Table  7-4. Governor Malfunction Testing PROBABLE TERMINAL NORMAL  VALUE CAUSE  OF  NON-NORMAL  READING CORRECTIVE   ACTION S 1.0  volt  AC-RMS  minimum 1. Defective   magnetic   pickup. 1.    Replace magnetic pickup. while  cranking. 2. Gap  too  large  between  magnetic  2.  Readjust  magnetic  pickup. pickup  and  gear  teeth. 3. Improper  or  defective  wiring    3.  Replace  wiring  harness. to  the  magnetic  pickup. K L N R 10.1 + .20 volts DC while 1. D.C. power not connected or  1. Connect D.C. power supply; energized   (Internal   regu- low  battery  voltage. replace  D.C.  battery. lated  D.C.  supply). 2. Frequency  trim  potentiometer    2.  Replace  Control  Unit. shorted,  grounded  or  miswired. 3. Wiring  error. 3. Replace  wiring  harness. 4. Defective  control  unit. 4. Replace  control  unit. Above 5.1 volts D.C. while 1. Frequency  adjust  set  too  low.  1.  Turn  Frequency  adjust  screw running.  (inverse  speed clockwise. error  signal). 2. Defective  control  unit. 2. Replace  control  unit. Above  5.1  volts  is  under speed signal. Below 5.1 volts  is  over  speed signal. On  speed  will  indicate  a steady  5.1  volts. 8.5 to 9.5 volts D.C. while 1. Battery voltage may be too 1. Charge  D.C.  battery;  replace cranking. (Proportional low  while  cranking. D.C. battery. actuator   voltage). 2. Defective  Control  Unit. 2. Replace  Control  Unit. 2.5  volts  D.C.  maximum 1. Output  transistor  open  (defec-  1.  Replace  Control  Unit. while  cranking.  (Tran- tive  Control  Unit). sister  voltage). 2. Defective  Actuator. 2. Replace  Actuator. 3. Error  in  wiring  to  Actuator.    3.  Replace  Wiring  Harness. (6) Measure the center to center distance between the hole in the fuel shutoff lever and the hole in the actuator lever. Adjust the rod ends on the threaded linkage rod so that the center to center distance of the rod ends is the same  or  slightly  longer  than  that  measured  between the  fuel  shutoff  lever  and  the  actuator  lever. (The 3.75 dimension is only approximate. If the linkage is too short, the actuator lever will attain  its  “no  fuel”  position  [full  clockwise] before  the  fuel  shutoff  lever  reaches  its  “no  fuel” position;  the  fuel  shutoff  lever  will  never  reach “no fuel”. If the linkage is too long, the actuator  lever  will  reach  its  “full  fuel”  position [full  counterclockwise]  before  the  fuel  shutoff lever  reaches  its  “full  fuel”  position;  full  load will not be reached.) It may be necessary to readjust  the  position  of  the  fuel  shutoff  lever and/or  the  actuator  lever  to  accommodate  the center to center distance of the rod ends and to assure  complete  fuel  shutoff  and  full  load  opera- tion. Fuel  shutoff  and  actuator  lever  adjustments will  be  covered  under  replacement  procedures. Tighten  the  nuts  on  the  linkage  rod  against  the rod ends to maintain proper spacing. (7) Return the generator set START-RUN-STOP switch  to  the  STOP  position  and  the  BATTLE  SHORT switch to the OFF position. (8) Reconnect the actuator linkage rod end to the engine fuel shutoff lever. (9) Adjust the control unit gain control to its  approximate  mid-range  position. (10) Adjust the control unit stability control  to  its  fully  counterclockwise  position. (11) Adjust the generator set frequency adjust  potentiometer  (pot)  (located  on  the generator  set  control  panel)  to  mid-range. (12) Using a small screwdriver, turn the control  unit  frequency  adjust  screw  (located  on the  left  side  vertical  face  of  the  control  unit) at  least  22  turns  counterclockwise  (opposite increase  arrow). This  will  give  the  lowest possible  engine  governed  speed. NOTE Two people will be rewired to adjust the control unit. Ensure  that  the  actuator linkage  rod  and  all  levers  are  securely fastened  and  move  freely  (without  binding) before operating the engine. Manually overcome  the  actuator  until  adjustment  of the  control  unit  is  completed  and  the governor is in control. Adjustment of the  control  unit  will  be  made  with  the engine  operating  in  a  no-load  condition. (13) Start the engine, manually operating the fuel  shutoff  lever. Change    9 7-21