ZERO, turn OFF the Heinzmann Tester and turn it ON again, or turn the Load potentiometer fully CCW for several seconds in order to reset the Heinzmann Tester. Verify the Heinzmann Tester has a good battery.

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When the Heinzmann Tester is turned ON, the actuator and linkage is operating and the moving parts could result in personal injury.

Adjust the potentiometer marked MAX (6) until the Heinzmann Tester reads approximately 2 percent above the desired RATED frequency. Always adjust the Rated speed before adjusting the Idle speed.

NOTE: Use the following formula to convert rpm to Hertz (Hz):

For 3600 engines with a standard 255 tooth flywheel use the following chart:

NOTE: Remember, the Heinzmann Tester reads in Hertz.

Idle Speed

1. With the Heinzmann Tester still set from Step 2 above, turn the Remote Speed Setpoint potentiometer to MINIMUM (Idle).

2. Adjust the potentiometer marked MIN (9) until the desired Idle frequency is attained.

3. After the Idle and the Rated speeds are set, move the Remote Speed Setpoint potentiometer from IDLE to RATED several times in order to confirm the Idle and Maximum speeds are correct.

NOTE: Turn the Load potentiometer on the KG30 Governor Control Unit clockwise (CW) and CCW several times in order to move the fuel system linkage and verify all connections are correct. Make sure there are no binding or sticky spots in the linkage.

Droop Adjustment

1. When running in DROOP, put the Droop Isochronous switch (10) in DROOP position (left most position).

2. Set the Droop potentiometer (7) to the 80 percent position as a starting point.

3. With the Remote Speed Setpoint potentiometer in the RATED position, adjust the Load potentiometer on the Heinzmann Tester until the actuator opens to the same position (same mm of fuel rack) as RATED LOAD at Rated speed.

4. Adjust the Maximum Speed potentiometer (6) approximately 2 percent above the Rated speed.

5. Turn the Load potentiometer on the Heinzmann Tester until the Rated speed (NO LOAD FUEL position) is reached. The frequency on the Heinzmann Tester increases.

NOTE: The frequency should be about 2 percent above the NO LOAD RATED speed.

6. If the No Load frequency is too high, turn the Droop potentiometer (7) CCW 10 percent and recheck the frequencies. Turn the Droop potentiometer CW if the No Load frequency is too low.

7. Adjust the Maximum Speed potentiometer (6) and Droop potentiometer (7) using the above steps until the desired speeds are attained. See the Idle Speed section in order to set the Idle speed.

Start Fuel Limit Adjustment

KG30 Governor Control Unit
(11) Diode. (12) Start Fuel Limit potentiometer. (13) OV (-). (14) TP6 (+). (15) Start Fuel Limit slide switch. (16) Green LED light.

NOTE: For applications NOT requiring Start Fuel Limiting, the Start Fuel Limit function can be eliminated by placing the Start Fuel Limit slide switch (15) in position 2 or 3, or by turning the Start Fuel Limit potentiometer (12) fully CW.

1. With the power to the KG30 Governor Control Unit turned OFF, turn the Start Fuel Limit potentiometer (12) CCW until a "clicking" noise is heard (end point of potentiometer).

2. Turn the Start Fuel Limit potentiometer 10 turns CW as a starting point. Put the Start Fuel Limit slide switch (15) in position 4 (START FUEL LIMITING position).

3. Install an 8T-1000 Electronic Position Indicator. Refer to Special Instruction, SEHS8623, "Using The 8T-1000 Position Indicator Group" for use of this tool group.

4. Connect the multimeter (0 to 5 VDC range) to TP6 (+) (14) and OV (-) (13) in order to measure actuator feedback voltage (ACTUATOR position).

5. Turn the power ON to the KG30 Governor Control Unit. Manually move the fuel rack to the desired START FUEL LIMIT position by reading the 8T-1000. Electronic Position Indicator. Record the actuator feedback voltage. For the following steps, use the actuator feedback voltage as an indicator of fuel rack position.

6. The Heinzmann Tester should be turned OFF and connected from previous steps at this point. Put the selector switch on the Heinzmann Tester in position 3.

7. Turn the Load potentiometer on the Heinzmann Tester to the 8 O'clock position.

8. Turn ON the Heinzmann Tester and slowly turn the Load potentiometer CW until the actuator opens to a certain LIMITING position, stays in that position for several seconds and then goes to SHUTOFF. Record the actuator feedback voltage at the LIMITING position. If the digital display on the Heinzmann Tester reads Zero, turn the Load potentiometer fully CCW for several seconds to reset.

NOTE: The green LED light (16) that indicates the Fuel Limit is working, must be ON during all steps.

9. Adjust the actuator feedback voltage from the LIMITING position of Step 8 until it is the same as the desired feedback voltage recorded in Step 5. Turn the Start Fuel Limit potentiometer (12) CW in order to increase the fuel on STARTUP, CCW to decrease the fuel on STARTUP.

NOTE: As a guide, one complete turn CW of the Start Fuel Limit potentiometer (12) increases the actuator feedback voltage at the START FUEL LIMIT position, approximately .2 volts.

10. Turn OFF the power to the KG30 Governor Control Unit. Disconnect the Heinzmann Tester and the multimeter. Reinstall the magnetic pickup cable and the accessory cable (if used) to the KG30 Governor Control Unit. Install the cover.

NOTE: The Start Fuel Limit is turned OFF automatically when the setpoint speed is reached and is reset for the next START.

Energized Governor Checks (Static)

KG30 Governor Control Unit
(1) Red LED. (2) Start Fuel Limit slide switch. (3) Green LED.

When 20 to 35 VDC is applied to the KG30 Governor Control Unit and all of the cables are connected correctly, the red LED (1) lights. The light will go out when the magnetic pickup frequency is greater than 150 Hz (or when the Heinzmann Tester is used). If the Start Fuel Limit slide switch (2) is in position 4 (FUEL LIMITING) the green LED (3) is on when the engine is static or below the setpoint speed.

Dynamic Checks

Initial Engine Operation

1. Make sure all static checks are completed before dynamic checks are started.

2. Turn ON the power to the KG30 Governor Control Unit.

3. Set the Remote Speed Setpoint potentiometer to the MINIMUM (Idle) position.

KG30 Governor Control Unit
(1) Gain potentiometer. (2) Stability potentiometer. (3) Derivative potentiometer. (4) Start Fuel Limit potentiometer.

4. Remove the cover from the KG30 Governor Control Unit. Be prepared to adjust the Gain potentiometer (1) or Stability potentiometer (2) if the engine is unstable.

5. START the engine. If the engine will NOT START, but the actuator does rotate slightly, turn the Start Fuel Limit potentiometer (4) in 1/2 turn increments CW until the engine starts easily. If the engine starts easily but has excessive smoke, turn the Start Fuel Limit potentiometer (4) CCW in 1/2 turn increments until the smoke is acceptable.

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The engine must NOT be started when either the Heinzmann Tester or a frequency generator is connected to the KG30 Governor Control Unit. This could result in engine overspeed or personal injury.

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NOTICE

Be ready to control the engine SHUTOFF manually if there is no oil pressure, or if the oil pressure is too low. Damage to the engine can occur if the engine continues to run without the correct oil pressure.

6. If the engine is stable, refer to the following Stable Engine procedures. If the engine is unstable refer to the following Instable (Hunting) Engine procedures. After completing the Stable Engine or Unstable (Hunting) Engine procedures, continue to step 7.

Stable Engine

If the engine is stable (less than 10 rpm peak-to-peak speed fluctuation), optimize the dynamic settings as follows:

Turn the Stability potentiometer (2) fully CCW. Slowly turn the Gain potentiometer (1) CW until the engine is unstable, then CCW until the engine is stable.

Slowly turn the Stability potentiometer (2) CW until the engine is unstable, then CCW until the engine is stable.

Slowly turn the Derivative potentiometer (3) CW until the engine is unstable, then CCW until the engine is stable. Adjusting the Derivative potentiometer may require a slight readjustment of the Gain potentiometer and the Stability potentiometer.

Unstable (Hunting) Engine

If the engine has a "rapid hunt", slowly turn the Gain potentiometer (1) CCW until the engine is stable.

If the engine has a "slow hunt", slowly turn the Stability potentiometer (2) CW. If the rate of hunt increases, slowly turn the Stability potentiometer (2) CCW. If you are unable to stabilize the engine, slowly turn the Gain potentiometer (1) CCW, then turn the Stability potentiometer (2) CW. If you are NOT successful, turn the Stability potentiometer (2) CCW.

At the most stable operating point, slowly turn the Derivative potentiometer (3) CW until the stability is optimum.

7. After the above adjustments are complete, manually upset the actuator terminal shaft lever several times to verify the engine returns rapidly to the setpoint speed with little overshoot or undershoot.

NOTE: If there is excessive overshoot or undershoot, or if the engine does NOT return to setpoint speed rapidly, readjust the dynamic settings using the above procedure.

NOTE: Optimum performance is NOT necessarily obtained with the Gain potentiometer at the MAXIMUM STABLE clockwise position. In some cases, the gain must be reduced slightly for stability under widely varying conditions.

8. Slowly bring the engine up to the Rated speed with the Remote Speed Setpoint potentiometer. Readjust the Maximum (6) and Minimum (9) Speed potentiometers if necessary to achieve the desired RATED and IDLE speed. Always adjust the Maximum Speed potentiometer (6) first, then the Minimum Speed potentiometer (9).

NOTE: The Maximum Speed potentiometer is much less sensitive than the Minimum Speed potentiometer. Turn the Minimum Speed potentiometer slowly to avoid sudden speed changes.

KG30 Governor Control Unit
(11) OV (-). (12) TP6 (+).

9. If it is difficult to adjust the stability of the engine because of engine noise or distance from the engine, connect an analog DC voltmeter (0 to 5 volt range or greater) to the feedback voltage terminals. The feedback voltage terminals are marked TP6 (+) (12) and OV (-) (11). The stability of the engine is reflected by the stability of the feedback DC voltage. Disconnect the analog DC voltmeter when the engine is stable.

10. Install the cover on the KG30 Governor Control Unit when dynamic adjustments are completed.

NOTE: The DC Feedback Voltage [which is read at TP6 (+) (12) and OV (-) (11) with a 0 to 5 VDC high impedance voltmeter] can be used as an aid on a static or running engine during setup or in troubleshooting. The DC voltage is directly proportional to actuator angle, indicating the fuel rack position (although the DC voltage versus the fuel rack position is NOT necessarily linear). For example, record the feedback voltage at the important fuel rack settings START FUEL LIMIT Fuel Rack, RATED LOAD, NO LOAD. It is NOT necessary to read the fuel rack indicator each time. Read the feedback voltage to determine the fuel rack position. This is especially useful when the KG30 Governor Control Unit is located far from the actuator or when you are working alone. Always disconnect the voltmeter when you are finished with troubleshooting or setup, and never use the feedback voltage signal to power any external devices (such as variable pitch controllers, or other devices).