30 Years Strong!

KT230 Series
Caterpillar 3406
Governor System Installation Kit

Introduction

The KT230 Series Governor System Installation Kit provides Caterpillar 3406 series engines have a bell housing with a
the necessary brackets and hardware to install a GAC precise 5/8-18 UNF thread tapped hole to accept a MSP6720
Electronic Governor on a 3406 Caterpillar Engine. magnetic speed sensor. If a threaded hole is not available,
then the bell housing will need to be drilled.
The 225 series actuator is correctly sized for the application
and comes in both 12 or 24-volt variation. The speed control unit and 225 series actuator can be
selected by the customer to meet any specific needs

Pre-Installation
Disconnect the engine battery cables (negative connection The fuel injection pumps stop collar is not intended for
first) to prevent accidental engine starting. continuous duty. You can use the hardened Caterpillar
collar part # 2N453. If being used for stand-by then
The engine should be cool to avoid burns while installing the
there should be no need to replace it.
governor system.

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Figure 1
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Actuator Installation

The Actuator bracket mounts in the vacant are on the left 1. Install the 225 series electric actuator onto the
side of the engine, just below the pump and in front of the actuator bracket, using two ¼-20 x 1” bolts, flat
starter. The actuator must be positioned with its connector washers, lock washers and nuts.
pointing up and the label facing the starter. See Fig. 1.
2. Tighten all bolts securely.

Actuator Linkage Assembly

1. Thread a ¼-28 jam nut onto each end of the linkage rod.
Thread a Ball Bearing Rod end approximately ½” onto each rod end hole. Push the lever onto the shaft until the
end of the rod. Adjust the Rod ends so that their hole centers linkage is aligned. If necessary, slightly adjust the
length of the linkage. Adjust the lever on the shaft until
are parallel to each other and the distance between them is
approximately 11”. the linkage is vertical. Attach the linkage to the inboard
side of the actuator lever with a ¼-20 x 1” bolt and
2. Attach one end of the linkage rod assembly to the fuel lock nut.
pump shut off lever with a ¼-20 x 1” bolt and locking nut.
See Diagram 2. 4. Move the linkage assembly thru its full travel. There
should be no friction or binding in any position. Pull
3. Hold the fuel pump shut off lever in the no fuel position. the actuator lever and linkage to its full fuel position
Slide the actuator lever, flat side away from the actuator, (up) and release. The assembly should snap back to the
onto the actuator shaft so that the last hole from the shaft is no fuel position without binding. Recheck all fasteners.
aligned with the ball bearing

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Speed Control Unit Installation

Mount the Speed Control Unit in the engine control cabinet Site selection should allow access to the speed control
or engine mounted enclosure. unit adjustments.

If water, mist or condensation can come into contact with the The speed control unit case mounting holes can be used
controller, it should be mounted vertically. as a template for drilling holes.

Extreme heat should be avoided!

Magnetic Speed Sensor Installation

1. Remove the plastic plug from the tapped hole in the 3. Rotate the engine ring gear until a tooth crown is in the
engine bell housing. center of the tapped hole.

2. If there is no hole, drill and tap the engine bell housing. 4. Thread the Magnetic Speed Sensor into the tapped hole
The hole must be located perpendicular to the crankshaft until it bottoms on the ring gear tooth. Back the sensor out
centerline and centered over the flywheel. ½ turn and secure the lock nut
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Governor System Wiring

3. Install wire leads from the battery (-) and (+) to the
See specific Speed Control Unit publication for BATTERY input terminals of the Speed Control Unit
connection information. using solderless spade connectors. Battery polarity
1. Connect the electric actuator harness to the actuator. Cut must be observed. Fuse protection on the battery (+) of
the harness to length. Attach the solderless spade 15 amps is recommended.
connectors and attach to the ACTUATOR terminals of the
Speed Control Unit. Optional Speed Trim Control

2. Take and cut the Magnetic Speed Sensor harness to Panel mount and wire the speed trim potentiometer
length and connect it to the Speed Control Unit with 2 available from GAC. Connect the terminals of the
solderless connectors at the Pick-up terminals. potentiometer to the Speed Control Unit.

Speed Control Unit Adjustment

1. Remove the protective covers over the adjustments on the WARNING-An overspeed shutdown device,
Speed Control Unit. Independent of the governor system should be used.
Equipment damage or personal injury may result due
2. Check to ensure that the GAIN and STABILITY
to loss of engine control
adjustments are in their mid-positions.

3. If used, set the optional external speed trim control to its 4. Start the engine and rotate the engine SPEED
mid position adjustment to the desired engine speed (this is a 25 turn
potentiometer). Clockwise adjustment increases engine
speed.

Governor Performance Adjustments

If instability cannot be eliminated, or further

1.Rotate the Gain adjustment clockwise until instability
performance improvements are required, refer to the
develops. Gradually move the adjustment counter clockwise
Trouble Shooting Sections of the Speed Control Unit
until stability returns. Move the adjustment 1/8 of a turn
or Actuator publications.
further counter clockwise to insure stable performance.
4. Apply full load to the generator set. If it will not
2. Rotate the STABILITY adjustment clockwise until
carry full load, stop the engine and shorten the linkage
instability develops. Gradually move the adjustment counter
rod by turning the ball bearing rod ends in. Repeat the
clockwise until stability returns. Move the adjustment 1/8 of
load test. It may be necessary to back out the
a turn further counter clockwise to insure stable performance.
maximum fuel stop screw on the operating and/or the
3. Gain and stability adjustments may require minor changes shut off levers until full load is reached.
after engine load is applied. Normally adjustments made
under no load conditions achieve satisfactory performance.
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Parts for Complete Set-up

ITEM DESCRIPTION QUANITY
KT230 Installation Kit 1
225 Series Electronic Actuator 1
ESD5111 Controller 1
MSP6720 Mag-Pick-up 1

Options
TP501 5K-1 Turn Potentiometer 1
EEG6500 Digital Controller Replacement for the ESD5111 1

KT230 Components
Part Number Description Quantity
BK230 Actuator Bracket 1
HW01-109 3/8-16 x 1.250” 3
HW02-209 3/8” Lock-Washer 3
HW02-210 3/8” Flat Washer 3
HW03-303 ¼-20 Hex Nut 2
HW03-301 ¼-20 Lock Nut 2
RD102 ¼-28 x 12” plated linkage rod 1
HW01-112 5/16-18 x 1.25” Bolt 2
HW02-210 5/16” Flat Washer 2
HW02-211 5/16” Lock Washer 2
HW03-304 5/16-18 Nut 2
BB110 ¼-28 Bearing End 2
HW01-107 1/4 -20 x 1” Bolt 2
HW02-206 ¼ “Lock Washer 2
HW02-207 ¼” Flat Washer 2
HW03-300 ¼”-28 Nut 2
EC05-02-0007 Solderless Spade Connector 2
EC05-02-0006 Solderless Splice Connector 1
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KT230 Parts Illustration