Service Information System Page 1 of 11

Testing and Adjusting

2301A ELECTRIC GOVERNORS (LOAD SHARING) FOR
GENERATOR SET AN
Media Number -SENR3585-02Publication Date -09/01/1992Date Update

Testing and Adjusting

Initial Checks & Adjustments

Initial Checks And Adjustments At Installation
Introduction
This section is a guide to be used for first installation of the engine and
generator, or when a replacement of any of the equipment has been made.
Too often the equipment is damaged or destroyed before it ever has a
chance to be used because of incorrect wiring, lead shorts, wrong polarity
or a mechanical problem.

The information that follows contains a basic, step by step checklist to be

followed. Before any supply power is applied, all wiring and settings are
verified to be correct. Then the governor is energized and the components
are checked out to see if they function correctly. Finally the engine is
started, and the complete system is checked and adjusted dynamically.

The correct use of these initial checks will eliminate most of the early
failures that can occur.

Index
Static Checks

Check For Grounds

Energized Governor Checks

Initial Adjustments

Visual Inspection

Dynamic Checks

https://sis.cat.com/sisweb/sisweb/techdoc/content.jsp?calledpage=/siswe
... 11/1/2004
Service Information System Page 2 of 11

Initial Engine Operation

Load Sensing Phasing

Load Gain Adjustment

Reverse Acting Governor Procedures

Static Checks
Visual Inspection
At Engine

1. Governor Linkage Checks:

a. Moves freely, not binding, no free play.
b. Correct thread engagement of rod ends.
c. Full travel available to FUEL OFF position.
d. Full travel available to FUEL ON position.
2. Magnetic Pickup To Flywheel Ring Gear Tooth Clearance, 0.56 to
0.85 mm (.022 to .033 in). See Service Procedure H.
3. Magnetic Pickup Resistance (approximately 200 ohms).
4. EG-3P, EG-3PC & EG-10P Actuator Connector:

Jumper must be across pins C and D of mating connector for those

actuators that use 4 pin MIL connectors. (Two pin connectors do not
require a jumper).

5. Shielded Wire Checks:

a. Only governor end to be connected to terminals indicated on Wiring
Diagram in Service Procedure A.
b. Not in same conduit with high current cables.
At Governor

1. Check for shielded wire on the governor inputs that follow:

T10 & T11 (Paralleling Lines)

T28 & T29 (Magnetic Pickup)

T23 & T24 (Jumper Or Remote Speed Pot)

https://sis.cat.com/sisweb/sisweb/techdoc/content.jsp?calledpage=/siswe
... 11/1/2004
Service Information System Page 3 of 11

T25 & T26 (SPM Synchronizer)

2. Check for broken or loose terminals at all connections that follow:

T1 (Phase A) Potential Transformer

T2 (Phase B) Potential Transformer

T3 (Phase C) Potential Transformer

T4 & T5 (Phase A) Current Transformer

T6 & T7 (Phase B) Current Transformer

T8 & T9 (Phase C) Current Transformer

NOTE: Dynamic Checks must also be made for terminals T1 through T9.

T10 (+) & T11 (-) Paralleling lines common to all units.

T16 (+) & T15 (-) DC Voltage supply (Low Voltage Models).

T16 & T19 Rated Speed Switch - Close for Rated speed or open for Low
Idle speed (jumper for initial start-up).

T20 (+) & T21 (-) Actuator terminals:

a. Measure resistance (infinity) from T20 to ground and T21 to ground.

b. Remove actuator wires from T20 & T21. Measure resistance (30 to 40
ohms) across disconnected wire ends (with actuator still connected).
c. Install wires correctly back to terminals when finished.

T28 & T29 Magnetic Pickup - Measure resistance (approximately 200

ohms) in wires to and from magnetic pickup (with magnetic pickup
connected).

T23 & T24 Speed Trim - Use 100 ohm variable resistor or jumper across
terminals.

T16 & T17 Minimum Fuel - Keep jumpered unless used for minimum fuel
switch.

https://sis.cat.com/sisweb/sisweb/techdoc/content.jsp?calledpage=/siswe
... 11/1/2004
Service Information System Page 4 of 11

Do not use for emergency shutdown. The engine

should be equipped with a separate shutdown device,
to protect against overspeed which could result in
personal injury, loss of life, and/or property damage.

T25 & T26 SPM or SPM-A Synchronizer Input.

T14 & T16 - Open for droop, closed for isochronous operation.

T16 & T18 Failsafe Circuit - Keep open to activate failsafe circuit. This
will ensure a shutdown if there is a loss of magnetic pickup signal.

NOTE: If the failsafe circuit must be defeated for a static test, add a jumper
between T16 & T18 on the 2301A Control. Remove the jumper before
starting the engine.

NOTICE
Do not attempt to start an engine with the failsafe
defeated.

Check For Grounds

1. Measure the resistance between:

8272 Series: T22 and chassis (switchgear cabinet).9905 Series: T11 and
chassis (switchgear cabinet).

The resistance should be infinity.

2. With power off, measure the resistance between:

8272 Series: T15 and T22.9905 Series: T11 and T15.

The resistance should be infinity.

If a resistance other than infinity is obtained, remove the connections from

each terminal one at a time until the resistance is removed. Check the line
that was removed last to locate the fault. Correct the problem before

https://sis.cat.com/sisweb/sisweb/techdoc/content.jsp?calledpage=/siswe
... 11/1/2004
Service Information System Page 5 of 11

proceeding.

Initial Adjustments (Static)

1. Rated Speed

a. Set the Rated Speed potentiometer to minimum (fully counterclockwise).

(The maximum safe speed is preset for the 3600 Engines).

b. Set the external speed trim, if used, to mid-position. (For 3600 Engines,
turn the external speed trim potentiometer fully counterclockwise).

2. Reset - Set at mid-position.

3. Gain - Set at mid-position.

4. Ramp Time - Set at minimum (fully counterclockwise).

5. Low Idle Speed - Set at maximum (fully clockwise).

6. Load Gain - Set at mid-position. (For 3600 Engines set at 2).

7. Droop - Set at minimum (fully counterclockwise).

8. Actuator Compensation.

a. Set the Actuator Compensation potentiometer at 2 on the 0 to 10

potentiometer scale for diesel engines. (For 3600 Engines set at 0).

b. Set the Actuator Compensation potentiometer at 6 on the 0 to 10

potentiometer scale for spark ignited engines.

9. Start Fuel Limit - Set at maximum (fully clockwise).

10. Be sure the actuator is connected to terminals T20 and T21.

Energized Governor Checks (Static)

NOTE: The actuator or a 35 ohm, 10 watt load must be connected across
T20 and T21.

NOTE: Do not use a battery charger as the only source of DC voltage to

T16 (+) and T15 (-).

https://sis.cat.com/sisweb/sisweb/techdoc/content.jsp?calledpage=/siswe
... 11/1/2004
Service Information System Page 6 of 11

Energize Governor

1. T16 (+) to T15 (-) - Measure voltage supply (24 to 35 VDC).

2. T16 to T18 - Install jumper, failsafe should be defeated.

3. T20 (+) to T21 - Measure actuator voltage (approx 6 VDC).

4. T16 to T18 - Remove jumper for failsafe circuit operation.

5. T20 (+) to T21 (-) - Measure voltage (0 VDC). If voltage is incorrect,

refer to Problem No. 6, Step 2 of the Troubleshooting Section of this
module.

Dynamic Checks
Initial Engine Operation
1. Make sure all Static Checks are completed before Dynamic Checks are
started.

2. Make sure jumper is removed across T16 and T18 for failsafe circuit
operation.

3. Close the Rated Speed Switch (or put jumper across T16 and T19).

4. Activate 2301A Control with power.

5. Magnetic Pickup

a. Activate Manual Shutoff (or disconnect wires to actuator from terminals

T20 & T21).

b. Crank the engine and measure output voltage of magnetic pickup across
terminals T28 & T29 [should be greater than 1 VAC (measured as RMS
voltage)].

c. Release Manual Shutoff (or reconnect actuator wires to terminals T20 &
T21).

The engine can overspeed (run out of control) due to

https://sis.cat.com/sisweb/sisweb/techdoc/content.jsp?calledpage=/siswe
... 11/1/2004
Service Information System Page 7 of 11

improper governor assembly or adjustment, which

could result in personal injury, loss of life, and/or
property damage.

Be prepared to stop the engine by electrically

activating the emergency air shutoff, or by manually
closing the air inlets.

6. Connect a DC voltmeter to terminals T21 (-) and T20 (+) to get an

indication of actuator voltage stability.

7. Start the engine. It may be necessary to turn the Rated Speed

Potentiometer one or two turns clockwise before the engine will start. (For
3600 Engines, turn the external speed trim potentiometer clockwise until
start is achieved).

NOTICE
Be ready to control the engine shutoff manually if
there is no oil pressure, or if oil pressure is too low.
Damage to the engine will be the result if the engine
continues to run without the correct oil pressure.

8. Rated Speed Potentiometer

a. Set engine rated speed by turning this potentiometer CW to increase

speed setting. (For 3600 Engines, use the external speed trim potentiometer
to set rated speed).

b. Measure Magnetic Pickup output voltage at terminals T28 and T29.

Voltage should be less than 50 VAC (measured as RMS voltage). If voltage
is greater than 50 VAC, check clearance between magnetic pickup and gear
tooth. Make adjustment as necessary.

9. Gain, Reset, And Actuator Compensation Potentiometers

See Service Procedure G.

10. Low Idle Adjustment

a. Remove the jumper from T16 and T19 (often labeled Idle/Rated).

https://sis.cat.com/sisweb/sisweb/techdoc/content.jsp?calledpage=/siswe
... 11/1/2004
Service Information System Page 8 of 11

b. Open the external ramp switch, if used, or remove the oil pressure switch
wires from terminals T16 and T19.

c. Adjust the Low Idle Speed Potentiometer on the control to the

recommended speed.

11. Ramp Time Adjustment

Adjust the Ramp Time potentiometer to achieve satisfactory acceleration to

rated speed with minimum overshoot. First, start at the fully clockwise
(maximum Ramp Time) position and work back in the counterclockwise
direction until the unit ramps as rapidly as desired.

12. Start Fuel Limit Adjustment

See Service Procedure L.

13. Input Voltage Check (High Voltage)

Measure the AC voltage across terminals shown:

T1 to T2 (90 to 120 VAC) or (210 to 240 VAC)

T2 to T3 (90 to 120 VAC) or (210 to 240 VAC)

T1 to T3 (90 to 120 VAC) or (210 to 240 VAC)

If these three voltages are not the same, make reference to Wiring Diagram
in Service Procedure A for the correct Potential Transformer connections.

14. Linkage Calibration

See Service Procedure D.

Reverse Acting Governor Procedure

If it is required to go to the ballhead backup governor upon loss of "speed
pickup signal" you must do the following "before" starting the engine:

1. Turn the start fuel limit potentiometer fully clockwise (CW).

2. Put a jumper wire across the failsafe override (across terminals T16 and
T18 on low voltage models, and terminals T0 and T18 on high voltage
models).

https://sis.cat.com/sisweb/sisweb/techdoc/content.jsp?calledpage=/siswe
... 11/1/2004
Service Information System Page 9 of 11

If the failsafe override is not jumpered, the actuator will go to minimum

fuel (shutoff) with loss of "speed pickup signal".

If the failsafe override is jumpered correctly, but the start fuel limit is in
effect (potentiometer not fully clockwise), the actuator will go to the start
fuel limit position upon loss of "speed pickup signal".

In any of the above mentioned cases, loss of the actuator signal at the
actuator will cause a reverse acting actuator to go to the ballhead backup.

Load Sensing Phasing (Dynamic Check)

Current Transformer (CT) Phasing Check

NOTICE
Before starting phasing check, be sure potential
connections for phases A, B and C correspond to
control terminals 1, 2 and 3.

1. Label all wires connected to terminals T4 through T9.

2. Connect a DC voltmeter to Load Signal terminals T11 (-) and T13 (+).

3. Start the engine and fully load the generator set with a unity power factor
load. Do not parallel the generator.

NOTE: Full load is not required, if complete load is not available.

However, a steady load level is necessary.

4. Record the load signal voltage at T11 and T13.

This voltage is proportional to percent of full load (i.e., if 50 percent load is

3 VDC, then 100 percent load will be 6 VDC). See subject, Load Gain
Adjustment, for this proportional adjustment.

NOTE: The 2301A Control contains internal current transformers. Due to

their low impedance, shorting their terminals (T4 to T5, T6 to T7, T8 to T9)
is not effective. The current input must be removed from the 2301A
Control and shorted externally.

https://sis.cat.com/sisweb/sisweb/techdoc/content.jsp?calledpage=/siswe
... 11/1/2004
Service Information System Page 10 of 11

Never disconnect current transformers from the

2301A Control (terminals 4 through 9) when the
engine is running. The current transformers can
develop very high voltages when open circuited with
unit loaded, and the result can be serious injury or
death to personnel.

5. Unload and stop the engine. Disconnect the lead from T5 and connect
both leads from Phase A CT to T4.

6. Start the engine and apply the same load as in Step 3. Record the load
signal voltage at T11 and T13.

Compare this voltage reading to the reading in Step 4.

a. If Step 4 voltage dropped by 1/3, Phase A is correct. Go to Step 7.

b. If Step 4 voltage did not drop by 1/3, Phase A is not correct. Go to

Service Procedure M.

7. Unload and stop the engine. Reconnect the lead to T5 that was
disconnected in Step 5. Now disconnect the lead from T7 and connect both
leads from Phase B CT to T6.

8. Start the engine and apply the same load as in Step 3. Record the load
signal voltage at T11 and T13.

Compare this voltage reading to the reading in Step 4.

a. If Step 4 voltage dropped by 1/3, Phase B is correct. Go to Step 9.

b. If Step 4 voltage did not drop by 1/3, Phase B is not correct. Go to

Service Procedure M.

9. Unload and stop the engine. Reconnect the lead to T7 that was
disconnected in Step 7. Now disconnect the lead from T9 and connect both
leads from Phase C CT to T8.

10. Start the engine and apply the same load as in Step 3. Record the load
signal voltage at T11 and T13.

https://sis.cat.com/sisweb/sisweb/techdoc/content.jsp?calledpage=/siswe
... 11/1/2004
Service Information System Page 11 of 11

Compare this voltage reading to the reading in Step 4.

a. If the Step 4 voltage dropped by 1/3, Phase C is correct. Unload and

stop the engine. Reconnect the lead to T9 that was disconnected in Step 9.
Go to subject, Load Gain Adjustment.

b. If the Step 4 voltage did not drop by 1/3, Phase C is not correct. Unload
and stop the engine. Reconnect the lead to T9 that was disconnected in
Step 9. Go to Service Procedure M.

Load Gain Adjustment (Dynamic Check)

1. Connect a DC voltmeter to terminals T11 (-) & T13 (+).

2. Operate engine as single unit at Full Load.

3. Make adjustment to Load Gain Potentiometer for approximately 6 VDC

with engine at Full Load.

NOTE: All other units in the system must now be set to this same voltage.

Copyright 1993 - 2004 Caterpillar Inc. Mon Nov 1 14:22:41 UTC+0800 2004
All Rights Reserved.
Private Network For SIS Licensees.

https://sis.cat.com/sisweb/sisweb/techdoc/content.jsp?calledpage=/siswe
... 11/1/2004