Installation Instructions

Bosch RSV Governor

Shutdown Kit
with 1751 & 1751ES Solenoids









Manual 36706


WARNINGDANGER OF DEATH OR PERSONAL INJURY

WARNINGFOLLOW INSTRUCTIONS
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.

WARNINGOUT-OF-DATE PUBLICATION
This publication may have been revised or updated since this copy was produced. To verify
that you have the latest revision, be sure to check the Woodward website:
www.woodward.com/pubs/current.pdf
The revision level is shown at the bottom of the front cover after the publication number. The
latest version of most publications is available at:
www.woodward.com/publications
If your publication is not there, please contact your customer service representative to get
the latest copy.

WARNINGOVERSPEED PROTECTION
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.

WARNINGPROPER USE
Any unauthori zed modi fi cati ons to or use of thi s equi pment outsi de i ts speci fi ed
mechani cal , el ectri cal , or other operati ng l i mi ts may cause personal i nj ury and/or property
damage, i ncl udi ng damage to the equi pment. Any such unauthori zed modi fi cati ons: (i )
consti tute " mi suse" and/or " negl i gence" wi thi n the meani ng of the product warranty
thereby excl udi ng warranty coverage for any resul ti ng damage, and (i i ) i nval i date product
certi fi cati ons or l i sti ngs.


CAUTIONPOSSIBLE DAMAGE TO EQUIPMENT OR PROPERTY

CAUTIONBATTERY CHARGING
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.

CAUTIONELECTROSTATIC DISCHARGE
Electronic controls contain static-sensitive parts. Observe the following precautions to
prevent damage to these parts.
Discharge body static before handling the control (with power to the control turned off,
contact a grounded surface and maintain contact while handling the control).
Avoid all plastic, vinyl, and Styrofoam (except antistatic versions) around printed circuit
boards.
Do not touch the components or conductors on a printed circuit board with your hands
or with conductive devices.

IMPORTANT DEFINITIONS
A WARNING indicates a potentially hazardous situation which, if not avoided, could result in
death or serious injury.
A CAUTION indicates a potentially hazardous situation which, if not avoided, could result in
damage to equipment or property.
A NOTE provides other helpful information that does not fall under the warning or caution
categories.

RevisionsText 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 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 2008
All Rights Reserved

Manual 36706 RSV Type Bosch Governor Shutdown Kit


Woodward i
Contents


ELECTROSTATIC DISCHARGE AWARENESS .................................................. II
CHAPTER 1. GENERAL INFORMATION........................................................... 1
Description..............................................................................................................1
Dimensions.............................................................................................................1
Parts List.................................................................................................................2
CHAPTER 2. INSTALLATION.......................................................................... 3
Parts Removal........................................................................................................3
New Hardware Installation.....................................................................................3
Solenoid Wiring......................................................................................................5
Optional Connectors.......................................................................................5
Checking the Installation........................................................................................5
CHAPTER 3. SERVICE OPTIONS ................................................................... 6
Product Service Options.........................................................................................6
Returning Equipment for Repair.............................................................................7
Replacement Parts.................................................................................................8
How to Contact Woodward.....................................................................................8
Engineering Services .............................................................................................9
Technical Assistance............................................................................................10

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ii Woodward
Electrostatic Discharge Awareness

All electronic equipment is static-sensitive, some components more than others.
To protect these components from static damage, you must take special
precautions to minimize or eliminate electrostatic discharges.

Follow these precautions when working with or near the control.

1. Before doing maintenance on the electronic control, discharge the static
electricity on your body to ground by touching and holding a grounded metal
object (pipes, cabinets, equipment, etc.).

2. Avoid the build-up of static electricity on your body by not wearing clothing
made of synthetic materials. Wear cotton or cotton-blend materials as much
as possible because these do not store static electric charges as much as
synthetics.

3. Keep plastic, vinyl, and Styrofoam materials (such as plastic or Styrofoam
cups, cup holders, cigarette packages, cellophane wrappers, vinyl books or
folders, plastic bottles, and plastic ash trays) away from the control, the
modules, and the work area as much as possible.

4. Do not remove the printed circuit board (PCB) from the control cabinet
unless absolutely necessary. If you must remove the PCB from the control
cabinet, follow these precautions:

Do not touch any part of the PCB except the edges.

Do not touch the electrical conductors, the connectors, or the
components with conductive devices or with your hands.

When replacing a PCB, keep the new PCB in the plastic antistatic
protective bag it comes in until you are ready to install it. Immediately
after removing the old PCB from the control cabinet, place it in the
antistatic protective bag.



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.

Manual 36706 RSV Type Bosch Governor Shutdown Kit


Woodward 1
Chapter 1.
General Information


Description

The Woodward Bosch RSV Governor Shutdown Kit is designed for engines
using Bosch pump models A, MW, and P with an RSV governor. The kit comes
in left- and right-hand mounting styles. The solenoid included in the kit is either
the 1751ES externally switched (3 wire) solenoid or the 1751 internally switched
solenoid.

RIGHT-HAND MOUNTED KITS

PART NO. SOLENOID MODEL VOLTAGE
SA-3799-12 1751ES 12 Vdc
SA-3799-24 1751ES 24 Vdc
SA-3800-12 1751 12 Vdc
SA-3800-24 1751 24 Vdc

LEFT-HAND MOUNTED KITS

PART NO. SOLENOID MODEL VOLTAGE
SA-3742-12 1751ES 12 Vdc
SA-3742-24 1751ES 24 Vdc
SA-3765-12 1751 12 Vdc
SA-3765-24 1751 24 Vdc


Dimensions


RSV Type Bosch Shutdown Kit Manual 36706


2 Woodward

Parts List

Refer to Figure 1 for parts identification.
















Figure 1. Kit Components


REF NO. DESCRIPTION QTY.
1 M6 Split Lockwasher 5
2 Run/Stop Lever 1
3 Solenoid/Bracket Assembly 1
4 M6 Flatwasher 3
5 M6 x 55mm Mounting Screws 2
6 Support Rod 1
7 M6 x 16mm Hex Screw 1
8 M6 x 1 Hex Nut 1
9 Spring Clip 1
Manual 36706 RSV Type Bosch Governor Shutdown Kit


Woodward 3
Chapter 2.
Installation




NOTE
Before removing old parts or installing new ones, ensure
that the engine is turned off and the battery is disconnected.
Always use proper tools for the installation.


Parts Removal

Figure 2 shows the hardware to be removed before installing the shutdown
kit.

1. Remove all parts labeled "A through F in Figure 2.
2. Retain Parts A (screw) and C (spring cover) for use when installing
the new kit.



Figure 2. Removal of Old Hardware


New Hardware Installation

Refer to Figure 3.
1. Install the spring cover (C) removed previously.
2. Install the new run/stop lever (2). Note the proper orientation of this
piece as shown in Figure 3.
3. Install the lockwasher (1) and screw (A) that was removed
previously. Torque screw to 5-7 Nm (3.5 to 5 ft-lb).
4. Install the solenoid/bracket assembly (3), screws (5), lockwashers
(1), and flatwashers (4), to the pump. Torque screws to 5-7 Nm
(3.5 to 5 ft-lb).
RSV Type Bosch Shutdown Kit Manual 36706


4 Woodward
5. Slip the hook-shaped end of the solenoid linkage (the length setting is factory
preset) through the hole in the new run/stop lever. Attach spring clip (9) to
lock the solenoid linkage rod to the run/stop lever.
6. Install support rod (6) and insert the threaded end through the hole on the
solenoid/bracket assembly.
7. Insert the bolt (7) and lockwasher as shown in Figure 3 and torque the bolt
5-7 Nm (3.5 to 5 ft-lb).
8. Slip the flatwasher, lockwasher, and hex nut (8) onto the support rod. Note
that the support rod fits through a certain mounting hole in the
solenoid/bracket assembly. Tighten the hex nut until the solenoid/bracket
assembly is flush against the face of the washer on the support rod.
Figure 4 shows the kit completely installed.


Figure 3. Parts View



Figure 4. Completely Installed Kit
Manual 36706 RSV Type Bosch Governor Shutdown Kit


Woodward 5
Solenoid Wiring
1751ES SOLENOID



NOTE
For wiring and installation instructions refer to Manual
36542 Externally Switched Dual Coil Solenoid Wiring
Guide available on www.woodward.com.

Because this kit is designed only for fuel shutdown applications,
refer to the Electric Shut-Off Applications chapter in Manual 36542
for installation and wiring instructions.
The 1751ES model can use all the relay, coil commander, and
PCTM wiring methods mentioned in the wiring guide. Do not use
" S" Terminal wiring!
For leaded units, wire configurations are pull coil (white), hold coil
(red), common (black).

1751 SOLENOID



NOTE
For wiring and installation instructions refer to Manual
36575 Internally Switched Dual Coil Solenoid Wiring Guide
available on www.woodward.com.

Optional Connectors

For varied connection requirements, Woodward has many optional
connectors available: ES system connectors, Packard Weather Pack
connectors, Metri-Pack sealed connectors, etc.


Checking the Installation



NOTE
For detailed troubleshooting information on the solenoid
refer to Manual 36541 Solenoid Troubleshooting Guide
available on www.woodward.com.


To perform a solenoid installation final check:
1. Start and stop the engine to check for proper operation of the
shutdown system.
2. For the 1751 internally switched model, make sure that the solenoid
fully "bottoms out," since this action prevents solenoid burnout.
3. Follow the suggested wiring sizes and overload protection
instructions listed in the wiring guides mentioned above.

RSV Type Bosch Shutdown Kit Manual 36706


6 Woodward
Chapter 3.
Service Options


Product Service Options

The following factory options are available for servicing Woodward
equipment, based on the standard Woodward Product and Service Warranty
(5-01-1205) that is in effect at the time the product is purchased from
Woodward or the service is performed:
Replacement/Exchange (24-hour service)
Flat Rate Repair
Flat Rate Remanufacture

If you are experiencing problems with installation or unsatisfactory
performance of an installed system, the following options are available:
Consult the troubleshooting guide in the manual.
Contact Woodward technical assistance (see How to Contact
Woodward later in this chapter) and discuss your problem. In most
cases, your problem can be resolved over the phone. If not, you can
select which course of action you wish to pursue based on the available
services listed in this section.


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).

This option allows you to call in the event of an unexpected outage, or in
advance of a scheduled outage, to request a replacement control unit. If the
unit is available at the time of the call, it can usually be shipped out within 24
hours. You replace your field control unit with the like-new replacement and
return the field unit to the Woodward facility as explained below (see
Returning Equipment for Repair later in this chapter).

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.]

Return Shipment Authorization Label. To ensure prompt receipt of the
core, and avoid additional charges, the package must be properly marked. A
return authorization label is included with every Replacement/Exchange unit
that leaves Woodward. The core should be repackaged and the return
authorization label affixed to the outside of the package. Without the
authorization label, receipt of the returned core could be delayed and cause
additional charges to be applied.
Manual 36706 RSV Type Bosch Governor Shutdown Kit


Woodward 7
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.


Flat Rate Remanufacture

Flat Rate Remanufacture is very similar to the Flat Rate Repair option with
the exception that the unit will be returned to you in like-new condition and
carry with it the full standard Woodward product warranty (Woodward
Product and Service Warranty 5-01-1205). This option is applicable to
mechanical products only.


Returning Equipment for Repair

If a control (or any part of an electronic control) is to be returned to
Woodward for repair, please contact Woodward in advance to obtain a
Return Authorization Number. When shipping the item(s), attach a tag with
the following information:
name and location where the control is installed;
name and phone number of contact person;
complete Woodward part number(s) and serial number(s);
description of the problem;
instructions describing the desired type of repair.



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.
RSV Type Bosch Shutdown Kit Manual 36706


8 Woodward
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.


How to Contact Woodward

In North America use the following address when shipping or corresponding:
Woodward Governor Company
PO Box 1519
1000 East Drake Rd
Fort Collins CO 80522-1519, USA

Telephone+1 (970) 482-5811 (24 hours a day)
Toll-free Phone (in North America)1 (800) 523-2831
Fax+1 (970) 498-3058

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.

Facility Phone Number
Brazil +55 (19) 3708 4800
India +91 (129) 4097100
J apan +81 (476) 93-4661
The Netherlands +31 (23) 5661111


You can also contact the Woodward Customer Service Department or
consult our worldwide directory on Woodwards website
(www.woodward.com) for the name of your nearest Woodward distributor
or service facility.
Manual 36706 RSV Type Bosch Governor Shutdown Kit


Woodward 9
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 protected]
Websitewww.woodward.com

Technical Support is available through our many worldwide locations or our
authorized distributors, depending upon the product. This service can assist
you with technical questions or problem solving during normal business
hours. Emergency assistance is also available during non-business hours by
phoning our toll-free number and stating the urgency of your problem. For
technical support, please contact us via telephone, email us, or use our
website and reference Customer Services and then Technical Support.

Product Training is available at many of our worldwide locations (standard
classes). We also offer customized classes, which can be tailored to your
needs and can be held at one of our locations or at your site. This training,
conducted by experienced personnel, will assure that you will be able to
maintain system reliability and availability. For information concerning
training, please contact us via telephone, email us, or use our website and
reference Customer Services and then Product Training.

Field Service engineering on-site support is available, depending on the
product and location, from one of our many worldwide locations or from one
of our authorized 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. For field service engineering assistance,
please contact us via telephone, email us, or use our website and reference
Customer Services and then Technical Support.
RSV Type Bosch Shutdown Kit Manual 36706


10 Woodward
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

Prime Mover Information
Engine/Turbine Model Number
Manufacturer
Number of Cylinders (if applicable)
Type of Fuel (gas, gaseous, steam, etc)
Rating
Application

Control/Governor Information
Please list all Woodward governors, actuators, and electronic controls in your system:

Woodward Part Number and Revision Letter

Control Description or Governor Type

Serial Number

Woodward Part Number and Revision Letter

Control Description or Governor Type

Serial Number

Woodward Part Number and Revision Letter

Control Description or Governor Type

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.


Manual 36706 RSV Type Bosch Governor Shutdown Kit


Woodward 11








We appreciate your comments about the content of our publications.

Send comments to: [email protected]

Please include the manual number from the front cover of this publication.









































PO Box 1519, Fort Collins CO 80522-1519, USA
1000 East Drake Road, Fort Collins CO 80525, USA
Phone +1 (970) 482-5811 Fax +1 (970) 498-3058

Email and Websitewww.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.



2008/01/Niles