Woodward Actuator

Installation and Operation Manual
TG-10E, -13E, and –17E Actuator
Manual 04045 (Revision E)

This is the safety alert symbol. It is used to alert you to potential personal
injury hazards. Obey all safety messages that follow this symbol to avoid
possible injury or death.
• DANGER—Indicates a hazardous situation which, if not avoided, will result in death
or serious injury.
DEFINITIONS • WARNING—Indicates a hazardous situation which, if not avoided, could result in
death or serious injury.
• CAUTION—Indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury.
• NOTICE—Indicates a hazard that could result in property damage only (including
damage to the control).
• IMPORTANT—Designates an operating tip or maintenance suggestion.
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.
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.
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.
Any unauthorized modifications to or use of this equipment outside its specified mechanical,
electrical, or other operating limits may cause personal injury and/or property damage, including
damage to the equipment. Any such unauthorized modifications: (i) constitute "misuse" and/or
"negligence" within the meaning of the product warranty thereby excluding warranty coverage
for any resulting damage, and (ii) invalidate product certifications or listings.
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.
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.
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 1982
All Rights Reserved
Manual 04045 TG-10E/-13E/-17E Actuator
Contents
REGULATORY COMPLIANCE ........................................................................III

ELECTROSTATIC DISCHARGE AWARENESS ................................................. IV
CHAPTER 1. GENERAL INFORMATION ........................................................... 1
Introduction .............................................................................................................1
Description ..............................................................................................................1
Optional Actuators ..................................................................................................1
References .............................................................................................................2
CHAPTER 2. INSTALLATION.......................................................................... 3
Introduction .............................................................................................................3
Receiving ................................................................................................................3
Storage ...................................................................................................................3
Drive Shaft Rotation ...............................................................................................3
Installation ..............................................................................................................4
Linkage Attachments ..............................................................................................5
Heat Exchanger Installation (optional) ...................................................................5
When is a Heat Exchanger Necessary? .................................................................6
Oil Supply ...............................................................................................................6
CHAPTER 3. OPERATION AND ADJUSTMENTS ............................................. 13
Introduction ...........................................................................................................13
Initial Operation ....................................................................................................13
Cleaning the Filter Screens and The Pilot-Valve Plunger Orifice.........................14
Calibration Procedure ...........................................................................................16
CHAPTER 4. PRINCIPLES OF OPERATION ................................................... 21
Introduction ...........................................................................................................21
Component Operation ..........................................................................................21
Operation of the TG Actuator ...............................................................................23
CHAPTER 5. TROUBLESHOOTING ............................................................... 26
Introduction ...........................................................................................................26
Visual Inspection ..................................................................................................26
CHAPTER 6. REPLACEMENT PARTS ........................................................... 29
CHAPTER 7. SERVICE OPTIONS ................................................................. 31
Product Service Options .......................................................................................31
Woodward Factory Servicing Options ..................................................................32
Returning Equipment for Repair ...........................................................................33
Replacement Parts ...............................................................................................33
Engineering Services............................................................................................34
How to Contact Woodward ...................................................................................34
Technical Assistance ............................................................................................35
DECLARATIONS ......................................................................................... 36
Woodward i
TG-10E/-13E/-17E Actuator Manual 04045
Illustrations and Tables
Figure 1-1. TG Actuator ..........................................................................................2

Figure 2-1. Recommended Terminal Shaft Travel .................................................5
Figure 2-2. Heat Exchanger Piping Connections ...................................................6
Figure 2-3. TG Actuator Outline Drawing .............................................................10
Figure 2-4. TG-13E/-17E Outline Drawing ...........................................................11
Figure 2-5. TG-13E/-17E Outline Drawing ...........................................................12
Figure 3-1. TG Actuator with Cover Removed .....................................................15
Figure 3-2. Wiring Diagram for Actuator Calibration Circuit .................................17
Figure 4-1. TG Actuator Schematic Diagram .......................................................24
Figure 5-1. Actuator Test Circuit...........................................................................27
Figure 6-1. TG Exploded View .............................................................................30
Table 2-1. Oil Chart ................................................................................................9

Table 2-2. Viscosity Comparisons ..........................................................................9
Table 5-1. TG Actuator Troubleshooting ..............................................................28
ii Woodward
Regulatory Compliance
European Compliance:
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.
North American Compliance:

UL: UL Listed for Class I, Division 2, Groups B, C, & D.
For use in the United States.
UL File E158654
The TG Actuator is suitable for use in Class I, Division 2, Groups B, C, and D per
UL for the US or non-hazardous locations only. These listings are limited only to
those units bearing the UL logo.
Wiring must be in accordance with North American Class I, Division 2 wiring

methods as applicable, and in accordance with the authority having jurisdiction.
For use in NEC Class 2 circuits, 30 volts maximum.
EXPLOSION HAZARD—Do not remove covers or connect/disconnect

electrical connectors unless power has been switched off or the area
is known to be non-hazardous.
Substitution of components may impair suitability for Class I,
Division 2.
RISQUE D’EXPLOSION—Ne pas enlever les couvercles, ni

raccorder/débrancher les prises électriques, sans vous en
assurez auparavant que le système a bien été mis hors tension;
ou que vous vous situez bien dans une zone non explosive.
La substitution de composants peut rendre ce matériel
inacceptable pour les emplacements de Classe I, Division 2.
Woodward iii
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.
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.
iv Woodward
Chapter 1.
General Information
Introduction
This manual 04045 provides general information, installation, operation,
principles of operation, and troubleshooting for the Woodward TG-10E,
TG-13E, and TG-17E Actuators.
All actuators have the same mounting pad, drive shaft configuration, and terminal
shafts.
Rated work capacity is 10 lb-ft (14 Nxm) for the TG-10E and 13 lb-ft (18 Nxm) for
the TG-13E, both with 150 psi (1034 kPa) internal operating oil pressure. The
TG-17E offers 18 lb-ft (24 Nxm) rated work capacity with higher 200 psi (1379
kPa) oil operating pressure.
Maximum terminal shaft travel for the TG-10E is 30 degrees, and 40 degrees for
the TG-13E/-17E. Recommended travel from “NO LOAD” to “FULL LOAD” is 2/3
of maximum terminal shaft travel, or 20 degrees for the TG-10E, and 30 degrees
for the TG-13E/-17E. (See Figure 2-1, Recommended Terminal Shaft Travel.)
The internal pump is sized to operate over standard speed ranges: 1100 to 2400
rpm; 2400 to 4000 rpm; 4000 to 6000 rpm. The actuator is built for the speed
range specified by the customer. The high-speed actuator (4000 to 6000 rpm)
may require a heat exchanger in some applications. (See Chapter 2, When is a
Heat Exchanger Necessary?)
All other operating features and specifications of the TG actuators are the same
for each model.
Description
The TG actuator is a self-contained, proportional, electrohydraulic actuator used
for the positioning of valves. It can be used with all available Woodward
integrating electronic controls and accessories.
The TG proportional electrohydraulic actuator is a transducer which converts a

given electrical signal to a corresponding proportional angular output shaft
position to control the flow of steam or energy medium to the turbine. The
actuator is controlled by an external signal from an integrating amplifier. The
control signal must be unidirectional dc, thereby proportionally increasing the
mechanical output position. The exact control used depends upon the operating
scheme of the installation. Control assemblies are available to control speed,
frequency, load, pressure, and other variables.
Optional Actuators
A TG actuator is available which does not require a drive from the turbine (Figure
2-4). It uses an external, customer-supplied, hydraulic source and can be located
in a convenient location to operate the steam valve linkage.
Woodward 1
Also available is an electric motor-driven TG actuator (Figure 2-5) which can be
mounted in a convenient location and does not require a mechanical drive from
the turbine or an external oil supply.
A UL Listed TG (Class I, Division 2, Groups B, C, and D), is also available for use
in hazardous areas.
References
The following Woodward publications may prove useful:
Number Title
04044 Product Specification, TG-13E & -17E Actuator
25071 Oils for Hydraulic Controls
25075 Commercial Preservation Packaging for Storage of Mechanical-
Hydraulic Controls
36641 Governor Oil Heat Exchanger
50055 Service Bulletin, TG Actuators. Transducer Tightness Check
Oil Filter
Oil Breather/
Filler Cap
Terminal Shaft/
Output Shaft
Oil Sight
Glass
Electrical
Connector
Oil Drain
Plug
Figure 1-1. TG Actuator
2 Woodward
Chapter 2.
Installation
Introduction
This chapter describes receiving, storage, and installation requirements for the
TG actuator.
Use care while handling and installing the TG actuator. Be particularly careful to
avoid striking the drive shaft, terminal shafts, or the electrical connector. Abuse
can damage seals, internal parts, and factory adjustments. Do not rest the
actuator on its drive shaft.
Receiving
The TG actuator is shipped from the factory boxed and bolted to a wooden
platform in the vertical position. The oil sight gauges are factory installed on the
sides of the case, and a breather/filler cap is positioned on the cover for vertical
or horizontal actuator mounting and operation.
After factory testing and adjusting, the TG actuator is drained of oil, sealed, and
painted. This leaves a light film of oil covering internal parts to prevent rust.
External shafts are coated with a spray lubricant. No internal cleaning or flushing
is necessary before installation and operation.
Storage
The TG actuator may be stored for short periods of time as received from the
factory. For long-term storage, storage in an environment with large temperature
changes , humid or corrosive atmosphere, etc., or if the actuator is installed on
the turbine for storage, fill the actuator with oil and follow preservation packaging
instructions in Woodward manual 25075, Commercial Preservation Packaging for
Storage of Mechanical-Hydraulic Controls.
If the breather/filler cap has been set for horizontal governor operation and the
actuator is to be stored vertically, replace the cap with a plug before filling it with
oil to prevent oil from draining through the vent hole.
Drive Shaft Rotation

The actuator rotation is single rotation only. When looking at the actuator from
the top, the direction of rotation must be the same as the turbine shaft or the
electric motor driving the oil pump. The arrows on the actuator base indicate the
actual direction of rotation, when viewing in that plane. Use the following
procedure to change the direction of rotation of the oil pump:
1. Remove the four pump housing screws.
2. Rotate the pump housing assembly 180 degrees.
3. Align the arrows on the pump housing with the pointer on the actuator case.
The arrows indicate the actual pump drive shaft rotation.
Woodward 3
4. Replace the four screws and torque to 80 lb-in (9.0 Nxm).
5. Make sure that the pump drive shaft rotates freely.
Maintenance of the TG actuator is minimal due to few moving parts,

weatherproof design, and self-contained oil supply. The pump drive shaft
operates a Gerotor-type oil pump. Internal oil pump pressure is regulated by a
relief valve/accumulator. An oil sight glass is installed on both sides of the
actuator case for checking oil condition and oil level.
Installation
The actuator can be installed either vertically or horizontally. Installation is called
vertical or horizontal if the drive shaft is in a vertical or horizontal position when
viewing the actuator installed on its mounting base. Due to gravitational forces on
the transducer and resulting calibration shift, the actuator should be ordered from
the factory for horizontal or vertical installation. Changing the actuator from
horizontal to vertical installation, or vice versa, requires a recalibration of the
actuator. See Chapter 3, Calibration Procedure with Actuator on a Test Stand
OR Calibration Procedure with Actuator on the Turbine.
The breather/filler cap is factory installed on the cover for shipping. For horizontal
operation, the cap and drain plug must be moved to the alternate positions. This
places the servo-piston on the bottom, keeping it completely immersed in oil and
preventing air from being trapped in the servo. See Figure 2-3 (Outline Drawing)
for alternate cap and plug positions as well as actuator mounting hole locations
and hole sizes.
For horizontal operation, the TG actuator must be installed with the

oil sight gauge at the top of the actuator.
Make sure that there is adequate clearance for attaching the steam valve linkage
and electrical connector and for performing oil maintenance.
The actuator requires 1/2 hp (373 W) maximum to turn the oil pump drive shaft at
rated speed. A decal label on the side of the case indicates the direction of
rotation when the unit was shipped from the factory.
Be sure turbine drive and actuator drive rotation are the same.
Incorrect drive rotation may cause actuator damage.
Make sure the drive shaft turns freely before installing the TG actuator. Mount the
actuator squarely on the mounting pad, installing the correct length coupling with
a number 5 Woodruff key. A gasket between the actuator and mounting pad may
be used. There must be no binding, side loading, or backlash in the oil pump
drive. Improper alignment or too tight of a fit between parts can result in
excessive wear or seizure. There must be no force pushing the pump drive shaft
into the actuator. The actuator must slide onto the mounting pad by its own
weight without having to apply force. Tighten the four actuator mounting bolts
equally.
4 Woodward
Linkage Attachments
The terminal shaft extends from both sides of the case and provides 30 degrees
of travel for the TG-10E and 40 degrees of travel for the TG-13E/-17E.
Recommended travel from “NO LOAD” to “FULL LOAD” is 2/3 of maximum
terminal shaft travel (Figure 2-1).
Figure 2-1. Recommended Terminal Shaft Travel
Be sure to allow sufficient overtravel at each end of the terminal

shaft so that the actuator can shut down the turbine and also give
maximum steam flow when required.
Installed linkages must operate smoothly, free of binding. If there is a collapsible

member in the linkage, be sure that it does not yield each time the actuator
moves the linkage rapidly.
Adequate locking methods must be used on the linkage connections. The

terminal shaft must have a 0.625-36 serration to clamp to the output shaft of the
governor.
Heat Exchanger Installation (optional)

If it is necessary to install a heat exchanger, mount it below actuator oil level in
order to prevent overflow of oil through the actuator breather/filler cap. Flush the
heat exchanger before installation with the same grade and type of oil selected
for the TG (see information on Oil Supply below) to remove possible oxidation.
Woodward 5
Make the required piping connections to the cooler and the actuator. See Figure
2-2 which illustrates piping connections. The cooler must be installed in the line
to the cover filter.
Figure 2-2. Heat Exchanger Piping Connections
Use a pipe size that minimizes pipe pressure losses to less than 15 psi (103
kPa). Oil flow from the oil to cooler inlet tap (.125-27 NPTF) is 1.0 gal/min (3.8
L/min) on an actuator operating at 6000 rpm and using a 0.250 thick Gerotor
pump (0.250 is standard thickness on high rpm actuators). For the TG-17E, it is
1.2 gal/min (4.5 L/min) at 200 psi (1379 kPa).
We recommend that a throttling device be installed to the heat exchanger so that

coolant flow is regulated for optimum oil temperature. Excessive cooling of
actuator oil can cause sluggish operation.
When is a Heat Exchanger Necessary?

Some applications of the TG may require an oil heat exchanger be used to
prevent oil breakdown and subsequent problems due to excessive oil operating
temperatures. TG actuators operating at low and medium speed ranges (1100–
2400 and 2400–4000 rpm) do not normally require a heat exchanger. The high
speed actuator (4000 to 6000 rpm) may require a heat exchanger in some
applications. Factors such as oil viscosity, actuator speed, heat radiation from
surrounding sources, and mounting pad and ambient temperatures affect oil
conditions, necessitating an oil cooler (see Woodward Manual 25071, Oils for
Hydraulic Controls). Generally, when oil viscosity at operating temperature is
below 100 SUS (Saybolt Universal Seconds), an oil cooler is required.
A single pass, counter-flow heat exchanger with 1 to 2 ft² (0.09 to 0.19 m²) of
heat transfer area, provides adequate cooling for most high speed TG actuators.
If there is doubt concerning the need for, or size of, a heat exchanger, contact
Woodward. Heat exchangers can be purchased from Woodward.
Oil Supply
Use this information as a guide in the selection of a suitable lubricating/hydraulic
oil (for more information on oils, refer to manual 25071).
6 Woodward
Oil grade selection is based on the operating temperature range of the actuator.
Also, use this information to aid in recognizing and correcting common problems
associated with oil used in products manufactured by Woodward.
Normally, the oil recommended for the turbine by the turbine manufacturer is
acceptable for use in the actuator.
Actuator oil is both a lubricating oil and a hydraulic oil. It must have a viscosity
index that allows it to perform over the operating temperature range, and it must
have the proper blending of additives that cause it to remain stable and
predictable over this range.
Actuator oil must be compatible with seal materials (nitrile, polyacrylic, and
fluorocarbon). Many automotive and gas engine oils, industrial lubricating oils,
and other oils of mineral or synthetic origin meet these requirements. Woodward
actuators are designed to give stable operation with most oils with a viscosity (at
operating temperature) between 50 and 3000 SUS (Saybolt Universal Seconds).
At normal operating temperature, the viscosity should be between 100 and 300
SUS. Poor actuator response or instability may be an indication that the oil
viscosity is outside this range.
Excessive component wear or seizure in an actuator indicates the possibility of:

1. Insufficient lubrication caused by:
• An oil that flows slowly when it is cold especially during start-up
• No oil in the actuator
2. Contaminated oil caused by:
• Dirty oil containers
• An actuator exposed to heating up and cooling down cycles, which
creates condensation of water in the oil
3. Oil not suitable for the operating conditions caused by:
• Changes in ambient temperature
• An improper oil level which creates foamy, aerated oil
Operating an actuator continuously beyond the high limit temperature of the oil
will result in oil oxidation. This is identified by varnish or sludge deposits on the
actuator parts. To reduce oil oxidation, lower the actuator operating temperature
with a heat exchanger or other means, or change to an oil that is more oxidation-
resistant at the operating temperature.
A loss of stable actuator control and possible turbine overspeed may

result if the viscosity exceeds the 50 to 3000 SUS range. Loss of
governor control can cause damage to equipment and personal
injury or loss of life.
Specific oil viscosity recommendations are given on the Oil Chart (Table 2-1).
Select a readily available good brand of oil, either mineral or synthetic, and
continue using that same brand. Do NOT mix different classes of oils. Oil that
meets the API (American Petroleum Institute) engine service classification in
either the “5” group or the “C” group, starting with “SA” or “CA” through “SF” and
“CD” is suitable for actuator service. Oils meeting performance requirements of
the following specifications are also suitable: US MIL-L-2104A, MIL-L-2104B,
MIL-L-2104C, MIL-L-46142, MIL-L-46152A, MIL-L-46152B, MIL-L-45199B.
Remove the breather/filler cap on the TG actuator. Fill the governor or actuator
with 1.8 quarts (1.7 L) of oil to a level visible on the oil sight gauge. Additional oil
is required if the governor uses an oil heat exchanger. Be sure that the oil level is
visible on the oil sight gauge before starting the turbine. After the turbine is
started and the TG actuator is at operating temperature, add oil if necessary.
Woodward 7
For TG actuators which do not require a drive, but require a customer-supplied
oil pressure source, see Figure 2-4 for oil line connections. The external oil
pressure source must supply 1 to 4 gal/min (4 to 15 L/min) flow to regulate
accumulator between 150 and 170 psi (1034 and 1172 kPa). Supply oil must be
filtered to 25 µm (absolute). The TG actuator is fitted with a –6 filter fitting (70 µm
absolute) and a –10 drain fitting.
Replace the actuator oil if it is contaminated. Also, change the oil if it is

suspected of contributing to actuator instability. Drain the oil while it is still hot
and agitated, and flush the actuator with a clean solvent having some lubricity
(such as fuel oil or kerosene) before refilling with new oil. If drain time is
insufficient for the solvent to completely drain or evaporate, flush the actuator
with the same oil that will be used to refill. This will avoid dilution and possible
contamination of the new oil. To avoid recontamination, the replacement oil
should be free of dirt, water, and other foreign material. Use clean containers to
store and transfer oil.
Observe manufacturer’s instructions or restrictions regarding the

use of solvents. If no instructions are available, handle with care. Use
cleaning solvent in a well ventilated area away from fires or sparks.
Improper use of solvents can cause personal injury and/or property
damage.
Oil that has been carefully selected to match the operating conditions and is
compatible with actuator components should give long service between oil
changes. For actuators operating under ideal conditions (minimum exposure to
dust and water and within the temperature limits of the oil), oil changes can be
extended.
If available, a regularly scheduled oil analysis is helpful in determining the

frequency of oil changes. Any persistent or reoccurring oil problems should be
referred to a qualified oil specialist for solution.
The recommended continuous operating temperature of the actuator is 140 to

200 °F (60 to 93 °C). Measure the temperature of the actuator on the outside
lower part of the case. The actual oil temperature will be approximately 10
Fahrenheit degrees (6 Celsius degrees warmer).
8 Woodward
Table 2-1. Oil Chart
Table 2-2. Viscosity Comparisons
Woodward 9
Terminals C and D must be jumpered in

connecting plug. For reverse action,
switch polarity at Terminals A and B.
Figure 2-3. TG Actuator Outline Drawing
10 Woodward
Terminals C and D must be jumpered in

connecting plug. For reverse action,
switch polarity at Terminals A and B.
Figure 2-4. TG-13E/-17E Outline Drawing

(version that does not require a drive from the turbine)
Woodward 11
Wire motors according to the diagram that

comes with equipment. Rotation must be
correct for actuator pump to function.
Figure 2-5. TG-13E/-17E Outline Drawing

(electric motor driven version with drives and adapters)
12 Woodward
Chapter 3.
Operation and Adjustments
Introduction
This chapter provides initial installation, adjustment, and operating instructions of
the TG actuator.
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.
Initial Operation
Before initial operation of the TG equipped turbine, make sure that all previous
installation steps have been correctly accomplished and that all linkages are
secure and properly attached. See Chapter 2, Installation. Also, read all of this
chapter.
Be prepared to make an emergency shutdown when starting the

engine, turbine, or other type of prime mover, to protect against
runaway or overspeed with possible personal injury, loss of life, or
property damage.
Follow the turbine manufacturer’s instructions to start the turbine.
Normally, the only requirements for putting a new or overhauled TG actuator into
service are to fill the actuator with oil (see Chapter 2, Oil Supply) and adjust the
selected speed setting on the electronic speed control. Select a low-speed
setting on the electronic control to give low turbine speed at initial start-up.
Maximum terminal shaft travel is 30 degrees for the TG-10E and 40 degrees for
the TG-13E/-17E. Adjust the steam linkage so that terminal shaft travel from “NO
LOAD” to “FULL LOAD” is 2/3 of maximum shaft travel (see Figure 2-1).
Be sure to allow sufficient overtravel at each end of the terminal

shaft so the actuator can shut down the turbine and also give
maximum steam flow when required.
Open the steam valve slowly. Check the turbine speed and adjust as necessary
to bring the turbine to rated speed.
Woodward 13
Check the actuator and governor system for stable operation by manually
disturbing the terminal shaft linkage or speed setting. Stability is satisfactory
when the turbine returns to speed with only a slight overshoot or undershoot.
Cleaning the Filter Screens and The Pilot-Valve

Plunger Orifice
The source of most troubles and failures with the TG actuator is from
contamination of the filter screens and pilot-valve plunger orifice. Impurities can
be introduced in the actuator with the oil, or form when the oil begins to break
down (oxidize) or becomes sludgy. If this is the case, sluggish or erratic actuator
operation (or loss of actuator control) can be corrected by using the following
procedure to clean the filter screen and the pilot-valve plunger orifice.
Cleaning the Filter Screens

1. SHUT DOWN THE TURBINE, following the turbine manufacturer’s
instructions.
2. Drain the oil from the actuator through the oil drain plug (see Figure 1-1).
3. Use a 1-3/8 inch (35 mm) wrench and remove the oil filter hex nut. The filter
is attached to the nut and is pulled out as the nut is removed.
4. Wash the filter ultrasonically or by agitation in fuel oil. Dry the filter with a jet
of clean, dry, compressed air.
5. Reinstall the filter and torque the filter hex nut down.
6. Fill the actuator with clean, fresh oil, (see Chapter 2, Oil Supply).
Cleaning the Pilot-Valve Plunger Orifice

1. SHUT DOWN THE TURBINE, following the turbine manufacturer’s
instructions.
2. Drain the oil from the actuator through the oil drain plug (see Figure 1-1).
3. Remove the actuator cover and supply tube for cover filter.
4. Remove the two screws holding the transducer clamp bracket (brass
bracket). Do NOT change the settings of the level adjusting screw or the
range adjustment slider (see Figure 3-1 for identification of parts).
5. Turn the clamp bracket slightly to one side to release the restoring lever
from the terminal lever.
6. Remove the restoring spring.
14 Woodward
Figure 3-1. TG Actuator with Cover Removed
7. Lift off the transducer assembly and carefully move it to the side.
8. Pull out the pilot-valve plunger and its bushing.
9. Remove the snap ring from the pilot valve-bushing. Carefully pull out the
pilot-valve plunger and bushing. Do not bang the parts together.
10. Immerse the pilot-valve plunger and bushing in diesel fuel oil or approved
cleaning solvent and wash ultrasonically or by agitation. Use a non-metallic
brush or jet of compressed air to clean slots, bushing filter screen, holes,
and pilot-valve plunger orifice.
11. Reinsert the pilot-valve plunger into the bushing. Make sure that the pilot-
valve plunger slides freely of its own weight while shaking the bushing. If
not, disassemble and check for nicks or scratches on the plunger lands.
12. Reinstall the transducer assembly in reverse order from disassembly,

making certain that all parts are properly seated.
13. Torque the two screws evenly to 25 lb-in (2.8 Nxm) while holding the
transducer clamp bracket.
Uneven torque, misalignment of spacer rings, or improperly seated

rings can cause a large calibration shift.
14. Fasten the cover to the actuator with eight cover screws. Torque the screws
to 100 lb-in (11.3 Nxm). Reinstall the filter supply tube.
15. Fill the actuator with clean, fresh oil (see Chapter 2, Oil Supply).
Woodward 15
16. Recalibrate the TG actuator after completing the above procedure. See
below: Procedure with Actuator on the Turbine OR Calibration Procedure
with Actuator on a Test Stand.
Calibration Procedure
There are several conditions which require a recalibration of the TG actuator:
• When the installation is changed from vertical to horizontal, or vice versa.
• After performing a transducer assembly tightness check, disassembly, and
rework.
• After cleaning the pilot-valve orifice plunger.
• Any time a calibration shift is suspected.
Calibration Procedure with Actuator on the Turbine

1. CLOSE THE HAND-THROTTLE STEAM VALVE, following the turbine
manufacturer’s instructions.
When operating the hand-throttle, the system is not under actuator

control, and extreme caution must be taken to prevent overspeed. Do
not attempt if the overspeed device is not functioning.
2. Disconnect the actuator from the steam control valve linkage.
3. Remove the actuator electrical connection.
4. Manually rotate the actuator terminal shaft to its full minimum position and
mark that position with a reference mark.

property damage.
5. Following the turbine manufacturer’s instructions, carefully start the turbine

manually using the hand-throttle steam valve, and set the speed at the
following speed setting:
1500 rpm on actuators marked 2400 rpm
6. Apply a 0 to 200 mA power source to pins A and B of the connector to check

the level adjustment on the actuator (see Figure 3-2).
16 Woodward
Figure 3-2. Wiring Diagram for Actuator Calibration Circuit
7. With no current applied, make sure that there is no travel of the terminal shaft
from the minimum position.
8. A recalibration is required if any of the following conditions exists:

(1) With 20 mA current applied, if less than 1-degree movement or more
than 3-degree movement is seen from minimum position
than 39-degree movement is seen from minimum position (27 to 29
degrees for TG-10E)
(3) If the terminal shaft does not rotate smoothly from one position to
another, or if it does not take the same position for the same
potentiometer setting when rotated from the increase or decrease
position
9. SHUT DOWN THE TURBINE following the turbine manufacturer’s

instructions, remove the actuator cover and supply tube for actuator cover. (If
the actuator is mounted horizontally, first drain the actuator oil through the oil
drain plug.)
10. If condition (1) or (2) in Step 8 above exists, skip Step 11 below and go to
Step 12 to recalibrate the actuator.
11. If condition (3) in Step 8 above exists, the transducer assembly must be
disassembled before recalibrating the actuator to make sure that there is no
binding of the feedback lever, spring, transducer assembly, or pilot-valve
plunger.
Disassemble the transducer assembly as follows:

(1) Remove the two screws holding the transducer clamp bracket (brass
bracket). Do NOT change the settings of the level adjusting screw or
the range adjustment slider (see Figure 3-1 for identification of parts).
(2) Turn the clamp bracket slightly to one side to release the restoring
lever from the terminal lever.
(3) Remove the restoring spring.
(4) Lift off the transducer assembly and carefully move it to the side.
(5) Pull out the pilot-valve plunger and its bushing.
(6) Remove the snap ring from the pilot-valve bushing and pull out the
pilot-valve.
(7) Immerse the pilot-valve plunger and bushing in diesel fuel oil or
approved cleaning solvent and wash ultrasonically or by agitation. Use
a non-metallic brush or jet of compressed air to clean slots, bushing
filter screen, holes, and pilot-valve plunger orifice.
Woodward 17
(8) Make sure that the pilot-valve plunger slides freely of its own weight
while shaking the bushing, after reassembling the pilot-valve plunger
into the bushing. If not, disassemble and check for nicks or scratches
on plunger lands.
(9) Reinstall the transducer assembly in reverse order from disassembly,
making certain that all parts are properly seated.
(10) Torque the two screws holding the transducer clamp bracket evenly to
25 lb-in (2.8 Nxm).
Uneven torque, misalignment of spacer rings, or improperly seated

rings can cause a large calibration shift.
(11) If actuator oil was drained in Step 9, fasten the cover with eight cover
screws and torque screws to 100 lb-in (11.3 Nxm). Reinstall the filter
supply tube and refill actuator with clean, fresh oil.
(12) Proceed now to recalibrate the TG actuator as shown in the next step.
12. If no movement of the actuator terminal shaft was seen after starting the
turbine in Step 5 above, turn the level adjusting screw 1/8 turn clockwise with
a 1/8 inch (3 mm) Allen wrench. The level adjusting screw can be found
above the transducer (see Figure 3-1).
If too much movement of the actuator terminal shaft was seen after starting
the turbine, turn the level adjusting screw 1/8 turn counterclockwise.
13. Repeat Step 12 until 1 to 3 degrees of terminal shaft movement is seen when
the turbine is started and 20 mA is applied.
14. Check the range adjustment on the actuator. With 20 mA current applied,
terminal shaft travel must be 1 to 3 degrees from minimum position. With 160
mA current applied, terminal shaft travel must be 37 to 39 degrees from
minimum position (27 to 29 degrees on the TG-10E).
15. If terminal shaft travel is incorrect, adjust the range adjustment (see Figure
3-1). Moving the range lever slider away from the center of the actuator
decreases the range, and moving it towards the center increases the range.
16. Repeat Steps 12 and 13 (level adjustment) if the range slider has been
moved in Step 15 above (range adjustment).
17. Rotate the test circuit potentiometer to various positions while looking at the
movement of the actuator terminal shaft. The terminal shaft must rotate
smoothly from one position to another. It also must take the same position for
the same potentiometer setting when rotated from the increase or decrease
position.
18. Reconnect the actuator to the steam control valve with the control linkage.
Adjust the linkage so that there is approximately 5 degrees of terminal shaft
overtravel from minimum actuator position with the steam control valve at its
tightly closed position.
19. Reconnect the actuator electrical connector.
20. Fasten the cover with eight cover screws and torque screws to 100 lb-in
(11.3 Nxm). Reinstall the filter supply tube and refill actuator with clean, fresh
oil.
This completes the recalibration of the TG actuator on the turbine.

18 Woodward
Calibration Procedure with Actuator on a Test Stand

If a TG actuator requiring a customer-supplied hydraulic pressure source is to be
recalibrated, in addition to using the procedure described below, be sure to meet
the following requirements:
• Supply the filter fitting with the oil filtered to 10 to 30 µm (nominal). This
ensures that the 40 µm filter fitting is not contaminated.
• The drain flow must be approximately 1 to 2 gal/min (4 to 8 L/min) to ensure
that the accumulator is bypassing. The oil supply pressure must be 160 psi
(1103 kPa) minimum.
Use the following procedure to calibrate the TG actuator:
1. Mount the actuator vertically on the test stand.
2. Remove the cover and plug the oil line to the actuator filter.
3. Connect a test circuit to pins A and B on the pin connector to the actuator.
The test circuit is shown in Figure 3-2.
4. With no current applied, make sure that there is no travel of the terminal
shaft from the minimum position.
5. A recalibration is required if any one of the following conditions exists:

than 3-degree movement is seen from minimum position
than 39-degree movement is seen from minimum position (27 to 29
degrees for TG-10E)
(3) If the terminal shaft does not rotate smoothly from one position to
another, or if it does not take the same position for the same
potentiometer setting when rotated from the increase or decrease
position.
6. If none of the conditions listed in Step 5 above exists, a recalibration is not

required. Drain actuator oil; fasten the cover with eight cover screws and
torque screws to 100 lb-in (11.3 Nxm). Reinstall the filter supply tube.
7. If condition (1) or (2) in Step 5 above exists, skip Step 8 and go to Step 9 to
recalibrate the actuator.
8. If condition (3) in Step 5 above exists, the transducer assembly must be

disassembled before recalibrating the actuator to make sure that there is no
binding of the feedback lever, spring, transducer assembly, or pilot-valve
plunger.
Disassemble and reassemble the transducer assembly as explained

previously in Step 11 of the previous section.
9. Install and secure a protractor over the terminal shaft. Use the terminal shaft
as an indicator and rotate the output shaft over its full range of travel. Mark
the minimum and maximum shaft positions on the protractor. The total
terminal shaft travel must be 40 degrees.
10. Use SAE 10 oil at 60 degrees F to 180 F. Fill actuator to within 2 inches of
top. Always use an oil filter with 140 µm maximum rating on the accumulator
bypass during recalibration.
Woodward 19
11. Drive (rotate) the actuator drive shaft in the proper direction of rotation
(clockwise or counterclockwise) according to the actuator specification
sheet, and drive the actuator at the following speed setting:
12. All calibration is done open loop. Set the power supply to 20 mA. Turn the
level adjusting screw counterclockwise (see Figure 3-1) with a 1/8 inch (3
mm) Allen wrench, until the terminal shaft moves from 1 to 3 degrees from
the minimum position.
13. Set the power supply to 160 mA. The terminal shaft must move from 37 to
39 degrees from the minimum position. Adjust the range adjustment (see
Figure 3-1) if terminal shaft travel is incorrect. Moving the range slider away
from the center of the actuator decreases the range, and moving it toward
the center increases the range (27 to 29 degrees for the TG-10E.)
Repeat Steps 12 and 13 until the correct travel range is obtained.
14. If the actuator is to be horizontally mounted, the level adjustment will shift +6
degrees towards the minimum position. Set the power supply to 20 mA and
turn the level adjustment screw clockwise until the terminal shaft moves 7 to
8 degrees from the minimum position. The actuator is now correctly
adjusted for horizontal installation.
15. Rotate the test circuit potentiometer to various positions while looking at the
movement of the actuator terminal shaft. The terminal shaft must rotate
smoothly from one position to another. It also must take the same position
for the same potentiometer setting when rotated from the increase or
decrease position.
16. Fasten the cover with eight cover screws and torque the screws to 100 lb-in
(11.3 Nxm). Reinstall the filter supply tube.
This completes the calibration of the TG actuator on the test stand.
20 Woodward
Chapter 4.
Principles of Operation
Introduction
This chapter describes the operation of the TG actuator. The schematic drawing
(Figure 4-1) illustrates the working relationship of the various parts shown in the
relative position assumed during normal operation.
Internally, the TG actuator consists of the following basic components:

• Oil pump
• Oil accumulator
• Oil filter
• Transducer with flapper
• Pilot-valve plunger
• Power piston
• terminal lever with shaft
In Figure 4-1,the connecting oil passages between the components are simplified
for ease in visualizing the system.
Component Operation
A brief description of the operation of the components will facilitate understanding
the operation of the actuator.
The oil pump (14) is a Gerotor-type pump which provides oil pressure for the
actuator. The oil pump is driven by the actuator drive shaft, which in turn is driven
by the turbine or by an optional remote drive. The pump draws oil from the sump
and distributes it through the oil passages within the case. The accumulator (30)
maintains the operating pressure at rated speed (150 psi/1034 kPa for the TG-
10E/TG-13E or 200 psi/1379 kPa for the TG-17E). Excess pressure compresses
the accumulator springs, and oil flows through the accumulator bypass (17) to
the filter (26).
An increase or a decrease in current from the governor moves the pilot-valve

plunger downward or upward. Plunger movement opens the control port and
releases oil either to sump or to the under side of the power piston. During power
piston movement, the accumulator supplements the system oil supply with its
stored volume of high pressure oil and helps maintain the full work capacity of
the actuator.
The power piston (6) rotates the actuator terminal shaft (2) to the increase- or
decrease-steam position. The top end of the power piston (6) is connected to the
actuator terminal shaft (2) through a terminal lever (4) and link assembly (5). The
power piston is a differential type with oil pressure on both sides of the piston.
The underside of the power piston has a larger area than the upper side of the
piston. Therefore, if the oil pressure is the same on both the upper and underside
of the piston, the piston moves up to rotate the actuator terminal shaft in the
increase steam direction. The piston moves down only when oil under the piston
is released to sump. Constant oil pressure is applied to the upper side of the
power piston, always loading it in the decrease-steam direction. Oil to and from
the bottom of the power piston is regulated by the pilot-valve plunger system.
Woodward 21
The pilot-valve plunger system includes the nozzle/pilot-valve plunger (20) and
the pilot-valve bushing (7). When the nozzle/pilot-valve plunger (20) is lowered,
high pressure oil flows under the power piston (6), raising it. When the
nozzle/pilot-valve plunger is raised, oil is released to sump from under the power
piston (6), lowering it. When the nozzle/pilot-valve plunger (20) is in its “centered”
position, the control land covers the control port as shown in the schematic
(Figure 4-1), and there is no movement of the power piston and no movement of
the actuator terminal shaft (2).
The movement of the pilot-valve plunger (20) is controlled hydraulically by

varying the oil flow from the nozzle of the pilot-valve plunger with a flapper (11).
The upward and downward movement of the flapper is controlled by the
transducer (12). As the flapper (11) moves closer to the nozzle, the restriction to
oil flow at the nozzle is increased . As a result, the oil pressure acting on the
upper side of the differential power land (19) starts increasing. Since the area is
greater on the upper side than on the lower side of the differential power land
(19), the now greater force exerted on the upper side of the power land causes
the pilot-valve plunger (20) to move downward. As it moves downward, the pilot-
valve plunger control land uncovers the control port in the pilot-valve plunger
bushing (7). Pressure oil is now directed to the underside of the power piston (6),
causing it to move upward, rotating the terminal shaft (2) in the increase-steam
direction. As the terminal shaft (2) rotates in the increase-steam direction, the
restoring lever (13) moves up, decreasing the restoring spring (25) force. When
the terminal shaft (2) has rotated far enough so that the decrease in restoring
spring force equals the increase in magnetic force in the solenoid coils (23), the
pilot-valve plunger is re-centered.
The opposite sequence of movements takes place when the transducer (12)
causes the flapper (11) to move away from the nozzle (20).
As the flapper (11) moves away from the nozzle (20), the restriction to oil flow at
the nozzle decreases . As a result, the oil pressure acting on the upper side of
the differential power land (19) starts decreasing. The now greater oil pressure
acting on the lower side of the differential power land (19), causes the pilot-valve
plunger (20) to move upward. As it moves upward, the pilot-valve plunger control
land uncovers the control port in the pilot-valve plunger bushing (7). Oil from the
underside of the power piston (6) is now released to sump, and pressure oil
acting on the upper side of the power piston moves the power piston downward,
rotating the terminal shaft (2) in the decrease-steam direction. As the terminal
shaft rotates in the decrease-steam direction, it causes the restoring lever (13) to
move down, increasing the restoring spring (25) force. When the terminal shaft
has rotated far enough so that the increase in restoring spring force equals the
decrease in downward magnetic force in the solenoid coils (23), the pilot-valve
plunger is re-centered.
During operation, the pilot-valve plunger (20) and the transducer (12) act as if
they were a single piece, acting together, as the gap between nozzle and flapper
remains nearly constant . The upward and downward movement of the flapper is
controlled by the transducer (12).
The transducer (12) converts the electrical signal given by the electronic control
to a proportional downward movement of the permanent magnet (22) and its
attached flapper (11). Please refer to the applicable Woodward manual for
information regarding the electronic speed control selected.
22 Woodward
Opposing the downward magnetic force exerted by the transducer (12) is a
resultant spring force from the load spring (24). The load spring (24) sits on top of
the case in which the transducer (12) is located, and exerts a constant upward
force on the magnet (22) and its attached flapper (11). The restoring spring (25),
weaker than the load spring (24), exerts a downward force on the magnet (22)
and its attached flapper (11). The amount of downward force exerted by the
restoring spring (25) depends upon the position of the restoring lever (13).
When the power piston (6) which is attached to the terminal lever (4) moves up,
the terminal lever (4) and the restoring lever (13) also move up, decreasing load
on the restoring spring (25). When the power piston (6) moves down, the terminal
lever (4) and the restoring lever (13) move down, increasing load on the restoring
spring (25).
With a constant current, the resultant spring force and the constantly opposing
magnetic force always balance, and the pilot-valve plunger is “centered.” The
control land of the pilot-valve plunger exactly covers the control port in the pilot-
valve bushing, and no oil flows to or from the power piston.
Operation of the TG Actuator

General Information
Refer to Figure 4-1 to better understand the operation of the TG actuator.
The description that follows discusses the TG actuator operation. It must be

remembered that the actuator only responds to a change of dc voltage coming to
the transducer. The load or speed sensing must come from an electronic control.
The description that follows is based on load changes. The integrating control
senses the load change and proportionally varies the dc voltage going to the
actuator. (Changes in the system control speed setting produce the same
actuator movements as do changes in load on the turbine.)
Decrease in Load or Speed Setting

Assume that the turbine is running on-speed under steady-state conditions. The
control voltage to the actuator is therefore constant. The pilot-valve plunger (20)
is centered over the control port of the pilot-valve bushing (7) and the control land
stops the flow of the pressure oil through the bushing control port. There is no
movement of the power piston (6) and no movement of the actuator terminal
shaft (2).
A decrease in load (or speed setting) causes a decrease in control voltage to the
transducer (12). This in turn causes a decrease in the magnetic force tending to
raise the flapper (11). For the reasons explained above, the pilot-valve plunger
(20) always follows the flapper and the pilot-valve plunger moves upward, above
center, uncovering the pilot-valve bushing (7) port. Oil escapes from under the
power piston (6), causing the power piston to move downward and the terminal
shaft (2) to rotate in the decrease-steam direction. As the terminal shaft rotates in
the decrease-steam direction, it causes the restoring lever (13) to move down,
increasing the restoring spring force (25). The terminal shaft rotates until the
increase in restoring spring (20) force equals the decrease in downward
magnetic force in the transducer (12). Then the pilot-valve plunger (20) is re-
centered.
Woodward 23
The control port in the pilot-valve bushing (7) is covered by the land on the pilot-
valve plunger (20). This stops the power piston (6) and the actuator terminal
shaft (2) in the new position needed to run the turbine at the decreased load or
decreased-speed setting.
Figure 4-1. TG Actuator Schematic Diagram
Increase in Load or Speed Setting

Assume that the turbine is running on-speed under steady-state conditions. The
control voltage to the actuator is therefore constant. The pilot-valve plunger (20)
is centered over the control port of the pilot-valve bushing (7) and the control land
stops the flow of pressure oil through the bushing control port. There is no
movement of the power piston (6) and no movement of the actuator terminal
shaft (2).
24 Woodward
An increase in load (or speed setting) causes an increase in control voltage to
the transducer (12). This in turn causes an increase in the magnetic force tending
to lower the flapper (11) and the hydraulically controlled pilot-valve plunger (20).
As it moves downward, the pilot-valve plunger control land uncovers the control
port in the pilot-valve bushing (7). Pressure oil is now directed to the underside of
the differential power piston (6), causing it to move upward, and to rotate the
terminal shaft (2) in the increase-steam direction. As the terminal shaft (2) rotates
in the increase-steam direction, the restoring lever (13) moves up, decreasing the
restoring spring (25) force. The terminal shaft (2) rotates until the decrease in
restoring spring (25) force equals the increase in downward magnetic force in the
transducer (12) and the pilot-valve plunger is re-centered.
The control port in the pilot-valve bushing (7) is covered by the land on the pilot-
valve plunger (20). This stops the power piston (6) and the actuator terminal
shaft (2) in the new increase-steam position. The actuator has now reached the
new position to run the turbine at the selected speed setting with the increased
load or increased speed setting.
Woodward 25
Chapter 5.
Troubleshooting
Introduction
This chapter provides instructions for troubleshooting.
Poor governing may be due to faulty actuator performance, or it may be due to

the actuator attempting to correct for faulty operation of the turbine or the
equipment driven. The effect of any auxiliary equipment on the overall control
required of the actuator must be considered. Some actuator troubles can also be
related to control signal problems. Please refer to the appropriate manual for
troubleshooting information on the Woodward electronic control used with the TG
actuator.

property damage.
Visual Inspection
Actuator troubles are usually revealed in speed variations of the turbine, but it
does not follow that all speed variations are caused by the actuator. When
improper speed variations appear, the following procedure should be performed:
1. Check the load to be sure the speed changes are not the result of load
changes beyond the capacity of the turbine.
2. Check the control valve for proper operation.
3. Check the linkage between the actuator and the steam valve. There must be
no binding, no lost motion, and/or no inadequate travel.
4. Make sure that the oil level is in the oil sight glass at operating temperature.
Remove the breather/filler cap and add oil if necessary (see Chapter 2, Oil
Supply).
5. SHUT DOWN THE TURBINE.
6. While the turbine is shut down, disconnect the control linkage between the
actuator and the control valve or fuel rack.
During this test, the actuator is disconnected from the turbine.
7. Disconnect the leads from the actuator terminals. Hook up a circuit to the
actuator, as shown in Figure 5-1.
26 Woodward
Figure 5-1. Actuator Test Circuit
8. If necessary to provide drive or oil pressure to the actuator—depending on

the type of drive and source of oil pressure used on the particular TG—start
the turbine UNDER MANUAL CONTROL, following the turbine
manufacturer’s instructions.
9. Control prime mover speed MANUALLY and bring turbine speed to a SLOW
SPEED to develop actuator working pressure.
10. Slowly rotate the potentiometer through its range and observe the actuator’s
shaft movement.
The terminal shaft must move through its range of travel as the potentiometer
is rotated and must take the same position each time for a given
potentiometer setting.
If the terminal shaft positions or operates erratically, the problem is in the

actuator.
11. Check the removable cover filter element for possible clogging if actuator
control is sluggish or just stops. The cover filter filters all internal oil. Clean
and back-flush the filter in fuel oil or kerosene and reinstall. Remove this
filter only after the turbine has stopped rotating and the oil has been drained
from the actuator.
If an external oil supply is used, there is no cover filter element. Instead, the
actuator is fitted with a –6 filter fitting (70 µm absolute) and a –10 drain fitting.
Check the filter for possible clogging, clean and back-flush the filter with fuel
oil or kerosene, and re-install.
The TG actuator is also fitted with a filter screen (18) as a secondary filter,
which is part of the pilot-valve bushing. It is used to protect the nozzle supply
orifice from possible clogging. Checking the secondary filter requires partial
disassembly and recalibration of the actuator. See Chapter 3, Procedure for
Cleaning the Filter Screens and the Pilot-Valve Plunger Orifice, as well as
Chapter 3, Calibration Procedure.
Dirty oil causes most actuator troubles. Use new, clean, filtered oil. Oil
containers must be perfectly clean. Oil contaminated with water breaks down
rapidly, causing foaming and corrosion of internal parts. This usually results
in sluggish, erratic, or complete loss of actuator control.
Woodward 27
12. Check electronic control output for proper voltage. Refer to the applicable
Woodward manual for troubleshooting the electronic control.
Use the troubleshooting chart (Table 5-1) on the next page to determine the
probable cause of faulty operation and to correct these troubles.
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.
Table 5-1. TG Actuator Troubleshooting
Symptoms Cause Correction

1. The turbine hunts or surges. A. Low oil level Add oil to a level visible in the oil sight
glass.
B. Dirty oil Clean and back-flush cover filter in fuel oil
or kerosene. Change oil.
C. Binding terminal shaft linkage Align linkage as necessary.
2. The actuator has difficulty in A. Insufficient use of terminal shaft Check linkage and readjust.
accepting load, or is unstable as travel Recommended travel is 2/3 of maximum
evidenced by a slow and actuator shaft travel from no load to full
unsteady oscillation especially load.
after a load change. B. High steam valve gain Check that steam valve is not too large or
oversize for the particular application.
C. Dirt in actuator Drain, flush, and refill with fresh oil. Clean
cover filter.
3. The turbine cannot obtain rated A. Incorrect terminal shaft linkage Check linkage. Recommended travel is 2/3
speed. travel of maximum actuator shaft travel from no
load to full load.
4. The actuator does not start or A. Wrong actuator drive rotation Check turbine drive to the actuator.
control. Reverse pump parts for opposite direction
of rotation. See Chapter 2, Installation.
B. Key not properly installed or Remove actuator and properly install a No.
missing; drive shaft is not engaged 5 Woodruff key into actuator drive.
C. Incorrect control voltage Check electric control output for proper
voltage, and adjust. Check polarity.
5. Actuator does not provide A. Actuator oil too hot; oil viscosity Use higher viscosity oil and/or an oil
rated work capacity. Low oil too low cooler. See Chapter 2, Oil Supply.
pressure at low speeds. B. Improper speed range actuator Check actuator part number to verify
proper matching with turbine speed.
6. Erratic actuator control; A. Transducer assembly is not See Woodward Service Bulletin number
actuator may stick at maximum tight 50055 for transducer disassembly and
fuel. rework.
28 Woodward
Chapter 6.
Replacement Parts
When ordering replacement parts, include the following information:

• Governor serial number and part number shown on the nameplate
• Manual number (this is Manual 04045)
• Part reference number and part name from parts list
Ref. Part Description ..................... Quantity Ref. Part Description ......................Quantity

04045-1 Breather, Filler Cap ............................... 1 04045-42 Sleeve, Collar ....................................... 1
04045-2 Screw,. .250-20” x .750”...................... 12 04045-43 Seal, Oil ................................................ 1
04045-3 Cotter Pin .............................................. 1 04045-44 Bearing, Ball ......................................... 1
04045-4 Drilled Pin ............................................. 1 04045-45 Ring, Int. Bowed, Retaining .................. 1
04045-5 Restoring Lever Assembly .................... 1 04045-46 Tube, TG Accumulator Bypass............. 1
04045-6 Screw, 10-32 x 2.5”, Pan Hd ................. 2 04045-47 Plug, 1/2 Inch Pipe, Socket Hd ............. 1
04045-7 Screw, .250-20” x 1.000”....................... 3 04045-48 Screw ................................................... 4
04045-8 Lock Washer, .250” Spring Lock ........... 3 04045-49 Washer, No. 6 Split Lock ...................... 5
04045-9 Flat Washer, .250” ID ............................ 3 04045-50 Receptacle Retainer Plat ...................... 1
04045-10 Range Slider ......................................... 1 04045-51 Receptacle ........................................... 1
04045-11 Terminal Lever ...................................... 1 04045-52 Screw, NO. 2 x .125, Drive ................... 2
04045-12 Servo Piston Housing ........................... 1 04045-53 Nameplate, TG-13E ............................. 1
04045-13 Connecting Link Assembly.................... 1 04045-54 Elbow, 45°, 1/8 Pipe, 1/4 Ferulok
04045-14 Servo Piston ......................................... 1 Tube ..................................................... 1
04045-15 Magnet Assembly ................................. 1 04045-55 Shaft, TG Terminal ............................... 2
04045-16 Spacer, Lower Transducer.................... 1 04045-56 Oil Seal ................................................. 2
04045-17 Not used 04045-57 Needle Bearing..................................... 2
04045-18 Not used 04045-58 Case, TGE............................................ 1
04045-19 Spacer, Diaphragm ............................... 1 04045-59 Transducer Assembly ........................... 1
04045-20 Diaphragm, Magnet Centering .............. 2 04045-60 Retainer, Top Coil ................................ 1
04045-21 Pilot, Clamping ...................................... 1 04045-61 Support, Diaphragm ............................. 1
04045-22 Plunger, Transducer ............................. 1 04045-62 Spacer, Upper Transducer ................... 1
04045-23 Pilot, Transducer ................................... 1 04045-63 Spring, TG-10E Return ......................... 1
04045-24 Ring, Int. Retaining, .482 Free Dia. ....... 1 04045-64 Not Used
04045-25 Bushing, Power Servo .......................... 1 04045-65 Not Used
04045-26 Plunger Assy, Dog Valve Nozzle .......... 1 04045-66 Seat, Restoring Spring ......................... 1
04045-27 Washer, Spring ..................................... 1 04045-67 Screw, 6-32 x .750 Inch, Soc Hd Cap .. 1
04045-28 Filter Screen ......................................... 1 04045-68 Bracket, Transducer Clamp .................. 1
04045-29 Bushing Assy, Dog Valve, 04045-69 Washer, Split Lock, No. 10 ................... 2
Includes Screen .................................... 1 04045-70 Spring, Feedback ................................. 1
04045-30 Plate, TGE Transducer Mounting ......... 1 04045-71 Seat, Adj. Spring .................................. 1
04045-31 Ring, Ext. Retaining, Bowed, .461 Dia .. 1 04045-72 TG-10E Cover ...................................... 1
04045-32 Ring, Ext. Retaining, Flat, .461 Dia ....... 1 04045-73 Cover Gasket ....................................... 1
04045-33 Screw, .250-20 x 1.000 inch, 04045-74 O-Ring .................................................. 1
Thread Form ......................................... 4 04045-75 O-Ring .................................................. 1
04045-34 Pump Housing Assembly ...................... 1 04045-76 Filter Assembly ..................................... 1
04045-35 Pump, .375 Thick Gerotor ..................... 1 04045-77 Piston, Accumulator ............................. 1
04045-36 Pin, Pump Drive .................................... 1 04045-78 Spring, Accumulator, Outer .................. 1
04045-37 Gauge, Oil Sight ................................... 2 04045-79 Spring, Accumulator, Inner ................... 1
04045-38 Elbow, 1/8 Pipe Thd to 1/4 Tube ........... 1 04045-80 Seat, Accumulator Spring ..................... 1
04045-39 Decal, Drive Shaft Rotation................... 2 04045-81 Ring, Int. Retaining, 1.526 Inch
04045-40 Shaft, Pump Drive ................................. 1 Free Dia................................................ 1
04045-41 0-Ring, 2.000 x .062 Inch ...................... 1
Woodward 29
Figure 6-1. TG Exploded View
30 Woodward
Chapter 7.
Service Options
Product Service Options

If you are experiencing problems with the installation, or unsatisfactory
performance of a Woodward product, the following options are available:
• Consult the troubleshooting guide in the manual.
• Contact the manufacturer or packager of your system.
• Contact the Woodward Full Service Distributor serving your area.
• Contact Woodward technical assistance (see “How to Contact Woodward”
later in this chapter) and discuss your problem. In many cases, your problem
can be resolved over the phone. If not, you can select which course of action
to pursue based on the available services listed in this chapter.
OEM and 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. In some cases, the
programming is password-protected by the OEM or packager, and they are the best
source for product service and support. Warranty service for Woodward products
shipped with an equipment system should also be handled through the OEM or
Packager. Please review your equipment system documentation for details.
Woodward Business Partner Support: Woodward works with and supports a

global network of independent business partners whose mission is to serve the
users of Woodward controls, as described here:
• A Full Service Distributor has the primary responsibility for sales, service,
system integration solutions, technical desk support, and aftermarket
marketing of standard Woodward products within a specific geographic area
and market segment.
• An Authorized Independent Service Facility (AISF) provides authorized
service that includes repairs, repair parts, and warranty service on Woodward's
behalf. Service (not new unit sales) is an AISF's primary mission.
• A Recognized Engine Retrofitter (RER) is an independent company that
does retrofits and upgrades on reciprocating gas engines and dual-fuel
conversions, and can provide the full line of Woodward systems and
components for the retrofits and overhauls, emission compliance upgrades,
long term service contracts, emergency repairs, etc.
• A Recognized Turbine Retrofitter (RTR) is an independent company that
does both steam and gas turbine control retrofits and upgrades globally, and
can provide the full line of Woodward systems and components for the
retrofits and overhauls, long term service contracts, emergency repairs, etc.
A current list of Woodward Business Partners is available at

www.woodward.com/support.
Woodward 31
Woodward Factory Servicing Options

The following factory options for servicing Woodward products are available
through your local Full-Service Distributor or the OEM or Packager of the
equipment system, based on the standard Woodward Product and Service
Warranty (5-01-1205) that is in effect at the time the product is originally shipped
from Woodward or a service is performed:
• Replacement/Exchange (24-hour service)
• Flat Rate Repair
• Flat Rate Remanufacture
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 a flat-rate program and
includes the full standard Woodward product warranty (Woodward Product and
Service Warranty 5-01-1205).
This option allows you to call your Full-Service Distributor 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 Full-Service Distributor.
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 within 60 days, a credit for the core charge will be issued.
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.
32 Woodward
Returning Equipment for Repair

If a control (or any part of an electronic control) is to be returned for repair,
please contact your Full-Service Distributor in advance to obtain Return
Authorization and shipping instructions.
When shipping the item(s), attach a tag with the following information:
• return number;
• 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.
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.
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.
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.
Woodward 33
Engineering Services
Woodward offers various Engineering Services for our products. For these services,
you can contact us by telephone, by email, or through the Woodward website.
• Technical Support
• Product Training
• Field Service
Technical Support is available from your equipment system supplier, your local Full-
Service Distributor, or from many of Woodward’s worldwide locations, depending
upon the product and application. This service can assist you with technical
questions or problem solving during the normal business hours of the Woodward
location you contact. Emergency assistance is also available during non-business
hours by phoning Woodward and stating the urgency of your problem.
Product Training is available as standard classes at many of our worldwide

locations. 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.
Field Service engineering on-site support is available, depending on the product

and location, from many of our worldwide locations or 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.
For information on these services, please contact us via telephone, email us, or
use our website and reference www.woodward.com/support, and then
Customer Support.
How to Contact Woodward

For assistance, call one of the following 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.
Electrical Power Systems Engine Systems Turbine Systems

Facility --------------- Phone Number Facility --------------- Phone Number Facility --------------- Phone Number
Australia ----------- +61 (2) 9758 2322 Australia ----------- +61 (2) 9758 2322 Australia ----------- +61 (2) 9758 2322
Brazil ------------- +55 (19) 3708 4800 Brazil ------------- +55 (19) 3708 4800 Brazil ------------- +55 (19) 3708 4800
China ------------+86 (512) 6762 6727 China ------------+86 (512) 6762 6727 China ------------+86 (512) 6762 6727
Germany: Germany:
Kempen --- +49 (0) 21 52 14 51
Stuttgart ----- +49 (711) 78954-0 Stuttgart ----- +49 (711) 78954-0
India --------------- +91 (129) 4097100 India --------------- +91 (129) 4097100 India --------------- +91 (129) 4097100
Japan -------------- +81 (43) 213-2191 Japan -------------- +81 (43) 213-2191 Japan -------------- +81 (43) 213-2191
Korea--------------- +82 (51) 636-7080 Korea--------------- +82 (51) 636-7080 Korea--------------- +82 (51) 636-7080
The Netherlands - +31 (23) 5661111 The Netherlands - +31 (23) 5661111
Poland -------------- +48 12 618 92 00
United States----- +1 (970) 482-5811 United States----- +1 (970) 482-5811 United States----- +1 (970) 482-5811
You can also contact the Woodward Customer Service Department or consult our
worldwide directory on Woodward’s website (www.woodward.com/support)
for the name of your nearest Woodward distributor or service facility.
For the most current product support and contact information, please refer to the
latest version of publication 51337 at www.woodward.com/publications.
34 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 35
We appreciate your comments about the content of our publications.
Send comments to: icinfo@woodward.com
Please reference publication 04045E.
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.
2009/3/Fort Collins

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What precautions should be taken when handling electronic components?

What precautions should be taken when handling electronic components?

Installation and Operation Manual

TG-10E, -13E, and –17E Actuator

Manual 04045 (Revision E)

To prevent damage to a control system that uses an alternator or battery-charging

To prevent damage to electronic components caused by improper handling, read

REGULATORY COMPLIANCE ........................................................................III

Illustrations and Tables

Figure 1-1. TG Actuator ..........................................................................................2

Table 2-1. Oil Chart ................................................................................................9

North American Compliance:

Wiring must be in accordance with North American Class I, Division 2 wiring

For use in NEC Class 2 circuits, 30 volts maximum.

EXPLOSION HAZARD—Do not remove covers or connect/disconnect

RISQUE D’EXPLOSION—Ne pas enlever les couvercles, ni

Electrostatic Discharge Awareness

Follow these precautions when working with or near the control.

1. Before doing maintenance on the electronic control, discharge the static

3. Keep plastic, vinyl, and Styrofoam materials (such as plastic or Styrofoam

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

• Do not touch the electrical conductors, the connectors, or the

To prevent damage to electronic components caused by improper

The TG proportional electrohydraulic actuator is a transducer which converts a

Drive Shaft Rotation

1. Remove the four pump housing screws.

2. Rotate the pump housing assembly 180 degrees.

5. Make sure that the pump drive shaft rotates freely.

Maintenance of the TG actuator is minimal due to few moving parts,

For horizontal operation, the TG actuator must be installed with the

Figure 2-1. Recommended Terminal Shaft Travel

Be sure to allow sufficient overtravel at each end of the terminal

Installed linkages must operate smoothly, free of binding. If there is a collapsible

Adequate locking methods must be used on the linkage connections. The

Heat Exchanger Installation (optional)

Figure 2-2. Heat Exchanger Piping Connections

We recommend that a throttling device be installed to the heat exchanger so that

When is a Heat Exchanger Necessary?

Excessive component wear or seizure in an actuator indicates the possibility of:

A loss of stable actuator control and possible turbine overspeed may

Replace the actuator oil if it is contaminated. Also, change the oil if it is

Observe manufacturer’s instructions or restrictions regarding the

If available, a regularly scheduled oil analysis is helpful in determining the

The recommended continuous operating temperature of the actuator is 140 to

Table 2-1. Oil Chart

Table 2-2. Viscosity Comparisons

Terminals C and D must be jumpered in

Figure 2-3. TG Actuator Outline Drawing

Terminals C and D must be jumpered in

Figure 2-4. TG-13E/-17E Outline Drawing

Wire motors according to the diagram that

Figure 2-5. TG-13E/-17E Outline Drawing

The engine, turbine, or other type of prime mover should be

Be prepared to make an emergency shutdown when starting the

Follow the turbine manufacturer’s instructions to start the turbine.

Be sure to allow sufficient overtravel at each end of the terminal

Cleaning the Filter Screens and The Pilot-Valve

Cleaning the Filter Screens