Woodward UG-40 Installation And Operation Manual
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Woodward UG-40 Installation And Operation Manual

Dial and lever governors
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Product Manual 03039
(Revision C, 3/2014)
Original Instructions
UG-40 Dial and Lever Governors
Installation and Operation Manual

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Summary of Contents for Woodward UG-40

  • Page 1 Product Manual 03039 (Revision C, 3/2014) Original Instructions UG-40 Dial and Lever Governors Installation and Operation Manual...
  • Page 2 Revisions—Changes in this publication since the last revision are indicated by a black line alongside the text. Woodward reserves the right to update any portion of this publication at any time. Information provided by Woodward is believed to be correct and reliable. However, no responsibility is assumed by Woodward unless otherwise expressly undertaken.

  • Page 3: Table Of Contents

    PERATION   Introduction ......................12   Component Description ..................12   Speed Droop ......................15   The UG-40 Dial Governor ..................17   Synchronizer ......................18   Operation of UG-40 Governor ................18 4. O ..........22  HAPTER PERATION AND DJUSTMENTS  ...
  • Page 4 Figure 6-2. UG-40 Ballhead Parts Illustration ............41   Figure 6-3. UG-40 Base Parts Illustration ............43   Figure 6-4. UG-40 Front Panel Parts Illustration ..........45   Figure 6-5. UG-40 Case Parts Illustration ............47   Figure 6-6. UG-40 Dial Cover Parts Illustration ............ 49  ...

  • Page 5: Warnings And Notices

    Start-up On- and off-highway Mobile Applications: Unless Woodward's control functions as the supervisory control, customer should install a system totally independent of the prime mover control system that...

  • Page 6: Electrostatic Discharge Awareness

    Do not touch the components or conductors on a printed circuit board with your hands or with conductive devices. 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.

  • Page 7: Chapter 1. General Information

    The maximum work output of the UG-40 is 50 ft-lb (67 J) when using the full 38- degree travel of the terminal shaft. Useful work capacity is 2/3 or 33 ft-lb (45 J) using 25 degrees of terminal-shaft travel.

  • Page 8: References

    0 to 7.5% at 1000 rpm and 0 to 9.5% at 800 rpm. Both figures assume 38 degrees of terminal shaft travel, A load-limit control Is a standard feature on the UG-40 Dial governor. It limits the amount of fuel supplied by restricting the travel of the governor output shaft. An indicator dial shows the setting of governor-output-shaft limit position.

  • Page 9: Chapter 2. Installation

    Receiving When you receive your UG-40 governor, it will be bolted to a wood platform in a vertical position. After testing the governor at the factory, it is drained of oil. This leaves a light film of oil covering the internal parts, preventing rust.

  • Page 10: Linkage Attachments

    1/2 hp (373 W) at normal speed and operating temperature. The UG-40 governor may be driven either clockwise or counterclockwise. Operating temperature range for the UG-40 governor is –20 to +210 °F (–29 to +99 °C) with proper viscosity oil.

  • Page 11: Figure 2-1. Outline Drawing Of Dial Type Governor

    Manual 03039 UG-40 Dial and Lever Governors Figure 2-1. Outline Drawing of Dial Type Governor Woodward...

  • Page 12: Figure 2-2. Outline Drawing Of Lever Type Governor

    UG-40 Dial and Lever Governors Manual 03039 Figure 2-2. Outline Drawing of Lever Type Governor Woodward...

  • Page 13: Oil Supply

    Regular oil maintenance will prolong the life and the reliability of a governor. Use clean containers and pouring spouts when filling the governor. Partially used cans of oil must not be used. The UG-40 does not have a filter system, and oil must be clean when added.
  • Page 14 UG-40 Dial and Lever Governors Manual 03039 In general, change the oil If:  The oil looks different than when it was new.  The oil feels gritty when rubbed between your fingers.  The oil smells different than when it was new.

  • Page 15: Oil Viscosity

    Manual 03039 UG-40 Dial and Lever Governors Alternate Method If it is not possible to shut down long enough to remove the governor from the prime mover, proceed as follows: While the governor is hot and shut down (not operating), remove the oil drain plug (next to the needle valve adjustment cover on the front of the governor base) and drain the oil from the governor.
  • Page 16 UG-40 Dial and Lever Governors Manual 03039 The high-temperature limit shows an oil viscosity of 50 SUS. The governor will operate at temperatures near the high temperature limit, but governor operation can become unstable if the oil is too thin.
  • Page 17 Manual 03039 UG-40 Dial and Lever Governors Table 2-2. Equivalent Viscosities for Lubricating Oils Woodward...

  • Page 18: Chapter 3. Principles Of Operation

    Principles of Operation Introduction Basic UG-40 operation is similar for both dial and lever types. The only difference is in the method of setting speed and speed droop. Auxiliary devices provide different functions, but do not alter the basic operation of the governor.
  • Page 19 Manual 03039 UG-40 Dial and Lever Governors Oil Pump The oil pump (12, Figure 3-1) provides oil pressure for the governor. The pump gets oil from the self-contained sump (13). Four check valves (11) allow the positive displacement gear pump to operate either clockwise or counterclockwise.
  • Page 20 UG-40 Dial and Lever Governors Manual 03039 The bushing is rotated by the drive shaft (17), and, through this rotation friction between the pilot-valve plunger (PVP) and the bushing is reduced. The PVP has a control land that regulates oil flow through ports in the bushing.

  • Page 21: Speed Droop

    Adjustments.) Speed Droop The UG-40 Lever governor may be equipped at the factory with a speed-droop assembly (see Figure 3-2). The Dial governor has built-in droop and a droop- setting knob on the control panel (35, 37, and 39, Figure 3-3).

  • Page 22: Figure 3-2. Lever Governor Speed Droop Assembly

    UG-40 Dial and Lever Governors Manual 03039 As the governor output shaft moves to increase fuel, the speeder-spring compression Is reduced, which reduces the governor speed setting. The unit starts reducing its speed as load is applied. When the governor output shaft moves to decrease fuel, the speeder-spring compression is increased, which increases the governor speed setting.

  • Page 23: The Ug-40 Dial Governor

    The UG-40 Dial Governor Operation of the UG-40 Dial governor is identical to that of the UG-40 Lever governor just described, with the exceptions that speed droop, which may be changed by a dial setting, is incorporated in all UG-40 Dial governors, and all UG-40 Dial governors have load-limit control.

  • Page 24: Synchronizer

    Operation of UG-40 Governor Refer to Figure 3-1 with this text to better understand the operation of the UG-40 governor. This schematic diagram is of a basic design and does not include any auxiliary equipment. Figure 3-3 is the basic Dial governor schematic and includes the speed-setting additions which are not on the UG-40 Lever governor.

  • Page 25: Figure 3-3. Ug-40 Dial Governor Schematic

    Manual 03039 UG-40 Dial and Lever Governors Figure 3-3. UG-40 Dial Governor Schematic Woodward...
  • Page 26 UG-40 Dial and Lever Governors Manual 03039 Decrease in Load Assume the prime mover is running “on-speed.” The flyweights are in a vertical position for normal, steady-state operation. The control land of the pilot-valve plunger (14) is centered over the control port. As a result, there is no movement of the power piston (7) and no movement of the governor output shaft (6).
  • Page 27 Manual 03039 UG-40 Dial and Lever Governors This lowers the pilot-valve plunger, opening the control port in the rotating bushing. Pressure oil is released through the control port to the bottom side of the power piston. The pressure oil, acting on the greater area of the bottom side of the power...

  • Page 28: Chapter 4. Operation And Adjustments

    An overtemperature or overpressure shutdown device may also be needed for safety, as appropriate. Before initial operation of the UG-40, be sure all previous installation steps have been successfully accomplished and all linkages are secure and properly arranged and attached (see Chapter , Installation Procedures).
  • Page 29 Manual 03039 UG-40 Dial and Lever Governors Compensation must be properly adjusted to the particular engine and load to provide stable operation. When the engine, turbine, or other type of prime mover is started for the first time after the governor has been filled with oil, the governor may be stable at constant speed, yet need adjustment.

  • Page 30: Initial Operation For A Repaired Or Reassembled Governor

    If accurate tests and adjustments are to be made, it is best to use a test stand. It is difficult to make accurate tests when the governor is mounted on an engine. Contact Woodward for a copy of the test specifications for each governor designation.

  • Page 31: Test Procedures On The Engine

    Test Procedures on the Engine These adjustments and test procedures are provided for the particular type of governor being tested. Procedures are listed in entirety for testing the UG-40 Dial governor, the UG-40 Lever governor without droop, and the UG-40 Lever governor with droop.
  • Page 32 11. To prevent speed-setting changes because of engine vibrations, a friction drive is installed in the speed-setting mechanical drive to the UG-40 governor. If the friction drive is too tight, the speed-setting knob can no longer be turned manually.

  • Page 33: Figure 4-1. Friction Clutch

    Manual 03039 UG-40 Dial and Lever Governors Figure 4-1. Friction Clutch 12. Reassemble the friction drive. 13. Set the maximum- and/or minimum-speed limit on the governor. This adjustment can also be made with the prime mover running. To make the adjustment, first remove the governor dial plate.
  • Page 34 Adjust the cams by loosening the screws and turning the cams on the shaft. Tighten the screws again. 18. On governors equipped with solenoid shutdown, please refer to Woodward manual 03013 for setup procedures. 19. Turn the load-limit knob to zero. The load-limit indicator must move to zero.

  • Page 35: Figure 4-2. Lever Governor Droop Cam

    Manual 03039 UG-40 Dial and Lever Governors Figure 4-2. Lever Governor Droop Cam Set the compensation-adjusting pointer at mid-point on the pointer scale. If the governor is tested on the engine start the prime mover according to the instructions from the manufacturer, then run the governor until it is at operating temperature.
  • Page 36 Apply a pipe sealer to the threads and torque pipe plug to 90 lb-in (10 Nm). UG-40 Lever Governor without Droop Test Remove a pipe plug from the base and attach a pressure gauge capable of measuring In excess of 250 psi (1724 kPa). Pressure may be checked from any of the three positions on the base not on the same side as the needle valve.

  • Page 37: Test Completion

    Manual 03039 UG-40 Dial and Lever Governors The operator must manually control engine speed until it is proven that the governor will go to minimum position and cause the fuel valve to go to minimum position, Engine overspeed could occur if the governor is unable to move the fuel control to minimum.
  • Page 38 UG-40 Dial and Lever Governors Manual 03039 Table 4-1. Test Stand Tools Tool Description Woodward Number Application Hydraulic Test 205975, air drive; 8909- Engine simulator. Drives governor, Stand 094 electric drive or supplies pressure oil. Includes gauges equivalent for testing.

  • Page 39: Chapter 5. Troubleshooting

    Manual 03039 UG-40 Dial and Lever Governors Chapter 5. Troubleshooting It is Impossible to anticipate every kind of trouble that is encountered in the field. This manual covers the most common troubles experienced. Poor governing can be due to faulty governor performance, or it can be due to the governor attempting to correct for faulty operation of the engine or the equipment driven.
  • Page 40 UG-40 Dial and Lever Governors Manual 03039 Table 5-1. Troubleshooting Trouble Cause Correction 1. Engine hunts or A. Compensation adjustments Adjust needle valve and compensation surges. incorrect. adjusting pointer. B. Dirty oil In governor-sludge. Drain oil, clean governor, and refill.
  • Page 41 Manual 03039 UG-40 Dial and Lever Governors The keyed drive can be a source of trouble because of its installation problems which include: 1. Inherent side loading transmitted to the governor drive shaft from the bevel gear drive. 2. Shimming required to obtain proper mesh without binding or excessive backlash.
  • Page 42 UG-40 Dial and Lever Governors Manual 03039 Trouble Cause Correction 7. Load does not divide A. Speed settings of the Adjust speed setting so both engines properly on governors are not the same. have the same load. interconnect ed B. Speed droop adjustment Readjust droop to divide load properly.

  • Page 43: Chapter 6. Replacement Parts

    Manual 03039 UG-40 Dial and Lever Governors Chapter 6. Replacement Parts When ordering replacement parts, include the following information:  Governor serial number and part number shown on nameplate  Manual number (this is manual 03039)  Parts reference number in parts list and description of part or part name...
  • Page 44 UG-40 Dial and Lever Governors Manual 03039 Parts for Figure 6-1 Ref. No. Part Name ........Quantity 03039-1 Ballhead bracket ........1 03039-2 Screw, 0.312-24 x 0.750 ......2 03039-3 Shakeproof washer, 0.312 ......3 03039-4 Spring ............2 03039-5 Accumulator cylinder .........

  • Page 45: Figure 6-1. Ug-40 Controlet Parts Illustration

    Manual 03039 UG-40 Dial and Lever Governors Figure 6-1. UG-40 Controlet Parts Illustration Woodward...
  • Page 46 UG-40 Dial and Lever Governors Manual 03039 Parts for Figure 6-2 Ref. No. Part Name ........Quantity 03039-71 Speed droop lever ........1 03039-72 Cotter pin, 0.062 x 0.500 long ....3 03039-73 Pin ............. 1 03039-74 Speeder screw pin ........1 03039-75 Speeder screw ...........

  • Page 47: Figure 6-2. Ug-40 Ballhead Parts Illustration

    Manual 03039 UG-40 Dial and Lever Governors Figure 6-2. UG-40 Ballhead Parts Illustration Woodward...
  • Page 48 UG-40 Dial and Lever Governors Manual 03039 Parts for Figure 6-3 Ref. No. Part Name ........Quantity 03039-101 Base ............1 03039-102 Dowel pin ........... 4 03039-103 Check valve ..........2 03039-104 Plug, 0.125-27 ........... 4 03039-105 Plug, 0.250-18 ........... 1 03039-106 Compensating screw .........

  • Page 49: Figure 6-3. Ug-40 Base Parts Illustration

    Manual 03039 UG-40 Dial and Lever Governors Figure 6-3. UG-40 Base Parts Illustration Woodward...
  • Page 50 UG-40 Dial and Lever Governors Manual 03039 Parts for Figure 6-4 Ref. No. Part Name ......Quantity Ref. No. Part Name ......Quantity 03039-151 Retaining ring ........1 03039-186 Oil seal ..........1 03039-152 Friction drive cover ......1 03039-187 Pin ............

  • Page 51: Figure 6-4. Ug-40 Front Panel Parts Illustration

    Manual 03039 UG-40 Dial and Lever Governors Figure 6-4. UG-40 Front Panel Parts Illustration Woodward...
  • Page 52 UG-40 Dial and Lever Governors Manual 03039 Parts for Figure 6-5 Ref. No. Part Name ........Quantity 03039-226 Case ............1 03039-227 Roller bearing ..........2 03039-228 Oil seal ............2 03039-229 Terminal shaft ..........1 03039-230 Cotter pin, 0.094 D x 1.25 L ....... 1 03039-231 Pipe plug ............

  • Page 53: Figure 6-5. Ug-40 Case Parts Illustration

    Manual 03039 UG-40 Dial and Lever Governors Figure 6-5. UG-40 Case Parts Illustration Woodward...
  • Page 54 UG-40 Dial and Lever Governors Manual 03039 Parts for Figure 6-6 Ref. No. Part Name ........Quantity 03039-276 Motor assy ..........1 03039-277 Motor seal spring ........1 03039-278 Bracket ............1 03039-279 Fil. hd. screw, 8-32 x 0.438 ......4 03039-280 Shakeproof washer, 8 ........

  • Page 55: Figure 6-6. Ug-40 Dial Cover Parts Illustration

    Manual 03039 UG-40 Dial and Lever Governors Figure 6-6. UG-40 Dial Cover Parts Illustration Woodward...
  • Page 56 UG-40 Dial and Lever Governors Manual 03039 Parts for Figure 6-7 Ref. No. Part Name ......Quantity Ref. No. Part Name ......Quantity 03039-301 Oil cap ..........1 03039-343 Hex head bolt ........1 03039-302 Low speed stop screw ......1 03039-343A Lock washer ........

  • Page 57: Figure 6-7. Ug-40 Lever Case Parts Illustration

    Manual 03039 UG-40 Dial and Lever Governors Figure 6-7. UG-40 Lever Case Parts Illustration Woodward...

  • Page 58: Chapter 7. Product Support And Service Options

    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.

  • Page 59: Product Service Options

    Manual 03039 UG-40 Dial and Lever Governors 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.

  • Page 60: Replacement Parts

    Field Service engineering on-site support is available, depending on the product and location, from one of our Full-Service Distributors. The field engineers are experienced both on Woodward products as well as on much of the non- Woodward equipment with which our products interface.

  • Page 61: Technical Assistance

    UG-40 Dial and Lever Governors Technical Assistance If you need to contact technical assistance, you will need to provide the following information. Please write it down here before contacting the Engine OEM, the Packager, a Woodward Business Partner, or the Woodward factory: General...

  • Page 62: Revision History

    UG-40 Dial and Lever Governors Manual 03039 Revision History Changes in Revision C—  Added overhaul interval information to Chapter 7 Woodward...
  • Page 63 Email and Website—www.woodward.com Woodward has company-owned plants, subsidiaries, and branches, as well as authorized distributors and other authorized service and sales facilities throughout the world. Complete address / phone / fax / email information for all locations is available on our website.

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