Woodward 3161 Governor User manual

Product Manual 03108
(Revision B)
Original Instructions
3161 Governor
Air Pressure Fuel Limiter
Operation Manual

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.
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 1983
All Rights Reserved

Manual 03108 3161 Air Pressure Fuel Limiter
Woodward i
Contents
CHAPTER 1. GENERAL INFORMATION...........................................................1
Introduction.............................................................................................................1
Description..............................................................................................................1
References .............................................................................................................1
CHAPTER 2. PRINCIPLES OF OPERATION .....................................................3
CHAPTER 3. TROUBLESHOOTING,REPAIR,AND CALIBRATION......................5
Introduction.............................................................................................................5
Disassembly ...........................................................................................................7
Assembly................................................................................................................8
Calibration Procedures...........................................................................................9
CHAPTER 4. REPLACEMENT PARTS ...........................................................13
CHAPTER 5. PRODUCT SUPPORT AND SERVICE OPTIONS...........................15
Product Support Options......................................................................................15
Product Service Options.......................................................................................15
Returning Equipment for Repair...........................................................................16
Replacement Parts...............................................................................................16
Engineering Services............................................................................................17
Contacting Woodward’s Support Organization ....................................................17
Technical Assistance............................................................................................18
Illustrations and Tables
Figure 1-1. Outline Drawing of 3161 Governor with Air Pressure Fuel Limiter......2
Figure 2-1. Schematic of Air Pressure Fuel Limiter on the 3161 Governor...........4
Figure 3-1. Disassembly of Bellofram Assembly....................................................7
Figure 3-2. Air Pressure Fuel Limiter and Cover Assembly.................................10
Figure 3-3. Fuel Limit Level and Range...............................................................11
Figure 4-1. Exploded View of 3161 Air Pressure Fuel Limiter .............................14

3161 Air Pressure Fuel Limiter Manual 03108
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Manual 03108 3161 Air Pressure Fuel Limiter
Woodward 1
Chapter 1.
General Information
Introduction
This manual describes the operation, repair, and calibration of the Air Pressure
Fuel Limiter that is available for the 3161 governor. This device is installed and
calibrated at the factory.
Description
The Air Pressure Fuel Limiter limits fuel in proportion to air pressure from the air
manifold or air box.
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.
References
03101 3161 Governor
03102 3161 Governor product specification
03103 3161 Governor, Manual Shutdown Device
03104 3161 Governor, Pressure Shutdown Device
03105 3161 Governor, Electric Shutdown Device
03106 3161 Governor, Pneumatic Speed Setting Device
03107 3161 Governor, Speed Adjusting Motor with Manual Speed Adjust
03109 3161 Governor, Load Limit Control
25075 Commercial Preservation Packaging for Storage of Mechanical-Hydraulic
Controls

3161 Air Pressure Fuel Limiter Manual 03108
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Figure 1-1. Outline Drawing of 3161 Governor with Air Pressure Fuel Limiter

Manual 03108 3161 Air Pressure Fuel Limiter
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Chapter 2.
Principles of Operation
The Air Pressure Fuel Limiter is designed to allow adjustment to permit full fuel or
fuel limiting to the engine during cranking and start-up. If the adjustment has
been made for full fuel, the fuel limiter is inoperative until the engine has started
(see Figure 2-1).
If the limiter has been adjusted for full fuel on start-up, as speed or load is
increased to the prime mover, air pressure increases, raising the rolling
diaphragm assembly, compressing the limiter spring. As the rolling diaphragm
assembly moves up, the fuel limit plunger also moves up and closes off the port
in the limiter piston, trapping the supply oil. The trapped oil increases in pressure
until it is high enough to overcome the limiter spring and push the limiter piston
down. The lower edge of the fuel limit plunger uncovers the port in the limiter
piston, allowing supply oil to go to drain. The limiter is now “armed” and
operational.
If the limiter is calibrated to limit fuel on start-up, the arming adjustment screw
has been backed out (turned counterclockwise) to allow the fuel limit plunger to
move up and close off the port in the limiter piston, trapping the supply oil. The
trapped oil increases in pressure until it is high enough to overcome the limiter
spring and push the limiter piston, limiter output rod, limit lever, limit rod, and
limit/shutdown pilot valve plunger down. When the limit/shutdown pilot valve
moves down, governor control oil is allowed to drain back to sump, thus limiting
fuel.
If additional load is applied and pressure from the air manifold is increased
further, the rolling diaphragm assembly again moves up, raising the fuel limit
plunger. Pressure on the limiter piston drops due to the opening of the port, and
the limiter piston moves up until the port is closed again. As described, limiter
piston position is proportional to air manifold pressure.
The limit/shutdown pilot valve is activated through the action of the
limit/shutdown rod, limit rod, limit floating lever, limiter cam, limit lever, and limiter
output rod.
The limit range is determined by the positioning of the limit cam on the limit lever.
Moving the cam away from the shutdown rod lengthens the limiting range, and
moving it closer to the shutdown rod shortens the limiting range.
Assume the prime mover is running on speed with the limiter armed. Load is
applied to the engine and speed starts to decrease. The governor calls for an
increase in fuel, the power piston moves up and rotates the output shaft in the
increase direction. As the output shaft rotates, the right end of the limit floating
lever is raised, and because the limit floating lever is fixed to a pivot (positioned
by the fuel limiter), the left end of the lever pushes the limit/shutdown rod down.
The limit/shutdown pilot valve plunger closes off governor control oil to the servo,
limiting servo travel.
As the engine picks up load, air pressure increases to the fuel limiter. The rolling
diaphragm assembly moves up, raising the fuel limit plunger which uncovers the
limiter piston. Oil pressure on the limiter piston is lowered, letting the limit servo
spring raise the piston and output rod, allowing the limit/shutdown pilot valve to
raise. Fuel limit level is then increased.

3161 Air Pressure Fuel Limiter Manual 03108
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Figure 2-1. Schematic of Air Pressure Fuel Limiter on the 3161 Governor

Manual 03108 3161 Air Pressure Fuel Limiter
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Chapter 3.
Troubleshooting, Repair, and Calibration
Introduction
Use the following troubleshooting guide to troubleshoot the Air Pressure Fuel
Limiter.
If the Air Pressure Fuel Limiter is disassembled and repaired, it will require
calibration before being returned to service on the prime mover. Refer to the
Calibration Procedures at the end of this chapter to calibrate the Air Pressure
Fuel Limiter. Refer to manual 03101 to calibrate the governor.
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 03108 3161 Air Pressure Fuel Limiter
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Disassembly
Remove the Governor from the prime mover.
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.
Do not disassemble the device any further than necessary. All disassembly and
repair should be done by personnel experienced in repair and calibration of
precision controls. In all repair work, it is essential that tools, the work area, and
parts be kept clean.
Wear approved eye protection to prevent possible eye injury during
disassembly, cleaning, and assembly of parts.
Disassemble the device according to the following instructions. Reference
numbers in parentheses are assigned to each part in the exploded view (Figure
4-1).
1. Remove three screws (1) from limiter cover(5). Carefully separate cover (5)
from bellofram spacer (25).
2. Remove upper spring seat (6) and limiter spring (7). Lift off the bellofram
assembly and remove bellofram guide (8).
3. Hold screw (23) with a 3/32 inch pin punch while removing 7/16 inch nut
(29) (Figure 3-1).
Figure 3-1. Disassembly of Bellofram Assembly
4. Remove bellofram piston (28) and upper rolling bellofram (27).
5. Remove screw (23), lower rolling bellofram (24), bellofram guide (25), and
spacer (26).
6. It is not necessary to remove plug (2), O-ring (3), or screw (4) unless limiter
cover (5) has to be replaced.

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7. Carefully remove fuel limit plunger (10) and plunger return spring (11).
8. Remove seven screws (22) from orifice plate cover (21).
Be careful not to damage orifice plate (19) when removing upper
gasket (20) and lower gasket (18).
9. Turn cover (17) over. Remove retaining ring (16).
10. Remove lower spring seat (15), limiter return spring (14), output rod (13),
and limiter piston (12) from cover (17).
Cleaning
Clean parts with solvent and a stiff brush to remove foreign particles.
Observe manufacturer’s instructions or restrictions regarding the
use of solvents. If no instructions are available, handle with care. Use
the cleaning solvent in a well ventilated area away from fires or
sparks.
Clean parts with clean, lint-free wipes, or blow dry with clean, dry air.
Handle parts that have been machined to a close tolerance carefully, to prevent
damage caused by contact with other parts or objects.
Part Inspection
(Refer to Figure 4-1.)
Springs (7, 14,11)—Inspect springs for rust and corrosion and replace if any
damage is found.
Limiter Piston (12)—Inspect limiter piston (12) for nicks and scratches on sharp
corners.
Fuel Limit Plunger (10)—Inspect fuel limit plunger (10) for nicks and scratches.
The plunger must slip freely In limiter piston (12).
Orifice Plate (19)—Inspect orifice plate (19) for plugged or damaged filter and
orifices.
Assembly
To prepare to assemble the Air Pressure Fuel Limiter, lay the parts in an orderly
fashion on a clean, dry work surface.
Use only new O-rings and gaskets. Careful, precise assembly methods will save
time, and help to ensure correct calibration and operation of the device.
Torque all 1/4-20 screws to 10 Nm (90 lb-in).

Manual 03108 3161 Air Pressure Fuel Limiter
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Assembly Procedures
(Refer to Figures 3-1 and 4-1.)
1. Apply a light coat of white petroleum jelly on piston side of bellofram (24).
Install bellofram clamp screw (23) in bellofram (24) against the surface
marked “piston side”.
2. Place bellofram spacer (25) over bellofram (24). Lubricate both ends of
bellofram inner spacer (26) with white petroleum jelly and install it on
bellofram clamp screw (23).
3. Lubricate the bottom of bellofram piston (26) and install it In the side marked
“piston side” on upper rolling bellofram (27). Place bellofram (27) and piston
(26) on bellofram clamp screw (23).
4. Install nut (29) on bellofram clamp screw (23) (Figure 3-1).
DO NOT over-tighten nut (29). Turn nut down until it is snug, then
turn 1/8 additional turn.
5. Place lower gasket (18), orifice plate (19), upper gasket (20), and orifice
cover plate (21) on governor cover (17). (Observe “orifice plate side” on
gaskets 18 and 20). Secure with seven screws (22).
6. Turn governor cover (17) with bottom side up. Install limiter piston (12),
output rod (13), limiter return spring (14), and lower spring seat (15). Secure
these parts in place with retaining ring (16).
7. Turn governor cover (17) top side up. Install plunger return spring (11) and
fuel limit plunger (10) in limiter piston (12).
6. Place gasket (9) on the cover. Install the bellofram assembly (23 through
29) on the bellofram guide (8). Be sure the bellofram is not pinched.
9. Install the bellofram assembly (consisting of parts 23 through 29 and guide
6) on gasket (9).
10. Install limiter spring (7), upper spring seat (6), and limiter cover (5). Secure
parts to cover with three screws (1).
Calibration Procedures
Before attempting to calibrate the Air Pressure Fuel Limiter, refer to the engine
specifications and the governor test specifications for required speeds and air
pressures.
Install the governor on the test stand. Be sure test stand drive rotation is the
same as the governor pump rotation.
Fill the governor with 2.2 L (2.3 qt) of clean oil that has a viscosity of 100 to 300
SUS with an oil temperature for continuous governor operation of 66 to 82 °C
(150 to 180 °F).

3161 Air Pressure Fuel Limiter Manual 03108
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Install the cover on the governor. Remove the access plug over the fuel limit level
adjustment (Figure 3-2). Turn the fuel limit level adjustment screw clockwise until
it stops, then counterclockwise 10 full turns. Remove the access plug over the
arming adjustment screw in the fuel limiter cap. Turn the arming screw clockwise
five full turns.
Figure 3-2. Air Pressure Fuel Limiter and Cover Assembly
1. With the speed setting shaft rotated to the high speed position, do the
following:
a. Run the test stand and allow the governor to reach the temperature of
54 to 66 °C (130 to 150 °F).
b. Be sure the governor is functioning correctly and calibrated to governor
specifications.
c. Unhook feedback linkage to the test stand.
d. Adjust the test stand to run the governor drive shaft at 500 rpm less
than the designated high speed of the governor.
e. Turn the limit level adjustment screw (Figure 3-3) to position the output
shaft (terminal shaft) at 38 degrees travel.
2. Apply the specified arming air pressure to the limiter. (If the governor is to
be armed at all times, use 0 kPa/psi).

Manual 03108 3161 Air Pressure Fuel Limiter
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Figure 3-3. Fuel Limit Level and Range
3. Turn the arming adjustment screw counterclockwise until the output shaft
suddenly drops towards minimum fuel. The governor is now armed. (If the
governor is to be armed at all times, add two additional turns
counterclockwise and go to step 7).
4. Reduce limiter arming air pressure to 0. Reduce the speed of the governor
to 0. Wait one minute for governor oil pressure to bleed down.
5. To recheck arming point of the limiter:
a. Adjust the test stand to run the governor drive shaft at 500 rpm less
than the designated high speed of the governor.
b. Set the output shaft at 38 degrees travel with the limit level adjustment.
c. Apply specified arming air pressure to the limiter.
(a) If the limiter arms (output shaft position drops quickly to a lower
level) at less than specified minimum limit. turn the arming adjustment
screw clockwise and repeat steps 4 and 5.
(b) It the limiter arms at more than specified maximum limit, turn the
arming adjustment screw counterclockwise and repeat steps 4 and 5.
6. Reduce limiter air pressure to 0. With the speed setting shaft at the
maximum speed setting, run the governor at 500 rpm less than high speed.
Turn the fuel limit level adjustment screw (Figure 3-3) to set the output shaft
position at the specified degree of travel for 0 pressure.
7. Apply the specified maximum air pressure to the fuel limiter. If the governor
output shaft rotates to a position that is higher than specified for that air
pressure, reduce the test stand speed to 0. Wait one minute for the
governor oil pressure to bleed down before removing the governor cover.
To prevent hot oil from spraying over the work area, do not remove
the governor cover until the governor oil pressure has dropped to 0.
Remove the governor cover. Loosen the 7/16 hex head screw and move the
limiter cam (range adjustment) towards the front of the governor. Retighten the
screw. INSTALL THE GOVERNOR COVER and repeat steps 6 and 7.

3161 Air Pressure Fuel Limiter Manual 03108
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If the governor output shaft rotates to a position that is lower than specified for
that air pressure, reduce the test stand speed to 0. Wait one minute for the
governor oil pressure to bleed down before removing the governor cover.
Remove the governor cover. Loosen the 7/16 hex head screw and move the
limiter cam (range adjustment) towards the back of the governor. Retighten the
screw. INSTALL THE GOVERNOR COVER and repeat steps 6 and 7 until the
position of the output shaft at maximum pressure is within tolerance.
8. Raise and lower the control air slowly between the specified minimum and
maximum pressures. Output shaft position should respond to small changes
and seek positions between minimum and maximum specifications
proportional to the pressures applied.
9. Replace and tighten plugs over the level adjusting and arming adjusting
screws.

Manual 03108 3161 Air Pressure Fuel Limiter
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Chapter 4.
Replacement Parts
When ordering replacement parts, include the following information:
1. Manual number (this is manual 03108).
2. Governor serial number and part number shown on the nameplate.
3. Part reference number and part name from parts list.
Ref. No. Part Name...................................Quantity
03108-1 Screw .250-20 x 1.0 .................................3
03108-2 Plug .250-28.............................................1
03108-3 O-ring .176 ID x .070................................1
03108-4 Screw .250-28 x 1.0 .................................1
03108-5 Limiter cover.............................................1
03108-6 Upper spring seat.....................................1
03108-7 Limiter spring............................................1
03108-8 Bellofram guide ........................................1
03108-9 Gasket......................................................1
03108-10 Fuel limit plunger......................................1
03108-11 Plunger return spring................................1
03108-12 Limiter piston............................................1
03108-13 Output rod ................................................1
03108-14 Limiter return spring .................................1
03108-15 Lower spring seat.....................................1
03108-16 Retaining ring...........................................1
03108-17 Governor cover.........................................1
03108-18 Lower gasket............................................1
03108-19 Orifice plate..............................................1
03108-20 Upper gasket............................................1
03108-21 Orifice plate cover ....................................1
03108-22 Screw .250-20 x 1.0 .................................7
03108-23 Screw .......................................................1
03108-24 Lower rolling bellofram .............................1
03108-25 Bellofram spacer ......................................1
03108-26 Spacer......................................................1
03108-27 Upper rolling bellofram .............................1
03108-28 Bellofram piston........................................1
03108-29 Nut .250-28...............................................1
03108-30 Pin .3135 Dia. x .515................................1

3161 Air Pressure Fuel Limiter Manual 03108
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Figure 4-1. Exploded View of 3161 Air Pressure Fuel Limiter

Manual 03108 3161 Air Pressure Fuel Limiter
Woodward 15
Chapter 5.
Product Support and Service Options
Product Support Options
If you are experiencing problems with the installation, or unsatisfactory
performance of a Woodward product, the following options are available:
1. Consult the troubleshooting guide in the manual.
2. Contact the OE Manufacturer or Packager of your system.
3. Contact the Woodward Business Partner serving your area.
4. Contact Woodward technical assistance via email
([e-mail]) with detailed information on the
product, application, and symptoms. Your email will be forwarded to an
appropriate expert on the product and application to respond by telephone
or return email.
5. If the issue cannot be resolved, you can select a further course of action to
pursue based on the available services listed in this chapter.
OEM or Packager Support: Many Woodward controls and control devices are
installed into the equipment system and programmed by an Original Equipment
Manufacturer (OEM) or Equipment Packager at their factory. In some cases, the
programming is password-protected by the OEM or packager, and they are the best
source for product service and support. Warranty service for Woodward products
shipped with an equipment system should also be handled through the OEM or
Packager. Please review your equipment system documentation for details.
Woodward Business Partner Support: Woodward works with and supports a
global network of independent business partners whose mission is to serve the
users of Woodward controls, as described here:
A Full-Service Distributor has the primary responsibility for sales, service,
system integration solutions, technical desk support, and aftermarket
marketing of standard Woodward products within a specific geographic area
and market segment.
An Authorized Independent Service Facility (AISF) provides authorized
service that includes repairs, repair parts, and warranty service on
Woodward's behalf. Service (not new unit sales) is an AISF's primary
mission.
A Recognized Engine Retrofitter (RER) is an independent company that
does retrofits and upgrades on reciprocating gas engines and dual-fuel
conversions, and can provide the full line of Woodward systems and
components for the retrofits and overhauls, emission compliance upgrades,
long term service contracts, emergency repairs, etc.
A current list of Woodward Business Partners is available at
www.woodward.com/directory.
Product Service Options
Depending on the type of product, the following options for servicing Woodward
products may be available through your local Full-Service Distributor or the OEM
or Packager of the equipment system.
Replacement/Exchange (24-hour service)
Flat Rate Repair
Flat Rate Remanufacture

3161 Air Pressure Fuel Limiter Manual 03108
16 Woodward
Replacement/Exchange: Replacement/Exchange is a premium program
designed for the user who is in need of immediate service. It allows you to
request and receive a like-new replacement unit in minimum time (usually within
24 hours of the request), providing a suitable unit is available at the time of the
request, thereby minimizing costly downtime.
This option allows you to call your Full-Service Distributor in the event of an
unexpected outage, or in advance of a scheduled outage, to request a
replacement control unit. If the unit is available at the time of the call, it can
usually be shipped out within 24 hours. You replace your field control unit with
the like-new replacement and return the field unit to the Full-Service Distributor.
Flat Rate Repair: Flat Rate Repair is available for many of the standard
mechanical products and some of the electronic products in the field. This
program offers you repair service for your products with the advantage of
knowing in advance what the cost will be.
Flat Rate Remanufacture: Flat Rate Remanufacture is very similar to the Flat
Rate Repair option, with the exception that the unit will be returned to you in “like-
new” condition. This option is applicable to mechanical products only.
Returning Equipment for Repair
If a control (or any part of an electronic control) is to be returned for repair,
please contact your Full-Service Distributor in advance to obtain Return
Authorization and shipping instructions.
When shipping the item(s), attach a tag with the following information:
return number;
name and location where the control is installed;
name and phone number of contact person;
complete Woodward part number(s) and serial number(s);
description of the problem;
instructions describing the desired type of repair.
Packing a Control
Use the following materials when returning a complete control:
protective caps on any connectors;
antistatic protective bags on all electronic modules;
packing materials that will not damage the surface of the unit;
at least 100 mm (4 inches) of tightly packed, industry-approved packing
material;
a packing carton with double walls;
a strong tape around the outside of the carton for increased strength.
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.
Replacement Parts
When ordering replacement parts for controls, include the following information:
the part number(s) (XXXX-XXXX) that is on the enclosure nameplate;
the unit serial number, which is also on the nameplate.