aerese OODWARLD ® PG-200/300 CASE, ACCUMULATOR & POWER CYLINDER WOODWARD GOVERNOR COMPANY 36618DRead this entire manual and all other publications pertaining to the work to be performed betore installing, ‘operating, or servicing this equipment. Practice ali 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 (overtemperature, or overpressure, where applicable) shutdown device(s), that operates totelly independent of the prime mover control device(s) to protect against runaway or damage to the engine, turbine, or other type of prime mover with possible personal injury or loss of life should the mechantcst-hydraulic governor(s) or electric control(s), the actuator(s), fuel controlis). the driving mechanism(s), the linkage(s), or the controlled device(s) fi The letter designation following the manual number is changed to the next letter in alphabetical order when an important revision is made to the manual TEXT CHANGES ARE INDICATED BY A BLACK LINE ALONGSIDE THE TEXT. Woodward Governor Company reserves the right to update any portion of this publication at any time. Information arovided by Waodward Govsinor Company i Dalieved 10 De correct and relate, However, no fessonnibitly is assumed by Woodward Governor ‘Company for suse uniess otterwicn expressly undertexen © Woodward Governor Company. 1977 All Aights ReservedTABLE OF CONTENTS: TITLE PAGE TITLE PAGE SECTION 1 Adjustments ...... 10 General information. 1 Compensation Needle Valve Agjust- Introduction 1 MONS «eee eeesessseesesees Description : 1 1 Optional Accessories PG Governor Heat Exchangi (Remote Only) .........cee Booster Servomotor . References . SECTION 2 Installation - Introduction Receiving... Storage. Installation Requirements Installation Fuel System Linkage. Hydraulic and Electrical Connections. Booster Servomotor Heat Exchanger. oss sosscs Oil Supply Olls For Hydraulic Controls... sceeesee NANNNAR AREER SECTION Operation and Adjustment introduction Initial Operation. To Adjust the Needle Vaive: SECTION 4 Principtes of Operation . Introduction : Amplifier Section ........ ‘Oil Pump and Accumulator . Power Servo ..... Governor Section... Pressure Reducing Valve . Governing Section . PG-200/300 .. Increase of Speed Setting of Load. Decrease of Speed Setting or Load Compensation Cutoff... SECTIONS. Maintenance... Governor Oil......- ‘Troubleshooting ..... Repair and Disassembly SECTIONG Parts information . Parts Replacement Information LIST OF ILLUSTRATIONS FIGURE TITLE PAGE 1-1. Right Front View of PGA-200/300 1-3. Lifting Sting tor PG-200/300 . 2-1 Outline Drawing for PG-200/300 Governor... +8 2-2 Outline Drawing for Governor... 6 2-3 Viscosity and Operating Temperature Of O18. eeceeeereseenre 9 2-4 Equivalent Viscostties for Lubricating Oils 8 4-1 Schematic of PG-200/300.... 12 FIGURE TITLE PAGE 6-1 Parts for PG-200/300 Case,'Accumulator and Power Cylinder .. ce AT 6-2 Parts tor Power Piston Assembly and Pilot Valve Assembly ........-. 18 6-3 Parts for Output Assembly and Feaucing Valve assembly . we 19 6-4 Parts for Drive and Pump Assembly ...... 20 6-5. Parts for Servo ASSOMDIY «ees esesese 21 6-6 Parts for Accumulator Assembly wo. 22 6-7. Parts tor Optional Vibration Resistant Assembly 2.02.20... 23NOIeATOR SCALE (EnHEA SIDE) MOUNTING BASE Figure 1-1. Right Front View of PGA-200/300SECTION 1 GENERAL INFORMATION INTRODUCTION This manual describes the PG-200/300 case, accu- ‘mutator. and power eylindor operation. information is provided on governer installation, adjustments, and maintenance. Thore are six sections to this, manual: General information, Instattation, Opera tion and Adjustments, Principles of Operation, Maintenance and Replaceable Parts. DESCRIPTION ‘The PG-200/300 asembly is a PG type governor and anintegral, hydraulic amplifier unit. Tholarge accu- ‘mulator and oil pump supply high pressure cil (200/360 psi) tothe power servo. The power sorvais. differential in operation, needing oll pressure to move it in either the increase or decrease fuel direction. Tocontrol the governor output position of the power servo, oi! flow to, or from, the power servo is controlled by a relay pilot valve. The eelay pilot valve consists of a pilot valve bushing and pilct valve plunger. A pressure reducing valve reduces the high pressure ‘if (200/360 psi) to a lower prossura (110/120 psi) {or operation of the control section of the PG governor. 1m operation, a centrifugal tlyweight head and pilot valve assombly senses speed changes and controls the flow of governor oil toa relay oylinder. Therelay cylinder {a 12 tt. Ib. single acting piston) positions the relay pilot valve 10 control the power piston output position. Acompansating system gives stability tothe govern ing system. It includes the compensation needle valve, the compensation (and of the pilot valve plungor, a butfer piston and two buffer springs A snort description of the setting of governor speed Is givenin this manual to aid in tho understanding of the basic operation. OPTIONAL ACCESSORIES. The PG-200/300 is designed for the PGE, PGA, PG- PL.PGG, PGL, and PGD column assemblies to meet avariety of customer requirements. Different methods of setting speeds and optional auxiliary equipment are available on the column assembly for use, by themselves or in combination, with the PG-200/300 Tho auxiliary equipment performs a secondary function such as limiting engine load, controlling engine load to maintain constant power output for each speed adjustment, starting fuel limiting, per- mitting temporary overloads, etc. Optional accessories used on the PG-200/300 case assembly include: PG GOVERNOR HEAT EXCHANGER (REMOTE ONLY) ‘The heat exchanger is used to lower governor oil temperature when the governor operates in high ambient tomparatures. !t should be used whanever the governor will go above 200°F (90°C) maximum operating temperature. When a governor heat exchanger isneeded it canbe added without change or conversion to the PG-200/300, NOTE ‘Some PG-200/300 governors (manutac- tured before 1979) have a pressurizing valve which may have been disabled. Ifa heat exchanger is added to one of these governors the pressurizing valve, number 4, figure 6-1, should be removed and checked to be sure that it has not been disabled with a cotter pin. Ifa cotter pin is prosent it must be removed before the valve is repleced in the governor. BOOSTER SERVOMOTOR ‘The booster servomotor is used with the governor to help the prime mover start quickly by moving the governor output toward the maximum fuel position at startup. & high output booster having a 1:1 or higher pressure ratio is necessary when used with the PG-200/300 governor. A fuel limiter, an option on the PG column assemblies, is sometimes neces- saty when the booster servomotor is usedREFERENCES This manual is one of several that must be used to describe a model of the PG-200/300 governor. For help in selecting optional features of the governor, ‘or if tield conversion is necessary, write or call one ‘of the Woodward Governor Company offices shown ‘on the back of this manual Manual 25071 25038 25075 36036 36052 36404 36801 36604 36614 36615 36621 Title Oils for Hydraulic Controts Field Service Information ‘Commercial Preservation Packaging for Storage of Mechanical-Hydraulic Con- trots Starting Fuel Limiter for PG Governors ‘Magnetic Speed Pickups tor PG, UGB and UG-40 Governors Analysis and Correction of PG Governing Troubles Absolute Manifold Pressure Bias Load Control and Fuet Limiter PGA Marine Governor PG Governor Dial Type Speed Setting PG Govarnor Lever Type Speed Setting PG Governor Speed Droop Linkage Manual 36627 36630 Title PGG Governor Basic Load Controt System for PG Govor- 36641 36650 36651 36652 36663, 36661 36662 36686 36685 36686 36691 36694 36695 36698 Governor Oil Heat Exchanger Solenoid Operated Shutdown Assembly Pressure Actuated Shutdown Assembly Automatic Safety Shutdowns and Alarms Pressure Actuated Shutdown for PGD. and PGL Governors Manifold Gauge Pressure Fuel Limiter Torque Limit Control with Speed Droop Booster Servomotor PG Shutdown Solenoid Pneumatic Load Balance System for PGA Governors Electronic Speed Setting for PG Governors (PG-TR) PG-PL Governors Manifold Air Pressure Bias Fuel Limiter {Single Berrel Mode!) PGE Locomotive Governor PGA GovernorMYLON WER SLING. APPROKIMATELY Ss Feet LONG. ADPRONIMATE WEIGHT Op He paz 98 ‘ora G30 LBS) Figure 1-2. Lifting Sling for PG-200/300 GovernorSECTION 2 INSTALLATION INTRODUCTION Receiving, storage, and installation requirements for the PG-200/300 governor are covered in this section. See outline drawing, figure 2-1 ‘The engine, turbine, or other type of prime ‘mover should be equipped with an overspeed {overtemperaiure, or overpressure, where applicable) shutdown device(s), thal operates {totally independent of the prime mover Control device(s) to protect against runaway or ‘damage to the engine, turbine, or other type Of prime mover with possible personal injury (0 loss of lite should the mechanical-ydraulie Governor(s) or electric controi(s), the actuator(s), fuel control(s), the driving mechanism(s), the linkage(s), er the con- trolled device(s) tal. ae aie Be caretul when handling and installing the gover- nor. Do not hit the drive shaft and output shaft. Rough handling can cause damage to seals, parts and adjustments. RECEIVING ‘The PG-200/300 governor is shipped trom the fac- tory ina vertical position, bolted toa wood platform. The governor has beon calibrated at the factory to ‘exact specifications, then drained of oil. A light film ‘of oil covers the internal parts 1o help prevent rust. Calibration or internal cleaningis not needed before installation and operation. The drive shaft and out- put shafts are covered with a light film of oll and a soit seal preservative can be applied al the custo- mers request. The seal preservative is removed before installation with a cloth and mineral spirits. STORAGE it the P@-200/300 governor is to be in storage for a period of time, see the Woodward specification procedure, 25075, "Commercial Preservation Pack- aging for Storage of Mechanical-Hydraulic Con- trols." INSTALLATION REQUIREMENTS See figures 2-1 and 2-2 for: 1. Overall dimensions, 2, Location of installation holes, 3. Hydraulic fitting sizes, 4. Output and drive shatt dimensions, and 5. Adjustment locations. Enough clearance must be given for installation, removal, and servicing ot the governor. The gover- nor oil drain should be easily accessibia INSTALLATION Install the PG-200/300 governor on the engine accessory drive pad. Use # gasket betweon the governor and the installation pad. The drive shaft must slip into the accessory drive or mating coup- ting without force. Be careful not to push the drive shat into the governor. Improper alignment or too tighta fit betweon any of the parts can result in wear ‘or seizure, It can also cause jiggle in the governor ‘eutput. Damage tothe drive shalt, drive shalt seal, cor ather parts of the governor may occurif the governors droppedoraet onthedrive shaft or drive coupling. FUEL SYSTEM LINKAGE Correctly align and install the finkaga between the fuel system and the PG-200/300 governor. The finkage must move freely and not have excessive backlash. Use approximately 2/3 governor output travel (26°) between idle andfull fuel. Permit enough overtcavel, typically 7°, $0 the governor can cause complete shutdown and give ull fuel a full load. The governor output travel between shutdown position and idle speed must never be less than 5°, Many governors include an optional compensation cutoft and since this option cannot be seen without dis assembly of the governor, this caution must be {ollowed:JOUL9K05 00¢/002-Od 10) BulMeid BUIIINO “4-2 aunBly Essenaanganazeas E) prasseersessces | mek : | iJoULeA05 00¢/002-A0d 10} Bulmelg aUlTNO °2-z sinBi4 TT Ske iad wottSoS uae Beda RE a eH sak rH | ron wouaven ise eS Nl a ae ee ae o wy sae aesDue to the location of the compensation cutoff port In the relay servo wall, it Is necessary to adjust the governor output linkage to use no less than 5° travel between shutdown and idle. ‘Compensation cutott is more completely descr in Section 4, Principles of Operation. HYDRAULIC AND ELECTRICAL CONNEC- TIONS Make all other hydraulic and electrical connections, it any, for the particular model PG-200/300 being installed, Use the correct Woodward Governor Com- pany manuals. BOOSTER SERVOMOTOR The booster servomotoris remotely located from the governor. Make all hydrautic connections from the Dooster to the governor. Ses Manual 36684, Booster Servomotor. The booster servomotar is actuated by astarting air pressure of 180ta 200 psi, and pressure oil from the booster moves the servo piston to the maximum tuel position. Make the starting air connec- tion tothe booster at the optional air supply intet (the orificed inlet), Plug the other inlet, The governor fuel position during start up can be controlled by the fuel limiter (if available). Because of the large volume ot oil needed to move the PG-200/300 servo, tho booster limit screw should be adjusted to permit maximum booster servo output. HEAT EXCHANGER The neat exchanger is remotely iocated from the governor. Make all hydraulic connections for the heat exchanger to the governor. See manual 36641, Governor Oil Heat Exchanger. It aheat exchangers added to a governor manufactured before 1979 the pressurizing valve, number 4, figure 6-1, should be removed and checkedto be sure that ithas not been disabled with a cotter pin. Ifa cotter pin is present it must be removed before tne valve is replaced in the governor, if @ heat exchanger is added to a governor rat having @ pressurizing valve, ane is to be installed. OW SUPPLY Until the governor has been run and the acouru- lator filled, approximately tour quarts of oil will fll the governor. Governor oil capacity is 7% quartsano it is necessary to add oil after the governor is first started in order to restore oil to the full fevel mark on ‘the dipstick. Check tho oil fevel with the governor running, OILS FOR HYDRAULIC CONTROLS This Information is provided as a guide tn the selection of lubricating/hydraulic oil for governor use. Oil grade seloction is based on viscosity change over the temperature range of the governor. The information also provides an aid in recognizing and correcting common problems associated with oil used in products manufactured by the Engine and Turbine Controls Division of Woodward Governor Company. Itis not intended to suggest theselection of lubrication oil for the engine, turbine, or other type of prime mover being controlted Governor oil lubricates and provides hydraulic pow- er. The oil must have a viscosity index that allows it to perform over the operating temperature range and it must have the proper biending of additives to ‘cause it to remain stable and predictable over this range. Governor fluid must be compatibie with seal nittile, polyacrylic and tluorocar- bon). Many automotive and gas engine oils, indus- trial lubricating oils and other oils of mineral or synthetic origin meet these requirements. Wood- ward governors are designed to give stable opera- tion with most oils, if the fluid viscosity et the Operating temperature span is within e $0 to 3000 SUS (Saybolt Universal Seconds) range, Ideally, at the normal operating temperature, viscosity snoulc be between 100 and 800 SUS. Poor governor re- ‘sponse or instability usually is an indicazion thet the Oil is t00 thick or too thin. Excessive component wear or seizure ir a governor indicates the possibility of 1. Insufficient iubrication caused by: ‘A. An oil that flows slowly either when itis cold or during start-up.B. Anoillinerestriction, obstructions within or bends in the line. C. Noollinthe governor or governor oll level too low. 2. Contaminated il caused by: ‘A. Ditty oil containers B. governor exposed to heating and cool- ing cycles, creating condensation of water in the oit. 3, Oil not suitable for the operating con: 4. An improper oil tevel which creates foamy, aerated oil Operating a governor continuously beyond thenigh limit temperature of the oll will result inoil oxidation, identified by varnish or sludge deposits on the governor parts. To reduce oil oxidation, lower the governor operating temperature with 2 heat ex- ‘changer or other means, or change to an oll more oxidation resistant at the operating temperatures. loss of stable govemnor contrat and possible Prime Mover overspeed may result the viscosity ‘exceeds the 50 to 3000 SUS range. Overspeed ean damage the engine and cause personal Injury or death. ‘Specific oil viscosity recommendations are given on the chart. Select a readily available good brand of Gil, either mineral or synthetic, and continue using it. Do not mix the different classes of oils. Oil that meets the API (American Petroleum Institute) en- Gino service classification in either the “S" group of the"C" group, starting with “SA” and “CA” through “SF and "CD" is suitable for governor service. Oils, meeting performance requirements of the following specifications are also suitable: MIL-L-2104a, MIL- L-2104B, MIL-L-2104C, MiL-L-46152, MIL-L-46152A, MIL-L-46152B, MIL-L-451996. Replace the governor oil fit is contaminated, aril it is suspected of contributing to governor instability. Drain the oi! while hot and agitated; flush the governor with a clean solvent having some lubricity bofore refilling with new oil, If drain time is insuffi- cient for the solvent to completely drain or eve porate, flush governor with the same oil it is to be ‘efilled with to avoid dilution and possible contami- ration of the new oil. Ta avoid contamination re- placement oll should bo free of dirt, water and othor foreign material. Use clean containers to store and transfer oil il that has been carefully selected to match the operating conditions and is compatible with gover- nor components should give long service between oll changes, Under idea! conditions, i.e., minimum. ‘exposure to dust and water and within the tempera- ture limits of the oil, changes can be extended. A regularly scheduled oil analysis is helpful in determining the frequency of oil changes. Any persistent or recurring oil problems should be referred to a qualified oil specialist tor solution. The recommended continuous operating tempera- ture of the oil is 140°F {60°C) to 200°F (83°C). Measure the tomperature of the governor or actuator ‘on the outside lowor part of the case. The actual oil temperature will be warmer, about 10° F (6° C). Madaitional intormation for oll propertiesis required send for our Publication of FEN 41346.ecoumenceo ‘APT OU, USTED IS CRY A SUCESTION. USE THE OL oe Ge sOua ‘Gace mit ne Goeece MSCOSTY AS MoweateD N THe ART mote fats 2, ecounennco vente ua osmmene uate oPemaon a7 Pon pow tow TPO LY 90 Sus 100 Ss Pre oa an es ae arcomeroco Googe ACCEPIARLE OPERATING RANGE SrUPERATURE, Figure 2-3. Viscosity and Operating Temperature of Oils, Z Ey ‘eM, greRATNG UTED opeRanON AT MOH TEMPERATURE ue covmsrones ste woroR gaccon | wo ubpnomaate) | qarbrosiare) = ae 5 e o Figure 2-4, Equivalent Viscosities for Lubricating OilsSECTION3 OPERATION AND ADJUSTMENT INTRODUCTION This section describes the first start upandthe basic adjustments of the PG-200/300 assembly. INITIAL OPERATION Before the first start up of the PG-200/300, be sure that all steps in Section 2 have been done and are correct. ‘TO PROTECT AGAINST POSSIBLE PER- SONAL INJURY, LOSS OF LIFE and or PROPERTY DAMAGE WHEN STARTING the engine, turbine or other type of prime mover, BE PREPARED TO INITIATE AN EMERGENCY SHUTDOWN to protect ‘against runsway or overspeed should the mechanicsi-hydraulle governor{s) orelec- ‘rle control{s), the actuator(s), fuel con- ‘rol(s), the detving mechanlam(s), the link ‘age(s), or the controlled devices fail. ADJUSTMENTS Normally, the only requirementsfor puttinga new or repaired and calibrated governor into service are filling the gavernor with oil and adjusting the com- pensation needle valveto get maximum stability. All ‘other operating adjustments are made dusing 1ac- tory calibration to manutacturer’s specifications. Further adjustment should not be needed. Do not make aa intornal adjustmont of the governor unless completely familiar with the correct procedure. COMPENSATION NEEDLE VALVE ADJUST- MENTS: ‘The compensationneadle valveisan adjustable part of the compensation system. Its setting, which atfocts governor stabilty, is made according to the 10 individual characteristics of the prime mover (See figure 6-1, part number 12). TO ADJUST THE NEEOLE VALVE: 1, Withthe prime mover operating at IDLEspeed, open the compensation needle valve until the -governor begins to hunt. Letthe governor hunt severab minutes to remove trapped air in the hydraulic eiccuits. NOTE Itmay be necessary to upset the governor ‘speed momentarily to cause thegovernor to hunt. 2. Close the compensation needle valve slowly Until hunting just stops. Keep the needle vaive ‘open as far as possible to prevent slow gover- nor response. The needle valve setting can be from 1/16 to 2 turns open. Do not clase the needle valve tight. The governor cannot oper- ate correctly in this condition. 3. Check the governor stabilty by manually dis- turbing the governor speed setting. The com- pensation adjustment is satisfactory wnen the governor retums to speed with only a small overshoot or undershoot. Once the needle valve adjustment is correct, itis not necessary to change the setting unless there Is a large permanent change in temperature that will Change oil viscosity. Additional adjustment may be necesary if stability problems exist at {ull speed-full load conditions. PRESSURE Oil pump pressure in the 200 model should exceed 200 psi at operating speed. Pressure in the 300 foot- pound governor should exceed 300 psi at operating speed. To check the internal pressure attach a pressure gauge in the 562-18 straight-thread port indicated as oil from booster outlet number 1 in figures 2-1 end 2-2 of this manualSECTION 4 PRINCIPLES OF OPERATION INTRODUCTION This section describes the operation of the basic loments of the PG-200/300 case, accumulator and power cylinder assembly. A schematic drawing, figure 4-1, shows the working relationship of the various parts. The speed satting is in the column assembly of the PG-200/300 governor and only a short description is givento aid in understanding the basic operation ‘The description of operation is separated into two parts: 1. Amplifier section 2, Governor secti AMPLIFIER SECTION O/L PUMP AND ACCUMULATOR ‘The PG-200/200 has its own oll sump andi pump. The drive shaft is driven at a speed proportional to the engine speed by a mechanical connectiontothe engine, and rotates the pump drive gear and the rotating bushing. As theinner pump drive gearturns the outer gear, oil from the sump is drawn by the gear teeth to the discharge side of the pump. Oil is pushed from the spaces between the gear teeth as the two gears mesh. Four check valves, two on the suction and two on the discharge side of the pump, permitthe drive shaftto rotate in either direction without changing the PG- 200/300 operation. Ifthe pump gears were rotated in the opposite direction the open check valves would close anc the closed check valves wouta open, Oil on the discharge side of the pump pushes the accumulator piston against the accumulator spring When piston movement uncovers the bypass port. excess pressure oil from the pumpis returned tothe sump through the pressurizing valve or heat ox- changer. The accumulator is a reservoir for pressure oil and operates as a relief valve to limit maximum pressure inthis part of tne hydraulic circuit. Pressure is held at a minimum of 200 psi in the PG-200. Pressure in the PG-300 is 360 psi. When the PG- 200/300 is used with the optional heat exchanger, oil, flows through the heat exchanger from the accumulator bypass. If the oil flow through the ‘exchanger becomes restricted, and the pressure reaches 25 psi, the pressurizing valve opens and directs bypass oil back to sump. POWER SERVO ‘The relay pilot valve controls the flow of 200/360 psi oil to the power servo assembly. The power piston, working through connecting linkage, controls the engine or turbine. The power piston operates as a differential type, Fequiring pressure oil to move in either increase fuel ‘or decrease fuel direction. The differential piston has pressure oil continually directed to the small area side. The constant pressure tries to move the piston in the decrease fuel direction, but the piston ‘cannot move to decrease fuel until oil in the pas- sages between the relay piston and the (arge area ‘side of the servo piston is released to sump. Oil is, connected to the sump only when the relay pilot valve plunger is below its centered position. If the relay pitot valve plunger is above the centered Position, oit flows to the control (large area) side of the servo piston. The force that results fram oil pushing on the large surface area which is greater, than the constant force on the loading (small area) side, moves the piston iin the increase fuel direction. NOTE The power piston can move only when the relay pilot valve is uncentered and permits oil to flow. GOVERNOR SECTION The governing section of the PG-200/300 has @ pressure reducing valve, @ bailhead, pilot valve plunger, rotating bushing, a compensating system and a relay servo. "006/002-Dd 10 snEwaYDS “L-y BIN avi anaino Avv04, c (a wou to tae i 3 § i 2 EI PRESSURE REDUCING VALVE The pressure reducing vaive receivesthe full output of the oil pump and supplies 100 psi oll to the governing section and additional specd setting and auxiliary features included in the column assembly. 200/360 psioil enters the pressure reducing valveat, the metering piston and its flow is controllad by movement of the metering piston. Pressure on the metering piston that is greater than 100psi causes it to move left against a reterence spring, closing the Pressure reducer to restrict oil flow. Pressure lower ‘than 100 psi permits the reference spring to move the metering piston to enlarge the inlet, GOVERNING SECTION ‘The upper end of the rotating bushing holds the balinead assembly giving a direct drive from the Prime mover to the flyweights. The thrustbearingon top of the fiyweight toes permits the pilot valve plunger to remain stationary while the bushing fotates. This reduces friction between the bushing and plunger. spring driven, oil dampened balthead canbe used to filter objectionable input torsionals which could be transferred o the governor control output. These ballheads are more completely described in the Woodward Service Bulletin 50001, As tthe balihead rotates, centrifugal force developed by the flywaights tries to lift the pilot valve plunger and Is opposed by the force of the spaeder spring ‘fushing down. The greater of the two forces moves the pilot valve plunger. When the prime mover is on speed at any speed setting, these forces are equal anc the lyweights are ina vertical position. inthis position the control land on the pilot valve plunger is centered over the Control port in the rotating bushing. No oil, other than normal leakage, flows to or from the buffer ‘compensation system or the relay servo. A change in either of these two forces moves the plunger from its centered position. The plunger is lowered (1) when the governor speed setting is unchanged but additional load slows the prime mover and governor (decreasing flywelght centri- tugal forca). or (2) when prime mover speed is not changed but speeder spring force Is increases to raise the governor speed setting. In a similar way, the pilot vaive plunger is raised (1) when governor speed seiting is not changed but load is removed trom the prime mover causing an increase in speed (hence an increase in flyweight centritugal force), ‘oF {2) where prime mover speed is not changed but ‘speeder spring force is reduced to lower the gover- or speed setting. When thereis an underspeed condition, the plunger is lowered and pressure oil is directed into the butter, and compensation system and relay servo to raise the relay pilot vaive plunger and cause the power piston to move to increase fuel. In an overspeed ‘condition, the plungers|ifted permitting oil todrain ‘from these areas to the sump. A return spring moves ‘the relay piston to decrease and also lowers the felay pilot valve plunger, releasing oil from the left side of the power servo, allowing movement toward ‘decrease fuel. A butter piston-needie valve compensation system ‘which anticipatesthe inherent lag in accelerationor deceteration between throttle setting and final speed is provided in the PG-200/300 control system. With the governor reacting irectly on the fuel setting but sensing only actual engine or turbine speed, extensive over, or under, speed would occur at each speed change were it not for the butfer ‘compensation system. The buffer piston, springs and needle valve inthe hydraulic circuit between the pilot valve plunger and the relay servo make up the system When the flyweights move the pilot valve off the entered position, oll flow to, or from, the small power piston causes a pressure differential across the butter piston and needle valve. The restriction of flow through the needle valve causes oll to flow through the path that houses the buffer piston and springs and causes the buffer piston to move against the buffer spring on the low pressure side of the piston. The amount of pressure differential across this system is controlled by the combination of needle valve opening and butter spring scale. This pressure differential is sensed by the com- pensation land on the pilot valve, applying a force tending to oppose the change in force of the fiyweights and move the pilot valve back to the centered position before the set speed is reached This negative feecback (croop) reduces overshoot of the set speed and increases the stability of the contro! loop. The pressure differential gradually ‘equalizes through the needle valve anc the negative feedback disapates, returning speed to the set point, 8The rate at which this happens is controlled by the needle valve opening and by buffer spring scale. Stronger butter springs increase the effect, or gain, of the compensation and the needle vaive opening determines the recovery time. The smaller the open- ing the slower the recovery to set speed. The buffer spring scale is predetermined and specitied by the prime mover manufacturer or by Woodward Gover- nor Company. PG-200/300 The following two examples show the sequence of events during a spead setting change or load change. The sequence occurs within the governor almost ‘simultaneously ratherthan the step-by-step method described. INCREASE OF SPEED SETTING OR LOAD Increasing speed setting or increasing load on the prime mover operating at any given speed has an identical effect for the purpose of description. in either of these conditions, the rotating fiyweights mov in due to an increase in speeder spring force, or by the decrease in centrifugal force caused by the decrease in prime mover speed as load Is added. ‘When the flyweights movein, the pilot valve plunger moves down and directs pressure oil into the com- Penstion system, causing the butter piston to move tothe rightand forcing the relay servo to move inthe increase direction As the prime mover accelerates to the set speed the ‘compensation force gradually reduces to offset the increasing flyweight force. This isdone each time by balancing the pressures on both sides of the com pensation land through the needle valve. This re- duces overshaoot to quickly establish stable, on- speed operation, When large changes in speed setting or load af made. the bufter piston moves far enough to open a bypass port inthe butter cylinder. This permits oil to 4 flow directly to the relay servo and lets the governor respond quickly tolarge changes in speed setting or load. DECREASE OF SPEED SETTING OR LOAD ‘The results of decreasing the speed setting or load on the prime mover are the same, and cause an action in the reverse of that described above. The flyweights move out, lifting the pilot valve plunger, permitting oil to drain rom the compensating sys- tem and under the relay servo. The return spring causes the relay piston to move to decrease. The pressure differential across the compensation land this time causes a force down to help the speeder spring center the pilot valve plunger just before the prime mover has completely decelerated. This stops movement of the felay piston when the correct position is reached for the new lower speed setting or load, COMPENSATION CUTOFF With large decreases in speed setting or large load decreases, the small power piston moves to the ‘minimum fuel position and covers the compensation oil passage between the small servoand the needie valve to prevent normal balancing of the compen- sation pressures. This holds the butfer piston to the left of canter and increases the level of the pressure sent f0 the upper side af the compensation land. ‘The increased pressure differential, added to the compression of the speeder spring, temporarily increases the governor speed setting. The governor begins correcting a3 soon as the engine speed dropsbelow this temporary speed setting andstarts, the relay piston restoring the fuel supply in time to prevent a large underspeed transient. This action is called compensation cut off. When the relay piston ‘moves up and uncovers the compensation oil pas- Sage, normal compensation is again available and the engine keeps steady-state speed at the set speed of the governor.SECTIONS MAINTENANCE GOVERNOR OIL Use NEW OIL to fill the governor. Be sure that all containers used tor governor oil storage are clean, Contaminated governor oil will cause early wear of plungers, bushings, gears, bearings. etc., and can cause rust and corrosion on springs and other internal parts, Under normal operating conditions oil should be changed every 12 months. Oil must be changed ‘more often if the unit operates under unusual tem- perature or dirt conditions, “iter the governor is put in service, the oil ~vondition should be carefully monitored until a length of service can be established. A careful check of oil condition is suggested at least every three months untli length of service is established. Any time the oil looks dirty or appears to be breaking down from contamination or high pore, drain the governor oil while it is hot, lush with the lightest grade of the same oil and ‘ellll the governor with new off of the correct viscosity. (See oii viscosity table, (Ligure 2-2) or refer to Woodward manual 250714, Recommended Oils for Governors, Actuators.) TROUBLESHOOTING While a governor problem can show up as speed variations of the prime mover, not all speed vari tions of the prime mover are caused by a mi £ _ stion of the governor. When there is a problem, tonow these procedures: 1. Check that the load is not beyond the load limit of the prime mover. 2. Be sure the engine cylinders are firing and the fuel injectors are operating and correctly calibeated, 3. Check the linkage ‘rom the governor output to the fuel control. There must be no binding and a minimum amount of backlash. Check for fuel or steam pressure changes. 5. Be sure the compensating needle vaive is set correctly. 6. Check the governor external speed adjusting devices. 7. Check governor oil pressure at booster outlet port on the PG-200/300 case. Pressure in the PG-200 should be 200 psi. Pressure In the PG-300 should be 360 psi, Check at operating temperature and speed. 8 Check the governor oil and replace it if it is dirty. Sometimes the malfunction of the gover- nor can be corrected by flushing the governor ‘with fue! oil or Kerosene while the governor is operated through a cycle. 8. Check the drive to the governor for any evi- dence of the governor not being aligned cor- ‘rectly on the installation pad, rough gears, or backlash. 10. Manus number 36404, Analysis and Correc- tion of PG Governing Troubles, covers gover- nor malfunctioning and possible causes and corrective actions. REPAIR AND DISASSEMBLY ‘A governor can operate several years before it will need an overhaul if the oil is kept clean and tho drive from the prime mover is smooth and does not have torsional vibration. it disassembly and repair become necessary, the work must be done by personnel tained in the correct repair procedures. ‘The accumulator spring, (205) figure 6- 6, ls compressed and held in the accumu: tator assembly. Injury to person or da- mage to the equipment can result trom careless disassembly of this unit. Place the accumulator assembly In an arbor Press to permit a controlled rate of spring expansion. 15PARTS REPLACEMENT INFORMATION When ordering governor replacement perts, it is essential that the following information be given. 1. Governor serial number and part number as given on the nameplate. 2 Manual number (this is manual 36618). 3. Part reference number as given in the part fist, ‘ame of part, or description of part. REF. NO. 96618-7 36618-2 366183 3618-4 36618-5, 36618-6 3618-7 36618-8 16 PARTS LIST FOR FIGURE 6-1 PART NAME Relief valve plunger Relief valve spring Preformed packing -801 LD. x.070 Relief valve plug Retaining ring = 1.111 diameter Housing Preformed packing Plug - 438-20 UNF 2A ary aaae SECTION 6 PARTS INFORMATION REF. NO. 96618-9 3618-10 36618-11 36616-12 98618-13 98618-14 36818-15 96618-16 36618-17 36618-18 36818-19 36618-20 96818-21 96618-22 1368 18-23 96618-24 96818-25 966 18-26 96618-27 PART NAME Washer - 5001. Screw - .500-i3 x 2.500 Oil level gauge assembly Needle valve Preformed packing 301 1.0. x 070 Plug - 562-18 UNF 24 Preformed packing 468 1.0, x.078 Screw 500-13 x 2.000 (Screw, washers come from inside part 6) Washer .500 1.0. Washer, split lock Dowel Pin, 3742 dia. x 625 Gasket Case Plug - 082 pipe Plug -.750 Plug - .875-14 UNF 2A Preformed packing 755 LD. x 087 Plug - 125 Pin ary aaa passa panREF. NO. 38618-75 36618-76 38618-77 36618-78 3661879 3618-80 96618-81 36618-82 36618-83 96618-84 PARTS LIST FOR FIGURE 6-2 PART NAME ary REF. NO. ‘Screw -.250-28 x 500 2 36618-85 Washer -.250 2 96618-86 Washer -.7500.0.x 2661.0, 2 36618-87 Spring cover 1 36618-88 Preformed packing 36618-89 1.289 1,0. x.070 1 36618-90 Loading spring 1 36618-81 ‘Spring seat 1 36618-92 Pilot vaive sleeve 1 96018-93, Pilot valve spring seat 1 36618-94 1 Pilot valve plunger adjuster PART NAME Pilot valve lever assembly Cotter pin .062 Dia. x 375 Pin ~ 4862 Dia, x 900 Pin ~ 4871 Dia. x 531 Power piston assembly Tail rod lift nut Washer Not Used Pilot valve spring Pilot valve plunger assembly ae ae Figure 6-2. Parts for Power Piston Assembly and Pilot Valve Assembly ary