Woodward 3161 Governor User manual

Product Manual 03101
(Revision C)
Original Instructions
3161 Governor
Installation and Operation Manual
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DEFINITIONS
This is the safety alert symbol. It is used to alert you to potential personal
injury hazards. Obey all safety messages that follow this symbol to avoid
possible injury or death.
DANGER—Indicates a hazardous situation which, if not avoided, will result in death
or serious injury.
WARNING—Indicates a hazardous situation which, if not avoided, could result in
death or serious injury.
CAUTION—Indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury.
NOTICE—Indicates a hazard that could result in property damage only (including
damage to the control).
IMPORTANT—Designates an operating tip or maintenance suggestion.
The engine, turbine, or other type of prime mover should be equipped with an
overspeed shutdown device to protect against runaway or damage to the prime
mover with possible personal injury, loss of life, or property damage.
The overspeed shutdown device must be totally independent of the prime mover
control system. An overtemperature or overpressure shutdown device may also
be needed for safety, as appropriate.
Read this entire manual and all other publications pertaining to the work to be performed before
installing, operating, or servicing this equipment. Practice all plant and safety instructions and
precautions. Failure to follow instructions can cause personal injury and/or property damage.
This publication may have been revised or updated since this copy was produced. To verify that
you have the latest revision, be sure to check the publications page on the Woodward website:
www.woodward.com/publications
The current revision and distribution restriction of all publications are shown in manual 26311.
The latest version of most publications is available on the publications page. If your publication is
not there, please contact your customer service representative to get the latest copy.
Any unauthorized modifications to or use of this equipment outside its specified mechanical,
electrical, or other operating limits may cause personal injury and/or property damage, including
damage to the equipment. Any such unauthorized modifications: (i) constitute "misuse" and/or
"negligence" within the meaning of the product warranty thereby excluding warranty coverage
for any resulting damage, and (ii) invalidate product certifications or listings.
To prevent damage to a control system that uses an alternator or batter
y
-charging
device, make sure the charging device is turned off before disconnecting the battery
from the system.
To prevent damage to electronic components caused by improper handling, read
and observe the precautions in Woodward manual 82715, Guide for Handling and
Protection of Electronic Controls, Printed Circuit Boards, and Modules.
Revisions—Text changes are indicated by a black line alongside the text.
Woodward reserves the right to update any portion of this publication at any time. Information provided by Woodward is
believed to be correct and reliable. However, no responsibility is assumed by Woodward unless otherwise expressly
undertaken. Copyright © Woodward 1982
All Rights Reserved
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Manual 03101 3161 Governor
Woodward i
Contents
CHAPTER 1. GENERAL INFORMATION...........................................................1
Description..............................................................................................................1
References .............................................................................................................1
CHAPTER 2. INSTALLATION PROCEDURES....................................................3
Introduction.............................................................................................................3
Storage...................................................................................................................3
Installation Requirements.......................................................................................3
CHAPTER 3. PRINCIPLES OF OPERATION .....................................................6
Component Description..........................................................................................6
Operation of the 3161 Governor.............................................................................8
CHAPTER 4. TROUBLESHOOTING...............................................................11
CHAPTER 5. GOVERNOR REPAIR ...............................................................13
Introduction...........................................................................................................13
Parts Inspection and Replacement ......................................................................20
Governor Assembly..............................................................................................22
CHAPTER 6. GOVERNOR CALIBRATION ......................................................27
Introduction...........................................................................................................27
General.................................................................................................................27
Calibration ............................................................................................................27
CHAPTER 7. AUXILIARY DEVICES...............................................................29
Introduction...........................................................................................................29
CHAPTER 8. REPLACEMENT PARTS ...........................................................34
Parts Information..................................................................................................34
Parts List for Figure 8-1........................................................................................34
Parts list for Figure 8-2.........................................................................................36
CHAPTER 9. PRODUCT SUPPORT AND SERVICE OPTIONS...........................38
Product Support Options......................................................................................38
Product Service Options.......................................................................................38
Returning Equipment for Repair...........................................................................39
Replacement Parts...............................................................................................39
Engineering Services............................................................................................40
Contacting Woodward’s Support Organization ....................................................40
Technical Assistance............................................................................................41
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3161 Governor Manual 03101
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Illustrations and Tables
Figure 1-1. 3161 Governor Outline Drawing ..........................................................2
Figure 3-1. Schematic of the 3161 Governor.......................................................10
Figure 5-1. Common Tools Used on the 3161 Governor.....................................14
Figure 5-2. Special Tools Used on the 3161 Governor........................................14
Figure 5-3. Speeder Plug Removal......................................................................16
Figure 5-4. Terminal Lever Removal....................................................................16
Figure 5-5. Ballhead .............................................................................................17
Figure 5-6. Removing Ballhead Cover.................................................................17
Figure 5-7. Ballhead Disassembly........................................................................18
Figure 5-8. Accumulator Removal........................................................................18
Figure 5-9. Accumulator Loading Tool.................................................................19
Figure 5-10. Servo and Link Disassembly............................................................20
Figure 5-11. Limit Shutdown Assembly................................................................23
Figure 5-12. Drive Shaft Seal Assembly ..............................................................23
Figure 5-13. Drive Shaft Retaining Rings.............................................................24
Figure 5-14. Speeder Plug Bracket Assembly .....................................................26
Figure 7-1. Manual Shutdown ..............................................................................29
Figure 7-2. Pressure Shutdown............................................................................30
Figure 7-3. Electric Shutdown ..............................................................................31
Figure 7-4. Pneumatic Speed Setting ..................................................................31
Figure 7-5. Speed Adjusting Motor and Manual Speed Adjustment....................32
Figure 7-6. Air Pressure Fuel Limiter....................................................................33
Figure 8-1. Parts for 3161 Governor.....................................................................35
Figure 8-2. Parts for 3161 Governor.....................................................................37
Table 2-1. Oil Viscosity Chart.................................................................................5
Table 5-1. Common Tools....................................................................................15
Table 5-2. Special Tools.......................................................................................15
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Manual 03101 3161 Governor
Woodward 1
Chapter 1.
General Information
Description
The 3161 governor is a mechanical-hydraulic device that senses speed and is
mechanically linked to and controls the energy source of dual fuel engines, diesel
engines, or steam turbines.
The maximum work output is 6 ft-lb (8 J) over the full 42 degrees travel of its
output (terminal) shaft. The recommended travel of the output shaft is 28 degrees
between the no-load and full load positions. This provides a maximum useful
work of 4 ft-lb (5 J) for the 28 degrees output shaft travel.
The governor will operate as an isochronous governor (constant speed), or as a
droop governor. Principles of operation of the 3161 governor are described in
Chapter 3.
Governor speed setting can be achieved by a speed setting lever, or by various
remote operated devices. See Chapter 7, Auxiliary Devices.
References
03102 Product Specification, 3161 Governor
25071 Oils for Hydraulic Controls
25075 Storage of Mechanical-Hydraulic Controls
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3161 Governor Manual 03101
2 Woodward
Figure 1-1. 3161 Governor Outline Drawing
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Manual 03101 3161 Governor
Woodward 3
Chapter 2.
Installation Procedures
Introduction
The 3161 governor is a precision instrument and should be handled as such.
Damage can occur if the governor is dropped or set on the drive shaft, output
shaft, or speed adjusting shaft.
Storage
The governor may be stored for a short period of time as received from the
factory. Refer to manual 25075, Commercial Preservation and Packaging for
Storage of Mechanical-Hydraulic Controls, if long term storage or storage in a
hostile environment is necessary.
The engine, turbine, or other type of prime mover should be
equipped with an overspeed shutdown device to protect against
runaway or damage to the prime mover with possible personal injury,
loss of life, or property damage.
The overspeed shutdown device must be totally independent of the
prime mover control system. An overtemperature or overpressure
shutdown device may also be needed for safety, as appropriate.
Installation Requirements
Calibration fluid is drained from the governor before shipment from the factory,
and additional cleaning or calibration is not required before installation on the
prime mover.
Governor pump rotation is set at the factory. If a different rotation is required,
refer to the Governor Assembly section of Chapter 5, for instructions to change
the direction of governor pump rotation.
Be careful when setting the governor on the mounting pad. Use the correct drive
coupling between the prime mover and governor. Be sure there is no binding,
side loading of the drive shaft, or looseness in the drive coupling. The maximum
run-out of drive shaft to mounting pad pilot should be less than 0.004 inch (0.10
mm). Careless alignment or improper mating of parts can result in premature
wear or shaft seizure.
Output Shaft Linkage
Attach the prime mover linkage to the output shaft of the governor. The maximum
work output of the 3161 governor is 6.0 ft-lb (8.1 J) over the full 42 degrees travel
of its output shaft. The recommended travel of the output shaft is 28 degrees
between the no load and full load positions. This provides a maximum useful
work of 4.0 ft-lb (5.4 J) for the 28 degrees output shaft travel.
With the output shaft of the governor rotated to the minimum
position, the prime mover linkage must be adjusted to cause
shutdown.
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3161 Governor Manual 03101
4 Woodward
Speed Setting Shaft Linkage
Attach the speed setting linkage to the governor speed setting shaft. Typically,
there will be a 50 rpm speed change for each degree of speed setting shaft
rotation, however this may vary depending on the speed setting spring used in
the governor. Maximum and minimum speed stops are adjusted during factory
calibration of the unit.
Oil Supply
In general, the oil used in the prime mover will be satisfactory for use in the
governor.
Fill the governor with clean, non-corrosive, oxidation and rust inhibiting oil that
has minimum foaming or air retention qualities, and a viscosity of 100–300 SUS
(Saybolt Universal Seconds) at operating temperature (typically 140–200 °F/
60–93 °C). Fill to the line on the sight glass (approximately 2.3 US quart/2.2 L).
After start-up, and when the oil is at operating temperature, again check the oil
level and add more oil if necessary. Oil should be visible in the sight glass at all
times.
Oil Viscosities
Table 2-1 shows the viscosity of oil at the different operating temperatures. The
pour point (low temperature) is shown on the left and the temperature at which
the performance of the oil begins to decrease is on the right side.
The governor will operate at temperatures near the pour point of the oil, but
governor operation will be slow, and may be unstable. Do not operate the
governor at a temperature less than the pour point of the oil.
Operating the governor at temperatures greater than the high limit (50 SUS), will
decrease the stability of the governor, and may result in an inability to restart hot.
Operating the governor at a temperature greater than the point at which the
performance of the oil decreases can cause governor failure.
For specific oil recommendations, see manual 25071, Oils for Hydraulic Controls.
Start-up
Be sure all of the correct installation procedures have been followed. Start the
engine according to the engine manufacturer instructions.
Be prepared to make an emergency shutdown when starting the
engine, turbine, or other type of prime mover, to protect against
runaway or overspeed with possible personal injury, loss of life, or
property damage.
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Manual 03101 3161 Governor
Woodward 5
Table 2-1. Oil Viscosity Chart
Needle Valve Adjustment
After the prime mover has started and the governor is controlling, open the
needle valve (turn it CCW) until governor operation just becomes unstable. Then
slowly close the needle valve (turn it CW) until the governor just becomes stable.
Allow the governor and prime mover to reach operating temperature. As the
governor warms up, it may become unstable. If so, slowly close the needle valve
until the governor just becomes stable. DO NOT fully close needle valve. This
may cause excessive overspeed on start-up or load rejection.
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3161 Governor Manual 03101
6 Woodward
Chapter 3.
Principles of Operation
Component Description
Gerotor Oil Pump—The gerotor oil pump is located in the base of the governor.
The inner rotor of the pump is driven by a pin in the drive shaft, and carries the
outer rotor around in mesh, pumping oil to the accumulator piston.
Accumulator—A single accumulator, consisting of a piston and spring, acts as a
relief valve for the oil pump and provides a reservoir of high pressure oil for quick
servo movement. Oil is pumped to the accumulator by the governor pump, with
pressure increasing as the accumulator spring is compressed. When the
pressure builds to the predetermined level, oil is released back to sump through
relief ports in the piston wall.
Power Piston—The power piston is attached to the output shaft by a link and
lever assembly. The power piston is designed with a large area on the bottom
and a small area on top (differential piston). A small pressure increase on the
large area of the piston will move the piston up, causing the output shaft to rotate
in the “increase” direction. The piston can move down only when oil under the
piston is released to sump. Oil to or from the bottom of the power piston is
regulated by the ballhead pilot valve and ballhead pilot valve bushing.
Pilot Valve System
The pilot valve system consists of two components, the ballhead pilot valve
(rotating) bushing, and the ballhead pilot valve plunger. The bushing is rotated
relative to the pilot valve plunger to reduce friction between the two parts. The
control land of the pilot valve plunger regulates the flow of control oil through the
control ports of the ballhead bushing.
When the pilot valve plunger is lowered, high pressure oil moves through the
control port of the bushing, to the bottom side of the power piston, and the piston
moves up. When the pilot valve plunger is raised, the oil from the bottom of the
power piston is released to sump, and the higher pressure on top of the piston
moves the piston down. When the prime mover is running at steady state, the
control land of the pilot valve plunger covers the porting in the ballhead bushing
and the power piston does not move. The movement of the pilot valve plunger is
controlled by the ballhead assembly.
Ballhead Assembly
The ballhead system consists of a ballhead, fly-weights, speeder spring, thrust
bearing, and speeder plug. The ballhead, as part of the pilot valve bushing, is
rotated by the drive coupling and drive shaft.
As the ballhead rotates, the centrifugal force causes the flyweights to pivot
outward. At the same time, the speeder spring is forcing the thrust bearing down
on the flyweight toes opposing the centrifugal force of the flyweights. Pushing
down on the speeder plug increases the downward pressure on the speeder
spring, and the governor speed setting is increased. The prime mover then runs
at a higher speed to produce a higher centrifugal force on the flyweights to
overcome the speeder spring force and rebalance the system.
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Manual 03101 3161 Governor
Woodward 7
Speeder spring force or speed setting is controlled through the speed adjusting
shaft.
Compensation System
If the pilot valve plunger is lowered, pressure oil flows to the bottom of the power
piston pushing it up, lifting the terminal lever, which in turn rotates the output
shaft.
As the power piston moves up, the oil on top of the power piston is forced out
into the passage leading to the upper side of the buffer piston, and to the lower
side of the compensation land on the pilot valve. The buffer piston moves down,
partially relieving the compression of the upper buffer spring and increasing the
compression of the lower buffer spring. The force change of the buffer springs
tends to resist this movement, resulting in a slightly higher oil pressure on the
upper side of the buffer piston. This higher pressure is transmitted to the
underside of the compensation land of the pilot valve plunger. The pressure on
the lower side of the compensation land produces a force which acts to push the
pilot valve plunger back to its centered position.
The force of the pressure differential on the compensation land moves the pilot
valve towards its centered position. Due to the compensation forces, the pilot
valve re-centers, although the engine speed is not back to normal. Leakage of oil
through the needle valve orifice equalizes the pressures above and below the
compensation land, and allows the engine speed to return to normal. As the
pressures above and below the compensation land become equal, the buffer
springs return the buffer piston to the centered position.
Speed Droop
The 3161 governor is an isochronous governor with the ability to operate in the
droop mode by the adjustment of the internal droop pivot pin. The governor may
be used in the droop mode to allow for load division between two or more prime
movers connected to a single shaft or for operating in parallel.
The droop pivot pin is attached to the terminal lever located inside the governor.
if droop has been set, the following occurs: As the output shaft of the governor
rotates in the increase direction, the compression of the speeder spring is
reduced, which in turn reduces the governor speed setting. The speed of the
prime mover is reduced as load is applied. As the output shaft of the governor
rotates in the decrease direction, the compression of the speeder spring is
increased, which raises the speed setting of the governor as load is decreased.
Limit/Shutdown Pilot Valve
Shutdown of the prime mover is accomplished with the limit/shutdown pilot valve.
With the prime mover running on speed, the ballhead pilot valve is in the
centered position. When the limit/shutdown pilot valve is lowered, pressure oil
above the control land of the ballhead pilot valve is drained back to the sump
area. As prime mover speed begins to slow, ballhead flyweights move in,
lowering the ballhead pilot valve plunger. Oil under the power piston is then
drained to the sump area. As the power piston moves down, the output shaft is
rotated in the decrease direction, and the prime mover is shut down.
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3161 Governor Manual 03101
8 Woodward
Operation of the 3161 Governor
The schematic arrangement of the 3161 governor is shown in Figure 3-1, with
the governor pilot valve calling for increased fuel. The 3161 governor has a self-
contained oil supply (approximately 2.3 US qt/2.2 L). The oil passes from the
suction side to the pressure side of the gerotor pump as the drive shaft is rotated
by the prime mover. Pump pressure is regulated at approximately 100 psi (690
kPa) by the accumulator spring and piston. As the pressure increases, the
accumulator piston moves up in the cylinder until 100 psi (690 kPa) is obtained.
At this time, bleed ports in the piston are uncovered, and pump pressure is
regulated.
The pressure generated by the accumulator, determines the work capabilities of
the governor. Pump pressure is also used for the auxiliary devices installed on
the cover.
Increase in Speed Setting
Rotating the speed setting shaft clockwise (CW) increases the speed setting of
the governor. (The high speed stop screw limits the high speed setting of the
governor.) As the speed setting shaft rotates, the speed setting lever pushes
down on the floating lever which is attached to the speeder plug. The downward
pressure on the speeder plug compresses the speeder spring and overcomes
the centrifugal force of the ballhead flyweights to lower the ball-head pilot valve
plunger (pvp), increasing speed setting of the governor.
When the pvp is lowered, pressure oil moves under the power piston causing it to
move up, lifting the terminal lever and rotating the output shaft towards the
increase direction. Even before the prime mover has reached the new set speed,
the compensation system starts to re-center the pvp. As the power piston moves
up, the oil on top of the power piston is forced out to the buffer piston and to the
lower side of the compensation land on the pvp. The change in force on the two
buffer springs tends to resist the movement of the buffer piston, causing a slightly
higher oil pressure on the upper side of the buffer piston, with this pressure being
transmitted to the bottom side of the pvp compensation land. The difference in
pressures on the two sides of the compensation land produce a force which acts
to push the pvp back to its centered position.
Leakage, of oil through the needle valve orifice equalizes the pressures above
and below the compensation land, and allows the buffer piston to re-center
during speed changes. As the pressures above and below the compensation
land become equal, the buffer springs return the buffer piston to its centered
position.
Decrease in Speed Setting
Rotating the speed setting shaft counterclockwise (CCW) decreases the speed
setting of the governor (the low speed stop screw limits the low speed setting of
the governor). As the speed setting shaft rotates CCW, the force of the speed
setting lever on the floating lever is removed and the compression is reduced
from the speeder spring. Centrifugal force from the flyweights raises the ballhead
pilot valve plunger (pvp), uncovering the control port in the rotating bushing.
Control oil under the power piston now drains to sump, allowing the power piston
to move down. The output shaft rotates in the decrease direction, and the speed
(rpm) of the prime mover is decreased. The compensation system then brings
the governor under stable control.
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Manual 03101 3161 Governor
Woodward 9
Shutdown
The limit/shutdown pilot valve is located in the supply line to the ballhead pilot
valve plunger. When shutdown is initiated, the shutdown strap pushes the
limit/shutdown plunger below the supply passage and drains oil from the supply
to the ballhead pilot valve plunger. Control oil from under the power piston drains
past the control land of the pvp, lowering the power piston and rotating the output
shaft in the decrease direction. As the rpm of the prime mover decreases, the
ballhead flyweights move in, lowering the ballhead pilot valve, rapidly draining the
oil from under the power piston. As the power piston moves down, the output
shaft rotates to the shutdown position and the prime mover is shutdown.
With the output shaft of the governor rotated to the minimum
position, the prime mover linkage must be adjusted to cause
shutdown.
Be prepared to make an emergency shutdown when starting the
engine, turbine, or other type of prime mover, to protect against
runaway or overspeed with possible personal injury, loss of life, or
property damage.
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3161 Governor Manual 03101
10 Woodward
Figure 3-1. Schematic of the 3161 Governor
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Manual 03101 3161 Governor
Woodward 11
Chapter 4.
Troubleshooting
Governor faults are usually revealed as speed variations of the prime mover,
however, it does not necessarily follow that all speed variations indicate governor
faults. Troubleshoot the governor to localize a problem before attempting
disassembly and repair.
Use the following Troubleshooting Diagram to troubleshoot your governor. See
Chapter 6, Governor Calibration, or refer to the engine manufacturer’s
specifications for engine calibration.
Be prepared to make an emergency shutdown when starting the
engine, turbine, or other type of prime mover, to protect against
runaway or overspeed with possible personal injury, loss of life, or
property damage.
Problem Question Procedure
Engine cranks,
but governor
output shaft
doesn’t move
from minimum
position.
With manual
assistance, can
the governor
output shaft be
easily moved
towards
maximum while
cranking?
YES
—
1. Is governor filled with oil?
2. Is the rotation of the pump set correctly?
3. Have you cranked the engine for at least 10 seconds to allow the
governor time to develop pressure?
4. Is the drive shaft connected?
5. Is the oil viscosity greater than 50 SUS?
6. Is the cranking speed too low?
NO
—
1. Are any shutdown devices activated or incorrectly adjusted?
2. Is speed setting above cranking speed?
3. Is linkage free from excessive friction?
4. Is load limit set at zero?
5. If fuel limiter is used, is it correctly adjusted?
Governor opens
fuel, but is slow
and sluggish.
1. Are shutdowns properly adjusted?
2. Is the governor oil viscosity less than 50 SUS, or above 3000
SUS?
3. Is the need valve closed too far?
4. Is linkage to the engine free?
Governor opens
fuel, but only part
way.
1. Is load limited adjusted properly, and set out of the way?
2. Is there adequate manifold pressure? [applies to fuel limit type
governors]
3. Is fuel stop on engine adjusted properly?
4. Is fuel stop in governor set properly?
5. Is fuel linkage free?
Governor opens
fuel and prime
mover starts, but
trips out on
overspeed.
1. Is the linkage sticky?
2. Is the linkage properly adjusted?
3. Is the overspeed trip set properly?
4. Is the needle valve closed too far?
5. Is the governor speed setting too high?
System oscillates
and is unstable.
Check the following:
1. Is droop properly set?
2. Is the needle valve correctly adjusted?
3. Is linkage sticky or worn?
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3161 Governor Manual 03101
12 Woodward
Problem Question Procedure
Prime mover will
not accept full
load.
Is the governor at full
fuel?
YES
—
1. Is the linkage adjusted properly?
2. Is load excessive?
3. Is the voltage regulator (if used) set properly?
4. Is the fuel stop on the prime mover set correctly?
NO
—
1. Is the load limit out of the way, and adjusted properly?
2. Is the fuel limited (if so equipped) set too low?
3. Is there adequate air pressure for the fuel limiter?
4. Is the linkage sticky or improperly adjusted?
5. If electric start fuel limiter—is there adequate voltage for the
solenoid?
Needle valve
adjustment does
not eliminate
instability.
(1) Are the oscillations
periodic and smooth
(not intermittent)?
YES
—
Go to question (2).
NO
—
Check the following:
1. Is the fuel source adequate and constant?
2. Is the speed setting reference steady?
3. Is the governor oil level low?
4. Is the load erratic?
5. Is the governor oil clean?
(2) Is the frequency of
the oscillation above 5
Hz?
YES
—
Check the following:
1. Governor drive train.
2. Governor alignment.
3. Dirty spring-driven oil damped ballhead (if so equipped).
4. Bad injector or misfire?
NO
—
Go to question (3).
(3) Are the oscillations
related to speed setting
variations?
YES
—
The cause of the speed setting variation must be found and
corrected.
NO
—
Go to question (4).
(4) Does the oscillation
disappear when
blocking governor
output or operating
hand throttle?
YES
—
1. Is linkage loose or worn?
2. Is governor part number correct for this application?
3. Replace governor.
NO
—
1. Check for load fluctuations.
2. Check fuel supply.
3. Check for loose or sticky linkage.
When blocking governor output or operating the hand
throttle, the system is not under governor control, and
extreme caution must be taken to prevent overspeed. Do
not attempt if overspeed speed device is not functioning.
Governor will not
shut prime mover
down.
Is governor at minimum
fuel position?
YES
—
Linkage is improperly set to allow shutdown.
NO
—
1. Is shutdown actuation signal available at the governor?
2. Are shutdowns properly adjusted?
3. Is shutdown strap in governor properly adjusted?
4. Close off fuel and replace governor.
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Manual 03101 3161 Governor
Woodward 13
Chapter 5.
Governor Repair
Introduction
Chapter 5 provides instruction for the disassembly, inspection, cleaning and
repair of the 3161 governor.
Wear approved eye protection during disassembly, cleaning, and
assembly of parts, to prevent possible eye injury.
This governor Is a precision device and should be treated as such.
Set the governor upright on wooden blocks to protect the drive shaft.
Do not drop or set the governor on the drive shaft as this may cause
damage to the drive shaft, bearings, seals and other parts inside the
governor.
Troubleshoot the governor before disassembly and repair. Do not disassemble
any further than necessary to correct governor malfunction. All governor
disassembly and repair should be done by personnel experienced in governor
repair and calibration. In all governor repair work, it is essential that all tools, the
work area and governor parts be kept clean.
Remove Governor from Mounting Pad
1. After the governor has been removed from the engine, remove drain plug
(93) and drain as much oil as possible from the case.
2. Clean exterior surface of the governor with a cloth and solvent.
General Disassembly
1. Do not remove or disturb the position of screws or levers which function as
adjustments. Do not disassemble linkages further than required to effect
removal, unless replacement is necessary.
Handle critical parts with care. Keep them separated so mating
surfaces are not damaged. Sharp corners of plunger lands, piston
grooves, metering ports, etc., must be maintained. Rounded corners,
nicks or other damage to such areas will result in excessive internal
leakage and decreased control sensitivity.
2. Discard gaskets, O-rings, oil seals, retaining rings, cotter pins, and roll pins
removed during disassembly.
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3161 Governor Manual 03101
14 Woodward
Figure 5-1. Common Tools Used on the 3161 Governor
Figure 5-2. Special Tools Used on the 3161 Governor
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Manual 03101 3161 Governor
Woodward 15
Tools
See Figures 5-1 and 5-2 for tools to facilitate the disassembly and assembly of
the governor. Not all of these tools may be needed, depending on the degree of
disassembly.
Tools can be ordered from Woodward (Fort Collins, Colorado, USA). Include in
the order:
Description of the tool
Part number of the tool requested
Manual Number 03101
Table 5-1. Common Tools
Part Number Part Name
8992-919 1/8 inch T-handle Allen wrench
190510 5/32 inch T-handle Allen wrench
8995-047 3/16 inch T-handle Allen wrench
190511 5/16 inch T-handle Allen wrench
8992-917 3/16 inch ball end Allen wrench
8992-515 3/8 inch drive torque wrench (0–100 lb-in)
190497 Pliers—lD snap ring
189791 Pliers—ID snap ring
190862 Pliers—OD snap ring
Table 5-2. Special Tools
Part Number Part Name
8995-057 Torque wrench with clutch adapter
8995-058 Installation tool—pump seal and base bearing
8995-059 Loader—accumulator spring
8995-060 Insert tool—output shaft oilite bushings
8995-061 Two piece ballhead cover tool
8995-062 Adjuster—oilite bushing
8995-063 Wrench—fuel limit nut
8995-065 Press fixture—speeder plug
8995-067 Insert tool—speed setting shaft bearing
8995-068 Serrated Torque adapter—5/8-36 (not shown)
8995-069 Serrated Torque adapter—1/2-36 (not shown)
8995-070 Protractor
8995-071 Pointer
8995-072 Test cover
8995-073 Positioning tool—terminal lever
030943 Serration wrench—output shaft
Governor Disassembly
Disassemble the governor according to the following instructions. Reference
numbers in parentheses are assigned to each part in the exploded views,
Figures 8-1 and 8-2.
1. Remove eight 3/8 inch hex head cover screws (1), and cover (10). Turn the
governor upside down and drain the remaining oil from the case.
2. Remove nameplate (30). Loosen clamp screw (1) in speed setting lever
(36). Remove speed setting shaft (28)
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3161 Governor Manual 03101
16 Woodward
3. Remove three screws (1) and lift out speeder plug bracket (37),
shutdown/limit rod (40), limit floating lever (41), and limit rod (42).
4. Carefully push down on speeder plug (123) and turn it until the floating lever
(125) is clear of the terminal lever. Lift speeder plug (123) and speeder
spring (122) out of the ballhead (Figure 5-3).
Figure 5-3. Speeder Plug Removal
Do not disassemble the speeder plug assembly unless part
replacement is necessary. To remove pin (126), place the assembly
on press fixture 8995-065. Use 1/8 inch pin punch and an arbor press
to press the pin from plug (123).
5. Remove two screws (1) from the terminal lever (15). Pull output shafts (25)
from the terminal lever (15) and case (26).
6. Lift terminal lever (15) up and rotate it to rest on the governor case. Remove
cotter pin (14) and headed pin (22) to separate the terminal lever from servo
connecting link (102). Remove seat (18) and spring (19) (Figure 5-4).
Figure 5-4. Terminal Lever Removal
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