SG Governor: This Manual Replaces Manual 04022
SG Governor: This Manual Replaces Manual 04022
SG Governor: This Manual Replaces Manual 04022
SG
Governor
Manual 04048C
WARNING
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.
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.
CAUTION
To prevent damage to a control system that uses an alternator or battery-charging
device, make sure the charging device is turned off before disconnecting the
battery from the system.
IMPORTANT DEFINITIONS
WARNING—indicates a potentially hazardous situation which, if not avoided, could
result in death or serious injury.
NOTE—provides other helpful information that does not fall under the warning or
caution categories.
Woodward Governor Company reserves the right to update any portion of this publication at any time. Information
provided by Woodward Governor Company is believed to be correct and reliable. However, no responsibility is
assumed by Woodward Governor Company unless otherwise expressly undertaken.
© Woodward 1986
All Rights Reserved
Manual 04048 SG Governor
Contents
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SG Governor Manual 04048
ii Woodward
Manual 04048 SG Governor
Chapter 1.
General Information
Introduction
This manual provides description, operation, overhaul and replacement parts
information for SG governors (Figure 1-1) and various optional auxiliary features.
The SG governor is a hydraulic speed droop type governor used on small diesel,
gas, or gasoline engines where isochronous (constant speed) control is not
required. The design of the speed droop governor is such that the governor
operates at a slower speed as engine load increases. It is through this
characteristic that stability of the governed system is achieved, and division of
load between paralleled units made possible.
SG governors are available with 10.8 or 21.7 inch-pounds (1.2 or 2.5 J) of work
capacity over 36° of terminal shaft (output) travel.
NOTE
The torque, work capacity, and maximum work values of the SG governor
are based on 25 psi (172 kPa) supply oil pressure to the governor. These
values can vary depending on the supply oil pressure.
If not supplied with an internal return spring, the 10.8 inch-pound governor
requires an external return spring (not furnished by Woodward) that exerts a 20
pound-inch (2.3 Nxm) torque on the terminal shaft in the closing direction. The
21.7 inch-pound governor requires a spring that exerts a 40 pound-inch (4.5
Nxm) torque on the terminal shaft in the closing direction.
A new cover for the standard SG governor is a vertical return-spring type cover.
This cover is used with or without a return spring, and also, with or without a
Pittman PM (Permanent Magnet) speed-setting motor. For SG governors without
a motor, the cover is furnished with a guide plug for the low-speed stop screw
(see Figures 1-1 and 1-2).
The governor uses engine oil or oil from a separate sump (not furnished by
Woodward) as a control medium; it does not have an independent sump.
Governor Drive
The governor drive shaft is splined to fit into the engine drive (see Figures 5-11
and 5-12). The governor may be mounted vertically or horizontally. If mounted
horizontally, the terminal shaft must also be horizontal and a 3/8-inch drain line
provided to connect to a 1/4-inch pipe-tapped or 0.438-20 (-4) straight-thread
port in the tower end of the governor cover. For connection of the drain line on
the new-style cover, see Figure 1-2 for vertical installation or Figure 5-12 for
horizontally mounted governors.
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SG Governor Manual 04048
The governor drive shaft may be rotated in either direction. However, the
governor relief valve assembly must, when viewing the governor from the
nameplate end, be on the left if the governor is rotated clockwise (when viewed
from above). The relief valve assembly must be on the right for counterclockwise
rotation of the drive.
Speed Adjustment
The speed adjusting shaft is used to set the governor for the desired running
speed. Low speed and high speed stop screws are provided to limit the speed
range of variable speed governors. If the engine is to be operated at one speed
setting, the stop screws may be used to lock the position of the speed adjusting
shaft.
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Manual 04048 SG Governor
The terminal shaft may extend on either or both sides of the governor. Shutdown
of the engine can be accomplished by turning the speed adjusting shaft below
the idle speed setting position.
The Bodine motor is of the split field, series wound, reversible type (see Figures
3-8and 3-9). It is available in all standard voltages.
The Pittman motor is of the permanent magnet type 12 or 24 Vdc (see Figures
5-3 and 5-5). When motor supply voltage is other than 12 or 24 Vdc, the
following control boxes are available for conversion to 24 Vdc:
• 24 Vdc P/N 8272-515
• 110 Vdc P/N 8272-518
• 110 Vdc P/N 8272-516
• 220 Vdc P/N 8272-517
A manual speed adjusting knob with friction clutch assembly is included on units
fitted with a speed adjusting motor.
Subcap Assemblies
Different subcap assemblies are available to match the particular needs of the
SG governor installation (see Figures 5-7 and 5-12). Figure 5-7 illustrates the
subcap used for an installation with a linear output, Figure 5-12 illustrates a
rotary output with an internal return spring. Subcaps usually include a fuel-rack
stop screw.
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SG Governor Manual 04048
Chapter 2.
Principles of Operation
As described earlier, the governor uses engine oil as a control medium and does
not have an independent sump. The engine oil enters the governor at the relief
valve, drops down into the cavity on the suction side of the governor oil pump,
and is carried by the pump gears around to the pressure side of the pump. If the
supply of pressure oil is greater than is required for governing purposes, the
governor pump will build up pressure until the relief valve plunger is pushed to
the right against the force of the relief valve plunger spring. The governor pump
will then recirculate the oil within the governor.
If pressure oil is used for governing purposes, the pressure will be reduced and
the spring will move the relief valve plunger to the left. The recirculating passage
is thus blocked so that operating pressure is maintained.
The pilot valve plunger controls the movement of the power piston by directing oil
to and from the area beneath the power piston. The power piston, operating
through the power piston pin and terminal lever, positions the terminal shaft to
which the engine fuel linkage connects.
When the governor is running on-speed, the control land of the pilot valve
plunger covers the control port of the ballhead bushing, and the power piston
remains stationary.
If the engine load is increased, the governor speed decreases, and speeder
spring force—now greater than the lifting effect of the centrifugal force developed
by the rotating ballarms—pushes the pilot valve plunger down. Pressure oil is
directed to the area under the power piston and pushes the piston up. The power
piston and pin rotate the terminal lever and terminal shaft in the direction to
increase fuel.
Note that, as the terminal lever rotates in the “increase fuel” direction, the speed
droop pin is raised. The right end of the floating lever pivots about the speed
adjusting lever pin as the left end of the lever is raised. Raising the left end of the
floating lever raises the spring fork and decreases the speeder spring force.
Thus, the governor ballhead is enabled to re-center the pilot valve plunger at
lower speeds as fuel is increased, a characteristic described as “speed droop”.
Closing the control port stops further movement of the power piston
simultaneously with return of the engine to the lower speed, a speed determined
by the new speeder spring force.
If the engine load is decreased, the governor speed increases and the ballarms
lift the pilot valve plunger against the downward force of the speeder spring. The
uncovered control port in the ballhead bushing connects the oil under the power
piston to sump. The absence of pressure under the power piston allows the
external spring force to rotate the terminal shaft and terminal lever in the
“decrease fuel” direction.
When moving in the decrease fuel direction, the terminal lever lowers the speed
droop pin. The floating lever lowers the spring fork to increase the speeder spring
force. The increase in speeder spring force re-centers the pilot valve plunger,
and requires an increase in speed to keep it centered. Closing the control port
stops further movement of the power piston simultaneously with return of the
engine to the higher speed required by the higher spring force.
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Manual 04048 SG Governor
The amount of speed change for a given terminal shaft rotation depends upon
the setting of the speed droop pin. Moving the pin towards the ballhead
decreases the speed change; moving it away from the ballhead increases the
speed change.
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SG Governor Manual 04048
Chapter 3.
Installation and Adjustment
Installation
Introduction
These instructions apply to three types of SG governors differentiated by their
speed settings:
• Lever
• Pneumatic
• Electric
Direction of Rotation
Rotation of the governor drive shaft as viewed from the top of the governor must
be the same as that of the engine drive when looking down on the mounting pad.
When the governor is to be rotated clockwise (when viewed from above), the
governor relief valve assembly must, when viewing the governor from the
nameplate end, be on the left.
CAUTION
Be sure engine mounting-pad drive and governor drive rotation are the
same. Incorrect drive rotation will cause the governor to become inoperative
and may cause governor damage.
Place a gasket between the base of the governor and the engine mounting pad.
Mount the governor square with the engine drive and in line with the linkage. The
splined drive shaft must fit the engine drive freely with no tightness. Do not force
the governor onto the mounting pad.
CAUTION
Be sure the gasket does not block off the three drain holes In the base. See
Figures 5-10, 5-11, and 5-12.
Oil Supply
Connect a 0.250 inch ID oil supply line to the 0.125 inch pipe-tapped hole in the
relief valve. Oil from the engine must supply a minimum of 5 psi (34 kPa) to the
governor. If a separate sump is used, the distance the governor must lift the oil
should not exceed 12 inches (30 cm), and a foot valve with a capacity of 2 US
gallons per minute (7.6 L/min) must be used. Use a 2 USgal/min (7.6 L/min), 40
µm filter in the oil supply line. In suction lift applications, the filter must not be in
series with the inlet line to the governor. Keep oil lines as short as possible.
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Manual 04048 SG Governor
If mounted horizontally, the terminal shaft must also be horizontal and a 3/8 inch
external drain line provided to connect to either a 1/4-Inch pipe tapped hole or
0.438-20 (-4) straight-thread port In the lower end of the governor cover or
subcap. See Figure 5-12 to connect the drain to the new style cover when the
governor is mounted horizontally.
Use a supply system similar to Figure 3-1 for applications requiring quick starts.
Minimum drainage or siphon level is that oil level in the governor below which the
governor pump gears are no longer submerged in oil. Oil level in the oil tank
must always be as high as, or higher than, this line. If not, governor pump gears
are no longer submerged in oil and will cavitate when the prime mover is started,
causing possible loss of governor control.
CAUTION
Most problems of mechanical hydraulic governors occur because of dirty
oil. Be sure to use clean oil.
Keep the end of the overboard drain line above the engine sump oil level.
The pneumatic speed-setting cover has two tapped holes for the oil reservoir.
Use one of the two holes for the reservoir and plug the other. Always mount the
oil reservoir with the hole for the air connection up. Be sure the other hole is
plugged (see outline drawing, Figure 3-2 or 3-3). Install the governor on the
engine. Using a funnel, fill the oil reservoir to approximately 3/8 inch (10 mm)
from the top via the hole for the air connection in top of the reservoir.
Attach the air signal pressure line to the hole in top of the oil reservoir.
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Manual 04048 SG Governor
Electric Speed Setting
The Bodine motor and the PM motor are coupled to the governor speed-setting
mechanism through a friction clutch. If the operator runs the speed adjustment to
its limit, the clutch is set to slip, thereby protecting the speed-adjusting motor.
Connect the electric speed setting as shown in Figure 3-5 or 3-6. Figure 3-5 is for
the Bodine motor, and Figure 3-6 is for the PM motor. Voltage for the Bodine
motor is shown on the motor.
Figure 3-4. SG with Fuel Rod and Bodine Electric Motor for Speed Setting
Figure 3-5. Wiring Diagram for Bodine Motor (Switch not furnished)
CAUTION
The permanent magnet motor operates on dc power. If a 115 or 230 Vac or
Vdc power source is used, convert the power source to 24 to 32 Vdc. A
converter can be ordered from Woodward. See Chapter 1, Speed Adjusting
Motor.
If a new cover and PM motor is ordered for use on an existing governor, all that
is required to install the new cover is to remove the old cover and set the new
assembly In place. If some adjustment is necessary. loosen the screws holding
the PM motor in place and align the motor shaft with the clutch. Apply Loctite 242
or equivalent to the screws and tighten to 10 lb-in (1.1 Nxm).
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SG Governor Manual 04048
When the cover is used without the PM motor, a screw is placed in the hole
where the motor drive shaft normally fits. This screw is then used as a low-speed
stop. The cover also houses a vertical return spring when one is used.
Linkage
Linear
Use a linear linkage for diesel-engine applications. Adjust the fuel linkage to
provide control of engine fuel from the minimum to the maximum engine fuel
stops. Use two-thirds of the output shaft travel between the fuel rack’s no load
and full load positions. See Figure 3-7 for recommended governor terminal shaft
travel. Adjust the maximum-fuel-rack stop screw to obtain the maximum output
rotation. Maximum rotation for vertical-return-spring governors is 40°. Maximum
rotation for other units is 36°.
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Manual 04048 SG Governor
Attach the fuel rack linkage to the governor output shaft. Be sure there is no lost
motion or binding in the linkage. See Figure 3-8 for linear linkage arrangement.
WARNING
Be sure to allow sufficient overtravel at each end of the terminal shaft so the
governor can shut down the engine and also give maximum fuel when
required.
NOTE
The torque and work capacity values quoted are based on 25 psi (172 kPa)
supply pressure to the governor. These values can vary, depending on the
oil supply pressure.
Governor output can be with either terminal shaft or with fuel rod: connect
linkage accordingly. Some subcaps with a fuel rod have a knob which can be
pushed in to open the fuel racks when starting an engine, or pulled out to close
the fuel racks and stop the engine.
Non-Linear
Applications involving a butterfly valve, such as on a gas engine, require a non-
linear linkage.
Figure 3-9 illustrates the relationship between governor output shaft and butterfly
obtained with simple linkage of maximum non-linearity. When installing this
linkage, make sure the two following conditions are attained when the linkage is
in the no-load position:
1. The lever which is attached to the governor and the connecting link is in line
with the governor output shaft and the point of attachment of the connecting
link to the butterfly lever.
Refer to the prime-mover manufacturer’s manual for the correct linkage selection
and installation.
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SG Governor Manual 04048
Adjustment
Starting the Engine for the First Time
Start the engine as instructed by the engine manufacturer. For a safe start-up,
adjust the governor for a reduced speed and allow the engine to warm up.
WARNING
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.
NOTE
Make the following adjustments to the governor only if the engine does not
stabilize, The governor was adjusted at the factory and should not require
any adjustment.
SINGLE ENGINE OPERATION—If engine speed does nor stabilize, shut down
the engine. Increase droop slightly (about 0.0625 inch [1.588 mm] movement of
bracket away from the governor ballhead), and restart the engine. Manually
move the engine fuel linkage to cause a temporary engine speed change.
Continue to increase the droop until operation is satisfactory.
Not enough droop can cause instability in the form of hunting, surging, or
difficulty in response to a load change. Too much droop can result in slow
governor response in picking up or dropping off load.
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Manual 04048 SG Governor
On interconnected units, set the least amount of droop possible to provide
satisfactory load division.
NOTE
The no load to full load speed change must be equal for all paralleled units.
Adjust the speed setting of SG governors or other governors with speed droop to
get distribution of load between synchronized units. Increasing the speed setting
of a particular unit will increase the load on that unit.
NOTE
If the governor output shaft does not use the full 2/3 of available travel from
“NO LOAD” TO “FULL LOAD”, droop wilt also be reduced proportionately.
Normally, the amount of droop set into the SG governor to make it stable in a
system will be enough to allow the units to parallel.
Troubleshooting
If engine hunts or surges:
a. Adjust and align linkage, check for lost motion, binding, excessive friction,
and linearity of load to governor travel.
b. Increase speed droop.
c. Make sure that the ballhead cavity is not lull of oil. This could be a drain
problem.
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SG Governor Manual 04048
Chapter 4.
Overhaul
Introduction
The components of the SG governor have undergone substantial modification
since first introduced. For this reason it is imperative that requests for information
or parts for SG governors include:
• Governor model and serial number as shown on governor nameplate.
• Manual number (this is manual 04048).
• Part reference number and name or description of part.
Exploded views of the most recent and early versions of the SG governor are
shown in Figures 5-1 and 5-2.
Disassembly Instructions
Governor
It is suggested that the best mechanic available—preferably one with small parts
assembly experience—be assigned to all governor maintenance and repair work.
Cleanliness of tools and work area is essential to a satisfactory overhaul of any
governor. Aside from the usual hand tools, one would require only a pair of
Waldes No. 2 external snap ring pliers. A work bench with vise, an arbor press,
and containers for cleaning solvents should be provided.
1. Clamp the governor lightly in a vise; vise jaws must grasp the base below
the base-case joint on the sides under the terminal shaft.
2. Remove cover screws. Lift off cover. Use caution if a return spring is
present.
At this point, inspection of the terminal lever (13, Figure 5-1, or 113, Figure
5-2) will reveal whether the governor is of the type shown in Figure 5-1 or
Figure 5-2. The first number following in parenthesis identifies parts shown
in Figure 5-1; the second number, parts shown in Figure 5-2.
3. Remove speed droop screw (10/109), washer(s) (11 and 12/110), and
bracket (15/111).
5. Remove long terminal shaft (37/136) and synthetic rubber seals (36/135).
6. Insert a 5/16-inch diameter rod in the opening left by the long terminal shaft
and drive short terminal shaft (39/138) out; plug (32/139) will be forced out
at this time.
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Manual 04048 SG Governor
8. Make a note of the distance the high speed stop screw (29/128) protrudes
from the governor case so that it can be set approximately the same when
reassembling. Remove stop screw (29/1 28), locknut (30/129), and washer
(31/—).
Figure 5-1—
A. Using a 1/8-inch diameter punch or rod, drive roll pin (26) out of speed
adjusting lever (27) and into the governor case.
C. Lift out the assembly consisting of speed adjusting lever (27), pilot
valve plunger (20), thrust bearing (21), and connecting parts. Remove
torsion spring (34).
NOTE
If the governor is equipped with a spring-driven ballhead, see Figure 5-8 or
5-9. Parts are not available for the ballhead shown in Figure 5-9.
On those governors in which the speed adjusting shaft does not stick out through
governor case, remove shaft as follows:
D. Drive roll pin (26) out of speed adjusting lever (27) as in step A above.
E. Remove spring wire pin (28) and lift out floating lever (25), pilot valve
(20), thrust bearing (21), and connecting parts.
F. Using a soft (brass) rod against the speed adjusting lever—hold the rod
against either side of lever as close to the shaft as possible—drive
lever (27) and bushing (33) out until welch plug (32) pops out of case.
G. Insert a 5/16-inch diameter rod in the hole left by the welch plug and
drive the speed adjusting shaft back in the other direction, knocking the
other welch plug out.
H. Pull the shaft out, removing speed adjusting lever (27) and torsion
spring (34) as the shaft is withdrawn.
Figure 5-2—
A. Unscrew speed adjusting sleeve (133) and spacer cap (130)—each
with a copper gasket (131).
B. Lift out the assembly consisting of speed adjusting shaft (134), pilot
valve (118), thrust bearing (119), and connecting parts.
C. Remove cotter pin (124) and speed adjusting shaft (134) from
assembly just removed.
10. Disassemble speed adjusting lever (27/126), floating lever (25/125), and
spring fork (18/116) by twisting off the bent end of spring wire pin (28/123).
11. Remove plug (41/141) opposite the relief valve assembly and copper gasket
(42/131).
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SG Governor Manual 04048
12. Remove relief valve assembly as follows:
Figure 5-1—
A. Remove oil inlet plug (47) and copper gasket (42).
NOTE
If the plunger and sleeve cannot be removed easily with a small pair of long-
nosed pliers (or tweezers) and a hook scriber, leave them in place until step
17.
Figure 5-2—
D. Remove relief valve sleeve (146) and copper gasket (131). The sleeve
contains the other elements of the relief valve assembly.
13. Remove the governor from the vise and invert it, catching, in—
Figure 5-1—power piston pin (16), power piston (17), and roll pin (26)
(driven out of speed adjusting lever earlier);
14. If the governor has a spring-driven ballhead assembly (Figure 5-8 or 5-9),
remove snap ring (306/324) under the ballarms (310/329) and lift out the
ballhead (311/328).
15. Remove snap ring (S7/157) or collar (—/159) from drive shaft. Lift out
ballhead assembly (22, 23, 24, Figure 5-1; 120, 121, 122, Figure 5-2; 306
through 314, Figure 5-8). Remove press-fit collar (—/159) by driving the
shaft into the base using a plastic or other soft hammer.
16. Remove three screws (58/155), and remove governor base (55/154). If the
base does not separate easily from the case, clamp the base, governor
nameplate side of case up, lightly in a vise. Using a plastic or soft hammer,
tap the underside of the case to loosen it from base.
CAUTION
Hold a hand under the base-case joint to catch the pump gears which may
drop out as the base and case are separated.
Remove pump gears (52, 53/151, 152) and seal ring (54/153).
17. If the relief valve sleeve and plunger (Figure 5-1) could not be removed in
step 12C, insert a 3/16-inch diameter rod in the tapped hole opposite the
relief valve opening, push plunger (60) out, and pull out the sleeve assembly
(43).
Case
If necessary to replace the idler gear stud, terminal sleeves, oil seals, or
bushings, proceed as follows:
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Manual 04048 SG Governor
Figure 5-1—
1. Clamp idler gear stud (51) in a vise. Twist and pull the case to remove the
stud.
CAUTION
Be careful not to score the bottom surface of the case.
2. Drive out plugs (32) and bushings (33 and 38) using a 3/8-inch diameter rod
and a piloted driving block similar to that shown in Figure 4-1. In each
instance, drive the bushings outward (rather than towards the center of the
case).
Figure 5-2—
3. Remove idler stud (150) as outlined in step 1 above.
4. Drive terminal sleeves (137) out of case. Use the piloted driving block
shown in Figure 4-1, or insert a 5/1 6-inch diameter threaded rod through
one side of the case, install a nut, and drive out the sleeve.
2. Clamp spring fork (18/116) in a vise with the pin hole up. Using a thin
screwdriver or small punch, drive the speeder spring off the fork.
3. On some early modal governors (Figure 5-2), pilot valve plunger (161) may
be pressed out of spring seat (160). The pilot valve plunger and spring seat
are one piece in Figure 5-1.
Figure 5-8—
4. Twist speeder spring assembly (301) to detach from spring seat (304). The
speeder spring and spring fork are a bonded assembly and must not be
disassembled. Replace the assembly if the bond has separated.
5. Do not disturb the position of, or remove spring seat (304) from, pilot valve
plunger (305) unless replacement of parts is necessary. Should the
relationship of these parts be disturbed for any reason, the pilot valve
plunger must be re-centered in the bushing at time of reassembly. If
disassembly is necessary, hold the pilot valve plunger with a screwdriver
while loosening the nut.
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SG Governor Manual 04048
Relief Valve
Previous steps have removed the relief valve elements of governors shown in
Figure 5-1.
1. The relief valve assembly in Figure 5-2 will have either plunger (162) or
bushing (142) and plunger (143).
2. To remove plunger (162), insert long-nosed pliers in the end of the sleeve,
push the plunger down, and grip pin (145). Slide the pin out and remove the
plunger and spring (144).
3. To remove bushing (142) and plunger (143), insert a small sharp chisel in
the end of the bushing. With a sharp blow, cut pin (145). Remove the
broken pin. Insert a small rod in the threaded end of the relief valve and
push out the bushing, plunger, and spring (144).
Ballhead Assemblies
SOLID BALLHEAD ASSEMBLY—Grind off one end of ballarm pins (23/121 or
164) to remove ballarms.
3. Lift off ballhead (311) and remove pins (309) and ballarms (310).
4. Remove torsion spring (312) and ball bearing (313) from drive cup (314).
3. Lift the centering spring coupling assembly (325) out of ballhead (328).
Repair
Most repair work consists of cleaning and polishing of parts. Use 320 to 500 grit
emery cloth for polishing. All pistons should move freely without binding or
catching. Excessive clearance between mating parts, however, will result in
excessive leakage of pressure oil within the governor.
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Manual 04048 SG Governor
Pilot Valve Plunger
Be extremely careful when polishing the pilot valve plunger control land. Leave
the corners sharp. Broken or rounded corners on this land will ruin the pilot valve
plunger.
Case
If the ground bottom surface of the case is grooved or worn from rotation of the
pump gears, or scratched from mishandling, it may be surface ground to clean-
up. Up to 1/32 inch (0.79 mm) material may be removed. Lap the surface smooth
on a flat plate if a surface grinder is not available.
Base
If the ground flat surface of the base is warped, nicked, or deeply scratched, it
may be lapped smooth on a flat plate. Do not remove more material than
necessary to clean-up. If the depth of the gear pockets is reduced, the gears will
bind. In this event, the faces of the gears must be lapped to provide clearance.
Pump Gears
The pump gears should be laid in the gear pockets and tested for free rotation. If
the gears turn roughly, inspect for nicks or wear of gear teeth and for interference
at the internal corners of the gear pockets in the base.
Assembly Instructions
Handle parts with care during assembly. In general. the assembly procedure is
the reverse of the disassembly operation. Assembly suggestions follow.
Case
Figure 5-1—
If necessary to install new bushings (33 and 38), press the bushings in with an
arbor press to the dimensions shown in Figure 4-2. Press in the idler gear stud to
the depth shown in Figure 4-2.
After installing the bushings, line size or line ream with standard 3/8-inch
diameter line reamer.
Figure 5-2—
Press bushings (132) in flush with small end of terminal sleeves (137). Press the
terminal sleeves into the case; sleeve shoulder to be tight against case. (Insert a
support plate of exactly the correct width between the inside walls of the case.)
Press in the gear stud. The stud should project 3/8 inch (9.5 mm) out of the case.
Press bushings (132) in flush with each end of speed adjusting sleeve (133).
After installing the bushings, line size or line ream with standard 3/8-inch
diameter line reamer.
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SG Governor Manual 04048
Ballhead Assemblies
SOLID BALLHEAD ASSEMBLY (FIGURE 5-1 or 5-2)—Use new ballarm pins
(23/121) and lightly upset each end to retain in position.
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Manual 04048 SG Governor
3. Coat the surface of the base with oil. Do not use shellac.
4. Place base seal ring (54/153) in the base groove. If gasket (158, Figure 5-2)
is reused, it must not be torn or compressed to less than 0.003 inch (0.08
mm). If so, use a new 0.005-inch (0.13 mm) thick gasket. Do not tap out a
new gasket with a hammer since this may round the sharp edges of gear
pockets.
5. Place the case on the base, invert, and insert the ballhead-drive shaft
assembly through the bottom of the base to permit rotation of the pump
gears (the ballhead and ballarms now stick outside of the governor). On
governors in which the drive shaft is integral with the pump drive gear, the
shaft projects through the base to provide a means of rotating the pump
gears.
6. Insert the base screws and tighten while turning the ballhead (or drive shaft)
to ensure free rotation of gears.
7. Insert the dowel pins and drive them down approximately 1/16 inch (1.6
mm) below the base surface. Remove the ballhead drive shaft.
8. On governors using snap ring (57/157), place the ballhead and drive shaft
assembly into position in the governor case. Use snap ring pliers to install
the snap ring.
9. Turn the drive shaft with your fingers. If it binds, loosen the screws slightly
and free-up by striking at the corners of the base. Tighten screws and
recheck.
3. Wind the spring and fork assembly firmly into the spring seat on the pilot
valve plunger (20/118).
4. Each end of speeder spring must be securely attached to its mating part.
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Figure 5-8—
5. Remove pipe plug (50, Figure 5-1; 149, Figure 5-2) 50 that the control land
on the pilot valve plunger may be observed.
6. Assemble spring seat (304) and nut (303) on pilot valve plunger (305). Do
not tighten the nut.
8. Push the plunger downward as far as possible, moving the ballarms to their
innermost position.
9. Using a flashlight, observe the position of the upper edge of the control land
on the plunger with respect to the metering port in the pilot valve bushing
and note the amount of port opening (see Figure 4-3, A).
10. Hold the plunger in contact with the toes of the ballarms while pushing the
ballarms to their outermost position. Observe the position of the lower edge
of the plunger control land with respect to the metering port and again note
the amount of port opening (see Figure 4-3, B).
11. Openings A and B should be equal within 0.010inch (0.25 mm) or as nearly
as can be determined by visual observation.
12. If openings A and B are not approximately equal, hold the spring seat
stationary and turn the plunger in or out as required. Tighten the plunger nut
and recheck the centering adjustment. Readjust, if necessary.
13. Remove the plunger from the case and “wind” the speeder spring assembly
(301) firmly into the spring seal on the plunger. Reinstall the plunger in the
case.
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Manual 04048 SG Governor
Relief Valve
Figure 5-1—
Be sure relief valve plunger (60) moves freely in relief valve sleeve (43) (plunger
installed with small diameter towards inside of governor). The sleeve must fit
freely into the case bore.
Figure 5-2—
Plunger (143 or 162) must move freely in sleeve (146). If of the type using
bushing (142), rotate the bushing 90° from the previous alignment, press in flush
with the end of the sleeve, and drill a 1/16 inch (1.6 mm) diameter hole for new
pin (145). Use pin holes in relief valve sleeve (146) as pilot holes when drilling
the bushing.
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SG Governor Manual 04048
Chapter 5.
Parts Information
Figures 5-1 and 5-2 illustrate the most common versions of the SG governor.
Figures 5-3 through 5-9 illustrate the various optional features which may be
used with these governors.
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Parts List, Figure 5-2
Ref. No. Part Name ............................. Quantity Ref. No. Part Name ............................. Quantity
04048-101 Cover ..................................................1 04048-133 Speed adjusting sleeve...................... 1
04048-102 Low speed stop screw ........................1 04048-134 Speed adjusting shaft ........................ 1
04048-103 Hex, nut, 1/4-28 ..................................1 04048-135 Synthetic rubber seal ......................... 4
04048-104 Vent screw ..........................................1 04048-136 Terminal shaft (Long)......................... 1
04048-105 Lock washer........................................1 04048-137 Terminal sleeve.................................. 2
04048-106 Fil. hd. screw, 10-32 x 1......................3 04048-138 Terminal shaft (Short) ........................ 1
04048-107 Shakeproof washer, #10.....................3 04048-139 Welch plug ......................................... 1
04048-108 Cover gasket.......................................1 04048-140 Case................................................... 1
04048-109 Hex. hd. screw ....................................1 04048-141 Plug.................................................... 1
04048-110- Washer ...............................................1 04048-142 Bushing .............................................. 1
04048-111 Speed droop adjusting bracket ...........1 04048-143 Relief valve plunger ........................... 1
04048-112 Cotter pin ............................................2 04048-144 Relief valve spring.............................. 1
04048-113 Terminal lever .....................................1 04048-145 Pin...................................................... 1
04048-114 Power piston .......................................1 04048-146 Relief valve sleeve ............................. 1
04048-115 Pin.......................................................1 04048-147 Nameplate.......................................... 1
04048-116 Spring fork ..........................................1 04048-148 Drive screw, #2 .................................. 2
04048-117 Speeder spring ...................................1 04048-149 Pipe plug, 1/8 ..................................... 1
04048-118 Pilot valve plunger ..............................1 04048-150 Idler gear stud .................................... 1
04048-119 Thrust bearing.....................................1 04048-151 Idler gear............................................ 1
04048-120 Ballarm................................................2 04048-152 Drive gear .......................................... 1
04048-121 Ballarm pin..........................................2 04048-153 Base seat ring .................................... 1
04048-122 Ballhead—Pilot valve bushing ............1 04048-154 Base................................................... 1
04048-123 Spring wire pin ....................................1 04048-155 Screw ................................................. 3
04048-124 Cotter pin ............................................1 04048-156 Dowel pin ........................................... 2
04048-125 Floating lever ......................................1 04048-157 Snap ring............................................ 1
04048-126 Speed adjusting lever .........................1 04048-158 Base gasket ....................................... 1
04048-127 Pin.......................................................1 04048-159 Drive collar ......................................... 1
04048-128 High speed stop screw .......................1 04048-160 Spring seat......................................... 1
04048-129 Nut ......................................................1 04048-161 Pilot valve plunger.............................. 1
04048-130 Spacer cap..........................................1 04048-162 Relief valve plunger ........................... 1
04048-131 Copper gasket ....................................4 04048-163 Ballarm pin washer ............................ 4
04048-132 Bushing...............................................4 04048-164 Ballarm pin ......................................... 2
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Bearing Lubrication
Use Regal A oil or a good 10 weight oil for bearing lubrication. Under normal,
intermittent operation, apply 5 drops of oil to the oil hole and oil cup every year. If
the motor is run for long periods of time, apply 5 drops of oil to the oil hole and oil
cup every six months.
Gear Lubrication
The speed reduction gear housing of a new motor is filled with sufficient lubricant
to last for two years under normal, intermittent operation. Under extensive use,
when the motor is run for long periods of time, the lubricant will last about one
year.
To replace grease, clean out the old grease and refill the gear housing 3/4 full of
one of the following greases:
• Bodine
• Supermil Grease No. A72832, by Standard Oil Company
• Dow Corning Grease No, 44, when specified (temperature range is –40 to
+400 °F/–40 to +204 °C).
Make sure the ball thrust bearing is reinstalled with the gearbox.
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High-slip torque clutches use two springs (349) and are adjusted to 8 to 10 lb-in
(0.9 to 1.1 Nxm) slip torque.
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Subcap Assemblies
The parts comprising typical subcap assemblies are shown in Figures 5-6 and
5-7. Except for the subcap assembly, the operation and construction of a
governor equipped with a subcap are similar to the conventional governors
described in preceding pages.
Governors with subcaps do not require an external spring acting in the shutdown
direction since the subcap springs perform the same function.
The output of a governor with the subcap assembly shown in Figure 5-6 is at fuel
rod (235) rather than at a terminal shaft. As in other model SG governors, the
terminal lever (245) is rotated by the power piston movement as fuel changes are
called for by the governor ballhead and pilot valve. The terminal lever pin (247),
pushing against fuel rod collar (240), effects the movement of the fuel rod.
Maximum fuel to the engine is limited by the setting of stop screw (232) which
limits the angular travel of the terminal lever.
The fuel rod spacer (243) is positioned by the setting of hex nut (242), and must
be adjusted to match the engine linkage. The engine manufacturer’s manual
provides instructions for this adjustment. After the hex nut is properly set, use
knob (241) to lock it in position.
Knob (241) provided on the front of the subcap assembly may be manually
pushed in to open the fuel racks when starting, or pulled out to close the fuel
racks and stop the engine.
Some governors are equipped with the subcap assembly shown in Figure 5-7.
The purpose of this type of subcap assembly is to provide a spring force within
the governor to urge the terminal lever in the “fuel off” direction.
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Parts List, Figure 5-7
36 Woodward
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Parts List, Figure 5-8
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Parts List, Figure 5-9
Spring-driven ballheads have been replaced by oil-damped ballheads shown in Figure 5-8.
Spare parts are not available.
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Figure 5-11. Outline Drawing of SG Governor with Subcap (internal return spring)
and Speed Adjusting Motor
40 Woodward
Manual 04048 SG Governor
Figure 5-12. Outline Drawing of SG Governor with and without PM Motor, with
Pneumatic Speed Setting Assembly
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SG Governor Manual 04048
Chapter 6.
Troubleshooting
General
It is impossible to anticipate every kind of trouble that is encountered in the field.
This manual covers most common troubles experienced. Governor performance
or operation of auxiliary equipment may cause poor regulation. Consider the
effect of the auxiliary equipment used on the overall control required of the
governor.
You can correct approximately 95% of all trouble by following these instructions,
the other 55% may require the service of a governor engineering specialist.
Oil Trouble
Diesel engine lubricating oils are satisfactory, but if they contain additives
(inhibitors) which are used to free up rings, remove carbon, etc., a non-foaming
additive must also be present.
The oil must not foam or sludge excessively when agitated, or form gummy
deposits when heated to operating temperature and subjected to operating
pressure changes. Oil contaminated with water will cause foaming.
Dirty oil causes approximately 75% of all SG governor troubles. Change the
engine lubricating oil more often than essential for engine maintenance purposes
if proper filters are not used in the supply line to the governor.
WARNING
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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Chapter 7.
Service Options
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 is also a flat rate structured program and
includes the full standard Woodward product warranty (Woodward Product and
Service Warranty 5-01-1205).
Charges for the Replacement/Exchange service are based on a flat rate plus
shipping expenses. You are invoiced the flat rate replacement/exchange charge
plus a core charge at the time the replacement unit is shipped. If the core (field
unit) is returned to Woodward within 60 days, Woodward will issue a credit for
the core charge. [The core charge is the average difference between the flat rate
replacement/exchange charge and the current list price of a new unit.]
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Flat Rate Repair
Flat Rate Repair is available for the majority of standard 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. All repair work carries the standard
Woodward service warranty (Woodward Product and Service Warranty 5-01-
1205) on replaced parts and labor.
CAUTION
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.
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.
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Manual 04048 SG Governor
Return Authorization Number
When returning equipment to Woodward, please telephone and ask for the
Customer Service Department [1 (800) 523-2831 in North America or
+1 (970) 482-5811]. They will help expedite the processing of your order through
our distributors or local service facility. To expedite the repair process, contact
Woodward in advance to obtain a Return Authorization Number, and arrange for
issue of a purchase order for the item(s) to be repaired. No work can be started
until a purchase order is received.
NOTE
We highly recommend that you make arrangement in advance for return
shipments. Contact a Woodward customer service representative at
1 (800) 523-2831 in North America or +1 (970) 482-5811 for instructions and
for a Return Authorization Number.
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.
For assistance outside North America, call one of the following international
Woodward facilities to obtain the address and phone number of the facility
nearest your location where you will be able to get information and service.
You can also contact the Woodward Customer Service Department or consult
our worldwide directory on Woodward’s website (www.woodward.com) for the
name of your nearest Woodward distributor or service facility. [For worldwide
directory information, go to www.woodward.com/ic/locations.]
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SG Governor Manual 04048
Engineering Services
Woodward Industrial Controls Engineering Services offers the following after-
sales support for Woodward products. For these services, you can contact us by
telephone, by email, or through the Woodward website.
• Technical Support
• Product Training
• Field Service
Contact information:
Telephone—+1 (970) 482-5811
Toll-free Phone (in North America)—1 (800) 523-2831
Email—icinfo@woodward.com
Website—www.woodward.com/ic
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Technical Assistance
If you need to telephone for technical assistance, you will need to provide the following information.
Please write it down here before phoning:
General
Your Name
Site Location
Phone Number
Fax Number
Control/Governor Information
Please list all Woodward governors, actuators, and electronic controls in your system:
Serial Number
Serial Number
Serial Number
If you have an electronic or programmable control, please have the adjustment setting positions or
the menu settings written down and with you at the time of the call.
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50 Woodward
We appreciate your comments about the content of our publications.
Send comments to: icinfo@woodward.com
Please include the manual number from the front cover of this publication.
FM 57982
BS EN ISO 9001:1994
6 March 2001
03/10/F