II

/EG\
4 *

lnstructionBook
Partll

Section311 - 320

1.. -v

Bazan15

EngineType

7L23l30

MAN B&W Diese|A/S

lloleby Diesel

Ostervej2, DK-4960Holeby
Telephone
: +4553906O26
Telefax : + 15
53 9O6'676
Cables''

Edition02H
89.02

oildieselmaribo

ilarkcting
Telex

f0&16hodel dk

Scrvice
Telex
Teletax
Reg.No.

40280hodieldk
+ f55390 7426
24?31

EngineData

z
o

E
>tE
rr ll

o.

of Engine
Operation
andGondition
EnginePerformance
Tracing
Trouble
EngineFrameand Bedplate
and MainBearings
Crankshaft
CylinderHeadand GylinderLiner

PistonandConnecting
Rod
OperatingGearfor InletValveg
ExhaustValvesand FuelInjectionPumps
lJ

P
z<
z-fr

Turbocharger
System
FuelInjectionPump

2j-

E=
R;

FuelInjection

=z
=<

GamshaftandCamshaftDrive

ControlandSafetySystems
Automatics
andInstruments

F
l--

nrB
l
o

StartingSystem

Lubricating
Oil System
Specification
andTreatment
of LubricatingOil
FuelOil System
Fueland FuelTreatment
CoolingWaterSystem
Treatment
of CoolingWater
DrivenMachinery

SpecificPlantInformation

L23/30
F U E LI N J E C T I O N
DESCP
RT
I ION

311.01
Edition 07H

P la t e 3 ' l1 0 1

T h ef u e l i n j e c t o r c o n s i s t s o f a n o z z l e h o l d e r a n d a n o z z l ec o n n e c t e d
by a
s c r e wca p . T h e n o zzl e h o l d e rincludes a thr eadedp' ipe stub for mountin gtl .te
high-pressure
p ' i p e ,w h i c h i s l e d t h r o u g ha b o r i n g i n t h e t o p o f t h e c y i i n d e r
h e a d ,t o g e t h e rw i t h a n a d j u s t i n g s c r e w , a s p r i n g a n d s p r i n g s p i n d ' l ef r t h e
i n i t i a l t e n s i o n i n go f t h e n o z z l en e e d l e . T h e i n i t ' i a 1 t e n s i n b f t f r e s p r i n g ,
w h i c h de te rmi n e sth e o p e n i n gpr essur eof the nozzle, can be adjusted by m ns
o f t h e ce n tra l l y-mo u n te da d justing scr e$r .0n the upper mosttfr it<par t f the
h o l d e r , th e re a re th re e se a l' ingO- r ' ings.Betweenthe two lowest O- r ings , the
l e a k o i l f r o m t h e n o z z l en e e d l ei s l e d o u t i n t o t h e s p a c ' i n gb e t w e e nt e h i g h p r e s s u rep i p i n g a n d th e ,p ro tection tubing- Betweenthe two- upper m ost
0- r i nl s ,
w h e no pe ra ti n g w i th co o l e d nozzle, both the inlet and outlet ilow of the c ol
ling medium
is led.
A s a c o o l i n g m e d i u md, i e s e l o i l i s n o r m a l l yu s e d . T h i s i s l e d t h r o u g hb o r e d
d u c t s i n th e h o l d e r to th e conical bottomlur face of the nozzlewhih li es Ai r e c t l y in th e co mb u sti o nch am ber The
.
nozzle and needlear e lappedtoge ther as
a p a i r , a n d c a n n o tb e . r e p l a c e di n d i v i d u a l ' l y . T h e n o z z l e i s c o n l r o l l e d " b yt w o
p i n s a t ta ch e dto th e b o tto mof the holder . The joint sur face betweenth noz z l e a n d h o l d e r i s m a c h i n e - l a p p et od m a k ei t o i t - l i g h t . T h e f u e l i n j e c t o r i s
m o u n t edi n th e cyl i n d e r h e a dby meansof the integr al flange in te hol der and
t w o s t u d s w i th d i sta n ce p i e c es and nuts
F U E LO I L H I G H - P R E S SPUI R
PE
Plate 31102
T h e c o n n e cti o nb e tw e e ni n j e ction pumpand fuel injector is a shielded h i ghp r e s s u rep i p e . T h e h i g h -p re ssur epipe is equippedwith connectiontapers m atc h i n g t o si mi l a r-ta p e r fa ci n gs on the thr eadedconnector son the injection
p u m pa n d th e fu e l i n j e cto r. Theseconnect' ions
ar e to be tightenedwith a tor q u e o f 40 N m,th e sp a n n e rto be placed on the hexagonon sr ew2170,r es pec ti v e l y o n th e h e xa g o no n sh i e l ding cap 1824.
T h e s c r e w2 1 7 0i s scre w e d -j nwith loctite type 242 to the thr eads of the uni on
n u t 2 2 6 9a l g l i g h te n e d w i th a tor que of 60 Nm .The shielding cap 1824a nd the
u n i o n n u t 2 6 ? 5a re p re a sse mbled
similar ly. In case of dism atlingand r em antl i n g o f th e se p a rts sa mep ro cedur e( loctite z4z) and sam etor que- ( 60Nm )m us t
be used.
A ! t h 9 tyq l i n j e cto r e n d th e shield of the high- pr essur epipe is suppo r tedi n
t h e s h i e l . d i n gc a p l B 2 4 i n c ' l u d i n ga s e a l i n g r i g 2 0 8 1 . T h e s i r i e l d i n g ' t a pi s
s u p p o r t e di n a c l a m p0 8 4 5 , i n c l u d i n g t h e s e a l i n g r i n g 2 3 5 8 .T h e c l m pi s b o l t e d t o t h e c y l i n d e r h e a da n d s e a l e db y t h e r i n g - 2 4 4 1 .
At t h e in j e cti o n p u mpe n d th e shield of the high- pr essur epipe is suppo r tedi n
t h e s c r e w2 1 7 0 i n cl u d i n g a sealing r ing 2081. itr e scr ew/union- nutassemb'liys
s u p p o r t e di n a c l a m pl n c l u d i n g t h e s e a l i n g r i n g 2 3 5 8 .T h e c l a m pi s b o l t e d a n d
s e a l e d to th e co n n e cti o np i e ce of the injctio pump.

E#-E-------------

GENERATING SETS

L23/30

tv|AT\I
Et&ult

F U E LI N J E C T I O N
DESCRIPTI ON

311.02
Edition 07H

l, lh e nm o u n t i n gth e h i g h -p re ssu rep i pe, t' ighten the connectionsto injection

p u m pa n d t o f u e l i n j e cto r w i th 4 0 Nm ,and then tighten the clam psagainst cyl i n d e r h e a d .C h e c ka n d i f n e c e s s a r yr e n e ws e a l i n g r i n g s .

= G!

rF=EGt

GENERATIT\IG SETS

]YIAN
L23/30

E&U'
3 1 1. 5 1

F U E LI N J E C T I O N
O V E R H A U L IO
NFGF U E LI N J T C T O R

Edition 08

P l a t e 3 l 15 2
1.

Before dismantling the fuef injector, clean the lower part of the nozzle
o f c a r b o n ' i z e do i I d e p o s i t s .

2.

F ' i x f u e l i n j e c t o r t o c l a m p i n gb r a c k e t 0 2 0 6 a n d ' l o o s e n t h e l o c k n u t .
U n s t r e s s t h e n o z z ' l es p r i n g b y t u r n i n g o f t h e a d i u s t i n g s c r e w .
S w i n gt h e ' i n j e c t o r b y l 8 0 o C ( n o z z l e a t t h e t o p ) .

3 . L o o se nth e n o zzl e n u t b y counter - clockwiser otation and scr ewoff.

Remove
nozzle. Attention! Do not damagethe lapped surface.
4.

I f re q u i re d , th e n o zzl e spr ing and the spr ing spindle can be taken out by
t u r n i n g o f t h e a d j u s t i n gs c r e w .

A l l p a r t s m u s tb e c l e a n e dw i t h k e r o s e n e( i f n o t n o h a n du s e c l e a n l i g h t
f u e l o i l ) a n dw i t h a h a r d b r u s h .
'lapping,
e
and ar e ther efor e on' ly inter changeablas
6 . N ozzl e sa re ma tch e db y
u n 'ti .
q

I n s e rt n o zzl e n e e d l ew i th fuel o' il in the needle guide.

I t mu st b e co n tro l l e d , whetherthe nozzle needle slides downby its dead
w e i g h to n i t s s e a t .
7 . C l ea'lnth e n o zzl e h o l e s of char r ed coke by m eansof the suppliedspec i al
dri 1 with holder.
8.

ar e l ar C he ckth e n o zzl e h o l e s with the test m andr elwhosemeasur ements

g e r th a n n o rma ld i a me terof the holes. If the test mandr elcan go ' i n j us t
one of the holes, the nozzle must be scrapped.

I f th e h o l e s a re l r,o rno val, which is checkedby meansof a magnifyi ng

g l a ss, th e n o zzl emu st also be scr apped.

1 0 . C l ea nth e co o l i n g ch a mberand the coo' lingducts in the nozzleguide and

' i n j e c t o r b o d yb y ' l a y i n g t h e s e i n a c l e a n i n g ' l i q u i d a n d t h e n b l o w ' i n g
air .
t h r o u g hth e p a rts w i th c ompr essed
11

by
P e rfe ct d e n si ty a n d fu n ction of the nozzle can only be guar anteed
s t r i ctl y o b se rv'i n gth e exactly defined angular differ ence betweent he
s ea ts o f n e e d l eg u i d e a nd the nozzle neddle, as well as the accur a c yof
sin s.
t h e d 'i me n o
E ve ryo w ne ffo rt to re fi nish br ings about alter ations of the value s .
I f d u ri n g th e vi su a l i n spection of the par ts heavyabr asionsym pt om s '
s n be obser ved,the par t in questionmust be r er e sp e cti ve l y d a ma g eca
p 1a ce d .

E t.t!

- -----

Fgl=tt

GENERANNCSETS

]v|AhI

Et&ut

L23/30

3 11. 5 2

F U E LI N J E C T I O N

Edition 08

O V E R H A U L IO
NFGF U E LI N J E C T O R

D a m a g epdl a n e s u r f a c e ( h i g n p r e s s u r e t i g h t e n ' i n g p 1 a i n s ) c a n n o t b e r e p a i r e d b y t h e s e r v i c i n g s t a f f , b e c a u s et h e d e s ' i r e da c c u r a c y ( a n g l e s , p l a n e p a r a l l i s m ) c a n o n l y b e r e a c h e db y m e a n so f s p e c ' i a 1e q u i p m e n t .

1 2 . W h e na l l t h e p a r t s h a v e b e e n o v e r h a u l e d , f o u n d i n o r d e r a n d c a r e f u l l y
c ' le a n e d , a s s e m bel t h e f u e l i n i e c t o t ' a g a in .

1 3 . W h e na s s e m b l i n gt h e i n j e c t o r , t h e o p p o s i t e o r d e r w ' i t h r e g a r d t o d ' i s a s s e m b1y should be observed.Payattention to the following:

I n s e r t a l l t h r e a d s w ' i t h m o ' l y b d e n u smu l p h i d e .

O-rings are to be renewed.
The sealing plane surface of body and nozzle must be wiped dry with paper.
Tightening torque for nozzle nut 100 Nm.

1 4 . S w i n g t h e i n j e c t o r b y 1 8 0 oC ( n o z z l e i s p l a c e d u p s i d e d o w n ) .
M o u n tt h e t e s t p i p e 0 5 7 3 .
A f t e r v e n t i n g , a p p l y p r e s s u r e o n t h e c o o l i n g o i 1 s y s t e m- s e e d a t a - a n d

c h e c kt h e s e a l i n g t i g h t n e s s o f t h e 0 - r i n g s .
15. N o wc o n n e ctth e te st p 'i p e0 4 8 4.
I n c r e a s ep re ssu reb y me a n so f the test pumpunti' l fuel is ejaculatedfr om
t h e i n j e cto r n o zzl ew i th a sl i ght shatter ing. If the pr essur eindicated
b y t h e p r e ssu reg a u g ed e vi a te s fr om the pr escr ibedopeningpr essur e=
3 2 0 b a r , th e a d j su ti n g scre wmust be tur ned accor dingly.
I n c r e a s ep re ssu reb y me a n so f the test pum pti' 11 20 bar underopening
p r e s s u r e ,a n d p a y a t t e n t i o n t h a t n o f u e l o i ' l w i l l p e n e t r a t ef r o m t h e i n j e c t ' i o n h o l e s. Wh e nsl o w l y w o r king the lever of the test pum p( about 1
m o t ' i o n / 2se c.), th e i n j e cto r should shatter whenr eachingthe opening
p r e s s u r e .H e re b yi t i s th e q u estion of a so- called shatter ing near the
seat.

\\--

I f i t i s t h e q u e s t i o no f q u i c k l y w o r k i n gt h e l e v e r o f t h e t e s t p u m p
( a b o u t 1 m o t i o n / l s e c . ) , t h e f u e l o i l j e t m u s t p e n e t r a t ec o n t i n u o u s l ya n d
i n a s m a l l a t o m i z i n gf o r m f r o m t h e i n j e c t i o n h o l e s .
K e p po u t o f th e re a ch o f th e fuel jets as they will penetr atethe sk' in.
F u e ' lw h i ch h a s p e n e tra te dth e skin causespainful inflannnations( blood
p o is o n in g )!
P l a t e3 1 1 5 1
F o r d ' i s m a n til n g o f fu e 'l va l ve , u se tool 0148.
F o r g r i n d i n g o f fu e l va l ve se a t, u se tool 0237.

t.

Ft;trc'

CENERA'NNG

SETS

lvlAN

Er&ut
F U ELV A L V E L '0 ra n g e

PLATE31101-O9H

1220-r-1221-)
0143
121'l

ozso---

0965

0231

L
gTe

H i g h p r e s s u r ep i p e
Plate31102

]YIAN

Ett*ut
FUELVALVE L ' O r a n g e

Item No.

6oa-p_,
ofr!#.L-oa
| 0143
0?30
-.N-,#_!i#"fi0
*{o&# pYt#,o*l7 \ztt
-.s-.$,!,f,/. r.f.g 823?
.
t&.0&e 3."032I
*dagp,_t*?
Jooa,pg9au#f oqro
/0, 3 050e.-p*s-,.tf
I 06-98
!g{1,A 7$, #-?S
_6ca,#fffl. 06830787
l-*** pt"tl81{ 08.16
, 6 $ a * # 7 t # * r l J0 9 6 5
{q ttp""'#q
6 t}.e oo { 10,_
_!;i] Nj,0 tr18, {t#3Y11?2
1?11*f,rr,*^a I * I s$#"*i*
&tfi,i:.0,Yr0,,fi.j,F1ZZg
L??1_flllrf, fJ?{/,./iS#.

PLATE3110.|-091{*

Designation

Eenevnelse

Fuel valve, complete

Nut

B r a n d v e n t i l ,k o m p l e t
M otr ik

Stud

Tap

V a l v eh o u s i n g
Gu 'i d ep i n
N o z z l e ,c o m p l e t e

V e n t iI h u s
Styr esti ft
For stover , komplet

S cre wcap
Thrustspindle

Omlsber
Tr ykspindel

S p r in g
A d j u sti ng scr ew

Fjeder

L o c kn u t
S e a il n g r i n g
C a pn u t
Ga ske t
P lu g scr ew
Ga ske t

J u s t e r in g s s k r u e
Lsemstrik
Tetningsr ing
Kapselmstri k
Pakning
Pr opskr ue
P a k nni g

ae,=
I

-----

F==E
-

CNERANVG SETS

lYIAN
E &Ut
H I G H - P R E S S UFRUEE LP I P E

PLATE
3I IO2.()4H

2081
2170
2?69
2358

0756
2536

2081
2358
0845
107,|
|071
2447

0845

?447
1824

0756
2536
2625

E#.EEE

GNERATTNC SETS

lvlAh|

ct&ult
.-,
PLATE31,|02-041-i

H I G H . P R I S S UF
RU
EE LP I P E

Item No-

Designation

Benavnelse

too e7 /o ooc3

0112

S h ' i edl e d h i g h - p r e s s u r e
pi pe

Skarmethojtryksror

6,oooo7/oooj i

0756

S l e e v e d i v ' id e d

B o s n i n gZ - d e l t

ooo or?./nOO.i? 0 8 4 5
'":oo
o i 9 1071
i a lt ,'t
6 o o o o q / 0 o a * , ) 1B?4

C'lamp

Ter s

Screw
S h i e l d i n gc a p

Skr ue
i ng
Kappefor skr un

6 c Ot ,ro a'4fl 2 08 1

S e a li n g r i n g

Tetningsr ing

o o o o c i / r t o c t / | 2 17 0 ,
' ; 2 26 9
e . o o af q 4 C n

Screw

r " ' 6 C a- l : ' J

lr:t
.

c)

n.t

r1 ,,-,

' a

,
\

"

' - . r '

. '
2 l ' 1

' 1

2358

S e a l' i n g r i n g

Skr ue
Motr ik
Tatningsri ng

2447

S e a li n g r i n g

Tatningsr ing

Spring coil

Lsefjeder

Nut

Mstri k

2536
/2625

Nut

l*-

r----

---E

GENERAT\ESTS

IvlAhl

Er&ut
FUELVALVETOOLS

PLATE
3 11 5 1 . 0 6 H

+H-EE

GENERANNG STS

}IAt\t
El&ut
PLAT3
E11 5 1 - 0 6-H

FUELVALVETOOLS

Designation

Benavnelse

0148

Extractor for fuel

va lve

Aftrakker for
br andsel
sventiI

0237

G r i n d i n gr i n g f o r
valve seat

S li b e r i n g f o r
venti I sede

3.*-

*--

GENRANN(]SETS

FUELVALVTTOOLS

PLATE
311 52.03H I

0751

Effiffi

}IAN

Et&ut
FUELVALVTTOOLS

PLATE
31152-03H
-

Designation

Benavnelse

0 11 7

T e st p um p,com plete
incl. item No. 0206,
0 4 8 4 ,0 5 7 3

Pr ovepumpe,
komplet
incl pos. nr. 0206,
0 4 8 4 ,0 5 7 3

0206

C l a mp ingbr acket for

testing fuel injector
T e st p i pe for nozz' le
co o li n g oi 1
Test pipe for injecti on
C le a n 'i ngneedles i n
p a c k i n gt u b e , c o m p l .

Beslagfor kontr ol af
br endsel
sventiI
Prsversr for dyseko1i ng

Item No.

0484
0573
0751

Pr aver sr for indspr ojtni ng

Rensen' le
i holder ,
kompl
et

E: -=

!F-Es

GENERATIT\IGSETS

EngineData

z
o

of Engine
Operation

FEnginePerformanceandCondition
o
o-

Tracing
Trouble
EngineFrameand Bedplate
and MainBearings
Crankshaft
CylinderHeadand CylinderLiner

Rod
PistonandGonnecting
OperatingGearfor InletValveg
ExhaustValvesand FuelInjectionPumps
UJ
C)

Turbocharger
System

Gfr
zts

FuellnjectionPump

PE

E=
8i
?

g9

FuelInjection

CamshaftandCamshaftDrive

--

r-

FE
U,
,rg
l - r

UJ

Controland SafetySystems
Automatics
andInstruments
StartingSystem
Lubricating
Oil System
Oil
of Lubricating
Specification
andTreatment
FuelOil System
Fueland FuelTreatment
CoolingWaterSystem
Treatment
of CoolingWater
DrivenMachinery
Tools
SpecificPlantInformation

tvlAhl

cr&ut

L23/30
CAMSHAFT
AND CAMSHAFT
DRIVE

312- 01

DESCP
RT
I ION

Edition 06H

Plate 31201

T h ec a m s h a fot f t h e e n g i n ec o n s i s t s o f a n u m b eor f s e c t i o n sw h i c ha r e b o l t e d
t o g e t h e r . E a c hc y l i n d e r h a s i t s o w ns e c t i o n c o m p r i s i n qf j x e d c a m st o o p e r a t e
f u e l p u f f i pj,n l e t v a l v e , a n d e x h a u s tv a l v e .
0 n o n e e n d o f th e ca msh a ftther e is a hub 1448car r ying a gear wheel 12 60
w h ' i c h ,th ro u g ha n i n te rme d j atewhee', l is in connectionwith a gear whe e'lon
t h e c r a n ksh a ft. T h e g e a r w h eel on the cam shaftis secur edto the hub by m eans
o f t h e s c r e w s1 0 8 2 ,a n d t h e s c r e wh o l e s i n t h e g e a r w h e e la r e o b l o n g ,m a k i n g
i t p o s s i b l et o t u r n t h e c a m s h a f it n r e l a t i o n t o t h e g e a r w h e e la n d , c o n s e quently, also in relation to the crankshaft.
L u b r i c a t i o no i l f o r t h e c a m s h a f b
t e a r i n g Si s s u p p l i e dt h r o u g ha b o r e i n t h e
b e a r i n g l o ca te d n e a re st th e gear wheel, and the oi1 passesthr ougha centr al
b o r e t o t h e i n d i v i d u a ' ls h a f t s e c t ' i o n s ,i n w h i c h l u b . o i l h o l e s a d m i t t o t h e
shaft bearings.
Plate 31?0?
T h e i n t erme d i a teg e a ri n g w h 'ichtr ansmits the motionfr om the cr ankshaftto the
c a m s h a ftco n si sts o f 2 g e a r wheels, bolted together and fitted on a comm on
b u s h0 34 9 . T h e j n te rme d i a tegear ing r uns on a shaft pin 0250attachedto the
e n g i n efra meb y me a n so f b o l ts and fitted bolts so as to pr ovide a su' itab'l e
tooth flank clearance.

MAINTENANCE

T h e g e a r w h e e ld ri ve a n d th e camshaftdo not r equir e maintenance.

T h e g e a r w h e e l so n ca msh a ft,inter mediategear ing, and cr ankshaftar e p r ov i ded
w i t h m a rksfo r co rre ct mo u nting.Befor e taking out the cam shaft,the fuel oi l
p r i m a r y p u mph a s to b e d i smantled,following which the camshaftcan be separ at e d a t th e g e a r w h e e le n d a n d taken out.
I f t h e i n d i v i d u a l c a m s h a f st e c t i o n s h a v eb e e nd i s m a n t l e d ,i t s h o u l db e c h e c k e d
d u r i n g r e -a sse mb l yth a t th e y ar e fitted with the cor r ect angles betweenthe
m i d d l e o f th e fu e l p u mpca ms.
T h e c a msh a fta d j u stme n tca n be checkedby meansof pin gaugesplacedas i l 'l us t r a t e d o n p ' l a t e 3 1 2 5.1

,-

--L-

GENERAThG SETS

]IA1\l
B&Ut
Plabs

P4e r(2)

31201-14H

Camshaft

L23t30

68;:'

(*0g1a

I 082
1 1 71
1?60
13 5 9
1448

fi--1s37

*) 5009

-1626

1 71 5

0558
0647

0370
0469

3584
*) 7 Cyl.

,ts0,n,
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o2gl
90.13

HOLEY
GEI\ERAI|\ESENS

/-G\
General
Designatlon

Benevenelse

0192

Couplingpart

Koblingsdel60ri

0281

Pjn

sfi

6 0Oo l / 0 .

oool

0370

Nul

f\4ork

6OOp i / / a

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0469

Screw

Skrue

6 o oa i l , ' 0 c t 0 o {

Shafi

Aksel

6000 u/0

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tvfotrik

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c006

Item No.

0558

(eu
0736

-*u,

Item No.

I lt,!

nt:'\

_ _ 0825

Gear wheel

_ry1_4_

Key

Nol

1082

Scew

Skue

1171

Nul lock

i,fotriksikring6.!t:0. l, !

1260

Gear wheel

Tandhjul

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!35s
144a

Screw

Skue

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Hub

Nav

5C00 tit(

t5it7

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6 d C . , t o, l . i , -

1626

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o 0/6

1715

Guide rlng

tvtotriksiking 60 A0 //10
Styrering
6OoO.llA

3684

Camshaft, front

3713

Gamshaft,
Intermedate

Styreaksef,
mellem,j : t

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4207

Gamshaft, aft

Styreaksel,bagerst

s@9

IIOI.EBY
CEI\ERAT\EsEfS

Clrclip

Benavenelse

Fjedersikins6OOO
_10 I c o ". il:..\(,,
Tandhjuf
f:.''i':. /

Designation

, !,1!'!
6 0 c 0 / , / 0. 0 0 / 9
r,( /

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u
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torest [0, I i!: . ) o t Y

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komplet{:,ql lttl

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INTERMTDIATE
I,IHEEL

PLATE
31202- 05

0161

0250
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038
0527

0894
0983
1 05 1
11/*0

ffi.EEF
CENERATINCSETS

INTERMEDIATE
t^IHEEL

Item No.

600t il/o C , o Z / ,0 1 6 1
{;0iir.1 , . . }i ) , 1 - i 0 2 5 0
f :tt t)

/ t / ( ,i -tr' 0349

61J,, l,'/ !,.;.:- 0438

PLATE
31202- 05-

Designation

Benavnelse

S cre w
Axle journal

Skrue
A k s etl a p

Bush
Screw

For ing

0527

Ge a rw h eel

t: i' -.Jr)

i::.,
,J:",:i

Skr ue
Tandhjul

0616

Nut

M otr ik

ri ., .

''r,,

0705

Split

6,ry,

, .n l ?
0 0 30

0894

S p li t p i n
Gear whee'l
Cover

i!:.'
' t ' +.

1051

Nut
Sp1
it pin

Mstri k

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lnc
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Deksel
Split

=#-F=-:SETS

GENERATII\IC

]U|AN

cRr^t
CAMSHAFT

P L A T E3 f 2 5 1 - O 3 H

P i n g au g e f o r c h e c k o f
c a m s hfat a d j u s t m e n t

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c y l . N o . 1 in top deadcentr e

ffie;g

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PLATE31?51.03H

CAMSHAFT

0197
0 28 6

Designation

Benavnelse

Pin gauge

Sperm1
Sperm1

P in g a u g e

e .*,=

=-=EL-

GENERATTNG

SETS

EngineData

z
o

E
>tE
IJ

IJ

o-

of Engine
Operation
andCondition
EnginePerformance
Tracing
Trouble
EngineFrameand Bedplate
andMainBearings
Crankshaft
CylinderHeadand CylinderLiner

Pistonand ConnectingRod
Operating
Gearfor InletValveg
ExhaustValvesand FuelInjectionPumps
l

?
e
z-G
Zl-

Turbocharger
System
FuelInjectionPump

E=
R;

FuelInjection

CamshaftandCamshaftDrive
:z
= < ControlandSafetySystems
4 , 9 AutomaticsandInstruments

F
l - r

a,

6 lJg
c

StartingSystem

LubricatingOil System
Oil
of Lubricating
Specification
andTreatment
FuelOil System
Fueland FuelTreatment
CoolingWaterSystem
Treatment
of CoolingWater
DrivenMachinery

SpecificPlantlnformation

L23/30
AUTOMATICS
ANDSAFETY
SYSTEM,
ANDINSTRUMENTS
CONTROL
DESCRIPTI ON

lUIAhl
E&Ult
3 t3 . 0 1
E d it i o n 11 H

P l a t e3 1 3 0 1
T h ee n g i n ei s e q u i p p e dw i t h a h y d r a u f i c g o v e r n o ro f W o o d w a m
r da k e .R e g a r d i n g
d e s i g n , o p e ra ti o n , a n d a d j u stm entof the gover nor , r efer ence is m adeto the
W o o d w a irnds t r u c t i o n b o o ks u p p i e d .
T h e g o v e rn o rd ri ve i s l o ca te d at the f' lywheelend of the engineand cons i s ts
o f a c y l i n d e ri ca l g e a r w h e e l 1586, dr iven by a gear wheel on the camsh aft,and
a s e t o f b e v e l g e a r s 1 3 0 8a n d ? 4 7 6 .
T h e p u r p o seo f th e g o ve rn o ri s to r egulate the r ate of deliver y fr om the fuel
p u m' p
l osas, do. t h a t t h e e n g i n es p e e di s k e p t w i t h i n c e r t a i n l ' i m ' i t s oi n d e p e n d i nogn
the
T h e o u t pu t o f th e g o ve rn o ri s tr ansmitted thr ough lever s and pull r ods t o a
l o n g i t u d i n a l r e g u l a t i n gs h a f t . F o r e a c h f u e l p u m pt h e r e g u l a t i n g s h a f t i s f i t t e d w i t h a tw o -p i e cea rm, w h osear m attachment6581and spr ing ar m 4701ar e
k e p t t o ge th e r b y a sp ri n g 4 8 90. This makesit possible for the gover norto r eg u l a t e th e fu e l d e l i ve ry o f the pumpseven if a pum pp' lungerhas seized. F r om
t h e s p r i n g a rm th e mo ve me nt
i s tr ansmitted thr ough a linkage 2832to the fuel
p u m pr a c k.
0 n t h e re g u l a ti n g sh a ft i s a l so fitted a stop ar m 3366oper atedby a sto p c y l i n d e r w h i c h ' i s a c t u a t e dw h e nt h e o v e r s p e e d
t r i p o f t h e e n g i n ei s r e l e a s e d
( t h e o v e r s p e e tdr i p w i l l b e d e s c r i b e dl a t e r ) . T h e p i s t o n i n t h e s t o p c y l i n d e r
w j l l a c tu a te th e sto p a rm 3 3 66 ther eby tur ning the r egulating shaft and m ov i ng
t h e f u e l p u mp sto S T 0 Pp o s'i tion, thus stopping the engine ( see plate 31300) .
g o ve rn o rw i l l a ttempt to keep the r egulating shaft in RUNN INpoT h e W o od w a rd
G
s i t i o n , b u t b e tw e e nth e g o ver norand the r egulating shaft the ^eis a spr i ngl o a d e dp u l l ro d 6 7 6 9w h i ch can be compr essed,
thus allowing the r egulati ng
p
o
sition.
b
e
S
T
OP
mo ve dto
shaft to
I f t h e cyl i n d e r i s to b e p u t out of oper ation, for instance in or der to m eas u r e t h e co mp re ssi opnre ssu re, the spr ing ar m, and thus the r ack of the fuel
p u m pc o n ce rn e di s p re sse dto no- fuel position.
O v e r s p e etri
d p
P la t e 3 1 3 0 5
T h e e n g i n ei s e q u i p p e dw i t h a s t o p p i n gd e v i c ew h i c h s t a r t s t o o p e r a t e ' i f t h e
m a x i m u pme rmi ssi b l ere vo 'l u ti onnum beris exceeded.This device is fitted to
t h e n d co ve r o f th e l u b ri ca ting oil pumpand is dr iven fr om the pumpthr ough
a r e s iI i e n t c o u p il n g .
0 n t h e e n g i n ei s f i t t e d a p n e u m a t i c a l l yc o n t r o l l e d s t o p c y l i n d e r 5 2 1 1 .

E#.8F
GENERA'N\GSETS

]v|AN
L23/30

cr&ut

ANDSAFETYSYSTEM,AUTOMATICS
ANDINSTRUFIENTS
CONTROL
NF
T O V E R S P ETER
DI P
F U N C T I O NT,E S TA N DA D J U S T M TO

3 13 . 0 2
E d i t i o n 11 H
P a s e1 ( 2 )

T h e s y s t e mf u n c t ' i o n sa s f o l l o w s :
C o m p r e s saeidr ( q . S - 1 . 5b a r ) ' i s a d m i t t e dt o t h e o v e r s p e etdr i p a t F t o t h e
E n o t sv a l v e 5 1 2 2w h ' i c hi s k e p t c l o s e d , t h e v a l v e b a l l b e i n g p r e s s e da g a i n s t
i t s s e a t b y t h e a i r p r e s s u r ea n d b y t h e b u i l t - i n s p r i n g .
I f t h e p r e - s e t t r i p p i n g s p e e di s e x c e e d e dt,h e s p r i n g - l o a d e df l y w e i g h t 1 1 0 6
w'il l s w i n g o u tw a rd sa n d p re ss d o w nthe ar m 0583. The ar m is locked in its bott o m p o s ' i t i o nb y t h e l o c k p i n 3 8 9 7 ,w h i c h i s p r e s s e di n b y t h e s p r i n g 3 9 8 6 .A t
t h e s a m et i m e th e a rm 0 5 8 3p re sse sdownthe spindle 4787,and the tnots valve
opens.
Th e c o m p r e s seadi r p a sse sth ro u g hthe connectionK to the stop cylinder 5211,
in w h i c h t h e pi sto n i s p re sse dfo r-war dand, thr oughthe ar m 31301/3366,
tur ns
position. Ther ebythe enginestops, the
t h e f u e l p u m pre g u l a ti n g sh a ft to STOP
s p r i n g - l o a d e dp u l l ro d co n n e cti o n31301
/6769 to the gover norbeing compr essed.
T h ee n g i n ec a n b e s t o p p e dm a n u a l l yb y p r e s s i n gd o w nt h e b u t t o n 2 1 8 5 .
To m a k et h e e n g i n e re a d y fo r sta rti ng after the over speedtr ip has beenr ele a s e d , p u l l ou t th e kn o b 4 1 4 3(4 2 32)wher ebythe ar m 0583is r eleasedand
p re s s e du p w a rd sb y th e sp ri n g 4 8 7 6.The tnots valve closes, the stop cylinder
is v e n t e dt h r o u g ha b o re i n th e va l ve, and the spr ing will pr ess the piston
b a c k a n d t h e r eb y re l e a se th e fu e l pumpr egulating shaft.
Fu n c t i o n a l , T e st a n d A d j u stme n ot f Over speed
Tr ip
1 . T h e e n g i n ei s r u n u p m a n u a l l y ,a n d a t n o l o a d , w h i l e a n e y e i s k e p t o n t h e
t a c h o m e t e r.0 n re a ch i n gth e re volution numberindicated on the Data sheet ,
t h e o v e r sp e e dtri p p i n g d e vi ce shall function, thus actuating the stop cylinders. The fuel pumpcontrol rods are nowmovedto zero index, and the
e n g i n es t o p s .
Sh o u l dt h e o ve rsp e e dd e vi ce tri p at a r evolution numberwhich is differ ent
f r o m t h a t sta te d i n D a ta , th e over speeddevice must be adjusted:
R e m o vbeo th co ve rs o n th e h o u singof the over speedtr ipping device.
T u r n t h e e n g i n e u n ti l th e a d j u sting scr ew is opposite the openingon the
s ' i d e o f t h e h o u si n g . N o wl o o se n the Iock scr ewand tur n the adjusting
s c r e w , u s 'i n gth e tu b u 'l a r p i n spannersupplied. Tur n the adjusting scr ew
.
o u t w a r d s( sl a cke nfl yw e i g h t sp r ing) to r educethe r evolution num ber Be
careful not to screw the adjusting screw so far out that it maytouch the
r e l e a s e a r m. T i g h te n th e l o ck scr ewand test the over speeddevice again.
Refit the covers whenthe overspeeddevice functions at the correct revolution number.
2.

T h e o v e r s p e e dd e vi ce ca n b e te s ted manuallyby depr essingthe button on

t o p o f t h e h o u si n g .T h i s w i l l actuate the flyweight and the ar m for r eleas e o f t h e a i r va l ve fo r th e stop cylinder s, and the engine shouldthus
sto-n.
z ]GE

!r.{t

GENERAilVCSETS

TUIAI{
L23/30
CONTROL
ANDSAFETYSYSTEM,AUTOMATICS
AND INSTRUMENTS

FUNCTION,TTSTANDADJUSTMENT
OF OVERSPEED
TRIP

cr&ut
3 13 . 0 3
tdition | 1H
P a g e2 ( 2 )

(This test is also to be carried out without load).

It is recommende
nd
o wa n d t h e n , w h i l e t h e e n g i n e i s a t a s t a n d s t i l l , t o
m o v et h e f l y w e ' i g h t b y m e a n so f t h e p u s h b u t t o n t o e n s u r e t h a t t h e f l y w e i g h t c a n a l w a y s m o v ew i t h s u f f i c i e n t e a s e .

B u tto n
for test and emergency
stop

-Et#!
----- tE=tt -

CET\ERANIGSETS

L 2 3 /3 0
JET SYSTEM

313.15
Edition 02H
'PageI (3
)

- SAFETY
D E S C R I P T I O- NF U N C T I O-NI . I O R K I NPGR I N C I P L T

T o a c e r t a i n e x t e n t c h a n g e si n t h e l o a d c a n l e a d t o s m o k ef o r m a t i o n d u e
to inc o m p l e t ec o m b u s t i o n ,c a u s e db y t h e l a c k o f a i r ( o x y g e n ) . A s c o u n t e r r r e a s u r e
a
s m o k eI i m i t e r c a n b e ' i n s t a ll e d o n t h e e n g i n e .
T h e s m o k el i m i t a t i o n d e v i c e g i v e s s i g n i n f i c a n t l e s s s m o k ea t a ' l a r g e l o a d i n c r e a s e b y m e a n so f f e w c o m p o n e n t s .T h e s m o k el i m i t e r w i l j k e e p t h e e x c e s s a i r
'l
a b o v ea c e r t a ' i n p r e s e t i m i t w h e n t h e l o a d i n c r e a s e s .
F u r t h e r m o r e t, h e s m o k el i m i t e r w i l l i m p r o v et h e e n g i n e ' s a c c e l e r a t i o na b i ' l i t y
cons'iderably.
Function:
T h e s m o k el i m i t e r c o n s i s t s o f a c o n t r o l s y s t e m f o r m o n i t o r i n g t h e e x c e s s a i r
a n d a j e t a s s i s t s y s t e mf o r a c c e l e r a t i o n f t f r e f / C .
T h e c o n t r o l s y s t e mm e a s u r e st h e c h a r g e a i r p r e s s u r e a n d t h e f u e l i n j e c t i o n
p u m pi n d e x f o r c a l c u l a t i o n o f t h e e x c e s sa j r .
i f t h e e x c e s s a i r d r o p s b e l o w t h e p r e s e t l i m i t b e c a u s eo f a s u d d e nl o a d i n c r e a s e , t h e c o n t r o l s y s t e mw i l l a c t i v a t e a m a g n e t i cv a l v e f o r a i r s u p p l y t o t h e
j e t a s s ' i s t n o z z l e s i*n t h e t u r b o c h a r g e r .T h e j t a s s i s t s y s t e m
wiil -'in'a m1n.im u mo f t ' i m d - a c e l e r a t e t h e t u r b o c h a r g e ra n d b u i l d u p t - h en c e s s a r ye x c e s s
air
for the combustion.
T h e j e t a s s i s t n o z z l e so n l y n e e d a i r s u p p l y i n a f e w s e c o n d s .

Charge
air
recever

Pressure
transmitter
Calculator
Limit switch

Pump index

Jet assist system

in turbocharger

HELEBY

CEAIERATT\ESETS

}IAI

cr&ut

L?3130

3,t3.15

JET SYSTEM

Ed'it'ion 02H
P a g e2 ( 3 )

- NF U N C T I O-NI . O R K I NPGR I N C I P L E
. SAFETY
DESCRIPTIO

l . l o r k i n gP r i n c i p l e :
A n i n d e x c a m i s p l a c e d o n t h e f u e l i n j e c t i o n p u m pr e g u l a t i n g s h a f t . A n a n a ' l o g
p ' i c k - u pg i v e s a v o l t a g e s i g n a l d e p e n d i n go n t h e d i s t a n c e t o t h e i n d e x c a mT. h
d i s t a n c e f r o m t h e i n d e x c a mt o t h e a n a l o g p i c k - u p i s p r o p o r t i o n a l t o t h e p u m p
i n d e x - . T h ec h a r g e a i r p r e s s u r e i s m e a s s u r e db y a c h a r g e a i r p r e s s u r e t r a n s m i t m i t _ w h i c hg i v e s a m i l l i a m p . s i g n a l d e p e n d i n go n t h e p i e s s u r e ' i n t h e c h a r g ea i r
c o o le r .
T h e t w o s i g n a l s w i l l b e p r e p a r e di n a n a n a l o g c a l c u l a t o r w h i c h s e n d sa m i l l i ? m p - s i g n a l t o a I i m i t s w i t c h . l , l h e nt h e m i l I i a m p . s i g n a l e x c e e d sa c e r t a i n v a l u e , t h e l i m i t s w i t c h r e l a y w i l l c h a n g eo v e r . T h e r e b ya s o l e n o i d v a l v e o p e n s
up for the iet assistance air to the T/C. X the time whenthe signal frbm the
a n a l o g c a l c u l a t o r g o e s b e n e a t ht h e a d j u s t e d v a l u e o n t h e l i m i t s w t c h , t h e r e l a y i n t h e l i m i t s w i t c h c h a n g e sb a c k a g a i n , a n d t h e j e t a s s i s t a i r w i l t n e n
stop.
Safety:

T o m a k es u r e t h a t t h e s m o k el i m i t a t i o n d o e s n o t w o r k w h e n t h e e n g i n e i s i n a
standstjll, q potential free contact for "engine running" is buit in the outp u t c i r c u i t ( b e t w e e nt h e l i m i t s w i t c h a n d t h s o l e n o i d a l v e ) . f n s p r e v e n t s
t h e T / C f r o m r u n n i n g - a n d t h e r e b y b e i n g d a m a g e db e c a u s eo f a n i n s u f f i c i a n t
l u b r j c a t i o n - w h e nt h e e n g i n e i s n o t r u n i n g . -

}TELEBY

GIE\ERNESENS

---

123t30

t Bai

3 ' t 3 1. 5

JET SYSTEI4

E d i t i o n0 2 H
P a s e3 ( 3 )

ADJUSTMENT
OF SMOKE
LIMITATION

T h e J e t A ssi sta n cei s fu l l y adjusted fr om the factor y and is ther efor e not to
b e a d j u ste d a n y fu rth e r. If a total adjustmenthas to be made,the foll ow i ng
s t e p s s h o u l db e t a k e n :
A l l a d j u s t m e n t as r e t o b e m a d ew h e nt h e e n g i n ei s i n a s t a n d s t i l l

position:

1)

t ,Ji thth e p u mpi n d e x a t zer o, the distance fr om the analogpick- up to the

c a mo n t h e s h a f t f o r r e g u l a t i n g o f p u m pi n d e x s h o u l db e 0 . 5 m ma n d t h e
d i sta n ce fro m th e mi d dle of the pick- up to the edgeof the camshoul d be
10mm.

2)

S e t b o th n o tch e so n th e ljmit switch - r ed box 2236- to zer o ( ful l y C C t,'l ) .

a)

S e t th e p u mp'i n d e xto 20.

S e t th e p re ssu reb y m eansof "a test pump"on the pr essur etr ans m i tt e r t o 0 . 5 b a r ( + / - 0 . 1 b a r ) . A d j u s t t h e u p p e rn o t c ho n t h e l i m i t
sw i tch - th e r" e db ox 2236- so the r ed LEDjust is al' ight.

b)

T h e nse t th e p u mpi ndex to 25.

S e t t h e p r e s s u r eo n t h e p r e s s u r et r a n s m i t t e r t o 0 . , l [ ( + / - 0 . 1 b a r ) .
N o wa d j u st th e co m pensating
ter minal, i.e. the adjustable r es 'i s tant
b u i l d ' i n t o a t e r m i n a l , p l a c e di n t h e t e r m i n a ls t r i p , u n t l t h e r e d
L E Do n t h e l i m i t s w ' i t c hj u s t s t o p s b e i n ga l i g h t .

R e d u ceth e p re ssu reo n th e test pum pto ar ound0.5 bar and checkthat t he LED
i s a l i g h t . N o wr a i s e t h e p r e s s u r et o 1 . 0 b a r ( + / - 0 . 1 b a r ) t o e n s u r et h e L E D
g o e so ff a t th i s p re ssu re .l ,lhenthe equipmentis fully adjusted, seal t he
n o t c h e so n t h e l i m i t s w i t c h .
N o t ' i c e :T h e a n a l o gc a l c u l a t o r i s a d j u s t e df r o m t h e s u b s u p p l i e a
r n d s h o u l dn o t
b e a d j u ste d a n y fu rther .

Lt

Frl!t

GENERA'NNGSETS

1l|A]\|

EEUI'

L23/30
AND INSTRUMENTS
AUTOMATICS
ANDSAFETYSYSTEMS
CONTROL

313.20
tdition 01H
P a s e1 ( 2 )

DESCR
PIT I O N

Instrument panel

d n i n s t r u m e n tp a n e l i n c o r p o r a t i n g :
0 n t h e e n g i n ei s m o u n t e a
-

P r e s su reg a u g efo r

(")
Tachometers
for
S w i t ch fo r

LT water - inlet to air cooler

HTfresh water - inlet to engine
L u b r i c a t i n go i l - i n l e t t o f i l t e r
C h a r g i n ga i r - o u t l e t f r o m c o o l e r

N o z z l ec o o l i n go i l - i n l e t t o f u e l v a l v e s
Com pr essed
air - inlet to engine

Engine/Turbocharger
RPM(*)
Engine/Tur bochar ger
RPM

F u r t h e rmo reth e e n g i n e i s equippedwith a pane' lconsisting of:

-

P r e s su reg a u g efo r

Fue' loil - inlet to engine

L u b r i c a t i n go i l - i n l e t t o t u r b o c h a r g e r

Thermometers
for I ocal reading:
Thermoneters
LT water - inlet air cooler
LT water - outlet fr om air cooler
LT water - outlet fr om lubr icating a' ir c ool er
HT fr esh water - inlet to engine
HT fr esh water - outlet each cyl inder
(*)

L u b r i c a t i n go i l - i n l e t t o c o o l e r
Lubr icating o' il - outlet fr om fi' lter
C h a r g ea i r - i n l e t t o c o o l e r
Char geair - outlet fr om cooler
F u e ' lo i l - i n l e t t o e n g i n e
Fueloil - inlet to filter
N o z z l ec o o ' l i n go i l - o u t l e t f r o m f u e l v a l v e s
Exhaustgast - outlet each cyl inder
Exhaustgas - outlet tur bochar ger

( *) F o r h e a vyfu e l o 'i l se rvice only

HCLEEY

GEAERA'TIIG STS

lYlAhl

Et&ut

L2 3 / 3 0
AND INSTRUMENTS
AUTOMATICS
ANDSAFETYSYSTEMS
CONTROL
P IT I O N
DESCR

3 13 . 2 0
E d i t i o n0 1 H
P a s e2 ( 2 )

P r e s s o s t a t eas n d T h e r m o s t a t e s
f u n c t i o n s -T h e
T h ee n g i n e ' i s s u p p l j e dw i t h a n u m b eor f a ' l a r m -a n d s h u t - d o w n
a l a r m s - s h a l lv i a ' l h e a l a r m p a n e l w o r n a g a i n s t a n a b n o r m awl o r k i n gc o n d i t i o n ,
functjons shall stop the enwh i c h c a n l e ad to b re a k d o w na n d the shut- down
"wor
se"than an alar m becausea
g in e b e f o r e a b re a k d o w n . I.e . a shut- downis
i r t - o t u ni s g i v e n ' i f t h e e n g i n ec o u l d b e s e v e r ed a m a gbey r u n n i n go n t h e s e
conditions.
A s s t a n d a r dt h e e n g i n e i s e q u i p p e dw i t h :
Sh u t - d o w snw i tch e sfo r:
t o o l o w l u b r i c a t i n g o i l P r e s s u r e- i n l e t e n g i n e
t o o h ig h H T fre sh w a te r te mper atur e- o u t l e t e n g i n e
t o o h ig h e n g 'i n esp e e d(l o w er speed)
A la r m s w ' i t c h e sfo r:
I e a k ' in gfu e l o 'i l
t o o l o w l u b r i c a t ' i n go ' i l p r e s s u r e- i n ' l e t e n g i n e
t o o l o w p r e l u b r i c a t i n go i l p r e s s u r e( l e v e l a l a r m )
t o o h i g h p r e s s u r ed r o p a c r o s s l u b r i c a t i n g o i 1 f i l t e r
t o o h i g h H T fre sh w a te r te m per atur e- outlet eng' ine
t o o l o w s t a r t i n g a i r p r e s s u r e- i n l e t e n g i n e
t o o h i g h e n g i n e sp e e d(o ver sPeed)
of the alarm- and shut-downswitches for the plant
The actual numberand type
i
'
E
n g i n eA u t o m a t i cp a r t l i s t " i n t h i s s e c t i o n .
c a n b e s e e ni n t h e l i s t
Test of switches:
T e s t o f t h e sw i tch e si s d e scri b e din the pr ocedur eplates ( 609- 4) . The test
ought to be carried out every 6 th month to secure that the safety equipment
a n t h e a l a r m p a n e l i s w o rki n ga nd that a war ningis given underabnor mal
w o r k i n gc o n d i ti o n s to a vo i d a se r ious br eak down/dam age.

tffi-EtY
CCAIERA'NNG STS

lvlAhl

crr*ult

L23/30
AUTOMATICS
ANDINSTRUMENTS
ANDSAFETYSYSTEMS
CONTROL

3 13 . 2 5
E d i t i o n0 1 H
P a g eI ( l )

ADJUSTMENT
ANDTESTOF ON/OFFPRTSSOSTATE

Adj ustment
h l h e nt h e p r e s s o s t a t e c o v e r i s r e m o v e da n d t h e l o c k i n g s c r e w( 5 ) i s l o o s e n e d ,
t h e r a n g e c a n b e s e t w i t h t h e s p i n d l e ( 1 ) w h i l e a t t h e sam etim e the s c al e
( 2 ) ' is b ei n g r e a d .
I n p r e s s o s t a t e s h a v i n g a n a d j u s t a b l e d i f f e r e n t i a l , t h e s p i n d l e ( 3 ) m u s tb e
u s e d t o m a k e t h e a d j u s t n e n t . T h e d i f f e r e n t i a l o b t a i n e d can be r ead direc tl y
on the scale (4).
S e t p o i n t s : S e e " O p e r a t i n gd a t a " .
Test

I t ' i s p o s s i b l e t o m a k ea f u n c t i o n a l t e s t o f t h e
p r e s s u r es w i t c h . T h i s ' i s t o b e c a r r i e d o u t a c c o r d i n gt o t h e f o l l o w i n g p r o c e d u r e :
l ) S h u t o f f s y s t e mp r e s s u r ew i t h t h e v a l v e ( 8 ) .
2 ) D i s m a n t lt h e s c r e w( 7 ) .
3 ) M o u n tth e te sti n g a p p a ratuson the tr ial
f l a n g e( 6 ) .

|
2
3
{
5

8rn9 rpindt
Renge rcale
Diflercnlial rpindte
Olfforontial Blc
Locftng &rtry

Ala r m fo r fa l 'l i n g p re ssu re

P u m pup th e p re ssu reu n ti l the switch has change d . T h e p r e s s u r ew ' i l l s l o w l y b e r e l i e v e d , a n d i t
must be checkedthat the switch changeback to
t h e p r e s s u r e ,s t a t e d a s a l a r m p o i n t i n t h e l i s t
" 0 p e r a t i n gd a t a " .
A l a r mf o r r i s i n g p r e s s u r e
Pu m pu p th e p re ssu reu n ti l the switch changes,
a n d c he ck th a t i t h a p p e n sat the stated alar m
p oi n t .
4 ) M ou n tth e scre w (7 ) a n open the valve ( 8)
a f te r a fi n a l ch e cka n d adjustment.

HEEETY
GENERAINC SETS

IU|AT{

El&urt

L23/30
ANDINSTRUMENTS
AUTOMATICS
ANDSAFETYSYSTEMS
CONTROL

3 l3 . 3 0
Edition 0lH
P a s e1 ( 1 )

ANDTTSTOF ON/OFFTHERMOSTATE
ADJUSTMENT

Adj u s tment

l.lhenthe thermostatecover is removed,and the I o c k i n g s c r e w( 5 ) i s l o o s e n e d ,

t h e r a n g ec a n b e s e t w ' i t h t h e s p i n d l e ( 1 ) w h i l e a t t h e s a m et i m e t h e s c a l e ( 2 )
i s b e i n gr e a d .
T h e r m o s t a t ehsa v i n ga n a d j u s t a b l ed i f f e r e n t i a ' 1 , t h e s p i n d l e ( 3 ) c a n b e u s e d
w h ' i l et h e s c a l e ( a ) i s b e i n g r e a d .
S e t p o i n t s : S e e " 0 p e r a t i n gd a t a " .
Test
T h e f u n cti o n a l te st o f th e ther m ostateis to
b e c a r ri e d o u t a cco rd i n gto the followjng pr ocedure:
1 ) T a keo u t th e se n so ro f the pocket.
2 ) T e st th e th e rmo sta teb y diving the sensor
in the waterbath, whichis controlled by
t h e te mp e ra tu re o
, r a special testing apparatus.

l.
2.
3.
4.
5.

Rang spindtc
Rango scalo
Oitlrntal spndt
DitlGrontirt catc
Loctng 3cGw

A l a r m fo r fa l l i n g te mp e ra tur e
R i s e t h e te mp e ra tu reu n ti l the switch has
changed.Then the temperaturemust slowly be
r e d u ce d ,a n d ch e ckth a t th e switch changes
b a c k b y th e te mp e ra tu re a
, s stated in the list
" 0 p e r a t i n gd a t a " .
A I a r mfo r ri si n g te mp e ra tur e
R i s e th e te mp e ra tu reu n ti l the switch changes
a n d c he ck th a t i t h a p p e n sby the stated alar m
p o in t .
3) Adjust if necessary.
4 ) T h e s e n s o ri s m o u n t e a
dg a i n .

ffi.EEY
CENERA'IIC SETS

]Y|AN

Er&ut

L23/30

3 1 3. 3 5

ANDINSTRUMENTS
AUTOMATICS
ANDSAFETYSYSTEMS
CONTROL

Edition 01H
P a s e1 ( 1 )

LAL 25
LEVELSI,IITCH

T h e l e v e l s w i t c h L A L 2 5 , w h i c h i s m o u n t e do n t h e m a i n ' l u b r i c a t i n g o i l p i p e o f
t h e e n g i n e g i v e s a l a r m f o r m ' i s s i n gp r e l u b r i c a t i n g o ' i l .

F u n c t'i o n
B y s t a r t i n g o f t h e p r e l u b r i c a t i n g o i l p u m pt h e m a i n l u b . o i l p u m pw i l l b e f i l l e d w ' i t h l u b r i c a t i n go i l , w h i c hm e a n tsh a t t h e ' l e v e l s w i t c h i s l i f t e d a n d t h e
alarmis disconnected.
W h e nt h e p r e l u b r i c a t i n g i s i n t e r r u p t e d , t h e l u b . o i l w i l l r u n o u t o f t h e s y s t e m th ro u g h th e b e a ri n g s, which m eansthat the level swtch is lower edand
the alarmstarts.

V e n t p 1p e

switch
M a i nl u b r i c a t i n g o i l p i p e

Test
T h e t e s t i s c a r r i e d o u t w h e nt h e e n g i n ei s stopped.
1 ) S t a r t t h e p r e l u b r i c a t i n go i l p u m p ,a n d let the pumprun f o r a b o u t 5 m i n .
2 ) S t o p t h e l u b . o i l p u m p .T h e a l a r mm u s tbe r eleasedafter 0 - 5 m i n d e P e n d ing of the oil viscosity.

}TCLEIY

GGNER$TGSXS

lYlAhl
L ? 3 / 30
ANDINSTRUMENTS
AUTOMATICS
ANDSAFETYSYSTEMS
CONTROL
TRANSMITTER
ANDTESTOF ANALOGOUS
ADJUSTMENT

B&Ut
3 13 . 4 0

Edition 0lH
P a s e1 ( 1 )

' i t c h a n g et o
The pressure transm'itter rigisters the actual pressure and makes
a n e l e c t r i c a l s i g n a l , w h i c h c o r r e s p o n d st h e p r e s s u r e .

A d ju s tme n t
T h e p r e s s u r et r a n s m ' i t t e rs h a l l n o t b e a d j u s t e d , . b u tt h e a ' l a r ml i m i t m u s t b e
l a n t . K i n d l y s e e t h e i n s t r u c t i o n b o o kf o r t h e a l a r m p 1 a n t .
s e t b n t h e a l a r mp
"
O
S e t p o i n t s : S e e p e r a t i n gd a t a " .
Test
I t ' i s p o s s i b l et o m a k ea f u n c t i o n a l t e s t o f
t h e p r e s s u r et r a n s m i t t e r s . T h i s i s c a r r i e d o u t
a c c o r d 'i n gto th e fo l l o w in g pr ocedur e:
1 ) Sh u t-o ff th e syste mp re ssur ewith the valve (3).
2 ) D i s m a n t lt h e s c r e w( 2 ) .
3 ) M o u n t h e t e s t i n g a p p a r a t u so n t h e t r i a l
f ' l a n g e( 1 ) a n d p u m po n a p r e s s u r ew i t h i n
t h e w o rki n ga re a o f th e tr ansmitter . If the
a l a r m p l a n t h a s a n i n s t r u m e n tu n i t , t h e
p r e ssu reca n b e re a d o n this. If ther e is
n o i n stru me n ta lu n 'i t, the test can be car r i ed o u t b y w a tch i n gi f the alar m plant
g i v e s a n y a l a r m , w h e nt h e a l a r m l i m i t ,
" O p e r a t i n gd a t a "
w t r i c n' i s s t a t e d i n t h e I i s t
( t.f t h e a l a r m p l a n t i s a d i u s t e d ) .
is exceede
4 ) T h e scre w (2 ) i s mo u n ted,and the valve ( 3)
i s o p e n e da f t e r t h e t e s t i s f i n i s h e d .

ffi-EEY
CENERAI\G ST5

/=TeG\

Lz3/30
AUTOMATICS
AND INSTRUI4ENTS
ANDSAFETYSYSTEMS
CONTROL
ADJUSTMENT
ANDTIST OF ANALOGOUS
TEMPIRATURE
T R A N S M I T T(TPRT I O OS E N S O) R

3 1 3. 4 5
Edition 01H
P a s el ( l )

.|00
s e n s o r c o n s i s t o f a r e s i s t a n c e w ' i r e , w h i c h c h a n g e sr e s i s t a n c e d e The PT
pending on the temperature.
L o o k a n d d e s ' i g n v a r i f y d e p e n d ' i n go n t h e p l a c e o f m e a s u r e m e natn d m a n u f a c t u r e .
Adj ustment

T h e P T 1 0 0 se n so rca n n o t b e a d j u s t e d , b u t t h e a l a r m l i m i t m u s tb e s e t o n t h e
a l a r mp l a n t .
Se t p o'i n ts : S e e " Op e ra ti ngd a t a " .
Test
T h e f un cti o n a l tri a l o f th e PT 100 sensorcan be car r ied out accor din gto the
following procedure:
1) T a keo u t th e se n so ro f the pocket
2 ) T e st th e te rmo sta teb y diving the sensor in the water bath, which i s c ont r ol l e d b y th e te mp e ra tur eor a special testing appar atus.If the al ar m
p l an t h a s a n i n stru me n tunit, the tem per atur ecan be r ead on this. If ther e
t n i t , t h e t e s t c a n b e c a r r i e d o u t b y w a t c h i n gi f t h e a l a r m
i s n o i n s t r u m e nu
p l a n t g i v e s a n y a l a r m ,w h e nt h e a l a r m ' l ' i m i t ,w h i c h i s s t a t e d i n t h e l i s t
i ' Op e ra i i n gd a t " 'i s e i ceeded.( It the al ar m pl ant i s adiusted) .
dgain.
3 ) T h e s e n s o ri s m o u n t e a

PT TOOSENSORS

HLEBY
GEERATI\G SETS

P L A N T : B A Z A N1 4

15

N0. PAGED E S C R I P T I O N
DRV'IG.
| 605352-3

INFORMATIONSHEET

r 605352-3

D A T AL I S T

| 605352-3

P A R TL I S T

r 605352-3

4.5.6

| 605352-3

I.IIRING DIAGRAM
MEASURINGCONVERTERS
EXTERNALCONNECTION

REMARKS:
1 . P O S I T I O NO F CONTACTSSHOWNAT S T A N D _ B YE N G I N E
2. CABLE CORES TO BE MARKEDWITH TERMINAL NUMBERS

C A D A Md n o w i n g o n d s h o u I d

not

be connected bv
Poge: 1 of :7

eotoment fon Ident.

fe"

135980

No.:

7L23/30

ENGINEAUTOMATIC
SHEET
INFORMATION

1605352-3

CABLE I.'NIONSIN
TERMINALBOX

w 1 5 !,1 25 l ' l 3 3 f,l 75

M I N . / M A X.
CABLE o rnn

PG II

7 - 1 2

PG | 3.5

7 - 14

PG f 6

7 - 16
f f - 21

PG 2I

PG 29

22-30

l z
E L E C T R I C ADL A T A : V . A . W . k l r. H
START SOLENOIDVALVE 24Ydc. f lW
SHUTDOI'JN
SOLENOID ON GOVERNOR24Vdc. 6W.
SYNCHRONIZINGMOTORON GOVERNOR22OVoc
P R E L U B . O I L P U M P3 r 4 4 o V o c . 6 O H z . O . 6 6 k W . S T A R TT A . F U L L L O A D I . 5 A
P R E H E A T EF
RO R H . T . W A T E R3 r 4 4 o V o c . 7 . 5 k W
SOLEN0ID VALVE -rET ASSIST. SYSTEM24Vdc. 8W

This

is

o CADAMdnoring

ond shoutd

not

be _coq ected by

Poge: 2 ol 7
fe"

I 35980

7L23/30

ENGINE AUTOMATIC
DATA LIST

MAN-B&WDIESEL

1605352-3

CODE

MEASURINGSET
RANGE POINT

NAME
PICK-I-P ENGIh

r 02368-I

CHAISE-OVERSXITCH

| 09522-8

o- | ooo

sr 89-9( TACHOMETER

r 356385-2

o-oooo

| 1029t6-8

START SOLENOIDVALVE
PAL 22

PRESSOSTATE

O-8 bor

3.O bor

r 356352-8

PSL 22

PRESSOSTATE

O-8 bor

2.5 bo

| 356352-8

TSH 12

TFRMOSTATE

70- | 20' c

95'C

| 356362-4

SAH 8I
SSH 8I

MICROSXITCH
OVERSPEEO

TAH 12

TI{ERMOSTATE

70-r 20' c

9C'C

I 356362-

DIFF. PRESSOSTATE

O.2-2.5 bo

1.5 bon

I 356375-

TAH 22

THERMOSTATE

70- | 20' c

75'C

| 356361 -2

PAL IO

PRESSOSTATE

0-8

O.E bo

| 356352-E

LAL 25

LEVEL SI{ITCH
PRE LUB.OIL

PAL 70

PRESSOSTITE

LAH 2

LEVEL SI{ITCH
DRAIN 8OX

PAL 24

PRESSOSTATE

PT 3I

PRESS. TRANSMITTER
.JET ASSIST.
Sq-ENOID VALVE
.ET ASSIST.

PDAH2I-22

' . , n
l-t)ril.'

P A R TN O .

r 62355-2

bon

r 358963-8
tO-35 bor

l5.O bor

| 356355-3
| 358963-8

lO-35

bon

f6.0

bon

r 356355-3
,|356372-O

O-lO bor

| 408343-7

PAL 80

PRESSOSTATE

O-8 bon

4.5 bor

| 356352-8

PAL 40

PRESSOSTATE

I -.|0 bon

4.O bor

| 40t 980-8

MEASURINGCONVERTER
ENGINE RPM
MEASURINGCONVERTER
TURBOCHARGER
RPM

This

is

o C A D A Md n o r i n g

r6r1396-l
u262U40X

ond shoutd

not

be-cognected

bv hond

Poge: 3 of :7

I 35980

MAN-B&I{DIESEL
ENGINEAUTOMATIC
PARTLIST

1605352-3

X t', 75

IN TERMI
MOUNTEDON ENG

SUPPLY ?4YdC

PICK-UP ENGINE

SI{ITCH
CHANGE-OVER

TA.H'METER

START SOLENOID

STOP SOLENOID
ON GOVERNOR

22

@
@
@
@

21

LUB.OIL INLET
LOI{ PRESS. ALARM
LUB.OIL INLET
LOW PRESS. STOP
H . T . W A T E RS Y S T E MO U T L E T
HIGH TEMP. STOP
DEVICE
MICROSWITCH
OVERSPEED
OVERSPEEDSTOP

PICK-UP TURBOCHARGER

This

is

o C A D A Md n o r i n g

ond shoutd

not

be -co

by hond
Poge: 4 ol zJ

'o''

135980

7L23/30
tl.

ENGINE AUTOMATIC
WIRING DIAGRAM

1605352-3

TERI INALS IN TERMINALBOX W 75

TED ON ENGINE

- - -'r
r -l A
'

LowER

L - - - -

o -

73

74

YNCIIRONIZING MOTORON
SYNC
OVERIJOR
GOVE

L _ _ 8 4 1 S _ E _ 75

FORSYt[l-ROtIZItlGl'l0IOR
CO,IIACT
76
( n o t s u p p Ii e d b B & W )

77

G-_

78
o\

79

80
8f

G=r

82
83
84

85
86
87
88
-<-

89

90
9r

@
@
@
@
@
@
@
@

96

114

Ir5
12e
129

is

L U B .O I L F I L T E R
HIGH DIFF. PRESS. ALARM
L U B .O I L I N L E T
H I G HI T E M P . A L A R M
H . T . I{ATER SYSTEMINLET
L0w PRESS. ALARM
PRE
PRE LUB.OIL
LO!',
LO!', LEVEL ALARM
S T A R T I N GA I R
i
ALARM
LOW PRESS.
FUEL LEAKAGE
H I G H LEVEL ALARM
HIGH
OVERSPEEDD E V I C E
MICROShIITCH
M
ICR
OVERSPEEDALARM

FUEL O I L I N L E T
L0l{ PRESS. ALARM

97

This

H . T . I{ATER SYSTEMOUTLET
HIGH TEMP. ALARM

-{\

o C A D A Md n o r i n g

H I G H P R E S S . S E A L I N GO I L
LOW PRESS. ALARM

OVERSPEEDA I R I N L E T
LOI{ PRESS. ALARM
Lot{

ond shoutd not

be connec t ed br

hond

Poge: 5 of :7

'c"

135980

7L23/30

ENGINEAUTOMATIC
WIRINGDIAGRAM

MAN-B&I,I
DIESEL

1605352-3

I TERMINALSIN TERMINALBOX h' 75

MOUNTED
ON ENGINE
I

l--31

11 l- 1
j-lr-1-

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RuN'IGNAL
SNGINE
F R o M M E AcSo' N V R T E R

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T!'Ig?,y1'u8,.,."

ffi
ll34-I-[t
t
l
tt ll
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ArRouTLET
.HARGTNG
cooLER

FORJET ASSIST.
PRESS.TRANSMITTER

\Y

[-------;l

__-'^.^,-_l

I nT?:.ll?Eo'oo
I
I
I

ral
E7

FoR
THERM''TATE
PREHEATER

L_ _ _t_____J
PRE LUB.OIL PUMP

This

o C A D A Md n o w i n g o n d s h o u t d n o t

is

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ll

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135980

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7L23/30

Dote

DesJCk

9t o4o3

I E A PI F I F

MAN-B&W
DIESEL

aOt o r

ENGINEAUTOMATIC
WIRING DIAGRAM

1605352-3

TERMINALS
ON ENGIIIE
I

t l

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I
I

I
4 -'1I
5
I

5 - 6 < f 5 0 RPM

8-9>150 RPM

I
I

6-7>r50 RPM

- - - - - l

- l

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_ t
I

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t1

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24V dc

12
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ENGINE RPM

12
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r 0-'1
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9
I

6
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TC RPM

This

is

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ond shoutd

not

be connec t ed

6y hond

Poge: 7 of z7

135980

MAN-B&h'DIESEL
ENGINEAUTOMATIC
EXTERNALCONNECTION

1605352-3

PLANT

B A Z A N1 4

15

D R W GN. O .PAGE D E S C R I P T I O N
r 6 0 5 J 5 3- 5
! 6 0 5 3 5 3- 5
r605353-5
. |6 0 5 3 5 3 - 5
f 605353-5

I N t r O R M A T I O NS H E E f

FRONT VIEI{

'1.

JET ASSIST

TERMINALSTRIP

t)

E X T E R N A LC O N N E C T I O N

ptonent

'c''

135980

1..c.

7L23/30
c I o^

JET ASSIST. BOX

INFORMATICNSHEET

for

Ident.

No.:

M A N - B & WD I E S E L

16 0 5 3 5 3- 5

PANEL DIMENSION
HWrD = 3OOr2OO*155

This

is

o C A D A Md n o w i n g o n d s h o u t d

not

be

connected
Poge,

135980

7L23/30
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F R O N TV I E W

by

hond

2 oi':6

M A N . B & h ID I E S E L

I 6 0 5 3 5 3- 5

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I 35980

7L23/30

M A N - B & WD I
d.l

JET ASSIST. BOX

JET ASSIST.

No.

16 0 5 3 5 3- 5

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135980

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JET ASSIST.
JET ASSIST.

MAN-B&WDIESET-

16 0 5 3 5 3- 5

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SUPPLY 24Vdc

PICK-UP FORJET ASSIST.

3.6

4.1

ENGINE RUNhIING

4.1

AIR VALVEJET ASSIST.

3.7

PRESSURETRANSMITTER
FOR JET ASSIST.

This

is

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not

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Poge: 5 oi:

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13 5 9 8 0

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JET ASSIST. BOX

TERMINAL STRIP

MAN-B&!TDIES

16 0 5 3 5 3 - 5

T E R M I N A L ST N
J E T A S S I S T . BOX

I E R MI N A : S
ON ENGINE
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JET ASSIST. BCX

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EXTERNAL CONNECTION

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/-*C
Autorndlcsand Instruments

1991.05.19
Ref.to Draw.
1624016-1,
1624017-3

of Thermostates
ard Pressostates
Anangement

Page1 (1)

ItemNo.

tlescription

Type

0 1 ,3 9

Pressoslate,
10- 35 bar

KPS39

02

KPS80

03,04

Thermostate,
T0 - 120"C
- 120"C
Thermostate,T0

0 5 ,0 6 , 3 6 , 4 9

Pressostate,0-8bar

KPS35

07

Diff.pressostate,
0,2 - 2,5 bar

cAS1s5

37

Levelswitch

42

0 - 10 bar
Pressuretransmier,

Analogpick-up

50

P r e s s o s t a lt-e1, 0 b a r

KPS80

EMP2

KPS4}

T{OLEBY
CET\ERANGSETS

lUIAN

CIRUv
SPETDCONTROL
SYSTEM

P L A T 3E1 3 0 1 - 1 O H

OlI
9230
o3?e
18
o507
o9
0785

>im

rfii

$4{

o.78
al67
-

f-rs

F_

a25

r
ft3

a(t8
4917
tDr5
Ttoa
':n7
7382
7a7l
75O
t59
naE

8 18 3
8272
3fc8---{r

t&rrn

",--1'h/_*,
g

8361
8450
8549

ffi*
-

la-

E--

E tt===-=5
=
GENERANNGSTS

1||AN

Eteut
P L A T3E1 3 0 1 - 1 O H -

SYSTEM
SPEEDCONTROL

Item No.

Designation

Benavnelse

0 14 1
00
,".6a
-,,6ac-q lc tto t 0 2 3 0

Go ve rn or

R e g ual t o r

S cre w

Skrue

L o ck w a sher
L e ve r
Screw

Sjkringsskive
Arm

6loo. (?,'l ,t '- 0696

Nut

Mstri k

6 o t , :J . : ' o: o t 6 0 78 5

Split pin

Split

Screw
H o uisn g

Skrue

Nut
S p 'l'i t p i n
Axle journal

Motri k

Ge a rw h eel
Bush
Ge a rw h eel
Key

T a n d h uj l

We a rri n g
Lock screw

S 1i d r i n g

S p a ce rring

Afstandsring

S y n c h r o n i z i nmotor
g

Synkroni seri ngsmotor

S h u t-d own
D is c
B a lI b e a r i n g

Shut-down

Gearwheel
Key
Nut
S p i1t p i n

T a n d h uj l

600co3/0 0002 0 3 2 9
- 6llo 03,,0c.)!,i 0 4 1 8
6ltt4::'1lt-:1 lt:i'

0 5 07

( rtt 0874
6()4(,.03/
. $ _ t i ot = l , ' : : i r 0 9 6 3
i"'.

":t;,'^.

,:"r'! 1031
t ,: t 1124
o0tt 1219
r : , e r r a1 3 0 8

I i;!. ,:)o.;,;". i r';; 1497

_6oocaztoct:t 1586
6lct t://1 .^f
-(((,i

1675

{!,.,,r,'{ 1764

jooo e3r 1v 1853

6 a : : r ; . . ' ,1" : i r *1 94 2
2 0 10
!: t," t , 2i 7 ? 1 0 9
54,0_q
,r,., n2298
-*r:: ). o':
6oa( r 1,]v",:lrt 2387
6ort i:'l.i:i.:I 2476
'.:l r '1i',1.: 2565
-f:.:.]:'rl
"'t.: 't;!''' i 2654
-.zl:l
6o,c 03/l ti)Zv 2743

J la trlt col, 2832

lJl. {'ii"',C',: ?921
.^3i{ 93099
, l C ! , "Q 3 t ! , 0 0 ! :3f 1 8 8
5 , t ) oo 3 t o 3 t ' : ' q 3 2 7 7
"r!

Skrue

Hus
Split
A k s e lt a p
Bosning
Tandhjul
Feder
S ik r i n g s s k r u e

S k iv e
K u g le 1e j e
Feder
Motri k
S p ii t

L in k a g e
Sp'li t p'in

Split

P':n

Tap

G u i d ep i n
Screw

Styresti ft

Lenkeled

Skrue

3--

- -----

---5

CENERI\N\G SETS

PLAT3
E1 3 0-11 O H

SPEEDCONTROL
SYSTEM

Item No.

_ 6 lo o . o 3 /ooo j e 33 6 6
:,tr i.*: 3455
_6oaa
6ooo3/ooas3544

!!'r_il:i

,r't t 3722

6nocc3/t l1r;J 3811

6c00.t'ri0losC 3900
!.J!.3.:61 ,r!ci 4167
!1tt t:tt ('rty 4256
4345
ltr't t-:t! 1c.i!
t(,i.1.,\.,: " 6 /p 4434
!_Qo:t3l(!6q 4523
:!!!!,'\'''

!,::')tI 4612

f'ftA f j:il t';

4701

{ "'." :r,/?; t' 4890

4989
_!X_!i,r:.!_li t.*t7t

5057
!!!9!:g
/0 orc:5146
6sno.
-

ost.ooc65235
_6oot
( t o1t,t:;)r
"?,ll -': 53?4
600ac3!?rtJ2 5413

-e.45i!--,-:l-TQ?
'
!!i:, :nt' !t/\"'/5691
5780
lottt nsu rc

-t*:::::t:.i

5-8le

5968
l(!a.rlio rp5
6036
-6oooolt6 p6s3
600Qo'tQg6trt6125
r:'':i \'00:J-6214
l!':
_!oJ t:', tt)[], 6303
t 6942
6000"
0.J',t-,r::'!

Designation

Benavnelse

S to p a rm

Stoparm

L o c kw a s h e r

S'ikringsskive

Screw
G u i d ep i n

Skrue

P u lI ro d head
Split pin

T r a k st a n g s h o v e d

Styresti ft
Split

PulI rod end

P lu g screw
Ga ske t
Nut

Mstri k

S tu d

Tap

G u i d ep i n

Styrestift

S tu d
Pin

Tap

S p r i n ga r m
S p rin g
Bush

Fjederarm
Fjeder

B e a rin g

Leje

S p r i n gh o u s i n g
Pin

Fjederhus

Screw

Trekstangsende
Propskrue
Pakning

Tap

Bosning

srifr
Skr ue
Fjeder

S p r in g
G u i d er i n g
Pin

stift

G u i d er i n g
P u lI ro d

Styr er i ng
Trekstang

Nut
L o ck w a s her

Motri k

P u l 'l ro d head
Nut
S p li t p i n
Pin

Styreri ng

S ik r i n g s s kvi e
Trekstangshoved
Mstr i k
S p li t
sti ft

=-+= ==Ee=

= E!==L=-==

GENERANNGSETS

P L A T3
EI 3 0 1 - 1 O H

SPEEDCONTROL
SYSTEM

Item No.

-6!8t:43/465Y 6581
'.6000
nstr)oosV 6670

Designation

Benavnelse

Arm

Ar m hol
der

Screw

Skr ue

Lever

Fjedr endetr akstang,

kom pl
et
Skr ue
Arm

G u i d ep i n

Styr est' ifi

Screw
Guidep'in

Skr ue
Sikringssk'ive
Styr estift

Screw

Skr ue

B e ar i n g

Leje
Bosn
i ng

t.;r10.:)t}'')
{,3p.

67 69

R e s i l i e n t p u 1 1r o d ,
c o m pel t e

!t 1t,n
6t"t,1 .t-

6858

Screw

'r,f.i
ir,'r.r,-''l',1 t 6947
'':t.
7015
Jittt t:,i't
(6rt" CIi/tttj 7104

f r:t:t iiP l,q6 7293

6"i 7 382
cl) :.1il . "
_k t
.
, ),' )11,

,,. 747 1
_6 li.
'::"i:
.1.':;)
7560
_:;10

Lock washer

6pon.r;-to
ug 7659

Bush

l,:!,t:, --:l0 ,)0,1* 7748

Shaft

6 tto , ) 3 ; ' i1 i ! 7 8 3 7

[.lasher
Screw

Aksel
S k iv e
Stopr ing
Skr ue

P ic k - u p

P ic k - u p

Nut

M s t r ik

* 6 o o oJ/0.0d/y 8361

Index cam

Index kam

c'3.t0
col-r 8450
6C,tO.
^nr{ 8549
_!.0 ,',;;,;t
it:], fr'tia.t.:./t 8638

Bracket

B e sal g

Scnew
Bnacket

Skr ue
B e s al g

t):tO.,tf /t' 8727

_41'qn

Screw

Skr ue

*6clrl0o l t O o o l o 7 9 2 6
"
6,11".1",' l',r" 8094
'
8183
. .,ia1*.J1'l :',1.'i;-

6 0 0 J s 6 / j 8 2 7 2

Stop ring

-l
-

G:

- -----

-E-E

CENERATI\IG SETS

]YIAht

Et&ut

P L A T E3 I 3 O 5 . f1 H

O V E R S P ETER
DI P

2096
2185
r------227t'

=--#i;
E

r-L

2541
2630
2729
2818
2907
3075

osnwlm
\:zs
\::2
n
:

3L3l
,--3520

y--u"

C'learance0-0.Zun

fu=._,,aza
965
5033
-----------ii - - - - - - - -r
::,----f-i-''!

i-.

i:

.:

&--"

E#.EEY
GNERANNG SETS

t||Af{

Ereut
PLAT3
E1 3 0 5 - 1 l H

O V E R S P ETERDIP

Designation

Benavnelse

0127

Cover

Deksel

0216

Screw

Skr ue

0305
0 49 4
0 58 3

l,Jasher
Pin
Lever

Sk' ive

1017

Circlip
Flyweight

11 0 6
1295
1384
1473
1562
16 5 1
1 74 0
18 3 9

Nut
Ga ske t
Ball bearing
R e s i li e n t c o u piln g

Tap
Arm
S i k r i n g s r in g
Svingvegt
M str ik
Pakning
Kug' lel
eje
Fjedrendekobl'ing

S p in d le
Wa sh e r

Spindel
S k iv e

Screw

2096
2 18 5
2 27 4
2363

Socket
Button
S p r i n gp i n
S p rin g

Skr ue
Muffe
Knap
Fjeder stift
Fjeder

2452

Screw

Skr ue

2541

Cover

Deksel

2630
2729
2 8 18
2907

S p r i n gp i n
Pin
Lever
C u pp o i nt scr ew

Fjeder stift
sti ft
Arm
Kraterskrue

3075
3253

F 'l yw e i ghthousing
A d j u sti ng scr ew

Hus for svingvagt

334?
3431
3520

Go ve rnorspr ing

Instillingsskrue
Regulatorfjeder

Key
Ball bearing

Feder
Kuglel eje

3708

Hous
i ng

Hus

3897
3986

S p in d le
Spring

Spindel
Fjeder

con t.
.,r=

:-Eg

GENERA'II\IC

SETS

lvlAN
CEU'
PLATE
31305-I1H

O V E R S P TTER
DI P

Item No.

Designation

Benavnelse

4000

M'i croswitch

4 0 01

Screw

M icr o- afbr yder

Skrue

4?32

B u tto n

Knap

43?1
4509
4 69 8

S to p screw
S p in d le
S p rin g

Stopskr ue
S p in d e l
Fjeder

4787

S p in d 1e

4876

Spring

4965
s033
5122

V a l ve a ttachm ent
Screw
V a lve

5211

S to p cyl i nder

VentiI holder
Skr ue
V e n t il
Stopcyli nder

5300

S e ailn g r i n g

Tatningsring

S p in d e l
Fjeder

*E

-----

-a
r

CENERI\NNGSE'Ts

lvlAtrt
CEU'
PLATE
31306.1
1H

CYLINDERS
S T O PA N DL I M I T A T I O N

AIR
CONTROL

>

1
3 1 3 0 5/s21
PLATE

AIR
STARTING

?101
?102
2103
?.104

2 10 5
2106

21t17

2108
2109
2110

PLATE
3 1 30I

tt+E

Etlt

! EI=E.H
GNERATI\C

E
SETS

IvIAI{
E&Ul'
.PLAT3
E1 3 0 6 - 1 l H

CYLINDERS
S T O PA N DL I M I T A T I O N

Designation

Benavnelse

?.101
2102

L o ck w a sher

2103

L o c kn u t
L o c kw a s h e r

S i k r i n g s s kvi e
Mstr ik
Kontra motri k

Item No.

2104
?105
2106
2107

Nut

S to p scr ew
T h ru st s hoe
L i m i t a t i o n c y 1j n d e r

S j k r i n g s s kvi e
Stopskr ue
Tryksko
ngscyli nder
Begreensn'i

2 10 8
2109

Screw

Skr ue

G u i d ep i n

2 11 0

l.|asher

Styresti ft
S k iv e

E*

- -----

----

GENERATII\IG SETS

I|tAhl

Ereurt
3f308-O3H
PLATE

INSTRUMENTS

2000
2377
2?88
2644
0689
0690

ffi

/' ?466

h''"
2555

956

ts

--a-

GENERA.fII\IC SETS

lvlA{

Ereult

PLATE
3I 308- O3H

INSTRUMENTS

Item No.
d,.roo3F0t:0010133
,,;j l, :19:0689*
f,tt,r:)

t6ooo
olro ocos 0690*
lrtooIjttt ooaY0778
l

- . , - - , nj ^ ' , " 0 8 6 7
" '
l U U I l L

lttona,'79o

-0956

{4tr.' t"1 ia61391

.1952
{,)ry}lit:a. -c:
6ao o:loiaf 2ggg
4{tr C}t .}i.: _t 2199
''r
(,r". ...i r :'12288*
( 7 q r r1 ; / , ' i .t | i 0 2 3 7 7 *

t)n|':",x,1.) r t ; 2466*
itotl 1) t'''

n. ; 2555*

loJj j:t't,'2,2644*

2733*

i0tt .4)ln:.:t:,t,/

Designation

Benavnelse

T h e rmo m eter
0- l00oC
TI-,I1
P re sso stateKPS35
S e t t j n g r a n g e0 - 8 b a r

Ter m ometer
0- 1000C
TI-11
PressostaK
t P S3 5
Kontr olomr de
0- 8 bar

P re sso stateKPS39
S e t t i n g r a n g e1 0 - 3 5b a r
Thermometer
50-650oC

Pr essostatKPS39
Kontr olomr de
10- 35bar

J r- 6 1

Termorneter
50-650oc
T I- 6 1

pocket
Thermometer
for TI-61

Termometerl
onrne
for TI-61

Thermometer
0-30OoC
T I -3 0
T h e rmo meter
0- 100oC
T I - 0 1 ,T I - 0 2 ,T I - 1 0 ,
TI-31
T h e rmo meter
0- 100oC
TT-22

Termometer
0-3000C
T I- 3 0
Ter mometer
0- 1000C
T I - 0 1 ,T I - 0 2 ,T I - 1 0 ,
T,I- 31

Thermometer
50-650oC
T I -6 0
pocket
Thermometer
fo r T I-6 0
PressostateKPS43
S e t t i n g r a n g et - , | 0 b a r
ThermostateKPS80
S e t t i n g r a n g e7 0 - 1 2 0 ' C
L e ve l switch
D i ff. p ressostate
cA S1 5 5
S e tti n g range
0. 2 - 2 . 5 b a r
PressostateKPS35
S e t t i n g r a n g e6 - 1 8 b a r
P re ssu r etr ansmitter
EMP2
S e t t i n g r a n g e0 - 1 0 b a r

*'Xi'lt: t, t))'-- ?822

T h e rmo meter
0- l00oC
T I-0 2 , TI- 20

2911
:.'* ^ ,ltJ.,
,.:,,tJl

Thermometer
0-160oC
TI-40, TI-51

Ter m ometer
0- 100oC
IT-?2
Termometer
50-650oC
TI - 60
, Termometerlomme
for TI-60
Pr essostatKPS43
K o n t r o l o m r d1e- 1 0 b a r
TermostatKPS80
Kontromomrde
70-120uC
Niveaukontakt
Diff. pressostat
CAS155
Kontromomrde
0 . 2 - 2 . 5b a r
Pr essostatKPS35
Kontr olomr de
6- 18 bar
Tr yktr ansmtter
j
TMP2
Kontr olomnde
0- 10 bar
Ter m ometer
0- l00oC
TI-02, TI-20
Termorneter
0-t60oC
TI-40, TI-51

:- ---- -----

GENERATING SETS

1||AhI

Et&urt
INSTRUMINTS

PLATE
31309.08H

1271

rJ--r

1360
I460
t548
r637
31308032
1726
r904
3400
3401
3402

0r03
216r

0292
038r

2260

0170
0569
0470

2527

c..,||

FG.9

FE-F-EEE

GNERA'N{GSETS

lvlAhl

ct&ut
PLATE313O9.O8H

INSTRUMINTS

Item No.
: ,l03
t l. t , l J. ^ : , i " ' r . ,l , : 0
-

,6ar)
nzt. t g 0292
',6oqqc:t"
l''n 038l
' , { l t t , n: - . , . n : r , " l,l 0 4 7 0

6oto ll'i1 J t: L 0569

{,)1t)

^: ,t't.;,
.''' Q-/Q'/

oco037g6j0836
a3L|to:0925
6000
.6('rt!il!: t.:tt/1093

!!:!,,:'" at:t 1271

0./: 1360
6oto.t,it:
',rit l-:tt ''['lu:]469
l-cv 13/0,l:t:7 1548
.6!l:! tJ/!,ct:Y 1637
t : \ ' t t " t l l l $
f,1t4
q-zto'ttvc 1904
6_ooo
/):r..l' 2161
lCICA
,i,:/1,i:'3/'"r7',!;?250
{:t ::). t",i.'. ;:: 2251
'6noc.o:ilottJ 2260
lttta.t:/ 5,.2438
6 C l l : n . Jt ' , - ' t 5 t

,l:)0l;,,:,4ly 2616
',,|i:.1)
)-;l0 0lV 3400
;6ooocStttqf ir 3401
',:J:1!
i:'iitt7 3402
',600
o-tolrC 3410

Designation

Benavnelse

R u b b e r- bushed
coupling
!,lasher

Gummi
kobli ng

Nut
!l'ion
Un"ion

Sk've
i
Mstr ik
Forskruning
For "skr un
i ng

Screw

Skr ue

C a b l ee ntr y

Kabeli ndfor ing

3 -w a yvalve
Screw
_ N a mep l ate
In stru m entpanel
Tachometer
N a mep l ate
Screw
D a mp e(c
r har gingair )
Manometer
hose
Manometer
hose
Ma n o meter
valve
Ga ske t

3- vejsventiI
Skr ue
skilr
Instr umenttavl
e
Tachometer
skilr
Skr ue
Danper( ladeluft)
Manometersl
ange
Manometersl
ange
Manometerventi
I
Pakning

Union
N a mep l ate

For skr uning

C o n s o l ef o r i n s t r u me n t p a nel
P ip e
D a mp e(nozz
r
cool oil)
Union

Konsolfor instr umenttavle

Rar
Darnper(dysekoleolie)
For skr uning

Uno
i n
Op e ra ti onswitch

For skr uning

Oms
ki fterknap

skilr

- -----

--3t

GNERATII\G

SETS

TNSTRUMENT
PANELFORPI-24

PLAT E
31309-IH
1

3623

90.44

E.E=

FFEE-'

CENERAI\IC SE'TS

]v|AhI
P L A T 3E1 3 0 9 - 1 t H

PANELFORPI.24
INSTRUMENT

Item No.

Designation

Benavnelse

In stru mentpanel

I nstrumenttavle

,1
8!( ,1:t,l t ir 9 1 3 1
:l3.cro;0 3 19
Wo))
1}:t ,l .: ; ,1 :1i'i'j 0 4 0 8
{i
i6ototJf!')126 0 5 9 7
i r ^ ^ ^ . t 1 a t i j
' t ( t 0686
r'"

R u b b e r-bushed
coupling

Gummi
kobli ng

Nut
A n g l eu n i o n
U n 'i o n

Mstri k
Vinkelfor skr uning
Forskruning

) o oL ; ' . r ' . r 0 8 6 4

plate PI-24
Ngq.,.

sk' ilr PI- 24

n.;f ". 't,"' 0953

rl,..t1,

Ma n o meter
0- 25 bar
instrumenp
t ane1,
compl
ete

Manometer
0- 25 bar

i ! . . ' , . " . . ,t "r . 3 6 2 3

90.44

I n s t r u m e n t t a ev ,l
kom pl
et

a=

-----

E---

GNERANAGSETS

- TOOLS
SPEEDCONTROL
SYSTEM

PLAT3
E1 3 5 1 - 0 2

*XEBE

GENERANNG

SETS

'- _
PLATE
3 1351- 02

- TOOLS
SPEEDCONTROL
SYSTEM

Designation

Eenavnelse
N o g i ef o r i n d s t i l f i n g
af overspeed

E#.=EE

CENERATI{G SETS

UGDIAL
GOVERNOR

WOODWARDGOVERNOR
COMPANY
MANUALO3O4OD

WANMNG

READ THIS ENTIREMANUALAND ALL OTHERPUBLICATIONS

PERTAININGTO THE UORX TO BE
PERFORMED
BEFOREINSTALLING,OPERATINGOR SERVICINGTHIS EOUIPMENT.PRACTICEALL
PLANTAND SAFETYINSTRUCTIONS
AND PRECAUTIONS.
FAILURETO FOLLOWINSTRUCTK}TF
CAT'
CAUSEPERSONALINJURYAND/ORPROPERTY
DAMAGE.

Woodward Governor Company reservesthe right to update any porton of this publication at any trme Inlsr-: .? a'..cc
Woodward Governor Company is believedto be correct and reliable.However,no responsbilityis assumedDt .'.:/.t:3r,cra7
Company for its use unless otherwise expressly undertaken.

@ WoodwardGovernorCompany,1982
All RightsReserved

bt

I'@EWEED
TABLEOF CONTENTS
sEcrroN1
G E N E R A LI N F O R M A T I O N
..
Introduction.....
Description
References
S E C T I O N2
I N S T A L L A T I O NP R O C E D U R E S
Introduction.....
Receiving
Storage
M o u n t i n gR e q u i r e m e n t.s. . .
L i n k a g eA t t a c h m e n t s. . . .
OilSupply

2
4
4
4
4
4
5
o

s Ec T r o N3
P R I N C I P L E SO F O P E R A T I O N
I n t r o du c t i o n. . . . .
C o m p o n e n tD e s c r i p t i o n. . . . .
OilPump
A c c u m u l a t o.r. . . .
Power Piston
Pilot ValveSystem
B a l l h e a dS y s t e m
CompensationSystem
L o a d L i m i tC o n t r o r
Synchronizer
Speed Droop
O p e r a t i o no f t h e U G D i a l G o v e r n o r
G e n e r a lI n f o r m a t i o n
Decreasein Load
I n c r e a s ei n L o a d
S E C T I O N4
G O V E R N O RO P E R A T I O NA N D
ADJUSTMENTS.
I n t r o d u c t i o. n. . . .
I n i t i a lO p e r a t i o nf o r a N e w G o v e r n o r

I
9
9
I
o

I
I
11
11
12
12
12
13
13
13
14

15
15
15

Adjustments.....
C o m p e n s a t i oAnd j u s t m e n t .s
l n i t i a lO p e r a t i o nf o r a R e p a i r e do r
R e a s s e m b l eGdo v e r n o r
T e s tP r o c e d u r e.s.
T e s tC o m p l e t i o .n

........15
... 15
.... 16
... 18
.... 20

sEcTtoN5
TROUBLESHOOTING
..,.. 21
lntroduction
... 21
Troubleshooting.
....21
o i l. . .
. . . . . . .2 1
C o mp e n s a t i n gA d j u s t m e nat n d
N e e d l eV a l v e.
..... 21
Definitions
...... .. 21
P r e l i m i n a rIyn s p e c t i o n
... 22
T r o u b l e s h o o t i nC
gh a r t
.. 23-27
A d d i t i o n a Il n f o r m a t i o n
for Steam
T u r b i n e sG
, a s a n d G a s o l i n eE n g i n e s
. .. . 28
G o v e r n o r F i eRl ed o a i r s . . . .
.......28
R e m o v aol f G o v e r n o rf r o m E n g i n e
. .. . 28

sEcTtoN6
R E P L A C E M E NP
TA R T S
R e p l a c e m e nPt a r t sI n f o r m a t i o n
lllustratedPartsBreakdown.

... 31
. .. 31
.. 32-41

sEcTtoN7
A U X I L I A RE
YO U I P M E N T
....
Introduction
S y n c h r o n i z eM
r o t o ra n d S o l e n o i d
Shutdown
E o d i n eS y n c h r o n i z eM
r otor
P M S y n c h r o n i z eM
r o t o rw i t h H o u s i n g
Low Lube Oil PressureShutdown
M a g n e t i cS p e e dP i c k u p
M i c r oS w i t c h e sa n d W i r i n gH a r n e s s

42
42
42
42
43
44
44
44

L IST OF ILLUSTRATIONS
U G 8 D i a lG o v e r n o r
1 - 1 R e c o m m e n d e dO u t p u t S h a f t T r a v e l
'1
Adjustment
1 - 2 O u t l i n eD r a w i n go f U G D i a lG o v e r n o r. . . . . 3
2 - 1 L i n k a g eA r r a n g e m e n(tF o r N o n - L i n e a r
F u e lS y s t e m ). . . . .
3 - 1 S c h e m a t i cD i a g r a mo f t h e U G D i a l
Governor
10
4-1 Maximumand/orMinimumSpeedStop
Adjustmenton the UG DialGovernor
19
5 - 1 C o m m o n B e n c hT o o l s
29
5 - 2 N o r m a lF i e l dR e p a i rT o o l s
30
6 - 1 P a r t s l l l u s t r a t i o n sf o r t h e U G D i a l
Governor
... . 33-41

7-1 UG Coverwith BodineMotor and

S h u t d o w nS o l e n o i d
.. . 42
7 - 2 l n s t a l l i n gC o v e r w i t h B o d i n e
S y n c h r o n i z eMr o t o r
... 42
7-3 UG8 DialGovernorEquippedwith Bodine
S y n c h r o n i z eMr o t o r
... 43
7-4 Top View of WeatherproofHousingwith
P M S y n c h r o n i z eM
r o t o ra n d S h u t d o w n
Solenoid
....... 43
7-5 UG8 Governorwith PM Motor,Weatherp r o oH
f ousing...
.....43
7 - 6 L o w L u b e O i l P r e s s u r eS h u t d o w n. . . . . . . . 4 4
7 - 7 M a g n e t i cS p e e dP i c k u p
. . . .. 44
7 - 8 M i c r oS w i t c h eas n dW i r i n g
...... .. 45
7 - 9 W i r i n gH a r n e s so n C o v e r
.. .. 45

V@EEED

OIL FILLER CAP

covER\*
OIL SIGHT GLASS

OUTPUT SHAFT
(TERMINAL SHAFT)

9 p.<

rr lorr--

COMPENSATION
POINTER

COMPENSATIONNEEDLE
VALVE PLUG
OIL DRAIN
PLUG

U G 8 D i a lG o v e r n o r

Y@EMED

sEcfloN 1
GENERALINFORMATION
FULL

INTRODUCTION

FULL PRIME

T h i s m a n u a lc o v e r st h e U G D i a l G o v e r n o rl.t i s
Generallnformation,
arrangedintosevensections;
lnstallationProcedures,
Principlesof Operation,
Governor Operationand Adjustment,Troublen ta r t sa n d A u x i l i a r yE q u i p s h o o t i n gR, e p l a c e m e P
ment.
The UG DialGovernoris available
in threedifferent
w o r k o u t p u t s t, h e U G s . 7 ,U G 8 a n d U G 1 2 . 8T. h e
U G 5 . 7a n d t h e U G 8b o t hu s e1 2 0P S Io i l p r e s s u r e
a n dt h e U G 1 2 . 8
u s e s1 5 0P S l .
Adjustment,
Troubleshooting
BasicUG Operation,
and Replacement
of Partsis similarfor the UG5.7,
U G Ba n dU G 1 2 . 8 .

WANMNG
The engine, turbine, or other type of prime
moyer should be equippedwilh an overspeed
( o v e r t e m p e r a l u r e ,o r o v e r p r e s s u r e ,w h e r e
applicable)shutdown device(s),that operates
totally independentof the prime mover control
device(s) lo protect against runaway or
damage to the engine, turbine, or olher type
of prime mover with possible personal inury
or loss ol lile should the mechanical-hydraulic
governor(s) or electric control(s), the
a c t u a t o r ( s ) ,l u e l c o n t r o l ( s ) , l h e d r i v i n g
m e c h a n i s m ( s ) ,t h e l i n k a g e ( s ) ,o r l h e c o n trolled device(s)fa|.
Misc.-A_lsz

DESCRIPTION
T h e U G i s a m e c h a n i c a l - h y d r a u lA
i co v e r n o rf o r
c o n t r o l l i n g d i e s e l , g a s o r d u a l f u e l e n g i n e s ,o r
s t e a mt u r b i n e s .T h e U G i s m e c h a n i c a l l yl i n k e dt o
the fuel racks or to the fuel valves,dependingon
the system.

T h e m a x i m u mt r a v e lo f t h e o u t p u t( t e r m i n a ls) h a f t
i s 4 2 o . T h er e c o m m e n d e tdr a v e lo f t h e o u t p u ts h a f t
is 28o from no load to full load, which allows
sufficient overtravel at each end so that the
g o v e r n o rc a n s h u t d o w n t h e p r i m em o v e ra n d a l s o
g i v e m a x i m u mf u e l w h e n r e q u i r e dS
. e e F i g u r e1 - 2
for recommendedoutput shafttraveladjustment.

O V E R T R A V E LT O I N S U R E P R I M E M O V E R S T O P S A R E
REACHED
N O L O A D T O F U L L L O A D T R A V E L_ N O R M A L L Y2 / 3 O F
F U L LG O V E R N O RT R A V E LI S R E C O M M E N D E D

T H E P R I M EM O V E R
T R A V E LR E O U I R E DT O A C C E L E R A T E

T R A V E LR E O U I R E DT O D E C E L E R A T E
OR SHUT DOWN
P R I M EM O V E R

M A X I M U MW O R K C A P A C I T YO V E RF U L L G O V E R N O RT R A V E L
OF 42' IS {' FT.LBS. SEE AAOV FOR RECOMMENDED
G O V E R N O RO U T P U T T R A V E L . I N S P E C I A LA P P L I C A T I O N S
M I N A N D i I A X P R I M E M O V E R S T O P S M A Y B E O U T S I D ET H E
GovERNoR sroPs'
Mrsc.-a-r53

* s.z rt-taS for the uG5.7

9.7 FT-LBSfor the UG8
11 . 7F T - L B Sf o r t h e U G 1 2 . 8
F i g u r e 1 - 1 . R e c o m m e n d e dO u t p u t S h a f t T r a v e l
Adjustment
Normally,the UG operatesisochronously(constant
speed) regardlessof load on the engine, except
d u r i n g o p e r a t i o n a s d e s c r i b e di n S e c t i o n 3 ,
Principlesof Operation.
Speed droop is incorporated in the UG Dial
Governorto divideand balanceload betweenunits
drivingthe sameshaft or paralleledin an electrical
system.
A l o a d l i m i t c o n t r o l i s a l s o a s t a n d a r df e a t u r eo n
t h e U G D i a l G o v e r n o r .l t l i m i t st h e a m o u n to f f u e l
supplied by restrictingthe travel of the governor
output shaft.An indicatordial shows the governor
o u t p u ts h a f tl i m i t p o s i t i o n .
The load limit control may also be used for
s h u t t i n gd o w n t h e e n g i n e ,t u r b i n eo r o t h e rt y p e o f
prime moverby turning it to zero.

Y@EEED
REFERENCES
Sales.Serviceand ProductInformationare available
t h r o u g ht h e o f f i c e sl i s t e do n t h e b a c k c o v e ro f t h i s
m a n u a l .S o m e o f t h e m a n u a l sl i s t e d b e l o w a r e
t ection
b r i e f l yc o v e r e di n t h e A u x i l i a r yE q u i p m e n S
of the manual.

ITEM

NUMBER

Manual

03013

S h u t d o w nS o l e n o i df o r
UG Governors

Manual

03016

Low Lube Oil Pressure

Shutdown for UG Governors

Product
Spec.

03029

UG Governor

Manual

03035

TITLE

P M S p e e dA d j u s t i n g
Motor

TITLE

ITEM

NUMBER

Manual

03505

Speed Adjusting (Synchronizing) Motor Parts

Catalog and Lubrication
Guide

Manual

25071

Oils for Hydraulic

Controls

25075
Spec.
Procedure

CommercialPreservation
Packagingfor Storageof
Mechanical-Hydraulic
Controls

TITLE

ITEM

NUMBER

Manual

36052

Magnetic Speed Pickup

for PG, UG and UG40
Governors

Manual

36684

BoosterServomotor

A p p l i c a t i o n5 0 5 16
Note
Manual

56103

G o v e r n o rL i n k a g ef o r
ButterflyThrottleValve
U G D i a lR e p a i r

I/@EMED

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sEcTtoN2
I N S T A L L A T I O NP R O C E D U R E S
INTRODUCTION
T h i s s e c t i o n p r o v i d e si n f o r m a t i o nn e c e s s a r yf o r
r e c e i v i n g s, t o r a g e ,m o u n t i n ga n d s t a r t - u pa d j u s t MENTS,

3 . M o u n tt h e g o v e r n o rs q u a r e l yo n i t s m o u n t i n g
pad.
4 . M a k es u r et h e r ei s n o f o r c e p u s h i n gt h e d r i v e
shaft into the governor.
SeeFigure1-2 (OutlineDrawing),for mounting
h o l es i z e sa n d g o v e r n o rd i m e n s i o n s .

WARNING
The engine, turbine, or other type of prime
mover should be equippedwith an overspeed
( o v e r l e m p e r a t u r e ,o r o v e r p r e s s u r e ,w h e r e
applicable)shutdowndevice(s),that operates
totally independentof lhe prime mover control
device(s)to protect against runaway or
damage to lhe engine, turbine, or other type
ol prime mover with possiblepersonalinjury
or loss of life should the mechanical-hydraulic
g o v e r n o r ( s ) ,o r e l e c t r i c c o n t r o l ( s ) , t h e
actuator(s), fuel conlrol(s), the driving
m e c h a n i s m ( s ) ,t h e l i n k a g e ( s ) ,o r t h e c o n trolled device(s)fail.

6.

M a k e s u r e t h e c o u p l i n g r o t a t e sf r e e l y b u t
w i t h o u t b a c k l a s h I. n c o r r e c ta l i g n m e n to f t h e
g o v e r n o rs h a f tt o t h e c o u p l i n g o
, r notenough
clearance between any of the parts, can
result in excessivewear and/or seizure of
p a r t s .l t c a n a l s o c a u s ea n u n d e r s i r a b l h
eigh
frequencyvibrationor "jiggle"in the governor
o u t p u ts h a f t .( S e eD e f i n i t i o n si n S e c t i o n5 f o r
m o r ei n f o r m a t i o n . )
The standard UG Governor drive gives few
i n s t a l l a t i o np r o b l e m si f t h e a l i g n m e n to f t h e
governorshaftto the drivecouplingis kept.

RECEIVING
WARNING
W h e n y o u r e c e i v ey o u r U G g o v e r n o r i t w i l l b e
bolted to a wooden platform in a verticalposition.
After testing the governor at the factory, it is
d r a i n e d o f o i l . T h i s l e a v e sa l i g h t f i l m o f o i l
c o v e r i n g t h e i n t e r n a l p a r t s , p r e v e n t i n gr u s t . N o
i n t e r n a cl l e a n i n gi s r e q u i r e db e f o r ei n s t a l l a t i o n .
S o m e d r i v e s h a f t sa r e s p r a y e dw i t h a l i g h t f i l m o f
o i l w h i l e o t h e r s ( d e p e n d i n go n c u s t o m e rr e q u i r e ments) are coveredwith soft seal. Before installation, removethe soft seal with a rag saturatedwith
m i n e r a sl p i r i t s .

ST OR A GE
l f a g o v e r n o ri s b e i n gs t o r e df o r a n y p e r i o do f t i m e
pleasereferto Woodward'sspecificationprocedure
25075 "Commercial PreservationPackaging for
S t o r a g eo f M e c h a n i c a l - H y d r a u C
l i co n t r o l s " .

M O U N T I N GR E Q U I R E M E N T S
1. Make sure the drive shaft rotatesf reely.
2. Selectthe correct lengthof couplingbetween
the governorand the prime moverdrive.

In the event of a misaligned or broken

drive shaft, an overspeed condition or
runaway engine can develop. An overspeeding or runaway engine can result
in extensive damage to the equipment,
personalinjury and/or loss ol life.
l f a n o p t i o n a lk e y e dd r i v e i s u s e d w h e n i n s t a l l i n g
t h e g o v e r n o r ,c a r e m u s t b e t a k e n t o a v o i d t h e
f o l l o w i n gu n d e s i r a b lceo n d i t i o n s :
a. Roughgear teeth:
R o u g hg e a r t e e t ho r s h a f t o u t o f r o u n d ,
can causevibrationswhich can be transmitted to the governor and cause a
j i g g l e i n t h e g o v e r n o ro u t p u t s h a f t .T h e
j i g g l e c a n b e t r a n s m i t t e dt o t h e f u e l
c o n t r o l r e s ul t i n g i n a n u n d e s i r a b l e
condition.Replacegearsif necessary.
b . I n c o r r e cst h i m m i n g :
Check backlashand re-adjustif necessary to obtain proper mesh without
binding or excessivebacklash.Referto

V@UEED
t h e p r i m e m o v e r m a n u f a c t u r e r ' sp e c i f i cations for the correct amount of backlash.
7 . M o u n t t h e g o v e r n o rf l u s h w i t h t h e e n g i n e
drive pad. lf the engine drive pad is at an
a n g l e ( f r o m 0 ' t o 4 5 o m a x i m u m ) ,t h e U G
m u s t b e i n s t a l l e dw i t h t h e f r o n t p a n e l i n t h e
upperposition.Usea gasketbetweengovernor
a n d e n g i n ed r i v ep a d .
B e s u r e t h e r e i s a d e q u a t es p a c e a v a i l a b l e
around the governor to provide easy access
f o r i n s t a l l i n gt h e c o n t r o l l i n k a g e ,f i l l i n g t h e
g o v e r n o r w i t h o i l , a n d a d j u s t i n gt h e s p e e d
a n d c o m p e n s a t i o ns y s t e m . S e e O u t l i n e
D r a w i n g ,F i g u r e1 - 2 ,f o r m o u n t i n gh o l e s i z e s
a n d g o v e r n o rd i m e n s i o n s .
The recommended rated speed range for the
g o v e r n o rd r i v e i s 1 0 0 0 t o 1 5 0 0 R P M . T h e d r i v e
p o w e r r e q u i r e m e nits 1 / 3 H P a t n o r m a ls p e e da n d
o p e r a t i n gt e m p e r a t u r eT. h e U G g o v e r n o rm a y b e
d r i v e ne i t h e rc w o r c c w .
O p e r a t i n gt e m p e r a t u r er a n g ef o r t h e U G g o v e r n o r
is-20' to 210"F.

L I N K A GEA T T A C H ME N T S
A d j u s t m e n to f t h e f u e l l i n k a g e m u s t p r o v i d ef o r
c o n t r o lo f f u e l f r o m " O F F " t o " F U L L F U E L "w i t h i n
the limits of the 42o of governoroutput shaft
t r a v e l .l t m u s t a l s o p r o v i d ef o r a p p r o x i m a t e l 3y 0 o
output shaft travel between "NO LOAD" and
. . F U L LL O A D . ' '
A t t a c ht h e f u e l r a c k l i n k a g et o t h e g o v e r n o ro u t p u t
s h a f t .T h e r e m u s t b e n o l o s t m o t i o no r b i n d i n gi n
t h i s l i n k a g e .A d e q u a t el o c k i n g m e t h o d sm u s t b e
e m p l o y e do n t h e l i n k a g ec o n n e c t i o n s .

WARNING
Be sure to allow sufficient overtravelat
each end of the terminal shaft. Failureto
provide sufficient oyertravelat maximum
fuel positon can prevent the prime
mover lrom giving maximum fuel when
required. Failure lo provide sufficient
overtravelat minimum fuel position can
preventthe governorfrom shutting down
the prime mover and result in possible
damageto equipmentand personalinjury.
A linearlinkagearrangementis usedin applications
w h e r e t h e g o v e r n o r o u t p u t s h a f t p o s i t i o n i n gi s
d i r e c t l yp r o p o r t i o n a tl o t h e t o r q u e o u t p u t o f t h e
prime mover.Thus, the governoroutput shaft
t r a v e lw i l l b e d i r e c t l yp r o p o r t i o n atlo t h e a m o u n t
o f f u e ld e l i v e r e d
t o t h e p r i m em o v e r .
A l i n e a r l i n k a g ei s a l i n k a g ea r r a n g e m e nw
t hich
p r o v i d e s a s m u c h m o v e m e n to f t h e g o v e r n o r
o u t p u t s h a f t p e r i n c r e m e n to f v a l v em o v e m e n ta t
light loadsas it does at heavyloads.
I n a p p l i c a t i o n sw h e r e a g o v e r n o ri s c o n t r o l l i n ga
b u t t e r f l yv a l v e ,s u c h a s o n a g a s e n g i n e ,a l i n e a r
l i n k a g es h o u l dn o t b e u s e d .
T h i s i s d u e t o t h e i n h e r e n td e s i g no f t h e b u t t e r f l y
v a l v ew h i c h r e q u i r e so n l y a s m a l la m o u n to f v a l v e
t r a v e l( f o r e x a m p l e ,1 0 ' ) t o b r i n g a n e n g i n ef r o m
n o l o a d t o h a l f l o a d . B y c o n t r a s t ,t h i s d e s i g n
requiresa much greatermovementof valvetravel
( f o r e x a m p l e ,3 0 o ) t o b r i n g t h e e n g i n ef r o m h a l f
l o a dt o f u l l l o a d .
I n o r d e r t o i m p r o v e g o v e r n i n gc o n t r o l a t l i g h t
l o a d s ,a c o m p e n s a t i n gl i n k a g ei s d e v i s e d( " n o n -

INCREASE

OUTPUT
SHAFT
iilNrt|u PosrTroN

_J_
BUTTERFLY
LINKAGE

OUTPUTSHAFT

AUTTERFLYVALVE
OUTPUTSHAFT
0m-a-217

F i g u r e2 - 1 . L i n k a g eA r r a n g e m e n(tF o r N o n - L i n e aF
r u e lS y s t e m s )

Y@EEED
l i n e a r " l i n k a g e ) .T h i s l i n k a g e p r o v i d e sg r e a t e r
m o v e m e n to f t h e g o v e r n o rp e r i n c r e m e n to f v a l v e
m o v e m e n ta t l i g h t l o a d s t h a n i t d o e s a t h e a v y
the relationship
loads.Figure2-1 illustrates
between
governoroutput shaft and butterflypositions
o b t a i n e d w i t h s i m p l e l i n k a g eo f m a x i m u m n o n l i n e a r i t y .W h e n i n s t a l l i n gt h i s l i n k a g e ,m a k e s u r e
t h a t t h e t w o f o l l o w i n g c o n d i t i o n sa r e o b t a i n e d
w h e n t h e l i n k a g ei s i n t h e n o - l o a dp o s i t i o n :
1 . T h e l e v e rw h i c h i s a t t a c h e dt o t h e g o v e r n o r
a n d t h e c o n n e c t i n gl i n k i s i n l i n e w i t h t h e
governoroutput shaft and the point of attachm e n t o f t h e c o n n e c t i n gl i n k t o t h e b u t t e r f l y
tever.
2 . T h e b u t t e r f l yl e v e r m u s t b e a t 9 0 o w i t h t h e
c o n n e c t i n gl i n k .
See also Table 5-2 for a satisfactoryrelationship
betweengovernoroutput shaft traveland butterfly
v a l v et r a v e li n a n o n - l i n e asr y s t e m .
F o r m o r e i n f o r m a t i o no n n o n - l i n e a lri n k a g e p, l e a s e
r e f e r t o W o o d w a r d A p p l i c a t i o nN o t e 5 0 5 1 6 ,
"GovernorLinkagefor ButterflyThrottleValves."

OIL SUPPLY
U s e a n o i l d e p e n d i n go n o p e r a t i n gt e m p e r a t u r e
f o r t h e g o v e r n o r( s e eT a b l e2 - 1 ) .
NOTE
Primary concern is for the oil properties
in the governor.
'1
F i l l t h e g o v e r n o rw i t h a p p r o x i m a t e l y 1 / 2 q u a r t s
o f o i l t o t h e m a r k o n t h e o i l s i g h t g l a s s .A f t e r t h e
e n g i n e i s s t a r t e da n d t h e g o v e r n o ri s a t o p e r a t i n g
t e m p e r a t u r e ,a d d o i l i f n e c e s s a r y .O i l m u s t b e
v i s i b l ei n t h e g l a s su n d e ra l l o p e r a t i n gc o n d i t i o n s .
U s e t h e i n f o r m a t i o ng i v e ni n T a b l e s2 - 1 a n d 2 - 2 a s
a g u i d e i n t h e s e l e c t i o no f a s u i t a b l el u b r i c a t i n g /
h y d r a u l i co i l . O i l g r a d e s e l e c t i o ni s b a s e do n t h e
o p e r a t i n g t e m p e r a t u r er a n g e o f t h e g o v e r n o r .
gnd
A l s o ,u s et h i s i n f o r m a t i o nt o a i d i n r e c o g n i z i n a
c o r r e c t i n gc o m m o n p r o b l e m sa s s o c i a t e dw i t h o i l
b y t h e E n g i n ea n d
u s e d i n p r o d u c t sm a n u f a c t u r e d
TurbineControlsof WoodwardGovernorCompany.
F o r a p p l i c a t i o n sw h e r et h e g o v e r n o rs h a r e st h e o i l
s u p p l y w i t h t h e e n g i n e ,u s e t h e o i l r e c o m m e n d e d
b y t h e e n g i n em a n u f a c t u r e r .
6

G o v e r n o r o i l i s b o t h a l u b r i c a t i n go i l a n d a
h y d r a u l i co i l . l t m u s t h a v e a v i s c o s i t yi n d e x t h a t
allowsit to performover the operatingtemperature
r a n g e a n d i t m u s t h a v e t h e p r o p e r b l e n d i n go f
a d d i t i v e st h a t c a u s e i t t o r e m a i n s t a b l e a n d
p r e d i c t a b l oe v e rt h i s r a n g e .
Governoroil mustbe compatiblewith sealmaterials,
i . e . , n i t r i l e , p o l y a c r y l i c ,a n d f l u o r o c a r b o n .M a n y
a u t o m o t i v ea n d g a s e n g i n e o i l s , i n d u s t r i a l u b r i c a t i n g o i l s , a n d o t h e r o i l s o f m i n e r a lo r s y n t h e t i c
Woodwardgoverorigin meet these requirements.
n o r s a r e d e s i g n e dt o g i v e s t a b l e o p e r a t i o nw i t h
m o s t o i l s w i t h t h e v i s c o s i t y ,a t t h e o p e r a t i n g
temperature,between50 and 3000 SUS (Saybolt
U n i v e r s a lS e c o n d s ) .A t t h e n o r m a l o p e r a t i n g
t e m p e r a t u r et,h e v i s c o s i t ys h o u l db e b e t w e e n1 0 0
t o 3 0 0 S U S . P o o r a c t u a t o rr e s p o n s eo r i n s t a b i l i t y
m a y b e a n i n d i c a t i o nt h a t t h e o i l v i s c o s i t y i s
o u t s i d et h i s r a n g e .
Excessive
componentwearor seizurein a governor
y f:
i n d i c a t e st h e p o s s i b i l i t o
c a u s e db y :
1 . I n s u f f i c i e nl tu b r i c a t i o n
a . A n o i l t h a t f l o w s s l o w l yw h e n i t i s c o l d ,
e s p e c i a l ld
y u r i n gs t a r t - u P .
b. No oil in thegovernor.

2 . Contaminatedoil causedby:
a . D i r t yo i l c o n t a i n e r s .
b . A g o v e r n o re x p o s e dt o h e a t i n gu p a n d
cooling down cycles,which creates
condensationof water in the oil.

3 . O i l n o t s u i t a b l ef o r t h e o p e r a t i n gc o n d i t i o n s
causedby:
a . C h a n g e si n a m b i e n t e m p e r a t u r e .
b. An improper oil level which creates
foamy,aeratedoil.
O p e r a t i n ga g o v e r n o r c o n t i n u o u s l yb e y o n d t h e
h i g h l i m i t t e m p e r a t u r eo f t h e o i l w i l l r e s u l ti n o i l
o x i d a t i o n .T h i s i s i d e n t i f i e db y v a r n i s ho r s l u d g e
d e p o s i t so n t h e g o v e r n o r p a r t s . T o r e d u c e o i l
oxidation,lowerthe actuatoroperatingtemperature
w i t h a h e a t e x c h a n g e ro r o t h e r m e a n s ,o r c h a n g e
to an oil more oxidation resistantat the operating
temperature.

I,@omED

ANY OIL USTEOIS ONLY A SUGGEST]ON.USE

]H OIL OF Yot'R CHOCE V|IIH THE CORRECT
VSCOSITYAS INOICAIEDIN ]HE CHAR].

UMI]ED OFERANONAT

UMI'IEDOPERATION

50 sus
3000 sus
(5s0 csT)

25000-A-79

T a b l e2 - 1 . O i l C h a r t

vrscosrTYcoMPARrsoNs
SAYBOLT UNIVERSAL

CENTISTOKES
(sus)NoiarNAL
(csT,cs, oRcTs) sEcoNos
AT IOO'F
15

SAE MOOR
(APPROXTMAIE)

80

5W

106

5W

SAE GEAR
(APPROXIMAfE)

tso
15

t51

r0w

46

214

10

68

310

20

80

68

30

80

100

100

75
46

150

696

40

85

150

220

1020

50

90

220

320

t483

60

t15

320

460

2133

70

t40

460

T a b l e2 - 2 .V i s c o s i t yC o m p a r i s o n s

Y@EEEED

WARNING
A loss of stable governor control and
possible prime mover overspeed may
result if the viscosity exceeds the 50 to
3000 SUS range.An overspeedingand/or
runaway prime mover can result in
extensive damage to the equipment,
personalinjury and/o loss of life.

S p e c i f i co i l v i s c o s i t yr e c o m m e n d a t i o nasr e g i v e n
on the Oil Chart (Table 2-1). Selecta rxeadity
a v a i l a b l eg o o d b r a n d o f o i l , e i t h e r m i n e r a l o r
s y n t h e t i c a, n d c o n t i n u eu s i n gt h a t s a m eb r a n d .D o
N O T m i x t h e d i f f e r e n t c l a s s e so f o i l s . O i l t h a t
meets the API (American PetroleumInstitute)
e n g i n e s e r v i c e c l a s s i f i c a t i o ni n e i t h e r t h e " S "
g r o u p o r t h e " C " g r o u p ,s t a r t i n gw i t h " S A " o r " C A "
t h r o u g h " S F " a n d " C D " i s s u i t a b l ef o r g o v e r n o r
s e r v i c eO
. i l s m e e t i n gp e r f o r m a n c e
r e q u i r e m e n tosf
t h e f o l l o w i n gs p e c i f i c a t i o nasr e a l s os u i t a b l e :M I L L-21 04A, M I L-L-2 1048, M I L-L-21 04C, M I L-L-461 52,
M I L-L-46152A, M I L-L-461528, M I L-L-451998.
R e p l a c et h e g o v e r n o ro i l i f i t i s c o n t a m i n a t e da,l s o
c h a n g e i t i f i t i s s u s p e c t e do f c o n t r i b u t i n gt o t h e
g o v e r n o ri n s t a b i l i t yD. r a i nt h e o i l w h i l ei t i s s t i l lh o t
a n d a g i t a t e d ;f l u s h t h e g o v e r n o r w i t h a c l e a n
s o l v e n th a v i n g s o m e l u b r i c a t i n gq u a l i t y ( s u c h a s
f u e l o i l o r k e r o s e n e )b e f o r er e f i l l i n gw i t h n e w o i l .
l f d r a i n t i m e i s i n s u f f i c i e nfto r t h e s o l v e n tt o
c o m p l e t e l yd r a i n o r e v a p o r a t ef,l u s h t h e g o v e r n o r
w i t h t h e s a m e o i l i t i s b e i n g r e f i l l e dw i t h t o a v o i d
d i l u t i o na n d p o s s i b l ec o n t a m i n a t i o o
nf t h e n e wo i l .
T o a v o i d r e c o n t a m i n a t i o nt ,h e r e p l a c e m e n ot i l
s h o u l d b e f r e e o f d i r t , w a t e r ,a n d o t h e r f o r e i o n

m a t e r i a l .U s e c l e a n c o n t a n e r st o s t o r e a n d
transfeo
r il.

WARNING

Observe manufacturer'sinslructions or
restrictionsregardingthe use of solvents.
lf no instructions are available,handle
with care. Use the cleaningsolventin a
well ventilated area away from fires or
sparks.
Failureto follow abovesafetyinslructions
can result in dangerous fires, extensive
damage to equipment, personal injury
and/or loss ol life.

O i l t h a t h a s b e e n c a r e f u l l ys e l e c t e dt o m a t c h t h e
o p e r a t i n gc o n d i t i o n sa n d i s c o m p a t i b l ew i t h
g o v e r n o r c o m p o n e n t ss h o u l d g i v e l o n g s e r v i c e
between oil changes. For governors operating
u n d e r i d e a lc o n d i t i o n s i,. e . ,m i n i m u me x p o s u r et o
d u s t a n d w a t e r a n d w i t h i n t h e t e m p e r a t u r el i m i t s
o f t h e o i l , o i l c h a n g e sc a n b e e x t e n d e dl.f a v a i l a b l e ,
a r e g u l a r l ys c h e d u l e do i l a n a l y s i si s h e l p f u l i n
determining
t h e f r e q u e n c yo f o i l c h a n g e s .
A n y p e r s i s t e not r r e c u r r i n go i l p r o b l e m ss h o u l db e
r e f e r r e dt o a q u a l i f i e do i l s p e c i a l i sfto r s o l u t i o n .
The recommended
continuousoperatingtemperature
o f t h e o i l i s 1 4 0 " F ( 6 0 ' C ) t o 2 0 0 " F ( 9 3 ' C ) .T h e
a m b i e n tt e m p e r a t u r el i m i t s a r e - 2 O oF ( - 3 0 ' C ) t o
2 0 0 " F ( 9 3 ' C ) . M e a s u r et h e t e m p e r a t u r eo f t h e
governor on the outside lower part of the case.
T h e a c t u a lo i l t e m p e r a t u r e
w i l l b e s l i g h t l yw a r m e r ,
a p p r o x i m a t e l1y0 ' F ( 6 ' C ) .

I/@EEED

sEcTroN3
PRINCIPLES
OF OPERATION
INTRODUCTION
B a s i c U G o p e r a t i o ni s s i m i l a r f o r a l l t y p e s . T h e
o n l y d i f f e r e n c ei s i n t h e m e t h o d o f s e t t i n g t h e
s p e e d .A u x i l i a r yd e v i c e sp r o v i d ed i f f e r e nftu n c t i o n s
but do not alterthe basicoperationof the governor.
A l o n g w i t h t h e t e x t , a s c h e m a t i cd i a g r a m ,f i g u r e
3 - 1 , i s p r o v i d e df o r v i s u a lm e a n so f u n d e r s t a n d i n g
t h e o p e r a t i o n o f t h e U G D i a l G o v e r n o r .T h i s
s c h e m a t i cs h o w s a b a s i c d e s i g n a n d d o e s n o t
i n c l u d ea n y a u x i l i a r ye q u i p m e n t .

C O M P O N E N TD E S C R I P T I O N
B e f o r eg e t t i n gi n t o t h e o p e r a t i o no f t h e U G , a b r i e f
d e s c r i p t i o no f t h e c o m p o n e n t sw i l l f a c i l i t a t e
u n d e r s t a nidn g t h e o p e r a t i o n .
OIL PUMP
T h e p u r p o s eo f t h e o i l p u m p ( 1 4 ) i s t o p r o v i d eo i l
pressurefor the governor.
T h e p u m p g e t s i t s o i l f r o m t h e s e l f - c o n t a i n esdu m p
( 1 5 ) .T h e o i l p u m p i s a p o s i t i v ed i s p l a c e m e ngt e a r
p u m p w i t h f o u r c h e c k v a l v e s( 1 3 ) f o r e i t h e r
d i r e c t i o no f r o t a t i o n .O n e p u m p g e a r i s p a r t o f t h e
rotating bushing and the other is part of the
l a m i n a t e dd r i v e .T h e r o t a t i n gb u s h i n gi s d r i v e nb y
t h e g o v e r n o rd r i v e s h a f t w h i c h i s d r i v e n b y t h e
prime mover.As the bushing rotates,it rotatesthe
l a m i n a t e dd r i v e .T h e o i l p u m p g e a r sc a n b e d r i e n
e i t h e rc w o r c c w .
O i l f l o w i s d i r e c t e dt h r o u g ht h e c h e c kv a l v es y s t e m
i n t o t h e a c c u m u l a t osr y s t e m( 1 1 ) .
ACCUMULATOR
T h e p u r p o s eo f t h e a c c u m u l a t o r( 1 1 )i s t o s t o r eo i l
u n d e r p r e s s u r e f o r t h e o p e r a t i o no f t h e U G
g o v e r n o r .T h e a c c u m u l a t o r( t w o c y l i n d e r s )a l s o
acts as a pressure relief valve if oil pressure
i n c r e a s e sa b o v e 1 2 0 p s i ( U G 5 . 7a n d U G 8 ) o r 1 5 0
psi(UG12.8).
The accumulator (11) consists of two spring
l o a d e d p i s t o n s .O i l i s p u m p e d i n t o t h e c y l i n d e r s

a n d p r e s s u r ei s i n c r e a s e da s t h e a c c u m u l a t o r
s p r i n g sa r e c o m p r e s s e dW
. hen the oil pressure
e x c e e d s1 2 0 p s i ( U G 5 . 7 a n d U G 8 ) , o r 1 5 0 p s i
( U G 1 2 . 8 )o, i l i s r e l e a s e db a c k t o s u m p t h r o u g h a
r e l i e fp o r t ( 1 2 )i n e a c hc y l i n d e r .
O i l f l o w s f r o m t h e a c c u m u l a t o tr h r o u g h p a s s a g e s
t o t h e t o p o f t h e p o w e rp i s t o na n d t o t h e p i l o tv a l v e
system.
POWER P'STO'V
The purposeof the power piston (9) is to rotatethe
governoroutput shaft to the increaseor decrease
f u e lo o s i t i o n .
T h e p o w e r p i s t o n i s a d i f f e r e n t i a tl y p e w i t h o i l
p r e s s u r eo n b o t h s i d e so f t h e p i s t o n .T h e t o p e n d
o f t h e p o w e r p i s t o n i s c o n n e c t e dt o t h e g o v e r n o r
o u t p u t s h a f t ( 6 ) t h r o u g h a p o w e r l e v e ra n d l i n k
assembly.
The bottom of the power piston has a larger area
than the top of the piston. Therefore, less oil
p r e s s u r ei s n e e d e do n t h e b o t t o m t h a n o n t h e t o D
t o m a i n t a i nt h e p i s t o ns t a t i o n a r yl .f t h e o i l p r e s s u r e
is the same on both the top and bottom of the
piston,the piston moves up to rotatethe governor
o u t p u t s h a f t i n t h e i n c r e a s ef u e l d i r e c t i o n .T h e
p i s t o nm o v e sd o w n o n l y w h e n o i l u n d e rt h e p i s t o n
is releasedto sump.
O i l t o a n d f r o m t h e b o t t o m o f t h e p o w e r p i s t o ni s
regulatedby the pilot valvesystem.
PILOT VALVE SYSTE'U
T h e p u r p o s eo f t h e p i l o tv a l v ep l u n g e ra n d b u s h i n g
is to controlthe flow of oil to or f rom the bottom of
t h e p o w e rp i s t o n .
The pilotvalvesystemincludesthe rotatingbushing
( 3 8 )a n d t h e p i l o t v a l v ep l u n g e r( 3 9 ) .T h e b u s h i n g
(38) is rotatedby the driveshaft(36) while the pilot
v a l v e p l u n g e r i s h e l d s t a t i o n a r y .T h r o u g h t h i s
rotation,frictionbetweenthe pilot valveand bushing
i s r e d u c e d .T h e p i l o t v a l v ep l u n g e rh a s a c o n t r o l
l a n d t h a t r e g u l a t e so i l f l o w t h r o u g h p o r t s i n t h e
bushing.

V@-AED

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I/@EEED
W h e n t h e p i l o t v a l v ep l u n g e r( 3 9 ) i s l o w e r e d ,h i g h
pressure oil flows under the power piston (9),
raisingit. When the pilot valveplungeris raised,oil
is releasedto sump from under the power piston
(9), lowering it. The higher pressureon top of the
power piston(9),forcesthe pistondown. When the
pilot valve plunger (39) is in its centeredposition,
the control land coversthe control port as shown
i n t h e s c h e m a t i c ,f i g u r e 3 - 1 , a n d t h e r e i s n o
movementof the power piston.
The movement of the pilot valve plunger (39) is
controlled by the ballhead system (23) and the
dashpotcompensationpistons(34)and (35).

BALLHEADSYSTE'W
The purpose of the ballhead system (23) is to
sense speed changes of the prime mover as
comparedto the speed setting referencegiven by
the speeder spring (25) and to position the pilot
valveplunger(39).
The ballhead system includes a ballhead (23),
flyweights (241,a speeder spring (25), a thrust
bearing (30), a speeder plug (29) and a speed
s e t t i n gr o d ( 2 1 ) .
As the governor drive shaft (36) rotates,the gear
o n t h e l a m i n a t e dd r i v e ( 3 2 ) t u r n s a n d r o t a t e st h e
ballheadgears (23). The flyweights(24) are
attached to the ballhead with pivot pins, and a
thrust bearing (30) rides on the toes of the
f lyweights(24).The speederspring (25) is held in
p o s i t i o na g a i n s tt h e t h r u s t b e a r i n g ( 3 0 ) b y t h e
s p e e d e rp l u g ( 2 9 ) .T h e s p e e d e rp l u g ( 2 9 ) i s u s e d
to set a pressureon the speederspring (25).

As the ballhead (23) rotates,the flyweights (24)

pivot outward due to the centrifugalforce. At the
s a m et i m e t h e s p e e d e rs p r i n g( 2 5 )i s f o r c i n gt h r u s t
bearing(30) downwardon the flyweighttoes. This
downward force is opposingthe centrifugalforce
o f t h e f l y w e i g h t s . I n c r e a s i n gt h e d r i v e s p e e d
increasesthe centrifugalforce. Compressingthe
s p e e d e rs p r i n g ( 2 5 ) w i t h t h e s p e e d e rp l u g ( 2 9 )
increases the downward force applied to the
flyweighttoes, and in turn, increasesthe governor
speed setting.The prime mover must run fasterto
generate a centrifugal force greater than the
speederspring force to balancethe systemagain.

Speeder spring force or speed setting (25) is

c o n t r o l l e dm a n u a l l yt h r o u g h t h e s y n c h r o n i z e r
(speedsetting) adjusting knob (5). lt can also be
controlledfrom a remote area if the governor is
equippedwith a speedsettingmotor (1).

COMPENSATION SYSTEM
The purposeof the compensationsystemis to give
stability to the governor and obtain steady state
speed control. Also, when correctly adjusted,the
c o m p e n s a t i o ns y s t e m e f f e c t i v e l y r e g u l a t e st h e
a m o u n t o f f u e l n e c e s s a r yt o b r i n g t h e e n g i n e t o
the requiredoutput to adjust to a decreaseor an
increasein load.
The compensationsystemcreatesa smalltemporary
changeof speedsettingwith governoroutput shaft
movementto produce a stabilizingspeed droop
characteristicin the governor. The change of
speedsettingis followedby a slow returnof speed
setting to its original value. Compensation is
simply another word for temporary speed droop
characteristic.
The compensationsystemincludesa largedashpot
c o m p e n s a t i o np i s t o n ( 3 4 ) , a s m a l l d a s h p o t
compensationpiston (35), a floating lever (31), a
compensationadjustinglever (22) with a pivotable
f u l c r u m ( 1 8 ) a n d a n e e d l ev a l v e ( 3 3 ) . S e e f i g u r e
3-1.
The large dashpot compensation piston (34) is
connectedto the governor output shaft (6) by a
compensationadjusting lever (22). A pivotable
f u l c r u m ( 1 8 ) r i d e so n t h e c o m p e n s a t i o na d j u s t i n g
lever (22). Changing the fulcrum's (18) position
allows the compensationlever (22) to control the
amount of stroke availablefor the large dashpot
compensationpiston (34).
The small dashpot compensationpiston (35) is
c o n n e c t e dt h r o u g ha f l o a t i n gl e v e r( 3 1 )t o t h e p i l o t
v a l v ep l u n g e r( 3 9 )a n d t h e s p e e d e r o d ( 2 1 ) .
Moving the large dashpot compensation piston
(34) down forces oil under the small dashpot
c o m p e n s a t i o np i s t o n ( 3 5 ) . A s t h e s m a l l d a s h p o t
compensationpiston (35) is forced upward, it lifts
the pilot valveplunger (39) to close off the control
port which stops the flow of oil to the bottom of
the power piston (9).
The needle valve (33) is a variableorifice which
controlsthe flow of oil betweenboth the large (34)

11

Y@EMED
a n d t h e s m a l ld a s h p o tc o m p e n s a t i o n( 3 5 ) p i s t o n s ,
a n dt h e o i l s u m p .
NOTE
Compensationmust be properly adiusted
to the particular engine and load to
provide stab/e operation (see Section 4,
Com pe nsationAdj ustments
).
LOAD LIMIT CONTROL
The purpose of the load limit control is to
h y d r a u l i c a l l ya n d m e c h a n i c a l l yl i m i t t h e l o a d t h a t
c a n b e p l a c e d o n t h e e n g i n e b y r e s t r i c t i n gt h e
t r a v e lo f t h e g o v e r n o ro u t p u t s h a f t i n t h e i n c r e a s e
f u e l d i r e c t i o n ,a n d c o n s e q u e n t l yt h e a m o u n t o f
f u e l s u p p l i e dt o t h e e n g i n e .

SYNCHRO NIZER
T h e s y n c h r o n i z e irs t h e s p e e d a d j u s t i n gc o n t r o l ,
a n d i s u s e d t o c h a n g e e n g i n e s p e e df o r a s i n g l e
u n i t . O n e n g i n e sp a r a l l e l e dw i t h o t h e r u n i t s ,i t i s
u s e dt o c h a n g ee n g i n el o a d .
"SYNCHRONIZERo
"n
The upper knob called
" S P E E DS E T T I N G K N O B " o n
m o s t m o d e l s ,a n d
l a t em o d e l s i, s t h e c o n t r o lk n o b .
The lower knob, "SYN. INDICATOR"has no
f u n c t i o no f i t s o w n b u t h a sa n i n d i c a t o rd i s c w h i c h
s h o w s t h e n u m b e ro f r e v o l u t i o n so f t h e s y n c h r o nizer(speedsetting)control knob.

SPEED DROOP

The load limit control may also be used for

s h u t t i n gd o w n t h e e n g i n eb y t u r n i n gi t t o z e r o .

Speeddroop or simply droop is one methodof

. r o o pi s a l s ou s e d
c r e a t i n gs t a b i l i t yi n a g o v e r n o r D
t o d i v i d ea n d b a l a n c el o a d b e t w e e nu n i t s d r i v i n g
t h e s a m e s h a f t o r p a r a l l e l e di n t h e e l e c t r i c a l
syslem.

Do not manually force prime mover

linkage to increase fuel without first
turning the load limit control knob to
maximum position(10). Failureto do so
may cause damage and/or failure of
governor internal parts.

Droop is the decreasein speedtaking placewhen

the governoroutputshaft movesfrom the minimum
t o t h e m a x i m u mf u e l p o s i t i o ni n r e s p o n s et o a l o a d
increase, expressed as a percentage of rated
speed.

T h e l o a d l i m i t c o n t r o lc o n s i s t so f a n i n d i c a t o rd i s c
(7) gearedto a load limit rack (8). The control
k n o b i s a l s o a t t a c h e dt o t h e l o a d l i m i tc a m ( 1 6 ) .
L o a d i s l i m i t e d m e c h a n i c a l l yb y p o s i t i o n i n gt h e
l o a d l i m i t k n o b ( c a m 1 6 ) .W h e nt h e l o a d i n d i c a t o r
r e a c h e st h e p r e s e t p o i n t , t h e p i l o t v a l v e p l u n g e r
( 3 9 )i s l i f t e d ,s t o p p i n ga n y f u r t h e ri n c r e a s ei n f u e l .
T u r n i n gt h e l o a d l i m i t c o n t r o lt o z e r ot o s h u t d o w n
t h e e n g i n et u r n st h e c a m ( 1 6 )f o r c i n gt h e l o a d l i m i t
( s h u t d o w n )l e v e r ( 2 0 ) a n d s h u t d o w n s t r a p ( ' 1 7 )
d o w n .A s t h e r i g h te n d o f t h e l o a d l i m i t ( s h u t d o w n )
l e v e r ( 2 0 ) i s f o r c e d d o w n w a r d ,i t p i v o t sa b o u t i t s
fulcrum and lifts the pilot valve plunger (39),
r e l e a s i n go i l f r o m u n d e r t h e p o w e r p i s t o n ( 9 ) .
P r e s s u r eo i l a c t i n g o n t o p o f t h e p o w e r p i s t o n( 9 )
f o r c e s i t d o w n w a r d ,r o t a t i n gt h e g o v e r n o ro u t p u t
s h a f t ( 6 ) t o m i n i m u mf u e l a n d c a u s i n gt h e p r i m e
m o v e rt o s h u t d o w n .

12

lf instead of a decrease in speed, an increase

t a k e s p l a c e ,t h e g o v e r n o ri s s h o w i n g a n e g a t i v e
d r o o p . N e g a t i v ed r o o p w i l l c a u s e i n s t a b i l i t yi n a
governor.
N o t e n o u g h d r o o p c a n c a u s e i n s t a b i l i t yi n t h e
f o r m o f h u n t i n g ,s u r g i n go r d i f f i c u l t yi n r e s p o n s e
t o a l o a d c h a n g e .T o o m u c h d r o o p c a n r e s u l ti n
s l o w g o v e r n o rr e s p o n s ei n p i c k i n gu p o r d r o p p i n g
off a load.
U s i n g a n e x a m p l ew h e r e t h e g o v e r n o rs p e e d i s
1500rpm at no load and 1450rpm at full load,
d r o o pc a n b e c a l c u l a t e dw i t h t h e f o r m u l a :
o/oDroop _ No load speed Full load speed
F u l l l o a ds p e e d

x 100

_ 1500rp.[_-1450rpm X 100 = 3.Solo

o/o
D roo p
1 4 5 0r p m

I/@EEED
l f t h e d e c r e a s ei n s p e e d i s g r e a t e rt h a n 5 0 r p m
w h e n t h e g o v e r n o ro u t p u t s h a f t m o v e s f r o m t h e
m i n i m u m t o t h e m a x i m u mf u e l p o s i t i o n ,d r o o p
g r e a t e rt h a t 3 . 5 0 /ios s h o w n b y t h e g o v e r n o r .l f t h e
d e c r e a s ei n s p e e d i s l e s st h a n 5 0 r p m , d r o o p l e s s
is shown by the governor.
than 3.50/o
NOTE
lf the governoroutput shaff does not use
the f ull 30" of available travel f rom "NO
LOAD" to "FULL LOAD," droop will also
be reduced proporti onately.

M a r k s o n t h e d r o o p a d j u s t m e n st c a l e o n t h e d i a l
p a n e l a r e r e f e r e n c en u m b e r s o n l y , a n d d o n o t
r e p r e s e n td r o o p p e r c e n t a g e sT. h u s t h e 1 0 0 m a r k
does not represent1000/o
droop. lt representsthe
m a x i m u m d r o o p p e r c e n t a g ea v a i l a b l e o n t h a t
p a r t i c u l a rU G g o v e r n o rm o d e l .

lr

S p e e dd r o o p c o n s i s t so f a c o n t r o lk n o b ,c a m , a n d
linkage,which when preset,varies the
c o m p r e s s i o no f t h e s p e e d e rs p r i n g a s t h e o u t p u t
shaft rotates.Increasingthe fuel reducesspeeder
s p r i n g c o m p r e s s i o na n d i n t u r n t h e g o v e r n o r
s p e e ds e t t i n g .T h e u n i t g r a d u a l l yr e d u c e si t s s p e e d
a s l o a d i s a p p l i e d .T h i s r e l a t i o n s h i p
b e t w e e nl o a d
and speed acts as a resistanceto load changes
when the unit is interconnectew
d ith other units
e i t h e rm e c h a n i c a l loy r e l e c t r i c a l l y .
R e d u c i n gd r o o p t o z e r o a l l o w st h e u n i t t o c h a n g e
l o a d w i t h o u t c h a n g i n gs p e e d .N o r m a l l y ,s e t z e r o
d r o o p o n u n i t s r u n n i n g a l o n e .O n i n t e r c o n n e c t e d
u n i t s , s e t t h e l e a s t a m o u n t o f d r o o p p o s s i b l et o
providesatisfactoryload division.
F o r a c g e n e r a t i n gu n i t st i e d i n w i t h o t h e r u n i t s ,s e t
d r o o p s u f f i c i e n t l yh i g h ( r e f e r e n c en u m b e r s3 0 t o
5 0 o n t h e d i a l ) t o p r e v e n t i n t e r c h a n g eo f l o a d
between units. lf one unit in the system has
e n o u g h c a p a c i t y ,s e t i t s g o v e r n o ro n z e r o d r o o p
a n d i t w i l l r e g u l a t et h e f r e q u e n c y o f t h e p r i m e
mover system. lf its capacity is not exceededthis
u n i t w i l l h a n d l ea l l l o a d c h a n g e s .
O p e r a t e t h e S Y N C H R O N I Z E Ro, f t h e g o v e r n o r
w i t h z e r o d r o o p , t o a d j u s tt h e s y s t e m ' sf r e q u e n c y .
O p e r a t et h e S Y N C H R O N I Z E R So,f t h e g o v e r n o r s
t h a t h a v es p e e dd r o o p ,t o d i s t r i b u t el o a d b e t w e e n
units.

O P E R A T I O NO F T H E
U G D A LG O V E R N O R
INFORM ATION
GENERAL
Refer to figure 3-'1with the text to better
u n d e r s t a n tdh e o p e r a t i o no f t h e U G D i a l G o v e r n o r .
T h i s s c h e m a t i cd i a g r a mi s o f a b a s i c d e s i g n a n d
d o e sn o t i n c l u d ea n y a u x i l i a r ye q u i p m e n t .
C h a n g e si n g o v e r n o rs p e e d s e t t i n g p r o d u c e t h e
s a m eg o v e r n o rm o v e m e n t sa s d o c h a n g e si n l o a d
o n t h e e n g i n e . T h e d e s c r i p t i o nt h a t f o l l o w s i s
based upon speed changescaused by load
changes.

DECREASE IN LOAD
W h e n t h e p r i m e m o v e r i s r u n n i n g o n s p e e d ,t h e
f l y w e i g h t s( 2 4 )a r e i n a v e r t i c a lp o s i t i o nf o r n o r m a l
s t e a d ys t a t eo p e r a t i o nT. h e p i l o t v a l v ep l u n g e r( 3 9 )
is centered over the control port of the rotating
b u s h i n g ,a n d t h e c o n t r o l l a n d s t o p s t h e f l o w o f
p r e s s u r eo i l t h r o u g ht h e b u s h i n g( 3 8 )c o n t r o lp o r t .
T h e r ei s n o m o v e m e n o
t f t h e p o w e rp i s t o n( 9 ) ,a n d
n o m o v e m e not f t h e g o v e r n o ro u t p u ts h a f t( 6 ) .
W h e na d e c r e a s ei n l o a d o c c u r sa n d t h e s a m ef u e l
settingis maintained,a decreasein load createsan
i n c r e a s ei n s p e e d . T h i s g e n e r a t e st h e f o l l o w i n g
sequenceof governormovements:
1 . A s s p e e d i n c r e a s e st,h e c e n t r i f u g a fl o r c e o f
t h e f l y w e i g h t s( 2 4 ) i n c r e a s e sa n d b e c o m e s
s t r o n g e rt h a n t h e f o r c e o f t h e s p e e d e rs p r i n g
(25)
2 . T h e f l y w e i g h t s( 2 4 )t i p o u t w a r da n d r a i s et h e
s p e e d e rr o d ( 2 1 ) a n d t h e r i g h t e n d o f t h e
f l o a t i n gl e v e r( 3 1 ) .
3 . T h i s r a i s e st h e p i l o t v a l v e p l u n g e r ( 3 9 )
opening the control port in the rotating
b u s h i n g( 3 8 ) .O i l i s r e l e a s e df r o m t h e b o t t o m
o f t h e p o w e rp i s t o n( 9 ) t o s u m p .
4 . P r e s s u r eo i l o n t h e t o p s i d e o f t h e p o w e r
p i s t o n ( 9 ) m o v e s i t d o w n w a r d r o t a t i n gt h e
g o v e r n o ro u t p u t s h a f t i n t h e d e c r e a s ef u e l
direction.
5 . L i n k a g ef r o m t h e g o v e r n o ro u t p u t s h a f t ( 6 )
lowersthe compensationadjustinglever (22),
w h i c h r o t a t e sa t t h e f u l c r u m ( 1 8 ) ,r a i s i n gt h e
l a r g ed a s h p o tc o m p e n s a t i o p
n i s t o n( 3 4 ) .

13

V@EEEED
6 . S u c t i o ni s t h u s a p p l i e dt o t h e c h a m b e ro f t h e
s m a l l d a s h p o t c o m p e n s a t i o np i s t o n ( 3 5 ) ,
l o w e r i n gt h e l e f t e n d o f t h e f l o a t i n gl e v e r( 3 1 ) .
7. This lowersthe pilot valveplunger(39)
c l o s i n gt h e c o n t r o lp o r t ( 3 7 ) .

4 . The power piston is forced upward by the

p r e s s u r eo i l a c t i n g o n t h e l a r g e r l o w e r
surface area of the power piston, and the
governoroutput shaft is rotated in the
i n c r e a s ef u e l d i r e c t i o n .

8 . A s s u m p o i l f l o w s t h r o u g h t h e n e e d l ev a l v e
(33) from the sump into the dashpot
c o m p e n s a t i o np i s t o n a s s e m b l y( 3 4 a n d 3 5 )
t h e s m a l l d a s h p o tc o m p e n s a t i o np i s t o n ( 3 5 )
is returnedto its normal centeredpositionby
t h e c o m p e n s a t i o ns p r i n g ,a t t h e s a m e r a t ea s
t h e s p e e d e rr o d ( 2 1 ) . T h i s k e e p s t h e p i l o t
v a l v ep l u n g e r( 3 9 )i n i t s c e n t e r e dp o s i t i o n .

5 . L i n k a g ef r o m t h e g o v e r n o ro u t p u t s h a f t ( 6 )
l i f t s t h e c o m p e n s a t i n ga d j u s t i n gl e v e r ( 2 2 ) ,
w h i c h r o t a t e sa t t h e f u l c r u m ( 1 8 ) , l o w e r i n g
n i s t o n( 3 4 ) .
t h e l a r g ed a s h p o tc o m p e n s a t i o p

9 . T h e c o n t r o l p o r t i n t h e r o t a t i n gb u s h i n g( 3 8 )
i s k e p t c l o s e db y t h e l a n d o n t h e p i l o t v a l v e
p l u n g e r( 3 9 ) .

7 . T h i s r a i s e s t h e p i l o t v a l v e p l un g e r ( 3 9 )
c l o s i n gt h e c o n t r o lp o r t ( 3 7 ) .

10. This stops the governor output shaft and

power piston movementin the new decreased
f u e l p o s i t i o n .T h i s i s t h e p o s i t i o nn e e d e dt o
r u n t h e p r i m e m o v e r a t t h e s e l e c t e ds p e e d
settingwith the new load.

8 . A s p r e s s u r eo i l f l o w s t h r o u g h t h e n e e d l e
valve (33) from the dashpot compensation
p i s t o n a s s e m b l y( 3 a a n d 3 5 ) , t h e s m a l l
dashpotcompensationpiston (35) is returned
to its normal centeredposition by the
c o m p e n s a t i o sn p r i n g ,a t t h e s a m e r a t ea s t h e
s p e e d e rr o d ( 2 1 ) . T h i s k e e p s t h e p i l o t v a l v e
plunger(39) in its centeredposition.

'NCREASE IN LOAD
W h e n t h e p r i m e m o v e r i s r u n n i n go n s p e e d ,t h e
f l y w e i g h t s( 2 4 ) a r e i n a v e r t i c a lp o s i t i o na n d t h e
p i l o t v a l v ep l u n g e r( 3 9 ) i s i n i t s c e n t e r e dp o s i t i o n .
t f t h e p o w e r p i s t o n ,a n d n o
T h e r ei s n o m o v e m e n o
m o v e m e no
t f t h e g o v e r n o ro u t p u ts h a f t .
W h e na n i n c r e a s ei n l o a d o c c u r sa n d t h e s a m ef u e l
s e t t i n gi s m a i n t a i n e da, n i n c r e a s ei n l o a d c r e a t e sa
d e c r e a s ei n s p e e d .T h i s g e n e r a t e st h e f o l l o w i n g
sequenceof governormovements:
1 . A s s p e e d d e c r e a s e st,h e c e n t r i uf g a l f o r c e o f
t h e f l y w e i g h t s ( 2 4 ) d e c r e a s e sa n d t h e
o p p o s i n g s p e e d e rs p r i n g ( 2 5 ) f o r c e i s n o w
greater than the centrifugal force of the
f l y w e i g h t s( 2 4 ) .
2 . T h e f l y w e i g h t s( 2 4 ) t i p i n w a r d a n d l o w e r t h e
s p e e d e rr o d ( 2 1 ) a n d t h e r i g h t e n d o f t h e
f l o a t i n gl e v e r( 3 1 ) .
3. This lowersthe pilot valveplunger(39)
opening the control port in the rotating
b u s h i n g( 3 8 ) .P r e s s u r eo i l i s r e l e a s e dt h r o u g h
t h e c o n t r o lp o r t i n t o t h e l o w e rc y l i n d e ro f t h e
p o w e r p i s t o n( 9 ) .

14

6 . P r e s s u r eo i l i s a p p l i e dt o t h e b o t t o m s i d e o f
t h e s m a l l d a s h p o tc o m p e n s a t i o np i s t o n ( 3 5 ) ,
r a i s i n gt h e l e f te n d o f t h e f l o a t i n gl e v e r( 3 1 ) .

9 . T h e c o n t r o lp o r t i n t h e r o t a t i n gb u s h i n g( 3 8 )
i s k e p t c l o s e db y t h e l a n d o n t h e p i l o t v a l v e
p l u n g e r( 3 9 ) .
10. This stops the governoroutput shaft and
p o w e rp i s t o nm o v e m e n it n t h e n e w i n c r e a s e d
f u e l p o s i t i o n .T h i s i s t h e p o s i t i o nn e e d e dt o
r u n t h e p r i m e m o v e r a t t h e s e l e c t e ds p e e d
s e t t i n gw i t h t h e n e w l o a d .
l n b o t h c a s e s ,a d e c r e a s eo r a n i n c r e a s ei n l o a d ,
the compensationsystem operates in opposite
directions.
The compensation
o r a m o u n t o f m o v e m e n to f t h e
l a r g e d a s h p o t c o m p e n s a t i o np i s t o n ( 3 4 ) i s
c o n t r o l l e db y t h e c o m p e n s a t i o na d j u s t m e n tt,h a t
i s ,t h e p o s i t i o no f t h e f u l c r u m( 1 8 ) .
T h e r a t ea t w h i c h t h e s m a l ld a s h p o tc o m p e n s a t i o n
p i s t o n ( 3 5 ) i s r e t u r n e dt o n o r m a l i s c o n t r o l l e db y
t h e n e e d l ev a l v e a d j u s t m e n t t, h a t i s , t h e r a t e o f
f l o w o f o i l t h r o u g ht h e n e e d l ev a l v e( 3 3 ) .

Y@Em,D

sEcTtoN4
GOVERNOR
AND ADJUSTMENTS
OPERATION
INTRODUCTION
This section describesinitial operationand basic
a d j u s t m e n t so f t h e U G D i a l f o r p u t t i n g a n e w o r
repairedgovernorinto service.

I N I T I A LO P E R A T I O N
F O RA N E W G O V E R N O R
Before initial operation of the UG Dial Governor,
check that all previousinstallationsteps havebeen
c o r r e c t l ya c c o m p l i s h e d
a n d a l l l i n k a g e sa r e s e c u r e
and properly attached.See Section 2, lnstallation
Procedures.Also, read all of Section4.

a d j u s t i n gc o m p e n s a t i o nt o o b t a i n s a t i s fa c t o r y
s t a b i l i t y a n d r e s p o n s e .A l l o t h e r o p e r a t i n g
adjustmentsweremadeduringfactorycalibrationin
accordancewith the manufacturer's
specifications
and should not requirefurtheradjustments.

NOTE
Do not attemptinternal adustmentof the
governor unless you are thoroughly
familiar with the proper procedures,

C O M P E N SAT I O N A D J U ST ME'VIS
F i l l t h e g o v e r n o rw i t h o i l t o t h e t o p m a r k o n t h e o i l
sight glass. Close the needle valve carefully (cw)
u s i n ga P h i l l i p ss c r e w d r i v ear n d o p e n i t ( c c w )1 / 2t o
3 / 4 l u r n . L o o s e nt h e n u t h o l d i n gt h e c o m p e n s a t i o n
a d j u s t i n gp o i n t e re n o u g ht o m o v et h e p o i n t e ra n d
s e tt h e p o i n t e ri n t h e c e n t e ro f t h e s c a l e T
. i g h t e nt h e
nut.
l f r e p l a c i n ga g o v e r n o r ,t h e i n i t i a l c o m p e n s a t i o n
settingcan be that of the governorjust removed.

WARNING
T O P R O T E C TA G A I N S T P O S S I B L E
P E R S O N A LI N J U R Y ,L O S S O F L I F E
AND/OR PROPERTYDAMAGE WHEN
STARTING the engine, turbine or other
type of prime mover BE PREPAREDTO
M A K EA N E M E R G E N C Y
S H U T D O W Nt o
protect against runawayor over-speeding
should lhe mechanical-hydraulic
g o v e r n o r ( s )o r e l e c t r i cc o n t r o l ( s ) ,t h e
actuator(s), fuel control(s), the driving
m e c h a n i s m ( s ) ,t h e l i n k a g e ( s ) ,o r t h e
controlled device(s)fail.
Usethe prime movermanufacturer's
instructionsto
startthe engine.
ADJUSTMENTS
N o r m a l l y ,t h e o n l y a d j u s t m e n t sf o r p u t t i n g a n e w
g o v e r n o ri n t os e r v i c ea r eb l e e d i n ge n t r a p p e da i ra n d

The compensationneedle valve and pointer are

adjustablepartsof the compensationsystem.Their
settingsdirectlyaffectgovernorstability.
Compensationmust be properly adjusted to the
p a r t i c u l a re n g i n e a n d l o a d t o p r o v i d e s t a b l e
operation.
W h e n t h e e n g i n e ,t u r b i n e o r o t h e r t y p e o f p r i m e
moveris startedfor the first time afterthe governor
hasbeenfilledwith oil,the governormay be stableat
constant speed, yet the governor may need
adjustment.High overspeeds
and underspeeds
after
l o a d c h a n g e sa n d s l o w r e t u r n t o n o r m a l s p e e d
indicatethe need for compensationadjustment.

NOTE
Maximum compensationsettings
g e n e r a l l yp r o v i d e s t a b l es t e a d y s t a t e
operation, but result in greater offspeeds
on load changes.
After the oil in the governorhas reachedits normal
o p e r a t i n gt e m p e r a t u r e m
, a k et h e f o l l o w i n g
compensationadjustmentswithout load on the
p r i m e m o v e rt o b e c e r t a nt h a t t h e g o v e r n o rg i v e s
o p t i m u mc o n t r o l .S e ef i g u r e 1 - 1 f o r l o c a t i o no f t h e
adjustmentparts.
1 . T o b l e e d t r a p p e d a i r f r o m t h e g o v e r n o ro i l
p a s s a g e s ,f i r s t l o o s e n t h e n u t h o l d i n g t h e

't5

Y@ESED
compensationadjusting pointer and set the
pointer at its extreme upward position for
m a x i m u mc o m p e n s a t i o nT.i g h t e nn u t .
Next,removethe needlevalveaccessplug and
open the needlevalve two turns ccw. Use a
Phillips screwdriverto avoid damage to the
threadsinsidethe boreand to the needlevalve.
Damageto the threadsor to the needlevalve
will cause the governorto changefuel rhythm i c a l l y .T h i s i s c a l l e d g o v e r n o rh u n t . S e e
Section5 for more informationon hunting.
There are two screwdriverslots in the needle
valve,a shallowand a deepslot,locatedat right
anglesto eachother.The deeperslot is usedto
expand the head of the needle valve and
increase friction to prevent vibrationsfrom
c h a n g i n gt h e n e e d l ev a l v es e t t i n g .l f a p l a i n
screwdrivermust be used, be sure to use the
shallowslot of the needlevalve.
A l l o w t h e p r i m e m o v e rt o h u n t f o r a p p r o x i mately one-half minute to bleed trapped air
from the governoroil passages.

b y t u r n i n gt h e l o a d l i m i t k n o b t o i n c r e a s et h e
l o a ds l i g h t l ya n d b r i n g i n gi t b a c kq u i c k l yt o i t s
o r i g i n a lp o s i t i o n .G r a d u a l l yc l o s e t h e n e e d l e
valveuntil governorreturnsto speedwith only
a smallovershootor undershootand:
a.

The needle valve is between 1/8 to 1/4

t u r n o p e n o n a g o v e r n o rw i t h a n o i l s i g h t
g l a s s l o c a t e di n t h e c e n t e r o f t h e d i a l
panel.

b.

The needlevalve is between3/8 and 3/4

t u r n o p e n o n a g o v e r n o rw i t h a n o i l s i g h t
glasslocatedon the side of the governor.

adjustmentdeterminesoffspeedand
Compensation
needlevalveadjustmentdeterminesrecoverytime.

NOTE
For most responsivegovernor control,
use as Iittle compensation as posslb/e.
Toomuch compensationcausesexcessive
speed overshootsand undershootsupon
load changes.

2. Loosennut holdingthe compensationpointer

and set the pointeras far as it will go towards
m i n i m u mc o m p e n s a t i o nT.i g h t e nn u t .

3. G r a d u a l l yc l o s et h e n e e d l ev a l v eu n t i lh u n t i n g
just stops. lf hunting does not stop, open the
needlevalveone turn and movethe compensat i o n p o i n t e ru p b y o n e m a r ko n t h e f r o n t p a n e l
indicatorscale.Again gradually closethe needle
v a l v eu n t i l h u n t i n gs t o p s .
ff hunting does not stop, set needlevalve1/4
turn open and repeatsettingthe compensation
pointer up by one mark. Retestgovernoruntil
h u n t i n gs t o p s .

NOTE
Closing the needle valvemore than indicatedin a.and b. abovemakesthegovernor
slow to return to normal speedafter a load
change.
Opening the needle valve more than
indicatedabovedecreasesgovernorstability and can cause hunting.

Oncethe needlevalveadjustmentis correct,it is not

necessaryto change the setting except for large,
permanentchanges in temperaturewhich affect
governoroil viscosity.

NOTE
The obiective of the compensation
adiustment procedure is to find the
particularsettingsf or the compensation needle valveand compensation
adiustmnt pointer at which the
engine, turbine or other type ol prime
mover, will return quickly to speed
(needle valve adjustment) after a
speed disturbancewith only a slight
over or undershoot (compensation
pointer adiustment).
4 . From this setting,open the needlevalveone
turn and momentarilydisturbgovernorstability

16

W h e n t h e c o m p e n s a t i o na d j u s t m e n ti s c o r r e c t ,
t i g h t e nt h e c o m p e n s a t i opno i n t e rn u t a n d i n s t a l l t h e
needlevalveaccessplug with a copper washer.The
p l u ga n dt h e w a s h e rw i l l s e a lo i l s e e p a g ea r o u n dt h e
needlevalve.

I N I T I A L O P E R A T I O NF O R A R E P A I R E D
GOVERNO R
OR REASSEMBLED
to
Afterdisassembly
or repair,it is veryimportant
testthe governoron a teststand.lf a teststandis not
available,
testingof the governorcanbe done on the
engine.

Y@EEED
Before installationbe sure speed droop is not
negative.To check droop,first set the speeddroop
control knob to zero.

WARNING

lf testing of the governor is done on the

engine, the operator must be careful to
manuallycontrol the enginespeed until
he has proven that the governor will
control engine speed.
Attach a serration wrench to the output
shaft in additionto the normallinkageto
manuallycontrol engine speed with the
serrationwrench.
When satisfiedthat the governingsystem
i s f u l l y o p e r a t i v e ,r e m o v e s e r r a t i o n
wrench.
lf accuratetests and adjustmentsare to be made,
i t i s b e s t t o u s e a t e s t s t a n ds i n c e i t i s d i f f i c u l t o
m a k e t h e m w h e n t h e g o v e r n o ri s m o u n t e do n a n
e n g i n e .W r i t e o r p h o n e t h e W o o d w a r dG o v e r n o r
C o m p a n yf o r a t e s t s p e c i f i c a t i o fno r t h e g o v e r n o r
p a r t n u m b e rs h o w n o n t h e n a m e p l a t ef a s t e n e dt o
thegovernor.
Table 4-1 is a list of tools that are necessaryonly if
a l a r g en u m b e ro f g o v e r n o r si s b e i n gt e s t e d .F o r a
s m a l l n u m b e r o f g o v e r n o r s ,o n l y t h e p r e s s u r e
g a u g e i s n e e d e dt o c h e c k o i l p r e s s u r ed u r i n g
testing.
Table4-1.Test StandTools
Woodward
Tool
Description Number

Application

Woodward
Test Stand

E n g i n eS i m u l a t o r D
. rives
G o v e r n o r .S u p p l i e s
p r e s s u r eo i l . I n c l u d e s
gauges for testing.

Electronic
C o u n t e ra n d
Frequency
Pickup

Indicatesgovernor drive
speed. Must have an
output of at least 60
cycles per revolution,on
a one second time base.
Must indicate speed to
within+l rpm.Readouts
of display time must not
exceed 5 seconds.

Pressure
Gauge
(0 to 200 psi

T o c h e c k g o v e r n o ro i l
pressure.

Dial
lndicator

8995-037T o c h e c k a n d a d j u s t
droop setting.

1 . P u t a d i a l i n d i c a t o r( t o o l 8 9 9 5 - 0 3 7 o) n t h e
g o v e r n o rw i t h t h e i n d i c a t o rr o d t o u c h i n gt h e
top of the speedsettinggear.
2. Place the serrationwrench on the governor
output shaft.
3. Rotate the governor output shaft from
m i n i m u mt o m a x i m u mf u e lp o s i t i o na, n dc h e c k
t h e d i a li n d i c a t o r .
4 . N o m o v e m e not f t h e i n d i c a t o ri s z e r od r o o p .l f
movementis greaterthat .002in, adjustmentis
n e e d e d ( C w m o v e m e n to f t h e i n d i c a t o r i s
p o s i t i v ed r o o p .C c w m o v e m e not f t h e i n d i c a t o r
is negativedroop).
Loosen the locknut (190) on speed droop screw
( 1 8 9 )a n d t u r n t h e s c r e wc c w t o r e d u c ed r o o p .T u r n
the screwcw to increasedroop.
When zero droop is obtained (.002in or less ccw
m o v e m e n t )t ,i g h t e nt h e l o c k n u ta g a i n( 1 9 0 ) .
C h e c ka g a i nt h e a d j u s t m e nbt y m o v i n gt h eg o v e r n o r
o u t p u t s h a f t f r o m m i n i m u m t o m a x i m u mf u e l
positionD
. r o o pc a n b e z e r oo r p o s i t i v ei,t m u s tn o t
. h e c kt h e f i n a l d r o o p s e t t i n gw i t h t h e
b e n e g a t i v eC
governoo
r p e r a t i n go n t h e p r i m em o v e ra s s h o w ni n
"Test Procedures"in this Section.
Before operatinga repairedgovernorfor the first
t i m e , c h e c k t h a t a l l i n s t a l l a t i o ns t e p s h a v e b e e n
c o r r e c t l y c o m p l e t e d .S e e S e c t i o n 2 , I n s t a l l a t i o n
Also, read all of Section4.
Procedures.

WARNING
T O P R O T E C TA G A I N S T P O S S I B L E
PERSONALINJURY, LOSS OF LIFE
A N D / O R P R O P E R T YD A M A G E W H E N
STARTING the engine, turbine or other
type of prime mover BE PREPAREDTO
M A K E A N E M E R G E N C YS H U T D O W N
lo protect against runaway or
overspeeding should the mechanical, hydraulic governor(s)or electric
control(s), the actuator(s), fuel
c o n t r o l ( s ) ,t h e d r i v i n g m e c h a n i s m ( s ) ,
t h e l i n k a g e ( s ) ,o r t h e c o n t r o l l e d
device(s)fail.

1 1
I I

T'@EEED
TESTPROCEDURES
1 . Removepipe plug (33) in the base of the

governoron the side to the left of the needle

valveplug (30),and attacha 0-200psi pressure
gauge.(SeeFigure1-2orPressureTestPoint.)
2 . Installgovernoron a teststandor on the engine
pad. See Section2, InstallationProcedures.

3. F i l l t h e g o v e r n o rw i t h o i l . S e e S e c t i o n2 , O i l
S u p p l y .T h eo i l l e v e lm u s tb e t o t h e m a r ko n t h e
o i l s i g h tg l a s s .
4. lf the governoris testedon the engine,startthe
primemoveraccordingto the instructionsf rom
the manufacturer.
Run the governoruntil it is at operating
temperature.
5 . C h e c kt h a t t h e g o v e r n o rh a s a 1 1 0 - 1 2 0p s i o i l
pressureat normaloperatingspeed.
6 . Close the needle valve (32) and open it just
e n o u g ht o c a u s ea s m a l lh u n t ,u s i n ga P h i l l i p s
screwdriver.lf a plain screwdrivermust be
u s e d ,m a k es u r et o u s eo n l y t h e s h a l l o ws l o to f
the needlevalveto avoiddamageto the threads
insidethe bore and to the needlevalve.
L e t t h e p r i m e m o v e rh u n t f o r a p p r o x i m a t e l y
o n e h a l f m i n u t et o r e m o v et r a p p e da i r f r o m t h e
governoroil passages.
7 . C l o s en e e d l ev a l v ea n d o p e n i t a g a i no n e h a l f
t u r n .l f g o v e r n o cr o n t i n u e st o h u n t ,r e p e a st t e p
6.
L

system.SeeCompenAdjustthe compensation
sationAdjustmentsin this Section.

NOTE
Maximum speed tor constant operaton
for the UG Dial Governoris 1500rpm.
9 . W h i l e t h e e n g i n e i s r u n n i n g , r e - c h e c kt h e
governor or zero droop. Turn speed droop
k n o b t o z e r o a n d r u n t h e g o v e r n o ra t n o r m a l
load.Thenloadengine
operatingspeednear00/o
load. Speed must be within 0 to 3
near 1000/o
rpm lower.

18

l f t h ee n g i n ec a n n o tb e r u n a t f u l l l o a da n d m u s t
be run at partial load only, the rpm decrease
must be proportionalto the partialload.

1 0 . lf adjustmentis neededto obtain zero droop,

f o l l o wt h i s p r o c e d u r e :
Loosenthe locknut (190) on speed droop
s c r e w ( 1 8 9 )a n d t u r n t h e s c r e w ( 1 8 9 )c c w t o
reducedroop. Turn the screw cw to increase
d r o o p .T i g h t e nt h e l o c k n u t .
Repeat the above procedure until speed is
within 0 to 3 rpm lower when runningthe
e n g i n ef r o m n o l o a dt o f u l l l o a d p o s i t i o n s .

1 1 . To preventspeedsettingchangesbecauseof
, frictiondrive (255)is
e n g i n ev i b r a t i o n sa
i n s t a l l e di n t h e s p e e ds e t t i n gm e c h a n i c adl r i v e
of the UG Governor.
T h ef r i c t i o nd r i v e( 2 5 5 )m u s tb e t i g h te n o u g ht o
a v o i da s p e e ds e t t i n gc h a n g ed u e t o v i b r a t i o n s ,
and also tight enoughto permitthe speed
settingmotor,if used,to turn the speedsetting
gear.
l f t h ef r i c t i o nd r i v ei s t o o t i g h t ,t h es y n c h r o n i z e r
( s p e e ds e t t i n g )k n o b c a n n o l o n g e rb e t u r n e d
manually.
T o a d j u s tt h e f r i c t i o no n t h e f r i c t i o nd r i v e ,f i r s t
remove the governor cover (214), then the
r e t a i n i n gr i n g ( 2 5 0 )o n t h e f r i c t i o nd r i v eu s i n ga
No. 1 Truarcpliers.Do not letthe cover(214)or
the spring (252) all into the governoras the
frictiondrivecoveris underspringcompression.

C h e c kt h e t o r q u eo f t h e f r i c t i o nd r i v ea n d s e t i t
a t 1 1/ 2 t o 2 1/ 2 l b . i n .w i t h m a n u a sl p e e ds e t t i n g
o r 4 t o 5 1 / 2 l b . i n . w i t h s p e e ds e t t i n gm o t o r .
T o i n c r e a s ef r i c t i o n ,t u r n t h e n u t o n t h e s h a f t
c w w h i l e h o l d i n gt h e s p e e ds e t t i n gk n o b .T o
d e c r e a s ef r i c t i o n t, u r n t h e n u t c c w .
the friction drive.
12. Reassemble
1 3 . S e tt h e m a x i m u ma n d / o rm i n i m u ms p e e dl i m i t
. h i s a d j u s t m e n ct a n a l s o b e
o n t h e g o v e r n o rT
m a d ew i t h t h e p r i m em o v e rr u n n i n g .T o m a k e
t h e a d j u s t m e n tf,i r s t r e m o v et h e g o v e r n o rd i a l
p l a t e( s e ef i g u r e4 - 1 ) .

v@EwmD
E n g a g ea g a i nt h e s y n c h r o n i z eirn d i c a t o g
r ear
( 2 6 9 )w i t h t h e h i g h s p e e ds t o p p i n , e n g a g i n g
the intermediategear (278)to preventf urther
increasein speed.The high speedstop pin is
the pin closest to the gear center.

T u r nt h e s y n c h r o n i z e(rs p e e ds e t t i n g )k n o bc w
to increasethe speed settingof the governor
f r o m i t s s p e c i f i e dm a x i m u mp l u s 1 0 r p m .
l f t h e f r i c t i o nd r i v e s l i p s b e f o r er e a c h i n gt h e
required high speed setting, mark the intermediate(278) andthe synchronizer(269)(speed
setting) indicatorgears,d isengage
synchronizer
(speedsetting)gear (269),index it one tooth
c c w t o a l l o wa h i g h e rs p e e ds e t t i n ga n de n g a g e
g e a ra g a i n .

O n g o v e r n o r se q u i p p e d w i t h a n e l e c t r i c
s p e e da d j u s t i n gm o t o r ,b e s u r et h e m o t o rc a n
r u n t h e g o v e r n o ru p t o i t s m a x i m u ms p e e d
s t o p a n d d o w n t o i t s m i n i m u ms p e e d .R e s e t
torque on the friction drive,if necessaryas in
11 above.
14. To set the minimum speed limit, turn the
synchronizer (speed setting knob) ccw to
decreasethe speedsettingof the governorto
its minimumspeed position.
1 5 . S e t t h e s y n c h r o n i z ekr n o b a t z e r oo n t h e d i a l .

NE[[ffrArE rzzel

SYNCHRONIZER
(SPEEO SETTTNG)
KNOB
STOP PIN
(MAX. SPEEO)
SYNCHRONIZER
(SPEED STTTNG) (26e)
INDICATOR GEAR
-TO RAISE
HIGH SPEED
LIMIT
INDICATOR
POINTER
PULL GEAR
FORWARD
SYNCHRONIZER
(SPEED SETTING)
INDICAOR KNOE
REMOVEO

1 6 . S e t t h e s y n c h r o n i z e ri n d i c a t o r d i a l p a n e l
p o i n t e ra l z e r o .
1 7 . P o s i t i o n t h e s y n c h r o n i z e ri n d i c a t o r k n o b
'1116"
f r o m t h e s u r f a c eo f t h e d i a l .T h i s
about
preventsthe knob from binding the
s y n c h r o n i z e sr y s t e m g e a r t r a i n .
'18.

O n g o v e r n o r se q u i p p e dw i t h m i c r o s w i t c h e s ,
operatethe governorat the requiredhigh and
low speeds to verify correct positioning of
the cams that operate the micro/switches.
Adjust the cams by looseningthe screwsand
turning the cams on the shaft. Tighten
s c r e w sa g a r n .

19. On governors equipped with solenoid

shutdown, please refer to Woodward
G o v e r n o rC o m p a n ym a n u a l0 3 0 1 3f o r s e t - u p
proceoures.

20 T u r n t h e l o a d l i m i t k n o b t o z e r o . T h e l o a d
0r00-B-rc

F i g u r e4 - 1 . M a x i m u m a n d l o r M i n i m u m S p e e d
S t o p A d j u s t m e n tO n T h e U G D i a l
Governor
T h e a m o u n to f r p m c h a n g ei s n o t t h e s a m ei f
the speederscrew (177)has a coarsethread
( 1 8 t h r e a d s / i n c h )o r a f i n e t h r e a d ( 3 2
threads/inch
).

limit indicator must move to zero. The

governor output shaft will move to its
m i n i m u m f u e l p o s i t i o n .R e s e tt h e l o a d l i m i t
k n o b t o m a x i m u ml o a d .
2 1 . S h u t d o w n t h e e n g i n e .R e m o v et h e p r e s s u r e
g a u g e a n d i n s t a l la 1 / 8 " s o c k e t p i p e p l u g .
A p p l y a p i p es e a l e rt o t h e t h r e a d sa, n d t o r q u e
p i p e p l u gd o w n t o 9 0 l b - i n .
2 2 . I n s t a l tl h e g o v e r n o rc o v e ra n d d i a l p l a t e .

19

Y@EwA_ED
TESTCOMPLETION
F o r o p e r a t i o no f u n i t s r u n n i n ga l o n e ,s e t d r o o p a t
zero. Reducing droop to zero allows the unit to
change load without changing speed (zero droop
operationis also calledisochronousoperaton).
On unitsconnectedin parallelor to a singleshaft,set
the least amount of droop possible to provide
satisfactoryloaddivision.Droopallowsloaddivision
betweentwo or more prime moversthat drive the
s a m es h a f to r a r e p a r a l l e l e di n a n e l e c t r i c a l s y s t e m .
For ac generatingunits tied in with other units,set
droop sufficientlyhigh (referencenumber30 to 50
or more on the dial) to preventinterchangeof load
betweenunits.

W h e nt w o u n i t sa r es e t u p f o r o p t i m u ms i n g l eu n i t
performance,
paralleling
problemscan be encoungovernorresponse
can be too
tered.Forexample,
f a s to n o n e g o v e r n o rr,e q u i r i n gt o o h i g h a s p e e d
loadinterchange
a constant
droopsettingto prevent
when this occurs,the
betweenthe two governors.
settingshould be movedtowards
compensation
m a x i m u mr,e d u c i n gt h e s i n g l eu n i t t r a n s i e npt e r formancecapabilitybut allowingstable parallel
speeddrooprange.
withinthe allowable
operation
Also,checkamountof outputshafttravelon each
governor(seeNOTE,p.12).Too littleoutputshaft
t r a v eol n a g o v e r n ocr a n r e q u i r et o o h i g ha d r o o p
settingon that governorto obtain steadystate
control.

l f o n e u n i t i n t h e s y s t e mh a s e n o u g h g e n e r a t i n g
capacity,set its governoron zero droop,and it will
regulatethe f requencyof the primemoversystem.lf
i t s c a p a c i t yi s n o t e x c e e d e dt,h i s u n i tw i l l h a n d l ea l l
load changes.

When UG governorsare used on generatorsets

operatingin paralleland the leadunit is shiftedto
slaveandviceversa,zerodroopmustbe seton the
for whichit isset,
thef requency
leadunitto maintain
and droop must be set on the slaveunit for load
thetwo units.
distribution
between

of the governorwith
Operatethe SYNCHRONIZER
zerodroop to adjustthe system'sf requency.Operate
the SYNCHRONIZERSof the governorsthat have
speeddroop to distri'buteload betweenunits.

on loadsharing,pleaserefer
Formoreinformation
theControlof PrimeMoverSpeed,
to manual25031,
of Alternators.
Operation
Partlll, Parallel

\t

20

T'@EEED

sEcfloN 5
TROUBLESHOOTING
INTRODUCTION
T h i s s e c t i o n p r o v i d e s i n s t r u c t i o n sf o r
t r o ub l e s h o o t i n g .

I t i s i m p o s s i b l et o a n t i c i p a t ee v e r yk i n d o f t r o u b l e
thatis encountered
i n t h e f i e l d . T h i sm a n u a lc o v e r s
the most common troubles experienced. Poor
governing may be due to faulty governor
performance,or it may be due to the governor
attempting to correct for faulty operation of the
prime mover or the equipmentdriven. The effect
o f a n y a u x i l i a r ye q u i p m e n to n t h e o v e r a l lc o n t r o l
requiredof the governormust also be considered.

WARNING

T O P R O T E C TA G A I N S T P O S S I B L E
PERSONALINJURY, LOSS OF LIFE
AND/OR PROPERTYDAMAGE WHEN
STARTING the engine,turbine or other
type of prime mover BE PREPAREDTO
M A K E A N E M E R G E N C YS H U T D O W N
lo protect agalnst runaway or overspeedingshould the mechanical-hydraulic
governor(s) or electric control(s), the
acluator(s), luel control(s), the driving
m e c h a n i s m ( s ) ,t h e l i n k a g e ( s ) , o r t h e
controlled device(s)fail.

TROUBLESHOOTING
otL
Keep the governoroil level to the mark on the o i l
sight glass with the unit operating.The correct o i l
fevel is 3/4 to 1 1/4 inch below the top of t h e
governor case.
Dirty oil causesmost of all governortroubles.Use
c l e a n n e w o r f i l t e r e do i l . O i l c o n t a i n e r su s e d m u s t
be perfectly clean. Oil contaminatedwith water
breaks down rapidly,causing foaming and
corrodes internal governor parts.

ADJUSTMENTAND
COMPENSATING
NEEDLEVALVE
T h e c o m p e n s a t i n ga d j u s t m e n ta n d n e e d l e v a l v e
must be correctly adjusted with the governor
c o n t r o l l i n gt h e e n g i n eo r t u r b i n e ,e v e nt h o u g ht h e
compensationmay have been previouslyadjusted
at the factory or on governor test equipment.
Although the governor may appear to be
operating satisfactorilybecause the unit runs at
constant speed without load, the governor still
may not be correctly adjustedto the load and to
the engine it is to control.
High overspeedsand low underspeeds,or slow
return to speed, after a load change or speed
setting change, are some of the results of an
incorrectsetting of the compensatingadjustment
a n d n e e d l ev a l v e .

DEFINITIONS
Use the troubleshootingchart (Table 5-1) on the
following pagesto determinethe probablecauses
of faulty operationand to correct these troubles.
Terms used in the chart are defined as follows:
HUNT
A rhythmic variationof speedwhich can originate
in the governor or in the prime mover. (See
T a b l e5 - 1 , P a r . 1 A , f o r T r o u b l e s h o o t i n g
I n f o r m a t i o n .A
) h u n t u s u a l l yh a s a f r e q u e n c yo f
less than 50 cycles per minute.
SURGE
A sudden variationof speedoccurringat periodic
intervalswhich can also originatein the governor
o r i n t h e p r i m e m o v e r .( S e eT a b l e5 - 1 , P a r .1 A , f o r
TroubleshootingI nformation.
)
JIGGLE
A high frequencyvibrationof the governoroutput
shaft and fuel linkage. Do not confuse this with
n o r m a lc o n t r o l l i n ga c t i o no f t h e g o v e r n o r A
. jiggle
has a frequency of more than 50 cycles per
minute.

21

VI@EEEED
PRELIMINARY'NSPECTION
Governor troubles are usually revealedin speed
variations of the prime mover, but it does not
necessarilyfollow that such variationsare caused
by the governor.When improperspeed variations
a p p e a r , t h e f o l l o w i n g p r o c e d u r es h o u l d b e
performed:
1. Check the load to be sure the speedchanges
are not the resultof load changesbeyondthe
capacity of the prime mover.
2. Check engine operationto be sure all
c y l i n d e r sa r e f i r i n g p r o p e r l ya n d t h a t t h e f u e l
injectorsare in good operatingconditionand
p r o p e r l yc a l i b r a t e d .
3. Check the linkagebetweenthe governorand
f u e l r a c k so r v a l v e .T h e r em u s t b e n o b i n d i n g
or lost motion.
4. Check the setting of the needle valve and
compensation adjustment. (See Section 4,
C o m p e n s a t i o nA d j u s t m e n t s . )

The use of commercial solvents is not

recommendedas they may damagesealsor
gaskets.
C h a n g et h e o i l a n d f l u s ht h e g o v e r n o rt w i c ea
year if possible.
T o c h a n g e o i l , r e m o v et h e d r a i n p l u g a n d
d r a i n o u t t h e o l d o i l . F l u s ht h e g o v e r n o rb y
filling it with fuel oil, and with the prime
mover running at low speed, cycle the
governorby opening the needlevalvetwo or
three turns.
L e t t h e g o v e r n o rh u n t f o r a m i n u t e o r t w o ,
then stop the engineand drain the governor.
Flush the governoronce again. Refill the
g o v e r n o rw i t h o i l ( s e eS e c t i o n2 , O i l S u p p l y ) .

^
I

Restartthe engine and reset the

t n d n e e d l ev a l v e .
c o m p e n s a t i o na d j u s t m e n a
6. Check that the drive to the governor is
correctlyaligned and free of roughness,side
l o a d i n g ,a n d e x c e s s i v eb a c k l a s h .

5. Check that the oil is clean and oil levelis

correct at operating temperature.
T h e s o u r c eo f m o s t t r o u b l e si n a n y h y d r a u l i c
governor stems from dirty oil. Grit and other
impuritiescan be introduced into the
g o v e r n o rw i t h t h e o i l , o r f o r m w h e n t h e o i l
begins to breakdown (oxidize) or becomes
sludgy.
The internalmoving parts are continually
l u b r i c a t e db y t h e o i l w i t h i n t h e u n i t . V a l v e s ,
pistons and plungerswill stick and even
"freeze" in their bores, due to grit and
i m p u r i t i e si n t h e o i l .
lf this is the case,erraticoperationand poor
response can be corrected (if wear is not
e x c e s s i v eb) y f l u s h i n gt h e u n i t w i t h f u e l o i l o r
Kerosene.

WARNING

T O P R O T E C TA G A I N S T P O S S I B L E
PERSONALINJURY, LOSS OF LIFE
AND/OR PROPERTYDAMAGE WHEN
STARTING the engine, turbine or other
type of prime mover BE PREPAREDTO
M A K E A N E M E R G E N C YS H U T D O W N
to protect against runaway or overspeedingshouldthe mechanical-hydraulic
governor(s) or electric control(s), the
actuator(s),fuel control(s), the driving
m e c h a n i s m ( s ) ,t h e l i n k a g e ( s ) , o r t h e
controlled device(s)fail.

i
22

T'@EEED
Table 5-'1.TroubleshootingChart

TROUBLE
The engine,turbine
or other type of
prime moverhunts
or surges.

CAUSE
A . The trouble may be originating
i n t h e g o v e r n o ro r t h e p r i m e
mover.

I
i

Block the throttle, fuel racks or

steam valve in the direction of
i n c r e a s ef u e l . ( N e v e r b l o c k t h e
governor output shaft in the direction that would preventa complete
s h u t d o w n . )T h e s a m e b l o c k i n g
action can be performedby using
t h e l o a d l i m i tk n o b o n t h e g o v e r n o r
panel.
ff hunting and/or surgingcontinues while the governoroutput shaft
i s b l o c k e d ,t h e p r o b l e m i s i n t h e
prime mover.

lf, after removingthe block, hunti n g a n d l o r s u r g i n gs t a r t sa g a i n ,t h e

p r o b l e mc a n b e i n t h e g o v e r n o ro r
i n t h e p r i m em o v e r .G o t h r o u g ht h e
c o m p e n s a t i o na d j u s t m e n tp r o c e dure for the governor (see SecAdjustments).
tion 4, Compensation
lf the problemis still there, replace
the governor with a replacement
governorG
. o t h r o u g ht h e c o m p e n s a t i o n a d j u s t m e n t p r o c e d u r ef o r
the replacementgovernor. lf the
h u n t i n g a n d / o r s u r g i n gc o n t i n u e s ,
t h e p r o b l e mi s i n t h e p r i m e m o v e r .

rb

CORRECTION

B . C o m p e n s a t i o na d j u s t m e n t s
incorrect.

Adjust needle valve and compens a t i o n a d j u s t i n gp o i n t e r .

C . D i r t y o i l i n g o v e r n o r- s l u d g e .

D r a i n o i l , c l e a ng o v e r n o ra n d r e f i l l

D . L o w o i l l e v e lw h i c h p e r m i t sa i r
to enter and cause foaming.
T h i s i s e v i d e n ti n t h e g o v e r n o r
as spongy operation.

Add oil to the mark on oil sight

glass. lf oil level decreasesand no
external oil leaks can be seen on
the governor,checkthe driveshaftfor
oil leak.

t
I

l f f o a m i n gc o n t i n u e sd, r a i n o i l a n d
r e f i l l u s i n g a d i f f e r e n tt y p e o i l .

E. Oil varnish which causes

sticking of parts.

R e p a i rg o v e r n o r .

F . L o s t m o t i o n i n e n g i n el i n k a g e
or fuel pumps.

R e p a i r l i n k a g ea n d / o r p u m p s .

23

Y@EEED
CAUSE

TROUBLE
G.

CORRECTION

B i n d i n gi n e n g i n e - t o - g o v e r n o r Repair and realign linkage and/o

pumps.
l i n k a g eo r f u e l p u m P S .

H. Governor output shaft travel

t o o s h o r t t o p r o v i d ef u l l f u e l .

Adjust travel until proper travel is

obtained.

l . S p r i n go n y i e l d l i n k a g et o f u e l
racks too weak.

Install heavierspring.

J. Low oil pressure.Normal

o p e r a t i n gp r e s s u r e1 1 0 t o
1 2 0p s i f o r t h e U G 5 . 7a n d U G 8 ;
1 4 0t o 1 5 0 p s i f o r t h e U G 1 2 . 8 .
( S e eO u t l i n eD r a w i n g , F i g u r1e2 for pressuretest point location.)

Beturngovernorto factorYfor
repair.

P u m p c h e c k v a l v e sa r e n o t
s e a t i n go r a c c u m u l a t osrP r i n g s
weak.
K. Power piston is sticking.

C h e c k f o r s i d e p l a yo r b i n d i n g o f
output shaft.

L. Voltage regulator not

operating properly.

Check voltage regulator.OPerate

i n v o l t a g ed r o o p o r m a n u a l .D o n ' t
disconnectvoltageregulator.Adjust,
repairor replacevoltageregulator.

M. Fuel linkage incorrectlyset.

This might occur if the
governor has been changed
or removed and rePlaced.
Relationshipof governortravel
to power output of engine
s h o u l db e l i n e a r .

Rework or reset the linkage from

governor to unit to obtain the
l i n e a rr e l a t i o n s h i p .

N . F a u l t yl i n k a g e .

It should be free of bindingand lost

motion throughout service life of
unit. Check yield links, shutdown
arrangements,etc., to be sure that
primemovertorquechangesforvery
smallincrementsof governoroutput
shaft travel. Stability and good
steady-stateperformancewill suffer
unlessthis conditionis met.

O. Incorrect non-linearrelationship between governor travel

and horsepoweroutPut of the
p r i m e m o v e r .E n g i n e m a y
hunt with light loadsand be
stablewith a heavYload.

Adjust linkage from governor to

gas valve to obtain linear relationship between governor travel and
engine output. See figure 1-3.
Also, ApplicationNote 50516.

I
I

24

YGtrEEED
TROUBLE

|b

2. Fuel racks do not

open quicklywhen
cranking engine,
turbine or other
type of prime
mover.

3 . Jiggle at governor

output shaft.

CAUSE

CORRECTION

P. Gas or steam pressure

too high.

Adjust gas or steampressure.

O. Engine misfiring (Bad fuel

injector. Low pilot fuel on
dual fuel engine.)

Check pyrometerreadingsof each

cylinder and make necessary
repairs or adjustments.

R. Load limit indicator binding

on nameplate or load limit
shaft bent.

Damaged indicator disc or

nameplate must be corrected or
replaced.Load limit shaft must be
replaced if bent.

S. Negative droop when speed

droop knob at zero.

Droop calibration out of adjust

ment. Reset (see Section 4
Governor Operation and Adjust
ments).

T.

Return governor to factory for

repairs.

Governor worn.

A. Low oil pressurein governor.

See item 1.J. above.

B. Cranking speed too low.

May be necessaryto use a booster

servomotor. See booster servomotor manuals 01004 and 36684.

C. Boosterservomotor(if used)
not functioningproperly.

Check action of automaticair

starting valve. See Booster Servomotor Manuals 01004 and 36684.

A . R o u g h e n g i n e drive o r governor drive.

Inspect drive mechanism.

a. Check alignment of gears.
b. Inspect for rough gear teeth,
eccentric gears, or excessive
backlash in gear train.
c. Check gear keys and nuts or
set screwsholding drive gears
to shafts.
d. Check for bent drive shaft.
e. Check serrated or spline
coupling for wear and
alignment.
f. Tighten chain between
crankshaft and camshaft (if
used).

g. Check engine vibration

damper (if used).

25

YI@EEED
TROUBLE

CAUSE

CORRECTION

NOTE
It a keyed drive is used, backlash must be checked and the gear shimmed so
that there is no binding and the backlashis not too great. Thisshould be done
each time a new or replacement governor is installed.

ll a serrateddrive is used, concentricityof shaft to couplingshould be

maintained.Couplingshould be as long as possl/eto permit greater
flexibility.

B. Governor is not aligned

properly.

Loosen governor mounting screws

a n d m o v e t h e g o v e r n o rs l i g h t l yo n
i t s m o u n t i n gp a d t o a l i g n t h e d r i v e
shaft with its coupling.

C. Failure of flexible drive in

flyweight head.

Return governor to factory for

reparrs.

D. Other possible causes are:

- dirty or worn ballhead
bearing.
- rough or worn gear teeth.
- b e n t s p e e d e rs p r i n g .
- damaged drive shaft seal
retaner.

4. Load does not

divideproperly
on interconnected
e n g i n e s ,t u r b i n e s
or other types of
prime mover.

Return governor to factory for

reparrs.

Replaceseal retainer.

E. Air in governor system can

c a u s ea j i g g l ed u r i n gs t a r tu p s
or transients.

Bleed air. (see Section 4, Test

P r o c e d u r e s ,P a r a g r a p h 6 . )

A. Speed droop adjustment

incorrect.

R e a d j u s td r o o p t o d i v i d e l o a d
properly.

Increasedroop to resistpicking up
( o r d r o p p i n go f f ) l o a d .
Decreasedroop to increasepicking
u p ( o r d r o p p i n go f f ) l o a d .

5. The engine,turbine
or other type of
orime mover is
slow to respond
to a speedchange
o r a l o a dc h a n g e .

26

B. Speed settingsof the governors

are not the same.

A d j u s ts p e e ds e t t i n gs o b o t h p r i m e
moversrun at the samespeed.

A. Needle valve adjustment

incorrect.

R e a d j u s t c o m p e n s a t i n gn e e d l e
v a l v e .O p e n f u r t h e r i f p o s s i b l et o
do so without causing instability
when running without load.
Compensationpointer may be too
far toward maximum.

Y@ESED

rb

TROUBLE

o.

The engine,turbine
or other type of
prime mover will
not pick up rated
full load.

CAUSE

CORRECTION

B . G o v e r n o r i s n o t s e n s i t i v ei n
measuringspeed change
(deadband).

Friction or wear on flyweight

toes-sludge in governor, return
to factory.

C. Low oil pressurein qovernor.

Return governor to factory to

i n s p e c tp u m p a n d c h e c k v a l v e si f
o i l p r e s s u r ei s l o w .

D. Enginemay be overloaded.

R e d u c el o a d .

E. Restrictedfuel supply.

Clean fuel supplyfilters.

F. Load limit knob set to restrict

fu e l .

l n c r e a s el o a d l i m i t s e t t i n g .

Fuel racks will not open far

e n o u g h ,o r g o v e r n o ra t e n d o f
its stroke and the load
i n d i c a t o ri s s e t a t 1 0 .

Adjust engine to governorfuel

l i n k a g e .A d j u s t l o a d l i m i t i n gd e v i c e
or fuel pump stops.

C h e c k c o m p r e s s i o no f l o a d l i m i t
friction spring. Low compression
may permit load limit cam to
graduallywork toward reduced
load position.

|b

B. Restrictedfuel supply.

Clean fuel supply filters. Gas

pressure low. Gas with different
c a l o r i f i cv a l u e .

C . V o l t a g er e g u l a t o r( i f u s e d )n o t
fun c t i o n i n g .

Readjustor repair

D. Enginemisfiring.

Check pyrometerreadingsof each

cylinder and make necessary
repairs or adjustments.

E. Slippingclutch or belts
b e t w e e ne n g i n e a n d d r i v e n
load.

Make adjustments.

F. Load limitknob setto restrict

fu e l .

I n c r e a s el o a d l i m i t s e t t i n g .

7. Governordoes not
respond to synchronizermotor
switch.

S l i p p i n gc l u t c h . B i n d i n g o r
worn bevel gears.

I n c r e a s ec o m p r e s s i o no n c l u t c h
s p r i n g . R e p a i ro r r e t u r n g o v e r n o r
to factory.

8. The speed of the

prime mover
increaseswth an
increasein load.

Droop is negativewhen
adjustmentis zero on
the panel. Droop calibration out of adjustment.

Reset droop. See Section 4,

Governor Operation and Adjustments.

27

Y@EwA_ED
A D D I T I O N A LI N F O R M A T I O NF O R
S T EA M T U R B IN E S ,GA S A N D
G A S O L I N EE N G I N E S
The engine torque versus throttle position for a
steam turbine gives a wide variety of non linear
relations.Eachtype must be compensatedfor with
the correct compensating linkage to bring the
governoroutput shaft movementback into a near
l i n e a rr e l a t i o nw i t h t h e p r i m em o v e rt o r q u eo u t p u t .
Please refer to the prime mover manufacturer's
h a n d b o o kf o r t h e c o r r e c t l i n k a g es e l e c t i o na n d
installation.
The torque vs. throttlepositioncurvefor a gas and
g a s o l i n e e n g i n e w h i c h i s c o n t r o l l e dt h r o u g h a
butterfly valve is always very non-linear.When
adaptinga governorto this type of engine, if the
l i n k a g ei s m a d e l i n e a r ,o p e r a t i o na t i d l e a n d l i g h t
loads is never very stable.
The proper procedurefor adaptinga governorto
this engine with the butterflyvalve is to make the
linkageso that it requiresgreatermovementof the
governor per incrementof butterfly movementat
light loadsthan it does at high loads.
T h i s l i n k a g e t e n d s t o l i n e a r i z et h e r e l a t i o n
between engine developedtorque and governor
o u t p u t s h a f t p o s i t i o n( s e e f i g u r e 1 - 3 ) .
The chart below shows a satisfactoryangular
position of the governoroutput shaft for different
openingsof the butterflyvalvein order to have a
more stable operation at idle and at light loads.

Seals and bearing replacement require only a

partialdisassemblyof the governor.Seefigures51 , 5 - 2 ,a n d t a b l e s5 - 3 a n d 5 - 4 f o r a l i s t o f c o m m o n
bench tools and normal field repair tools.
Sealsand bearingscan be replacedwithout these
tools, howeverreplacementof parts is madeeasier
if these tools are available.
Ordertoolsf rom the WoodwardGovernorCompany,
Fort Collins, Colorado (see addresson the back
c o v e ro f t h i s m a n u a l ) l.n c l u d ei n o r d e r :
1. The tool description
2 . T h e t o o l n u m b e ro r p a r t n u m b e r o f t h e t o o l
required.
3 . T h e m a n u a l n u m b e r ( t h i s m a n u a l0 3 0 4 0 )

FROMEr,rcrrvE
REMOVALOF oOVERVOR
To replacea governoron the engine,or to replace
seals or bearings on the governor, remove the
g o v e r n o rf r o m t h e e n g i n e a s f o l l o w s :

Use care in handling and resiing ol the

governor on work area. Do not strike or
rest governor on end of drive shaft as
damage may result to drive shaft, oil
seal, bearing, or other internal parts or
surfaces. Set governor on wooden
block(s) to protect drive shalt when
performing maintenance operations.

G O V E R N O RO U T P U T
SHAFT TRAVEL
0"

B U T T E R F L YV A L V E
SHAFT TRAVEL
00

60
12"
150
18 0

30
90
200
300

l r a i np l u g
1 . D r a i no i l f r o m g o v e r n o ra n d i n s t a l d
again. Some governorsare equipped with a
drain cock for draining.

24"

82"

2. Clean exterior surfaces using a cloth

moistenedwith cleaning solvent.

Table 5-2. Governor Output Shaft Travel vs.

Butterfly Valve Travel

G O V E R N O RF I E L D R E P A I R S
Seals and bearingsof the governor output shaft
and drive shaft can be replaced in the field.

28

3 . D i s c o n n e c ta u x i l i a r y d e v i c e w i r i n g , a n d
p n e u m a t i co r h y d r a u l i ct u b i n g c o n n e c t i o n si f
applicable.
4. Before detaching output shaft and speed
setting linkages,mark both shaft and leverso
they may be easilyreinstalledat their original
positions.

rl

Y@EEED
5. Removethe four stud nuts holding the
g o v e r n o rt o t h e m o u n t i n g p a d a n d l i f t t h e
governor off. Remove the gasket between
g o v e r n o ra n d g o v e r n o r m o u n t i n g p a d .

6. Set governor on wooden blocks to protect

drive shaft. Be very careful to avoid striking
the end of the drive shaft.Damageto internal
parts of the governor may result.

Table 5-3. List of Common Bench Tools

REFERENCE
NUMBER

TOOL DESCRIPTION

'l

TOOL
NUMBER

T-Handle Hex Wrench 7/16"

" T " H a n d l eA l l e n W r e n c h
3/16"
Standard Allen Wrench 5/64"
Bench Block

2
3
4

189440
8995-047
8995-048
0 119 7 1

No. 2 Phillips Head Screwdriver

Hooked Scribe

5
6

8995-049
189792

APPLICATION
V a r i o u sb o l t s o n U G
T o i n s t a l l1 / 8 i n . p i p e p l u g s
For No. 8:32headlessset screw
To press out small bearings
and bushings
Various screws on UG
R e m o v i n ga n d i n s t a l l i n g
cotter pins

Ib

I
L

li;'K:*:::

-*-.

03000-A-f92

Figure5-1. Common Bench Tools

29

Y@EEED
Table 5-4. List of Normal Field Repair Tools
REFERENCE
NUMBER

TOOL DESCRIPTION

TOOL
NUMBER

W i l l i a mP l i e r s

8995-023

Bearing Seater
Seal Protector
(used with 030952)
Dial Indicator WBase
S e a l I n s t a l l i n gT o o l
(Micarta Type)
B u s h i n gD r i v e r

8
I

8995-024
030951

10
11

8995-017
030952

12

8995-028

SerrationWrench

13

030943

Toroue Wrench with 7/16" Socket

14

8995-038

APPLICATION
Replaceretainingring on
drive shaft
Replacedrive shaft bearing
Fit on output shaft to protect
seal
To check droop adjustment
lnstall output shaft seals (for
extra long shafts only)
To adjust output shaft bushings
T u r n i n go u t p u t s h a f t o r d r i v e
shaft
25 lb.-in.torque on drive shaft
bearing retainer plate screws

03000-a-r93

F i g u r e 5 - 2 . N o r m a l F i e l d R e p a i rT o o l s

30

'a

V@E$ED
S E C T I O N6
PARTS
REPLACEMENT
R EP L AC E ME N TP A R T SIN F OR MATION
W h e n o r d e r i n g r e p l a c e m e n tp a r t s , i n c l u d e t h e
f o l l o w i n gi n f o r m a t i o n :
1 . G o v e r n o r s e r in
au
l m b e r a n dp a r tn u m b e r s h o w n
on nameplate.
2 . M a n u a ln u m b e r( t h i si s m a n u a l0 3 0 4 0 ) .

3 . P a r t s r e f e r e n c en u m b e r i n p a r t s l i s t a n d
d e s c r i p t i o no f p a r to r p a r t n a m e .

See the back cover for Woodward Governor

C o m p a n yl o c a t i o n s .

WARNING
Referto RepairManual56103for correct
and safe procedures when disassembly
a n d a s s e m b l ya r e r e q u i r e d .P e r s o n a l
injury may resultif accumulatorsprings
are releasedsuddenly.Usean arbor press
to release or to install the compressed
accumulatorspring.

L
31

YI@EEED

P A R T SL IS T F OR FIGURE6- 1 (Sheet 1 of 5)
R E FN O ,
03040030400304003040-

P A R TN A M E

QUANTITY

1
2
3
3A

R e t a i n e r i n g ,1 . 2 8 3 "O D
2
Washer1
, . 1 8 5 "O D
2
A c c u m u l a t o sr p r i n g
2
A c c u m u l a t o sr p r i n g
( U s e di n U G 1 2 . 8o n l y )
2
2
03040- 4 Accumulatorpiston
03040- 5 S o c h d p i p e p l u g ,1 / 8 "
1
03040- 6 S o c h d p i p e p l u g ,1 / 8 "
1
p
i
n
,
7
.
0
6
0
x
1
/
2
"
1
03040Cotter
03040- 8 Laminateddrive shaft assembly 1
03040- I Sleeveretainer
1
03040-10 S p i r o lp i n
1
'l
03040-11 R e t a i n e r i n g . 6 7 1l D
1
03040-12 Washer
03040-13 Driverassembly
1
03040-14 L a m i n a t e dd r i v es p r i n g
12
1
03040-15 P u m pg e a ra s s e m b l y
03040-16 S t r a i g h tp i n
1
03040-17 Largedashpotcompensation
piston
1
03040-18 Largedashpotcompensation
spring
03040-19 Largedashpotcompensation
'l
link
03040- 20 Oilite bushing
2
2
03040- 21 Retainerring, 1.283"OD
1
03040- 22 Pilot valve bushing
03040- 23 Check valve
4
03040- 24 Dowel pin
2
03040- 25 Dowel pin
2
03040- 26 Base
1
03040- 27 Washer
5
03040- 28 Cap screw, 1/4-28x 1.000"
5
1
03040- 29 Pipe plug, 1/8" soc hd
03040- 30 Needlevalveplug
1
03040- 31 Washer
1
03040- 32 NeedleValve
1
03040- 33 Pipe plug, 1/8" soc hd
1
03040- 34 Power piston
1
03040- 35 Controlet
1
03040- 36 Soc hd pipe plug, 1/8"
1
03040- 37 Soc hd pipe plug, 1/8"
1
03040- 38 Ballheaddrive gear
1
03040- 39 Connectinglever
1
03040- 40 Straightpin
1
03040- 41 Cotter pin, .030x3/8"
2
03040- 42 through 49
Not Used

32

VI@EWEED
R E F E R E N C ENUMBERS 1 THROUGH 41 ARE ON THIS PAGE

\
REFEREN.E
NUMBERS
42 rHRoucH 4e
ARENOr USED

z-)t(2)
XA
\9
9-

.L zrzl

$}
t

q-

ACCUMULATOR
PISTON

41

Ir
ooXt

ACCUMULATOR
SPRING

El

CZ

W'r",

H g/
g ffi-oatzr

--AccuMULAroR

\ ( ) v -

f'"'='3""11:J3$ur,"o*,
WARN'NG

Injurymay resultif accumulatorsprlngs(3)

and (3A) are releasedsuddenly.Use an
arbor press to release the compressed
accumulatorsprings.

64

I
I
I

rr_".
364.
LAMINATED DRIVE
SHAFT ASSEMBLY

CONTROLET

\
21(2)

..

-
POWER
PISTON

OASHPOT
LINK

PILOT VALVE
BUSHING

?r,

u l z a

..l;dK

n
&,,
)k'nr"'

t i 4
{DI

iJ

@rz

nf

i t \

a!-

ft
a>

&,,
ffi

r.!

27(5)
BASE

03q,0-A-155

Figure 6-1. Pas illustration

U G D i a l Governor(Sheet1 of S)
33

N@EEED

P A R T SL IS T F OR FIGURE6- 1 ( Sheet2 of 5)
R E FN O .

PART NAME

QUANTITY

03040-50 P l u g
03040-51 O u t p u t s h a f t ( o p t i o n a l )
03040-52 Set screw, 1/4-28 x 5/16"
03040-53 O u t p u t s h a f t b u s h i n g
03040-54 O i l s e a l , 1 . 1 2 8O D
03040-54ACompensationadjustment lever
03040-55
03040-56
03040-57
03040-58
03040-59
03040-60
03040-61
03040-62
03040-63
03040-64
03040-65
03040-66
03040-67
03040-68
03040-69
03040-70
03040-71
03040-72
03040-73
03040-74
03040-75
03040-76
03040-77

34

pin stop
Washer, 7/16 x 5/8 x 1/32"
Compensationadj. pointer
Washer, .328 x .562 x .064 thick
Elastic stop nut 5/16-24
Keyed driveshaft
Key .188x .190x 1.062"
Spacer
Nut, 5/8-18 castle
Cotter pin, 1/8 x 1 1/2"
Pilot valveplunger
Spring seat
Pilot valve spring
Driveshaft
Ball bearing
Snap ring
Bearing retainer plate
Dr hd cap screw, 1/4-28 x 5/8"
O i l s e a l . 1 . 3 7 9 "O D
Oil seal retainer
Seal retainer gasket
Small dashpot compensation
piston assembly
Small dashpot compensation
spring
Small dashpot spring seat
(Not shown)

'l
1
2
2
2
2
I

1
1
'l

1
1
'l
1
1
'l
1
1
1
1
1
1
3
1
1
1
'l
2

REF NO.

PART NAME

QUANTITY

03040- 78

S m a l l d a s h p o tc o m p e n s a t i o n
piston guide
1
1
03040- 79 Hex lock nut, 1/4-28
1
03040- 80 Dashpot nut
'l
03040- 81 Shutdown lever bracket
1
03040- 82 S p r i n g
'l
03040- 83 W a s h e r ,. 1 7 8 | D
1
03040- 84 Cotter pin
1
03040- 85 Headed pin
1
03040- 86 S h u t d o w n l e v e r
2
03040- 87 Washer
2
03040- 88 Screw
1
03040- 89 Cotter pin
1
03040- 90 Washer
03040- 91 P o w e r p i s t o n l i n k
'l
03040- 92 Cotter oin
1
03040- 93 Power lever
2
03040- 94 T a p e r p i n , N o . 3 x 1 1 / 4 "
'l
03040- 95 P i n
1
03040- 96 Cotter pin, .060 x 3/4"
1
03040- 97 Comoensationlever
1
03040- 98 S t r a i g h tp i n
1
03040- 99 D r i l l e d s t r a i g h t p i n
'l
03040-100 Cotter pin, .060 x 3/4"
1
03040-101 S t r a i g h t p i n
1
03040-102 C o m p e n s a t i o nl i n k
1
03040-103 C o m p e n s a t i o nl e v e r f u l c r u m
1
03040-104 Compensationlever assembly
P
a
c
k
i
n
g
R
i
n
g
,
03040-105 P r e f o r m e d
1
. 3 0 1l D x . 0 7 0 "
1
03040-106 Case
03040-107 O u t p u t s h a f t
Not Used
03040-108t h r o u g h 1 4 9
I

'l

V\@E,A-ED

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s?

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l
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t'-.9

PARTS

]
F i g u r e6 - 1 . P a r t sl l l u s t r a t i o n
f o r t h e u G D i a l G o v e r n o r( s h e e t2 o f 5 )

35

YI@EEED
PARTSLISTFORFIGURE6-1 (Sheet3 of 5)
R E FN O .

PART NAME

QUANTITY

F r i c t i o ns p r i n g p i n
1
Load limit speed droop spring 1
Load limit cam
1
1
Speed droop cam assembly
Washer..265 lD x .438 OD x
.207-.197
thick
1
03040-1
54
Rack pin
6
03040-1
55
Load indicator gear
(includes items 285 and 286)
03040-1
56
Load limit lever
03040-1
57
Load limit strap
Load limit rack
03040-1
58
03040-1
59
Dial Panel
03040-'160 Ballheadcover
03040-1
61
Flyweight
Flyweightbearing
03040-1
62
03040-1
63
F l y w e i g h tp i n
03040-1
64
Torsion spring
03040-1
65
T o r s i o ns p r i n g ( e a r l y m o d e l )
03040-1
66
Ball bearing
03040-1
67
Ballheadgear assembly
03040-168 Spirol pin
03040-169
Spring damped ballhead
03040-170
Speeder rod
71
03040-1
B a l l h e a da s s e m b l y
03040-172
Speeder rod spring
03040-1
73
Thrust bearing
03040-174
Flexloc stop nut
75
03040-1
Speederspring assembly
03040-176
Speedergear
03040-177
Speeder screw
03040-178
Shakeproofwasher,No.8
Phil. hd screw, 8-32 x .375
03040-179
03040-180
Speed setting screw pin
03040-1
81
Cotter pin, .030 x .375
03040-1
82
Washer..375 OD
03040-183
S p e e dd r o o p l i n k
03040-184
Cotter pin, .030 x .375
D r i l l e ds t r a i g h tp i n
03040-185
03040-186
Speed droop lever
03040-187
S p e e dd r o o p f u l c r u m
03040-188
Speed setting screw guide
03040-189
Speed droop screw
03040-'190 Nut, 8-32
E x t e n s i o ns p r i n g
03040-1
91
03040-192
Speed droop lever screw
Washer,.500 OD
03040-193
03040-194
Cotter pin, .060 x .500
03040-195
Speed droop lever
0 3 0 4 0 - 1 9t6h r o u g h1 9 9
Not Used

03040-1
50
03040-1
51
03040-1
52
03040-1
53
03040-1
534

36

I'@EEED
R E F E R E N C EN U M B E R S 150 THROUGH 195 ARE ON THIS PAGE
R E F E R E N C EN U M B E R S
196 THROUGH 199
ARE NOT USED

SPEEDDROOP
ASSEMBLY

194

,rul'-'
,ro
DETAIL B

--e

189

OETAILA

03000-A-1s7

Figure6-1. Partslllustrationfor the UG Dial Governor(Sheet3 of 5)

37

Y@M-AED

P A R T SL IS T F OR FIGURE6- 1 ( Sheet4 of 5)
R E FN O .

P A R TN A M E

QUANTITY

1
03040-200 115 V acldc Bodine motor
1
03040-201 Motor seal sPring
4
O3O4O-202Phil fl hd screw, 10-32x .375
1
03040-203 Oil CuP
8
O}O4O-204Phillipshd screw,10-32x 1/2"
8
03040-205 Lockwasher,No.10
1
03040-206 Cover gasket
'l
03040-207 Soc hd PiPePlug, 1/8"
1
O3O4O-208 Base gasket
4
03040-209 Washer
4
03040-210 Cap screw,1/4-28x 1.000"
1
1 Front Panelgasket
O3O4O-21
1
03040-212 Elbow,l/8"
1
0 3 0 4 0 - 2 1 3 O i l s i g h tg l a s s
1
03040-214 Cover
1
03040-215 Motor bracket
4
03040-216 Shakeproofwasher,No.8
4
0 3 0 4 0 - 2 1 7 P h i lr d h d s c r e w , S - 3 2 x . 3 1 2
1
0 3 0 4 0 - 2 1 8 O i l f i l l e rc a p ( o p t i o n a l )
1
03040-219 Cover (optional)
Not Used
through 249
O}O4O-220

38

f,

5il'q

,o

v@EwmD
REFERENCENUTBERS 200 THROUGH 219 ARE ON TH|S pAGE\
zoo

REFERENCE
NUMBERS
220 THROUGH249
ARE NOT USED

OPTIONAL COVER

c
( S E E F I G U R E6 - 1 )
S H E E T5 O F 5

POWER PISTON
LINK

OASHPOT
LINK

F i g u r e6 - 1 . P a r t sl l l u s t r a t i o n
f o r t h e u G D i a lG o v e r n o r( s h e e t4 o f 5 )

39

U@EMED

P A R T SL IS T F OR FIGURE6- f ( Sheet5 of 5)
R E FN O .

P A R TN A M E

QUANTITY

03040-250 R e t a i n e r
03040-251 Frictiondrive cover
03040-252 F r i c t i o nd r i v es p r i n g
03040-253 Elasticstop nut, .250-28
03040-254 Frictiondrive spring
03040-255 Frictiondrive case
03040-256 Driveplate
03040-257 R o l l p i n , . 0 9 4d i a .x . 5 0 0
03040-258 Needlebearing
03040-259 Needlebearing
03040-260 Needlebearing
03040-261 Horiz.synch.adj. gear
03040-262 Taper pin, 6/0
03040-263 N e e d l eb e a r i n g
03040-264 Synch.adj. shaft
03040-265 L o c k w a s h e rN, o . 1 0
03040-266 Socket hd screw 10-32x 5/8"
03040-267 Synchronizerindicatorshaft
03040-268 S p r i n gc l i p
03040-269 S y n c h r o n i z eirn d i c a t o rg e a r
03040-270 I n d i c a t o rp o i n t e r
03040-271 Set screw
03040-272 K n o b
03040-273 P l u g
03040-274 D i a l p l a t e
03040-275 K n o b
03040-276 Taper pin, 6/0 x .750
03040-277 Shaft
03040-278 ldler shaft gear assembly
03040-279 S t r a i g h tp i n
03040-280 O i l s e a l
03040-281 K n o b
03040-282 L o a d l i m i tc o m p .s p r i n g
03040-283 Washer,.365OD
03040-284 PreformedPackingRing,
.239lD x .070

03040-285 B u s h i n gi n c l u d e di n i t e m2 0 9
03040-286 B u s h i n gi n c l u d e di n i t e m2 0 9
03040-287 Oil seal
03040-288 K n o b
03040-289 R o l l p i n , . 0 9 4d i a .x . 5 0 0
03040-290 Speeddroop collar
03040-291 L o a d l i m i ts p e e dd r o o p s p r i n g
03040-292 O i l s e a l
03040-293 Phillipshd screw,8-32x 3/8"

40

t
/\

V@EEED
REFERENCENUITIBERS2S0 THROUGH 293 ARE ON TH|S PAGE

{t

250

251 ,Tt

zszS
zse-@
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25sl

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see o_emt a l-

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- ,r/

,,,,
191 | loustmer

b fzcems

"&"D),P---,^.,,

,"
zgz
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263

291 |

2U
: . /

io

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(sEE FtcURE6-1)
SHEET4 OF 5

l/t/

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80| I

<
'll
279|

159
SEE OETAIL B
SHEET 3 OF 5

"

V"
-l

F i g u r e6 - 1 . P a r t sl l l u s t r a t i o n
f o r t h e U G D i a l G o v e r n o r( S h e e t5 o f 5 )

41

Y@6mED
S E C T I O N7
A U X I L I A R YE Q U I P M E N T
INTRODUCTION
A n u m b e r o f o p t i o n a la u x i l i a r yf e a t u r e sa n d
d e v i c e s a r e a v a i l a b l ef o r u s e w i t h t h e U G D i a l
G o v e r n o r .T h e s e d e v i c e sp e r m i t t h e g o v e r n o rt o
p e r f o r m o t h e r s e c o n d a r yf u n c t i o n ss u c h a s f u e l
l i m i t i n g ,l o w l u b e o i l p r e s s u r es h u t d o w n ,o r e f f e c t
a s h u t d o w n t h r o u g h a n e l e c t r i c a ls o l e n o i d .
A u x i l i a r y e q u i p m e n ts h o u l d b e s u p p l i e d a s
o r i g i n a l e q u i p m e n t o n t h e g o v e r n o r .l t i s
r e c o m m e n d e dt h a t t h e c u s t o m e r c o n t a c t
W o o d w a r dG o v e r n o rC o m p a n yi f f i e l d i n s t a l l a t i o n s
a r ed e s i r e d .
T h e f o l l o w i n g p a r a g r a p h sp r o v i d ea b r i e f
d e s c r i p t i o no f t h e a u x i l i a r ye q u i p m e n ta v a i l a b l e
a n d l i s t t h e m a n u a l sw h e r e d e t a i l e di n f o r m a t i o n
maybe obtained.

SYNCHRONIZER
MOTOR
A N D S O L E N O I DS H U T D O W N
E a r l y m o d e l s o f t h e s y n c h r o n i z e (r s p e e ds e t t i n g )
motor use an AC-DC Bodine motor, externally
m o u n t e d , a n d a v a i l a b l ei n a n y o f t h e f o l l o w i n g
v o l t a g e s :1 2 ,2 4 , 3 2 , 4 8 ,6 4 , 1 1 5 ,1 2 5 , 2 3 0a n d 2 5 0 .
t a g n e t )m o t o r
L a t e m o d e l su s e a P M ( p e r m a n e nm
using a 115 Vac, or 24 and 32 Vdc, internally
mounted.

Figure 7-'l shows a UG cover equipped with

s o l e n o i ds h u t d o w n l. t a l s os h o w st h e s y n c h r o n i z e r
( s p e e ds e t t i n g )m o t o r a s u s e d o n t h e U G D i a l
Governor.

Two models of the shutdown solenoidare

a v a i l a b l eO
. n e p r o v i d e ss h u t d o w nw h e n e n e r g i z e d
a n d t h e o t h e r w h e n d e - e n e r g i z e dE. a c h c a n b e
e q u i p p e dw i t h o r w i t h o u tl a t c h .S e e M a n u a l0 3 0 1 3
for set-upproceduresand partsbreakdown.

WARNING

T O P R O T E C TA G A I N S T P O S S B L E
P E R S O N A LI N J U R Y , L O S S O F L F E ,
and/or PROPERTYDAMAGE,DO NOT
use lhe shutdown solenoid lor
overspeed protection. Any lailure that
would cause the governor to be
i n o p e r a t i v ew o u l d a l s o c a u s e t h e
shutdown solenoid to be inoperative.
Overspeedprotection must come from a
unit completely separatefrom the UG
Governor.

BODINE SYNCHBO NIZER MOTOR

(EXTERNALLY MOUNTED)

03000-A-159

F i g u r e7 - 1 . U G C o v e r w i t h B o d i n e
S h u t d o w nS o l e n o i d

F i g u r e 7 - 2 . I n s t a l l i n gC o v e r w i t h B o d i n e S y n c h r o n i z e rM o t o r

42

T'@EEED
T h e s y n c h r o n i z e r( s p e e d s e t t i n g ) m o t o r i s
a v a i l a b l es e p a r a t e l yo r w i t h t h e s o l e n o i d
shutdown. lt provides the ability to remotely
c o n t r o l t h e g o v e r n o r ' ss p e e d s e t t i n g . T h u s ,
alternator frequenciescan be matched or, when
o p e r a t i n gi n d r o o p m o d e ,l o a d d i s t r i b u t i o nm a y b e
c h a n g e d a s r e q u i r e d ,r e m o t e l y .R e f e r t o m a n u a l
0 3 5 0 5 f o r t h e o a r t s r e f e r e n c ea n d l u b r i c a t i o n
guide.

s o l e n o i d . T h e r e a r e s e v e r a ls u p p l y v o l t a g e s
a v a i l a b l ef o r t h e s o l e n o i d .C a l l o r w r i t e t h e
Woodward Governor Company, addresseslisted
o n t h e b a c k c o v e r o f t h i s m a n u a l ,f o r a d d i t i o n a l
i n f o r m a t i o nA. c o n d u i tc o n n e c t i o na n d a p i n - t y p e
c o n n e c t o ra r e a l s oa v a i l a b l e .

F i g u r e 7 - 2 s h o w s t h e m e t h o d f o r i n s t a l l i n gt h e
c o v e r ( 2 6 7 )w h e n e q u i p p e dw i t h a m o t o r .T u r n t h e
s y n c h r o n i z e rk n o b t o a l i g n t h e c l u t c h w i t h t h e
motor'sshaft as the cover is loweredinto position.
Figure 7-3 shows the completedUG8 Dial
G o v e r n o r e q u i p p e dw i t h a B o d i n e S y n c h r o n i z e r
Motor.

f ousing
F i g u r e T - 4 . T o p V i e w o f W e a t h e r p r o oH
w i t h P M S y n c h r o n i z e rM o t o r a n d
S h u t d o w nS o l e n o i d

Figure 7-5 shows the UG8 governorwith PM

motor,weatherproofhousing.

0300-a-160

F i g u r e7 - 3 .

U G 8 D i a l G o v e r n o r E q u i p p e dw i t h
B o d i n eS y n c h r o n i z eM
r otor

P M S Y N C H R O N I Z E RM O T O R
WITH HOUS'NG
F i g u r e 7 - 4 s h o w s a U G 8 D i a l G o v e r n o rw i t h a
p e r m a n e n t m a g n e t s y n c h r o n i z e rm o t o r ( s p e e d
s e t t i n gm o t o r )a n d a s h u t d o w ns o l e n o i d e, n c l o s e d
i n a w e a t h e r p r o ohf o u s i n g .
A t r e s t , t h e p e r m a n e n tm a g n e t m o t o r a c t s a s a
b r a k et o r e s i s ts p e e dc h a n g e sd u e t o v i b r a t i o n s .
T h e w e a t h e r p r o o fh o u s i n g f o r t h e P M
s y n c h r o n i z e rm o t o r c a n a l s o b e e q u i p p e dw i t h a
shutdown

F i g u r e7 - 5 . U G 8 G o v e r n o rw i t h
W e a t h e r p r o oHf o u s i n g

43

Y@EEED
A n e x p l o s i o n - p r o o fh o u s i n g ( U L l i s t e d ) i s a l s o
a v a i l a b l ef o r u s e i n h a z a r d o u sa r e a s .T h e h o u s i n g
i s e q u i p p e d w i t h a 2 4 V d c p e r m a n e n tm a g n e t
motor and, as an option, a 24 Vdc shutdown
s o l e n o i d( e n e r g i z et o s h u t d o w nt y p e o n l y ) .

For more information,see manual36042.

SEAL

SEAL

NUT
IIAGNETIC PICKUP

L O W L U B EO I L P R E S S U R E
SHUTDOWN
Figure 7-6 shows a low lube oil pressure
shutdown. This device stops the prime mover
w h e n e n g i n eo i l p r e s s u r ef a l l s b e l o w a s a f e l e v e l .
T h e r ei s n o a d d i t i o n ael x t e r n a l i n k a g er e q u i r e d .
F o r m o r e i n f o r m a t i o na n d p a r t s i l l u s t r a t i o ns, e e
M a n u a l0 3 0 1 6 .

CASE WALL
03000-8.8

F i g u r e T - 7 . M a g n e t i cS p e e dP i c k u p

WARNING

TO PROTECTAGAINST POSSIBLE
P E R S O N A LI N J U R Y , L O S S O F L I F E ,
and/or PROPERTYDAMAGE,DO NOT
use the magnetic speed pickup for
overspeed protection. Any lailure thal
would cause the governor to be
i n o p e r a t i v ew o u l d a l s o c a u s e t h e
magnelic pickup to be inoperative.
Overspeedprolection musl come from a
unit completely separate from the UG
Governor.

03000-a-67

F i g u r e7 - 6 .

L o w L u b e O i l P r e s s u r eS h u t d o w n

M I C R OS W I T C H E SA N D
W I R I N GH A R N E S S
M i c r o s w i t c h e sa r e m o u n t e do n t h e s y n c h r o n i z e r
indicator shaft as shown in Figures7-8 and 7-9.
A l s o s h o w n a r e t h e w i r i n g c o n n e c t i o n sa n d
t e r m i n a sl t r i p .

WARN'NG
The micro switchesare used in one of two ways.
Any failurethat would causethe governor
to be inoperativewould also cause the
shutdownsolenoidto be inoperative.

M A G N E T I CS P E E DP I C K U P
The magneticspeed pickup monitors governor
speed without having to provide an additional
drive pad on the engine.Figure7-7 shows the
a s s e m b l yo n a U G g o v e r n o r .

44

1 . T h e y e n e r g i z ea l i g h t w h i c h i n d i c a t e st h e
m o t o r h a s r e a c h e di t s m i n i m u mo r m a x i m u m
speedsettingposition.
I n s t e a do f e n e r g i z i n ga l i g h t , t h e y m a y b e
used to shut off the electric motor after
r e a c h i n gt h e m i n i m u m o r t h e m a x i m u m
speedsettingposition.
When used to shut off the electricmotor,
micro switchesalso protectthe synchronizer

Y@EEED
( s p e e ds e t t i n g ) m o t o r s h o u l d t h e o p e r a t o r
r u n t h e s p e e da d j u s t m e ntto i t s l i m i t
The externalwiring to the governor is not
p r o v i d e db y W o o d w a r dG o v e r n o rC o m p a n y a n d
s h o u l d b e w i r e d i n t o t h e c o n n e c t o rf o r t h e
p a r t i c u l aar p p l i c a t i o n
as required.

o
03000-a-'t62

F i g u r e7 - 8 .

M i c r oS w i t c h e sa n d W i r i n g

Figure7-9.

Wiring Harnesson Cover

45

MANUALS
ORDERING
TO ORDERMANUALS,WRITETO:
WoodwardGovernorCompany
AttentionTechnicalServices
P.O.Box1519
FortCollins,Colorado80522-1519
PLEASEINCLUDETHE FOLLOWINGINFORMATION:
o Yourname
o Thenameandaddressof yourcompany
(writeon letterhead
or includebusinesscardif available)
o Theaddresswhereyouwantthe manualssent(ifdifferent
fromabove)
o Thequantitywantedof eachmanual
Themanualnumber(s)
youareordering
ol the manual(s)
OR
o Thepartnumberandserialnumberfromthe nameplateon yourWoodward
Equipment
-

THEREIS NO CHARGEFOR MANUALSORDEREDIN SMALL QUANTITIES

I-

WOODWARD GOVERNOR COMPANY

ENGINE CONTROLS/TURBOMACHINERY CONTROLS
o Phone:(303)482-5811o Facsimile:(303)498-3058
1000EastDrakeRd. o P.O.Box 1519o FortCollins,CO 80522-1519
GULF STATES REGIONAL OFFICE: . Houstqr,fi. Phone:Ql3)ffi-2211
EAST COASI RFfIONAL OFFICE. Nonisown, PA . Phqre:(215)278-1900. SOUTHFiASTRDGIONAL OFFICE. Bimingham,AL. Phone:(205)987-8686
U.S.A.. Phone:(303)482-5811. Facsimile:(303)498-3050
INTERNATIONAL OPERATIONS. 1000EastDrakeRd. . P.O.Box 1519. FortCollins,CO 80522-1519,
INTERNATIONAL LOCATIONS :
Wiesbaden,
GermlnJr. Phone'49 61179 0l 46 . Facsimile:49 6l I 79 Ol 55
o Verissieux
Cedex,FYence. Phone:33 78 @ 69 47 . Facsimile:3379 00 46'16
Slough,Englend Phone:44-753-?835.Facsimile:44-753-76199
-2322.
o
S.P.,Brzll . Phone:55-192424788. Facsimile:55-192-42-2992
N.S.W.Austrll,e Phqre:6l-2-758
Facsimile:6l-2-7fi6272
Cempinas,
Kingsgrove,
frbaguq ChjbaJref\Jepan. Phcre:81476ry3.46f.1.Facsimile:8147,93:l%9o H'rcgoken,Jpn. Ihorc:81-7892&8321' Facsimile:81:18928-$n
o Hooforp,The Netherlnds. Phqre:31-2503-l3Zl. Facsimile:31-2503-36529
3l:70-3656297
TheHague,TheNethcrlnds. Bhqre:31-70-3169660.
Facsimile:
IIYDRALILIC TURBINE CONTROIS . StevensPoint,WI . Phqre: (l 15) 344-2350. Facsimile:(l lS) 34453
CORFORATE HEADQUARTERS/AIRCRAFT COTROLS . Rockford,IL . Phone:(815)8771441. Facsimile:(815)8774001

- reloeo

\-

S H U T D O WSNO L E N O I D
\,

FOR
UG GOVERNOR

\-

WOODWARDGOVERNORCOMPANY
03013N

WANN'}IG
PERTA|XITGfO THE WORKTO BE
READ THIS ENTIRETANUAL AND ALL OTHERPUBTICATIOXS
PERFORTEOBEFOREII{STALLING,OPERATIIIG,OR SERVICIXGTI{I3 EOIJIPIEXT. PRACTICE ALL
FAILURETO FOLTOUIXSTRUCTIONSCAN
PLANTAXD SAFETVINSTRUCTIOilSAND PRECAUTIONS.
DATAGE.
CAUSEPERSONALIilJURV AND/ORPROPERTY

\t

TABLE OF CONTENTS
Page No

Title
Description
Operation
D e - E n e r g i z e t o S h u t D o. w n
E n e r g i z e t o S hD
u to w n

..... '.1
....'...1
........1
......1

Page No.

Title
Adjustments
D e - E n e r g i z eSt oh u tD o w nM o c l e l
E n e r g i zt eo S h u tD o w nM o d e l
S o l e n o i dS u p p r e s s i o O
n r o c l e.
PartsList

......'l
..........1
........3
. .. . .. . ..4
.........5

T h e l e t t e r d e s i g n a t i o nf o l l o w i n g t h e m a n u a l n u m b e r i s c h a n g e d t o t h e n e x t l e t t e r i n
alphabeticalorder when an importantrevisionis madeto the manual.

T E X T C H A N G E SA R E I N D I C A T E DB Y A B L A C K L I N EA L O N G S I D ET H E T E X T

LISTOF ILLUSTRATIONS
Figure No.

PageNo.

to Shut Down Model

1 De-Energize
... . .. .. .2
W i t hL a t c h
2 Energizeto Shut Down Model
.........3
W i t hL a t c h
3 E n e r g i z et o S h u t D o w n M o d e l ,
W i t h o uLt a t c hV, i b r a t i oRn e s i s t a n t . . . .. .. . . . . . . 4
.....4
4 SolenoidSuppressionDiode.

Figure No.
C o v e r A s s e m b l y( S h o w nw i t h S P e e d
Motor)
Setting
6 E n e r g i z et o S h u t D o w n M o d e l
7 D e - E n e r g i zteo S h u t D o w n M o d e l
8 E n e r g i z et o S h u t D o w n M o d e l ,
V i b r a t i oR
ne s i s t a n t

Page No

......6
.. . ' '6
.. . .. . .7
...... '.8

WANN'NG

This shutdown solenoid must not be used lor

overspeed shutdown because overspeed could be
caused by failure of the governor system. The
shutdown could be made inoperable by the same
governorfailurewhich causedthe overspeed.Engine
overspeed can cause property damage, personal
injury and death. Use the shutdown only lor
protectionfrom low oil pressure,high oil pressure,
water lemperalure, or other system protection.
Woodward Governor Company reserveslhe right to update any portron ol lhis publrcattonal any time Informatton provrded by
Woodward Governor Company is believedto be correct and reliable.However,no responsrbilrtyasassumedby Woodward Governor
Company lor ts use unlessotherwiseexpresslyunderteken.

o WoodwardGovernorCompany, 1985
All RightsReserved

Y@EMED
S H U T D O W NS O L E N O I DF O R U G G O V E R N O R
DESCRIPTION
A s h u t d o w ns o l e n o i di s a v a i l a b l ef o r u s e o n t h e d i a l t y p e
U G 8 , U G 3 2 ,a n d U G 4 0 g o v e r n o r sT. w o b a s i cm o d e l sa r e
a v a i l a b l eO
. n e w i l l c a u s es h u t d o w nw h e n e n e r g i z e da n d
t h e o t h e rw h e n d e - e n e r g i z e dI n. t h e e n e r g i z et o s h u t d o w n
mode, a vibration resistantmodel is also available.
H o w e v e r ,t h e l a t c h i n g d e v i c e i s n o t a v a i l a b l ew i t h t h e
v i b r a t i o nr e s i s t a nt y p e s h u t d o w ns o l e n o i d .
WANN'NG

\'

The shutdown solenoid musl nol be used as

an overspeed protective device. Overspeed
protection must come from a unit entirely
separatefrom the UG governor.
Both basic models can be equipped with a latching
d e v i c e .W i t h a l a t c h i n gd e v i c e ,t h e s o l e n o i dm u s t b e s e t
m a n u a l l yt o a l l o w r e s t a r t i n gw h e n n o v o l t a g ei s a v a i l a b l e .
WANNING
After the unit is started check that the
solenoid lock pin has moved to the unlatched
position.
l f v o l t a g e i s a v a i l a b l e ,y o u m a y s t a r t w i t h o u t m a n u a l
r e s e t i f t h e s o l e n o i dw i t h l a t c h i s o f t h e e n e r q i z e - t o - r u n
Iype.

The solenoid can be supplied with various coils to

a c c o m m o d a t et h e m o r e c o m m o n d c v o l t a g e s .l f
o p e r a t i o no n a c i s d e s i r e d ,r e c t i f i e r sc a n b e i n c o r p o r a t e d
i n t h e c o v e r a s s e m b l yt o r e c t i f ye i t h e r1 1 0o r 2 2 0v o l t st o
d c . I n a d d i t i o n , o t h e r a c v o l t a g e sc a n b e a d a p t e d o n
s o e c i a lo r d e r .
T h i s s p e c i a lg o v e r n o rc o v e r ,r e q u i r e df o r m o u n t i n gt h e
u n i t , i s a v a i l a b l ew i t h o r w i t h o u tt h e a c c o m m o d a t i o nfso r
t h e s p e e da d j u s t i n gm o t o r .
In both models the solenoid plunger moves the load
limt strap down to effect shutdown. A detailed
d e s c r i p t i o no f t h e o p e r a t i o nf o r t h e e n e r g i z et o s h u t d o w n
a n d t h e d e - e n e r g i z et o s h u t d o w nm o d e l si s g i v e n i n t h e
f o l l o w i n gp a r a g r a p h s .
OPERATION
D E - E N E R G I Z ET O S H U T D O W N M O D E L : T h e d e e n e r g i z et o s h u t d o w n m o d e ls h o w n i n f i g u r e1 w i l l s h u t
t h e e n g i n ed o w n o n l o s so f c u r r e n t o t h e s o l e n o i dT. h e
s o l e n o i dp l u n g e rm o v e su p t o a l l o wt h e e n g i n et o r u n .
T o s t a r t a n e n g i n e w h e n n o c u r r e n t i s a v a i l a b l ef o r
e n e r g i z i n gt h e s o l e n o i d , l i f t t h e s o l e n o i d p l u n g e r

m a n u a l l yb y m e a n so f t h e s h u t d o w n l a t c h k n o b ( f i g u r e
1 ) . A s i t a p p r o a c h e st h e t o p o f i t s s t r o k e ,t h e l o c k p i n
m a y b e p r e s s e di n w i t h t h e f i n g e r t o l a t c h t h e s h u t d o w n
l a t c h k n o b j u s t b e l o w i t s u p p e r p o s i t i o n .T h i s p e r m i t s
s t a r t i n g a n d r u n n i n g t h e e n g i n e , b u t n o p r o t e c t i o ni s
provided.
W h e n c u r r e n t i s a p p l i e dt o t h e s o l e n o i d ,i t w i l l m o v e t o
t h e f u l l u p w a r dp o s i t i o n u, n l o a d i n gt h e l o c k p i n w h i c h i s
m o v e d o u t w a r d b y t h e c i r c u l a rl a t c h s p r i n g .W i t h l o s s o f
c u r r e n t ,t h e l o a d s p r i n gw i l l c a u s et h e s o l e n o i dp l u n g e r
to move down, lifting the governor pilot valve and
c l o s n go f f f u e l .

WARN'NG

During start-up,if for any reasonthe solenoid

has no current and the lock-pin is latched
the solenoid will be inoperative.
T h e d e - e n e r g i z et o s h u t d o w n m o d e l c a n a l s o b e
supplied without the latching feature, generally for
o p e r a t i o ni n a u t o m a t i cp l a n t s .T h i s a r r a n g e m e n its a l s o
s h o w ni n f i g u r e1 .
E N E R G I Z ET O S H U T D O W N M O D E L : T h e e n e r g i z et o
s h u t d o w n m o d e ls h o w n i n f i g u r e s2 a n d 3 w i l l s h u t t h e
e n g i n ed o w n a s c u r r e n ti s a p p l i e d( e v e nm o m e n t a r i l yt)o
the solenoid.The solenoidplungermovesdownwardthrough
a tapered plunger stop which contains seven spring
loaded steel balls. The solenoid is preventedfrom
r e t u r n n gb y t h e b i n d i n ga c t i o no f t h e s t e e lb a l l sa g a i n s t
t h e s h u t d o w nr o d .
T o r e s t a r tt h e e n g i n e , r e t u r n t h e p l u n g e rt o i t s o r i g i n a l
p o s i t i o n b y p r e s s i n gt h e r e s e t b u t t o n ,w h i c h f o r c e s t h e
steel balls away from the plunger and allows spring
force to push the load limit strap and the solenoid
p l u n g e rt o t h e i r u p p e r m o s tp o s i t i o n s .
The energizeto shut down model can be supplied
w i t h o u t t h e l a t c h i n g f e a t u r e .T h i s a r r a n g e m e n ti s a l s o
s h o w ni n f i g u r e2 .
ADJUSTMENTS
S o l e n o i d s h u t d o w n d e v i c e ss u p p l i e d o n g o v e r n o r sa s
o r i g i n a le q u i p m e n ta r e a d j u s t e da t t h e f a c t o r y .H o w e v e r ,
i t w i l l b e n e c e s s a r yt o m a k e t h e f o l l o w i n g a d j u s t m e n t s
o n u n i t s w h i c h a r e t o b e i n s t a l l e do n q o v e r n o r sa l r e a d v
nservce.
DE-ENERGIZE
T O S H U T D O W N M O D E L : S e e f i g u r e' t .
1 . P o s i t i o nt h e s h u t d o w nr o d a s s e m b l yi n t h e s o l e n o i d
p l u n g e r w i t h t h e e n d o f t h e p l u n g e rf r i c t i o n s c r e w

U@D

SETSCREW
t / 16-27
PIPEPLUG
I.OCK NUT
SOLENOID
GUIDE
PTUNGER

r /8 rNcH

RODEXTENSION
IATCH PIN

SPRING
CIRCUI.AR

L O C KN U T

ST{UTDOWNLATCHKNOB
SHUTDOWNROD

r /a rNcx

SOLENOID

colt
sotENotD

sorENorD
cort
SOLENOIDPLUNGERGUIDE

PLUNGER

SHUTDOWN
ROD

SOTENOIDPI.UNGER

T O S H U T D O W NM O D E L
DE-ENERGIZE
WITHOUT LATCH

\t

PI.UNGERFRICTIONSCREW
GOVERNORCOVER
SHUTDOWN SPRING
SHUTDOWN ROD
LOAD LIMIT STRAP
(IN GOVERNM)

D E - E N E R G I Z ET O S H U T D O W N M O D E L
W I T H LATCH
F I G U R E1
1 / 8 o f a n i n c h i n s i d e t h e s o l e n o i dp l u n g e r n o s e a s
s h o w n i n f i g u r e 1 . T h i s a d j u s t m e n its n e c e s s a r yo n l y
w h e n t h e s h u t d o w n d e v i c eh a s b e e n d i s a s s e m b l e d
f o r c l e a n i n go r r e p l a c i n gp a r t s .N e w a s s e m b l i e s e n t
out from the factory will have this adlustment
completed.
2. Loosen the lock nut and, with the solenoid
d e - e n e r g i z e dt,u r n t h e s o l e n o i d p l u n g e r g u i d e
c l o c k w i s e u n t i l i t i s t i g h t a g a i n s tt h e p l u n g e r .T h e
p l u n g e r ,a t t h i s t i m e , s h o u l d b e s e a t e da g a i n s tt h e
g o v e r n o rc o v e r .B a c k o f f t h e s o l e n o i dp l u n g e rg u i d e
3 t o 4 t u r n s a n d t i g h t e nt h e l o c k n u t .

3. Attach the cover assembly (including shutdown

d e v i c e )t o t h e g o v e r n o rc a s e .
4. Remove the set screw from the hole in the rod
extension. With the governor in operation and
c o n t r o l l i n gt h e s p e e d ,d e - e n e r g i z et h e s o l e n o i da n d
use a screwdriverto turn the shutdown rod assembly
clockwise until the governor just starts to shut

down, then screw the shutdown rod down one

a d d i t i o n a tl u r n .
D e - e n e r g i z et h e s o l e n o i d .L i f t t h e s h u t d o w n l a t c h
k n o b a n d p r e s si n t h e l a t c h p i n s o t h e p i n r e m a i n s
e n g a g e dw h e n t h e k n o b i s r e l e a s e d .
o . W i t h a s c r e w d r i v e irn t h e s l o t o f t h e s h u t d o w nr o d t o

prevent it from turning, screw the rod extension

c l o c k w i s eu n t i l t h e s o l e n o i dp l u n g e r i s p u l l e d u p
a g a i n s tt h e s o l e n o i dp l u n g e rg u i d e .
E n e r g i z et h e s o l e n o i d .B a c k o f f t h e r o d e x t e n s i o n
. ack off 1/4 turn more.
u n t i l t h e l a t c h p i n r e l e a s e sB
L o c k i n p l a c ew i t h t h e # 1 0 - 3 2s e t s c r e w .
8 . C h e c k f o r n o r m a l o o e r a t i o nw i t h t h e s o l e n o i d
e n e r g i z e da n d f o r s h u t d o w n w h e n t h e s o l e n o i d i s
d e - e n e r g i z e dC. h e c k t h e l a t c h i n gd e v i c et o s e e t h a t
i t w i l l l a t c h u p t o a l l o w s t a r t i n ga n d u n l a t c h w h e n
t h e s o l e n o i di s e n e r g i z e d .

\t

UADMED
RESET
EUTION
PI.UNGER
S T O PP t U G

RESET
BUTTONRETAINER

BALL
IOCK NUT
PI.UNGER
STOP
S H U T D O W NR O D
PLUNGER
FRICfIONSCREW

SHUTDOWN

SOI.ENOIDPTUNGER

r /a rNcx

SOTENOID
P T U N G EG
RUIDE
l/8 |NCH
OIL CUP

SOTENOID

sorENotDcoil.
E N E R G I Z ET O S H U T D O W N M O D E L
WITHOUT LATCH

GOVERNORCOVER
S H U T O O W NR O D
LOAD LIMIT STRAP
(IN GOVERNOR)

ENERGIZE TO SHUT DOWN MODEL

WITH LATCH
FIGUR
E2
n s t r u c t i o n s5 , 6 , a n d 7 p e r t a i n i n gt o t h e l a t c h
ad,ustments.
E N E R G I Z ET O S H U T D O W N M O D E L : S e e f i g u r e2 .
1 . P o s i t i o nt h e s h u t d o w nr o d a s s e m b l yi n t h e s o l e n o i d
p l u n g e r w i t h t h e e n d o f t h e p l u n g e rf r i c t i o n s c r e w
1 / 8 o f a n i n c h i n s i d et h e p l u n g e rn o s ea s s h o w n i n
f i g u r e 2 . T h i s a d j u s t m e n ti s n e c e s s a r yo n l y w h e n t h e
s h u t d o w nd e v i c eh a s b e e nd i s a s s e m b l efdo r c l e a n i n g
o r r e p l a c i n gp a r t s . N e w a s s e m b l i e ss e n t o u t f r o m
t h e f a c t o r yw i l l h a v et h i s a d j u s t m e n ct o m p l e t e d .
2. Attach the cover assembly (including shutdown
d e v i c e )t o t h e g o v e r n o rc a s e .
3. Unscrew the knurled reset button retainer and
removethe reset button and spring. Loosenthe lock
n u t . T u r n t h e p l u n g e rs t o p d o w n u n t i l t h e s o l e n o i d
p l u n g e r i s t i g h t a g a i n s tt h e s o l e n o i dp l u n g e rg u i d e .
B a c k o f f 3 t o 4 t u r n s .T i g h t e nt h e l o c k n u t .
4. Wth the governor in operation and controlling
s p e e d , e n e r g i z et h e s o l e n o i d a n d t u r n t h e s l o t t e d

shutdown rod clockwise until shutdown occurs.

Turn clockwise one more turn past the point of
s h u t d o w n ,a n d i n s t a l lt h e s p r i n g , r e s e t b u t t o n a n d
reset button retainer.
5 . C h e c k f o r n o r m a l o p e r a t i o nw i t h t h e s o l e n o i d
d e - e n e r g i z e d ,m a k i n g s u r e t h e g o v e r n o r i s n o t
s l u g g i s hi n a d d i n gf u e lt o p i c k u p l o a d .
6 . E n e r g i z et h e s o l e n o i d .A f t e r s h u t d o w n ,c h e c k t o s e e
t h a t t h e g o v e r n o rr e m a i n si n o p e r a t i v eu n t i l t h e l a t c h
i s r e l e a s e db y p r e s s i n gt h e r e s e t b u t t o n . R e c h e c k
f o r n o r m a lo p e r a t i o n .
T h e e n e r g i z et o s h u t d o w n m o d e l w i t h o u t t h e l a t c h i n g
f e a t u r e i s a d j u s t e di n t h e f o l l o w i n g m a n n e r ( s e ef i g u r e
2 ) : R e m o v et h e p l u n g e r s t o p p l u g a n d , w i t h t h e u n i t
r u n n i n g , e n e r g i z e t h e s o l e n o i d .W i t h t h e g o v e r n o r I n
o p e r a t i o n a n d c o n t r o l l i n gs p e e d , t u r n t h e s l o t t e d
s h u t d o w n r o d c l o c k w i s eu n t i l s h u t d o w n o c c u r s . T u r n
c l o c k w i s eo n e m o r e t u r n p a s t t h e p o i n t o f s h u t d o w n .
R e p l a c et h e p l u n g e r s t o p p l u g a n d s c r e w i t d o w n u n t i l
the solenoid plunger is tight against the solenoid
p l u n g e rg u i d e .B a c k o f f 3 t o 4 t u r n s o n U G 5 . 7 ,U G g ,a n d

UEEMED

U G 1 2 . 8g o v e r n o r so r 4 t u r n s o n U G 3 2 o r U G 4 0 g o v e r n o r s ;l o c k i n p l a c ew i t h t h e l o c k n u t . M a k ef i n a l c h e c ka s
describedin 5 and 6 above.

E N E R G I Z ET O S H U T D O W N M O D E L ,W I T H O U T
LATCH,VIBRATIONRESISTANT:Seefigure3'

8. Check that solenoid shuts down governorwith

800/o
of rated voltageaPPlied.
9. Check for normal operation with the solenoid dee n e r g i z e dm a k i n gs u r et h e g o v e r n o ri s n o t s l u g g i s h
i n a d d i n gf u e l t o P i c k u P t h e l o a d '
1 0 . l f t h e g o v e r n o ri s s l u g g i s hi n a d d i n gf u e l t o p i c k u p
the load, check for excessivedrag in the movement
o f t h e s o l e n o i d p l u n g e r , a m i s a l i g n e ds h u t d o w n
rod, a bent plunger guide, or a solidified
p r e s e r v a t i v el u b r i c a n to n a n y o f t h e m o v i n g p a r t s '
Repeat the adustment procedure described in 1
through 9 above.
SOLENOID SUPPRESSION DIODES

SOLENOID PLUNGER

WASHEF

SOLENOIO PLUNGER GUIOE

S o l e n o i dc o i l s u s e d b y W o o d w a r dG o v e r n o rC o m p a n y '
whether operated on ac or dc, have two diodes wired in
t h e c i r c u i ta s s h o w n i n f i g u r e4 .
D i o d e sn o t o n l y r e c t i f ya c t o s u p p l y d c t o s o l e n o i dc o i l s
b u t t h e y a l s o p r o v i d e s h o c k h a z a r d p r o t e c t i o nw h e n
u s e d o n a c , w h e n t h e a c i s d i s c o n n e c t e da t a p e a k o f a
c y c l e . ( C o u n t e r - E M Fi s g e n e r a t e dw h e n t h e p o w e r i s
r e m o v e df r o m t h e c o i l )

WIRE SPLICE
AOJUSTTNGNUT

A (+)

soLEl{otD
SHUTDOWN
B (-)

T O S H U T D O W NM O D E L
ENERGIZE
W I T H O U TL A T C H ,V I B R A T I O NR E S I S T A N T
F I G U R E3
W i t h g o v e r n o r c o n t r o l l i n ga n d g o v e r n o r c o v e r
r e m o v e d : L o o s e n t h e l o c k n u t .T u r n t h e p l u n g e r
s t o p a l l t h e w a y i n t o i m m o b i l i z et h e p l u n g e r 'a n d
r u n t h e a d j u s t i n gn u t a l l t h e w a y i n t o s e c u r e a
s t a r t i n gp o s i t i o n .
Place cover gasket between governor and cover,
a n d i n s t a l lc o v e r .
K e e p e x t e n d i n gt h e a d j u s t i n gn u t g r a d u a l l yu n t i l
g o v e r n o rj u s t s h u t s d o w n w i t h t h e c o v e r c o r r e c t l y
installed.
W h e n t h i s a d i u s t m e n ti s o b t a i n e d ,e x t'le n d n u t o n e
turn, or a lttlemore--butnot morethan 1/2 turn--to
a l g nt h e s l o t t o t h e r o l l - p i nh o l e .
S e c u r en u t w i t h r o l l - P i n .
A t t a c h t h e c o v e r a s s e m b l y( i n c l u d i n gs h u t d o w n
d e v i c e )t o t h e g o v e r n o rc a s e .
B a c k o u t t h e p l u n g e rs t o p f o u r t u r n s a n d l o c k i n
p l a c ew i t h t h e l o c k n u t .

BLACK
0 3 0 0 0 - A - 3 13
5-9 -89GA

Diode
F i g u r e4 . S o l e n o i dS u p p r e s s i o n

WANN'NG
Open or shorted diodes impair operation ol
the shuldown solenoid.
D i o d e s s h o u l d b e u s e d o n d c p o w e r e d s o l e n o i dc o i l s
a l s o b e c a u s eo f c o u n t e r - E M F .

INFORMATION AND PARTSREPLACEMENT

W h e n r e q u e s t i n gi n f o r m a t i o nc o n c e r n i n gt h e s o l e n o i d
s h u t d o w nd e v i c e ,o r w h e n o r d e r i n gr e p l a c e m e npt a r t s ,i t
i s e s s e n t i a lt h a t t h e f o l l o w i n g i n f o r m a t i o na c c o m p a n y
the request.
1 . S e r i a ln u m b e ro f g o v e r n o r( o n n a m e p l a t e ) .
2 . T h e p a r t r e f e r e n c en u m b e ra s s h o w n i n t h i s m a n u a l .
3 . A d e s c r i p t i o no r n a m eo f t h e p a r t .

Y\@EEED
P A R T SL I S T ( S E EF T G U R E S
5, 6,7, and g)

REF.
NO.
03013-1
03013-2
03013-3
03013-4
03013-5
03013-6
03013-7
03013-8
03013-9
03013.10
0 3 0 1 311
03013-12
03013-13
03013-14
03013-15
0 3 0 1 31 6
03013-17
03013-18

03013.1I
03013-20
03013-21
03013-22
03013-23
0301324
03013-25
03013-26
o3013-27
03013.28
03013-29
03013-30
03013 31
0 3 0 1 33 2
03013-33
03013-34
03013-35
03013-36
03013-37
03013-38
03013-39

P A R TN A M E
C a b l eC l a m p
Plug
S c r e w# 4 - 4 0x 5 / 1 6 F i l . H d .
Receptacle
Cover
S e tS c r e w# 1 O - 3 2x 1 1 4
# 1 0 - 3 2 x 3 1 4 F i l .H d .
# 1 0 S p l i t L o c kW a s h e r
Grommet
Motor SealSpring
OilCup
B o d i n eM o t o r
SolenoidCase
L o a dS p r i n g
I n s u l a t i nP
g aper
S o l e n o i dC o i l
P a r a l l eCl o n n e c t o r
W i r e ,W h i t eF l a m e n o-l 1 0 5 o C
.1100.D.
WireStrap-2Wires
Screw,Fil. Hd. #8-32 x 114
ClearTubing 314" Long
A i r G a pW a s h e r
S o l e n o i dP l u n g e r
S o l e n o i dP l u n g e Lr o c k i n gP i n
Not used
r uide
S o l e n o i dP l u n g eG
ShutdownSpring
Washer(ShutdownSpring
Retainer)
R o l lP i n 1 1 1 6 x 1 1 4
P l u n g eF
r r i c t i o nS c r e w
ShutdownRod
R o l lP i n
P l u n g e rG u i d e B u s h i n g
r uide
S o l e n o i dP l u n g eG
LatchSpring
S n a pR i n g
ShutdownLatch Knob
LockPin
Rod Extension

NO.
REO'D.
1
I
4
1
1
'|
4
4
1
1
t
I

1
,|
I

1
'l
2
AR
2
2
2
'l
1
'l
1
1
1
1
1
1
1
2
'l
1
1
1
1
1

REF.
NO.
03013-40
03013-41
03013-42
03013-43
03013-44
03013-45
03013-46
03013-50
03013-51
03013-52
03013-53
03013-54
03013-55
03013-56
03013-57
03013-58
03013-59
03013-60
03013-61
03013-62
03013-63
03013-64
03013-65
03013-66
03013-67
03013-68
03013-69
03013-70

03013-71
03013-72
03013-73
03013-74
03013-75
03013-76
03013-77
03013-78

P A R TN A M E
Lock Wire
1 1 1 6 P i p eP l u g
J a mN u t
r uide
S o l e n o i dP l u n g eG
R
o
d
Shutdown
SolenoidCase
r uide
S o l e n o i dP l u n g eG
B a l l L o a d i n gS p r i n g
Washer
L a t c hS p r i n g
ShutdownPushButton
P u s hB u t t o n R e t a i n e r
P l u n g eS
r t o pP l u g
"o" Rins
AdjustingScrew
S n a pRi n g
S h u t d o w nR o d
S o l e n o i dP l u n g e r
S o l d e r i nS
g h i e l dW a s h e r
V a r n i s h eT
d u b i n g3 / 1 6 L o n g
ShutdownRod
Latch Rod
S n a pRi n g
WasherAssembly
B a Il
B u s h i n gB, a l l R e l e a s e
P l u n g eS
r top
D i o d e s( F i g u r e4 )
(Not shownin Parts
Breakdown)
P l u n g e rS t o p A s s e m b l y
Preformed Packing
. 7 3 9l . D . x . 0 7 0
W a s h e r. 8 7 5x 1 . 1 2 5x 0 . 4 7S . S
P l u n g e rA s s e m b l y
R o l l P i n . 0 6 2D i a .x . 3 1 2S . S .
S o l e n o i dC o i l A s s e m b l y
S o l e n o i dP l u n g e rG u i d e
Assembly
A d j u s t i n gN u t

NO.
REO'D.
AR
I

I
1
1
1
1
1
1
1
1
1
1
2
1
1
I
I

2
2
1
1
1
1
7
1
1

1
1
1
'l

'l

Y@EEED

iff:
i 9--'

!'

"A-B-C"

t0
I
L

9 l

v++
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l

lgH

I e-501 g

tl

I
.

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n

i FillH-1

I iil-,,1
n-] e

lfiH]
i
030qlB-47

&u wlrrour

LATCH

i FI

i lulr,
lr--)

COVER ASSEMBLY
(SHO\IN
WITH SPEEDSETTINGMOTOR)

o3flo-&4e

WITH LATCH
F i g u r e5

ENERGTZETO SHUT DOWNMODET

F i g u r e6

L
6

U@EEED

b
--'1

,,-]@i

J+
I
ril
i
i"9'.,'1.)
o

!!)gt,*W

IF\J

I '81==Zf
Hr-cl) t',tO
Ir I F l r r !r- - g

t ru, li"-@
gl

-I

r'.",.

rr1r.:
e

l$-

Lv/
:

lr-{9

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l a
r

ilJ
''--lli I s--.o

l l i l

l l l l r l

iliiil

'{L,,l "-Jl"
n
/ I
2
ll lF"i

[J{,I,YITHOUT
LATCH

i llJ i '+;
@
L
H
'
E ) r

B,- , . 9 _9--u
ll

o30(XlB-48

WITH LATCH
DE.ENERGIZE
T O S H U T D O W NM O D E L
F i g u r e7

v@6mED

.4

42

71

72

73

k
vv

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21

W I T H O U TL A T C H _ V I B R A T I O NR E S I S T A N T
E N E R G I Z ET O S H U T D O W N M O D E L
F i g u r eI

v
ORDERINGMANUALS
TO ORDER MANUALS, WRITE TO:
W o o d w a r dG o v e r n o rC o m p a n y
Attention: Technical Services
P . O .B o x 1 5 1 9
FortCollns
Colorado 80522-1519
PLEASE INCLUDE THE FOLLOWING INFORMATION:
.
.
o
.
.

Your name
The name and address of your company
(wrateon letterheador include businesscard if available)
The address where you want the manuals sent (if dlfferent from above)
The quantity wanted of each manual
T h e m a n u a l n u m b e r ( s )o f t h e m a n u a l ( s )y o u a r e o r d e r n g

-oR-

The part number and serial number from the nameplateon your Woodward Equipment

THERE IS NO CHARGE FOR MANUALS ORDERED IN SMALL OUANTITIES.

WOODWARDGOVERNORCOMPANY
C O R P O R A T E H E A D O U A R T E R SA
. I R C R A F T C O N T R O L S D I V I S I O N . 5 0 0 lN o r t h S e c o n d S t . . P . O . B o x 7 0 0 1. R o c k f o r d l L 6 11 2 5 - 7 0 0 1 , U . S . 4
. Phone: (815\877-7441 . Teler:25-7410
E N G I N E & T U R B I N E C O N T R O L S D I V I S I O N . 1 0 0 0E a s tD r a k e R d . o P . O B o x 1 5 1 9 . F o r t C o l l i n s ,C O 8 0 5 2 2 - 1 5 1 9U, . S . A .
. Phone: (303) 482-5811 o Telex: 4-5691
1 0 0 0 E a s t D r a k e R do. P . O . B o x . l 5 1 9 . F o r t C o l l i n s , C O 8 0 5 2 2 - 1 5 1 9 , U . S . A .
T N T E R N A T I O N A L O P E R A T I O N S D I V I S IoO N
I Phone: (303) 482-5811 o Telex: 4-5691
INTERNATIONAL OIVlSIONS
Woodward Governor (U.K.) Ltd. o P.O. Box 15 . 664 Ajax Ave. o Slough, SL'l 4DD, England . Phone: 44-753-26835. Telex:848181
Woodward Goyernor Nederland B.V. o P.O. 8ox 34,2130 AA Hoofddorp . Hoofdweg 601-,2131 BA Hoofddorp, The Netherlands
. Phone: 31-2503-13241o Telex: 74508
Woodward Govemor (Japan) Ltd. . Tomsato P.O. Box 1 . Inba-gun, Chiba-ken, 286-02,Japan . Phone:81-476-93-4661. Telex: 3762-164
Woodward Goyernor Company r Kobe ServiceStaton o 86-1, Edayoshi 4-chome o Nish-ku, Kobe-sh . Hyogo-ken, 673, Japan
. Phone: 81-7 8-928-8321
Woodward Govemor Company . P.O. Box 319 o Unt 1-1 Wirega Ave. . Kingsgrove,N.S.W.2208,Australia
. Phone: 61-2-758-2322 . Telex: 24175
W o o d w a r d G o v e r n o r C o m p a n y ( R e g u l a d o r e s ) L t d a . .C a i x a P o s t a l1 7 8 5 . R u a F e r n a o P o m p e o D e C a m a r g o1, 3 0 6 . l 3 1 0 0 C a m p i n a s , S . P . , B r a z i l
. Telex: 191844
. Phone:55 (192) 43-4852/43-7207/42-3420/43-3879
7 ,. S A .
H Y D R A U L I CT U R B I N E C O N T R O L S D I V I S I O N . 2 3 0 1C o u n t r y C l u b D r i v e o P . O . B o x 2 8 7 . S t e v e n sP o i n t ,W l 5 4 4 8 . 1 - 0 2 8 U
. Phone: (715) 344-2350 . Teler:671-4868

\,

glJ,loslF

)909t0

BUtTETtN
03505C

(SYNCHRON|Z|NG)
SPEED
ADJUST|NG
MOTOR
PARTS
C A T A T O GA N D L U B R I C A T I OGNU I D E

il
WOODWARD GOVERNORCOMPANY
ENGINE& TURBINE
CONTROI.S
DIVISION

FT. COu.tNs,COIORADO,U.S.A.

03505C

}@EMED
v

St

Figure I

S/

Figur e2
S-

u@trmED
\t

MOTOR
ADJUSTING
S P EED
G E N E R A LI N F O R M A T I O N
The motor most often used for speedadjustingor synchronizing purposeson Woodward engineand turbne controls
is the Bodine type V10R motor with integral worm gear
speedreducer. This butletin describesthe maintenanceof
these motors.
LUBRICATING I NSTRUCTIONS
The following instructions apply to this motor model re'
gardlessof voltage input or output shaft speed.
Bearings:
The Bodine V10R motor usesporous bronze sleevebearings. Virgin wool wicks supply oil to the bearings. Use a
good gradeof oil. Apply a few drops of oil to oil hole and
oil cup (seefigure3l aery six months - more often if the
motor is run for long periodsof time.
Speedreduction gearbox:
The gear housingis packed 1/4 full when shipped. This lubricant is sufficient for one to two years of running. To re
place grease,removescrewsa, b. and c (Figure 2) and slip
off gear housing (Section A-A, Figure 3). Clean out old
greasefrom housing. lf used in a low or normal temperature area,fill to 1/4 capacity with Texaco EP or equal low
temperature greaseand reinstall housing. lf the motor is
used in a low or high ambient temperatureareaor mounted
with the gearbox up, then lubricate by puttng DowCorning No. 33 a siliconelubricant, directly on the gears,
then fill to 114 capacity with Dow-Corning No. 33 and
replacehousing.Make sure ball thrust bearingis reinstalled
with gearbox.
ADJUSTMENTS
Adjustments are unnecessaryunless one of the locknuts
securing the adjusting screws stotld loosen, changing the
adjustment. In this casethere are three adustmentspossble with the gear housing remored.
1st Adiustment - At d of Figure2, turn screw in untl t s
hand tigfrt, then back it off one quarter
turn and tghten the locknut while hold'
ing the adiusting scre!,\,statonary. Ro
tate the bakelite gear (No. 5 of Figure 2!
to make sure it turns freely. Check the
output straft for endplay by pulling it in

directionwhile holdingthe
the lengthwise
gearhousingfirmly. Whenadjustedproperly, the output shaft should show no
visible movement.
2nd Adjustment - At e of Figure 2 (both sidesof the
worm shaft) turn worm adlusting screws
to center the worm shaft with the output
shaft. Checkvisuallyto determneproper
alignment of the two gears. The worm
adjustingscrewsshould be positioned so
each protrudes equally from its locknut
when hand-tight. After hand tightening,
the worm adiusting screws should be
loosenedust enough so that the bake
lite gear (No. 5 of Figure 2l turns freely
and there is no side play in the worm
shaft.
3rd Adjustment - With gear housing reassembledon the
motor, hold motor firmly and shakeit in
a lengthwisedirection. lf a faint clicking
sound is heard inside the motor, then an
adjustmentshould be made. At f of F9
ure 3. with locknut loosened,turn screw
in just enough to take play out of the
armature straft. Adjust screw so that the
clicking sound is absent,then back screw
up a few degrees. Check bY shaking
motor again. lf clicking sound is there
again, adjust screw forward approximate
ly one-half the number of degreesit was
reversedand tighten the locknut while
holding the adlusting screw statonary.
Check again,and with the absenceof the
clicking sound,this should be the approximate adiustment. IMPORTANT: Do
not bind armature.
3rd Adiustment on Optional Bodine Motor Friction Loading Kit This adjustmentcan be made onlY on
V10R motors equiPPed with Bodine
Motor Friction Loading Kits. This is
shown in Figure 4. To take play out of
the armature shaft, start with re adjustment screw loose and tigrtenuntil motor
slows. Then back up screw untl normal
speed is iust regained. Tighten locknut
while holding adiustingscrew stationaryWARNING: This adiustments not to be
used to dow the speedof the motor. lt s
onlY used to take end PlaY out of the

G 4 '

}@MED
\'
annature shaft and to stop possiblearmature rotaton caused bv vibration from
the engine when the motor is not
powered.

l4

r5

OIL CUP

OILHOLE

Figure4

Figure3

P R I N C I P A LR E P L A C E M E N TP A R T S
When requesting information concerning V10R Bodne
Motors,or when orderingrepair parts.it is essentialthat the
following information accompanythe request:
1. Serialnumber of governorand motor
type
2. Voltageof motor
3. Part numbr, nameof part, or description of part
4. Bulletnnumber(thssbulletin
03505).

Reference No.

Part Name

03s05-1
03505-2
03505-3
03505-4
03505-5
03505-6
03505-7
03505-8
03505-9
03505-10
03505-1
1
03505-12
03505-13
03505-14
03505-15
03505-16

Motor Brush
BrushSpring
Brushand SpringAssy.
Worm Shaft
BakeliteGear
BrushholderCap Screw
Brushholder
BronzeGear
End Shield,Front
GearHousingAssy.
Field FrameAssy.Complete
ArmatureWound Complete
Output Shaft
Ball Thrust Washer
Spring
Screw

wooowAto GovEtNor cotaNY

MAIN OFFIC: Retfd,
llli(it, U.S.A.
Fd Colkq Coldno. U.S.A- - Tokvo. J4n
Sydey, A6rral

vrooowato GovctNor Ntottaaaoa.v

H@l!qp.

Tha NatE

lrd

wooDw^rD Govct|ot $J.f-l tro.

Slegh.

8t3..

Enghd

Qtv.
2
2
2
1
1
2
2
1
1
1
1
1
1
1
1
1

\-,

EngineData

z
o

E
ff
o.

of Engine
Operation
EnginePerformance
andCondition
Tracing
Trouble
EngineFrameand Bedplate
and MainBearings
Crankshaft
CylinderHeadand CylinderLiner

Rod
PistonandConnecting
OperatingGearfor InletValves,
ExhaustValvesand FuelInjectionPumps
ll

?e

Gfr
2loz
3=

Turbocharger
System
FuellnjectionPump
FuelInjection

8e

Camshaftand CamshaftDrive

=- =o
- ^ -

GontrolandSafetySystems
Automatics
andInstruments

FE

StartingSystem

6 lJg

LubricatingOil System
Oil
of Lubricating
andTreatment
Specification

-.-

J<

g9
F

U'

FuelOil System
Fueland FuelTreatment

CoolingWaterSystem
Treatment
of CoolingWater
DrivenMachinery

SpecificPlantInformation

STARTING
AIR SYSTEM
DESCRI
PTION

3 14 . 0 1
Edition12H

Pl a t e 31 4 0 0sh o w sa sce ma ti car r angement

of the star ting a' ir system .
P l a t e3 1 4 0 1
T h i s s yste mco mp ri se sth re e main com ponents,
viz. the starting piston valve
3 0 4 8 ,t h e s t a r t i n g a i r d j s t r i b u t o r 0 1 9 0 ,a n d t h e s t a r t i n g v a l v e s o n t h e c y i i n der heads.
W h e nt h e s h u t - o f f v a l v e o f t h e s t a r t ' i n g a i r r e c i e v e r i s o p e n e d t, h e a ' i r e n t e r s
t h e s t a rti n g p i sto n va l ve th r ough spaceB and continuesthr ougha small bor e
i n t h e v a l v e p i s t o n 2 3 3 6t o s p a c eD . T h e v a l v e p i s t o n i s c l o s e da g a i n s t i t s
s e a t b y t h e a i r p r e s s u r ei n s p a c eD , a n d t h e s p r i n g 2 2 4 7 .
S t a r t i n g Jt e ffe cte d b y p re s sing the star ting button 2425,wher ebythe pr es s u r e ' i n t h e c h a m b eDr i s r e l i e v e d t h r o u g ht h e b o r e H . I n t h e c a s eo f p l a n t s
a r r a n g e df o r e l e c t r i c a l s t a r t i n g ( r e m o t e - c o n t r o l i e da, u t o m a t e pd l a n t ) , v e n t i n g
o f t h e ch a mb eD
r ta ke s p l a ce thiough a soleno' idvale
f ! , q l i r _ p re ssu re a t B w i l l n owpush for war d and open the va' lvepiston 2336,
w h ' i c ha l l o w s a j r to e n te r th e cham berL. At the smetim e the quide of the
v a l v e p i s t o n b l o c k s t h e v e n t d u c t K . w h e nt h e e n g i n ef i r e s , l e t g o o f t h e
s t a r t i n g b u t t o n , a n d t h e p r e s s u r et h a t a r i s e s ' i n t h e c h a m b eDr w i l ' l p r e s s t h e
v a l v e p i s t o n a g a i n s t i t s s e a t , a n d a t t h e s a m et i m e t h e s t a r t i n g a i r p i p e s a r e
v e n t e dth ro u g hth e d u ct K .
T h e _ c h a m bLe o
r p e n si n t o a m a i n M s u p p l y i ' n gs t a r t i n g a i r t o t h e c y l i n d e r s a s
well as a boreN to the starting air distributor.
T h e a i r f o r m t h e s t a r t i n g p i s t o n v a l v e . , e n t e r tsh e s t a r t i n g a i r d i s t r i b u t o r
t h r o u g hth e b o re N a n d fl o w s thr oughthe mil1ed gr oovein the distr ibuto r di s c
1 2 6 8t o th e b o re s th a t h a ve beenuncover edby the distr ibutor disc, and pas s es
o n t h r o u g hp 'i p e sto th e re sp ective star ting valves on the cylinder s. Du r i ng
t h e r o t a ti o n o f th e d i stri b u tor disc the bor es ar e uncover ed,cor r espo ndi ng
to
t h e p o s i t i o n s o f t h e p i s t o n s i n t h e r e s p e c t i v ec y l i n d e r s .
T h e c h a mb eAr B i n a l l sta rt'i ng valves ar e pr essur izedthr oughthe pipes M fr om
t h e s t a rti n g p 'i sto n va l ve , b ut the valves ar e kept c' losedby the spr ing s
3 0 6 0 2 / 0 5 8a4n d t h e s l i d e s 3 0 6 0 2 / 0 6 7 3W
. h e na i r f r o m t h e s t a r t i n q a j r d i s t r i b u t o r e n t e r s t h e c h a m b eTr , t h e s l i d e i s p r e s s e di n w a r d s ,a n d t h e v a l v e s p i n d l e
3 0 6 0 2 / 0 1 2w8' i l l a d m i t t h e s t a r t i n g a i r w h e nt h e p r e s s u r ei n t h e c y l i n d e r i s
l o w e rt h a n t h e s t a r t i n g a i r p r e s s u r e .
W h e nt h e s t a r t i n g a i r d i s t r i b u t o r c u t s o f f p i l o t a i r t o t h e s t a r t i n q v a 1 v e ,
t h e s p r i n g w i l l p r e s s t h e s l i d e w i t h v a l v e b a c k , a n d t h e s t a r t ' i n ga i r s u p p l y
to the cylinder is cut off.
?
B e f o r ef i t t i n g t h e s t a r t i n g a i r d i s t r i b u t o r a f t e r d i s m a n t l ' i n gt,u r n t h e e n g i n e
u n t i l t h e p i s t o n i n c y l i n d e r 1 i s i n T D Co f t h e p o v , , esrt r o k e - ( U o t fvr a l v e s n
t h e c y l ' i n d e rh e a dc l o s e d , c l e a r a n c ea t t h e p u s hr o d s ) .

I{OI.EBY
GENERANIGSETS

AIR SYSTEM
STARTING

314.02
E d i t i o n1 2 H l
19 8 6 . 0 9 . 0 9

DESCRI
PTION

T h es t a r t i n g a i r d i s t r i b u t o r i s m o u n t e o
d n t h e e n g i n ew ' i t h t h e d ' i s t r j b u t o r
d i s c 1 2 6 8l o o s e l y a t t a c h e dt o t h e s h a f t c o n e .
Th e s c r e w0 7 3 4i s re mo ve d
a n d th e checkpin 3,|37inser ted in the aper tur e.
T h e nt u r n t h e d i s t r i b u t o r d i s c u n t i ' l t h e c h e c kp i n e n t e r s t h e g u i d e n o t c ho f
t h e d i s c , w h e r e a f t e rn u t 1 4 4 6i s t i g h t e n e da n d l o c k e d .

MAINTENANCE

A p p il c a t i o n o f a th i n l a ye r o f " Mo lykote"of the contact faces betweend' istr ib u t o r d i s c a n d h o u s'i n gi s re co mmended

dur ing over hau'of
l the startinqair distri butor.

}IOtEBY
GENERAN{G SETS

MAr\r
Eteut
Deecripon
Pag1 (1)

PressureReductionStation for
High Pressure
Oil System

314.40
Edition 02H

General
PressureReductionStation.

Mantenancof Pressure Reduc-tionValve.

The highpressure
sealingoil pumpis drivenby
meansof airfromthebultoninternalcompressed
air system,the air is ledto the sealingoil pump
througha pressure
reduction
station,
consisting
ofa
pressure
reduction
valve,manometer
anda safety
valve.
Adustmentof Air Pressure

Erraticregulatoroperationor loss of regulationis

mostalwaysdueto dirtin thediscarea.Clean,shut
off and depressurizeair line and disassemblethe
regulator,clean parts with soap and blow out the
body with compressedair. When reassembling,
makesurethatthedisc.assemblyis firmlyin place
and that the disc stem fits into centerof hole of
diaphramassembly,do not tightencage slightly
morethanhandtight(to5.6 Nm).

The outletpressurefrom the reductionvalveis

adjusted
bytheknobonthetopof thevalve.

Safety Valve

byturningtheknobclockwise
thepressure
is raised
andreversethe pressure
is lowered
by turningthe
knobanticlockwise.
Seealsosection315.

91.07- ESoU

The safetyvalverequiresno maintance.The openingpressuressetto7bar.lfthesafetyvalveneeds

furtheradjustment,removethe plastcapandadjust
the openingpressurewiththe lockscrew.

I{OLEV
GEI\ERATESETS

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clii,i,lc e

}|AN
E&Ut
P L A T 3E1 4 0 I . 1 H

STARTING
AIR DISTRIBUTOR
ANDSTARTINGAIR VALVE
30602
/ 0584

AB

3l 37

30602/0128
30602/0673

144
| 357
0378

055
045

0t90

:,:ii,2)

c-

^\

(l
"'-Y

1179

3226-r

I28

3315

I
I,

t7t3

r 357
tM6

2r58

2425

254 -\

r802

l99l

3 I 30{8

203

il'

2792288
2217
2336

209
1985.12.10

2970

I{OLEBY
GENERAN\|G SETS

STARTING
AIR DISTRIBUTOR
ANDSTARTINGPISTONVALVE

Item No.

P L A T 3E1 4 0 1 .11H

Designation

Benavnelse

0 19 0

Startingair distrib u to r, com plete

0378
0556
0645
0734

Ge a rw h eel
S h a ft
Bush

Star teluftfor del er ,

kompl
et
Tandhj
uI

Screw

Skr ue

0823

Ga ske t

P a k nni g

0912
1080

H o u isn g
Screw
Seal'ing ri ng
D i s t r i b u t o rd i s c
L o ck w a sher

Hus
Skr ue
Tatnj ngsri ng
For deler ski ve

1179
1268
135 7

Aksel
For ing

S ik r i n g s s k i v e
M str ik

1446
15 3 5
1624
1 71 3
180 2
19 9 1

Nut
G u i d ep i n
Nut
Gasket
H o u isn g
Circlip

Styr est' ift

Mstri k
P a k nni g
Hus

2069
2 15 8

Screw
Ga ske t

2247

S p rin g
V a l v ep i s t o n

Skr ue
P a k nni g
Fjeder

2336
2425

Button

S i k r i n g s r in g

Gli der
Knap

2514
2603
2792
2 88 1

Pin
S p r in g
V a l v eh o u s i n g

2970

V a l v es p i n d l e
Starting piston valve,
complete
C h e c kp i n

Vent'ilsede
Vent1
i s p in d e l
S t a r t e g il d e r ,
kom plet
Kontr olpi nd

Ga ske t

Pakn' ing

P1'ug5qsuf
*Not installed on engi ne 'for remote'start

Pr opskr ue
*Anvendes,ikke p motorer medfjernstart

3048
3137
*3 ?2 6
*3315

V a l v es e a t

sti ft
Fjeder
V e n t ' ihl u s

+tE-EtY
GENERAI\IG SETS

lYIA|

Et&ult
SOLENOID
VALVEFORREMOTE
STARTING

IX

PLATE
31 402- O3H

5423

I{OLEBY
GENERATIT{G SETS

PLAT3
T1 4 0 2 - 0 3 H

STARTING
VALVEFORREMOTE
SOLENOID

Item No.

4 00 0
404s
4171
4 5 19
5423

Designation

Benavnelse

S o l e n o i dv a l v e ,
compl
ete
C o iI
D 'i a p h ragm

M agnetvent', i1
kompl
et

D 'i a p h ragm
r etai ner
d
w'ithseat isc
P 1u n g e rwi th seal

Spole
Membran
medtetMembran
n i n g s r in g
Stempelmedtatn i n g s r in g

{EEY
GENERATI\TGSTS

Plabs
Pagp 1(2)

PressureReductionStationfor
HighPrcssure
Oil System

31460-01H

General

oe
13

0r

(x)'
10'

11'
1t

90.44

HO|.trY
CENER/{INESETS

PressureReductionStationfor
HighPrcssureSealingOil System

3146G01H

P|ab
Pqe2(21

General
Deslgnation

Benavenelse

01

Regulator completc

Regulator komdet

02

Spring gage kt
comprislng O3{+
ofltfl7

Fjeder sat bestende

af:03{4-OS0647

03r

Screw

Skue

04.

Knob

knap

05'

Adjusting
screw,
comprising scrw
end nut

Justerngsskue, bestende af skrue og

mofik

t}6*

Sprirq gage

Fjeder kurv

0r

Spacer

Plade

08

Regulator repair kit

comprislng {t9-1G
11-12-13

Regulator reparations
s@t bestende af OS
'tG11-12-13

(x).

Diaphragm

il/bmbran

10.

Gasket

Pakning

11'

Dlsc asey, comprbng: stem,Orlng

(dlsc), disc, Grlng
(bottom)

Skive samling bestende af spindel, O

ilng(skive), skive, Oring(bund)

12.

Sprlng

Fedr

f3

Regulator Sprng

Regulator Feder

14

llanomeler

It anomete

15

Saety valve

Sikkerhedsvenl

Itdn No.

Itemnos.markedwith ' areonlyavailableas partof a sparepartskit.

HOLEY

cEr\EfiArGsElls

90.14

EngineData

z
o

E
ff
o-

Operation
of Engine
EnginePerformance
andCondition
Tracing
Trouble
EngineFrameand Bedplate
Crankshaft
andMainBearings
CylinderHeadand CylinderLiner

Rod
PistonandConnecting
Gearfor InletValveq
Operating
ExhaustValvesand FuelInjectionPumps
ll

Turbocharger
System

?e

FuellnjectionPump

oz

s=
R

FuelInjection

:z
=<

CamshaftandCamshaftDrive

a9
- ^ -

ControlandSafetySystems
Automatics
andInstruments

FE

StartingSystem

6 lJg

Lubricating
Oil System
Oil
of Lubricating
Specification
andTreatment

l'fr
Zl-

g9
p r

FuelOil System
Fueland FuelTreatment

CoolingWaterSystem
Treatment
of CoolingWater
DrivenMachinery

SpecificPlantInformation

L U B R I C A T I NOGI L S Y S T E M

3 15 . 0 1

DESCR
P IT I O N

Edition 2ZH

A l l m o v i n gp a r t s o f t h e e n g i n ea r e l u b r i c a t e d w i t h o i l c i r c u l a t i n g u n d e rp r e s s u r e i n a c l o s e d s y s t e m .T h e l u b r i c a t i n g o i l i s f u r t h e r m o r eu s e di o r t h e
[urp o s eo f c o o l i n g t h e p i s t o n s .
T h el u b r i c a t i l g o i l R u m R
p r e s s e st h e o i l t h r o u g ha c o o l e r a n d a f i l t e r
m a i n l u b r c a t i n g l i p e , f r o m w h e r et h e o i l i s d s t r i b u t e d t o t h e i n d i v i dtuoa tl h e
pointsto be lubrict.
T h ee n g i n e . p l a n ti s e q u i p p e dw i t h a n e l e c t r i c d r i v e n p u m pf o r p r i m i n gt h e
lub. i c a t i n g o i ' l s y s t e mb e f o r e s t a r t i n g a n d w h e nc h e c k i n g ' t n !u a r l n g s .
.

T h el u b r i c a t i n g o i 1 p u m pw
, h i c h i s o f t h e g e a r w h e e lt y p e , i s m o u n t e d
e n d o f th e e n g i n e re mo tefro m the flywheel] r ne pumpis dr iven thr ougrorn t h e
c o u p l i n gf r o m t h e f n e e e n d o f t h e , c r n k s h a f t , . o r ' t h r o u gah . i i l l e n i " g e Ji r -c' -l i"w
t r a n s m i s s i o nT
- h e o v e r s p e e tdr i p ( s e c t i o n 3 l ) i s f i t t i o i e e n o c o v e r
of
the pump.
T h e p r e ssu rere g u l a to r fo rms par t of the lubr icating oil pump.Adjustm ent
of
the oil pressur.
r e m o v i n gt h e c a p n u t 0 1 4 9a n d ' t u i ^ n i n tgh e a d j u s t i
:
_
d
o
n
e
.
b
y
i n g s c r e w0 4 1 6u n t i l r e a d i gt h e p r e s s u r es t a t e d i n s e c t i o n 3 0 1 , d a t a 3 0 3 .
.

T h e l u b r i c a t i n g . o i l f i l t e r i s a d o u b l ef i l t e r w h i c hi s g e n e r a l l yu s e d
l y o n e f i l t e r c h a m b ebr e i n g i n o p e r a t i o n , t h e o t h e r f i ' l i e r . h u * 6 . . b e iwn igt h o n in
s t a n d - b y.
I f t h e fi l te r ch a mb eirn o p er ation needsto be ser viced, the oper ation
be
s w i t c h e dto th e o th e r fi l te r chamberwithout a n y i n t e r u p t i o n i n l u b r i c acan
ting
o i l s u p p l yt o t h e e n g i n e .
S e r v i c i l . gi s g e n e r a l l yr e s t i c t e d . t o r e p l a c i n go f t h e p a p e rc a r t r i d g e s ,
cleani n g o f t h e r a d i a l n e s h i n s e r t a n d i n s p b c t i o n " o is e a l i h ; : t i a t t e r
t
o
be rep ' l a c e di f d a ma g eosb se rve d .
Ea c hf i l t e r ch a mb eirs e q u i p pedw' ith 1 or 2 r eplaceablepapercar tr idge s
of
f i n e n e s s1 0 - 1 5m i c r o n s .
I n t h e ce n tre o f e a ch fi l te r cham bera fi' lter basket ( centr al e1ement)
s i t u a t e d . T h i s f i l t e r b a s k e ti s a c t i n g a s a s a f e t y , t i v i n g f i n e n e s sois
f about
60 microns.
D u r i . n gop e ra ti o n a n .-i n cre a sed
pr essur edr op acr oss the filter w.ill be obs er v ed
p
a
r
t
i
c
l
e
s
.
w
i
l
l
d
e
p
o
s
i
t eo n t h e f i l t r a t i o n s u r f a c e so f t h e p a p e rc a r ls-qirt
t r i d g e s a n d th u s i n cre a seth e flob, r esistance tr oughthe filter
.
I f t h e p r e s s u r ed r o p a c r o s st h e f i l t e r e x c e e d s2 , 0 b a r , a r e l e a s e
valvewill
o p e na n d b y - p a st h e 1 0 - 1 5m i c r o n sf i l t e r e l e m e n a, n d - t h e
e
n
l
i
n
e
w
ill run
w i t h o n l y t h e 6 0 m i c r o n ss a f e t y f i l t e r .

*H.EBY
GE|YERANNC SETS

lIAh|
E&Ut

L23/30
LUBRICATING
OIL SYSTEM

3 15 . 0 2

DESCR
P IT I O N

Edition22H

T o e n s u r es a f e f i l t e r i n g o f t h e l u b r i c a t i n g o i l , n o n eo f t h e b y - p a s sv a l v e s
m u s t o p e nd u r i n g n o rma lse rvi ce a nd the elementsshouldbe r epiacedat a pr es s u r e d r o p a c r o s st h e f i l t e r o f 1 , 5 b a r ( 2 2 p s i ) .
S e r v i c i n gi s e s s e n t i a l l y t h e e x c h a n goef t h e p a p e rc a r t r i d g e s .
W h e n _ e x c h a n gci an rgt r i d g e s , i t i s a d v i s a b l et o r e l e a s ea n y o l d r e m a i n i n gi n
t h e f i l t e r h o u si n gb y me a n so f th e dr ain plug pr ovidedfoi this pur pose,and
t o w i p e o u t t h e h o u s i n gw i t h a c l o t h .
T h e f i l t e r c h a mb e rs
ca n b e se rvi ced successivelydur ing oper ation or whenthe
e n g i n ei s a t s t a n d s t i l l .
I t i s e s s e n t i a l t o c l o s e l y f o l l o w t h e i n s t r u c t i o n s i n 3 1 5 . 5 1w h e nr e p l a c i n g
filter cartridges.
F i l t e r c a r t r i d g e s m u s t u n d e rn o c i r c u m s t a n c ebse c l e a n e da n d u s e da g a i n .
O p e r a t i o no f p r e l u b r i c a t i n qp u m p .
T h e s e p a r a t e l yd ri ve n (e l e ctri c) p r elubr icating pum pmust be ar yangedfor aut o m a t i c o p e r a t i o n ,e n s u r i n gs t a n d s t i l l o f t h e p r e l u b . p u m pw h e nt h e n g i n ei s
r u n n i n g ,a n d r u n n i n go f t h e p r e l u b . p u m pd u r i n i e n g i n e ' s t n d s t i l ' il n s i a n d - b y
p o si t i o n .
Ru n n i n gp e r i od o f th e p re l u b . p u mpis pr efer able to be continuos. If inter m it t e n t r u n n i n g i s re q u i re d fo r e n e rgysaving pur pose,the timing equipm entshoul d
b e s e t f o r s h o rte st p o ssi b l e i n te rvals, sy 2 minutesof r unning, lb minutes
of standstill, etc.

i ng
Runn
ENGII{E
Stand-by
Running
PRELUB.
P!IP.
Standsti I I
Running
PRELUB.
PI.IP.
StandstiI I
Interuittent

FH.EEY
SETS

CET\ERAN{G

]Y|AN

L23/30
L U B R I C A T I NOGI L S Y S T E M

VALVE
THERMOSTATIC

Et&ut
3t 5 . 0 3
Edition 22H

P l a t e 3 15 0 4
T h e t h e r m o s t a t i cv a l v e i s d e s i g n e da s a T - p i e c ew h o s ei n l e t i s t h r o u g ht h e
The outlet to
c o v e r A un d e rw h i ch th e th e rmostaticelem ent0543 is located.
"
C
"
.
"
B
"
i
s
m
a
r
k
e
d
t
h
e
c
o
o
l
e
r
andthat to
t h e e n g ' i n ei s m a r k e d
r o u n dt h e
I n t h e p e r i o d w h e nt h e e n g i n ei s w a r m i n gu p , t h e o i l i s b y - p a s s e d
tem
per
atur
e( see s ec the
nor
m
al
c o o l e r , w h e nth e o i l fro m-th e engine r echs
t
h
e
c
o
o
l
e
r
.
p
a
s
s
e
s
through
t i o n 3 0 1 ) a c o n t r o l l e d a m o u not f o i l
T h e t h e r mo sta ti ce l e me n tmu st be r eplacedif dur ing nor m aloper ation, th e tem p e r a t u r e d e vi a te s e sse n ti a l l y fr om that stated in the test r epor t ( section
320).
T h e v a l ve ca n n o t b e se t o r a diusted, and it r equir es no maintenance.

E!+=

tEtE

E FE==.:E
GENERATI\IG

E
ST5

]|lAhl

L23/30
OIL
L U BR IC A T IN
G SYSTEM
DESCRIPTI ON

Et*ut
3ls.t0
tdition 01H

L u b r i c a t i n go i l c o o l e r .
d n t h e e n g i n e ,o r i n s t a l l e d s e p a r a T h el u b r i c a t i n g o i l c o o l e r c a n b e m o u n t e o
te in the lub. oil system.
T h e c o o l e r i s co o l e d b y th e 1owtemper atur ecooling water systemT h e c o o l e r i s o f t h e p l a t e t y p e , c o n s i s t i n go f a n u m b eor f h e a t t r a n s f e r p l a t e s c o r r e sp o n d i n gto th e a ctual engine per for mance.
E a c hp l a t e h a s a g a s k e tw h i c h s e a l s a g a i n s t t h e a d i a c e n tp l a t e , a n d t h e w h o l e
p l a t e p a ck i s mo u n te di n a com m on
fr ame.
A s t h e c o o l e r c o n s i s t s o f a p a c ko f i n d i v i d u a l p l a t e s , a d e f e c t i v e p l a t e c a n
e a s i l y b e re mo ve d
a n d re p l a ced.
see the separ atei nF o r d e ta i l e d i n fo rma ti o na b out over hauland maintenance,
s t r u c t i o n b o o k P a r t I I , e q u i p m e nitn l u b . o i l s y s t e m .

#-EEY
GENERATnGSETS

1||Ah|

Er&urt

L23/30
OIL
L U B R IC A T IN
G SYSTEM

3 15 .2 0
E d i t i o n0 1 H
P a g e1 ( 6 )

PUMP
DESCRIPTION
OF PRELUBRICATING

P r e l u b r i c a t i n gP u m p
T h e w orki n g p a rts o f th e p relubr icating pumpar e the thr ee scr ewsand the s ur r o u n d i n gc a s i n gw i t h i n w h i c h t h e y r o t a t e . T h e t h r e a d s u r f a c e sa r e s o d e s i g n e d
t h a t t h e y fo rm ti g h t se a l s both in r elation to each other and to the p um pc as i n g . W h e nt h e s c r e w sr o t a t e . T h e s e a l s m o v ea x i a 1 1 y ,t h e r e b yf o r c ' i n gt h e l i q u i d e n cl o se db e tw e e nth e mto m ovefor war dsso that a pum pingaction res ul ts .
T h ew o r k i n gp r i n c i p l e o n w h i c h t h e f u n c t i o n i s b a s e di s t h a t t h e m o v i n gp a r t s
a r e l u b r i c a t e d b y t h e p u m p eldi q u i d . T h e p u m pi s s e l f - p r i m i n g .T h e p u m pi s
b u i l t fo r o n e ro ta ti o n a l a nd one pumpingdir ection and the constr uctionof
t h e p umpi s i l l u stra te d b y the sectional view on plate. For adjustmentof the
p u m pd e l i v e r y h e a dd u r i n g o p e r a t i o n , a b u i l t - i n , . a d j u s t a b l e b y p a s sv a l v e i s
p r o v i de d . A t d e l i ve ry e x w or k the pr e- set pr essur eof this valve am ou ntsto
a b o u t 3 b a r.
T h e s h a ft se a l i s a me ch a nicalseal, for medby two flat sealing sur facesw hi c h
a r e i n co n ta ct w 'i th e a cho ther - one r otatinq with the shaft and one s tati onary.
T h e s u rfa ce sa re l u b ri ca te d by the pumped
liquid and the contact pr ess ur ei s
m a i n t a i n e dw i t h a s p r i n g . T h e s e a l i n g a b i l i t y d e p e n d u
s p o nc l e a n a n d u n s c o r e d
s u r f a ce s.
0 p e r atin g
Be f o r e S ta rti n g .
A f t e r i n sta l l a ti o n o r a fte r dism ant' lingand subsequent
r eassembly,the pum p
m u s t b e fi l l e d w i th o i l . Only under these conditions the pum pcan be s tar ted
w i t h o ut ri sk o f d ry ru n n i n gwhich could causedamage
to the r otating p ar ts and
shaft seal.
Directionof Rotation.
W h e nth e p u mp i n gi s re a d y to be- star ted, check that the dr ive motor r o tates i n
t h e c orre ct d i re cti o n a s i ndicatb( on the pumpby br iefly switching it on and
b y w a tch i n gth e fa n i mp e l l er of the- - e- lctr icmotor . Note. Do not chec kthe di r e c t i o n o f r o t a t i o n w i t h o u t p r i o r f i l ' l i h g t h e p u m pw i t h o i l .
S t a r t in g .
St a r t in g sh o u l d a l w a ysta ke p l a c e w i t h f u l l y o p e nv a l v e s i n t h e s u c t i o n a n d
d e 1i v e r y I i n e s .
A s t h e p u mpi s se l f-p ri mi n g i t c a r r i e s o f f t h e a i r i n t h e s u c t i o n l i n e a n d t h e
n o ' i s ere ve a l s w h e nth e p u mpb e g i n st o w o r k . I t i s e s s e n t i a l f o r t h e a i r t o l e d
o f f w ith o u t a n y a p p re ci a b lecounter - pr essur ein the deliver y line.

t.Cf;!

F!!!tG.rt

CENGRA'ruVCSETS

]v|Ah|

Et&ut

L2 3 / 3 0 ,
LU B R I C A T IOIL
NG S Y S T E M

3t s . 2 0

- OVTRHAUL
DESCRIPTION

E d i t i o n0 l H
P a g e2 ( 6 )

As soon as the pumphas started to wor k nor ma' |1y,the bypassvalve m ust be se t
by m e a n so f a p re ssu reg a u g ea t the r equir ed pr essur e.
S e t t h e b y p assva l ve , w i th th e screwon the end cover of the pumpbodybeneath
t h e t r a d e m a rk. T u rn i n g to th e ri ght incr easesthe openingpr essur e.Do not
s e t t h e v a l v e a t p r e s s u r e sh i g h e r t h a n n e c e s s a r y .
T h i s p r e s s u r es e t t i n g s h o u l db e m a i n t a i n e dw h i l e t h e p u m pi s i n o p e r a t i o n .
I f _ t h e p u m pre fu se s to w o rk p ro p er ly after having beenstar ted, it must not b e
al l o w e dt o r u n mo reth a n a b o u t h a lf a m inute. Fr eshattem ptsto m akethe pum p
g o m a yb e m ad ea t i n te rva l s a t a b out a m inute and in conjunctionwith these
a t t e m p t st h e b yp a ssva l ve te n si o n should be incr easedslightly. If this does
n o t h e l p , s ome th i n gmu st b e w ro n gand the fault m ust be lcated and r emedie d
be f o r e t h e p u mpi s p u t i n to o p e ration. See "Tr oubr eshooting".
A t t e n t i o n a n d M a i n t e n a n cdeu r i n g 0 p e r a t i o n .
W h e nc o r r e c t l y i n s t a l l e d a n d p r o p e r l y s t a r t e d t h e p u m pr e q u i r e b u t l i t t l e a t t e n t i o n . E x c e p tw h e no th e n i se d i ctated by special cir cum stances,
they ar e
o p e r a t e da n d l o o ke da fte r i n th e s ame$r ayas any other pum p.W hichintlude
c h e c ko f t h e p u mpfu n cti o n a n d th at ther e ar e no distur bancesas leakage,inc o r r e c t p r e ssu reo r a b n o rmanl o i se.
P e r i o d i cO v e r h a u ' l s .
Pe r i o d i c o v e rh a u l sfo r th e p u rp o seof avoiding functional tr ouble ar e not nor m g l l y n e c e s s a ryfo r th e p u mp .t'l h enpr oper ly used, ther e is ver y little wear on
the screws.
Ne v e r t h e l e ssp e ri o d i c o ve rh a u l sshould be car r ied out so that wor n par ts can
b e r e p l a c e di n g o o dti me . T h e i n ter vals betweensuch over haulsar e deter mined
b y e x p e r i e n cei n e a ch i n d i vi d u a l case.
Aft e r p e r i o d s o f a b o u t 3 -6 ye a rs the shaft seals usual' lyneedto be r eplaced
o n a c c o u n ta f a g i n g o f th e co n ta i ning r ubber par ts.
T r o u b l eS h o o t i n g
T h ef o l l o w i n g f u n c t i o n a l d i s t u r b a n c e a
s r e i n m o s t c a s e se a s i l y r e m e d i e d :
W r o n gD i r e c t i o n o f R o t a t i o n .
- I n t h r e e - ph a semo to rs, tw o o f the electr ic connectionwir es m ust be r ever sed.
Pu m p0 i 1 o u t p u t to sma l l (p u mpa l so gets too war mwhile in oper ation) .
- T h es h u t - o f f v a l v e s i n t h e s u c t i o no r d e l i v e r y l i n e s a r e n o t f u l l y o p e n .

=.E-5E=E
i =-r=-=.=
GENERA1IING

!l
STS

]||AN
Et&l

L23/30

3 15 . 2 0

OIL
L U BR IC A T IN
G SYSTEM

E d i t i o n0 1 H
P a g e3 ( 6 )

i
OVERHAUL

- T h e b y p a s sv a ' l v e ' i s s e t a t t o o l o w a p r e s s u r e .
P r e s su reto o L o w
- C o u n t e r p r e s s u irne t h e d e l i v e r y l i n e t o o l o w .
- T h e b y p a s sv a l v e t e n s i o n i s i n s u f f i c i e n t .
- T h e b yp a ssva l ve h a s g o t iar uned.
- T h e p u mpi s w o rn .
D r i v e Mo to r d i ffi cu l t
I o a d s.

to S tar t or tends to stop by tr ipping of the motor ov er -

- C o un te rp re ssu re
to o h i g h .
- 0 i l t o o c o l d a n d t h e r e f o r eo f h i g h e r v i s c o s i t y t h a n a n t i c i p a t e d .
- M o t o ro u t p u t i n a d e q u a tfeo r t h e p r e v a i l i n g c o n d i t i o n s .
- M o to r o ve rl o a dre l a y cu t-out setting too low.
P u m pn o i s y w h e nR u n n i n g( c a v i t a t i o n n o i s e )
- 0 ' i 1 f l o w t o p u m pi n s u f fi c i e n t .
- Su c ti o n p i p e to o l o n g o r too small in pr opor tion to the volumetr icfl ow and
viscosityof the oil.
- C l o g g e ds h u t v a l v e i n t h e s u c t i o n ' l i n e .
gauge.
C a nb e ch e cke dw i th a va cuum
- S u c t i o nl i f t

too great.

- A i r l e a k a g ei n t o s u c t i o nl i n e .
- C h ecksu cti o n p o si ti ve p ressur eif oi' l temper atur eis above600 C ( 1 400F ) .
( N O T EH! e a v yw e a r i n t h e p u m pc a n o c c a s i o n a l l yb e a s o u r c eo f n o j s e ) .
at ShaftSeal.
0il Leakage
- Se al i n g ca p a ci ty d e cre a seddue to incor r ect contact betweenthe sea l i ng s ur f a c e s. T h e ca u sema yb e aged r ubber par ts or damage
sliding sur facesdue to
impurities in the oil or to dry running.
A p u m pc a n g e t w o r n i f u s e df o r u n s u i t a b l el i q u i d s , f o r t h i n o r i m p u r eo i l a n d
t o o h i g h a w o r k i n gp r e s s u r e . O i l t e m p e r a t u r eisn e x c e s so f 9 0 o C ( t g q o F ) c a n
th e p u mpsh a ft seal.
a l s o d a ma g e

!l

!..!

F-!.J

GENERA'ruVGSETS

L23/30,

l|AhI
E&UV
3| 5.20

OIL SYSTEM
LUBRICATING
OVERHAUL
i

E d i t i o n0 t H
P a g e4 ( 6 )

W h e na p u m pi s to be reconditioned after heavy !{ear, the screws and that part

o f t h e p u m pwh i ch s u p p o r t s t h e s c r e w s s h o u l d b e r e p i a c e d .
Sh a f t S e a l
Th e a x i a l t y p e sh a ft se a l o f th e pumpis intendedto pr event the leakageof
f lu i d a l o n g th e d ri ve n sh a ft o f a pump.The seals ar e intendedfor miner al
o i l s a n d s i m i l a r f l u i d s . I n o r d e r t o e n s u r et h a t t h e s e a 1d o e sn o t w e a rd u r i n g
o p e r a t i o n , i t m u s t b e l u b r i c a t e d b y t h e p u m p eldi q u i d . A n i n s i g n i f i c a n t a m o u n t
o f l e a k a g em a yth e re fo re o ccu r a nd suitable pr ovision should be madefor colle c t i n g t h i s l e a ka g efro m th e d ri p r ing of the pump.
M e c h a n i c aSl e a l s T yp e2 /W-se a t(C r ane) Plate 61520
T h e r o t a t i n g s e a l ( 2 0 0 0 )r e s t s a g a i n s t a c o l l a r o n t h e p o w e rr o t o r ( t g E Z ) . T h e
s e a l ( 2 0 0 0 ) ro ta te s th ro u g hth e i nter mediar yof the r ubbing of the bellowsag a i n s t t h e s h a ft. A ro ta ry se a 'l ri ng ( 2377) - of car bon- is pr essedlightly
by t h e s p r i n g a g a i n st th e sta ti o n ar y seat ( 2466) in the fr ont' cover ( 0408)of
the pump.
Th e b e l l o w s se a l a l o n g th e sh a ft and against the back of the r otar y seal r ing
(? 3 7 7 ) . T h e p re ssu reo f th e ro ta ry seal r ing ( 2377) against the stationar y
seat (2466) forms an effective seal betweenthe lapped surfaces of these two
c o m p o n e n t sT.h e o -ri n g g a ske t (2 288) , finally, sea' lsagainst the fr ont cover
( 0 4 0 8 ) ,i . e . a g a i n s tt h e s u r o u n d i n gp u m pc a s i n g .
Di s m a n t l i n g /R e a sse mb l P
y l a te 6 1520
I m p u r i t i e s i n t h e p u m p eldi q u i d o r c a r e l e s sh a n d l i n gd u r i n g d i s m a n t l i n ga n d
e lappedsealing sur faces. The tasks of
re a s s e m b lcyan re su l t i n d a ma g to
di s m a n t l i n gan d re a sse mb l i n g
th e seal' should ther efor e be car r ied out in con di t i o n s o f s cru p u l o u scl e a n l i n e ss and car efulnessand ever y effor t must be
m a d et o a v o id to u ch i n gth e se a l i n g sur faceswith the finger s. The car bonr ing
m u s t b e c a r e fu l l y h a n d l e d .It mu st not comein touch with gr ease.
l. l h e na t t e n d i n g to o r ch a n g i n gth e shaft seal, pr oceedin the following manner ,
u s i n g t h e t o o l s a n dm a t e r i a l l i s t e d b e l o w :
-

\--

Bo x - e n dw r e n ch , si ze 1 5 mm.
O p e n - e nwre
d n ch ,si ze 1 3 n rn .
0 p e n - e n dwre n ch ,si ze 1 5 mm.
l,lrenchkey for hexagonsocket screw, size 2.38 mm.
S p a n n ea
r nd scre wd ri ve r.
L u b r i c a t i n gl i g h t o i l a n d g r e a s e .
V e s s e l sf o r c l e a n i n gr e m o v e p
da r t s a n p a r a f f i n , w h i t e s p i r i t , e t c . , a n df o r
a
n
y
w
a
s
t
e
oil.
collecting

tl+!l

- -----

tFttrlEa/

CENERA.IYGSTS

rl|AI\|

Et&urt

L23/30|

3 15 . 2 0

OIL SYSTEI'I
LUBRICATING

E d ' i t i o n0 1 H
P a g e5 ( 6 )

OVERHAUL

D i s m a n tl
ing

P l a te 6 1 5 2 0

- T u r n th e mo to r, u si n g th e fan beneaththe fan casing, until the set s c r ew

(0131
) w h i c h l o c k s t h e p u m ps h a f t t o t h e m o t o r s h a f t i s a c c e s s i b l ei n o n e o f
t h e i n sp e cti o n h o l e s i n the pumpbody. Backoff the stop scr ewall t he w ay .
- Sh ut o ff th e su cti o n to the pumpand block the' electr ic motor star ti ng button.
- Loosenthe screwswhich hold the motor and pumptogether and lift
m o t o r.

awaythe

- Remove
the front end cover of the pump(0408).-Do not damagethe joint
(OSSZ)betweenfront end cover and pumpbody.
- Press the stationary seal with o-ring (2466/2288)out of the front cover.
- Remove
the powerrotor (,|932) from the pumpbody.
I f on l y th e se a l i s to b e r eplaced, the idler s can r em ainin the pum pbody .
- Remove
the rotary seal ring (2377).
- Pr e ss th e ro ta ti n g se a l (2000) out of the powerr otor ( 1932) . Dueto the
rubber bellows the necessarypress-off povrermaybe comparativelybig.
Reassemb'ly
The fit of the rotary seal on the pumpshaft is rather hard. To prevent damage
o f t h e b e l l o w s i t i s a d vi sable to clean the pumpshaft fr om possible c oati ng
l i k e pa rti cl e s o f co ke fro m oil etc. Polish the pumpshaft by m eansof an
e m e r yo r cl e a n i n g cl o th to get a sm oothfinish. This pr epar ationfacili tates
t h e m ou n ti n go f th e ro ta ry seal.
T h e r e a sse mb lw
y i l l ta ke p l ace in r ever seor der .
- A f t e r cl e a n i n g w i p e th e shaft over with light oil ( not gr ease) . Pr es s the
r o t ati n g se a l (2 0 0 0 )w i th r em ovedr otar y seal r ing ( 2377)onto the rotor
shaft.
- C h e ckth a t th e b e l l o w s a re pr essedagainst the locating r ing of the s pr i ng.
K e epd u ri n g h a l f a mi n u te the seal pr essedin that position until the bel lowsstick.
- M o u n tth e ro ta ry se a l ri n g ( 2377)with its sm aller sur face tur ning u pw ar ds ,
t a k i n g ca re th a t th e g ro ovesin the sea' l r ing ar e in line with the d i m pl es
of the retaining sleeve.
- I n s e rt th e p o w e rro to r i n the pumpcasing ( 0686) .
- t l i p e o ve r th e o u tsi d e o f the stationar y seat with its o- r ing gasket ( 2466/
2288\ with light oil and press the seat into the front cover.
r

tql

Fttt

CENERA'fII{G

SETS

fvfAh|

ET&Uv

L23/30li
LUBRICATING
OIL SYSTEM

3 15. 2 0
E d i t i o n0 l H
P a g e6 ( 6 )

OVERHAUL

- M o u n tt h e fro n t co ve r (0 4 0 8 ) to the pumpcasing ( 0686)m akingsur e not to

f o r g e t t h e j o i n t (0 5 9 7 )w h i ch seals betweenth pumpcasing nd the fr ont
cover.
- Sc r e wt h e se t scre w (0 1 3 1 ) i n to the powerr otor far enoughto be guidedint o
the keywayin the motor shaft.
- M o u n tt h e el e ctri c mo to r o n th e pumpso that the set scr ew( 0131)enter s th e
m o t o r - s h aftke yw a y.T i g h te n th e scr ewsjoining pumpand m otor flanges.
-

Itg powerrotor shall be forced up on the motor shaft by meansof a screw

d r i v e r p u t.i n to .th e g ro o veo f the powerr otor shaft. Thr eafterscr ewthe
s e t s c r e w(0 1 3 ,|)fi rmty a g a i n st the m otor shaft. This.is necessar yto ensur e
a c o r r e c t p l a y o f th e i d 'l e r^ro tor s.

- C h e c kt h a t th e p u mpro ta te s fre ely whenthe m otor is r otated by hand.

O p e nt h e v a l v e s i n t h e p i p e l i n e s a n d r e - e s t a b l i s ht h e e l e c t r i c s u p p l yt o t h e
m o t o r . P r o c e e di n a cco rd a n ce
w i th the instr uct' ions "star ting up".
N0 T E:D o n o t l e t th e p u mpru n fo r mor ethan one minutewithout wor king.
M a n' i t e n a n c e.
T h e s e a l i s s e l f - a d j u s t i n ga n d r e q u i r e s n o s u b s e q u e nt itg h t e n i n g .
I f c o p i o u sl ea ka g eo ccu rs, th i s i s the usual sign of wear , whichmaybe due to
s u c hc a u s e sa s i n c a u t i o n ss t a r t i n g , d i r t y o i l n p o o r a l i g n m e n o
t r r u n n i n gw i t h outoil.

c.c,!

F=rtrt

GENERAI\|G

SETS

]IlAht
CEU'

L23/30

3 t5 . 5 1

L U B R I C A T I NOGI L S Y S T E M

Edition 03H
Pase1 ( 3)

AN
N DS E R V I C E
OPERATIO

T h e l u b r i c a t i n g o i l f i l t e r i s s p d i m e n s ' i o n et hda t e a c ho f t h e t w o f i l t e r h a l v e s h a d s u f f i c i e n t t o t r e a t t h e ' a m o u not f l u b r i c a t i n g o i l d e l i v e r e db y t h e

pump.
T h e t h r e e -w a yva l ve p o si ti o n ed is deter miningfr om whetherthe left handor the
r i g h t h a n df i l t e r c h a m b ei rs i n p o s i t i o n , a n d a l s o g i v e s t h e p o s s i b i l i t y t o
h a v eb o t h f i l t e r c h a m b e r'si n o p e r a t i o ns i m u l t a n e o u s l y .
T h e t h r e e - w a yv a l v e i s m a r k e dw i t h f l o w d i r e c t i o n s a n d t h e f i g u r e i n d i c a t e s
t h e o p e r a t i o nm o d e sa c c o r d i n gt o v a ' l v ep o s i t i o n s .
T h r e e - w avya l v e p o s i t i o n s
Eoth eldes

Both ides

<;3

3. oo
.::

Left hand
f i l t e r ch a mb e r
in operation

t
Right hand
fi I ter chamber
in operation

Both fil ter

chambers
in operation

Servicing:
S e r v i c i n gc o m p r i s e sr e p l a c e m e notf p a p e rf i l t e r
f e t y f i l t e r a n df i l t e r h o u s i n g .

c a r t r i d g e s , c l e a n i n go f s a -

Se r v i c e p ro ce d u re .
l . T u rn th e th re e -w ayvalve 6 into the position setting the sta ndb y fi l te r ca mb e rin oper ation and the filter camberr equir ing
s e r v i c eo u t o f o p e r a t i o n .
r on the top of the filter
2 . O p e n t h e v e n t s c r e $6
sureout of the filter half.
3 . O p e nt h e d r a i n p ' l u g8 u n d e rt h e f i l t e r

to get the pres-

h o u s i n ga n d d r a i n o f f o i i .

4 . F i l t e r h o u s i n gc a p i s d i s m a n t l e d .
th e i n n e r safety elen ent.Clean the elem entwith deter 5 . R e mo ve
g e n t o r i n u l tra sonic washingm achine.Checkthat it is intac t.

FTTT.^EBY

GET{ERA:fI\CSETS

Lz3/30

/=G\

L U B R I C A T I NOGI L S Y S T E M

3 ts . 5 l
Edition 03H
P a g e2 ( 3 )

OPERATION
ANDSERVICE

6 . R e m o vteh e o u t e r e ' l e m e n t ( s )F
. i l t e r e l e m e n ti s o f d i s p o s a b l et y p e .

C h a n g e'i t a l w a ysto n ewor i gi nal f i I ter

7 . C l e a nt h e f i l t e r h o u s i n ga n d t h e c a p . B e c a r e f u l o f n o t t o l e t t h e
o i l f r o m t h e d i r t y s i d e t o g o i n t o t h e c l e a n o ' i l c h a n n e li n t h e
m i d d l eo f b o t t o m .

1 . - L e f t h a n df i l t e r c h a m b e r
2 . - R i g h t h a n df i l t e r c h a m b e r
3. - Inlet
4. - 0utlet
5. - Vent screhl

r
I

-a- .
I

ta

6. - T h r e e - w a va
y l ve /sw i tchva l ve
7. - Fill-up valve
8 . - D r a i np l u g
8 . C h e ckth e se a l s o n th e b o ttomof t h e f i l t e r
C h a n g ei f n e e d e d .

h o u s i n ga n d i n t h e c a p .

9 . C h e c kt h e O - r i n g o n t h e c a p a n d c h a n g e i f n e e d e d .
1 0 . A s s e m b l et h e f i l t e r

in opposite order.

F I L L - U PV A L V EP O S I T I O N S
OPERATI
CN

S w i t c hi n
normal
o p e r a t io n
position

ffi
qw

CHANGING
OVER
S w i t c hi n
fill
posi tion

H.TETY
GET\ERA{O SETS

}IAT

Et&ut

L23/30

3 15 . 5 1

OIL SYSTEM
LUBRICATING

Edition 03H
P a g e3 ( 3 )

OPERATION
ANDSERVICE

t 1 L e t t h e a i r v a l v e b e o p e na n d f i l l

t h e f i l t e r h o u s i n gw i t h o i l b y
m e a n os f t h e s l o w f i l l - u p v a l v e 7 i n p o s i t i o n F I L L . T h i s v a l v e i s
i n s i d e t h e t h r e e - w a yv a l v e a n d b y u s i n g i t , t h e f i l l i n g c a n b e
ma d eso sl o w l y that the pr essur eon the other par t of the fi l ter
d o e s n o t d ro p to o m uch.

1 2 . C l o s et h e v e n t s c r e w5 a f t e r t h e h o u s i n gi s f i l l e d u p w i t h o i l .
1 3 .O p e nt h e t h r e e - w a yv a l v e 6 a n d c l o s e t h e f i l l - u p v a ' l v e7 b y t u r n i n g i t t o p o s ' i t i o nC L 0 S E D .

1 4 . T h e f i l t e r j u s t s e r v i c e d i s n o u ,r e a d y t o b e s e t i n o p e r a t i o n .
I n s p e c tf o r o i 1 l e a k a g e si n o r d e r t o a s c e r t a i na l l s e a l i n g st o
be tight.
C h e c kt h a t p r e s s u r ed r o p a c r o s sf i l t e r
C l e a nt h e o t h e r s i d e o f t h e f i l t e r

is correct.

correspondingly.

E!.TEBY

GCrrERAflf\C SETS

tvlAht
L23/30
L U B R I C A T I NOGI L
LUBRICATIN
OG
IL SPECIFICATION

ct&ult
D315
Edition 0lH
P a s e1 ( 1 5 )

T h e l u b r i c a t i n g o i l o f a 4 - s t r o k e e n g i n e' i s a c a r d i n a l e l e m e n ti n g o o de n g i n e
o p e r a t i o n ,a s i t s e r v e sq u i t e a f e w i m p o r t a n tp u r p o s e s ,s u c ha s :
' l . L u b r i c a t i n gt h e b e a r i n g s ,t h e c y f i n d e r s a n d p i s t o n r i n g s a n d o t h e r m o v i n g
parts of the eng'ine.
2.

N e u t r a l i z i n gt h e e f f e c t o f s u l p h u r i n t h e f u e l o i l t o p r e v n tc o r r o s i o no f
c y f i n d e r I i n e r a n dp i s t o n r i n g s .

3.

C o o l i n go f b e a r i n g sa n d p i s t o n s a n d k e e p i n gt h e e n g i n ei n t e r i o r c l e a n .

4.

T r a n s p o r t i n gc o n t a m i n a n tssu c ha s d u s t , r u s t , w a t e r , f u e l r e s i d u e s ,l u b r i c a t ' i n g o 'i l re si d u e s, e tc. awayfr om the engine to the filter s and se par ators.

C o n s e q u e n t l yt h, e l u b r i c a t i n g o i l i s a f i n e l y b a l a n c e dm i x t u r eo f a s u i t a b l e
b a s eo i 1 t o p r o v i d el u b r j c a t i o n a n d c o o l i n g , a n d a s e r i e s o f l u b r i c a t i n go i 1
a d d i t i v e s t o t a k e c a r e o f t h e n e u t r a l i z i n g t a s k , t h e c l e a n i n ga n d t r a n s p o r t a t i o n o f c o n t a m j n a n t sa,s w e l l a s o t h e r a d d i t i v e s t o e n s u r et h e c o n t i n u ' i t yo f
s u c ha b iI i t ' i e s o f t h e I u b r i c a t i n g o i 1.
L u b r i c ati n g 0 i l S p e ci fi ca ti o n for B&t.l
4- str oke Engines.
I n t h e g u i d i n g l ' i n e s b e l o ww e h a v ec l a s s i f i e d t h e s y s t e mo i ' l s b y u s i n g t h e
on alkalinity in r elati on
A P I C o m rn e rci C
a ll a ss S yste mand addedsomecomr nents
t o s u l p h u rc o n t e n t .
H o w e v e rr,e f e r e n c et o a n y k i n d o f l u b r i c a t i n g o i l s y s t e m ,e . g . t h e A P I o r s i m i l a r s y ste ms,sh o u l d b e ta ke n only as a guide, as no cur r ent specification s y s t e m f u ll y co ve rs th e n e e d sand r equir ementsof m ar ine lubr icating oil w hether
d u r i n g d i e s e l o i l o r i n t e r m e d i a t ef u e l o i l r u n n i n g . S u c hr e q u i r e m e n tcso m p r i se:
A n t i - f o a mc h a r a c t e r i s t i c s ,a n t i - w e a rp r o p e r t i e s , l o a d - c a r r y i n ga b ' i 1 i t y , d e t e r g e n c yl eve l , o xi d a ti o n re si stance, anto- cor r osionpr oper ties, water separ ati on
a b i l i t y ( d e m u l s i b i l i t y ) ,n e u t r a l i z a t i o na b i l i t y a n d a l k a l i n i t y ( T B N ) .
S u c hp r op e rti e s sh o u l db e a ccountedfor in specific cases by the Iubr icati ng
o i ' l s u p p i' el r .
systemoi l w i th
F o r 4 - s tro ke e n g i n e su se d fo r mar ineappfication, v' r er ecom m end
a d e t e r g e n cyl e ve 'l a t l e a st cor r espondingto API ser v' iceCCICD.
A l t e r a t i o n a n d s t a b i l i z a t i o n o f T B N - v a l udeu r i n g a p e r i o d o f o p e r a t i o n .
F o r e n gi n e su se d fo r sta ti o n ar y pur poses,we r econr nend
systemoils with a det e r g e n cyl e ve l a t l e a st co rrespondingto API ser vice CD.
I 9 8 7. 0 4 . 0 8
I L-!
Fr-t
E !itE-E-|l'B
t
CENERAN\|G
SETS

lvlAf\t

Er&ut

L23/30
L U B R I C A T I NOGI L

D315

E d i t i o n0 1 H
P a g e2 ( 1 5 )

OG
IL SPECIFICATION
LUBRICATIN

TBN
TBN
i n i ti ot

Re fjJlne)

TBN
equilibrium

Service hours

T B N -va l u ei n re l a ti o n to fuel o' i1 su' lphurcontent.

T h e v i s c o s i t y o f t h e l u b r i c a t i n g o i l s h o u l db e w i t h i n S A EC l a s s3 0 .
T B N( t o t a l b a s en u m b e r i)n d i c a t e s t h e a ' l k a l i n i t y o f t h e l u b r i c a t i n g o i l a n d
c on s e q u e n t l y i, ts n e u tra l i zi n g e ffe ct on acids developedfr om the sulphur in
t he f u e l o i l . Th e T B Ni s n o rma l l y reducedgr adua' l' lydur ing the time of oper at ion . T h e i n f l u e n ti a l e l e rn e n tsa i e the sulphur content in the fuel oil and the
amo u not f r e f i ll i n g d u e to n o n ra l consum ption.After a cer tain time of oper at i o n , t h e T B Nw i l l s t a b i l i z e a t a l o w e r v a l u e , t h e T B Ne q u i l i b r i u m .

I987.04.08
lJ+E

tE3tt

E F==E-5
E
GENERAN\GSETS

lYIAh|

Er&ut

L23/30
LUBRICATIN
OG
IL
LUBRICATIN
OG
IL SPECIFICATTON

D315
Edition 0lH
P a s e3 ( 1 5 )

T.B.N.
35
30
25
20
15
10

F""lfurl,
A l t e r a t i o n a n d s t a b i l i z a t i o n o f T B N - v a l u de u r i n g a p e r i o d o f o p e r a t i o n .
Ab o v et h e 're l a ti o n sh i p b e tw eenfuel oil sulphur content and adequateTBNof
t h e l u b r i c a t ' i n go i l i s i l l u s t r a t e d . W h e ns e l e c t i n g a l u b r i c a t i n g o i 1 , t h e a r e a
" T B Ni n i t i a l " i s t o b e u s e da n d t h e s t a b i l i z e d l e v e l o f t h e l u b r i c a t i n g o i 1
s h o u l db e k e p t w i t h i n t h e a r e a " T B Ne q u i l i b r i u m " . R e f i l l i n g d u e t o n o r m a l u b r i c a t i n g o i 1 c o n s u m p t i osnh o u l db e c a m i e d o u t w i t h l u b r i c a t i n g o i ' l o f i n i t i a l
TBN.
ar ea "TBNequilibr ium " i s
I f t h e T B Nva l u e sta b i l i ze d within the r ecom m ended
d i s t u r be d d u e to te mp o ra ri l y abnor maloper ation conditions and thus for c ed to
TBNequilibr ium , it might be adjustedby r ea l e v e l o u tsi d e th e re co rmended
f i l l i n g w i t h a l u b r i c a t i n go i l o f a s i m i l a r t y p e a s u s e di n t h e e n g i n eb u t
w i t h a n o t h e rT B N - i n i t i a l.
T h i s m e th o do f a d j u sti n g th e TBNvalue should only be used in concer t wi th the
I u b r i c a t i n g o i ' l s u p pile r .
I f , d u r i n g n o r m a lo p e r a t i o n ,t h e T B N ' i sf o u n d t o s t a b i l i z e a t a l e v e l o u t s i d e
t h e a r e a o f re co mme n dTeB
d Nequil ibr ium , a changeto a lubr icating oil of m or e
s u i t a b l e T B Ni n i t i a l s h o u l db e c o n s i d e r e d .
'list
T h eo i l
o v e r l e a f m a yb e u s e da s a g u i d e i n s e l e c t i n g l u b r i c a t i n g o i l t y p e s f o r B & l .el n g i n e s .T h e l u b r i c a t i n g o i l s i n c l u d e di n t h e l i s t h a v ea l 1 g i v e n
s a t i s f a cto ry se rvi ce i n B & l ,|
engines. The list must not be consider edcom pl ete
maybe chosen.
u b ri ca ti n g o i l s fro m o ther com panies
1987.04.08

EE.EBY
CE{ERAN\G SETS

0 3 15

L U B R I C A T I NOGI L

E d i t i o n0 1 H
P a g e4 ( ' 1 5)

G SS A E3 0
L I ST O F H DL UB R IC A T IN
OIL

Specif ic
9ravrly
15.C

Flash
point'C

0.923
0.924
0.908
0.926
0.932

231
234
254
240
230

CASTROL Caslrol Marine MPX 30

Castrol215 MX Super
Castrol215 MXD
Caslrol MXD 303

0.895
0.898
0-901
0.909

CHEVRONChevron Delo 1000 MarineOil

Chevron Delo 2000 MarineOil
Chevron Dlo 3OO0Marine Oil

Name ot ol

Company

BP Energol DS3-r03
BP Energol DS3-153
BP Energol DL-MP 30
BP Energot IC-MB 30
BP Energol IC-HF 303

BP

coc

Viscosily n
csi at
10'C

100.c

128
128
tr4 {

12r
1r8

12.3
12.3
11 . 5
lr.6
r t.5

2U
252
246
260

105
r03
113
112

I r.5
1r.8
12.2
12.2

0.897
0.900
0.9r0

215
240
240

r12
r06
flo

t2.1
r2.o
12.3

TBN
I

'r0
r5

15

r5
9

r6

16
22
30

9
10

25
30

CD
CD

12
12
12

Tro Mar SD 30
Tro Mar SR 30

o.899
o.90s

246
246

112
112

12-2

12

FINA

Fina Dilano 3lO

Fina Stellano325
Fina Stellano330

0.898
0-909
0.912

226
226
226

r08
1r0

11.7
12.O
rl3

r0.4

Gull Veritas DPO 30

Gull Veritas SD 30
Gulf Veritas Select 30

0.893
0.894
0.903

250
226
242

113.4
98.1
104

12.1
11.0
11.5

t3
r0.6

Mobilgard 312
Mobilgard 324

0.895
o.905

2r8

r02
1tt

r1.8
1r.8

12

218

NOROL

Norol Marine TMA 330

Norol Marine HA 253

o.923
o.928

235
230

r28
1r8

r2.2
rt5

r5

NYNAS

Nymarol 30 OL
Nymarol 30 OM
Disola M30r5
Aurelia 3030

o.899
0.900
o.904
o.9r0

235
240
248
235

1r0
120

12.O
12.0
12.O

t1

r15

r2.3

SHELL

S h e l l G a d i n i aO l 3 0
Shell Rirnula Oil 30
Shell Argina Ol T 30

0.897
o.916
0.9r0

227
232
226

1(N

11.8
10.8
11.8

1t

r?4
1(X

TEXACO

Texaco Ursa Super LA 30

Texaco Taro XD 30
TexacoTaro DP 30

0.908
0.923
o.929

240
240
230

r05
122
122

1r-8
1r.2
11-2

7
16

Total Ruba 530

Total HMA 30

0.897
o.903

248
235

100
1r0

12.O

Thc list

intends to be used es guidanceonly.

llc take no reponsibility

cusedby lub. oils.

for difficulties

r2.o

It
8/9
8/9

CD
CD

ESSO/
EXXON

CD

ll

10
11

30

CD

r0

CD
CD

9
l2

'cD
25
15

CD

cc

11
10

r0
72

26

CD
CD
CD

16
30

CD
CD
CD

12
I
10

CD

12

CD

11

125

r6

10
10
l0
10

25

r2.0 12.5
26
r2.3

r5

tl
l0

72

tl4
115

TOTAL

co

10
10

CD
CD

23s

114

CD
CD
CD

20
30

248

MOBL

r0

CD

72

o.904
0.910

GULF

co

30 CD

Disola M 3015
Aurelia 3030

108

FZG
load

cc
r 5 cc

ELF LUB
MARINE

r2.2

API
clasS

72
tl

cD. 1 1

30

CD

34

te do not cxclude oils of siailr types but

fron.firms not comPrisedby the list to be
uitable for our engines.

The llst states lub. oils rhich hve proven

satisfactory service results.

19 8 7 . 0 4 . 0 8

E#.EEY
GENERATIAG SETS

L23/30
L U B R I C A T IN
G
OIL

0315
E d i t i o n0 l H
P a g e5 ( 1 5 )

M A I N T E N A NO
CFEL U B . O I L C O N D I T I O N

D u r i n go p e r a t i o no f t r u n k e n g i n e s ,t h e l u b r i c a t i n g o i l w i l ' l -b-e
ct o n t a m i n a t e d
s l o w 1 yb y s m a l l p a r t i c l e s o r i g i n a l i n g f r o m r c o r i i o n . T h eb u r " n i n g
o f h e a v yf u e l s w i l l n o r m a l l yi n c r e a s et h i s c o n t a m i n a t i o dn u e
to
t h e i n c r e a s e dc o n t e n to f c a r b o nr e s i d u ea n d o t h e r i m p u r i t i e i .
C o n t a m i n a t i oonf l u b r i c a t i n g o ' i l w i t h w a t e r , f r e s h o r s a l t ,
can also take place.
A c e r t a i n a mo u n ot f co n ta mi .in
ngnt_scan be kept suspended
the lub. oil withoutaffecting
the lubricating properties.

Mrintcnncc

B u t t h e c o n d i t i o no f t h e l u b .
o i l s h o u l db e k e p t u n d e ro b s e r v a t i o n b y a n a l y s i n go f o i l s a m p
Ies.
T h e e n g i n e b e a ri n g sa re p ro te cted by the full-flow lub. oil
f i l t e r b u i l t - o n t h e e n g i n e ,t h e
f i l t e r c a r t r i d g e s h a v i gu
f i n e n e s so f l 5 m i c r o na d t h e
s a f e t y f i l t e r a f i n e n e s so f 6 0
micron.
T h ec o n d i t i o no f t h e l u b . o i l
c a n b e m a i n ta i n e d /re e sta ibsh
l ed
by exchange
o f th e o i l a t fi xe d
scheduleo
s r b a s e do n a n a l y s i s
r e s u lt s .
A m o r ee co n o mi cso l u ti o n i s to
m a i n t a i nt h e c o n d i t i o n b y c o n t i n u o u s t re a tme n t

of Lubricaring Oil Condirion

Lrb.Oll Mint.nrncc

Erclungc
- oo clrcdule
o(
- oncondatb

Condition
Moniroring
. oil samptes .
erulysb.

Filtrtion lor
Ecrring Protccrion.
- fltcr l5 u - safety filtcr 60 u -

Eng. lub.ol !ytt.m

E x p e r i e n ceh q s p ro ve dth a t ce n tr ifuging is super ior to other

methodsfor cl eani n g l u b r i c a t i n go i l s .
O p t t ' m ucm
l e a n i n ge f f e c t i s a c h i e v e d . b ky e e p i n gt h e l u b r i c a t i n g
oil in a state
o f l o w v i sco si ty fo r a l o n g p e riod in the tenir ifuge bowi
L o wv i s c o si ty i s o b ta i n e db y p reheatingthe lubr icating
oil to a temper atur eof
8 5 0 C- 9 5 0 C -

E#H.EEY

GENERATIT\IC STS

lYIAI{
L23/30

E&U'

LUBR I C A T IO
N IL
G
MAINTINANC
OEF L U B . O I L C O N D I T I O N

D315
Edition0lH
P a g e6 ( 1 5 )

S l o * p u r r a g eo f t h e ' l u b r i c a t i n g o i l t h r o u g ht h e c e n t r i f u g a l s e p a r a t o ri s o b t a in e d b y u s i n g re d u ce df'l o w ra te a nd by oper ating the separ ator24 hour s a

d a y , o n l y s t o p p i n gw h e nc l e a n i n go f t h e b o w l ' i s n e c e s s a r y .
[ , { h e tnr e a t i n g d e t e r g e n tt y p e l u b r i c a t i n g o i l , t h e f l o w r a t e i s u s u a l l y r e c o m mendedto be reducedto 15-25%of the rated flow of the separator.
F o r k e e p i n gt h e a m o u not f l u b r i c a t i n g o i l i n t h e e n g i n ei n g o o dc o n d i t ' i o n ,i t
i s n e c e s s a r yt o t r e a t 0 . 2 7 1 / k Wp e r h o u r ( 0 . 2 0 I / B H Pp e r h o u r ) .
A c e n t r i f u g e f or tre a t'i n g th i s a mo untof lubr icating oil under the m entioned
d e r a t e df l o w c o n d i t i o n ss h o u l dh a v ea r a t e d c a p a c i t yo f 1 . 0 8 - 1 . 8l / k l , l p e r h o u r
( 0 . 8 - 1 . 3 l / B H Pp e r h o u r ) , b u t i n e a c hc a s e t h e s e p a r a t o rm a n u f a c t u r e r 'rse c o m m e n d a t i o na
s b ou t ca p a ci ty a n d i n structions about oper ation should be followed.
F o r e n g i n e sw i t h c a r t r i d g e - t y p eo i 1 f i l t e r s ( d e p t hf i l t e r s ) , c o n t i n u o u sa n d
e f f i c i e n t p u r i f i c a t i o n o f t h e o i ' l i n t h e s e p a r a t o ri s e s s e n t i a l t o e n s u r el o n g
serviceIift of the cartridgefilters.
B y i n s t a l l a t i o n o f a s e l f - c l e a n i n gf i l t e r i n ' l i n e w i t h , a n d p l a c e db e f o r et h e
c a r t r i d g e - t y p ef i l t e r , t h e l i f e t i m e o f t h e p a p e rf i l t e r e l e m e n t sc a n b e p r o l o n g e dc o n s i d e r a b l y .
Tre a t m e not f t he L u b ri ca ti n g 0 i l
F I L L I N GU P
ilh e t h e r t h e o i l syste mi s n e wo r w hetherthe oil in the systemhas beenem pte d
owin gt o r e p a i r o n th e e n g i n eo r re newalof cir cu' lating o' il, utm ostcar e shoul d
b e t a k e n t o a v o i d t h e p r e s e n c eo f a b r a s i v ep a r t i c l e s . F i l t e r s a n d p u r i f i e r s w i l l
on'ly slowly removethese and someare boundto find their way to bearings in
t h e e n g i n e .M e t i c u l o u sc l e a n i n go f p i p e s , c o o l e r s a n d b o t t o mt a n k a s d e s c r i b e d
b e lo w i s f o r t hi s re a so nve ry g o o deconompr
y ior to filling up the system.
C l e a n i n go f L u b r i c a t i n g0 i l S y s t e ma f t e r a M a j o r R e p a i r
T h e b e l o w r e c o mme n d a t'ihoans b e e nw or kedout, basedon our exper ience,in or der t o g i v e t h e ya rd s a n d th e o p e rator s the best possible advice to avoid
mis h a p sa f t e r a ma j o r re p a i r.
Norma o
l v e r h a u la n d re p a i r d o e s n o t necessitatedism antlingor opening- upof
t h e l u b r i c a t i n g o i 'l co n n e cti o nb e tweenthe papercar tr idge filter and main
b e a r in g s.
Eef o r e t h e r e p ai n w o rk sta rts, th e filter car tr idges ar e to be r eplacedby new
o n e s ( s e e s p e c i a l i n s t r u c t i o n s ) . T h i s i s d o n ei n o r d e r t o b e a b l e t o r u n t h e
e n g i n ef o r ' a f a i r l y l o n g p e r i o d o f t i m e a f t e r t h e f i n i s h e d r e p a i r w i t h o u t
c h a n g ' i ntgh e f i l t e r c a r t r i d g e sd u e t o b l o c k i n g - u p .
Du ri n g t h e r e p ai r, th e fi l te r sh o u l d be kept closed in or der to pr eventabr asi v e p a r t i c l e s e n t e r i n gt h e c l e a n s i d e .
t L-rt
F]rtt
E E!I'E.=.E''
E
CENERA'I\G STS

]Y|AI

cr&ut

L23/30
L U B R I C A T I NOGI L

03 15

M A I N T E N A NOCFEL U B . O I L C O N D I T I O N

E d i t i o n0 1 H
P a g e7 ( 1 5 )

I f p i p e s , c o o l e r o r p u m p ' i nt h e l u b r i c a t i n g o i ' l s y s t e mb e f o r e f i l t e r
m a n t l e d ,c a r e f u l c l . e a n i n go f t h e e n t i r e s y s t e mm u s t t a k e p l a c e .

are d'is-

I f t h e l u b r i c a t i n g o i l s y s t e ma f t e r f i l t e r i s , i n e x c e p t i o n a lc a s e s ,o p e n e d ,
i t i s e s s e n t i a l f o r t h e o p e r a t i o no f t h e b e a r i n g st h a t t h e e n t i r e s y s t e mi s
a b s o l u t e l yc l e a n b e f o r e t h e e n g i n e i s r e - s t a r t e d .
A s t h e l u b r i c a t i n g o i l i s l e d t o t h e m a i nb e a r i n g st h r o u g hb o r e s i n t h e f r a m e ,
b y - p a s s ' i ntgh e b e a r i n g sw h e nf l u s h i n g i s n o t p o s s ' i b l e .l ' l h e nc l e a n i n gt h e b o r e s
i n t h e f r a n p , th e co rre sp o n dingmain bear ing shells should be r emoved
an d the
l u b r i c a t i n g o ' i l b o r e i n t h e c r a n k s h a f ts h o u l db e c l o s e d .
I f t h e p a i n t i n s i d e w e l d e dl u b r i c a t i n g o i l p i p e s i s d a m a g eddu r i n g r e p a i r ,
c l e a n i n ga n d r e p a i n t i n g s h o u l dt a k e p l a c e b e f o r e r e m o u n t i n g .
F o r r e p a i n t i n g , a n o i l - r e s i s t a n t p a i n t m u s t b e u s e da n d i t i s i m p o r t a n t h a t
t h e p r e p a r a t i o no f s u r f a c e sa n d a p p l i c a t i o no f t h e p a i n t i s d o n ea c c o r d i n gt o
t h e r e c o mme n d a ti ofo
n sr th i s pr oduct.
C a r e f u l ma n u a cl
l e a n i n g o f the oil pan/bedplateshould alwaystake place after
a n y t y p e o f w o rk h a s b e e nca rr ied out in the cr ankcase.
P a r a m e t e risn f l u e n c i n g t h e C o n d i t i o no f L u b r i c a t i n g0 i l
C l e a n i n go f t h e l u b r i c a t i n g o i 1 d u r i n g o p e r a t i o no f t h e e n g i n ei s c a r r i e d o u t
by the in-line lubricating oil filter andthe lubricating oil separator.
I n o r d e r to o b ta i n sa ti sfa ctor y oper ation of the separ ator , it is impor tant
t h a t t h e fl o w ra te a n d th e te m per atur ear e adjusted to their optimum,as describedin the following:
(Pentoneinsolubles)

Smoll
vblumes

Lorge volume

Timc

S t a b i l i z a t i o n o f t h e l e v e l o f c o n t a m i n a t i o inn l u b r i c a t i n g o i l s y s t e m s .
I G.C,t
Fflt
E T-=.=.E5

CENERA'ru\|cSETS

lvlAhl

Et&ut

L23130

0 3 15

L U B R I C A T I NOGI L

Edition0lH
P a g e8 ( 1 5 )

OF LUB. OIL CONDITION

MAINTENANCT

A c e n t r i f u g a l s e p a r a t o rw o r k i n go n a c h a r g eo f o i 1 w i l l , i n p r i n c i p l e a f t e r a
n a t e r i a l p e r h o u rw h i c h ' i s
c e r t a i n t i n e r e m o v ea n a m o u not f c o n t a m i n a t i o m
pr
oducedby the engine in the
m
ater
ial
co
n
ta
mi
n
a
tion
equ a l t o t h e a mo u not f
s a m es p a no f t i me
T h i s m e a n st h a t t h e s y s t e m( e n g i n e ,o i l a n d s e p a r a t o r )i s i n e q u i l i b r i u ma t a
c e r t a i n l e v e l o f l u b . o i l c o n t a m i n a t i o n a m e dP e qa n d u s u a l l y m e a s u r eads p e n tane insolubles.
I n a l a r g e l u b . o i l s y s t e m ,e q u i l i b r i u mw i l l t a k e p l a c e a f t e r a l o n g e r t i m e
t h a n i n s m a l l s y s t e m a, s s h o w ni n t h e f i g . , b u t t h e l e v e l a t w h i c he q u i l i b riu m o c c u r sw i l l b e th e sa me ,b e causethe systemoil can be r egar dedonly as
n aterial.
a c a r r i e r o f c o n t a m i n a t i om
T h e C l e a n i n gP r o c e s s
A s e p a r a t o r c a n b e o p e r a t e da t a g r e a t l y - v a r y i n g f l o w r a t e ( c a l l e d Q ) .
Practical experiencehas revealed that the lubricating oi1 content of pentane
insolubles before and after the separator is related to the separator flow
r a t e a s s h o w ni n t h e f i g u r e .

100%

Cleaningeffect

'in relation to separator flow

rate.

T h i s n e a n st h a t p = p ( b e f o r e ) - p ( a f t e r ) w i l l d e c r e a s ew i t h r i s i n g Q .
I t i s o b v i o u st h a t a l o w Q , o n l y a s m a l l p o r t i o n o f t h e o i l i s b e i n g c l e a n e d ,
A t h i g h Q , m u c ho i l i s b e i n g l i t t l e a f f e c t e d .
I t-,t
|FGE
E ttE =-=-tr'
E
GEf\ERAN\C SETS

L U BR I C A T IN
G
OIL

0315
Edition 0lH
P a g e9 ( 1 5 )

M A I N T E N A NO
CFEL U B . O I L C O N D I T I O N

H o w e v e rb, y c o r r e c t l y a d j u s t i n g t h e s e p a r a t o rf l o w r a t e , a n o p t ' i m a e
l quilib r i u mc a n b e o b t a i n e d .
T h e o p t i m u mi s o b t a i n e db y a p p l y ' i n ga s u i t a b l e f l o w r a t e t h a t i s o n l y a f r a c t ' i o n o f th e sta te d ma xj mu capacity
m
of the separ ator .
T h i s i l l u s t r a t e d i n t h e f i g . w h i c h s h o w st h e d e p e n d e n cbee t w e e np e q u i ' l i b r i u m
a n d t h e fl o w ra te . It i s o b v ious that the optimumflow r ate is aT- Thecur v em ini m u m .

100"/"

Optimum
c ' l e a n i n gf l o w r a t e .

T h e a b i l i ty o f th e syste mo i l to "car r y" contam inationpr oductsis expr es s ed

b y i t s d e te rg e n cy/d i sp e rsa ncy
level .
T h i s m e a n st h a t a g i v e n c o n t e n to f c o n t a m i n a t i o n, . g . 1 %w i l l , i n a d e t e r g e n t
q i l , b e p r e s e r i ta s s m a l l e r , b u t m o r en u m e r o upsa r t i c l e s t h a n i n a s t r a i g h t - o i l .
F u r t h e r mo re th
, e p a rti cl e s i n the deter gent oil ar e sur r oundedby additi v es ,
w h i c hg i v e s a r e s u l t i n g s p e c i f i c g r a v i t y v e r y c l o s e t o t h a t o f t h e o i l i t s e l f ,
h a m p e r i ntgh e p a r t i c l e i n s e t t l i n g i n t h e s e p a r a t o r .
T h i s i n f l u e n c e st h e p o s i t i o n o f t h e m ' i n i m uim
n the fig. which,for a detergent
o i l , w i l l b e s i t u a t e da s i n t h e f i g u r e .
I t - a p p e a r st h a t t h e e q u i l i b r i u mc o n t e n to f p e n t a n ei n s o l u b l e si n a d e t e r g e n t
oil will be higherthan in a straight oil, andthe optimum
flow rate will be
s m alle r
t l.-l
Ftlt
E 5=LE.E5
E
CGNERA\IGSTS

TYIAN

Et&ult
LUBRICATIN
OG
IL

D3t5

M A I N T E N A NOCFEL U B . O I L C O N D I T I O N

E d i t i o n0 1 H
P a s e1 0 ( 1 5 )

P"o

Pd
PS

oo o,
0 p ti mu mse p a ra to rfl o w r ate whencleaning str aight
t y p e / d e t e n g e nt ty p e o f l u b r i c a t i n g o i ' 1 .

A s t h e _ i m p o r t a nfta c t o r i s t h e p a r t i c l e s i z e ( w h i c hm i g h t i n v o l v e t h e r i s k o f
we a r o f t h e j o u rn a l s) mo reth a n th e actual content of nsolubles, the above
n e n t i o n e dd i f f e r e n c e i n e q u i l i b r i u m' l e v e l s i s o f m i n o r i m p o r t a n c I.n g e n e r a ' l
,
the optimumflow rate for a detergent oi1 is about 15-ZS%'ofthe maximm
cafac i t y w h e r e a sf o r a s t r a i g h t o i l , i t i s a b o u t 5 0 - 6 0 U .F o r m o s t s y s t e mo i l s o i
lg d a y , w h i c h i nco rp o ra tea ce rta i n deter gency,the optimumwill- be about 1525%.
Th e t e m p e r a t u resh o u l d b e a b o u t 8 5 -95oC.

EE.ETY

GENERATU{GSETS

L U B R I C A T I NOGI L

M AI N T EN A N
CL
EU B .OIL C ONDITION
OF

D3t5
Edition 0tH
Page 11 ( r s )

D ET ER IOR A TOF
ION
OIL
0 i l s e l d o ml o s e s i t s a b i l i t y t o l u b r i c a t e , i . e . t o f o r m a n o j l f i l m w h i c hr e d u c e st he fri cti o n , b u t i t might become
cor r osive to the steel jour nals of the
b e a r i n g si n su ch 9 w a y th a t the sur face of these jour nals becom s
too r o ugh
a n d w i p e s th e b a b b j tt. In th at case not only the bear ing metal must be reew ed,
b u t t h e j o u r n a l s ( s i l v e r y w h i t e f r o m a d h e r i i r gw h i t e n r e t l )m u s tb e p o l i s h e d ,
w h i c h . i s c o s t l y . C o r r o s i v e n e sosf t h e l u b r i c t i n g o i l i s d u e t o e i t l e r t a r v a n c e do x i d a t i o n o f t h e o i l i t s e ' l f ( T A N )o r t o t e p r e s e n c eo f i n o r g a n i ca c i d s
( s A N ) -I n b o t h c a s e s , t h e p r e s e n c eo f w a t e r w i l l m u i t i p l _ vt h e f f e c t ,
especial1y with an influx of seawatea
r s t h e c h l o r i d e i o n s a c t a s a n i n o r g a n i ca c i d .
O x i d a t i o no f 0 i l s
At normal service temperaturethe rate o f o x i d a t i o ni s i n s i g n i f i c a n t ,b u t t h e
f o l l o w i n g f a c t o r s w i l l a c c e l e r a t et h e p r o c e s s :
High Temperature
T h e t e m p e ra tu rel e ve l w i l l g ener ally be r aised if the cooler s ar e not effec ti ve.
H i g h t e m p e r a t u rw
e i l l a l s o a r i s e i n e l e c t r i c a ' l p r e h e a t e r si f c i r c u l a t i o n i s
n o t c o n ti n u e dfo r 5 mi n u te sa fter the heating hs beenstopped,or if the heater is only partly filled with oil.
Catalytic Action
O x i d a t i o no f t h e o i l w i l l b e c o n s i d e r a b l ya c c e l e r a t e di f c a t a l y t i c p a r t i c l e s
a r e p r e s e n t i n tl 9
We a rpar ticles of copperar e especially tr ar intul ,but
a l s g f g l ro u s.p a rti cl9ei ls. a n d ru st' ar e active. Fi r ther mo.u,th. lcquerand v ar n i s h - l i k e o x i d a t i o n p r o d u c t so f t h e o i l i t s e l f h a v ea n a c c e l e r a t i n ge f f e c t .
C o n t i n u o u sc'l e a n i n go f th e o i l is, ther efor e, im por tant to keepth slud gec ontent low.
S i g n so f D e t e r i o r a t i o n
I f c i r c u l a t i n g o i l o f i n f e r i o r q u a l i t y i s u s e da n d t h e o x i d a t i v e i n f l u e n c eb e c g m e sg r ave ' p ro mp ta ct'i o n i s necessar yas the last stages in deter ior ati on
m i g h t d e v e l o ps u r p r i s i n g q u i c k l y , i . e . w i t h i n o n e o r t w o w e e k s .E v e ni f t h i s
s e l d o mh ap p e n s,i t i s p ru d e n t to be acquaintedwith ttr e sigi- f d"t..ior ati on.
T h e s em ayb e so meo r a l l o f the following:
S l u d g eq r e c ! p i t a t i o ni n p u r i f i e r m u l t i p l i e s .
S m e l lo f o i l b e c o m easc r i d o r p u n g e n t .
Machinedsurfaces in crankcasebecomecoffee-brownby thin layer of laquer .
P a i n t i n c r a n k c a s ep e e l s o f f o r b l i s t e r s .
Ex c e s s i v eca rb o n i s fo rme di n piston cooling c h a m b e r .

FEEBY
GEIWRAff\GSETS

L23/30

}IA]\t
E&U7

LUB R I C A T IO
NIL
G
M A I N T E N A NOCFEL U B . O I L C O N D I T I O N

D3t5
E d i t i o n0 1 H
P a q eI 2 ( 1 5 )

I n a g r a v e c a s e o f oi l. d e t e r i o r a t i o n , t h e s y s t e ms h o u l d b e c l e a n e d t h o r o u g h l y
a n d r e f i l l e d w i t h new o i l .
WATER
WASHING
l . J a t e rw a s h i n g o f H D - o i l s m u s t n o t b e c a r r i e d o u t .
WATER
IN THEO I L

I f th e T A Ni s 1 o w ,a mi n o r i n cre a se in the fr eshwatercontent of the oil is

n o t i m m e d i a t e ldy e t r i m e n t a lw h i l e t h e e n g i n ei s r u n n i n g . N a t u r a l l y , i t s h o u l d
b e b r o u g h t - 9 9 wal gr a i n a s q u i c k l y a s p o s s i b l e ( b e ' l o w0 . ? %w a t e r c o i e n t , w h i c h
i s p e r m i s s i b l e ) .I f t h e e n g i n ei s s t b p p e dw h e nc o r r o s i o nc o n d i t i o n sa r e u n s at i s f a c t o r y , i t sh o u l d b e tu rn e d j ust over I /2 r evolution once ever y hour
{ t o . s t o p i n d i f f e r e n t . p o s i t i o n s )w i t e t h e o i l c i r c u l a t i o n a n d p u r i f y i n g a t a
h igh . p r e h e a t i ngte mp e ra tu reco n ti n u e to r em ovewater . W ater in the oit ay Ue
n o t e d b y d e wd o rma ti o no n th e si g h t glasses, by appear ance,or ascer taineby
i m r n e r s i nag p i e c e o f g l a s s o r a s o l d e r i n g i r o n h e a t e dt o 2 0 0 - 3 0 0 o iCn a n o i l
s a m p l e I. f t h e r e . i s . a h i s s i n g s o u n d ,w a t r i s p r e s e n t . I f a l a r g e q u a n t i t yo f
wa t e r h a s e n t e re d th e o i l syste m, i t m aybe pr ofitable to suck up dedim ented
w a t e r f r o m t h e b o t t o mo f t a n k . T a s t e t h e w a t e r f o r s a l t . I f s a l t y , a n o i l
s a m p l es h o u l db e a n a l y z e di m m e d i a t e l yf o r c h l o r i d e i o n s .

El+E

E l!=.=-

=Ettt

GENERATI\G SETS

LUBRICATIN
OG
IL
CHECO
K FOIL CONDITION

D315
Edition 0lH
P a g e1 3 ( 1 5 )

A s d e s c r j b e dj n t h e f o r e g o i n gs e c t i o n " s i g n s o f d e t e r i o r a t i o n " a n d " W a t e ri n

t h e o i 1 " , t h e s u r v e i l l a n c eo f t h e o i l c o n d i t i o no n b o a r dc o n s i s t si n k e e p i n g
c h e c ko n a l t e r a t i o n s i n s e p a r a t e ds l u d g ea m o u n t ,a p p e a r a n caen d s m e l l o f ' t h
o i l , a n d d e wo n s i g h t g l a s s e s .
T e s t i n go f a c i d i l v ( T A N )m a d er e g u l a r l y o n b o a r d i s a v a l u a b l ec o m p l e m e tnot
t h e p e ri o d i c a n a l yse so f sa mplessent ashor e, but should not r eplate thes e
a n a ' l y s e sI.f , h o w e v e rT, A Nr i s e s q u i c k l y a n d i m m e d i a t e
i n f o r m a t i o ni s d e s i r a b l e , a n a n a l y s i s o n b o a r dw i l l b e a g o o dh e l p . A s c r e wm e m b e rasr e n o t c h e m i s t s
t e s t k i ts co n si sti n g o f se a l ed bottles to be thr ownawayafter use ar e mos t
l a n d y a nd l e a st u n ce rta i n . T he bottles contain a meter eam ountof r eady - m ade
i n d i c a t i n gI i q u i d .
0 i l s a m p l e s h o u l db e s e n t a s h o r ef o r a n a l y s i s a t l e a s t o n c ee v e r y t h r e e
m o n t h s . . T hsea m p l e s h o u l db e t a k e n f r o m a t e s t c o c k o n a m a i np i p e t h r o u g h
w h i c ht h e o i ' l c i r c u l a t e s , w h i l e t h e e n g i n ei s r u n n i n g .
A n a l y s i so f 0 i l
A n a l y s i sm a yb e c a r r i e d o u t i n t h e l a b o r a t o r i e so f t h e o i 1 c o m p a n i e sI .t i s
n o r m a ls e rvi ce fo r th e se to c omm ent
on the condition of the oii baseduponthe
result of the analysis.
A r e p o r t o n a u s e d - o i l a n a l y s i su s u a l l y g i v e s t h e f o l l o w i n g c h a r a c t e r i s t i c s :
1 ) S P e c i f i c . g r a v i ! y :U s u a l l y0 . 9 - 0 . 9 8g r / c u . c m .M a i n l y u s e df o r i d e n t i f i c a E ' r o no T t h e o ] t .
2)

F l a sh p o i l t: L o w e stte mper atur eat which the oi1 gives off com bust i bl e
v a p o u r .G i v e sa n i d e a o f c o n t a m i n a t i ow
n ith fuel il.

3)

n ith heavy
Y i s g o s j ! y : V i s c o s i t y r i s e s b y o x i d a t i o n , o r b y c o n t a m i n a t i ow
TTTollor water. becreasein the viscsity maybe due to dilution byd i e s e lo i l .

4) Iqlalacid

num!g"-llA!: This is the total content of organic and inorgag a n i c ( o r w e a k) a c i d s a r e d u e [ o o x i d a t i o n .

5 ) S t f q n g . a c i dn u m b e (r S A N ) :T h i s i s t h e a m o u not f i n o r g a n i c( o r s t r o n g )
sua1lysulphuricacidfromihecombustioncamb e r o r cl o ri n e -f-ro mse a water( ought to be stated ) . SnUmakesthe o i l
c o r r o s i v e ,e s p e c i a l l y i f w a t e r i s p r e s e n t .
6 ) n l k a l i n i t y ( l o t a l b a s en u m b e rT, B N ) :G i v e sr e m a . i n i nagl k a l i n i t y i n o i l s
m i x e dw i t h a c i d n e u t r a il z i n g a d d i t i v e s .
7 ) W a t-e r:P e rmi ssi b l eu p to 0,2%. Risky if TANand SANar e high. Seawaterhas
a 'i-gtrercorrosive eifect on bearin-gsand journals than freshwater.

E#.EEY
GNERATUVGSETS

IvIAht

Er&ut
D3t5

L U B R I C A T I NOGI L

E d i t i o n0 l H
P a s e1 4 ( 1 5 )

CHECO
K FOIL CONDITION

8)

C o n r a d s e nC a r b o n : R e s i d u e f o r m i n c o m p l e t e c o m b u s t i o no f f u e l o r c r a c k e d
F r e q u e n ti n t r u n k p i s t o n e n g i n e s .
@

e)

P r e c i p i t a t i o n n u m b e rT
: h e a m o u not f i n s o l u b l e i n g r e d i e n t si n t h e o i l .
milsamp1earedilutedbybenzene(C6H6)andnormal
p e n t a n e( C SH l 2 ) . A s o x i d i z e do i ' l ( l a c a u e ra n d v a r n i s h - l i k e c o m p o n e n t s )
' i s o n l y s o l u b l e i n b e n z e n et,h e d i f f e r e n c e i n t h e p r e c i p i t a t i o n n u m b eirs
i n d i c a t i v e o f t h e d e g r e eo f o x ' i d a t i o no f t h e o i l .

1 0 ) As h c o n t e n t: S o mea d d 'i ti ve sl e ave ash, which maybe used to indicate the

a r n o r n T Ta d i ti ve s. T h e a sh also consists of wear par ticles, sandand
rust.
E v a l u a t i o no f a n a l y s i s ' r e s u l t s
F u r t h e r t o v a l u e s f o r t h e p a r a m e t e r isn v e s t j g a t e d ,a n a l y s i s f o r u s e dl u b r i c a t i n g o i l u s u a l l y a l s o w i l l c o n t a i n a b r e i f c o m m e nt ot t h e g e n e r a 'cl o n d i t i o no f
t h e o i l , c o n c l u d i n gw h e t h e rt h e o i l i s s u i t a b l e f o r f u r t h e r s e r v i c e o r s h o u l d
b e e x c h a n g e d.
Th e d e t e r m i n ati o no f th e g e n e ra l condition and the suitability of the oil is
b a s e do n c e r t ai n l i mi ts fo r th e i n dividual par ameter sor changesin values
c o m p a r e tdo t h o se fo r th e o 'i 'l i n u nusedcondition.
T h e l i s t s t a t e s s u c hg u i d i n g l i m i t a t i o n - v a l u e sf o r u s e d l u b r i c a t i o n o i l o f t h e
heavyduty detergent type for four-stroke medium-speed
engines.
Th e l i m i t a t i o n -va l u e s a re b a se do n exper ienceand infor m ation fr om oil com pa nies.
I t s h o u l db e n o t e d t h a t : t h e v a l u e sa r e o n l y g u i d i n g , n o t d e f i n i t i v e .
Var i a t i o n s m a yo ccu r, b o th i n fo rm of m or er estr ictive and r ncr etoler ant dem a n d s a, l l i n d e p e n d e n coef t h e c h a r a c t e r i s t i c so f t h e l u b r i c a n t o i l t y p e i n
question.
C o n c l u s i o nos n t h e c o n d i t i o n o f u s e dl u b r i c a t i o n o i l s h o u l dn o t b e b a s e da ' l o n e
o n va l u e s f o r th e i n d i vi d u a l p a ra meter s,but mainly on the coher enceof par ameters.
I n t h e l i s t t h e l i m i t a t i o n - v a l u e sa r e s t a t e d a s m a x i m urme s p e c t i v e l ym i n i m u m
a l ' l o w a b l ev a l u e s , o r a s a l l o w a b l ev a r i a t i o n f r o m t y p i c a l v a l u e f o r t h e o i l t y p e i n u n u s e dc o n d i t i o n .

t,=

Fttt

CENERATTIG

ST5

L U B R I C A T I NOGI L

0 3 15
E d i t i o n0 1 H
P a s e1 5 ( , | 5 )

C H I C KO F O I L C O N D I T I O N

G u i d i n gL i m i t a t i o n - v a ' l u ef o
s r E v a l u a t i o no f A n a l y s i s ' R e s u l t s
f o r u se d L u b ri ca ti n g 0 i l of the Deter gent,HDType.

Parameter

M a x .V a l u e
Min. Value
M a x .V a r i a t i o n

S p e c i f i c G r a v i t y , M a x .V a r i a t i o n

F ' la shP o i n t ( 0 p e n C u p

Min.180oC

V i s c o s i t y ,M a x .V a r i a t i o n

40

15

Total Acid Number( TAN

Max.

Strong Acid Number SAN

M a x .0 , 1

Al k a l i n i ty, T o ta l BaseNumber( TBN

fo r MDO- oper ation
fo r HF0- oper ation

M in . 3
M in . 7

l.Jater
Fresh
S a li n e

Max.0,2-0,5
M a x .0 , 1 %

ConradsonCarbon

Max.

Noncoagul
ated
P e n t a n eI n s o l u b l e s

Max.

N on co a gaute
l d
B e n z e n Ien s o l u b l e s

Max.

A s h C o n t e n t ,M a x . V a r i a t i o n

t t,t
F|!tt
E ttt==-!'
E
GENERANNGSETS

'tt
c
o
3

l '? 5 .

-r
t
o

a.v'o

o
o
a
.

.o - l
I

t c Z
OH

-.-o

ta

It
l3

9'l

t:
t;

z9lo 6
;
|
g'txsolf I.
:
. >
- l
|
f-- t" -

l.
o
c

o g .
aO
OCc c
.- oZ
- uO.
o
9 4 .
.- otf)
!c(\|
o o
)-Z
JtO

c
o
o
c

r+

)
o

\ o
o -rO lo
O

o c Z
O H

.-a

2
2
:

o
a
s

ll

tt

zal

r!:

c
O

r.o

O Cc c
.- oZ
- e A
o
a o .
.- oto

o
C

o
e

o
o
c
o o
o
o t l )
ft

o
o

J
q

r cn|

o
c
o

! o
)- C
JLc]

o
o

\o

rli
ii

( )

,l >e.
l o :
o c

O U .

ia

.-a

(J

iil
i!t
;!;

"A

, C Z
OH

l:i
li

l;l
:ii

9r'

i z
:Uoo
o O .
.- o)
L C(\
o
)-Z

Jlicf,

F !

o
C
t
q

:,

c .
. D
> t

,l t:,
.1!tl

I
!

,
. a
C

!iti:9

U-

-.i.t:tI

q
x

o
o

7
22
. i' t: :. .2
z :2' 2
ia -a a a -a 1- - . ,
l:li:l:
i! t'.i !z t

x
(\

o
j

tzt'tl

f\

(J

'

3l!.i!::::
6

-..:22lZt

o ,2.'?.,.

' 'i'iziii

it;iiiilt
: : r . . . .
t

i:il-:!r

i:irrii
2.ziailti

i i !iji 1::

Iv|AT\T
ct&l,lt
L U B R I C A T I NOGI L P U M P

-11
P L A T E3 1 5 0 1

osos--g

,:,::?B
*r./-@

'::"4
t039
I r28
t?t7

2t07
?296
?385

E{LEBV

GENERAN\GSETS

PLAT3
E1 5 0 1 -11

L U B R I C A T I NOGI L P U M P

Item No.
f1

0l49

f /.

::T J.

:,t/0^

0 4 16
0 5 05

c: ,jo -

0 6 94

S o cke t

.:lf

028_3
0872
0 9 6I

Ball bearing
Circlip
C o gw h e el

i :_

/ L

10 3 9
1128

)
'

,'/l

1217,
13 06

6 Jt)4.

14 95
1584

t l,l

1673
1 76 2
1851
19 4 0

l''

\'
';

\i'

.i .":,/ t2

' i.'a- /

':.'
,r.-]'n
;l:4
e

',
'^

.
'

::

.1

- - ' .-1 : .' :I '

r')

6 ).) Li')
,:j:..

"

'

201B
2107
2296
2385
2474

- 2652
:. 2741

,! 1'

tod )i',i!
,t

C a pn u t
-Gasket
Nut
Springousing

0 2 38
0327

Designation

. . : "2 8 3 0
.' 2929
, 'r 3097
, ' v 3 1 86

Pin

_- Gasket
C o ve r
- Serew
S p rin g
Cyli nder
Pi s_ton
j ng
Punp_
hq,us
Key
B u sh
_ Gu i d p
ei n

Benavnelse

Hattemstrik
Pakn
i ng
M otr ik
Fjeder hus
sri ft
Muffe
Kugle1eje
Si kr i ngsr ing
K o n ' i s kt a n d h j u l
Pakn
i ng
Deksel
Skr ue
Fj eder
Cyfi nder
Stempel
Pumpehus
Feder
Bosn
i ng
Styr estift

5-ererr

Skr ue
Endedaksel
K o n i s kt a n d h j u l
Si kr i ngsr ing
A k s e lm . t a n d h j u l ,
1a n g
Akselm. tandhjul,
kor t
Skr ue

Pog
C o u piln g

Medbringer
Kobli ng

-,_Kev
P l u g screw

Feder
Pr opskr ue

.5c-rew
End cover
Cogwheel
Circlip
S h a ft w . gear whee1,
1o n g
Shaftw. gearwheel,
sh o rt

Ga ske t

P a k nni g

t.tlE

---E

lFrl|..t
-

GENERATII\E SETS

tU|AhI

Er&ut

31502-1OH
PLATE

L U B R I C A T I NOGI L F I L T E R

8325
8414
8503
5388

8781

8692

5744

5655

5g33+

5922+
6090
9215
9304

.""u.

19 8 8 . 0 .12 7

+ L s s d e l es e / f o r d e t a i l s s e e p l a t e 3 1 5 0 2 - 1 l H

E-EEE
GENERATT\G SETS

/**?\
L U B R I C A T I NOGI L F I L T I R

Item No.

ltat, l:.',i

Designation

Benavnelse

capc o m p l e t e ,i n c l .

thksel kompl
et , i nk1.
d e k s e l ,f l a n g e r , s k r u e ,
tatningsring,federe,
0-ri nge
Tatn' ingsr ing

flanges, screu/,
se a l, s p r i n g s , 0 - r i n g s

c d P'

" ' 1 . 1 ,5' 3

, BB, ,
{n;:,; e.; ,n
l 0 0 o ' ; , ! 0 noo ! 5477
_6 0t. , ;y ;:C,i.' 5566
-- 6nt q, . 1 : i i : ! - 1 . i j : 5 6 5 5

5144
6 cct1,i/C )tt:

5833+

6ala,_N10)r:)i'/

5922*

',
:f,0..:' n-' ,',' . - ' 6 0 9 0
'-, ' t.t"'j 6189
"'
-'-,,^.
" ; ; ! l J : 0 ' : , r:{ _!,} 6?_78

-:
) i

't'...j,

6-367
6Q00!:10. 00:7 6456*

.:

::,:...)

P L A T3
E1 5 0 2 - 1 O H -

P a p e re l em ent

Papirel enent

S a fe ty element
H o uisn g, ' incl.
housing,0-ring
S p i n d l e ,i n c l .
s p i n d l e ,f i l l - u p v a l v e
0-ring, cdp
V a lve h ous'ng
i , i ncl .
h o u s i n g t, h r u s t r i n g ,
t y p e c o d ep l a t e , p i n
B y-p a ssval ve, ' incl.
p l u g , b y - p a s sv a l v e ,
s e a t , b y - p a s sv a 1 v e ,
s p i n d l e , b y - p a s sv a l v e ,
s p r i n g , c o p p e rs e a l
Plugto indicator
hole, incl.
p l u g s c r e w ,0 - r i n g s
0 p e n i n gg u a r d , i n c l .
o p e n i n gguar d, ventscre$,

Si kker hedsel
em ent
H u s ,i n k l .
hus,0-ring
S p i n d e l ,i n k l .
s p i n d e l ,o p f y l d n i n g s ventil, 0-ring, daksel
V e n t Ii h u s , i n k l .
hus, tr ykr ing, m ar kep' lade, sti ft
B y - p a s sv e n t i l , i n k l .
p r o p , b y - p a s sv e n t i l
s a d e , b y - p a s sv e n t i l ,
s p i n d e l , b y - p a s sv e n t i l ,
feder , kobber pakning

V e n ts c r e w ,i n c 1 .
v e n t s c r e w ,p i n ,
copper seal
Drainplug
S e a l k'i t
0 -ri n g

P r o p s k r u et i l i n d i k a t o r
hu' l, inkl .
pr opskr ue
, O- r inge
Abningsbeskyttel
sesskar m , inkl .
sker m ,luftskr ue
L u f t s k r u e ,i n k l .
luftskrue, tdp,
kobber pakn
i ng
Dranskrue
Pakni ngsset

60,,1t.oi i. ,t t tty' 8147

{CI13 }:,/t 'Jl t / 823_6,

0-ri g

0- r i ng
Stottetap
0- r i ng

Nut

Mstri k

a a c , l : . i t . , 1 : ,i._ 8325

Screw
Ga ske t
Screw

Skrue
Pakni ng

6 ! t 2 : :t ,

Stud

I i !;,:.r___8414
icrt)':.^..'
" r' I
:
.
tt?.
9503

Skr ue

r e v . 19 8 8 0
. 1- 2 7
=

**r

--a:

GENERATINGSETS

]v|AN

Er&w

L U B R I C A T I NOGI L F I L T E R

60d 0:{/

6 o t t . ' :t ! "
60c0.}s/a,

'i ia . =1.''
.9t\l

la

PLAT3
E1 5 O 2 . I O H

Item No.

Designation

Benavnelse

,8692
8781
BBTO

Gaske_t_

Pakn
i ng

F!1.11qg__va1ve
Pin

0pfy1dni ngsventi1
Tap
P a k nni g

ooo -o;c_

sket

p..2pi,,;r'
6ooo"o-;:t
! 12!

Thrus_!
ns
f_iQ_

6,4!0.0riprr,v-9215-_
*_
'* oto.!-,/,rlf93o4

Tr ykr i ng

_o_-ri
ns_

Tap
0-ri ng

Qri ng

0-ri ng

Not shownon the

front side of the
p la t e

* Ikke vist p forsi d e n a f p ' l a t e n .

For details see

p l a t e 3 1 5 0 2 -11H

+ Lssdele se plate
3 15 0 2 - 11 H

r e v . 19 8 8 0
. 1. 2 7

ffir=H

IvIAN

Er&l^t

L U B R I C A T I0NI LG F I L T E R( S U P P LF. o Rp L A T t3 1 5 0 2 - t 0 H )

PLAT3
E1 5 0 2 -11H

31502/5833

31502/8147

31502/7435
3I 502/5388

31s02/5299
7524
7613

6634
6723
6812
6 9 01
7079

7168

31s02/s922
E E.G.E

FII+'

GENERATT^G

SETS

IYIAI

ct&urt
L U B R I C A T I NOGI L F I L T E R( S U P P L .F O RP L A T T3 1 5 O 2 . I O H )

Designation

Benevnelse
Flange

QT?1-

F la n g e
F la n g q

6812

S p r in g

Fjeder

6 9 0I
70 7 9

Screw
ng
5,p_rl
0 -ri n g

Skrue

cap
0-ri ng
S p rin g

Daksel

Item No.

6 0 J J . , l J ,l 0

oo/8

(/'
6ooa. cJ i,l ,f)n ?

60)| 0:,'?

/\ ') ,r .,/

-n

6ot0..Qs/0. / ; . "
'l 0,11. i.1','t
1:" .) . l.l 'i'
? A A 4

'

/
?
.t

. - ! -

,":.-

-.'

t9/--/.

1';.

a i

tl ,'}'t.':9-9
'
,,1),') lt.i n
.-',i

/i

7168

72s7
7346

,,' '":

/ a
,.a.a
;
a.:!? . s'r'

66 3 4

i:l

F la n g e

Fjeder
0-ri ng
0-ri ng
Fjeder

. 4 "

7524
76 1 3
78 9 1

^ ',': '

7980

Plug screw

Propskrue

8058

Ga ske t

Paknn
i g

,.,:) ,._
,4n,'

J - ' -

31502-llhPLATE

V a l v es e a t
S p in d 1e

Vent'il sede
S p in d e l

}ffi.EEY

GENERAU\G SETS

]||AN
E&UT'
THERMOSTATIC
VALVE

PLATE
31504- O2H

vf----ro,

E#.EBF
GENERATil\C SETS

lY|AN

Et&ut
PLATE
31504.02H

THERMOSTATIC
VALVE

Item No.

6c::. :,-t- I i--i*--01-87

:J -lI:---95
':: i^,,';0454
1.' ,

)|t!

0543

0!6J )Cnl 0632

" ' / n ct:) 0721

": 't t t . . \ 0 9 0 9
4 .:'l a 1077
lrl

,'

," 1166
1 ?.5 5

Oesignation

Benavnelse

T h e r m o s t a t i vc a l v e ,
complete
Screw

I,
Ter m ostatsventi
kompl
et

S e ailn g r i n g

Skr ue
P a k nni g
Fslerel ement
Tatningsri ng

S u p p o rting r i ng
L o ckw a sher

Stotter i ng
Fjederskive

Nut

Mstri k

Gasket
F 1a n g e

Pakning

Ga ske t
T h e rmo staticelement

F1ange

E.=EY

GENERATIIVCSETS

/**G
High PrcssungSealing Oil pump and Filters

General
05"

06'09.

14*
13*
11'

(x).

24'
2:i'

24* 6'

27

27'

HTH$

MAN

E&u'
HighPrcssung
SealingOil Pumpand Filters
General
Itr No.

6o_ux;t

D..lgnltl,on

Eonalurdc

It m No-

: 01
Paknhgssd
w xyr*6
1::3:''

:-

llcrSnallon

Earanndgc

Pad<lng !.t for Inlctoct vlrca cornprfefng: 2l-Z-*25

2'.2tr..

Pakningssatfor ind{g
udsqnirBsrcnl bestaondosi:.21-2-&
2+?5?s..

Packlng ..t
for
florng lldc vdru
comprlrlng: 02{I}
o4-0s-06.

glklerbeteode d: O20341{5{6.

(R'

Griqg

Gdng

21'

Valve seat

Venfsade

(N'

Grlng

O{rg

Grlng

O<ing

05'

Grlng

Ging

zt

retalnlng cprlng

EeOertolOer

06r

Grlng

O*ing

24'

valve sprlng

Tryklieder

'

wlwplate

Venldade

26'

valve scrcw

Venlskrue

Seallng oll , FumpcomplGte

Pumpekomplet

Sealing oll lte complete

Flterkornplet

Fle. cartrldge

Flterpafon

Suctlon filte

Sugefilter

_6ulJL:!2_i)o.i=-o7

Pacldng ct ior l-PPakningssatbr LT{el

part comprlrlng:
bsteende d: @4$
08-{x)-11-12-13-'tt- 1 G 1 1 - 1 2 - 1 $ 1 4 - 1 S 1 6 .
f 5-'t6.

lgoe, ?.2!. t-:,zt_

08'

USIT*Ing

US|T*ing

(x)r

Glng

O{ing

l0'

Grlng

O<ino
'

11.

Otlng

fing

l?

Grlng

Odng

13'

Ollng

GrirE

l4'

Plcton rlng

Stempelring

15'

O'rlng

O<ing

16r

Parf<lng

Paknirg

Packlng eet for HPpsl comprlslng:

1&t9.

Pakningssat for HTdel besterde af: 1&

19.

HP-packlng

HTaakning

Rod guldlng rlng

Stangforirqsring

6crt; :

i":'!(.

a,.:i. ;) (; (, | 2g

f'1 l!-'":r.)arl A
Et":n

i_ ?{._tc; n

Item nc. marted with ' are only available as part of a spare parts kif

HOI^EBY

cEcru[E-fs

27

]}|AN

Et&ut
PLAT3
E1 5 2 0 - 0 1 H

P R E L U B R I C A T IPNUGM P

0 4 0 80 5 9 70 6 8 6

21

0319

19

0224

t0

0131

209
398
487

21992377 1932

1843 1754

1665 1576

2377

-r----l----ri

i---.I.--l

=l+
g tr7=-L=5=Ett g
GENERATINGSETS

}IAN

Eteut
PRELUBRICATING
PUMP

P L A T3
E1 5 2 0 - O I H -

Item No.

Designation

Benavnelse

0l 3 1

6 o c .) : . ' t . ( c 6 Z g 2 ? 0

Set sere-w
Socket

Satskrue
Muffe

: , : . ' " : : ' i " - ' n ' ' < , -0 3 1 9

Screw

Skrue

; ' o4o8
6iti,. )..: .:,',.

Fro_ntc.ev_gr
J o in t
P u mpcasing

Fordaksel
Pakn
i ng

Counter f l ange_._
cqryl .
J o in t

Modtryksflange, kompl
et
Pakn
i ng

u - : . : ' :! : ' . : i 0 1 0 2 1

J o in t
Rear c_over
Idler rotor

L n \,\

Regulati ng scre!,,
R e t a i n i n gr i n g
V a 'l vecover

P a k nni g
Endedaksel
Fr i I obsr otor
Regul
er ingsskr ue

{ { lc, .4:,-jt : .,.:! {,:

6"tl:_ 0ji{,

''r: i

0597

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i''.:' ^" lo Jt," 1487
: 't.), i ! l,t lt;:
1576

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6 o o o .C J - 6 . tl ,. j ' : - 1 6 6 5

_o_-ing

i ro0.ri / 0,r " ,r 1754

V a l v es p r i n g
V a l v ep i s t o n
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,);,.t .'-' | 0 l:1''' ; 1843

[.t':.'

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i'

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' 1 . ' -t 2 0 0 0
. ' , r, I 2 1 9 9
-.,,,1 2288*
t)ti12377*
,.::)ti 2466

S h a ft s eal
Drip ring
0 -ri n g
R o ta ry seal r ing
S ta ti o nar y seat

Pumpehus

Lser ing
VentiI deksel
Pakning
0-ri ng
VentiI fjeder
VentiI stempel
Dr ivr otor
Akseltatning
Dren
0-ri ng
Tatningsring
Stationer sede

ffi-==Y

GENERA'NNGSETS

/-G\

Data

1990.09.2s

Comb.Lub.oiland F.W.Cooler

Make:

Alfa Laval

Type:

P2-VB-H

Data1 (1)

PressurePlate
T1: Coolingwateroutfet
T2: Freshwateroutlet
T3:
T4: Freshwaterinlet

FramePlate
Coolingwaterinlet
Lub.oil inlet

51:
52:
53:
to\

Lub.oiloutlet

I
\

Forinstruction,
seetheseparate
AlfaLavalmanual.

tl

F=5

.===E

GENERA'TTNG SETS

O( ALFA.LA\'AL
INDUSTRI

lnstructionBook
for Heat Exchanger

type.P.+.;.v.S............

UNPACKING
For safe transport it is necessary to deliver
for the plate heat exchanqer unmounted

valve

tubes,

etc.

Please
Check all enclosed loose parts against the packing list.
the supplier immediately if any parts are damaged or misnotify
sing.
PRINCIPLE
plates,
frame,
heat exchanger consist-s of heat transfer
The plate
The plates
are made of
device and connections.
tightening
for optimum
designed
compression moulded sheet metal with patterns
the
Each plate
has a gasket which seals against
heat transfer.
pack is tightened
between the
plate.
The whole plate
adjacent
plate.
In
the pressure
fj-xed part,
the frame and the mobile part,
channels
can be pumped through
heat exchanger,
li-quids
the plate
flow in a great
flow or counter
parallel
concurrent
or in series,
ways.
number of different
by the
heat exchanger is determined
in a plate
The heat transfer
and
velocities
their
between the liquids,
difference
temperature
characteristics.
and other physical
density
turbulence,

DRAWING
with each heat
A drawing is delivered
of the heat exchangrer, the
dimentions
to
and the data according
connections
exchanger is dimensioned.

It shows the main

exchanger.
and
arrangement
of plates
heat
which the plate

Note: Plate heat exchanqers P0I-VB-H and P2-VB-H have the whole
the
towards
pack turned
side of the plates
with
tfre gasket
Fffi
plate
is
the pressure
nearest
frame. In the example, the plate
the frame.
I is nearest
end plate
II whilst
end plate
therefore

PLATES
In the heat exchanger the plates are
plate is an A-plate and every other
morrnted with the herringbone pattern
plates have the gasket side towards

mounted so that every other

a B-p1ate. The A-plate is
pointing
downwards. All
the frame plate.

PLATE HEAT EXCHANGER

7'

P R E S S U RPEL A T I

E N D P L A T EI I
C H A N N EP
L LATE
C H A N N EP
LLATE
C H A N N EP
LLATE
C H A N N TP
L LATE
C H A N N EP
L LATE
E N D P L A T EI
F R A M EP L A T E

CX ALFA.LAVAL

INDUSTRI

CHANNELPLATE

P L A T EN U M B I R

C ALFA.LA\'AL
INl'USTRI

FAULT FINDING
The efficiency
temperatures

of the heat exchanger drops

change, reduced heat transfer.

and the

liquid

Open the plate

heat e:<changer and check the heat transfer
surfaces
for deposits
of sludge etc.
Such deposits
must be removed mechanically
or chemically.
Leaki-ng of

gaskets

This

is

fault

are

visible

eliminated

on the

by renewal

of

outside
one or

of

the

plate

pack.

more gaskets.

REGASKETING
For exchange of gaskets on plates,
a special
glue is reconrmended. (See cementing) .
1.

nitrilerubber

based

PuIl out the old gaskets

from the groove,
normally
by hand,
necessary,
heat the back of the gasket groove with a hot-air
heater.
A butanegas burner carr also be used, but great care
must be taken.
Loose cement and rubber
can be removed with
tools,
e.g. by means of a rotating
brush.

DO NOT USE ACETYLENE GAS

2 . Degrease the gasket groove with

3 . Apply a thin layer
of the groove with
means of a plastc
must be evened out
clean the gun if it

a suitable

detergent.

(0.1-0.2mm) of the cement on the bottom

a narrow, stiff
brush or, better,
by
gun. If a gun is used the cement strip
with a brush. It is not necessary to
is filled
immediately and used again.

4 . Place the gasket in the groove and fix it with tape.

Remove cement from areas outside the gasket groove with a
The front of the gasket may be coated with talcum
cloth.
powder. Then coat the gasket surfaces with a mixture of
252 by weight whj-te spirit,
258 silicone
oil and 508 talcum
powder.

it

5. Stack the plates A-A-A or B-B-B and load them in such a manner
that it ensures that all parts of the gasket are in contact
with the bottom of the groove. The pressure must be applied
before max. 2 hours.
6. The plates can be inspected after 10 hours at room
temperature and any excess cement can be removed. Then
fit
the plates in numerical order (see platage table
Increased temperature,
at the back of this booklet).
max. 100 degr.C., at the cement joint reduces the curj-ng
time. Humid heat and steam must not be used. If the operating
temperature of the heat exchanger is less than 100 degr.C. it
can be put into operation after 10-12 hours, otherwise L6 hours
after the cement has been applied.
CEMENTING
ALFA-LAVAL has a type of cement for repair - Pliobond- which is
ternperature
a one-component rubber based cement with limitea
g
a
s
k
e
t
c
a
n
u
s
u
a
lly be carried
Future removal of the
resistance.
j
o
i
n
t
.
out without heating of the cement
Guide values
Protective

- \-

for

amount of plates

per litre

cement is

100 plates.

Measures

Industrial
cement contains dangerous substances that may cause skin
headaches etc. when a person has been exposed to them
irritation,
be carried
out
for a long period of time. A1I work should therefore
a
n
d
s
k
i
n
b
e
a
v
o
i
d
e
d
rooms. Skin contact should
in well ventilated
been in contact with the cement should always
that has temporarily
be washed with soap and warm water.

PLAIE HEAT EXCHANGER

o
@
@
@
@

F R A M EP L A T T
P R E S S U RPTL A T I
S E R V I CB
EO L T
TII BOLT
CHANNEP
L LATES
q ALFA.LA\'AL

INDUSTRI

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r-i
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r,-rLffr

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325

C O N N E C T I O N( O C A T I O N S

PLArE

t*ffr.

\-

Koblirq

Motor lype :

@_
Work

Plcte motr.:

Sup-pliel re!

Nel. Weight

L i q u i c ti n t h e P H E

ffirTf/Tesl Pressure

!:6/0.9

Mp o

26/26 + 7/7

159

<o

23.5

Custom ref
Tested by

L .

Conneclion locolion

Medio

Fl ow rol es

Inlet

S2

Ib.oiJ-

13 n3/h

70

0.42 bar

Out let

S4

Irb.OiJ-

13 n3/h

56.8

O.42 bar

lntet

T4

Jackebr

36 m3/h

77

u.b4 Dar

Outlet

T2

.Jacetrter

36 n3/h

71.3

0.64 bar

Inlet

S1

ftestnater

18 n3/h

35

0.86 bar

C- let

T1

| festnaer

I 18 n3/h

51.5

0.86 bar

Tffis#"
l(tOia.aLo

ll Pz-vB t"tc

ll

rem&

Jorc

Pressure drop

lurwg.

lconl.

EngineData

z
o

E
ffi
o-

of Engine
Operation
andCondition
EnginePerformance
Tracing
Trouble
EngineFrameand Bedplate
Crankshaft
and MainBearings
CylinderHeadand CylinderLiner

Rod
PistonandConnecting
Gearfor InletValveq
Operating
ExhaustValvesand FuelIniectionPumps
lJ

?e

Gfr
ZF

Turbocharger
System
FuelInjectionPump

E=
R;

FuelInjection

=z
=<

a,g

CamshaftandCamshaftDrive

ControlandSafetySystems
Automatics
andlnstruments

F
a

d ]Ug
o

StartingSystem
Lubricating
Oil System
Oil
of Lubricating
andTreatment
Specification
FuelOil System
Fueland FuelTreatment

CoolingWaterSystem
Treatment
of CoolingWater
DrivenMachinery

SpecificPlantInformation

Tv|Ahr

Eteut

L23/30
F U E LO I L S Y S T E M

3 f6 . 0 1
Edition 13H
| 987.03.02

DESCR
P IT I O N

T h e f u el o ]l syste mco n si sts of fuel oil pr im ar y pum p,fuel oil filter ,

p u m p( s e c t i o n3 1 0 ) a n d f u e l v a l v e ( s e c t i o n3 1 , | ) .
FUTLOIL SURCHARGE
PUMP

fuel

PLATI 31601

The fuel oil surchargePUmp,which is of the gear pumptype, is mountedto the

front end of the engine frame and driven byrte camshft-itriougna splined
s h a f t c o u p il n g .
T h e p u mph o u si n g!s-e q u i p p e dwith a spr ingloadedadjustable by- passval v e,
w h i c h i n o p e np o si ti o n co n n ectsoutlet and inlet chm ber of
s itr e pump.
The outlet pressureof the surchargepumpcan be adjusted by meansof an adj u s t i n g scre wi n th e b y-p a ssvalve- assem bly.
T h e s u r c h a r g ep u m pi s s i t u a t e d i n t h e f u e l o i l i n l e t l i n e o f t h e e n g i n e .
A b y - p a ssl i n e to th e su rch ar gepumpwith a non- r etur nvalve allows- for fuel
o i ' l t o b e su p p l i e d to _ th e e n gineeven in standstill by gr avity feed or b y a
s e p a r a te l yd ri ve n fu e l ci rcu lat.ing pum p.
F U ELO IL F IL T E R

PLATE
3 1 602

T h e f u e l o i l f i l t e r i s a d u p l e xf i l t e r w i t h s l i t - t y p e f i l t e r e l e m e n t s T
. he
f i l t e r i s e q u i p p e dw i th a th ree- waycock for chang' ofboth inlet and outl et
s i d e i n to si n g 'l e o r d o u b l eo per ation of the filter s.
D u r i n g no rma lo p e ra ti o nb o th filter s should be in oper ation, single oper ati on
o n l y t o b e u se dw h e nd i sma n tlingone of the filter s for m analcieaniir gor i nspecto
i n.

POSITIONOF THREE.WAY
COCK
'left

Filter right interrupted

Fi I ter

This position is only for

c l e a n i n go f t h e r i g h t f i l t e r ,
Both fil ters l n
n o t f o r co n ti n u o u so p e ra ti o n. oper ation.

This position is on' ly f or

c l e a n i n go f t h e l e f t f i l t e r
not for continuousope r ati on.

i nterrupted

E*G.EBY
CNERA'TI\G SETS

123/30
FUELOIL SYSTEM
D I S C RPI T I O N

I}AiNI
| E&Ut
316.02

Edition13H
1987
. 03.02

lg ry u l l y t h e f i l te rs a re cl e a n e dd ur ing oper ation by tur ning the handleon the

f i l t e r h o u s i n gt o p a c o u p l eo f t u r n s .
S imu l t a n e o u s'lwyi th tu rn i n g o f th e handle, the dr ain cock in bottomof the
f ilt e r l g y t i n g sh o u l d b e o p e n e di n or der to dr ain off the dir t being scr aped
of the filter element.
. I f ! 9 d r a i n a g eo ccu rs w h e nth e d ra in cock is opened,the filter
b e d i s m a n t l e dfo r ma n u a cl
l eaning.

housingshoul d'

Th e f i l t e r e l eme n ti tse l f sh o u l d n ever be dismantled,but has to be r eplaced

if d a m a g o
e r m a l fu n cti o ni s e xp e ri enced.

g#H-EEY
GENERI\'I\IC SETS

]Y|Ah|
L23/30

Et&ut

FUELOIL SYSTEM

D3t6

F U E LO I L Q U A L I T Y

E d it ' i o n 0 l H
P a g eI ( 1 4 )

G e n e r alC o n si d e ra ti o n s
T h e q u a l i t y o f a f u e l o i l i s , i n a n a l y s i s d a t a , s t a t e d i n p h y s i c a la n d c h e m ' i c a l
p r o p e r t i e s ,w h i c ha r e d e c i s i v e f o r t h e s u i t a b i l ' i t y o f t h e f u e l o i l f o r d i f f e r e n t a p p l i c a t i o n s . F o r d i e s e l e n g i n ef u e l s t h e c o m b u s t i o qn u a l i t y , t h e i m p u r i t y c o n t e n t , a n d h a n d l i n gp r o p e r t i e sa r e t h e m a i n q u a l i t y c r i t e r i a .
Si n c e r esi d u a l fu e l s a re tra ded and designatedaccor dingto viscosity, i t has
become
co rrmopnra cti ce to a ssociateviscosity with quality. This pr actic e c an,
e s p e c i a l l y w i t h m o d e r nr e s i d u a l f u e l s , b e v e r y m i s l e a d i n g ,a s a f u e l o i l o f
l o w v i s co si ty o fte n ca n b e j ust as bad, or even wor se, than anotherfue l oi l
o f v e r y h i g h vi sco si ty.
T h e q u al i ty o f re fi n e ry re si duesar e dependent
on the or igin of the cr u de oi l ,
t h e g r a d e o f u ti l i za ti o n w h enr efining the cr ude oil, and the r efiner y tec hniqueused.
So m eo f th e re si d u e su se d i n fuel oil pr oductionar e of a viscosity r equi r i ng
v i s b r e aki h g , d p ro ce ssw h i ch will r educethe viscosity without im pr ovingthe
qualityat aI1.
W h e np r o d u ci n gre si d u a l fu e l s fr om visbr eaked,cr ackedr esiduesand fr om
"s t r a i g h t ru n " re si d u e s, th e final adjustm entof viscosity to fulfil the r eq u i r e me n tso f th e d i ffe re n t gr adesof inter mediatefuels' is doneby addi nggas
oil.
H o w e v e r,i t i s to b e n o te d that consider ab' le
lower ing of the viscosity i s ac h i e v e db y a d d i n ga r e l a t i v e l y s m a l l a m o u not f g a s o i l , w h i c hw i l l g i v e o n l y a
m i n o r i mp ro ve me notf th e q u a' lity of the blend. This m eansthat the qual i ty to
a major extent is dependenton residues present in the blend.
As a c on se q u e n ce
o f th e p o ssible var iations in quality of r esiduesand the i nf l u e n c e o f a d d i n gg a s o i '|, the quality of blendedfuels can be var ying ev en
f o r f u el o i l s o f e q u a l n o mi na'viscosity.
l
C o m b u sti oQu
n a l i ty
C o m b u s t i oqnu a l i t y i s t h e a b i l i t y o f t h e f u e l o i l t o i g n i t e a n d b u r n i n a p r o p e r w a y. T h e i g n i ti o n q u a l i ty, com bustionintensity, lenght and completenes s
o f c o mb u sti o na re p ro p e rti e s influencedby the chemicalcompositionand s tr uc t u r e o f th e fu e l o i l .
I g n i t i o n q u a ' l i t y r e l a t e s t o ' i g n i t i o n d e l a y , i . e . t h e t ' i m ee l a p s e db e t w e e n
s t a r t of i n j e cti o n a n d th e s tar t of com bustion.
I g n i t i o n q u a l i ty i s e xp re ss edby the cetanenumber ,diesel index or cet ane i nd e x , i n a l 'l ca se sth e h i g h e r the value, the better the ignition qua' lity .
F o r d i e se l o i l th e i g n i ti o n quality is expr essedby the cetanenumber deter
,
m i n e dby a sp e ci fi e d me th o din a standar dengine r unning understandardc ondi t i o n s.

F#.EEY

GENE?A.fIf\G SETS

tvlAN

L23/30

cr&ut

FUELOIL SYSTEI4

D3t6

FUELOIL QUALITY

E d i t i o n0 1 H
P a g e2 ( 1 4 )

Fo r r e s i d u a l f u e l s th e i g n i ti o n q u ality can be expr essedby the diesel index

or c e t a n i n d e x , b o th to b e ca l cu l a ted fr om physical pr oper ties such as the
a n i l i n e p o i n t , s p e c i f i c a r a v i t y a n d m i d - d i s t i l l a t i o n t e m p e r a t u r eT. h ec e t a n e
n u m b e r ,d i e s e l i n d e x o r ce ta n e i n d ex of a cer tain fuel oil will showr easona b l e c o r r e l a t i o n s b e tw e e nth e n u mer icalvalues.
T h e c o m b u s t i onco n d i ti o n o f th e fu el oils is nor m allyevaluatedfr om Conr adson
Ca r b o nr e s i d u e a n d th e a sp h a l te n ec ontents.
Impurity Content
T h e i m p u r i t y co n te n t o f d i e se l e n g ine fuels should be kept as low as possible ,
and h a r m f u l a nd u n w a n te di mp u ri ti e s should, to the gr eatest possible extent,
be removedin the pre-treatment systemin order to minimizewear and corrosion
o f e n g i n ec o mp o n e n ts.
Imp u ri ti e s d er ive fr om the cr ude oil itse' lf, fr om r efiner y p r o c e s s e sa n d fro m h a n d l i n g a nd stor age of oils. Som eimpur ities;suchas
s ulp h u r a n d v an a d i u m
a re o i l so l u b le and ther efor e impossibleto r emovein a
conventionalmechanicalfuel oil treatment system,while the amountof water
a n d s o l i d ' i m pu ri ti e sca n b e re d u ce dby centr ifuging and filtr ation.
San d ,r u s t o m eta l o xi d e s a n d ca ta l y st par tic' les can be found as solid par ticles in fuel oil.
Fu e l r e l a t e d we a r a n d co rro si o n i n diesel enginestakes the for m of mechanic al
wea r a n d c h e m'i ca l l yi n d u ce dco rro si on, the latter in the for m of high and 1ow
temperaturecorrosion.
T h e s o l i d i m p uri ti e s a n d p a rti cl e s pr oduceddur ing com bustion,collectively
knownas ash, causemechanica'l
wear of engine components.
E s p e c i a ' l l yc a t a l y s t p a r t i c l e s , s i l i c o n e a n d a l u m i n i u m
o x i d e sa n d s i l i c a t e s i n
the form of sand are very abrasive. Fromvanadiumand sodium,corrosive ash in
the form of oxides, carbonatesand sulphates are created during combustion.
The sulphur content of a fuel oil may lead to low temperaturecorrosion of
combustionchambercomponents
and formation of deposits on these. The corros iv e e f f e c t i s d u e to th e fo rma ti o n of sulphur ic acid.
hlater in the fuel oil may lead to several detrimental effects to the fuel syst em a n d t o t h e d i e se l e n g i n e i n g e ner al by giving r ise to mechanicaland cor rosi v e h , e a r ,as w e l l a s fo u l i n g .
Ha n diln g Pr o p e rti e s
Han d l i n go f t h e fu e l , i .e . sto ra g e , pum pingand tr eatm ent, is mainly affected
by p h y s i c a l p r o p e rti e s su ch a s vi scosity, density, flash point and pour point,
but o t h e r f u e l o i l p ro p e rti e s su ch as stability, em ulsification tendency,visc o s i t y i n d e x a n d th e n a tu re a n d a mountof water and solid im pur ities will also
in f l u e n c e t h e ha n d l i n gsyste m.
The nominal viscosity is decisive for the preheating temperaturenecessaryto
obt a i n a d e q u a tevi sco si ty fo r p u mping,settling, centr ifuging and injection.

E#.EBY

CEINER\.M{C SETS

L23/30
0316

FUELOIL SYSTEM

E d i t i o n0 1 H
P a s e3 ( 1 4 )

F U T LO I L QU A L IT Y

T h e d e n si ty i n fl u e n ce s th e g r avitational settling of water and solid contam i n a n t s i n se ttl 'i n g ta n ks. S p ecific gr avity is also an im por tantpar amet eri n
t h e c e n tri fu g i n g p ro ce ss.T h e flash point is, for safety r easons,lim ited to a
minimum
o f 6 0 0 C b y c l a s s i f i c a t i o n s o c i e t i e s a n d o t h e r a u t h o r i t ' i e s .T h e f l a s h
p o i n t i s re l a te d to th e vo l a tility of the amountand natur e of lighter fr ac t i o n s i n t h e f u e l o i l , a n d m i g h t t h u s b e u s e dt o e s t i m a t et h e l i a b i l i t y o f
g a s i f i c ati o n i n n o n -p re ssu rized
par ts of the fuel system .
T h e p o u r p o i n t d e fi n e s th e temper atur eat which wax cr ystallization will tak e
place and prevent the fuel oil from flowing and from being pumped.
The pour point therefore must be taken into accountwhendeciding the presence
a n d c a p a ci ty o f h e a ti n g co i l s in bunkertanks.
Quali ty
c r i t e ri a

Fuel oil
characteristi cs

Combusti
on
quali ty

Conradson
carbon
Asphaltenes

Igni tion abi' li ty

Combustion
conditions
Fouling of gasways

S u lp h u r

Corosive wear

Vanadi
um
Sodium

Formationof deposits on exhaust

valves and tur bochar ger shigh
temperaturecorrosi on.

Impurity
content
t'later

Ash
C a ta l yst fi n es

H a n dli n g
p r o pe rti e s

Main effects

Disturbanceof combustionprocess
Increasedheat-load of combustion
chambercomponents,
fouling of gasways, mechanicalwear and cavitation of fuel injection system .
Mechanicaland corrosive wear of
combustionchambercomponents
form ation of deposits.
Mechanicalwear of fuel injection
system ,cylinder liner s and piston
r i ngs.

Vi scosi ty
Density
P o u rp o i n t

pressuresand capaciTemperatures
ties of fuel oil systemsfor storage,
pumpingand pre-treatment.

F 'l a shp o i n t

Safety requirements

Fuel properties affecting diesel engine and fuel systems

E!+t

g==t

E EEE'E.!E

cNEfAnf\c sETs

Lz3/30

/-=?\

FUELOIL SYSTEM
ANALYSISDATA

0316
E d i t i o n0 1 H
P a g e4 ( 1 4 )

Co n r m e not n
s A n a l ysi s D a ta fo r F u e l Oils
Carb o nR e s i d u e
Th e c a r b o nr e s id u e o f a fu e l o i l i n dicates its coke- for mingtendencyand can
cham b e u s e d t o d e t ermi n eth e te n d e n cyo f for m ing deposits in the com bustion
b e r a n d g a s w a ys;th e h i g h e r th e ca rbon r esidue value, the higher the fouling
tendency.
S o m ec h a n g e si n th e co mb u sti o np ro cess, r equir ing adjustmentof the maximum
p re s s u r e ,f f i d yal so b e a ttri b u te d to a high car bon r esidue content. The value
or Ramsis m e a s u r e b
d y sta n d a rd i ze dca rb o n i zingtests, such as the Conr adson
b o t t o mt e s t s , w h i c hg i v e s i m i l a r r e s u l t s .
T h e n o n - v a p o ri ze dre si d u e fro m th e c ar boniz' ingtest consists of car bonaceous
m a t e r i a l a n d i no rg a n i c i mp u ri ti e s a nd is expr essedin weight per centageof
the fuel sampletested. Carbonresidue and asphaltenecontent generally move
r atio with incr easingvain p a r a l ' l e l , b o th re l a te d to th e ca rbon- to- hydr ogen
lues fr higherratio.
on
Th e c a r b o n - t o - h yd ro g era
n ti o a n d th us the car bon r es' iduetoo, is dependent
the source of the crude o'il and the type of refinery processingused.
The effect of carbon residue is impossible to counteract by pre-treamentof
t h e f u e l o i l , a s c e n t r i f u g i n g o n l y i n f l u e n c e ss o l i d i n o r g a n i cc o n t a m i n a n tasn d
h a rd a s p h a l t s , w h i ch a re o n l y sma l l amountsof the weight per centageca' lled
c arb o nr e s i d u e.
A s p h at le n e s
As p h a l t e n e a
s r e d e fi n e d a s th e p a rt of a fuel oil samplebeing insoluble in
heptane. The content of asphaltenesis expressedin weight percentageof the
f uel o i l s a m pl ete ste d .
As p h a l t e n e swh
, i ch a re a ro ma ti c, sl ow- bur ning,simi- solid hydr o car boncompr opu n d sd i s p e r se di n th e fu e l o i l , h ave a similar effect on the com bustion
c e s s a s t h e c a rb o nre si d u e , th e ma in im pact being fouling of gasways.
T h e s t a b i l i t y of th e fu e l o i l i s re lated to the content of asphaltenes.
A s p h a l t e n e sa l so i n fl u e n ce th e l u b ri cation pr oper ties of the fuel oil and, in
ex t r e m ec a s e s , h i g h a sp h a l te n eco n tent m aylead to fuel pum psticking.
Fu e l o i l s w i t h a h i g h co n te n t o f a sphalteneswill have a tendencyto for m slud g e , e s p e c i a l l y i f th e vra te rco n te n t is also high. The asphaltenescontent of a
f ue' l o i l i s i n fl u e n ce db y p re -tre a tm ent,the heaviest sem i- solid asphaltenes
a n d a s p h a l t e n e sb o u n dto w a te r a s sludge can be separ atedby centr ifuging.
Die s e l I n d e x
Die s e l i n d e x i s a ca l cu l a te d va l u e s for deter miningthe ignition quality of a
f u e l o i l . T h e ig n i ti o n q u a l i ty i S related to the hydr ocar boncomposition,par af f in b e i n g o f h i g h q u a l i ty, n -h e p tanesof moder ateand ar om aticsof low quality .
Et+=

E FI':E'

Et$tt

GENERI\NWSETS

FUELOIL SYSTEM
ANALYSIS
DATA

0316
Edition 01H
P a g e5 ( 1 4 )

P r o p e r t i e so f t h e a n i l i n e p o i n t a n d t h e s p e c i f i c g r a v i t y r e f l e c t , w i t h c e r t a i n
e x c e p t i o n s,th e h yd ro ca rb o composition
n
of a fuel oil, and ar e ther efore us ed
i n t h e f o l l o w i n g s i m p l e f o r m u l aa s a n e x p r e s s i o no f i g n i t i o n q u a l i t y :
D i e s e li n d e x= ( a n i l i n e p o i n t o F x A P I g r a v i t y ) x 0 . 0 1 .
T h e a n i li n e p o i n t i s th e l o w est tem per atur eat which equal volumesof the fue'l
j u st mi sciple. The test dependson the fact that ar om ati c
a n d a n i li n e b e co me
h y d r o c arb o nmi
s x co mp l e te l yw' ith aniline at com par etively1owtemper at ur es ,
w h e r e a sp a ra ffi n s re q u i re co nsider ablehigher tem per atur esbefor e they ar e
c o m p l e t e l ym i s c i p l e .
T h u sa h i g h a n i l i n e p o i n t i n d i c a t e s a h i g h l y p a r a f f i n i c f u e l , a n d c o n s e q u e n t l y
a f u e l o i l o f g o o di g n i t i o n q u a l i t y . S i m i t a r i l y , a h ! g h A P I g r a v i t y n u m b edr e n o t e s a l o w s p e c i f i c g r a v i t y a n d h i g h p a r a f f i n i c i t y , a n d a g a i n a g o o di g n i t i o n
q u a li t y .
T h e d i e s e l 'i n d e xp ro vi d e sa reasonableidea of the ignition quality, but gener a l l y g i v e s f i g u r e s s l i g h t l y a b o v et h e c e t a n en u m b e r .
F u e l o i l s w i t h p o o r i g n i t i o n q u a l i t y a n d l o w d i e s e l i n d e xm i g h t e s p e c i a l l y
c a u s ep r o b l e msi n th e sta rti n g of the diesel enginesand r unning at low l oads .
I n a d d i t i o n t o s t a r t i n g d i f f i c u l t i e s , a p r o l o n g e di g n i t i o n d e l a y m a yg i v e r i s e
pr essur e, leading to incr easedm echanicaor
t o a l t e ra ti o n s i n th e ma xi mum
l
thermalload.
F u r t h e rmo refu
, e l o i 'l s w i th poor ignition quality m aycauser etar ded co m bus t i o n a n d su b se q u e nfo
t u l i n g of gasways.
S u lp h u r
S u l p h u ri s p re se n t i n fu e l o il mainly in or ganic com pounds,
the am ountp r es ent
b e i n g e xp re sse da s w e i g h t p e r centageof an oil sam pletested. If fr ee su l phur
'is present, it maycause comosion in the fuel system. The main problemcaused
b y s u l p hu r i s l o w te mp e ra tu r ecor r osion. Dur ing com bustion,sulphur oxid es ar e
p r o d u c e di n th e fo rm o f g a sses.Since hum idity also is pr esent, sulphuri c ac i d
maybe formedon components
in the combustionchamberand in the gas!{ays,where the temperatureis be'lowthat of the dewpointfor sulphuric acid.
T h e d e t ri me n ta l e ffe ct o f su lphur in fuel oil is counter actedbe m aintai ni ng
adequatetemperaturesof the combustionchambercomponents
and by using alkal i n e ' l u b r i c a t i n g o i l t o n e u t r a l i z e t h e s u l p h u r i ca c i d p r o d u c e d u r i n g t h e c o m b u s t io n .
Va n a d i u m
and Sodium
Va n a d i u m
a n d so d i u ma re co n s tituents of the ash content. The amountsof these
are measuredby analysing the res'iduefrom the combustiontest used for determ i n a t i o n o f th e a sh co n te n t.

I tA!
FGrEt
EllE
E.E.Es
E
GENERA'NCSETS

]YIAN

Et&ut
D3f6

FUELOIL SYSTEM
ANALYSISDATA

Edition 0lH
P a g e6 ( 1 4 )

a n d so d i u mp r esent is expr essedin PPm,par ts per milT h e a m o u n ot f va n a d i u m

be' ingtested for . ash contentsamp' le
lion b y w e i g h t re l a te d to th e fu e l oil
'
i
t
s
e
l
f
a
n
d
, b e i n go i l s o l u b l e , i t c a n n o t
d e i i v e s f r o m t h e c r u d eo i l
Vanadium
derives from
Sod'ium
pre-treament.
be removedfrom the fuel o'il by conventional
storage.and
d
u
r
i
n
g
w
a
t
e
r
w
i
t
h
s
a
l
t
i h e c r u d eo i l , a n d a l s o f r o m c n t a m i n a t ' i o n
of der ivar
egar
dless
and,
solub'
le
t ra n s p o r t o f i he fu e l o i l . S o d i u mi s water
f
u
e
l
o
i
l
.
p
r
e
s
e
n
t
i
n
t
h
e
e ith the water
tion, trendsto combinw
0 w i n gt o i t s w a t e r - s o l u b i l i t y , i ! i l p o s s i b l e . t o r e m o v eo r r e d u c et h e a m o u n t
cor r osive ash is for med
o f s i u mp r e se n t i n th e fu e i -o i l . Dui^ingcom bustion
an d so d i u m.
f rom v a n a d i u m
exceedsl:3, ash with
Es p e c i a l l y i f th e w e i g h t ra ti o o f sodiumto vanadium
for
medgiv' ing r ise to high
is
v i: Vl o w m e l t i n g p o i n l a n d sti cti o n temper atur e
in turbochargers.
formation
temperaturecoryoiion of exhaust valves and deposit
It is possible to reducethe tendencyto forml!!on of detrimental vanadiumiod i u m ' a s hb y e ffe cti ve ce n tri fu g i n g, which will r emovesodiumsalts together
wit h w a t e r . i t a ve ry l o w co n te n l of sod' iumis ensur ed,a r elative high vanad iu m c o n t e n t m i g h t b e a cce P ta b l e .
Water
by a standar dizeddistillation test
T h e w a t e r c o n te n t o f fu e l o 'i l i s measur ed
un ir expressedas a volumepercentageof ltre samp'letested. l,fater in fuel
oil maylbad to several detrimental effects of the fuel oi'l system, corrosion
and c a v i t a t i o n o f fu e l p u mp sa n d fuel valves, and causefouling of exhaust
systemand turbochargers.
Sal t w a t e r , d u e to i ts co n te n t o f sodium,contr ibutes in combinationwith vanadiumto ihe formation of low-melting corrosive ash, which attacks exhaust_
v al v e s a n d t u rb o ch a rg e rs.Wa te r, w hen- it distur bs the fuel atom ization,will
cham n su l ti n g i n higher heat loads of the combustion
le a d t o p o o r co mb u sto re
ber components.
I t i s p o s s i b l e to re d u ceth e w a te r content of a fuel- oil pr im ar ilY !V centr if u g i n g , a n d t hi s sh o u l db e d o n eto the widest possible extent in or der to avol [tre detrimental effects of water in the fuel oil.
Ash
m ater ial pr esent in the
A s h c o n t e n t i s a me a su reo f i n o rg a nic non- combustible
test, and it is excom
bustion
by
a
d
e
te
rm
ined
i
s
f ue l o ' i l . T h e a sh co n te n t
of the oil
combustion
from
complete
percentage
residue
prsseAas a weight
s a m p l et e s t e d.
of
materials are present in the fuel oil as natural components
Ash-form'ing
fuel
oil.
the
of
c ru d e o i l n d d u e to e xte rn a l co n tamination

E#.EEY

GENERA'NI{C STS

Lzs/30
FUELOIL SYSTEM
ANALYSIS
DATA

}IAN
C&U'
0316
Edition 01H
P a g e7 ( 1 4 )

A s h - f o r m i nm
g a t e r i a ' l se x i s t b o t h a s s o l i d c o n t a m i n a n tasn d i n s o l u b l e c o m p o u n d s .T h e so l i d co n ta mi n a nts
may lead to abr asive wear in the fuel inje c ti on
s y s t e m .Ash fo rme dd u ri n g co mbustionmaylead to abr asive as well as cor r os i v e
wear of combustioncharnber
components
and give rise to formations of detriment a l d e p o s i t s . I t i s t h e r e f o r e e s s e n t i a l , t o t h e g r e a t e s t p o s s i b l ee x t e n t , t o
r e d u c et h e a mo u n ot f a sh -fo rm ' ing
mater ials by centr ifuging.
S o l i d c on ta mi n a n ts
su ch a s sa nd, r ust, cer tain m etal oxides and catalyst fi nes
c a n b e r e mo ve d
b y ce n tri fu g i n g, and the sam egoes for water - solub' lesalts s uc h
a s s o d i u m.
Someof the components
included in the ash content have beenfound to be part i c u l a r l y h a rmfu la n d a re th e refor e stated individually in the analysis data.
S i l i c i u m a n dA l u m i n i u m
Oxides
R e s i d u alfu e l s p ro d u ce db e re finer ies using fluid catalytic cr ackingm aybe
c o n t a m i n a t ebdy c a t a l y s t p a r t i c l e s i n f o r m o f s i l i c i u m a n d a l u m i n i u m
oxides.
C a t a l y s t p a rti cl e s, i f a n y, a r e compr isedby the value for ash content.
S e p a r a t eva l u e s fo r th e si l i ci um oxides content and the a' luminium
oxides c ontent are measuredby analysing the ash content.
T h e a m ou not f si l i ci u m a n d a l uminiumoxides is expr essedin ppmr elated to the
w e i g h t o f th e o ri g i n a l fu e l o il samplebeing tested for ash content.
As catalyst particles are very hard and abrasive, they can causeextrememec h a n i c a l w e a r o f th e fu e l i n j ection system ,cylinder liner s and piston r ings .
C a t a l y s t p a rti cl e s, b e i n g so l id and insoluble, can be r em ovedfr om the fu el
o i l . T h e g u i d e - 1 i n e sf o r d i m e n s i o n i n tgh e c e n t r i f u g e s i z e i s b a s e do n t h e f a c t
that approx. 1/3 of the catalyst particles with regard to weight is removed.
Vi scosi ty
V i s c o s i ty i s a me a su reo f th e inter nal fr iction or r esistanceof an oil to
fl ow.
T r a d i t i o n a l l y, th e vi sco si ty of fuel oils have beenexpr essedin second sR edw o o dN o . 1 ( s R 1 ) .
I n 1 9 7 7,h o w e ve r,th i s d e si g nationwas officially super seded
by the metr i c
u n ' i t o f Ki n e ma ti cvi sco si ty, centistokes ( cSt) , and the tem per atur eat whi c h
n o m i n a lvi sco si ty i s to b e re lated was also changed.
C o n r n e rci adle si g n a ti o n so f re sidual fuels for mar ineuse, still being r el ated
t o n o m in a lvi sco si ty, h a ve th us changedfr om viscosity expr essedin seconds
R e d w o oNdo . 1 a t 1 0 0 0F to vi s cosity expr essedin centistokesat 50o C. The
r e l a t i o n sh i p b e tw e e nth e tw o methodsof expr essingthe nominalviscosity i s
s h o w ni n ta b 'l e .

E#.EBY

CENERANNGSETS

lvlAl

Et&ut

L23/30

D3t6

F U E LO I L S Y S T E M

E d i t i o n0 1 H
P a s eB ( 1 4 )

ANALYSISDATA

F u r t h e r m o r et,h e d e s i g n a t i o nh e a v yf u e l o i l ( H F O ) ,b u n k e rC f u e l o j l a n d N o . 6
fueloilfortheheaviestandcheapestgradeofresidualfueloilformarine
designationm ar inefuel oil ( MFO)or
us e, h a v e b e e nsu p e rse d ebdy th e co m m on
(
l
F
)
g
r
a
d
e
so f r e s i d u a l f u e l s f o l l o w e db y a n u m for all
i n t e r m e d i a t ef u e l o i l
b e r i n d i c a t i n g t h e n o m i n a lv i s c o s i t y .
0ld designation
Sec. Redwood
No. 1/1000 F

N e wd e s i g n a t i o n
cSt/50oC

200sR1
3 0 0 ''
400 ' ,
600 '
800 ' '
1 0 0 0 'r
1200 !
1500 ''
2 0 0 0 ''
2 5 0 0 '
3 0 0 0 ',
3 5 0 0 ',
4 0 0 0 ''
4500 ''
6 0 0 0 ''

IF 30
" 4 0

7000

!'

t'

"
"
"
"
"
"
"
"
"
"
"
"
"

60

8 0
100
120
150
180
240
280
320
390
420
460
600
700

Th e u s e o f t h e S ;I.i syst ma l so i n fl ,uencesthe nominalviscosit- vdesignation

a n d ma ri n ediesel oil ( M D0) ,both nowto be expr essed
f o r m a r i n eg a s o i 'l (MGO)
in c e n t i s t o k e sa t 4 0 o C .
Vis c o s i t y i s a n i mp o rta n tp a ra me terin connectionwith pumping,pr e- tr eatr nent
a n d i n j e c t i o n o f f u e l o i l , s i n c e t h e p o s s i b i l i t y a n d e f f i c i e n c y o f t h e s ep r o on adequateviscosity.
c es se st o a l a rg e e xte n t i s d e p e n d ent
Adju s t m e not f th e vi sco si ty i n to a d equatevalues is possible by taking advanbetweentemperatureand viscosity index of the
tage of the interdependence
fuel oil.
Th e n o m i n a lv i sco si ty o f a fu e l o i l is the deter miningfactor for or eheat' ing
t emp e r a t u r e n
s e ce ssa ryto o b ta i n a d equateviscosity for pum ping,centr ifuging
i
n
j
e
c
t
i
o
n
of th e fu e l o i l , a n d thus also is the deter miningfactor for the
and
c a p a c i t i e s o f th e p re h e a ti n ge q u i p m entin the fuel oil system.
i ty
Dens
De n s i t y i $ d e f i n e d a s th e ma sso f a unit volum eand it is expr essedin g/cm 3
at a temperatureof 15o C.

E#.EBY

GENRA'NNGSTS

FUELOIL SYSTEM

D3t6
E d i t i o n0 1 H
P a g e9 ( 1 4 )

ANALYSISDATA

'liquid
9 p e c i f i c g r a v i t y i s t h e r a t i o o f t h e m a s so f a g i v e n v o l u m eo f
at 600F
( 1 5 . 6 ' .C
, ) a n d t h e m a s so f a n e q u a l v o l u m eo f water at the sametemperature.
F o r _ ag i v e n I i q u i d , t h e s p e c i f i c g r a v i t y w i l l gener a' llygive the samenum er i cally as the density.
A P l - g r a v i t y i s a n a r b i t r a r y s c a ' l ec a l i b r a t e d in degr eesand r elated to spec i fic gravity by the following formula:
A P I - g r a v i t y( d e g r e e s= )

+ 131.5

A s t h e fo rmu l a i n d i ca te s, th e APl- gr avity is in inver se r atio to density and

specific gravity.
D e n s i t y i s a n i mp o rta n t p a ra meterin the centr ifuging pr ocess,wher esepar at i n g w a te r a n d w a te r-d i sso l vedimpur ities fr om th r ei oil ii basedupbn
d i f f e r e nce i n d e n si ti e s. If the dbnsity of the tul it pp"o."rthat of the
w at e r , . c e n tri fu g i n g th u s b e co mes
less efiective, necessitatilr gr educedflo w r J i e
a n d t h e re fo re 'i n cre a se dce n trifuge capacity.

ANALYSIS
DATAFORFUTLOILS

EN GIN E
RELEVANT
PROPIRTI
ES

C ar bonResidue

ol
p

weight

Asphaltenes
Diesel Index

ol
lo

weight

Ash
S ulphur

ol
b

weight

ol
h

l.later

ol
lo

weight
vol umen
ppm

V anadium
Sodium
S i l i c i u mO x i d e
Aluminium
Oxide

INSTALLATION
RELEVANT
P R OP E R T IE S

ppm
ppm
ppm

Vi scosi ty

s e c . R e d w . l / 1 0 0Fo
cSt/$gog

Densi ty

9/ml

FlashPoint

oc
oc

P our Point

FE.EEY

GENERANAC SETS

]YIAhl
L23/30
FUELOIL SYSTEM
ANALYSISDATA

cf&ut
0316

E d i t i o n0 l H
P a g e1 0 ( 1 4 )

T h e w a t e r s e p ara ti o na b i l i ty o f fu el oil is incr easedby pr eheatingthe fuel

o il p r i o r t o c e n tri fu g i n g si n ce th e densities of fuel oil and water change
w i t h t h e t e m p e r a t u r ae t d i f f e r e n t r a t e s , t h u s g i v i n g p o s s i b i l i t i e s o f o b t a i n i n g o p t i m a ld i f f e r e n c e i n d e n s i t i e s .
T o so m ee x t e n t, th e q u a l i ty o f a fu el oil can be judged by the density, since
r atio, which again is
t h is i s d i r e c t l y p ro p o rti o n a l to th e car bon- to- hydr ogen
in d i r e c t r a t i o to a ro ma ti vi ty, ca rbonr esidue and asphaltenecontent, but in.
reverse r:atio to cal ori f i c val ue.
P o u rP o i n t
T h e p o u r p o i n t i s th e l o w e st te mp er atur eat which an oil will flow or can be
p o u r e d .T h e p ou r p o i n t i s me a su re under
d
specified test conditions. Fuel oil
pumped
must be stored, handledand
at temperaturesabovethe pour point to av o i d w a xc r y s t a l l i z a t i o n , w h i c hm a yr e s u l t i n p r e c i p i t a t i o n i n s t o r a g et a n k s ,
b l o c k ' i n go f f i l t e r s a n d p i p e ' l i n e s a n d p r e v e n t i o no f p u m p a b ' i l i t y .
Nor m a l l yt h e p o u r p o i n t o f re si d u a l fr el oil does not give any pr oblem ssince
levels will be ade t h e t e m p e r a t uren e e d e dto re d u ceth e viscosity to pum pable
q u a t e l y i n e x c e s so f t h e p o u r p o i n t .
F l a s hP o i n t
Th e f l a s h p o i nt o f a n o i l i s d e fi n ed as the tem per atur eat which it gives off
s u f f i c i e n t v a p o u rto cre a te o n i n fl anunable
mixtur e with air . This m ixtur e wil' l
ign i t e o r f l a sh u n d e r th e i n fl u e n ce of an open flame, but will not suppor t the
c o m b u s t i o ni t s e l f. T h e fl a sh p o i n t of fue' l oil is nor m ally tested by the Pens k y - M a r t e n cs l ose d -u pme th o d .
I n o r d e r t o p ro vi d e a su ffi ci e n t mar ginof safety fr om fir e r isk dur ing stor a g e , h a n d ' l i n ga n d tra n sp o rta ti o n , fuel oils for shipboar duse m ust m eet the
of
c l a s s i f i c a t i o n s o c i e t i e s ' r e q u i r e m e not f f l a s h p o i n t , l i m i t e d t o a m i n i m u m
6 0 0c .

E#FEEEY

GENERATVG SETS

1||Ahr
Et&ut

L23/30

0316

FUELOIL SYSTEM

Edition 0fH
P a s e1 1 ( 1 4 )

F U T LO I L C L I A N I N G

Puri fi cati on Recommendati

ons

F u e ' lo ' i l s a re a l w a ysco n ta minated

and should ther efor e be thor oughlyc' l eaned
f o r s o l i d a s w e l l a s l i q u i d c o n t a m ' i n a nb
t se f o r e u s e . T h e s o l i d c o n t a m i n a n tisn
t h e f u e l a r e m a i n ' l yr u s t , s a n d , d u s t a n d r e f i n e r y c a t a l y s t s . L i q u i d c o n t a m i n a n t s a r e m a i n l yw a t e r , i . e . e i t h e r f r e s h w a t e r o r s a l t w a t e r .
T h e i m p u ri ti e s ca n ca u sed a mage
to fuel pum psand fuel valves, can r esul t i n
i n c r e a se dcyl i n d e r l i n e r w e a r and deter ioate the exhaustvalve seats.
Also increasedfouling of gas v',aysand trbochargerblades mayresult from the
u s e o f i n a d e q u a t e l cy l e a n e df u e l o i l s .
Effective cleaning can only be ensuredby meansof a centrifuge. l,lerecorrnend
t h e c a p a ci ty o f th e i n sta l l e d centr ifuges to be at least accor dingto th e m ak e r ' s i n stru cti o n s. T o o b ta i n optim umleaning it is of the utm ost im po r tanc e
t o o p e r a te th e ce n tri fu g e w i th as low a viscosity of the fuel oil as po s s i bl e
a n d a l l ow th e fu e l o i l to re m ainin the centr ifuge bowl as long tim e as pos s i b le .
L o wv i s c o si ty i s o b ta i n e db y oper ating the centr ifuge pr eheaterat the m ax i m um
temperaturecorrespondingto the fuel viscosity concerned.
C L E A N I NO
GF H . F . O . B Y C E N T R I F U G I N G

Operating
opti ons

Normal
c o nd i tio n s

Extreme
c o nd ti
i ons

S i n g l e c e n t r i f u g ea s p u r i f i e r
Twocentr ifuges in par allel
Twocentr ifuges in ser ies
Op ti mum
oper ating configur ations
Water Content
Parallel operation
b e l o w1 %
Pur ifi er lPur ifier
or
D e n s i t ya t 1 5 o C
Ser ies oper ation
b e l o w0 . 9 9 1
Purifier + Clarifier
Water Content
a bove1%
Par a' lle1oper ation
Pur ifi er lPur i fi er
D e n s i t ya t l 5 o C
a b o v e0 . 9 9 1
HighContent
Ser i.esoper ation
of
P
u
rifier + Clarifier
catalyst fines

Es p e c i a l l y fo r fu e l s a b o ve1 80 c s t / s 0 oC ( 1 5 0 0sec.Rw/l00oF) the highes t pos s i b l e t emp e ra tu re9 8 o C sh o uld b e m a i n t a i n eidn the centrifuge oil preheater.

EJE

E ttt=-E--t

TT!=tg

CENERANWSTS

lv|Ah|

creut

L23130

D3t6

FUELOIL SYSTEM

E d i t i o n0 1 H
P a g e1 2 ( 1 4 )

F U E LO I L C L E A N I N G

T h e f u e l i s k e p t i n t h e c e n t r i f u g e a s l o n g a s p o s s i b l eb y a d i u s t i n g t h e f l o w
rate through the centri fuge so that 'it correspondsto the amountof fuel rer e - c i r c u ' l a t i n g . C o n s e q u e n t l yt h, e c e n q u i r e d b y t h e e n g i n ew i t h o u t e x c e s s ' i v e
t rif u g e s h o u l dop e ra te fo r 2 4 h o u rs a day except dur ing necessar ycleaning.
T a k i n gt o d a y ' s f u e l q u a l i t i e s i n t o c o n s i d e r a t i o nt h e n e e df o r c l e a n i n gc e n t r i f uge s ( "s h o o t i n g fre q u e n cy" )sh o u l d not be under estim ated.Cor r ect choice and
and/or the gr avity discs ar e of special
adju s t m e n o
t f t h e re g u l a ti n g scre v,rs
impo r t a n c ef o r effi ci e n t vra te r re moval.The centr ifuge manualstates the disc
t h i ch sh o u l d b e chosenon the basis of the specific gr avio r s c r e wa d j u s tme nw
f
u
e
l
.
ty of the
Norma lp r a c t i c e i s to h a vea t l e a st two centr ifuges avai' lable for fuel cleanl o rk on centr ifuges tr eating today' s qualities
in g . R e s u l t s f r om e xp e ri me n taw
th
a
o f re s i d u a l f u e l h a ve sh o w n t th e best cleaning effect espec' ial1yas r eg a rd s r e m o v a lof ca ta l yst fi n e s i s a chievedwhenthe centr ifuges ar e oper ated
in series, 'in purifier/clarifier mode
RATEOF FLOW
RL^fO fO RAIO C^PICY F

CETRFUG

Therefore - series operation of

centr ifuges ensur inga maximum
of
safety is a fully acceptedalter native to the previously recomm endedpar allel oper ation pr ovided the oper ating capasity of
each individual centr ifuge can
handle the total amountcif fuel
r equir ed by the engine, without
exceeding the flow rate recorrnended by the centrifuge makerfor
the oper ating modein question.

oc SEPARATIONTEMPERATURE
t00
90

to
?0
60
5d
(0
75r00 130

5
l09
dat

0 E0
.@

. tt.a aO.C

tE(r

3E) 600

I f t h e i n s t a l l e d c e n t r i f u g ec a pacity is on the low side com espondingto the specific viscosity

of the used fuel oil, and if m or e
than onecentrifugeis available,
par allel oper ation in or der to
obtain an even lower flow r ate
,
maybe consider ed.Howeverin
view of the abover esults and r eser ious consider acom m endations
t i o n s s h o u l db e g i v e n t o i n s t a l ling newequipmentin cor r espondancewith today' s fuel qua' lities
ons.
and f I ow recorrunendati

itlr!{lt

s00 60(x
e

ar6t

ETGLEBY

CNERATI\GSETS

TvIAhl

Et&ut

L23/30
FUELOIL SYSTEM

D316
E d i t i o n0 1 H
P a s e1 3 ( 1 4 )

F U E LO I L C L E A N I N G

F o r t h e d e te rmi n a ti o no f ce n tr ifuging capacity, we gener ally advise to f ol l ow

the recornmendations
of the centrifuge maker, but the curves can be used as a
g u id a n c e .
A h o m o g e n i zema
r yb e i n sta 'l l ed in the fuel o' i1 systemas a supplement
to the
p o ssible water and sludge st' il1 pr esent in the fuel
c e n t r i f u g e s to h o mo g e n i ze
after centrifuging.
F U E LO I L C O N D I T I O N I N G
FueI oil temperatureand primary pumppressure have to be adjusted accrding
t o t h e a ctu a 'l fu e l o i 'l q u a l i ty used in or der to ensur ecor r ect atomizati on, to
p r e v e n t o ve rl o a d i n go f th e fuel oil system ,and to pr event gasification.
T h e f u e l o i l p re h e a ti n gi s to be adjusted in accor dance
with the viscosi ty of
t h e o i l a n d t h e f u e l i n j e c t i o n p r e s s u r e .I f t h e p r e h e a t i n gi s c o n t r o l l e d b y
t h e r m o sta ts,th e se a re to b e adjusted accor dingto the gr aph below, whic h i nd i c a t e s th e p re h e a ti n gte mp er atur eas a function of the fuel oil viscsi ty i n'
c St / 5 0 o C .
T h e v i s c o s i t y s h o u l db e a t t h e r a n g e 1 2 - 1 8c S t .
F U E L O I L P R E H E A T I NT
GE I ' I P E R A T U R 4E-,S T R O K EE N G I N E S
r am9

{-

2cSt

3cSt

5cSl

TcSt

r50
tro

r 1 5

oo

t SOcS

rOO0cSl

cst/50'c
lF-80

tF- 80

tF-380 rF-600

T h e c r o s s - h a t c h eadr e a i n d i c a t e s t h e r e c o r u n e n dvei ds c o s i t y ( 1 2 - l g c S t ) a t - i n j e c t i o n pre ssu re .

E x a m p l eF: u e l o i l , | 8 0c s t / 5 0 o C ( 1 5 0 0s R 1 / 1 0 0 F
o ) s h o u l db e h e a t e dt o
1 1 0 - 1 2 5C
0 , r e s u l t i n g i n a v i s c o s i t y i n t h e r a n g e 1 8 - 1 2c S t a t i n l e t
engn
i e.
E ttg

tFllEit

FTSE.EE

CENERA1rIG STS

lvlAhl

Et&ut

L23

D3t6

FUELOIL SYSTEM

Edition 01H
P a g e1 4 ( . | 4 )

F U E LO I L C O N D I T I O N I N G

The primary pumppressure h a s t o b e i n c r e a s e d i n a c c o r d a n c ew i t h t h e p r e h e a t'ing temperature'in order to prevent gas formation and a consequent uneven
p u m pf i l l i n g :

F U E L O I L P R I M A R YP U M PP R E S S U R ,
bar
7

lF 600

,t#a"-9.ri:iiiiijl'#

tF 380
IF 180

F 80
F 1

tF 40
F 60

"l

IF 30

70

80

90

lOO

11O

12O

13O

14O

15O oC

primary pumppressureas a function

The hatchedarea indicates the recormended
of t h e f u e l o il v'i sco si ty.
running on IFO 180 the fuel oil is heated to a temperatureof
Example: l.lhen
, | 1 0 - 1 2 5Co. A t t h i s temperaturerange the priming pumppressure
s h o u l db e 4 - 5 b a r .

E#H.EEY
CENERA'il\IGSETS

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Eteult
PLATE
31601.10H

FUELOIL PRIMARY
PUMP

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GENERA'N\|GSETS

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PLAT3
E1 6 0 1 . 1 O- H

PUMP
FUELOIL PRIMARY

Item No.

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B u sh
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Styresti ft

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sh o rt
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Pl ug screw

A k s e lm . t a n d h j u l ,
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Pr opskr ue

Gasket
Screw
P isto n
C yli n d e r

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Coupli ng
Bolt

Skrue
Stempel
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GENERAI\GSETS

TIAN
E&U'
F U ELO IL F IL T E R

PLATE
31 602.09H

POSITIONOF THREEI.IAYCOCK

Filter at left in operation

T h i s p o s i t i o n i n u s ew h e n
filter at right has to be
openedfor maintenance.

Filter at right in operation

Bothfilters in
operation.

This position in usewhen

filter at left has to be
openedfor maintenance.

to drain tank

FFTEEY
GENERAING SETS

lvlAht

Et&ut
PLATE
31602.09H

FUIL OIL FILTER

Item No.

-60*oa/U,;aILQJQT
6 o o ct z i 6 - t " : : o - 2 5 9

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Filter eleqent

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sol i efi I ter ,
komplet
Fi I ter i ndsats

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D ra i n co_gk,com plete

Pakning
Aftapningshane,kom plet

_ F u e 1o _ ' i filtqr ,
compl
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Forskrun'ing
Rsr

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GENERATII\IC SETS

lYIAN

Eltult
FUELOIL DRAINBOX

PLATE
3 I605.H 1

0122
77
0766

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GENERAU\GSETs

PLATE
31605- H-1

FUELOIL DRAINBOX

Item No.

Designation

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Dranbeho'lder
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GENERA'N\G

SETS

EngineData

z
o

of Engine
Operation

o-

andCondition
EnginePerformance

E
ff
o

I?oubleTracing
EngineFrameand Bedplate
Crankshaft
and MainBearings
GylinderHeadand GylinderLiner

Rod
PistonandConnecting
Gearfor InletValveg
Operating
ExhaustValvesand FuelInjectionPumps
UJ

Tirbocharger
System

?e
l'fr
zts

FuelInjectionPump

:z
=<

Camshaftand CamshaftDrive

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a,g

Fuellnjection

ControlandSafetySystems
Automatics
andInstruments

F
F -

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c

StartingSystem
Lubricating
Oil System
Oil
of Lubricating
Specification
andTreatment
FuelOil System
Fueland FuelTreatment

CoolingWaterSystem
Treatment
of CoolingWater
DrivenMachinery

SpecificPlantInformation

L23/30
COOLING
I.ATER
SYSTEM

3 l7 . 0 3

TREATMENT
OF COOLING
WATER

Edition09H

T h e c ' l e a n i n ga g e n t ss h o u l dn o t b e d i r e c t ' l y a d m i x e d b, u t s h o u ' l db e d i s so l ve d j n w a te r a n d then addedto the cooling water s_vstem .

N o r m a l l y ,c l e a n i n gc a n b e e x e c u t e dw i t h o u t a n y d i s m a n t l i n go f t h e e n g i l e . W ep o ' i n to u t t h a t t h e w a t e r s h o u ' l db e c i r c u l a t e d i n t h e e n g i n et o
a c h i e v et h e b e s t p o s s i b l e r e s u l t .
A s cl e a n i n g ca n ca u seleaks to become
appar entin poor ly assem bl ed
j o i n t s o r p a r t l y d e f e c t i v e g a s k e t s ,i n s p e c t i o ns h o u l db e c a r r i e d o u t
d u r i n g t h e c l e a n i n gp r o c e s s .T h e a c i d c o n t e n t o f t h e s y s t e mo i l s h o u l d
a l so b e ch e cke di mme diatelyafter cleaning, and 24 hour s after var ds .
2.

C o o l i n gW a t e r- I n h i b i t o r s
T h e f i l l i n g - u p w i t h c o o l i n g w a t e r a n d t h e a d m i x t u r eo f t h e i n h ' i b i t o r i s
t o b e ca rri e d o u t d i rectiy after the cleaning in or der to pr even t for ma ti o n o f ru st o n th e cleanedsur faces.

2 . 1 . R a wW a t e r
T h e fo rma ti o no f l i me stone on cylinder liner s and in cylinder h eads
ma yre d u ceth e h e a t transfer , which will r esult in unacceptab' lhyi gh
te mp e ra tu re si n th e mater ial.
T h e re fo re , i t i s re co mmended
that deionizedor dist' il' led water ( for ex amp 'l efro m th e fre sh watergener ator ) is used as cooling water .
H o w e v e ro, n a c c o u n to f i t s l a c k o f h a r d n e s s t, h i s w a t e r w i l l b e r e l a t i ve ]y co rro si ve , a n d comosion inhibitor should ther efor e alwaysb e added.
I f d e i o n i z e do r d i s t i l l e d w a t e r c a n n o tb e o b t a i n e d ,n o r m a ld r i n k i n g w a t e r ca n b e u se d i n e xceptional cases. If so, the tota' l har dnessof the
water must not exceed90 dH (Germanhardnessdegrees).
F u rth e rmo re i,t sh o u l d be checkedthat the pH vlue of the water l i es
between5-8 at 20o C.
T h e c h l o r i d e , c h l o r i n e , s u l p h a t e ,a n d s i l i c a t e c o n t e n t sa r e a l s o t o b e
ch e cke d .T h e seco n te nts should not exceedthe fotlowing values:
C h 'l o rid e
Clrlorine
S u l p h a te
S iI i c a t e

50 ppm
10 ,l00 15 0 -

( 5 0 m s / li t r e )
( 1 0 m g / ]i t r e )
( 1 0 0m g / li t r e )
( 1 5 0m g / li t r e )

T h e resh o u l d b e n o su lpide and anr nonia

content. Rain water m ust not be
u se d , a s i t ma yb e h e avily contam inated.

+H.EB\f

GNERATTAG SETS

IvlAhl

Ett*ut

L23/30
COOLINGWATERSYSTEM
TREATMENT
OF COOLINGI,IATER

3 1 7 0. 4
Edition 09H

I t s h o u l db e n o te d th a t so ftening of the water does not r educeits sulp h a t ea n d c h l o r i d e c o n t e n t s .

2 . 2 . C o r r o s i o nI n h i b i t o r s
T o p r o te ct fre sh w a te rco o l i n g system sin mar inediesel enqinesalainst
c o m o s i o n ,v a r i o u s t y p e s o f i n h i b i t o r s a r e a v a i l a b l e .
G e n e r al l y,o n l y n i tri te -b o ra te basedinhibitor s ar e r econm ended.
A numberof the products marketedby majorrcompaniesare specified on
t h e e n cl o se dl i st, to g e th e r with the necessar ydosagesand adm ixing
p r o c e d u re s.Were co mme nthda t these dir ections ar e str ictly obser ved.
T r e a t me not f th e co o l i n g w a ter with inhibiting oils is not r econnended,
a s s u c h tre a tme n ti n vo l ve s the r isk of oil adher ingto the heat tr ansmitting surfaces.
C h r o m a te
i n h i b i to rs mu st n o t be used' in plants connectedto a fr eshw a t e r g e n e ra to r.
Ev a p o ra te co
d o l i n g w a te r i s to be r eplacedwith noninhibitedwater ,
w h e r e asa l o ss o f w a te r th ro ugh leakagemust be r eplacedwith inhibited
water.
l,lhenoverhauli ng i ndivi dual cyl i nders, a net{dosageof i nhibi tor must,
i f n e c e ssa ry,b e a d d e di rrn e diatelyafter completingthe job.
3.

Checkingof the Cooling Water System

a n d t h e C o o l i n gWa te rd u ri n g Ser vice
I f t h e co o l i n g w a te r i s co n taminated
dur ing ser vice, sludge or deposits
mayform. The condition of the cooling water systemshould therefore be
r e g u l a r l y c h e c k e d e" s p e c i a l l y i f d e i o n i z e do r d i s t i l l e d w a t e r i s n o t
u s e d . I f d e p o si ts a re fo u n d i n the cooling spaces, these spacesor , if
necessary,the entire systemshould be cleaned.
A c c o r di n gto e xp e ri e n ce ,a zinc aalvanizedcoating in the fr eshwater
c o o ' l i n gsyste mi s o fte n ve ry susceptible to cor r osion, which r esults in
h e a v yf orma ti o no f sl u d g e , e v en if the cooling water is cor r ectly inhib i t e d . T h e i n i t i a l d e s c a l i n gw i t h a c i d w i l l , t o a g r e a t e x t e n t , r e m o v e
t h e g a lva n i ze dco a ti n g . Ge n er ally, ther efor e, we advise against the use
o f g a l v a n i ze dp i p i n g i n th e fr eshwatercooling system.
T h e q u al i ty o f th e co o l i n g w ater is to be checkedr egular ly, if poss i b l e , o n ce a w e e k.T h e i n h i bitor concentr ation, the pH value, which
s h o u l dbe 7 -1 0 me a su readt 2 0o C, and chlor ide concentr ation,which is
n o r m a l l yn o t to e xce e d5 0 p p m( 50 mg/litr e) , shou' ldbe deter mined.

EE.EEY

GENERATU{G STS

L23/30

TY|AN

Et&ut

COOLING
WATER
SYSTEM
HATER
TRIATMENT
OF COOLING

3 1 7 0. 5
Edition 09H

Fo r th i s p u rp o seth e i nhibitor m anufactur er snor m ally supoly simpl e

test kitsTh e co n ce n tra ti o no f i nh' ibitor m ust under no cir cum stances
be allow ed
to fa'|] below that recommended
by the producer, as this wou'ldincrease
the risk of corrosion.
Th e w a te r sa mp l e -fo rthese tests is to be taken fr om the cir culat i ng
s yste m,a n d n o t fro m the expansiontank or the pipe leading to it.
A cl e a r re co rd o f a l l measur ingr esults should be kept, so that the ac tual condition and trend of the systemmaybe cumenlly ascertainedand
eva lu a te d .
A su d d e no r g ra d u a l i n cr ease in the chlor ide content of the cooli ng
w a te r ma yb e i n d i ca ti ve of salt water leakages.Suchleakagesar e Io be
t r a ce d a n d re p a i re d a t the fir st oppor tunity. A chlor ide cntent i n the
c o o l i n g w a te r h i g h e r than the 90 ppr nspecified m ight, in excepti onal
c a se s, b e to l e ra te d . However in
, that case the upfer limit spbcifi ed by
t he i n d 'i vi d u a l i n h i b i tor supplier must not be exceeded.
A su d d e no r g ra d u a l d e cr easein pH value, or an incr easeof the s ul phat e co n te n t, ma yi n d i ca te exhaustgas leakage.The pH value can be i nc re a se db y a d d i n g i n h i bitor ; however ,if major quantites ar e neces s a ry, th e w a te r sh o u l d be r eplaced.
Eve ry th i rd mo n tha co oling water sam pleshould be sent ashor efor l abo ra to ry a n a l ysi s, i n par ticular to ascer tain the contentsof inh i bi t or, su l p h a te , a n d i ro n' as well as the total salinity of the water .
C L E A N INAG
N DIN H IB IT IN G
P R OCEDURT
T h e e n g i n emu st n o t b e ru n n i ng dur ing the cleaning pr ocedur e,as this m ayi nv o l v e t h e ri sk o f o ve rh e a ti n gwhendr aining.
Degreasi
ng
U s ec l e a n t a p w a t e r f o r f i l l i n g - u p . T h e c o o l i n g water in the systemcan be
used, i f i t does not contain i nhib'itors .
Heat the water to 60o C and circulate the water continuously.
D r a i n t o l o w e st w a te r l e ve l i n expansiontank.
Add the amountof degreasingchemical specified by the supplier , pr efer abl .v
from the suction side of the freshwater pump.

Jt!

EErt

E F-=-E-85
CENERA'TI{G

E
SETS

]Y|AN
L23/30

E &Ut
3 17 . 0 6

SYSTEM
WATER
COOLING
I,IATER
OF COOLING
TREATMENT

Edition 09H

Dra i n t o l o w e st w a te r l e ve l i n th e expansiontank dir ectly after war ds.

C i r c u l a t e t h e c l e a n i n gc h e m i c a fl o r t h e p e r i o d s p e c i f i e d b y t h e s u p p l i e r .
T h e c o o l i n g w ate r syste mmu st n o t b e

ffi

Dra i n t h e s y s te ma n d fi l l u p co mp l etelywith clean tap water n in or der to

f lus h o u t a n y oi 1 o r g re a sefro m th e tank.
Circ u l a t e t h e w a te r fo r 2 h o u rs, a n d dr ain again.
D e s c a l i n gw i t h A c i d S o l u t i o n
F i l l u p w i t h c l e a n t a p w a t e r a n d h e a t t o 7 0 - 7 5 oC .
in a clean ir on dr umwith hot
Dis so l v e t h e n e ce ssa ryd o sa g eo f a cid compound
water.
B e c a r e f u l - u se p ro te cti ve sp e cta clesand gloves.
F o r e n g i n e sw h i ch h a ve b e e ntre a te d befor e the tr ial tr ip, the lowest concent rati o n r e c o mn e n d ebdy th e su p p l i e r will nor mallybe sufficient.
F o r u n t r e a t e de n g i n e s, a h i g h e r co ncentr ation- dependingon the condition of
t h e c o o l i n g s yste m- w i l l n o rma l l ybe necessar y.
while stir F ill t h e d r u mha 'l f u p w i th w a te r a nd slowly add the acid compound,
rin g v i g o r o u sl y. T h e nfi l l th e d ru mup completelywith hot water while cont i n u i n g t o s t ' i r ( e . g . u s i n g a s t e a mh o s e ) .
Drain somewater from the systemand add the acid solution via the expansion
tank.
The cooling water systemmust not be put under pressure.
Keepthe temperatureof the water between70o C and 75o C and circulate it
constantly. The duration of the treatment wil'l dependon the degreeof fou'lby the supplier will be suffiin g . N o r m a l l y,th e sh o rte st ti me re comm ended
tr ial tr ip. For untr eatedenbefor
e
the
a
re
tre
a
te
d
c ie n t f o r e n g in e sw h i ch
with
gin e s , d l o n g e r ti me mu st b e re cko nedwith. Checkever y hour , for examp' le
desA
num
ber
of
been
up.
has
used
not
p H- p a p e r ,t h a t th e a ci d i n th e so 'l ut' ion
acid
the
of
the
state
indicator
s
which
show
c ali n g p r e p a r a ti o n sco n ta i n co l o u r
be
can
added,
s o lu t i o n . I f t he a ci d co n te n t i s e xhausted,a newacid so' lution
concentr ationshould be used.
in w h i c h c a s e , th e w e a ke stre co mm ended
T h e s o l u b i l i t y o f a ci d s i n w a te r i s often lim ited. Ther efor eif, in exc' ept ion a l c a s e s , d l a rg e a mo u n its re quir ed, descalingcan be car r ied out in two
and clean water . Nor m allythe sups t a g e sw i t h a n e wso l u ti o n o f a ci d c ompound
p l i e r w i l l s p e c i f y t h e m a x i m usmo l u b i l i t y .

FH.EEY

GENERA'I{G STS

L23/30
COOLING
I.IATERSYSTEI'I

317.07

TREATI'IENT
OF COOLING
I.IATER

Edition 09H

Af t e r c o mp 'l e n
tig th e d e sca il n g, dr ai n the systemand flush with water . c i d
r e s i d u e sc a n b e n e u t r a l i z e dw l t h c l e a n tap water contain' ing10 kg sodaA
per ton
o f w a t e r . C i rcu l a te th e mi xtu re for 30 m i n u t e s ,t h e n d r a i n a n d f l u s h
t
h
e sys tem.
The coolin

water systemmust not be put nder pr essur e.

C o n t i n u eto fl u sh u n ti l th e w ater u s e d i s n e u t r a ' l( p H a p p r o x .l ) .

A d d i n go f In h i b i to rs.
F i l l u p t h e co o l i n g w a te r.systemwith water fr om the evapor atorto
the low es t
w a t e r l e ve l i n .th e e xp a n si o ntank.
l ' l e i g h t - ou tth e q u a n ti ty o f i n hibitor s specified by the supplier
and dissol v e
i n a c l e an i ro n d ru mw i th h o t water fr om the evapor ator .
A d d t h e so l u ti o n vi a th e e xp a nsiontank to the system .Thenfill
water level with water from the evaporator.

up to nor m al

A l l o w t h e e n g i n e to ru n fo r n ot less than 24 hour s to ensur e

that a stabl e
p r o t e c t i o n o f th e co o l i n g su rfaces is for m ed.
f r l p s e q u e n tl y,te st th e co o l i n g water with a test kit ( available fr om the i nh i b i t o r . s u p p l i e r ) t o e n s u r et a t a n a d e q u a t ei n h i b i t o r c o n c e n t r a t i o n
hasbeen
o b t ai n e d .
T h i s s h o u l d b e ch e cke v i y w e ek.
The acid content of the systemoil is to be checkeddirecgy
after the desc a l i n g w i th a ci d , a n d a g a i n 2 4 hour s after var ds.

E#=.EEY

GENERAII\IG SETS

]Y|AT{

E&Ut

L23/30
WATER
COOLING
SYSTEM

3 t7 . 0 8

CT
OR
NI T R I T E - B O R A
E R OS ION
IN H IB IT ORS

Edition 09H

Deli very
Form

M a k e r ' sm i n i m u m
Reconrnended
Dosage,kglton
Cooling water

Fi rm

Nameof
Inhibi tor

Atl a s Pr o d u c ts&
Se r v i c e sL t d .
Erith, Kent, England

AtlasC 11
Atlas C 12
Atlas C 14

Liquid
L i q u id
Powder

12
?3
2.5

DIAProsim
V itr y - s u r - Se i n e , F ra n ce

R D1 1 m

Powder

?.4

DR E W
C h e m i caC
l o rp .
N e wY o r k , U . S . A .

Ameroid
DEWT-NC

Powder

3.5

GamlenChemicalCompanyn
U x b r i d g e ,E n g l a n d

GamcorNB

Powder

Houseman
Hegro
B u r n h a mS1
, o u g h , E n g 'l a n d

C o o l tr eat ,|01

Powder

2.5

Ma g n e M
s a r i t ec
I n t e r n a t i o n a lI n c .
Edgewater,NewJersey
U .S .A .

Boroni te

Powder

?.3

Nalfloc Limited
N o r t w i c h ,C h e s h i r e ,
E n gal n d

Nalfleet 9-121

Powder

2.5

T h e P e r o l i n C o mp a n y,
In c.
l. lil t o n , C o n n e cti cu t,
U .S .A .

Formet 326

Powder

2.4

Rochem
Ships Eq. A/S
Oslo, Nonray

Rocor NB

Powder

" v Ec 0 M B
" .V.
M a a s s l u i sH
, olland

VecomD99

Powder

T h e l i s t i s t o b e u s e da s a g u i d e a n d m u s t
not be consideredcomplete.l,le undertake
no responsibilityfor difficulties that
might be causedby these or other water
t re a t m e n t s .

2.5

Suitable cleaner scan

nor m ally be supplied
by these fir m s.

T h e f i r m s a r e li ste d i n a l p h a b e ti cal or der .

ETg.EEV

CENERAI\CSFS

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EngineData

E
ff
o.

of Engine
Operation
andCondition
EnginePerformance
Tracing
Trouble
EngineFrameand Bedplate
and MainBearings
Crankshaft
CylinderHeadand CylinderLiner

Rod
PistonandConnecting
Operating
Gearfor InletValveg
ExhaustValvesand FuellnjectionPumps
lJ

?e
frfr

Turbocharger
System
FuelInjectionPump

Zj-

E=
R;

FuelInjection

:z
=<

Camshaftand CamshaftDrive

ControlandSafetySystems
a,g, Automatics
andInstruments

F
F

d lJg
o

StartingSystem
Lubricating
Oil System
Oil
of Lubricating
Specification
andTreatment
FuelOil System
Fueland FuelTreatment
CoolingWaterSystem
Treatment
of CoolingWater
DrivenMachinery

SpecificPlantlnformation

L?3/30
DRIVENMACHINERY
DESCR
P IT I O N

318.0r
Edition05

T h e e ng i n eca n b e tu rn e d b y meansof star ting air . 0pen the indicator v al v es

o 1 t h g cyl i n d e rs, d e p re ssthe star ting butto of the' piston valve, and c aut i o u s l y o p e nth e sh u t-o ff valve on th star ting air r bceiver , so that the
e n g i n et u r n s s l o w l y .
T h e e ng i n eca n a l so b e tu rn ed with a bar r ing r od used a lever in the hl es
i n t h e fl yw h e e l .

EE.EEY

GI\RTNCSETS

EngineData

z
o

of Engine
Operation

E
fr
andCondition
EnginePerformance
oo

Tracing
Trouble
EngineFrameand Bedplate
and MainBearings
Crankshaft
CylinderHeadand CylinderLiner

Rod
PistonandConnecting
OperatingGearfor InletValves,
ExhaustValvesand FuelInjectionPumps
tJ

Turbocharger
System

?e

Gfr
zts

FuelInjectionPump

=z
=<

Camshaftand CamshaftDrive

E=
R;
a,g

FuelInjection

GontrolandSafetySystems
Automatics
andInstruments

F
F r

6 lg
c

StartingSystem
Lubricating
Oil System
Oil
of Lubricating
Specification
andTreatment
FuelOil System
Fueland FuelTreatment
CoolingWaterSystem
Treatment
of CoolingWater
DrivenMachinery
Tools

SpecificPlantInformation

]v|Ah|
E&U'

L23/30

3 19 . 5 1

TOOLS

TIGHTENI
NG-UPINSTRUCTIONS

Edit'ion 06

H Y D R A U LTIC
IGH T E N IN G
P l a t e3 1 9 5 1
Nuts on studs providedwith threaded ends for a hydraulic tens'ioningtool may
be'loosenea
d n d t i g h t e n e do n ' l yw i t h t h e s p e c i a l t o o l s s u p p ' l i e d .P l a t e 3 1 9 5 1
i l l u s t r ate th e d e s'i .g an n d u se of a hydr auli.ctool.
The hydraulic tools consist of a jack with internal thredd to suit the draw
t h r e a d o n th e stu d o r b o l t, and a spacer r ing ( base) which is to be pla c ed
under the jack and aroundthe nut that is to be loosenedor tightened. The
j a c k i s co n n e cte dto a h i g h -pr essr epum p,which is set to deliver :hydr aul .i c
o i l a t th e p re ssu rei n d i ca te d on the jack and in the data sheets for the engine plant. The stud or bolt concernedis thereby lengthenedto the oil press u r e a p p l i e d a n d th e p i sto n ar ea, and the nut can be loosenedor tightened,
respect'ively, with the aid of a tomrnybar.
The jacks must never be overloadedor exposedto blo!{s or impacts. They are
m a r k e dw i th a " Ma x.l i ft" , w hich must not be exceeded.
I n t h e hyd ra u l i c to o l s w h i ch ar e so designedthat the pr essuneis r eliev ed at
the bottomof the pnessurechamberin the event that the "Max. lift" limit is
exceeded,the oil will be pressedout into the space betweenthe stud and the
s p a c e rr i n g .
W h e nt h e p re ssu rei s re l i e ve d in this br ay,the lower mostsealing r ing w i l l i n
most cases be damaged.
Therefore inspect and, if necessary,replace this sealing ring.
T h e . o i l w h i c h i s u s e dm u s t b e p u r e h y d r a u l i c o i l o r t u r b i n e o i l . 0 i l s s u c ha s ,
f o r i n sta n ce , l u b ri ca ti n g o i l ( systemoil) or cy]inder lubr icating oil m us t
N O Tb e use da s th e se o i l s-a re nor m ally alkaline which can damage
the suppor ting rings.
NOTE:I^IHEN
USINGHYDRAULIC
T00LSEYEPROTECT0RS
SH0ULD
BE USED.
a.

D i smo u n ti n o
g f n u ts.

1.

Carefully clean the draw thread, the nut and the surroundingparts.
G r e a seth e d ra w th re a d with copaslip, m olycoteor with a gr aphite a nd oi l
m i xtu re .

2.

Position the base around the nut in such a position that the tonmybar can
be used through the slot of the base for unscrewingthe nut, and so that
the milling for the feeler blade is turned towards the contact face for
the nut.

F3GE..EBY

GENERAU\C SETS

]UIAN
L23/30
TOOLS
I NPS T R U C T I O N S
TIGHTENING.U

Et&ut
3 19 . 5 2
Edition 06

3.

Sc r e wt h e ja ck o n to th e d ra w thr ead and adjust so, that the clear ances( S )

b e t w e e nt h e p i sto n a n d th e c.vl i nder , to pr ovide for contr action of the
b o l t / s t u d , i s a p p ro xi ma te 'loyn e- thir d of the "M ax. Iift" stam pedon the
too'l .
C h e c kt h a t th e cyl i n d e r i s ti g h t against the base and that the base is guid e d i n t h e re ce ss o f th e cyl i n d er .

4.

C o n n e ch
t i g h -p re ssu rep u mpto the quick coup' lingon the iack, loosenthe
v e n t i n g s c r e u ,,a n d fi l l u p w i th oil until it flows out of the venting scr e w
w i t h o u t a i r b u b b l e s,w h e re a fte rthe venting scr evrshould be closed.

5 . Nowraise the oil pressure to the pressure stated on the iack. If the nut
c a n n o tb e lo o se n e dw i th th e p re ssur e, incr easethe pr essr eslowly while
continuing to seeiwhetherthe nut has loosenedby meansof the tommybar,
however,the pressuremust not exceedthe stated pressure by morethan 10%.
I f t h e n u t i s sti l l n o t'l o o se , test with a 0.05 r r nfeeler blade whetherthe
n u t i s c l e ar o f th e su p p o rt. If the nut is clear but cannot be loosened'
reduce the pressureuntil the blade can just be inserted under the nut'
whereafter try to loosen the nut by knocking the tonrnybar. If the nut is
that the nut has beentighten o t c l e a r of th e ,su p p o rt, i t must be pr esumed
ned with a wrongpumppressure, so the pumppressuremust again be increased until the nut can be loosened.
of the
Examinethe bolt and nut for deformities and check the manometers
pump.
6.

By meansof the tonrnybar, screw the nut upwardsand check that it does not
g o a g a i n s t th e cyl i n d e r o f th e iack.

7 . Relieve the oil pressure from the system.

8.

Remove
the connectionto the pumpand dismountthe hydraulic iack.

b . T i g h t e n i n go f n u ts
1 . C a r e f u l l y cl e a n th e d ra w th re a d, the nut and the sur r oundingpar ts.
Greasethe draw thread with copaslip, molycoteor with a graphite and oil
mixture.
2.

Screwthe nut on the thread and tighten lightly with the tonmybar, check
with 0.05 nnfeeler blade that it lies true around the whole circumference.

3.

Place the base aroundthe nut in such a position that the tonunybar can be
used through the slot of the spacer ring whentightening the nut and so
that the milling for the feeler blade is turned towards the contact face
for the nut.

4.

Press the piston and the cylinder firmly together. Screwthe hydraulic jack
on to the draw thread. l,lakesure that the cylinder of the jack bears firmlr
against the spacer ring and that the parts are guided correctly together.

I#..ffiY
GEilERATU\EsETS

L23/30
TOOLS
T I G H T E N I N G - IUNPS T R U C T I O N S

tvlAfr|
E &Ut
3 t9 . 5 3
Edition 06

5.

T h e h i g h -p re ssu rep u mpi s to be connectedto the quick coupling on t he

j a c k , t h e v e n t i n g s c r e wl o o s e n e da n d t h e p u m pf i l l e d w i t h o i l u n t i l i t
f l o w s o u t, w i th o u t a j r b ubblesfr om the venting scr ew, wher eafterthe v ent i n g s c r e wi s t o b e c l o s e d .

6.

N o wra i se th e Oi 'l p re ssur ein the jack to the stated pr essur e,w' ith m ax i m u md e v i a t i o n + 2 %
0

7.

T i g h te n th e n u t l i g h tl y with the tonm ybar thr ughthe slot in the b as e

a n d ch e ckth a t i t'l i e s true against the contact face by m eansof the 0.05
r r n fe e l e r b l a d e .

8.

The oil pressure in the systemcan now be relieved, the connectionto the
pumpremovedand the jack dismounted.

9 . After tightening newstuds or bolts for the first time, do not removethe
j a c k b u t l o o se n th e n u t as stated under "dismountingof nuts" item s 5 to 7.
T h e nti g h te n th e n u t a g ain as stated in item s 6 to 8. This is donet o r educe the effects from perrnanent
deformations, if any, on the contact faces
a n d i n th e stu d s (b o l ts) fr om the fir st tightening.
c.

Maintenance

1 . T h e h yd ra u l i c to o l s re q uir e no m aintenanceexcept exchange

of sealing r i ngs
on rare occasions. Eachring groove is provided with an o-ring and a supporting ring. l,lhenexchangingrings, it is important to fit them so that
the supporting rings are furthest awayfrom the pressurechamberas shown.
B e fo rea sse mb l i n gp i sto n and cylinder again, checkthat the sliding fac es
are clean and without scores. The presenceof metal particles would ruin
t h e se a l i n g ri n g s. |.|h e nassem blingpiston and cylinder , use the tool
3 1 9 5/0
1 1 4 0 . T h e ,:o i lw h i c h is used m ust be pur e hydr alic oil or tur b i ne
o i l . 0 i I s u c ha s , f o r i n s t a n c e , l u b r i c a t i n g o i l ( s y s t e mo i l ) o r c y l i n d e r
l u b ri ca ti n g o i l mu st N OTbe used as these oils.ar e nonnally alkaline w hi c h
c a n d a ma g e
th e su p p o rti ngr ings.
d.

T i g h te n i n gw i th to rq u e spanner

1 . Before the nuts are scnewedon, the threads and the contact faces should
b e g re a se dw i th a mi xtu re of gr aphite and oil in the pr opor tion l:1 or
with "Molykote"grease, the tightening torques being basedon a coeffic i e n t o f fri cti o n i n th e thr eads.
? . T h e n u ts sh o u l d fi t e a si ly on the thr ead, and it should be checkedt hat
they bear on the entire contact face.
3.

In the case of newnuts and studs, tighten and loosen the nuts 2 or 3 timesso that the thread mayassumeits difinite shape, thus obvaiting the
risk loosenuts.

TE."EBV
GENERATU{CSETS

L23130

TYIAh|

Er&ut

TOOLS
TIGHTENING.UP
INSTRUCTIONS

4.

3 19 . 5 4
Edition 06

N u t s s e c ure dw i th a sp l i t p i n ar e tightened to the stated tor que and then

to the next split-pin hole.

5 . T h e f o l l o w i n g i n stru cti o n s a p ply to the use and maintenance

of tor que
spanners:
e.

R a h s o lt o rq u e sp a n n e r

1 . T h e h a n d leo f th e to rq u e sp a n neris pr ovidedwith a scale indicating the

torque at which the spannercan be set.
2.

F o r s e t t i ng th e sp a n n e ra t th e tor que r equir ed, ther e is a ball on a sm al l

arm at the end of the hand'le.

3 . W h e np u l l in g th e b a l l w i th th e ar m outwar ds,a sm all cr ank handleis for

med.
A s p r i n g - l o a d e dsl i d e i n th e h andle is pr ovidedwith a mar kwhich, when
l y r n i n g t he cra n k h a n d l e , ca n be set at the r equir ed tor que on the scale.
T h e t o r q u e sp a n n e rfu n cti o n s a s fol' lows:
4.

The above-mentioned
spring acts an a pawl systemin the handle, and when
using the spanner, this pawl systemwil'l be released whenthe pre-set torque has been reached,at which momenta small jerk is felt in the spanner
a n da s m a l l c l i c k i s h e a r d .

5 . The-torquespannermust not be used for torque higher than those stamped

on it, and it must not be damaged
by hanrneringon it or the like.

TG.EEV

GEI\ERAil\ICSTS

/=TeG\

Lz3/30

3 1 95. 5

TOOLS

E d i t i o n0 1 H
P a g e1 ( 5 )

OF TOOLS
APPLICATION
ANDDESIGNATION

T h e c o nte n ts o f th i s l i st o f tools ar e a summ arof

y STANDARD
T00LSfor nor m al
m a i n t e n a n ceE, X T RTA0 0 L Sfo r r econdit' ioning,T00LSfor LOt.l
DISMANTL IN
G
H EIGH
,
and HAND
T 0 0 L Sw h i ch ca n b e supplied fr om M ANB&t{Diesel A/S, Holeby.Thus ,
t h e l i s t co mp ri se sth e -T o ta l extent of tools available for this enginety pe.
F o r e a c h s p e c i f i c p 1 a n t , t h e a m o u not f t o o l s d e l i v e r e d d e p e n d si n t h i s r e s p e c t
o n c o n t r a c t u a 'sl p e c i fi c a t j o n s .
T h e t o o l s l i ste d a re a sse mbled
in sections cor r espondingto the split- up of
t h e i n stru cti o n b o o ka n d to the section to which the tools apply.
H o w e ve r,so meto o l s, su ch a s handtools, tor que spanner s,hydr aulic too l s etc .,
m a ya l s o b e u se d i n o th e r a pplications. Infor mationabout exact use of the
t o o l s ap p e a rsfro m th e re l e v ant sections in the instr uction book.
N o t o n ly a re sp e ci a l to o l s which might be par t of the M ANB&l.lDiesel A/ S,
H o ' l e b y,su p p l y me n t'i o n eodr i I lustr ated in descr iptions of over haulpr o c edur es ,
b u t a l s o c o m m ohna n dt o o l s a n d m a c h i n i n gt o o l s w h i c ha r e u s u a l l y a v a i l a b l e o n
b o a n ds h i p s .
I n t h e fo l l o w i n g , th e to o l s ar e mar kedaccor dingto .the gr oup to which they be1o n g .
STANDARD
T00LSare marked : S
EXTRA
T00LSare marked

: E

T00LSFORLOl,lDISMANTLING
and HAND
T00LSapply to separate paragraphs(gtg.56
a n d3 1 9 . 5 7 )i n t h e ' l i s t .

Eltt

trEtg

CE$ERA'il\G

56T5

}IAhl
E&U'

L?3/30
TOOLS

3 19 . 5 5
E d i t i o n0 1 H
P a g e2 ( 5 )

ANDDESIGNATION
OF TOOLS
APPLICATION

Standard Tools
P la t e
No.

Ite m
No.

30551

3231

stu d s, co mp l e te

30ss1

I184

Lever

30551

1906

D i s m a n t l i n gt o o l f o r b e a r i n gs h e l l s

30s51

1s40

S u p p o rti n gto o l

30551

2163

l,lire for bearing cap

30551

0164

T u rn i n gro d

30551

3419

Distributing piece

30551

2985

Extra Tools

No.
off

Engine Frame and Bedplate

Crankshaft and Main Bearings
Section 3O5
S

Autolog

Hydraul'ictool for main bearing

Cylinder Head and Cylinder Liner

Section 306
S

Distributing piece

30651

0ts4

Hose

30651

0243

Hose

3065.|

0 5 t0

H yd ra ui lc j a ck, compl
ete

306s1

0798

Oi l p u mp

30651

0421

Support

3065.|

0609

L i fti n g b ra cke t for cy1inder head

30651

1955

i n g to o l fo r valves, complete
D i sma n tl

30652

0123

Wrenchfor ring n u t, fuel valve liner

30652

0490

Grinding mandrelfo r fuel valve liner

30652

0589

t L.I
E II'=E.E

Fllrl|'
E

CEIERAT\E SI1S

}IAN

ct&ut

L23130

3t9.55

TOOLS

E d i t ' i o n0 l H
P a g e3 ( 5 )

OF TOOLS
APPLICATION
ANDDTSIGNATION

S t a n d a r d T o o ls
txtra Tools

No.
off

P la t e
No.

Item
No.

G r i n d i n gm a c h i n ef o r v a l v e s e a t s

30652

0767

r
L

D i sma n tl i n gto o l for valve seat r ings

30652

0 945

D is c

30652

t0t9

Mo u n ti n gto o l fo r valve seat r ings

306s2

1657

H a n del

30653

0281

G r i n d i n gd i s c

30653

0 370

Grindstone

30653

0647

H o n i n gb ru sh

30553

0 736

l'faste tray, comp'lete

30653

0825

G r i n d i n gt o o l

30653

1 71 5

Lifting tool for cylinder liner, complete

30653

1804

Worktable for cyl inden head

30662

0 8 15

3075,|

038,l

P i sto n a n d C o n n e cti n g Rod

Section 3OZ
S
In te rn a l l i mi t g a u ge,complete
S

G u i d er i n g f o r p i s t o n

30751

0470

R e ta i n i n gto o l fo r cylinder liner

3075,l

0 569

P i sto n ri n g o p e n e r

30751

0658

Seegersforceps

30751

0660

G u i d ep i n

3075.|

1093

E xtra cto r to o l , co mplete

3076I

0251

Eye screw

30761

| 230

tt+=
rtttttt
E F-LETEE

GCNERAru\ESETS

]v|AN

L23/30

Er&urt

TOOLS

3t9.55
E d i t i o n0 1 H
P a g e4 ( 5 )

ON
F TOOLS
A P P L I C A T I OANN DD E S I G N A T I O

S
E

S t a n d a r d T o o ls
Extra Tools

No.
off

S h a c kel

P la t e
No.

Item
No.

30761

l 507

Operating Gear for Inlet Valves,

Exhaust Valves and Fuel Injection Pumps
Section 3O8

Wre n chfo r th ru st piece in fuel

p u mpro l 'l e r g u i d e

3085'l

0152

G r i n d i n gm a c h i n e

3085r

0241

F e e l e rg a u g ef o r i n l e t v a l v e

30851

0330

F e e l e r g a u g efo r e xhaustvalve

30851

0429

30951

0834

31051

0290

Turbocharger System
Section 3O9
E

C l e a n i n gv e s s e l , c o m p l e t e

Fuel Injection Pumps

Section 3 1O
S

S p e c i a l s p a n n e rf o r f a s t e n i n g f o r
fuel pump

Fuel Injection
Section 31 1
S

Extractor for fuel valve

3f15t

0148

Grinding ring for valve seat

311s.l

0237

Test pump, complete

311s2

0117

C l e a n i n gn e e d l e s i n p a c k i n g t u b e , c o m p l .

31152

0751

r.l+r

tftt

E t!===-Et
E
CENERAT\|CSETS

TOOLS

3 1 9 5. 5
Edition 0fH
P a g e5 ( 5 )

APPLICATION
ANDDESIGNATION
OF TOOLS

Standard Tools
Extra Tools

No.
off

P la t e
No.

Item
No.

Camshaft and Camshaft Drive

Section 312
S

Pin gauge

31251

0197

Pjn gauge

31?51

0286

31351

0146

3' t503

2060

Gontrol and Safety Systems

Automatics and lnstruments
Section 313'
S
S p a n n e rf o r a d j u s t i n g t h e
o v e r s p e e dt r i p
Lubricating Oil System
Specification and Treatment of Lub. Oil
Section 3 15
S

Roller mandrel

Tools
S e c t i o n3 1 9
S
Ma xp re ssu rei n d i ca tor

3 19 s 6

02

Torquespanner

31955

0304

Torquespanner

3 t9 5 5

02ts

C o mp re ssi oto
n ol

31951

0t40

02.89

rJtE

trElt

GENERATI\CSETs

HAh|
EAU'

L23/30
TOOLS

319.56

SPECIALTOOLSFORLOI,IDISMANTLING
HEIGH

E d i t i o n0 1 H
P a s e1 ( 1 )

Cylinder Head and Cylinder Liner

Section 3O6
For lift

of cylinder liner:

L ' i fti n g to o l , co mp l e te

Piston and ConnectingRod

Section3O7
F o r l i ft o f p i sto n a n d connectingr od:
C o 'l l a r fo r co n n e cti n gro d, complete
S h a c k l ef o r p u l l l i f t
Pull lift,

complete

t tt

at Hrlr

cenERift{G sEnS

Lz3/30

3 1 9 5. 7

TOOLS

E d i t i o n0 l H
P a g e1 ( 2 )

HANDTOOLS

Tools
S e cti o n3 1 9

N o . Plate
No.
off

Set of openend s p a n n e r ,c o m p r r s r n g :

319s3

Spanner
Sp a n n e r
Sp a n n e r
Sp a n n e r
Sp a n n e r
Sp a n n e r
Sp a n n e r
Spanner
Spanner
Sp a n n e r
Sp a n n e r
Sp a n n e r
Sp a n n e r
Spanner
Spanner

31953
31953
3r953
31953
31953
31953
31953
31953
31953
31953
31953
31953
31953
31953
31953

2310
2312
2313
2314
2317
2319
232?
2324
2327
2330
?332
2336
2341
?346
2350

31954

0100

1 0 mm
12 mm
13 mm
1 4 mm
17mm
1 9 mm
22 mm
24 nn
27 nn
30 mm
32 mm
36 mm
41 mm
46 mm
50 mm

S e t o f so cke t sp a n n e rs,small set,

c o mp risi n g :
Ratchet
Slide T-handle
U n i v e r s a lj o i n t
Extension
Extension
Socket
Socket
Socket
Socket
Socket
Socket for
Socket for
Socket for
Socket for
Socket for
Socket for

.|2,5 mm
1 2 , 5m m
1 2 , 5m m
12,5125
12,5250
10 mm
13 mm
17 rrun
19 mm
22 run

interna'l hexagon 5 m m
internal hexagon 6 m m
internal hexagon 7 rrn
internal hexagon 8 nun
internal hexagon I 0 m m
internal hexagon I 2 rrun

Se t o f so cke t sp a n n e r,l ar ge set,

comprising:
Ratchet
Sl id e T -h a n d l e

20 rrn
20 run

0 15 0

C ont.

E#.EEY

GEYCRA'ilVCSETS

TYIAIIT

E&U'

L23/30

319.57

TOOLS

E d i t i o n0 l H
P a g e2 ( 2 )

HANDTOOLS

N o . P la t e
No.
off
U n i v e r s a lj o i n t
Extension
Extension
Socket
Socket
Socket
Socket
Socket
Socket

Item
No.

20 mm
20.0200
20.0400
24 mm
27 nm
30 mm
32 mm
36 mm
41 mm

Socket for internal hexagon

Socketfor internal hexagon
Socketfor internal hexagon

14 mm
17 rnn
19 rrn

Set of socket wrenchesfor internal hexagon,

comprising:

3 19 5 4

01 6 0

31954

0t 6 l

Pl i e r fo r l o c k r i n g , a n gle

31955

01t0

Pl i e r fo r l o c k r i n g , stra i ght

31955

01t9

Socketwrench
Socket wrench
Socket wrench
Socketwrench
Socketwrench

7mm
12 mm
1 4 mm
1 7 mm
1 9 mm

Set of socket wrenchesfor internal hexagon,

comprising:
Socket wrench
Socket wrench
Socketwrench
Socketwrench
Socket wrench
Socket wrench
Socket wrench
Socketwrench
Socketwrench

1 1 5 mm

2 mn
mm
3 fnm
4 I[n
5 mm
6 mm
8 nm
1 0 mm

215

P li e r fo r l o c k r i n g , stra i ght

3195s

0120

Pl i e r fo r l o c k r i n g , a n gle

31955

0219

P l i er fo r l o c k r i n g , a n gle

31955

0319

tGr

Fiilct

GNCRAflrcSETS

1I|Ah|

ct&ult
Max.PressureIndicator
General
Safetyprecautons:
D
n
fI
I
I
[J

Specialtools:

Stoppedengine
Snut-olstartingair
Shut-offcoolingwater
fueloil
Snut-ott
Shut-otfcoolingoil
Stoppedlub.oilcircul.

Plateno.

ltemno.

Note.

Description:
Operation.
Overhaulintervals.
Dismantling,
overhaul
andassembly.

Handtools:
Allenkey,3 and6 mm.

Startingposition:

Relatedprocedure:

Manpower:
Workingtime :
Capacity
:

I
xxx Hours
xxx man

andwearingparts:
Replacement
Phte no.

ltem no.

Qty.pr. cyl.

Seeplate31956-01H
Data:
Datafor pressureand tolerance
Datafortorquemoment
Declarationof weight

90.36-ESOS

r1o.EBY

GEI\ERANEsETs

/-At
Max.PressureIndicator
General
Operating:
1) Open the indicatorvalve and blow throuoh
shortly.
2') Connectthe max. pressureindicatorto the
indcator
vafve,andopenthe valve.
3) After 3-5 secondssecondsread the max.
pressureon thegauge.
The measuringperiod shoufdnot exceed30 se_
conds.
4l Closethe indicatorvalveandopenthe valve
screw(5),fig.1.
5) Disconnect
the max.pressureindicatorand
closethe valvescrew.

1 Housng
3 Seafing
5 Valve screw

6) Carryon measuring
the remaining
cylinders.

2
4

Allen scerv
Screw

OverhaulInlervals:

Fig. t.

1) After 200 measuringperiodsdisrnountand

clean the non-returnvalve. lf the pressuredrop
within60secondsis higherthanSbar(testpressure
100 bar) we recommendto relapthe non-return
valve.

4) Alter separatingof the upperand lowerpart

takeoff the non-return
valveassembly.

2l After 1.000 measuringperiodsor after .t2

monthusecheckthe pressuregauge.
Attention: For testingthe pressuredrop and the
pressure
gaugeuseonlyexhaustgasor nitrogengas
andneveroil.Incaseofusingoilcarbonwilleposit
insidethe measuring
instrument.
Dismantlingand Assembly.
1) Dismountthevalvescrew(5),fig. 1
2l Turn the screw (4) into the instrumentto
enabledisnnuntingof the housing(1).
3) Loosenthescrew(2)(4 pieces)for separating
upperand lowerpart.

IIS.EBY

CEIGRANFSES

5) Lap the valveand thevalveseat.

6) Renewthe sealngrrq (3) ard screw(2), if
necessary.
7) When mountingthe upper and lower part
pleasetakecarelo useoriginalscrewsonly.
8) Coalthe screw(2)wthmolykoteandt(htento
1 0N m .
9) After assemblythe inslrumentcan be used
withoutany newcalibration.
Checkof the pressuregauge:
1O) Testingof the instrument
shouHonlybe made
by experts,so we reommerdto serdthe instrumentto MAN B&W Diesd A/S, Hotebyfor catibration.

90.34- ESOS
; : : ,; . ' , . , . '
' r t 1_ '

: '

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6
o
r

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0

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: $ $ g';$
ta

:l
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Ho

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:l
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=.1 e b u !i!;EI
q l

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ts

C F

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oo

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;,-----------r-

' J

INGINE TYPE:
7L23/30

LIST OF EXTERNAL to'Boro* i-15.

CONNEC
T I ONS
DIAM.
NOM.

D I S C RI P I i O N

STANDARD :LANGES/F
I TTIIf REMARKS

FUELOIL SYSTEM.
A I FUEL OIL
A

FUEL OIL

A 3 I{ASTEOII-

INLET
20
O U T L E T 20
OUTLET r 5

,lD t 6 D I N 2 5 0 1 ]TEEL FLANGE

'lD t 6 D I N 250r JTEELFLANGE
,D t 6 D I N 2 5 0 f JTEELFLANGE

N O Z Z L EC O O L I N GO I L S Y S T E M
N O Z Z L EC O O L I N GO I L
A 8 N O Z Z L EC O O L I N GO I L

r5
INLET
OUTLET 1 5

N D 1 6 D I N 2 5 0 lsrEEr- FLANGE
!D 1 6 D I N 250 ,| JTEEL FLANGE

OIL SYSTEM
LUBRICATING
vI

c3

L+

%
VT
%

INLET
OIL
LUBRICATING
OUTLET
L U B R I C A T I I . JO
GI L
25
OIL FROM
SEPARATOR INLET
LUBRICATING
OIL TO SEPARATOR OUTLET 25
LUBRiCAING
PUIP
INLET
OIL FRO.{
SEPARAIE
LI-ERICAIIT,6
PIJMP OUTLET
OIL TCSEPARATI
LUBRICAIIN6
OIL FRS{FII.L FLOIFILTER
LTBRICATI$

INLET

OIL IO FII.I FLOFILTTR

LI.BRICAIIG
FROt.{
FTJLL
FLOXFILTER
BACK-FLUSS

OULET

>r

FILITR
OILFRO4
8Y-PASS
LTBRICATII'IG
FILITR
OIL TOBY-PASS
LI,tsRICATING

DISCHARGE
OIL VAPOUR
L U B R I C A T I N GO I L D R A I N
L U B R I C A T I N GO I L O V E R F L O W

INLET
OUTLET
OUTLET 50
OUTLET
CUTLET
25
INLET

INLET

\D 6
!D 6
\D 6
!D 6
!D 6
\D 6
!D 6
!D 6
!D 6

DIN
DIN
DIN
DIN
DIN
DIN
DIN
DIN
DIN

250
250
250
250
250
250
250
250
250

STEHL FLANGE

;TEEL FLANGE
;TEEL FLANGE
]TEEL FLANGE
JTEELFLANGE
JTEELFLANGE
;TEEL FLANGE
;TEEL FLANGE
;TEEL FLANGE

.r(

>n
>(,
>r
I
I

LUBRICATING OIL SUPPLY

\D 16 DIN
\U t 6 D I N
\Dt6 DIN
\D16 DIN

2 5 0 1 JTEELFLANGE
2 5 0 1 JTEELFLANGE
2 5 0 1 ]TEEL FLANGE
2 5 0 1 ;TEEL FLANGE
{D t 6 D I N 2501JTEELFLANGE
{ D 1 6 D I N 2 5 0 1;TEEL FLANGE

SYSTEM.
C O O L I N G W A T E R- H I G H T E M P E R A T U R E

HI FRESH
IATER

v2

HI FRIg{ IATTR

IO EXPANSIOI'I
TAI(
F 3 VENTIIS

60
80
OUTLET t 5

{D 1{, DIN 250 ;TEEL FLANGE

{ D 1 6 D I N 2 5 0 JTEEL FLANGE
{ D 1 6 D I N 2 5 0 r JTEELFLANGE
\D t 6 D I N 2501JTEELFLANGE
\D r 6 D I N 2 5 0 1 ;TEEL FLANGE

INLET

OUTLET

74.

*5

FRO,I
HTFRESH
TAIER
PRTI-TATIR

INLET

HI FRESH
IATERTOPREI.ATER

OUTLET

SYSTEM .
C O O L IN GWA T E R- L OW T EMPERATURE
|AIER..STTAIEP..RAI |AITR
G I LI FRESH
RAI|AITR
IATIR-.STA
TATIR-.
G 2 LTFREg{

80
INLET
OU]i-ET 80

AD
IR SYSTEM.
COMPRESSE
K1

K2

AIR IIEI
COMPRESSED
A
CONTROL IR INLET

INLET
INLET

20
15

{D t 6 D I N 2 5 0 1 ;TEEL FLANGE
\D r 6 D I N 2 5 0 1 ]TEEL FLANGE

{D 4 0 D I N 250,| vrELPXRr{IruK
{D 1 6 D I N 2 5 0 1 ;TEEL FLANGE

C O M E U S T I OANI R S Y S T E M
wf

CHARGE A I R

INLET

ICS AIR FROM MAIN ENGINE

INLET

E X H A U S TG A S S Y S T E M .
P6 DRAIN FROMTURBOCHARGER
W A S H I N GT. U R B I N ES I D E
P ] WATER
P 2 E X H A U S TG A S

OUTLET t 5
INLET
O U T L E T 350

r$rTbdt#tlPCD
490

S T A N D A RLDi S T F O R T 2 3
ANDL23l30
D R A W I NNGO . :

1 / 2 " BSP. INSIDT

I / 2 " W A T E RH O S E

1 ? MMPIPE
FLANGE

D A T E :9 1 . O 2 . 0 5 K L K

| 445

HHht
12

HYhh
o22

LIST NO:

1620391-1

IY|Ah|

ct&ut
TIGHTENING-UP
INSTRUCTIONS

PLATE
3 t951- 03

Quickcoupting
Pulting threod
Venting screr/
Piston
Cylinder
Seoling rings
Bose
Tommy bor
Nut
Stud or bolt

I{.EBY

CNERAIT{G SETS

}IAhl

cr&ut

PLATE
3,| 951- 03

TIGHTENING.UP
INSTRUCTIONS

Designalion

Benavnelse

C o mp ression
tool

Sam m enpr esni

ngsverktoj

fG!

l|Iill

GENERAru{GSETS

IYlAhl
E&UI'
PLATE
31953- O5H

TOOLS

Comb

S i ze
1 0 mn
12 nrn
13 mm
14 m
17 mn

Standar dNo.
N 5 5 4 Kt 0
N 5 5 4 Kt 2
N 5 5 4 Kt 3
N554Kt4
N 5 5 4 Kt 7

Item No.
2310
?312
2313
2314
2317

19 mnr

N 5 5 4 Kt 9

?319

2? wn

N554K22

2322

24 rn

Nss4K24

27 rvrt

N554K27
N554K30
N554K32
N554K36

23?4
23?7
2330

30 rm
32 run
36 mm
4l mm
46 rm
50 mr

?332

N 5 5 4 K4 f

2336
?341

N554K46

??46

N 5 5 4 K5 0

2350

E#.EBY
CENERA.IU\CSETS

]v|Ah|

Er&ut
TOOLS

PLATE31953.05H

Designation

Benavnelse

2310

Spanner

Noge
l

?312

Nogle

2313

Spanner
Spanner

2314
2317
2319

Spanner
Spanner
Spanner

Nogle

2 32 2

Spanner

Nogle

2324

Spanner
Spanner

Nogle

Spanner
Spanner
Spanner

Nogle

Spanner

Nogle

Spanner
Spanner

Nogle

2 32 7
2 33 0
2332
?336
2341
2346
2350

Nog'le
Noge
l
Nogle

Nogle
Nogle
Nogle

Nogle

t c.a-, t!.rrt
CENERAI{G SETS

TYIAN

Et&ut

PLATE
31954-O3H

Standard No.
Smoll cet

Desiqnotion
Complete
Rotchet
Slide T - hondle
Universol ioint
xtension
Extension
iocket

N53Hl

N50B| 2, 5

Lorge set
N53H2
N 5 O BZ U . U

N50A20,0
N50P20,0
N50P| 2, 5
-N50or
12,5125 N50F20,0200
N50F12,5250 N50F 20, 0400
N50A | 2, 5

N50L | /

N50L 24
N50L 27
N50L 30

N50L l9
N50L 22

N50L 32
N50L 3

N50Gs

N5OG14

N5OG
N50G 7
N50G 8

N50G | 7
N50G l9

N50L I O
N50L | 3

N50L 4l
Socket for internol hexogon

N50G 12
N53G I

Box

5ocke t wrench et for internol hexogon

Size

lCornPlcte

7mm

N54gA | 4
Nf9A | 7
N549A | 9

wrench ct for internol hexogon

4 mrn

5mm
mm

8mm
l0 mm

Standard No.
N549G I
N549A 7

N549A t 2

12 mrn
14 mm
l7 mr
19 mm

Sizc
I .5 mm
2mm
2.5 mm
3mm

N53G 2

lComplerc

Standard No.N549E I
N549A 1,5
I

9A2
Nf9A

2,5

NI9A 3
N549A
N5494
N5494
N549A

4
5

Nt9A

|0

FF1TEBY

GEIERAru{CSETS

TOOLS

0 10 0
0 15 0
0160

0161

PLATE
31954.03H-

Designation

Benavnelse

S o cke tspanner ,
sma 'l lset
S o cke tspanner ,
large set
Socketwrenchset for
i n te rn al hexagon,
complete

T o p n a g l e s e lti,l l e

Socketwrenchset for
internal hexagon

Topnogleset,stor t
Unbraconsgl
esat,
kompl
et
Unbraconsgl
eset

t ..q!:
;.!rtt
F==-=-E''|'
CGNERAffSETS

lYIAN

Et&urt
TOOLS

PLATE
31955.07H

_-.f[l

f f i - l

* N515Dt9
* N5t5Et0
* N5t5Et9
* N5t5Ht
*N5t5Jt9
N5t5Ll

0215
0304
0493i

HS..EBlf

CE{ERATII|OSEIIS,_.
:.,,.,'r' i:i)l':.: !:",1

TYIAhl

Et&ult
PLATE
31955-O7H

TOOLS

Designation

Benavnelse

0 11 0
0 11 9

P li e r f o r I o c k r i n g

0 12 0

Pl'ier for

0125

P l i e r fo r p i s t o n p i n
lock ring

Tang for I ser ing

Tangfor I s e r in g
Tangfor I ser ing
pi nd
Tang
' l s efor
r i stempel
ng

0215

Torquespanner
20-120
N m , 1 5 - 9 l0b s . f t
Plier for lock ring

20- 120Nm
M omentnogle
f5-90lbs.ft.
Tangfor lser ing

Torquespanner
5 0 -3 0 0Nm
3 5 -2 2 0l bs.ft.
Plier for lock ring

Momentnogle
50- 300Nm
35- 220lbs.ft.
Tangfor lser ing

Torquespanner
1 4 0 - 7 6 0N m ,
100-500'lbs.ft.

Momentnogle
.|40- 260Nm ,
1 0 0 - 5 0 l0b s . f t .

Item No.

0219
0304

0319
0493

Pl'ier for lock ring

'lock

ri ng

E#..EBY
GE{EIAT{G SE!]S
;r:

--,
.

/*C\
Plate
Page 1 (2)

Max PressureIndicator

31956-01H
General

90.41- ESoS

EEY
t{ot
GE^ERA'NESETS

/-G\
Max.PressureIndicator
General
Designation

Benavnelse

01

Valve screw

Ventilskrue

02

Max. pressure
indicator,complete

Tryk indikator,komplet

Non relurn valve.

complete incl. seals
and housing screws

Kontraventil,complet
incl.ttnngsringog
skruer

Connecting nut
incl. wedge for
mountng

Tilslutningsomlober
incl. kiler for monterng

Pressure gauge
0-'180bar

Manomebr0-18Obar

Item No

Item nos. rnarked with * are only available as part of a spare parts kl

T{OLETY

GEI\ERAT\EsTS

90.ll- ESoS

/-G\
TOOLS
PANEL (EXTRA
TOOTS)

PLATE
31 960- 01H

T
g
,,8

1,,
I{S.EEY
GENERA'IG SETS

lUIAl

Eteut

TOOLS
PANEL(EXTRA
TOOLS}

PLATE
31960.0IH\-

Designation

Benavnelse

t.fire for lejeoverfald

05

Lifting straps for

ma i n b ear ing
T o rq u espanner
T o rq u espanner
P i n w r e n c h- h i g h p r e s stre fue'l pi pe
T - handle

06
07

P i n sp anner
R i n g i n pact spanner

Tapnogl
e
Slagnogle

09

Spannerfor starting
air pipe
Seegersforceps

Noglefor star telufrgr

T a n gf o r s i k r i n g s r i n g

Pistonring opener
T u rn i n g r od
E ye b o l t for piston

Stempel
ri ngsbner
Tornestang
Ojebolt for stempel

Levers for main

b e a ri n g caps
Extractor for fuel
val ve
Toolsfor lub. oil
co o l e r
H o l d i n gn u t
Gu i d etube
Tool panel

Vagtstang for hovedI ejeoverfal d

Trekverktsj for br.
ventiI

Item No.

01
02
03
04

10
11
12
13
14
15
16
17
t8
?0

Momentnog'le
Momentnogl
e
Noglefor hsjtr yksr or
Hndtag

Va'lsedornfor smsreol ieksler

Holder
Styreror
Varktojspanel

tl=
- ---- tE=ts -

GENERA'Iru\G SETS

TUIAN

Et&ut
TOOLS
PANEL (EXTNN
TOOLS)

PLATE
31 96I.( ) IH

Ff.ETY

GENERATTYGSETS

TUIAh|

Et&ut

PLATE
3196I- OIH-

T00LSPANEL(EXTRA
T00LS)

Item No.

01
02
03
04
05
06

Designation

Benevnelse

Wa stetray for honing

M o u n t ' i ndgr i f t valve seat rings
E xtra ctor ' valve
seat ring

Tr agt for honing

Monteringsvarktojventi I saderinge
Aftr akker - ventilsadering
Slibevar ktsj for br .
venti I sede

Gri n d i n g tool for

seat for fuel va'lve
Tool panel
Grindstone

Verktojspanel
Sl i besten

-+t lflErEs

E Er==--=5
E
GENERATINGSETS

TOOLS
PANEL (EXTRA
TOOLS)

PLATE
3 1962- 01H

10

tl

T#.ETY

GENERAilVGSETS

T00LsPANEL(EXTRA
T00LS)

Item No.

PLATE
31 962- 01H -

Designation

Benavnelse

01

l..|rench

Nog' le

02

S o cke tspanner
C h e c kp i n
R e t a i n i n gt o o l
cylinder I iner
G u i d er i n g f o r p i s t o n
P i n g a ugefor cr anksh a ft
P i n g a ugefor cam sh a ft
Lifting tool for
cyl i n d e r I iner
G r i n d i n gh a n d l ef o r
cylinder I iner
Mo u n ti ngtool for
va lve s
Gu i d efor main bear inq
Tool panel

Topnogl
e
Kontr olpi nd
M o d h o l d- c y l i n d e r fori ng
Styrering for stempel
Spermlfor krumtap

04
05
07
OB
09
10
11
1?
13
17
18
19
20

G r i n d i n gr i n g f o r
fu e l va l ve
F e e l e r gauge
F e e l e r gauge

Sparmlfor styreaksel
Lsfteverktsj for
cy1i nderfori ng
Slibeverktsj for
cy1i nderfori ng
Monteringsverktojfor
ventiI er
Styr for lejeoverfald
Varktojspanel
Slibering for brardventiI
Soger
Soger

!.aEl|

llFrlGGlt

GENERA'ff{CSETs

EngineData

E
ffi
o-

of Engine
Operation
andCondition
EnginePerformance
Tracing
Trouble
EngineFrameand Bedplate
and MainBearings
Crankshaft
CylinderHeadand GylinderLiner

Rod
PistonandConnecting
Gearfor lnletValveq
Operating
ExhaustValvesand FuelInjectionPumps
lJ

?e

Turbocharger
System

Grt
zr-

FuelInjectionPump

= <z
g

Camshaftand CamshaftDrive

E=
R;
-

4,9

FuelInjection

Gontroland SafetySystems
Automatics
andInstruments

F
a

6 llg
o

StartingSystem
Lubricating
Oil System
Oil
of Lubricating
andTreatment
Specification
FuelOil System
Fueland FuelTreatment

CoolingWaterSystem
Treatment
of CoolingWater
DrivenMachinery

SpecificPlantInformation

/-G\
Dscripon
PagpI {2)

ResilientMountingof GeneratingSets

320.01
Edilion OgH

General
ResilientMountingof Generatingsets
generating
mounted
sels,the diesel
On resilient
engineandthegenerator
areplacedon a oomron
rigidbaseframemountedon the ship's/erection
hall'sfo.ndation
bymeansofresilient
supports,
type
Conical.

conicalntountingcan
The supportof the indivirJual
be madein oneof the followingthreeways:
1. The supportbetweenthe bottomflangeand
the fqrdation of the conir:alnountingis madewith
a loosesteelshim.Thissteelshimis adiustedto an
(min.35 mm)for eachconical
exactmeasurement
mounting.

Allconnectbns
fromthegenerating
settotheenernalsystemsstrorld
withflexibleconbe equipped
necions,and pipes,gangrway
etc. must not be
weldedto theextemalpartof the installation.
ResilientSupport
A resilientmounting
of thegenerating
setis made
witha numberof conicalnrcuntings.
The number
between
themdependonthesize
andthedistance
of theplant.Theseconicalrnuntingsareboltedto
onthebaseframe(seefi9.1).
brackets
Thestandardheightoftheconicalrnorntingsis 175
-whenloadedthesetting
mminunloaded
condition
is rormally5-7mm.
Theexactsettingcanbefoundin thecabulation
of
theconicalmorntingsfortheplantin question.

Ftg.2. Suppqtof @lnials

Unloaded
Mnimtmdisfiance

2. The supportcan also be madeby meansof

atthetopalooseshimof at least35
twosteelshims,
mm and belowa shimof approx.10 mm whbh are
adjustedfor eachconicalmolnting andthenwelded
to the foundation.

mantiry of gfwatiry e
FE. l. Rgs'l&|nt

.4

TId.EEY
CE\RAESET:;

320.01
Edon OgH

ResilientMountingof GeneratingSets

tlEscrbon
Pagp2 (2)

General
Adustment of Engine and Generatoron Base
Frame
3. Finally,the supportcanbe madeby meansof
choc*fast.lt is recommended
to usetwosteelshims,
top
shim
shor.ld
loose
the
be
and havea minimum
thicknessof35 mm,thebottomshimstprldbecast
in chockfastwith a thicknessof at least10 mm.
Inespectiveof the methodof supporl,it is recommendd to use a loose steel shim to facltatea
possibleftlure replacementof the conbal mountings.

The resilientmountedgeneratingset is normaly

deliveredfromthefac{orywithengineandgenerator
mwnted on the comrrclnbaseframe.Eventhotgh
engine and generatorhave been adjustedin the
factorywith the generatorrotorconectlyplacedin
the stator,and the crankshaftbend of the engine
(autolog)withinthe prescribedtolerances,it is recommendedto makean autologbeforestaftingup
the plant.

90.28

lU|Ah|

Eteut
ConicalElement
General

0170
0269
0358
o47

NOTE! Whenordering,be awarethatconical

elementsalwaysshouldbe replacedin pairs,
No.of existingconicalelements.
statemanufacturng

90.t5

t{ol-BY

GEIERATNESETS

/*A\
ConicalElement
General
Deslgnatlon

Benovnelse

0170

Screw

Skrue

0269

Washer

Skive

0358

Conical element

Koniskunderstotning

0447

Adiustng scew

Justerskru

Item No.

I{O.EBY
GENERA'T\ESETS

90.f5

FLEXIBLEHOSE

PLATE
32O()().O1H

Connec
t i on

A3
F3

A7
A8

c4
c3-c| 6

KI

AI
A2

D e s c r ip t i o n

Item N o.

D r ai n b o x ,
o u t le t
F.t' !. venting
to expansion
tank, outlet
Nozzlecooling
oil, inlet
N o z z l ec o o li n g ,
oil, outlet
L u b r i c a t i n go i ' l
to separ ator ,
outI et
Lubr icating oi' l
from separator
andlubricatino
oil supply, inet
Starting air,
inlet

0164
0253

0342
0431
0520

06r9

0708

Fuel oi'l, inlet

Fuel oi'l, outlet

08 97
0986

0il vapour
d i s c h a r g e ,o u t l e t

90.36.

GI

Sea water, ravt water

inlet

1t43

G2

Sea water, raw water

outlet

1232

F1
F2

Fr esh water , inlet

Freshwater,outlet

132
t
1410

ffiffi

MAN

Beut
Worklngcard
Pry 1(3)

FiingInstructionsfor ResilientMountingsof GenSets

32&1
Edition O3H

General
Safetyprecautons:
E
E
fl

E
I

Specialtools:

Stopped
engine
Strutottstartingair
Shutoffcoolingwater
Shutofftuetoil
Shutottcoolingoil
lub.oilcirculation
Stopped

PlateNo.

ltemNo.

Note.

Description:
Mountingand adjustment
nstruction
for new
GenSet,andadjustment
instruction
for existing
plants.

Hand tools:

Startingposition:

Rirq and openend spanner 2 . m m

Ringand openend spanner 30 mm
Allenkey
6mm
1-2mm
Feelergauge
Measurement
tool
Hydrauliciack (f necessary)

The fxndationshqlH be weldedand milledoff

on shimsurfaces.

Relatedprocedure:
Checkof crankshaft
bend(autolog)
Changeof conicalelements

Man pourer:
Capacity
: xxx Men
Workinghours: xxx Hours

Spareand wearingparts:
PlateNo.
Data:
Datafortorquemoment
Datafor pressureandtolerance

.4

D319
D319

32001-01H
32001-01H
32001-01H
32001-01H

ItemNo.
0170
02@
0358
0447

Qty.pr. cyl.
4
4
1
4

32$1
Edon OSH

Fitting Instructionsfor Resilient Mountingsof GenSets | "r$fr,'

General
Mounting and Adiustment Instructbns for New
GeneratingSets (Method 1)
1. In casethe conicalrlountngshavenot been
mountedn the fadory, they are mountedon the
preparedbracketson the baselrame.
2. The preparedsurfaceson the fqrdationare
equippedwith proteclbn shims, 245 x 210 mm height approx.20 mm, preparedon both sides.
These shims are used to protec[ the foundatbn
during adjustmentand shorH rpt be fastenedas
they are to be removedafter adjustment.

Theadjustment
of thegeneratingsetshouldbedone
carefullyto securethaltheconicalelementsarerpt
overloaded.
6. Leveland loaddistributionis nowcheckedby
measurirqthe he(htof the irdividualconicalelements(heightin unloadedcondition175 mm).The
differerce betweenthe mountirqs sho.lld be as
smallas possibleand shq.Hnot exceedt 2 mm
(frcmthe average).
Example:
Average=

3. Lowerthe generatingset until it rests completelyon the proteclionshimson the foundation.

4. Rernovefixingbdt (7), sprirq washer(8) and
top lockring(6),checkthatintemalhffer (2)canbe
movedfreelyby tumingthe top of this.
In casethesecanrotbe rnovedfreely,the generatr
set must be liftedwith craneor hydraulicjack, and
intemalbutfer(2)mustbetumedanti+lockwise,
and
the generatingset can be relowered urtil it rests
ompletely on the foundation.This operationmust
be repeated until all intemal buffers (2) can be
movedfreely.
5. The generatingset can rx,w be adjusted by
ncans ol adjustingsaews placedin tappedhole(9)
in the bdtom flangeof the indivirlualconir:al
rpuntings.

H, + H, + Ho ----- Hu

Numberof conicalselemenl

7. The/thoseconical
nnnting(s)withthelargest
(fromtheaverage)
first.
shor6beadiusted
deviation
ll stpub besecured
thatallinternalbuffers(2)can
be movedfreely dudngthe entire adjustment
procedure.
withintheprescribed
Hangobtained
anadjustment
tolerarrces,
the heigtof the steelshimscan be
measured.
Measrringof SteelShlms
8. Steelshimsshcrldcoverthe entireboom
tlangeof theconicalrountingsard be at leaslSS
mmhigh.
with
Thecompleted
steelshimsstrorldbeequipped
freeholesbr bolts.
numbered

6
5

onseve.
9. Thesteelshinsshoubbemeasured
ral pointsto obtainthe hbheslpossibleaccuracy
duringpreparation.

4
3

lrlote!Remererto
inchde
theexistirqsteelshimin
thecabulation.

2
1

fu.lM*natt

Mountingo,fthe completed$eel Shlms

10. Whenmountrpthe ompletedsteelshims,
setshotldbe liftedwithcrane
theentiregneratng
or hydrauliciackin oder to relievethe adustment
screwsfor rernoval.

Frr+-:il

f,tr.9Y
cFFril36EnS

90.28

FittingInstructionsfor ResilientMountingsof Gensets

General
14. To make sure that the adjustmenthas been
conectlymade,makea checkof the heightof the
conicalelements.
15. ln casethe checkmeasurement
s notwithin
the prescribedtolerarces,
a newadlustmenthasto
be made(seepoint6).
Adjustment with two shims (tethod2)
16. The adjustmentof the Gensd is made as
describedin points $15. lt has to be eonsidered,
however,that the final heightbetweenthe bottom
flangeon the conbal nnunting andthe forndationis
amrox.45mm (seefig.3).
Fg. 2 Catal eleftrent with ore shim.

11. Theapprox.20mmhighprotection
shimsare
replaced
bythecompleted
steelshms
ofapprox.35
mm(seef9.2).
12. The entireGenSetis loweredurilit rests
completely
in itsetf.Foundation,
steelshmsand
bottomflangeontheconbalelemerts
arefastened
withbosandnuts.
13. To obtaincleararcefor intemalbuffer(2),
these are screwedupwards(antictockwise)to
maximum
upperpositionandthentwir:edorrnyards
(clochrise).
Checkwith a feelergaugebetweenthe bdtom
flangeontheoonical
element
andthesteelshimthat
theintemalhffer(2)doesnotto,chthesteelshim
and with it the fqlndation.

Intemalbuffer(2) is lockedby remotntingtop lock

dng(6)andtum this to neare$threadho6, and it is
seq.rredwithfixingbolt (7) ard springwasher(g).

Ftg.3 Cutid elenentwith tv'toshlms.