Usage:
Governor Adjustments
Droop Setting Procedure
Internal Adjustment
Internal Droop Adjustment
(1) Locknut.
When the position of the droop pivot pin (internal or external) is changed on the terminal lever, the percent of governor droop changes.
To change the droop pivot pin setting on governors not equipped with an external adjustment lever, the governor top cover must be removed.
The droop pivot pin is fastened to the terminal lever with locknut (1). With the nut loosened, the pivot pin can be moved from minimum droop to maximum droop. It is shown here in the minimum droop position.
The terminal shafts are clamped in the ends of the terminal lever by two bolts. A line can be drawn through the center of the two bolt heads and used for reference in adjusting the droop pivot pin position.
When the pivot pin and nut is moved near the reference line as shown, the governor is set for minimum droop. As the pivot pin and nut are moved farther away from the reference line, the droop is increased. When the pivot pin and nut are moved to the farthest point away from the reference line the governor is set for maximum droop.
External Adjustment
On the 3161 Generator Set Governor, the internal droop pivot pin locknut must be kept loose enough to be moved by the external droop adjustment lever. The external droop adjustment lever is held in place with a bolt which retains the droop setting.
External Droop Adjustment
(1) Adjustment lever bolt.
To change the droop setting, loosen the adjustment lever bolt (1), and move the lever down to decrease droop, and up to increase droop.
Engine Speed Droop
Illustration 1
The internal and external adjustments change the slope of the overrun curve and also change high idle speed (see Illustrations 1) so that high idle has to be adjusted after droop settings are changed.
Measurement of droop is difficult and requires the ability to measure engine speed under near full load conditions.
NOTE: Overrun is governed engine speed, above rated speed, between no load rpm and a point just before full load rpm. The governor controls fuel to the engine and has the ability to change engine speed. The fuel or governor control linkage is not in contact with the fuel stop or torque spring.
The curves shown in Illustration 1 show that the full load point is not on the overrun curve and the formula:
will not give an accurate droop measurement.
To be accurate, droop measurement must be done on the overrun curve. The following formula gives an accurate measurement of droop, as long as × is between 50 percent and 90 percent.
Measurement Of Full Throttle Speed At A Given Load Or Fuel Linkage Position
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Droop measurement should be performed on stationary engines only. Droop calculations require measurements of rack position at various load and speed conditions, which can result in personal injury or loss of life if attempted on captive applications. If adjustments are necessary, they must be performed on a test stand by an authorized Caterpillar or Woodward dealer. |
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1. With engine stopped, install and zero dial indicator, see Steps 2 through 7 in the installation procedure for 3161 Governor With Fuel Air ratio Control And Torque Rise Governor To Engine Synchronization. This dial indicator is used to read fuel control linkage position.
Install Linkage Position Indicator
(1) 8T2819 Linkage Position Indicator. (2) Cover over fuel setting screw. (3) 8T1000 Dial Indicator.
NOTE: Clean the contact, inside plastic nut, with a pencil eraser before using the linkage position indicator.
2. Remove synchronizing pin, and install the 8T2819 Linkage Position Indicator in its place.
3. Connect the 6V4060 Set Point Indicator with 6V2100 Multitach. Follow Steps 1 through 3 on page 14 of Special Instruction SEHS7931-02. Instead of connecting to rack contact screw, connect 1P7446 Cable to the 8T2819 Linkage Position Indicator.
4. Decide on the fuel linkage position where you want to measure engine speed. Loosen the setscrews and turn plastic nut of the linkage position indicator until it indicates contact closure at the desired linkage position. Listen for the contact closure indication and observe the dial indicator as the governor is moved in the "FUEL ON" direction. Tighten the setscrews to lock plastic nut in position. Again, check to make sure that contact closure is indicated at the desired point.
5. Start the engine and measure the speed at which the contacts in the 8T2819 Linkage Position Indicator close when engine is loaded at full throttle. Follow Steps 4 and 5 on page 14 of SEHS7931-02. This Special Instruction refers to contact closure as "set point". Use the hold source switch (see Step 7 on Page 15 of SEHS7931-02). Load the engine until the lug light and overrun lights are both off. Try to hold this load for 3/4 second while the set point indicator averages speed.
Record this speed and repeat this process. Take at least five readings of contact closure speed and average the readings as in Step 8 on Page 15 of SEHS7931-02. The highest and lowest reading used should not be more than 25 rpm apart. This average is the full throttle engine speed at the fuel linkage position set in Step 4.
6. To determine the percent of full load of the fuel linkage position, we also need to measure fuel linkage position. With the engine running at high idle, turn the plastic nut of the linkage position indicator clockwise until the lug light and overrun lights are both off.
7. Shut the engine down and manually move the governor in the "FUEL ON" direction while listening for an indication of contact closure and observing the dial indicator. Record the dial indicator reading of high idle fuel linkage position "I". This reading will be negative (approximately -4 mm).
Matching Droop Settings On Multiple Engine Installations
In some applications it is necessary to set 2 or more engines so that they have the same droop. For such applications use the following procedure.
On Engine No. 1 do the following:
1. Measure high idle speed.
2. Load the engine to a fuel linkage position above 50 percent load and measure speed. (For the procedure, see Measurement Of Full Throttle Speed At A Given Load Or Fuel Linkage Position.)
3. Calculate speed differential:
speed differential = HI -X percent load
On Engine No. 2 do the following:
4. Do Steps 1 through 3 on engine No. 2.
5. If speed differential is greater than that of engine No. 1, reduce droop setting. If speed differential is less than that of engine No. 1, increase droop setting.
6. Repeat Steps 4 and 5 until the speed differential is the same as engine No. 1 for the same loads or the same fuel linkage positions.
7. Adjust the high idle speed to match the high idle of engine No. 1. Both engines now have identical overrun curves.
Compensation Needle Valve Adjustment
After the engine has started and is under governor control, open the needle valve (turn it counterclockwise) until governor operation just becomes unstable (starts to hunt), then turn the needle valve in until engine speed has stability. Let the governor and engine get to operating temperature by operating a minimum of one-half hour. After the engine and governor are at the operating temperature, again check for stable operation. Adjust as necessary. DO NOT fully close the needle valve. This can cause excessive overshoot on startup, or load rejection.
Needle Valve Adjustment
With the engine at normal operating temperature and no load, operate the engine at low idle speed. Open the governor compensation needle valve and let the governor increase and decrease engine speed (hunt) for a minimum of 30 seconds to remove air from the system. If the governor does not hunt, rapidly move the speed control shaft to change governor stability.
After 30 seconds and the air is removed from the system, turn the needle valve in (clockwise) until the engine runs smoothly.
With the engine running at medium (mid) speed, load the engine (at least one-quarter load) to find the stability of the setting. Quickly remove the load. A slight overshoot of speed is ideal, as it reduces response time. The engine speed should return to smooth steady operation. If it does not have a slight overshoot and return to a smooth steady operation, adjust the needle valve and repeat the above procedure.
Governor terminal shaft "jiggle" or surge is an indication of:
- 1. Too little compensation (needle valve out too far);
- 2. Torsional vibration (pulsing);
- 3. Improperly aligned governor drive spline;
- 4. A binding or loose fuel control mechanism.
- 2. Torsional vibration (pulsing);
Low And High Idle Adjustments
Make sure the engine fuel setting is correct before low and high idle adjustments are made. See the Testing & Adjusting section of the Engine Service Manual for the fuel setting procedure.
NOTE: The pneumatic speed control can prevent the engine from reaching high or low idle. See Pneumatic Speed Setting Control Adjustments in the Auxiliary Controls section for more information.
Idle Adjustment
(1) Low idle speed stop screw. (2) High idle speed stop screw. (3) Plate.
The adjustments made to high idle change the torque rise settings (where applicable). If adjustments are made to high idle, see the Torque Rise Setting Procedure section for torque rise calibration.
Low and high idle speed stop screws (1 & 2) are on the left side of the governor case, and are adjusted from the outside of the governor.
D11N
(4) Detent speed setting screw.
NOTE: For D11N applications, the detent speed setting screw (4) is used to adjust low idle speed. To ensure proper operation of the detent shutdown feature, the low idle speed stop screw must not be set to a higher speed than the detent speed setting screw.
The low and high idle speed stop screw is covered by plate (3). The plate is held to the governor case with two wire lock bolts. Install a wire and seal on the high idle speed adjustment cover bolts after any governor work to prevent tampering.
A 1/8 inch hex wrench is used for turning both low and high idle speed stop screws.
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The engine may overspeed due to improper reassembly or adjustment, which could result in personal injury, loss of life, and/or property damage. Be prepared to stop the engine by activating the emergency air shut off or closing the air inlets. On natural gas engines, the fuel must also be shut off. |
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For non D11N applications, to increase low idle speed, turn the low idle speed setting screw (1) clockwise.
For D11N applications, to increase low idle speed, turn the detent speed setting screw (4) clockwise. Back the low idle speed setting screw (1) out (counterclockwise) at least two turns to ensure that it will not affect proper operation of the detent shutdown. Verify detent shutdown operation after adjustment.
NOTE: If the governor is equipped with an electric speed adjusting motor or a pneumatic speed control, reduce engine speed before the high idle setting is reduced to prevent binding of the internal linkage.
Turn high idle speed stop screw (2) clockwise to decrease high idle speed.
Install Cover
(3) Plate.
When the high and low idle speeds are adjusted to the specifications given in the TMI (Technical Marketing Information) or Fuel Setting and Related Information fiche, install the plate and the two bolts. Put a seal wire through the holes in the bolt heads and install the seal as required on other Caterpillar fuel systems.
Torque Rise Setting Procedure
Governors With Single Or Dual Slope Torque Rise Springs
The D11N and 994, have a single slope rise governor. The 776B, 777B, 785, 789 and 793 all have dual slope torque rise governors.
1. Refer to the "Static Fuel Settings" in the TMI (Technical Marketing Information) or Fuel Setting and Related Information fiche to find the correct settings for the FULL LOAD breakpoint and FULL TORQUE setting.
In the past "Static Fuel Settings" in the TMI (Technical Marketing Information) or Fuel Setting and Related Information fiche for the 3500 Engines. This fuel setting was "MAXIMUM RACK TRAVEL" and was listed as "STATIC FUEL SETTING".
For those 3500 Engines equipped with a 3161 Generator Set Governor, or an earlier Standard Governor, the fuel setting procedure has not changed. The fuel setting screw is used to set the "MAXIMUM RACK TRAVEL", but, the specification in the TMI (Technical Marketing Information) or Fuel Setting and Related Information fiche is shown as "FULL LOAD". "FULL LOAD" and "FULL TORQUE" dimensions will be the same number.
For those 3500 Engines equipped with 3161 Governors that have a single or dual slope torque rise, there are tow static fuel dimensions. The first dimension is "FULL TORQUE", which is maximum rack travel, and is set with the fuel setting screw. The second dimension is "FULL LOAD", which is a "reference position" where the fuel control linkage is held, while the torque rise spring is adjusted. This is a temporary dimension, set with the synchronizing pin. This dimension is shown in the TMI (Technical Marketing Information) or Fuel Setting and Related Information fiche as "FULL LOAD".
The dual slope torque rise governor has an additional dimension "first breakpoint". This "first breakpoint" dimension is 5.43 mm (0.214 in) less than the "FULL LOAD" dimension. This is also a temporary dimension that is set with the synchronizing pin. This dimension is NOT shown in the TMI (Technical Marketing Information) or Fuel Setting and Related Information fiche.
Altitude Deration
Refer to ALTITUDE DERATING DATA under the STATIC FUEL SETTINGS in the TMI (Technical Marketing Information) or Fuel Setting and Related Information fiche to find the correct dimension for the "FULL LOAD" breakpoint and "FULL TORQUE", for operation at a specific altitude. On dual slope torque rise governors the "first breakpoint" will be 5.43 mm (0.214 in) less than the "FULL LOAD" dimension in all altitude ranges.
NOTE: Before removing the top cover of the governor, make sure that the entire area surrounding the governor is free from dirt and debris. A high pressure wash is recommended to clean the governor and governor area before adjustment.
(1) Synchronizing pin. (2) Test port. (3) Test port.
2. Remove plugs from test ports (2) and (3).
3. Remove synchronizing pin (1) from the fuel setting cover. Remove the washer from the synchronizing pin. Install the synchronizing pin in test port (2). Tighten synchronizing pin (1) to a torque of 10 ± 2 N·m (90 ± 18 lb in).
(4) Bolts. (5) Cover. (6) Gasket.
4. Remove bolts (4) that hold the top cover in position on the governor. Make sure that the oil level of the governor is below the joint face of the top cover and the governor housing. This will eliminate the loss of oil due to spillage.
Remove top cover (5) and gasket (6).
(7) 4C6101/4C6099 Terminal Shaft Torque Arm. (8) 4C6103 Weight.
5. Install the 4C6101/4C6099 Terminal Shaft Torque Arm (7) on the terminal shaft and turn the shaft to a fully clockwise (CW) position.
The Terminal Shaft Torque Arm handle must point toward the center of the engine and be within ± 30 degrees horizontal when it is installed and turned clockwise (CW). Hold the shaft in position and hang the 4C6103 Weight [4 kg (9.0 lb)] (8) on the hole in the handle of the arm.
The arm and weight are used to hold the terminal shaft of the governor in the full clockwise (CW) position. This puts the fuel control linkage stop lever against the end of the synchronizing pin.
(9) 4C6098 Speeder Shaft Torque Arm. (10) 4C6102 Weight.
6. Install the 4C6098 Speeder Shaft Torque Arm (9) on the speeder shaft and turn the shaft clockwise (CW) to a full throttle position.
The Speeder Shaft Torque Arm handle must point toward the radiator and be within ± 30 degrees horizontal when it is installed and turned clockwise (CW). Hold the shaft in position and hang the 4C6102 Weight [2.3 kg (5.0 lb)] (8) on the hole in the handle of the arm. The arm and weight are used to hold the throttle (speeder shaft) in the "FULL ON" position.
NOTE: The use of the Torque Arms and Weights, puts the fuel control linkage in position for adjustment. Do Not Operate The Engine With These Tools On The Governor. The Tools Are Designed For Adjustment Purposes Only.
7. Install and zero the indicator. Either an 8T1000 Electronic Position Indicator Group, or, the 6V3075 Dial Indicator are acceptable to use. Installation instructions for both indicators are as follows:
a. 8T1000 Electronic Position Indicator Group Install the 5P4814 Collet in test port (3). Slice the 8T1002 Probe with the 5P7263 Contact Point into the 5P4814 Collet until 8T1002 Probe sleeve bottoms in the 5P4814 Collet. Tighten the collet enough to hold the probe in this position. Attach the probe to the 8T1001 Indicator. Turn the indicator ON and set it to measure millimeters. With the indicator ON, touch the zero button. The indicator is now ready to be used for the adjustment.
b. 6V3075 Dial Indicator Install the 5P4814 Collet in test port (3). Slide the 6V3075 Dial Indicator with the 5P7263 Contact Point into the 5P4814 Collet. When the contact point seats against the fuel stop lever, slide the indicator IN or OUT, until the indicator dial reads "ZERO". Tighten the collet enough to hold the indicator in this position. The indicator is now ready to be used for the adjustment.
(11) Null screw. (12) Screw balls, pads and control spring sides.
8. Use a 3/32 hex wrench to turn null screw (11), on the governor torque control group, in a clockwise (CW) direction until it stops. This positions the pilot valve to the static adjust/test position for torque control setting screws.
NOTE: Clean screw balls, pads and control spring sides (12) with solvent to insure electrical contact while testing.
NOTE: Steps 9 and 10 do not apply to single slope torque rise governors. Proceed to Step 11 when adjusting a single slope torque rise governor.
9. Loosen the synchronizing pin until the dimension for the "first breakpoint" setting is read on the indicator.
Apply a slight amount of pressure (tapping) on the 4C6099 Terminal Shaft Torque Arm (7) and 4C6103 Weight (8), to make sure the fuel stop lever is solidly against the synchronizing pin.
(13) 8T0500 Circuit Tester. (14) Top leaf spring adjustment screw.
10. Connect the clip end of the 8T0500 Circuit Tester (13) to the governor case-to-cover bolt hole. Touch the probe end of the circuit tester to the edge of the first spring (top leaf spring) in sandwich portion of the control group.
NOTE: Do not touch the probe end to the top surface of the leaf spring because the oxide film will cause faulty continuity readings.
Use a 3/32 hex wrench to turn top leaf spring adjustment screw (14). Turn top leaf spring adjustment screw (14) in a clockwise (CW) direction until the circuit tester light just comes on (a dim light). If the circuit tester light is already lit, turn the top leaf spring adjustment screw (14) counterclockwise (CCW) until light goes off and then turn the adjustment screw clockwise (CW) until light is dimly lit.
11. Loosen the synchronizing pin (1) until the "FULL LOAD" dimension is read on the indicator.
Apply a slight downward "tapping" pressure on the 4C6099 Terminal Shaft Torque Arm (7) and 4C6103 Weight (8), to insure that the fuel stop lever is solidly against the synchronization pin (1).
(13) 8T0500 Circuit Tester. (15) Bottom leaf spring adjustment screw.
12. Connect the clip end of the 8T0500 Circuit Tester (12) to the governor case-to-cover bolt hole. Touch the probe end of the circuit tester to the edge of the bottom leaf spring in sandwich portion of the control.
NOTE: Do not touch the probe end to the top surface of the leaf spring because the oxide film will cause faulty continuity readings.
On single slope torque rise governors there is only one spring.
Use a 3/32 hex wrench to turn bottom leaf spring adjustment screw (15). Turn bottom leaf spring adjustment screw (15) in a clockwise (CW) direction until the circuit tester light just comes on (a dim light). If the circuit tester light is already lit, turn the bottom leaf spring adjustment screw (15) counterclockwise (CCW) until light goes off and then turn the adjustment screw clockwise (CW) until light is dimly lit. Single slope torque rise governors have only one adjustment screw.
13. Use a 3/32 hex wrench to turn null screw (11), onv the governor torque control group, in a counterclockwise (CCW) direction until it stops. This releases the torque control pivot (pilot valve) to the run position.
NOTE: Null screw (11) must be in the run position before installation of the top cover and running the engine. Failure to return the screw to the run position will result in failure to start, erratic operation of the engine and failure to accept a load.
14. Loosen the synchronizing pin (1) and back it out a minimum of 15.4 mm (1.00 in). Apply a slight downward pressure on the 4C6101/4C6099 Terminal Shaft Torque Arm (7) and 4C6103 Weight (8). The dimension of the indicator should be equal to the "FULL TORQUE" setting.
If adjustment is necessary, refer to the topic entitled Fuel Setting Adjustment in the Testing & Adjusting section of the Service Manual for the adjustment procedure.
(4) Bolts. (5) Cover. (6) Gasket.
15. Install the top cover (5) with a new gasket (6) on the governor. Install bolts (4) and tighten them to a torque of 10 ± 2 N·m (90 ± 18 lb in). After the top cover is installed, put a seal wire through the holes in both the plug and bolt head. Install the governor seal.
17. Remove synchronizing pin (1) from test port (2). Install the washer on the synchronizing pin, then install the synchronizing pin in the fuel setting cover.
18. Install the test port plugs in test ports (2) and (3).
Auxiliary Controls
Shutdown Rod Adjustment
(1) Manual shutdown device. (2) Electric shutdown device.
1. Remove the two bolts that hold Manual shutdown device (1) to the Pressure shutdown device (not shown) or Electric shutdown device (2). Remove the Manual shutdown device and gasket from the governor.
2. Remove the two bolts that hold the Pressure shutdown device (not shown) to Electric shutdown device (2) or governor cover and remove the Pressure shutdown device and gasket.
3. If the Electric shutdown device is used in conjunction with a diode, (64 volt Shutdown) remove the bolt that holds the diode to the governor and the remaining bolts from Electric shutdown device (2) and remove the Electric shutdown device and gasket.
(3) Shutdown rod nut.
4. With engine running, place a straight edge across the shutdown rod opening and shutdown rod nut (3) as shown. Use a 7/16 open-end wrench and start turning shutdown rod nut (3) counterclockwise until the governor just starts to shutdown. Once shutdown starts, turn the nut back clockwise one full turn.
Shutdown Device Adjustment
NOTE: The Electric shutdown device and Pressure shutdown device should be checked prior to installation and tested after installation, plus, tested at 1000 hour intervals thereafter.
| NOTICE |
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Failure to test, inspect and maintain these items could result in faulty operation and possible severe engine damage if an emergency shutdown situation occurs. |
The Electric shutdown group is either an ETS (Energized To Shutdown) or ETR (Energized To Run) shutdown. Identify which type you have and make a note of it.
1. Visually inspect the Pressure shutdown components for signs of burrs, nicks, scoring and/or wear. If there is evidence of problems, repair or replace as necessary. Inspect the Pressure shutdown mounting gasket and determine if it is reusable. Replace if necessary.
2. Visually inspect the Electric shutdown device and determine if there is any component wear. If the shutdown is an ETS version, pay particular attention to the connection of the shutdown solenoid plunger and the shutdown lever link pin.
If there is evidence of wear (the plunger pin hole is oval in shape), replace the Solenoid. Inspect the shutdown group mounting gasket and determine if it is reusable. If necessary replace it.
Check size of spacer on the electric shutdown solenoid plunger. Refer to Service Magazine article "Field Replacement of Spacer to Correct Possible Sticking in Woodward 3161 Governor Electric Shutoff Group", November 19, 1990.
Electric Shutdown Solenoid Adjustment
(1) Solenoid coil. (2) Jam nut. (3) Set screw. (4) Shutdown plunger. (5) Limit shutdown rod. (6) Shutdown lever. (7) Pivot pin. (8) Solenoid plunger. (9) Shutdown rod nut.
Energized To Shutdown
1. Place the electric shutdown housing in a vise using copper jaws or shop towels to protect the sides of the aluminum die-cast shutdown housing. Do NOT over tighten the vise.
Loosen the jam nut (2) that holds the solenoid in the electric shutdown housing. Remove solenoid coil (1) exposing the shutdown solenoid plunger (8).
NOTE: Loctite 222 is used on the solenoid coil threads at the time of manufacturing. In addition the jam nut is torqued to 75 N·m (55 lb ft).
2. Carefully clean any dirt, metal filings or metal chips from the solenoid plunger and from the cavity in the solenoid coil. Turn the jam nut on the solenoid coil counterclockwise a couple of turns so it will not interfere with the adjustment of the solenoid coil. Reinstall solenoid coil in the electric shutdown housing only three or four turns.
3. Holding the shutdown housing and gasket on a clean flat surface, adjust the set screw (3) until the shutdown plunger (4) contacts the flat surface, then turn the set screw counterclockwise 1/4 turn.
4. Holding the shutdown housing and gasket on a clean flat surface turn the solenoid coil clockwise into the electric shutoff housing until it stops. Turn the solenoid coil counterclockwise two full turns.
Apply a new coat of 9S3263 Thread Lock to the solenoid coil threads and turn the solenoid coil clockwise one full turn.
5. Do not allow the solenoid coil to turn inside the housing. Place the electric shutdown housing in a vise using copper jaws or shop towels to protect the sides of the aluminum die-cast shutdown housing. Do NOT over tighten the vise.
Torque the jam nut to 68 ± 7 N·m (50 ± 5 lb ft) without allowing the solenoid coil to move.
Energized To Run
1. Place the electric shutdown housing in a vise using copper jaws or shop towels to protect the sides of the aluminum die-cast shutdown housing. Do NOT over tighten the vise.
Loosen the jam nut (2) that holds the solenoid in the electric shutdown housing. Remove solenoid coil (1) exposing the shutdown solenoid plunger (8).
NOTE: Loctite 222 is used on the solenoid coil threads at the time of manufacturing. In addition the jam nut is torqued to 75 N·m (55 lb ft).
2. Carefully clean any dirt, metal filings or metal chips from the solenoid plunger and from the cavity in the solenoid coil. Turn the jam nut on the solenoid coil counterclockwise a couple of turns so it will not interfere with the adjustment of the solenoid coil. Reinstall solenoid coil in the electric shutdown housing only three or four turns.
3. Holding the shutdown housing and gasket on a clean flat surface, adjust the set screw (3) until the set screw (3) contacts the shutdown plunger (4), then turn the set screw counterclockwise 1/4 turn.
4. Holding the shutdown housing and gasket on a clean flat surface apply the appropriate voltage to the solenoid leads to energize the solenoid. With the shutdown in the energized position turn the solenoid coil clockwise until the shutdown plunger contacts the set screw.
Turn the solenoid coil counterclockwise one turn and apply a new coat of 9S3263 Thread Lock to the solenoid coil threads. Turn the solenoid coil clockwise 1 and 1/4 turns. Disconnect voltage from solenoid leads.
5. Do not allow the solenoid coil to turn inside the housing. Place the electric shutdown housing in a vise using copper jaws or shop towels to protect the sides of the aluminum die-cast shutdown housing. Do NOT over tighten the vise.
Torque the jam nut to 68 ± 7 N·m (50 ± 5 lb ft) without allowing the solenoid coil to move.
Shutdown Device Installation
1. Install the Electric shutdown device with gasket on the governor top cover. Torque the three hold down bolts to 10 ± 2 N·m (90 ± 18 lb in).
If the Electric shutdown is equipped with a diode, attach the diode to the cover. Thread the electric leads through the conduit fitting on the governor cover.
2. Install the Pressure shutdown device with gasket on the Electric shutdown group. Torque the hold down bolts to 10 ± 2 N·m (90 ± 18 lb in).
3. Install the Manual shutdown device with gasket on the Pressure shutdown device. If Pressure shutdown device is not used, install Manual shutdown device with gasket on Electric shutdown group. Torque the hold down bolts to 10 ± 2 N·m (90 ± 18 lb in).
4. Check that the terminal shaft goes to fuel off when each shutdown device is activated. Refer to "Shutdown Device Checks" for procedures.
The PSC and FARC MUST be checked and recalibrated (if necessary), whenever the top cover has been removed. Refer to Pneumatic Speed Setting Control Adjustments and Fuel Air Ratio Control Adjustment procedures.
Pneumatic Speed Setting Control Adjustments
Pneumatic Speed Setting Control
(1) Bellows. (2) Plug (over low idle adjustment screw).
The pneumatic speed setting control has two adjustments. One is the speed range adjustment made by turning the bellows (1) inside the housing to increase or decrease the speed range.
The other is the pneumatic speed level (bias spring) adjustment, made by removing plug (2) and turning the adjustment screw with a 1/8 inch hex wrench.
An incorrectly adjusted pneumatic speed control, or incorrectly adjusted control air pressure can cause unexplained speed changes or an inability to reach high or low idle. Before any adjustment of the pneumatic speed setting control is made, the control air pressure from the remote throttle must be correct. To check control air pressure connect a pressure indicator between the pneumatic speed control and the air supply.
Connect Pressure Indicator
(3) 8T0846 Pressure Indicator. (4) 2D7325 Tee.
The control air pressure range should be 35 kPa (5 psi) below the pressure at which the governor reaches low idle and 35 kPa (5 psi) above the pressure at which the governor reaches high idle. For example, if the governor's pneumatic control is factory set to reach low idle at 35 kPa (5 psi), the signal pressure at the minimum throttle setting should not exceed 0 kPa (0 psi). If the governor's pneumatic control is factory set to reach high idle at 365 kPa (53 psi), the signal pressure at the maximum throttle setting should be 400 kPa (58 psi) or 35 kPa (5 psi) more.
Make sure that the control air pressure is moving the governor to high and low idle. Remove the governor name plate and see if the speed setting shaft lever makes contact with both the low idle and high idle adjustment screws when air pressure is applied and removed.
If the speed setting shaft lever does not contact the low idle adjustment screw (no control air pressure to the pneumatic control), the engine speed will not drop when the low idle screw is backed out. The speed level adjustment screw (for the pneumatic speed control) must be turned until the governor speed setting shaft lever contacts the low idle adjustment screw.
Feedback Spring
To use the pneumatic speed setting control with different air pressure ranges and engine speed settings the feedback spring must be changed.
Remove Oil Line
(1) Tube assembly. (2) Plate.
NOTE: Step 1 is not necessary on later governors.
1. Remove tube assembly (1) and plate (2) from the governor.
Remove Plug
(3) Plug.
2. Install one of the bolts for plate (2) into plug (3) as shown and pull plug (3) out of its bore.
Feedback Spring And Speed Setting Piston Position
(3) Plug. (4) Piston. (5) Feedback spring.
3. With plug (3) out of the bore, speed setting piston (4) and feedback spring (5) can be lifted out of the bore with a magnet.
4. Find the correct feedback spring to use for the air pressure range and engine speed rating from the pneumatic speed control spring chart.
(5) Feedback spring. (6) PSC air inlet port.
5. Install feedback spring (5) in the bore over the speed setting rod. The feedback spring should be rotated so the spring coil end on the bottom is located on the bore centerline as shown.
NOTE: Feedback spring (5) may be either left or tight hand wound.
6. Place piston (4) over feedback spring (5) and push it down into the counterbore.
7. Install a new seal on plug (3), if the original seal is not in good condition.
8. Push plug (3) down in the bore and remove the bolt.
9. Put plate (2) in position, and install the three bolts and tighten them to 10 N·m (90 lb in).
10. Install tube assembly (1) on the governor.
| NOTICE |
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Be careful not to get paint or other foreign material down in the bore, as this will affect the control operation. |
Speed Range Adjustment
The bellows is made off-center (eccentric) to the top flange area. The bottom of the bellows has a swivel pin that engages the hole in the end of the speed setting lever. The swivel pin is set off-center (eccentric) to the bottom of the bellows but is in line with the center of the air inlet port in the top of the flange.
Speed Setting Bellows And Lever
There is an index mark (notch) 0.76 mm (.030 in) deep on the outer face of the bellows flange. The index mark is approximately mid range position when it is turned to the front of the governor (when facing the governor name plate).
Speed Setting Control
(1) Air inlet port. (2) Feedback spring. (3) Pivot.
Control air pressure enters the bellows through air inlet port (1) at the top of the flange. Control air pressure expands the speed setting bellows, which pushes down on the lever at the left of pivot (3), raising the right end of the lever against feedback spring (2). The force of the feedback spring is marked on the end of the spring.
When the bellows is turned, the eccentric changes the position of the bellows on the speed setting lever. This changes the length of the lever arm. The lever arm is the distance from pivot (3) to the outer edge of the bellows.
Lower Speed Setting
When the bellows is turned with the index mark to the right side of the governor (counterclockwise as seen from governor nameplate), the bellows moves closer to the pivot pin. This makes the lever arm shorter and lowers engine speed for a given amount of air pressure.
Higher Speed Setting
With the index mark to the left side of the governor (as seen from governor nameplate), the bellows is farther away from the pivot pin. The lever arm is now longer and engine speed is increased for a given amount of air pressure.
Connect Pressure Indicator
(4) 8T0846 Pressure Indicator. (5) 2D7325 Tee. (6) Clamp (over speed setting bellows). (7) Plug (over speed level adjustment screw).
Before the control adjustment can be made, install a pressure indicator as shown in the control air supply line. Also, connect a tachometer with good accuracy to the engine.
1. Disconnect the air supply to pneumatic speed control.
2. Remove the governor nameplate to observe the speed setting control shaft lever movement.
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Work carefully around an engine that is running. Engine parts that are hot, or parts that are moving, can cause personal injury. |
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3. Start the engine and check low and high idle engine speeds by turning the speed setting control shaft by hand. See the Engine Information Plate and the TMI (Technical Marketing Information) or Fuel Setting and Related Information fiche for the correct specifications.
NOTE: Because of speed control shaft bearing clearance, engine speeds can increase by 15 to 20 rpm above normal operating conditions when torque is applied on the control shaft.
4. Turn the low idle adjustment screw and reduce engine low idle speed by 50 rpm (for example 800 - 50 = 750 rpm).
5. Apply the recommended low idle control air pressure to the pneumatic speed setting control with the engine at low idle [for example 35 kPa (5 psi)].
Adjust Low Idle Speed
6. Clean the top of the governor and remove plug (7) from the pneumatic speed control. Use a 1/8 inch hex wrench and turn the speed level adjustment screw to adjust engine low idle speed to its original setting (800 rpm).
7. Increase control air pressure slowly and watch engine speed increase to the high idle setting (for example 1800 rpm). The object is to reach high idle (control shaft lever in contact with high idle adjustment screw) at 35 kPa (5 psi) lower than maximum system control air pressure. For example: Maximum system control air pressure is 480 kPa (70 psi) - 35 kPa (5 psi) = 445 kPa (65 psi).
8. If high idle speed is reached before the desired control air pressure [example above 445 kPa (65 psi)], lower the control air to the low idle air pressure 35 kPa (5 psi).
Adjust Bellows
Loosen the two bolts that hold the bellows clamp down. With a 3/4 inch wrench, turn the bellows in a counterclockwise direction (as seen from above the governor) and tighten the clamp bolts. Use the 1/8 inch hex wrench to turn the speed level adjustment screw and adjust the low idle speed setting (back to 800 rpm) at low air pressure [35 kPa (5 psi)].
9. If the high idle speed is not reached at the desired control air pressure [example 445 kPa (65 psi)], lower the control air to the low idle air pressure 35 kPa (5 psi).
Loosen the two bolts that hold the bellows clamp down. With the 3/4 inch wrench, turn the bellows in a clockwise direction (as seen from above the governor) and tighten the clamp bolts. Use the 1/8 inch hex wrench to turn the speed level adjustment screw and adjust the low idle speed setting (back to the 800 rpm) at low air pressure [35 kPa (5 psi)].
10. Again, increase the control air to the pressure required for the high idle speed. If the speed range is still incorrect, repeat the above steps until the correct low idle speed and high idle speed setting is reached for each required air pressure. Make sure to tighten the bellows clamp bolts after the speed setting is correctly adjusted.
11. Turn the low idle adjustment screw back to its original setting (example 800 rpm).
12. Check the pneumatic speed setting control for external leaks. Remove the pressure indicator from the control air supply line.
Fuel Air Ratio Control Adjustments
There are two adjustments for the fuel air ratio control. One adjustment is the fuel limit adjustment. The other adjustment is a gain rate which is factory set and must not be changed.
Check And Adjustment Of Fuel Limiter
1. For the correct fuel ratio control setting dimension refer to TMI (Technical Marketing Information) or the Fuel Setting and Related Information fiche.
(1) Synchronizing pin. (2) Test port. (3) Test port.
2. Remove the plug from test ports (2) and (3).
3. Remove synchronizing pin (1) from the fuel setting cover. Remove the washer from the synchronizing pin. Install the synchronizing pin (1) in test port (2). Tighten synchronizing pin (1) to a torque of 10 ± 2 N·m (90 ± 18 lb in).
Caterpillar Vehicular Engines.
(4) 4C6101/4C6099 Terminal Shaft Torque Arm. (5) 4C6103 Weight.
4. Install the 4C6101/4C6099 Terminal Shaft Torque Arm (4) on the terminal shaft and turn the shaft to a fully clockwise (CW) position.
The torque arm handle must point toward the center of the engine and be within ± 30 degrees of horizontal when it is installed and turned clockwise (CW). Hold the shaft in position and hang 4C6103 Weight (5), [40 kg (9.0 lb)] on the hole in the handle of the arm.
The arm and weight are used to hold the terminal shaft of the governor in the full clockwise (CW) position. This puts the fuel control linkage stop lever against the end of the synchronizing pin. The 4C6101/4C6099 Terminal Shaft Torque Arm (4) is to be attached only with the engine "shut down".
Commercial Engines
(6) FT1819 governor Torque Arm.
5. Install FT1819 Governor Torque Arm (6) on the terminal shaft. The FT1819 Governor Torque Arm (6) is used to hold the terminal shaft of the governor in the full clockwise (CW) position. This puts the fuel control linkage stop lever against the end of the synchronizing pin. The FT1819 Governor Torque Arm (6) is to be attached only with the engine "shut down".
NOTE: On some applications, FT1819 Governor Torque Arm (6) can not be used. Move the governor output shaft in the "FUEL ON" direction by hand. Hold the governor output shaft and fuel control linkage against the synchronizing pin with a force of 10 N·m (90 lb in) to give an accurate dial indicator reading.
(2) Test port. (3) Test port.
6. Install and zero the indicator. Either an 8T1000 Electronic Position Indicator Group, or, the 6V3075 Dial Indicator are acceptable for use. Installation instructions for both indicators are as follows:
a. 8T1000 Electronic Position Indicator Group Install the 5P4814 Collet in test port (3). Slide the 8T1002 Probe with the 5P7263 Contact Point into the 5P4814 Collet until 8T1002 Probe sleeve bottoms in the 5P4814 Collet. Tighten the collet enough to hold the probe in this position. Attach the probe to the 8T1001 Indicator. Turn the indicator ON and set it to measure millimeters. With the indicator ON, touch the zero button. The indicator is now ready to be used for the adjustment.
b. 6V3075 Dial Indicator Install the 5P4814 Collet in test port (3). Slide the 6V3075 Dial Indicator with the 5P7263 Contact Point into the 5P4814 Collet. When the contact point seats against the fuel stop lever, slide the indicator IN or OUT, until the indicator dial reads "ZERO". Tighten the collet enough to hold the indicator in this position. The indicator is now ready to be used for the adjustment.
7. Remove 4C6101/4C6099 Terminal Shaft Torque Arm (4) and 4C6103 Weight (5), or, FT1819 Governor Torque Arm (6) from the governor terminal shaft. Make sure the terminal shaft returns to the "FUEL OFF" position.
8. Disconnect the boost line from the fuel ratio control. Plug the boost line to keep dirt and foreign material out of the engine.
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Work carefully around an engine that is running. Engine parts that are hot, or parts that are moving, can cause personal injury. |
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9. Start the engine.
10. Rapidly move the speed control shaft in the speed increase direction. The rack position indicator will go up to the fuel limit position, pausing momentarily at this position as the engine accelerates to Hi idle and then drops back to the idle rack position as the engine speed reaches Hi idle. Repeat this procedure several times and read the rack position indicator during each pause.
At the point where the rack position indicator pauses is the limit for fuel control linkage movement set by the fuel ratio control. If the fuel limit setting is in need of adjustment, proceed to Step 11. If the fuel limit setting is correct, stop the engine and proceed to Step 13.
(7) Plug.
11. Remove plug (7) from the right front corner of the top cover. Put a 3/16 hex wrench through the hole in the top cover until it engages the adjustment screw. Rapidly move the speed control shaft in the speed increase direction. The rack position indicator will go up to the fuel limit position, pausing momentarily at this position as the engine accelerates to Hi idle and then drops back to the idle rack position as the engine speed reaches Hi idle.
During the momentary pause, turn the limit adjustment screw until the dimension on the rack position indicator is the same as the specifications given the TMI (Technical Marketing Information) or Fuel Setting And Related Information fiche.
Turning the limit adjustment screw clockwise (CW) will decrease the limiter setting, while turning the limit adjustment screw counterclockwise (CCW) will increase the limiter setting.
12. When the adjustment is correct, stop the engine. Remove the hex wrench and install the plug in the top cover. Put a seal wire through the holes in both the plug and the bolt head. Install the governor seal. Remove the plug from the boost line. Connect the boost line from the inlet manifold to the fuel ratio control.
14. Remove synchronizing pin (1) from test port (2). Install the washer on synchronizing pin (1) and install the synchronizing pin in the fuel setting cover.
15. Install the test port plugs in test ports (2) and (3).