Installation and Operation Manual: Booster Servomotor

Installation and Operation Manual
Booster Servomotor
Single Cylinder (8901-037, -043, -051)

Tandem (8901-065, -067)
Two-Stage (8901-091, -103)
Manual 36684M
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.
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
WARNING—indicates a potentially hazardous situation which, if not avoided, could
result in death or serious injury.
CAUTION—indicates a potentially hazardous situation which, if not avoided, could

result in damage to equipment.
NOTE—provides other helpful information that does not fall under the warning or
caution categories.
Revisions—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
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 1974, 1998
All Rights Reserved
Manual 36684 Booster Servomotor
Contents
CHAPTER 1. GENERAL INFORMATION ........................................................... 1

Introduction.............................................................................................................1
Description..............................................................................................................1
Types of Boosters...................................................................................................1
Regulatory Compliance ..........................................................................................2
CHAPTER 2. INSTALLING AND ADJUSTING A BOOSTER SERVOMOTOR ........... 7
General Rules.........................................................................................................7
Installing and Adjusting a Single Cylinder Booster.................................................7
Installing and Adjusting a Tandem Booster............................................................8
Installing and Adjusting a Two-Stage Booster .......................................................9
CHAPTER 3. PRINCIPLES OF OPERATION ................................................... 15
How Single-Cylinder and Tandem Boosters Operate ..........................................15
How a Two-Stage Booster Operates ...................................................................16
CHAPTER 4. REPLACEMENT PARTS ........................................................... 18
Ordering Replacement Parts................................................................................18
Parts List for Figure 4-1 ........................................................................................18
CHAPTER 5. SERVICE OPTIONS ................................................................. 23
Product Service Options.......................................................................................23
Returning Equipment for Repair...........................................................................24
Replacement Parts ...............................................................................................25
How to Contact Woodward...................................................................................25
Engineering Services ...........................................................................................26
Technical Assistance............................................................................................27
Illustrations and Tables
Figure 1-1. Schematic of Single Booster Connections to PG-Type Governor.......3

Figure 1-2. Schematic of Tandem Booster Connections to PG-Type Governor....3
Figure 1-3. Outline Drawing of Single Booster.......................................................4
Figure 1-4. Outline Drawing of Tandem Booster....................................................5
Figure 1-5. Outline Drawing of Two-Stage Booster ...............................................6
Figure 2-1. Governors Used with Single-Cylinder Boosters ................................11
Figure 2-2. Governors Used with Single-Cylinder Boosters ................................12
Figure 2-3. Governors Used with Tandem Boosters............................................13
Figure 2-4. Governors Used with Two-Stage Boosters .......................................14
Figure 3-1. Single Booster, Phase 1 ....................................................................15
Figure 3-2. Single Booster, Phase 2 ....................................................................15
Figure 3-3. Two-Stage Booster, Phase 1.............................................................16
Figure 4-1. Exploded View of Single Boosters.....................................................19
Figure 4-2. Exploded View of Tandem Boosters..................................................20
Figure 4-3. Exploded View of Two-Stage Boosters .............................................22
Woodward i
Booster Servomotor Manual 36684
ii Woodward
Chapter 1.
General Information
Introduction
This manual covers the three types of Woodward booster servomotor:
• Low-volume, single-cylinder booster
• Medium-volume, double-cylinder (tandem) booster
• High-volume, two-stage booster
Description
A booster servomotor supplies pressurized oil to mechanical-hydraulic governors
and electro-hydraulic actuators at the instant starting air reaches the engine. This
instant oil pressure eliminates the time required for the rotary gear pump in the
governor to build up enough oil pressure to move the linkage. This produces a
faster start, which conserves starting air, and in vessels with direct reversible
engines, improves maneuverability.
When the booster is inactive, a piston is held at one end of a cylinder by a spring.
The cylinder is full of oil supplied from a line from the governor's sump.
Compressed air applied to the side of the piston opposite this oil forces the
piston against the oil, which flows through ports at the other end of the cylinder to
the governor.
When air is removed from the piston, the spring returns the piston to its rest
position. Reduced pressure in the cylinder causes oil to flow into it from the
sump.
Check valves at all oil ports allow oil to flow in only one direction. This prevents
oil in the booster from flowing back to the governor's sump when the booster
operates, and prevents oil in the booster outlet lines from flowing back into the
booster when it is inactive.
Types of Boosters
Boosters are available with different air-to-oil pressure ratios, making them
suitable for both high and low air pressure applications:
Model Type Pressure Ratio
(Oil Out to Air In)
8901-037, -043 single-cylinder 1:1
8901-051 single-cylinder 2:1
8901-065 tandem 1:1
8901-067 tandem 2:1
8901-091 two-stage 2:1
8901-103 two-stage 3:1
Single-cylinder boosters supply enough oil for governors with small and medium
work outputs, such as UG-8/-40, EGB-10/-13, 3161, and PG governors with
outputs of 16 and 23 J (12 and 17 ft-lbs).
Woodward 1
Tandem boosters, with larger volumes of oil and three oil outlets, are appropriate
for PG-29/-58, EG-29/-58, and PG-TM 58 governors (39/79 J; 29/58 ft-lb).
Two-stage, high-volume boosters meet the boost oil requirements for PG, EGB,
and PG-TM governors with 271, 407, and 678 J (200, 300, and 500 ft-lb) power
cases.
Single-Cylinder Booster (Figures 1-1 and 1-3)

Single-cylinder boosters have two oil outlets: one is unrestricted, and one has a
built-in orifice-type restriction. Outlet #1 (unrestricted) is connected directly to the
governor's oil pressure system. Outlet #2 (restricted) can be used to pressurize
the speed setting servo, which compresses the speeder spring of PGA, PGPL,
and PGG governors equipped with any shutdown feature.
A single-cylinder booster has two air inlets, one restricted and one unrestricted.
Using the restricted air inlet results in slower movement of the fuel rack.
Tandem Booster (Figures 1-2 and 1-4)

Tandem boosters have two cylinders and three oil outlets. Outlet #1 is
unrestricted. The other two outlets are restricted by an adjustable needle valve.
Oil outlet #1 is connected to the governor's accumulator. Outlet #2 is connected

to the speed setting servo (of PGA, PGPL, and PGG governors equipped with
any shutdown feature). Outlet #3 is connected to a point directly under the power
piston.
If outlet #2 is used, its needle valve determines the rate at which the speeder
spring is compressed. The needle valve in outlet #3 controls the rate at which the
power piston moves.
Two-Stage Booster (Figures 1-5, 2-4, and 3-3)

Two-stage boosters have three oil outlets, but a two-stage feature allows oil to
flow through outlet #2 before it flows through the other two outlets.
In most applications, outlet #1 supplies oil to the power piston in the governor.
Outlet #2 supplies oil to the speed setting servo (of PGA, PGPL, and PGG
governors equipped with any shutdown feature). Outlet #3 supplies oil to the
relay piston.
Regulatory Compliance
Compliance with the following European Directives or standards does not qualify
this product for application of the CE Marking:
Machinery Directive: Compliance as a component with 98/37/EC

COUNCIL DIRECTIVE of 23 July 1998 on the
approximation of the laws of the Member States
relating to machinery.
Pressure Equipment Compliant as “SEP” per Article 3.3 to Pressure
Directive: Equipment Directive 97/23/EC of 29 May 1997 on
the approximation of the laws of the Member States
concerning pressure equipment.
2 Woodward
Figure 1-1. Schematic of Single Booster Connections to PG-Type Governor
Figure 1-2. Schematic of Tandem Booster Connections to PG-Type Governor
Woodward 3
Figure 1-3. Outline Drawing of Single Booster
4 Woodward
Figure 1-4. Outline Drawing of Tandem Booster
Woodward 5
Figure 1-5. Outline Drawing of Two-Stage Booster
6 Woodward
Chapter 2.
Installing and Adjusting a Booster
Servomotor
General Rules
Observe the following rules when you install a Woodward booster servomotor.
Location
Install the booster servomotor at a lower level than the governor to prevent air
from being trapped in the booster and oil lines.
Oil Lines
Oil lines must slope up from the booster to the governor with a minimum of loops
and bends.
Oil Leakage
It is not unusual for small oil particles (from assembly oil) to come out of the vent
hole at initial use of the booster and after several starts in a row, due to oil
particles in the bleed air.
Starting-Air Valve
A starting-air valve (supplied by the customer) must be installed in the air line to
the booster. This valve must admit compressed air to the booster at the same
time that starting air is supplied to the engine, and it must vent the air cylinder of
the booster to atmosphere when starting air is removed from the engine. Air
pressure at the booster air inlet must not exceed 3500 kPa (500 psi).
CAUTION
Purge air from the booster's oil chamber, the tubing, and the governor
before starting the engine, by cycling the booster piston with start-air or air
from a separate source. Failure to purge air completely may result in
sluggish governor response.
Installing and Adjusting a Single Cylinder Booster

Models 8901-037, -043, and -051 (Figures 1-3, 2-1, and 2-2)
Refer to the general rules at the beginning of this section.
Figures 2-1 and 2-2 show locations of inlet and outlet ports on Woodward
governors with which a single-cylinder booster can be used. Figure 1-3 shows
locations of ports and the stroke limit screw on a single-cylinder booster.
Install 10 mm (3/8 inch) steel tubing from the sump of the governor to the oil inlet
on the booster.
Install 6 mm (1/4 inch) steel tubing from oil outlet #1 on the booster to the power
piston (the inlet marked “OUTLET #1”) of the governor.
Woodward 7
If the governor is a PGA, PGPL, or PGG equipped with any shutdown feature,
install 6 mm (1/4 inch) steel tubing from oil outlet #2 on the booster to the speed
setting servo (the inlet marked “OUTLET #2”) of the governor. Otherwise, plug
outlet #2 (this plug is delivered with the booster).
Connect a line containing an air-starting valve from the starting-air supply to the
appropriate air inlet on the booster. Use the inlet with the built-in orifice if you
want to move the fuel racks at a slower rate. The other air inlet needs to be
plugged.
Fill the governor with oil to the proper level (refer to the installation manual for the
governor).
When all air and oil connections are secure, purge air from the booster and oil
lines by cycling air to the booster from a remote source without cranking the
engine. Add oil to the governor as needed.
When there is no more air in the booster and oil lines, set the initial opening of
the fuel racks by adjusting the stroke of the booster piston. Turn the stroke limit
screw counterclockwise to increase starting fuel, and clockwise to decrease it.
This screw limits the intake stroke of the booster and the volume of oil supplied
to the governor in one stroke of the booster servomotor.
Installing and Adjusting a Tandem Booster

Models 8901-065 and 8901-067 (Figures 1-4 and 2-3)
On PGA governors, decals indicating where to connect lines from the booster do
NOT apply to tandem boosters. Refer to Figure 2-3 when connecting a tandem
booster to a PGA governor.
Figure 2-3 shows locations of outlet and inlet ports on governors with which a
tandem booster can be used. Figure 1-4 shows locations of stroke limit screws
and ports on a tandem booster.
Connect 10 mm (3/8 inch) steel tubing from the sump of the governor to the oil
inlet on the booster; and from oil outlet #1 of the booster to the accumulator of
the governor.
On PGA, PGPL, and PGG governors equipped with any shutdown feature,
connect 6 mm (1/4 inch) steel tubing from oil outlet #2 on the booster to the
speed setting servo of the governor.
On PGA, PGPL, and PGG governors, connect 6 mm (1/4 inch) steel tubing from
oil outlet #3 on the booster to the power piston of the governor.
Connect a line with an air-starting valve from the starting-air supply to the air inlet
on the booster.
Plug the unused oil outlet(s) and air inlet (these plugs are delivered with the
booster).
Fill the governor with oil to the correct level (refer to the installation manual for
the governor).
8 Woodward
When all oil and air connections are secure, purge air from the booster and oil
lines by cycling air to the booster from a remote source without cranking the
engine. Add more oil to the governor as needed.
When there is no more air in the booster and oil lines, limit the volume of oil
going to the governor by adjusting the two stroke limit screws. The positions of
these screws determine the maximum volume of oil supplied by the booster.
This, in turn, determines the maximum travel of the fuel racks. Turn the screws
clockwise to reduce the travel of the racks, and counterclockwise to increase the
travel.
Adjust the needle valves in oil outlets #2 and #3. If outlet #2 is used, its needle
valve controls the rate of oil flow to the speeder spring servo, which determines
how fast the speeder spring servo moves. The needle valve in outlet #3 controls
the rate at which the power piston moves. Turn the needle valve clockwise to
restrict oil flow, and counterclockwise to increase flow.
NOTE
Outlets #2 and #3 are connected to separate cylinders. Outlet #1 is
connected to both cylinders, with check valves preventing flow between the
cylinders. Unequal amounts of oil will flow through the two outlets if the
stroke limit screws are adjusted unequally. It is usually best to adjust both of
these screws the same distance, and regulate the rate of oil flow through
outlets #2 and #3 with their respective needle valves.
Installing and Adjusting a Two-Stage Booster

Models 8901-091 and 8901-103 (Figures 1-5 and 2-4)
On PGA, PGPL, and PGG governors, decals indicating where to connect lines
from the booster do NOT apply to two-stage boosters. Refer to Figure 2-4 when
connecting a two-stage booster to a PGA, PGPL, or PGG governor.
Connect 12 mm (1/2 inch) steel tubing from the sump of the governor to the oil
inlet port on the booster, and from oil outlet #1 on the booster to the power piston
of the governor.
On PGA, PGPL, and PGG governors equipped with any shutdown feature,
connect 8 mm (5/16 inch) steel tubing from oil outlet #2 on the booster to the
speed setting servo of the governor.
Connect 8 mm (5/16 inch) steel tubing from oil outlet #3 on the booster to the
relay piston of the governor.
If you have an EGB-200, -300, or -500 actuator, leave oil outlet #3 of the booster
plugged and loosen the plug in outlet #2. Turn the shuttle piston adjusting screw
fully clockwise, thereby opening up the passage to outlet #1 (otherwise, the
booster servomotor remains inactive). Tighten the plug in outlet #2.
Connect a line with an air-starting valve from the starting-air supply to the air inlet
on the booster.
Fill the governor with oil to the correct level (refer to the installation manual of the
governor).
Woodward 9
When all air and oil connections are secure, purge air from the booster and oil
lines by cycling air from a remote source to the booster without cranking the
engine. Add oil to the governor as needed.
When there is no more air in the booster and oil lines, regulate the volume of oil
going to the governor by adjusting the stroke limit screw. If you are not using an
EGB-200, -300, or -500 actuator, adjust the shuttle piston adjusting screw and
the needle valve in oil outlet #3.
Remember that:
• The stroke limit screw limits the volume of oil going to the governor through
oil outlets #1 and #3. This controls the maximum amount of fuel output
during a booster-assisted start.
• If you use outlet #2, the shuttle piston adjusting screw limits the volume of
oil going to the speed setting servo through oil outlet #2.
• The needle valve limits the rate of flow of oil through oil outlet #3; this
controls the rate at which the output shaft of the governor moves. The
needle valve setting also limits the stroke of the power piston in the
governor.
Turn the stroke limit screw clockwise to reduce the volume of oil to the governor
and fuel to the engine, and counterclockwise to increase volume.
Turn the needle valve clockwise to reduce the rate and volume of oil flow, and
counterclockwise to increase the rate and volume.
10 Woodward
Figure 2-1. Governors Used with Single-Cylinder Boosters
Woodward 11
Figure 2-2. Governors Used with Single-Cylinder Boosters
12 Woodward
Figure 2-3. Governors Used with Tandem Boosters
Woodward 13
Figure 2-4. Governors Used with Two-Stage Boosters
14 Woodward
Chapter 3.
Principles of Operation
How Single-Cylinder and Tandem Boosters Operate

First Phase of Operation
Refer to Figure 311 (which represents a
single-cylinder booster; a tandem booster
has two pistons and three oil outlets, but its
principle of operation is the same).
When compressed air enters the booster,

the piston(s) moves up, forcing oil through
the outlets to the governor's pressurized oil
system. The governor's power piston moves
to increase fuel.
A check valve in the oil inlet prevents oil

from flowing from the booster back to the
sump in the governor.
Figure 3-1. Single Booster, Phase 1
Second Phase of Operation

Refer to Figure 3-2 (which represents a
single cylinder booster; a tandem booster
has two pistons and three oil outlets, but
its principle of operation is the same).
When starting air is removed, the booster

is vented to atmosphere through the
starting-air valve (customer supplied) in
the booster's air line. Spring force returns
the booster's piston(s) to the original
position. Oil stops flowing out of the
booster. Reduced pressure in the
booster causes sump oil to flow back into
the booster. The booster is ready to start
again.
Check valves in the oil outlets prevent oil

from flowing back through the oil outlets
into the booster.
Figure 3-2. Single Booster, Phase 2
Woodward 15
How a Two-Stage Booster Operates

First Phase of Operation
Figure 3-3. Two-Stage Booster, Phase 1
When compressed air enters the booster, the main piston moves to the right,
forcing oil to the shuttle piston cavity and moving the shuttle piston up. The
shuttle piston forces oil through oil outlet #2 and blocks oil outlets #1 and #3.
The shuttle piston adjusting screw limits the stroke of the shuttle piston, which
limits the amount of oil supplied through oil outlet #2.
Second Phase of Operation

When the shuttle piston reaches the end of its stroke, it uncovers the passages
to outlets #1 and #3, and oil flow through outlet #2 ceases. Oil remaining in the
booster flows through outlets #1 and #3 to the relay and power pistons in the
governor, moving them to increase fuel.
The needle valve in outlet #3 limits the amount of oil that goes through this outlet
and its rate of flow. This, in turn, limits the stroke of the power piston in the
governor and the rate at which fuel is supplied to the engine.
The stroke limit screw limits the stroke of the main booster piston, which limits
the total amount of oil supplied to the governor by the booster.
Check valves prevent oil from flowing from the booster into the governor's sump.
16 Woodward
Third Phase of Operation
The air side of the main piston is vented to atmosphere through the starting-air
valve. Spring forces return the main booster piston and shuttle piston to their
original positions. Reduced pressure in the booster causes sump oil to flow back
into the booster.
Check valves prevent oil from flowing into the booster from the oil outlet lines.
Woodward 17
Chapter 4.
Replacement Parts
Ordering Replacement Parts

When ordering replacement parts, include the following information:
1. The booster servomotor part number shown on the nameplate.
2. The manual number printed on the cover of the manual (this is manual
36684).
3. The part reference number in the parts list, and the description of the part or
part name.
Figures 4-1, 4-2, and 4-3 and their associated parts lists illustrate and name all
the replaceable parts of the various booster servomotors. The numbers assigned
are used as reference numbers and are not specific Woodward part numbers.
Woodward will determine the exact part number for your particular booster.
Parts List for Figure 4-1

Part No. Name................................................ No. Req'd
36684-6 0-ring ...............................................................1
36684-7 Glide Ring ........................................................1
36684-15 5/16"-24 Nut.....................................................4
36684-16 0-ring ........................................................ 1 or2
36684-18 1/8"-27 Steel Plug ............................................2
36684-23 Glide Ring ................................................ 1 or 2
36684-24 0-ring ....................................................... 1 or 2
36684-25 Check Valve Assembly ....................................3
36684-31 Cylinder Head ..................................................1
36684-32 Booster Spring .................................................1
36684-33 Accumulator Cylinder.......................................1
36684-34 Piston...............................................................1
36684-35 End Cap...........................................................1
36684-36 5/16"-24 Screw ................................................4
36684-37 Flat Washer .....................................................8
36684-38 5/16" Shakeproof Washer................................4
36684-39 1/4" Thread Seal..............................................1
36684-40 Flat Washer .....................................................1
36684-41 1/4"-28 Nut.......................................................1
36684-42 1/4''-28 Stroke Limit Screw ..............................1
36684-44 Cylinder Head ..................................................1
36684-45 0-ring ...............................................................1
36684-46 Reducing Bushing............................................1
36684-47 Booster Spring .................................................1
36684-48 Accumulator Cylinder.......................................1
36684-49 Piston...............................................................1
18 Woodward
Figure 4-1. Exploded View of Single Boosters
Woodward 19

Part No. Name ...................................... No. Req'd Part No. Name...................................... No. Req'd
36684- 6 0-ring ......................................................2 36684-40 Flat Washer ........................................... 2
36684- 7 Glide Ring ..............................................2 36684-41 1/4"-28 Nut............................................. 2
36684-15 5/16"-24 Nut ...........................................6 36684-47 Booster Spring ....................................... 2
36684-18 1/8"-27 Steel Plug ..................................4 36684-49 Piston..................................................... 2
36684-23 Glide Ring ...................................... 2 or 4 36684-52 Needle Valve ......................................... 2
36684-24 0-ring .............................................. 2 or 4 36684-53 0-ring ..................................................... 2
36684-25 Check Valve Assembly...........................6 36684-55 1 /4"-28 Stroke Limit Screw.................... 2
36684-32 Booster Spring .......................................2 36684-56 End Cap................................................. 1
36684-34 Piston .....................................................2 36684-57 Accumulator Cylinder............................. 2
36684-36 5/16"-24 Screw.......................................6 36684-58 Gasket ................................................... 4
36684-37 Flat Washer............................................6 36684-59 Servo Head............................................ 1
36684-38 5/16" Shakeproof Washer ......................6 36684-61 Accumulator Cylinder............................. 2
36684-39 1 /4" Threadseal .................................... 2 36684-62 Reducing Bushing..................................2
Figure 4-2. Exploded View of Tandem Boosters
20 Woodward

Part No. Name ................................................No. Req'd
36684-25 Check Valve Assembly.................................... 4
36684-63 Booster Servo Piston ...................................... 1
36684-64 Seal................................................................. 1
36684-65 Block Vee Seal................................................ 2
36684-66 Backup Ring.................................................... 1
36684-67 Seal Retainer .................................................. 1
36684-68 .500 Springlock Washer .................................. 9
36684-69 .500-13 Cap Screw.......................................... 1
36684-70 2:1 Ratio Spring .............................................. 1
36684-71 Reducing Bushing ........................................... 1
36684-72 Booster Servo Sleeve ..................................... 1
36684-73 Booster Servo End Cap .................................. 1
36684-74 4.234 ID O-ring................................................ 1
36684-75 .500 Thread Seal............................................. 1
36684-76 .500 Flat Washer............................................. 1
36684-77 .500-13 Hex Nut .............................................. 1
36684-78 .500-13 Stroke Limit Screw ............................. 1
36684-79 3.484 ID O-ring................................................ 1
36684-80 Servo Head Assembly..................................... 1
36684-81 Steel Ball ......................................................... 1
36684-82 Ball Check Spring............................................ 1
36684-83 Int. Retaining Ring........................................... 1
36684-84 Oil Failure Piston............................................. 1
36684-85 Spring.............................................................. 1
36684-86 .864 ID O-ring.................................................. 1
36684-87 Booster Servo Plug ......................................... 1
36684-88 Int. Retaining Ring........................................... 1
26684-89 Needle Valve................................................... 1
36684-90 .301 IDO-ring................................................... 1
36684-91 Stop Screw...................................................... 1
36684-92 .312 UNF Steel Plug ....................................... 1
36684-93 .562 UNF Steel Plug ....................................... 1
36684-94 .486 ID O-ring.................................................. 3
36684-95 Breather Filter Cap.......................................... 1
36684-96 .239 ID O-ring.................................................. 2
36684-97 Threaded Rod ................................................. 4
36684-98 .500-20 Hex Nut .............................................. 8
36684-104 .351 ID O-ring.................................................. 1
36684-105 .438 UNF Steel Plug ....................................... 1
Woodward 21
Figure 4-3. Exploded View of Two-Stage Boosters
22 Woodward
Chapter 5.
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.
Woodward 23
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.
24 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) 230 7111
Japan +81 (476) 93-4661
The Netherlands +31 (23) 5661111
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.
Woodward 25
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—[email protected]
Website—www.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.
26 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
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.
Woodward 27
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 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.
04/11/F

Installation and Operation Manual: Booster Servomotor

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What safety precautions should be followed when working with the equipment?

What safety precautions should be followed when working with the equipment?

What steps are involved in installing and adjusting a single cylinder booster?

What steps are involved in installing and adjusting a single cylinder booster?

Installation and Operation Manual

Single Cylinder (8901-037, -043, -051)

Electronic controls contain static-sensitive parts. Observe the following

CAUTION—indicates a potentially hazardous situation which, if not avoided, could

Revisions—Text changes are indicated by a black line alongside the text.

CHAPTER 1. GENERAL INFORMATION ........................................................... 1

Illustrations and Tables

Figure 1-1. Schematic of Single Booster Connections to PG-Type Governor.......3

Single-Cylinder Booster (Figures 1-1 and 1-3)

Tandem Booster (Figures 1-2 and 1-4)

Oil outlet #1 is connected to the governor's accumulator. Outlet #2 is connected

Two-Stage Booster (Figures 1-5, 2-4, and 3-3)

Machinery Directive: Compliance as a component with 98/37/EC

Figure 1-1. Schematic of Single Booster Connections to PG-Type Governor

Figure 1-2. Schematic of Tandem Booster Connections to PG-Type Governor

Figure 1-3. Outline Drawing of Single Booster

Figure 1-4. Outline Drawing of Tandem Booster

Figure 1-5. Outline Drawing of Two-Stage Booster

Installing and Adjusting a Single Cylinder Booster

Refer to the general rules at the beginning of this section.

Installing and Adjusting a Tandem Booster

Refer to the general rules at the beginning of this section.

Installing and Adjusting a Two-Stage Booster

Figure 2-1. Governors Used with Single-Cylinder Boosters

Figure 2-2. Governors Used with Single-Cylinder Boosters

Figure 2-3. Governors Used with Tandem Boosters

Figure 2-4. Governors Used with Two-Stage Boosters

How Single-Cylinder and Tandem Boosters Operate

When compressed air enters the booster,

A check valve in the oil inlet prevents oil

Figure 3-1. Single Booster, Phase 1

Second Phase of Operation

When starting air is removed, the booster

Check valves in the oil outlets prevent oil

Figure 3-2. Single Booster, Phase 2

How a Two-Stage Booster Operates

Figure 3-3. Two-Stage Booster, Phase 1

Second Phase of Operation

Figure 3-4. Two-Stage Booster, Phase 2

Figure 3-5. Two-Stage Booster, Phase 3

Ordering Replacement Parts

Parts List for Figure 4-1

Figure 4-1. Exploded View of Single Boosters

Parts List for Figure 4-2

Figure 4-2. Exploded View of Tandem Boosters

Parts List for Figure 4-3

Figure 4-3. Exploded View of Two-Stage Boosters

Product Service Options

If you are experiencing problems with installation or unsatisfactory performance

This option allows you to call in the event of an unexpected outage, or in

Return Shipment Authorization Label. To ensure prompt receipt of the core,

Flat Rate Repair

Flat Rate Remanufacture

Returning Equipment for Repair

Return Authorization Number