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Wartsila Manual

wartsila

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florent rey

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0% found this document useful (0 votes)

255 views286 pages

Wartsila Manual

wartsila

Uploaded by

florent rey

We take content rights seriously. If you suspect this is your content, claim it here.

Available Formats

Download as PDF, TXT or read online on Scribd

You are on page 1/ 286

Engine Operation and

Maintenance Manual Attachments

ATTACHMENTS

Document ID DBAE529722-

Date of issue 9.8.2017

Product type W8L20

Product number PAAE319083, PAAE319084, PAAE319090, PAAE319091

© Copyright by Wärtsilä Finland Oy
All rights reserved. No part of this booklet may be reproduced or copied in any form or by any means (electronic,
mechanical, graphic, photocopying, recording, taping or other information retrieval systems) without the prior
written permission of the copyright owner.
THIS PUBLICATION IS DESIGNED TO PROVIDE AN ACCURATE AND AUTHORITATIVE INFORMATION WITH
REGARD TO THE SUBJECT-MATTER COVERED AS WAS AVAILABLE AT THE TIME OF PRINTING. HOWEVER,
THE PUBLICATION DEALS WITH COMPLICATED TECHNICAL MATTERS SUITED ONLY FOR SPECIALISTS IN
THE AREA, AND THE DESIGN OF THE SUBJECT-PRODUCTS IS SUBJECT TO REGULAR IMPROVEMENTS,
MODIFICATIONS AND CHANGES. CONSEQUENTLY, THE PUBLISHER AND COPYRIGHT OWNER OF THIS
PUBLICATION CAN NOT ACCEPT ANY RESPONSIBILITY OR LIABILITY FOR ANY EVENTUAL ERRORS OR
OMISSIONS IN THIS BOOKLET OR FOR DISCREPANCIES ARISING FROM THE FEATURES OF ANY ACTUAL
ITEM IN THE RESPECTIVE PRODUCT BEING DIFFERENT FROM THOSE SHOWN IN THIS PUBLICATION. THE
PUBLISHER AND COPYRIGHT OWNER SHALL UNDER NO CIRCUMSTANCES BE HELD LIABLE FOR ANY
FINANCIAL CONSEQUENTIAL DAMAGES OR OTHER LOSS, OR ANY OTHER DAMAGE OR INJURY, SUFFERED
BY ANY PARTY MAKING USE OF THIS PUBLICATION OR THE INFORMATION CONTAINED HEREIN.
Wärtsilä 20 Engine O&MM Attachments

Table of Contents

1. Installation-specific drawings..................................................................................................................... 1-1

2. Vendor manuals............................................................................................................................................ 2-1

2.1. Damper.................................................................................................................................................... 2-3
2.2. Turbocharger........................................................................................................................................... 2-5
2.3. Pumps.................................................................................................................................................... 2-67
2.4. Engine air starter.................................................................................................................................. 2-139
2.5. Speed Control Devices........................................................................................................................ 2-159
2.5.1. UG A.............................................................................................................................................. 2-161

DBAE529722- i
This page has intentionally been left blank.
Wärtsilä 20 Engine O&MM Attachments 1. Installation-specific drawings

1. Installation-specific drawings

DBAE529722- 1-1
1. Installation-specific drawings Wärtsilä 20 Engine O&MM Attachments

This page has intentionally been left blank.

1-2 DBAE529722-
23.11.2016 cgr005 Grannas
23.11.2016 tve001 Vesterbacka
3x0.75 LS7506
Device definition Wire definition:
3x0.75 TE7501
IOM = IOM-10 W1 - W6 1 x 120 Ω + 2 x 0,5 mm² 3x0.75 TE7502
3x0.75 TE7503
LDU = LDU-20 WA1, WFE, WE1 2 x 120 Ω + 2 x (2 x 1,5) mm² 3x0.75 TE7504
3x0.75 TE7505
WIP
MCM -1 = MCM-11 WGEN-1 37 x 0,75 mm²
PDM = PDM-20 IOM-E1 GENERATOR 3x0.75 TE7512
BOX
ESM = ESM-20 WGEN-1 37 x 0,75 mm² 3x0.75 TE7514
WIP = WIP-11
2x1.5 CV153-1
WCP = WCP-10 2x1.5 CV153-2
3x0.5
ST173
3x0.5 ST174
3x0.75
ESM TEZ402
2x0.75
PTZ201

WE1 2x120 ohm + 2x2x1.5 mm²

2x1.5 CV381
2x1.5
CV656
3x0.5
GS792
2x0.75 PT301
2x0.75 PT311
2x0.75
PT201
2x0.75
PT241
3x0.75 TE201
2x0.75 PT312
IOM-DE 3x0.75
TE482
3x0.5
GS171
3x0.75 2x0.5 2x0.75
LS103A TE5011A PT291A
2x0.5 TE5021A
3x0.75 2x0.75
LS204 2x0.5 PT601
2x0.75 TE5031A
SE518 2x0.5
2x0.75 TE5041A
PT101 2x0.5
2x0.75 PT401 TE5051A
2x0.75 PT471 2x0.5 2x1.5
TE5061A CV321
2x0.75 2x0.5
PT271 TE5071A
3x0.75 2x1.5
TE101 2x0.5 CV161
3x0.75 TE5081A
3x0.75
TE401 MCM 3x0.5
GT165
TE402 2x0.5
IOM-FE
3x0.75 TE600 b IOM-A1 2x0.5
ST196P
ST196S

2x0.5 TE511
2x0.5 TE517
3x0.75
TE272
LDU
3x0.75 TE471
3x0.75 TE601

WFE 2x120 ohm + 2x2x1.5 mm² WA1 2x120 ohm + 2x2x1.5 mm² PDM

CABINET
M201
M
PRELUBE PUMP

Wärtsilä Finland Oy WIRING DIAGRAM release 2012a.0

PowerTech
PME
Automation system UNIC C2
El & Automation TC in Free End
e LPE013 JRE002 CN-A069097 31 05 2017 Generator signals TE7503-05 connections corrected (15)

d LPE013 JRE002 CN-A064944 29 03 2017 Generator signals TE7503-05 connections corrected (15)
PRODUCT W8L20 UNIC C2 Change Notice CN-A057957 VARD 848-49
TTAX02/ Takalo ENG. NO SIZE A3
c LPE013 JRE002 CN-A064388 22 03 2017 Generator signals TE7503-05 connections corrected (15)
MADE 14 12 2016 PROJ. NO SP/02770-71
PAAE319083-084 PAGE DRG.
b LPE013 JRE002 CN-A062970 01 03 2017 TE600 added (1, 11) CHKD 14 12 2016 JKA087/ Kalijärvi PAAE313090-091
a LPE013 JRE002 CN-A061250 06 02 2017 SI173 Engine speed output removed (8) APPD 14 12 2016 JRE002/ Remsu
PAAE319095-098 NO.
- 1 /15
NO.
DAAF360495 e
REV.
Rev. Rev by Appr. by CN-note Rev. Date This drawing is the property of Wärtsilä Finland Oy and shall not be copied, shown or communicated to a third party without the consent of the owner.
PDM-20-1

2.5 mm² 1.5 mm² 1.5 mm² Brown (WE1)

24 VDC BUS 1 X21-5 X2-1 MCM-1-X24-1 IOM-DE-X11-1 24 VDC BUS1 TO IOM-E1 PAGE 9/D2

ESM-X11-1
1.5 mm² 1.5 mm²
X2-2 WIP11-X11-1 LDU-20-X21-8
24 VDC BUS1 TO ENGINE MOUNTED MODULES PAGE 10/B2

2.5 mm² 1.5 mm² 1.5 mm² Grey (WE1)

24 VDC BUS 2 X21-13 X2-3 MCM-1-X34-1 IOM-DE-X21-8 24 VDC BUS2 TO IOM-E1 PAGE 9/D2

ESM-X12-1
1.5 mm² 1.5 mm²
X2-4 WIP11-X12-1 LDU-20-X22-8
24 VDC BUS2 TO ENGINE MOUNTED MODULES PAGE 10/B2

2.5 mm² Blue 1.5 mm² Blue 1.5 mm² Blue (WE1)
0 VDC BUS 1 X21-7 X2-5 MCM-1-X24-2 IOM-DE-X11-2 0 VDC BUS1 TO IOM-E1 PAGE 9/D2
MAIN SWITCH
HS801-1 1.5 mm² Blue
RTFRO 2x2x2.5 mm² ESM-X11-2
PRIMARY
ENGINE EXTERNAL CABLING

2.5 mm² Brown 1.5 mm² Blue Blue 1.5 mm²

24 VDC 1 2 X11-1 24 VDC PRIMARY X2-6 WIP11-X11-2 LDU-20-X21-7
0 VDC BUS1 TO ENGINE MOUNTED MODULES PAGE 10/B2
2.5 mm² Blue 1
0 VDC 3 4 X11-3 0 VDC PRIMARY
2.5 mm² Blue 1.5 mm² Blue 1.5 mm² Violet (WE1)
0 VDC BUS 2 X21-11 X2-7 MCM-1-X34-2 IOM-DE-X21-7 0 VDC BUS2 TO IOM-E1 PAGE 9/D2
SECONDARY 1.5 mm² Blue
2.5 mm² Grey ESM-X12-2
24 VDC 5 6 X12-1 24 VDC SECONDARY 1.5 mm² 1.5 mm² 1.5 mm²
1.5 mm² Blue Blue Blue Blue
X2-8 WIP11-X12-2 WIP11-X12-4 WIP11-X13-4 LDU-20-X22-7
2.5 mm² Blue 2
0 VDC 7 8 X12-3 0 VDC SECONDARY 0 VDC BUS2 TO ENGINE MOUNTED MODULES PAGE 10/B2

PE PE
F3
2.5 mm² 1.5 mm²
24 VDC AUX X21-9 X2-9 24 VDC SUPPLY TO WCS (PAGE 4/B2)
2A 24 VDC SUPPLY TO IS7602 (PAGE 5/B3)
2,5 mm² Gr/Ye
X11-2 PE X2-10 24 VDC SUPPLY TO SI518 (PAGE 4/C3)
2,5 mm² Gr/Ye
X12-2 PE
F4
1.5 mm²
X2-13 24 VDC SUPPLY TO BUTTONS (PAGE 3/E5)
2A 24 VDC SUPPLY TO ESM SIGNALS (PAGE 5/B3)
X2-14 ESM-X21-5
24 VDC SUPPLY TO WCS (PAGE 4/B2)
X2-15 24 VDC SUPPLY TO MCM SIGNALS (PAGE 5/B3)
24 VDC SUPPLY TO U165 (PAGE 7/B3) ESM-X12-3
X2-16 24 VDC SUPPLY TO RESET FUNCTION (PAGE 3/C4)
Spare

GROUND

2.5 mm² Blue Blue Spare

0 VDC AUX X21-10 X2-11
Blue
Spare
Blue
X2-12 0 VDC SUPPLY TO MCM SIGNALS (PAGE 3/A5)
Blue
0 VDC SUPPLY TO WCS (PAGE 4/B2)
Blue 0 VDC SUPPLY TO K1 (PAGE 3/F6)
X2-17
Blue 0 VDC SUPPLY TO WCS (PAGE 4/B2)
X2-18 Blue 0 VDC SUPPLY TO RESET FUNCTION (PAGE 3/D3)
Blue 0 VDC SUPPLY TO U165 (PAGE 7/B3)

X31-3 IOM-DE-X41-1 DIO 1

NS7800-1 PDM SYSTEM SUPPLY FAILURE
X31-4

X31-5 IOM-DE-X41-2 DIO 2

NS7799-1 PDM SYSTEM SUPPLY EARTH FAULT
X31-6 IOM-DE-X41-7 DIO 5

GROUND

PAGE DRG.
All wires black unless otherwise stated
All wires 0.75 mm² unless otherwise stated
NO.

2 /15
NO.
DAAF360495 e
REV.
This drawing is the property of Wärtsilä Finland Oy and shall not be copied, shown or communicated to a third party without the consent of the owner.
CABINET ENGINE EXTERNAL

WCP REF FOR LOCAL/

REMOTE INDICATION
X31-19 XM7-9
LOCAL INDICATION
X31-20 XM7-10
REMOTE INDICATION
X31-21 XM7-11

MCM
START OS7302
X31-5 X12-4 DI 2
ENGINE START

STOP
DI 3 OS7304
X31-9 X12-6
ENGINE STOP

TO K7343-14 (Page 5/B6) X4-1 X12-8 DI 4

OS7343
ENGINE BLOW
X31-26 TO K7343-13 (Page 5/B6)
OS7344
X31-27 X13-2 DI 5
ENGINE BLOCKED

IB724
X31-28 X13-4 DI 6
LOCAL CONTROL

X4-2 DI 1 OS7308
RESET X31-11 X12-2
SHUTDOWN RESET

X31-13 X33-7 IB725

0 VDC SUPPLY DO 4
TO MCM SIGNALS Blue X33-8
WAITING FOR RESET
(PAGE 2/D5)
TO X2-16 (Page 2/D5) X33-5
DO 3 IS872
X4-3 READY FOR START
X31-17 X33-6

X31-18 TO X2-18 (Page 2/D5)

ESM
X16-12 OS7308 SHUTDOWN RESET

X12-8 ENGINE STOP 2

TO MCM-1-X13-7 OS7305 EXTERNAL SHUTDOWN 4 +

X16-7 XM7-5
(Page 5/B4) (EMERGENCY STOP)

23 13 R 22 kΩ
HS723 R 22 kΩ
EMERGENCY STOP BUTTON
24 14

OS7305 EXTERNAL SHUTDOWN 4 -

X31-1 TO MCM-1-X13-8 X16-8 XM7-6
X31-3
X31-10
X31-12 24 VDC SUPPLY TO BUTTONS (PAGE 2/C5)
X31-25 X4-4 XM7-3
X4-5 OS7304 REMOTE STOP
X31-4 XM7-4

XM7-7
OS7308 REMOTE SHUTDOWN RESET
XM7-8

XM7-1
OS7302 REMOTE START
X31-2 XM7-2

K1
A1 13
IS872 READY FOR START
Blue
0 VDC SUPPLY FROM X2-17 (PAGE 2/D5) 14
Blue
0 VDC SUPPLY TO K2 (PAGE 5/A3) A2

All wires black unless

PAGE DRG.
otherwise stated

All wires 0.75 mm² unless

NO.

3 /15
NO.
DAAF360495 e
REV.
otherwise stated
This drawing is the property of Wärtsilä Finland Oy and shall not be copied, shown or communicated to a third party without the consent of the owner.
MCM WCS-10 LDU20 IOM-DE
W1 W2 W3 WE1 CABINET ENGINE EXTERNAL
CAN1 White CAN1 White CAN1 White CAN1 White
X24-3 X11-3 X21-6 X11-3
CAN BUS 1
CAN1 Blue CAN1 Blue CAN1 Blue CAN1 Blue
X24-4 X11-4 X21-5 X11-4
W4 W5 page 9/E2
X34-3 CAN2 White CAN2 White CAN2 White
X22-6 X21-6
CAN BUS 2
CAN2 Black X22-5 CAN2 Black CAN2 Black
X34-4 X21-5
PAGE 9/C2

X11-1 GROUND *
PAGE 2/C5 24 VDC FROM X2-9
Blue
PAGE 2/D5 0 VDC FROM X2-12 X11-2
X12-4
X12-8 LDU ID=1
PAGE 2/C5 24VDC FROM X2-14 X12-1
Blue
PAGE 2/D5 0 VDC FROM X2-17 X12-2

* WIRE LENGTH BETWEEN CABLE SCREEN AND EARTH MAX 150 MM

CAN 4 D-SUB 9 CONNECTOR
FOR SERVICE TOOL
X13-2 CAN L
X13-3 PWR OUT-
X13-7 CAN H
X13-9 PWR OUT+

ESM
R 120 Ω W6 REMOVE JUMPER AT SITE INSTALLATION IF SIGNAL IS IN USE
CAN3 White
X24-5 X11-3 Check CANopen term resistor
CAN OPEN DIP switch is on
CAN3 Blue
X24-6 X11-4 SI518 TC SPEED

XM7-21 *Loop resistance <750ohm

XM7-22
GROUND
MCM
SI518 TC A SPEED OUTPUT X42-2 WIP
+ X2-10 X42-1 AO 5
PAGE 2/C6
X12-3

ESM
PTZ201 LO PRESS, ENGINE INLET
4-20 mA + X14-7 X4-24 TO PTZ201 SENSOR PAGE 13/D2
X4-25
X12-5
- X14-8 X4-6 X12-6

TEZ402 HT WATER TEMP + X28-1 X4-7 X11-5

- X28-2 X4-8 X11-6
4-20 mA
ENGINE SPEED OUTPUT + X28-7 X4-9 X11-3
4-20 mA - X28-8 X4-10 X11-4

X12-7
Alarm LED 2
X12-8

X13-7
Alarm LED 3
X13-8

X11-7
Alarm loop 1
MCM X11-8

X14-7 X13-5
NS869 WIP FAILURE DI 12
X14-8 X13-6

PAGE DRG.
All wires black unless
otherwise stated
All wires 0.75 mm² unless
NO.

4 /15
NO.
DAAF360495 e
REV.
otherwise stated
This drawing is the property of Wärtsilä Finland Oy and shall not be copied, shown or communicated to a third party without the consent of the owner.
CABINET ENGINE EXTERNAL

K2
IS7602 STOP/SHUTDOWN STATUS 1 A1 13

Blue
O VDC SUPPLY FROM K1 (PAGE 3/F6)
14
A2

Blue
OS441 PREHEATER CONTROL /
K3
CV223 PRELUBRICATION PUMP CONTROL A1 13

14
A2
OS441 PREHEATER CONTROL /

Blue
K4
24 VDC SUPPLY TO MCM SIGNALS (PAGE 2/C6) CV223 PRELUBRICATION PUMP CONTROL A1
13
24 VDC SUPPLY TO ESM SIGNALS (PAGE 2/C5)
A2 14
24 VDC SUPPLY TO IS7602 (PAGE 2/C5)
Blue

MCM
ESM To HS723:23
ESM (PAGE 3/D4) X45-7 BLOW DEACTIVATION RELAY
X14-9 To HS723:24 DO 8
22 kΩ K7343
X45-8
Engine shutdown 2 A1 13
TO WCP-X31-26 (PAGE 3/B2)
X24-1 X13-7 +
X14-10 DI 8 TO X4-1 (PAGE 3/B6)
IS7602 STOP/SHUTDOWN STATUS 1 14
X24-2 X13-8 s
X13-11 A2
22 kΩ
Engine shutdown 3 + X13-7 X33-1
OS7342 ENGINE STOP DO 1
X13-12 - X13-8 X33-2

+ X14-11 X33-3
OS820 MAIN CONTROLLER SHUTDOWN
- X14-12 22 kΩ DO 2 * r TO BE INSTALLED IN MCM CONNECTOR
X13-9
22 kΩ X33-4
Engine shutdown 1
X21-7
X13-10 MODULE ID
X21-8

X15-7 X22-7 +
DI 24
IS7306 STOP/SHUTDOWN OVERRIDE STATUS s
X15-8 X22-8

IOM-DE
X26-9
NS718 ESM FAILURE
X26-10 X41-4 + DIO4

X27-1 X41-7 + DIO5

ST173-1 ENGINE SPEED ESM TO MCM
X27-2 X31-1 + FI 1

PAGE DRG.
All wires black unless
otherwise stated
All wires 0.75 mm² unless
NO.

5 /15
NO.
DAAF360495 e
REV.
otherwise stated
This drawing is the property of Wärtsilä Finland Oy and shall not be copied, shown or communicated to a third party without the consent of the owner.
CABINET ENGINE EXTERNAL CABINET ENGINE EXTERNAL

MCM MCM
X24-7
MODBUS OUTPUT RS 485 ADD 120 OHM RESISTOR IF END OF BUS LINE
X24-8

EXTERNAL CAN-BUS X34-5

LOADSHARING CAN 4 ADD 120 OHM RESISTOR IF END OF BUS LINE
X34-6

X45-1
IS875 START FAILURE DO 5
X45-2

X45-3 GS772 BUSBAR BREAKER STATUS, AFTER + X14-5

IS7331 TRIPPED TO DROOP DO 6 DI 11
X45-4 s X14-6

+ X15-1
OS7312 EXTERNAL START BLOCK 1 DI 13
"From switchboard" s X15-2

X44-1 + X15-3
NS886 ENGINE CONTROL SYSTEM, MAJOR FAILURE DO 9 DI 14
OS7320 BLACKOUT START MODE
X44-2 s X15-4

X44-3
OS7315 LOAD REDUCTION REQUEST/INDIC. DO 10
X44-4

X44-5 OS7329 ISOCHRONOUS LOAD SHARING ENABLE + X15-7

OS7602 GENERATOR BREAKER OPEN COMMAND DO 11 DI 16
X44-6 s X15-8

+ X25-1
GS798 GENERATOR BREAKER STATUS NO DI 17
s X25-2

+ X25-3
OS7321 ENGINE UNLOADING DI 18
s X25-4

X43-3 + X25-5
GSY101 MDF SELECTED, CALCULATED DO 14 OS163 SPEED/LOAD INCREASE DI 19
X43-4 s X25-6

X43-5 + X25-7
NS885 COMMON ENGINE ALARM DO 15 OS164 SPEED/LOAD DECREASE DI 20
X43-6 s X25-8

X43-7 + X23-5
NS881 ENGINE CONTROL SYSTEM, MINOR ALARM DO 16 DI 21
X43-8 OS7327 EMERGENCY LOADING RATE s X23-6

CT7001 LOAD FOR PROPULSION X32-5

4-20 mA AO 3 OS7326 FIXED SPEED SELECT + X22-5
X32-6 DI 23
s X22-6

GS771 BUSBAR BREAKER STATUS, BEFORE + X21-1

X32-7 DI 25
IT797 MAX AVAILABLE POWER AO 4 s X21-2
4-20 mA X32-8

X41-5
UT793 ENGINE LOAD FEEDBACK AI 7 + X21-3
4-20 mA X41-6 OS5270 ENABLE EXH. GAS TEMP DI 26
s X21-4

All wires black unless

PAGE DRG.
otherwise stated

All wires 0.75 mm² unless

NO.

6 /15
NO.
DAAF360495 e
REV.
otherwise stated
This drawing is the property of Wärtsilä Finland Oy and shall not be copied, shown or communicated to a third party without the consent of the owner.
CABINET ENGINE EXTERNAL

LDU20

X31-1 (TX+)

X31-2 (TX-)

X31-3 (RX+)

X31-4 (RX-)

0 VDC FROM X2-18 (Page 2/E5) Blue

24 VDC FROM X2-15 (Page 2/D5)

U165 9 12

24 VDC

0 VDC
FUEL RACK POSITION
X4-28
GT165 FUEL RACK POSITION SENSOR
X4-29 4 in + out + 7
I
I
(Page 14/E2) 5 in - out - 8

Blue MCM
X4-30
X31-1
Blue AI 1
X31-2

PAGE DRG.
All wires black unless
otherwise stated

All wires 0.75 mm² unless

NO.

7 /15
NO.
DAAF360495 e
REV.
otherwise stated
This drawing is the property of Wärtsilä Finland Oy and shall not be copied, shown or communicated to a third party without the consent of the owner.
CABINET ENGINE EXTERNAL

ESM
SI196 ENGINE SPEED OUTPUT + X27-7 XM7-19
Blue
4-20 mA - X27-8 XM7-20

OS7309 EXTERNAL SHUTDOWN 1 + X16-1 XM7-13

22 kΩ
"Not used" - X16-2 XM7-14

OS7310 EXTERNAL SHUTDOWN 2 + X16-3 XM7-37

22 kΩ
"From switchboard shutdown"
- X16-4 XM7-38
OS7311 EXTERNAL SHUTDOWN 3 + X16-5 XM7-39
"Not used" 22 kΩ
- X16-6 XM7-40

+ X16-9 XM7-27
OS7306 STOP/SHUTDOWN OVERRIDE
- X16-10 XM7-28

IS181 SPEED SWITCH 1 X21-1 XM7-15

ENGINE RUNNING
X21-2 XM7-16

X21-3 XM7-41
IS182 SPEED SWITCH 2
X21-4 XM7-42

X23-1 XM7-43
IS184 SPEED SWITCH 4
X23-2 XM7-44

X23-3 XM7-29
IS7601-1 SPEED WINDOW 1
X23-4 XM7-30

X23-5 XM7-31
IS7601-2 SPEED WINDOW 2
X23-6 XM7-32

X25-9 XM7-17
IB7324 SHUTDOWN STATUS
X25-10 XM7-18

X24-3 XM7-25
IS7603 STOP/SHUTDOWN STATUS 2
X24-4 XM7-26

X26-11 XM7-33
IS7323 SHUTDOWN PRE-WARNING
X26-12 XM7-34

MCM
XS7323 SHUTDOWN PRE-WARNING X44-7
DO 12
X44-8

PAGE DRG.
All wires black unless
otherwise stated

All wires 0.75 mm² unless

NO.

8 /15
NO.
DAAF360495 e
REV.
otherwise stated
This drawing is the property of Wärtsilä Finland Oy and shall not be copied, shown or communicated to a third party without the consent of the owner.
CABINET ENGINE CABLING

SYSTEM SUPPLY IOM10-A1 IOM10-FE

WA1 WFE
Brown Brown
24 VDC from X2-2 (Page 2/A5) X11-1 X11-1
Blue Blue
0 VDC from X2-6 (Page 2/B5) X11-2 X11-2

Grey Grey
24 VDC from X2-4 (Page 2/B5) X21-8 X21-8
Violet Violet
0 VDC from X2-8 (Page 2/C5) X21-7 X21-7

CAN-BUS MCM R 120 Ω

White White
H X24-3 X11-3 X11-3
Blue Blue
L X24-4 X11-4 X11-4
*
(PAGE 4/B1) R 120 Ω * LEAVE INNER SHIELDS UNCONNECTED AT THIS END
White White
H X34-3 X21-6 X21-6
Black Black
L X34-4 X21-5 X21-5
*

(PAGE 4/A2)

GROUND GROUND

SYSTEM SUPPLY IOM10-E1

WE1
Brown
24 VDC from IOM-DE (Page 2/A7) X11-1
Blue
0 VDC from IOM-DE (Page 2/B7) X11-2

Grey
24 VDC from IOM-DE (Page 2/B7) X21-8
Violet
0 VDC from IOM-DE (Page 2/B7) X21-7

IOM-DE
CAN-BUS
R 120 Ω
White
H X11-3 X11-3
Blue
L X11-4 X11-4
*
(PAGE 4/A6) R 120 Ω
White
H X21-6 X21-6
Black
L X21-5 X21-5
*

GROUND

All wires black unless

PAGE DRG.
otherwise stated

All wires 0.75 mm² unless

NO.

9 /15
NO.
DAAF360495 e
REV.
otherwise stated
This drawing is the property of Wärtsilä Finland Oy and shall not be copied, shown or communicated to a third party without the consent of the owner.
IOM-DE IOM-DE

VIC CONTROL VALVE LT WATER TEMP, LOC OUTLET

CV381 RTFRO 2 x 1.5 mm² TE482 RTFRO 3 x 0.75 mm² X23-5
Black Black
+ X11-5 1 X23-6
Brown AI 10
HSD 1 2 X23-7
Blue Blue
- X11-6 t 3 X23-8
PE

AIR WG CONTROL
CV656 RTFRO 2 x 0.75 mm²
Red
+ X41-7
I Black
- X21-4
X21-3 AO 1
P SLD X41-5

TURNING GEAR POSITION

GS792 RTFRO 3 x 0.5 mm²
Black
+ X41-8
Brown
s X41-3 DI 3
Blue
- X41-6
PE

STARTING AIR PRESS, ENGINE INLET

PT301 RTFRO 2 x 0.75 mm²
+ Black
X32-1 AI 1
I Blue
- X32-2
X32-3
P SLD X32-4

CTRL OIL PRESS AFT VIC VALVE A-BANK

CONTROL AIR PRESS PT291A RTFRO 2 x 0.75 mm²
PT311 RTFRO 2 x 0.75 mm² + Black
X22-5
Black I - Blue AI 14
+ X32-5 X22-6
I Blue AI 2 X22-7
- X32-6
X32-7 P SLD X22-8
P SLD X32-8

LO PRESS, ENGINE INLET

PT201 RTFRO 2 x 0.75 mm²
Black
+ X42-1
I Blue AI 3
- X42-2
X42-3
P SLD X42-4

CA PRESS, ENGINE INLET

LO PRESS, FILTER INLET PT601
PT241 RTFRO 2 x 0.75 mm² RTFRO 2 x 0.75 mm²
Black Black
+ X42-5 + X12-5
I Blue AI 4 I Blue AI 16
X42-6 - X12-6
-
X42-7 X12-7
P P SLD X12-8
SLD X42-8

LO TEMP, ENGINE INLET

X31-3
TE201 RTFRO 3 x 0.75 mm²
X33-1 X31-5 MODULE ID=1
Black
1 X33-2
Brown X33-3 AI 5
2 Blue
t 3 X33-4

INSTRUMENT AIR PRESS GROUND

PT312 RTFRO 2 x 0.75 mm²
Black
+ X43-5
I Blue AI 8
- X43-6
X43-7
P SLD X43-8

GROUND

All wires black unless

PAGE DRG.
otherwise stated

All wires 0.75 mm² unless

NO.

10 /15
NO.
DAAF360495 e
REV.
otherwise stated
This drawing is the property of Wärtsilä Finland Oy and shall not be copied, shown or communicated to a third party without the consent of the owner.
IOM10-FE IOM10-FE
HT WATER TEMP, JACKET INLET
TE401 RTFRO 3 x 0.75 mm²
Black X33-5
1 Brown X33-6 AI 6
2 X33-7
Blue
t 3 X33-8

HT WATER TEMP. JACKET OUTLET A-BANK

TE402 RTFRO 3 x 0.75 mm²
Black X43-1
1 Brown X43-2
2 AI 7
X43-3
t Blue
3 X43-4

FUEL OIL LEAGAKE, CLEAN PRIMARY, A-BANK

LS103A RTFRO 3 x 0.75 mm²
Black
+ X41-8
Blue
- X41-6
Brown DIO 1
S X41-1
cap

AIR TEMP, TC INLET

LO LOW LEVEL, OIL SUMP TE600 RTFRO 3 x 0.75 mm²
LS204 X23-5
RTFRO 3 x 0.75 mm² Black
1 X23-6
Black Brown AI 10
X23-7
+
-
Blue X41-7
X41-5
b t
2
3
Blue
X23-8
Brown
S X41-4 DI 4
cap

EXHAUST GAS TEMP, TC A INLET

TE511 TC type K 2 x 0.5 mm²
Green
X13-2
White AI 11
X13-3

EXHAUST GAS TEMP, TC A OUTLET

TC SPEED
TE517 TC type K 2 x 0.5 mm²
SE518
RTFO 2 x 0,75mm² Green
X13-6
Blue AI 12
n 1+ D X41-5 White
2- B Brown FI 1 X13-7
X31-1
f 3 F *Black wire not used

X_SE518
0050A030221/22 LO TEMP, TC A OUTLET
TE272 RTFRO 3 x 0.75 mm²
Black X22-1
FO PRESS, ENGINE INLET
1 Brown X22-2
PT101 RTFRO 2 x 0.75 mm² AI 13
2 X22-3
Black Blue
+ X32-1 t 3 X22-4
I Blue AI 1
- X32-2
X32-3
P SLD X32-4
LT WATER TEMP, LT CAC INLET
TE471 RTFRO 3 x 0.75 mm²
Black X22-5
HT WATER PRESS, JACKET INLET 1 X22-6
PT401 RTFRO 2 x 0.75 mm² Brown AI 14
2 Blue X22-7
+ Black t 3 X22-8
I X32-5
- Blue AI 2
X32-6
X32-7
P SLD X32-8 CA TEMP, ENGINE INLET
TE601 RTFRO 3 x 0.75 mm²
X12-1
LT WATER PRESS, LT CAC INLET Black
1 X12-2
PT471 RTFRO 2 x 0.75 mm² Brown AI 15
2 X12-3
Black Blue
+ X42-1 t 3 X12-4
I - Blue AI 3
X42-2
X42-3
P SLD X42-4

X31-3
LO PRESS, TC A INLET
X31-6 MODULE ID=2
PT271 RTFRO 2 x 0.75 mm²
+ Black
I Blue X42-5 AI 4
- X42-6
X42-7
P SLD X42-8
GROUND
FO TEMP, ENGINE INLET
TE101 RTFRO 3 x 0.75 mm²
Black X33-1
1 X33-2 DRG.
All wires black unless 2 Brown
X33-3
AI 5 PAGE
otherwise stated

All wires 0.75 mm² unless

t 3
Blue
X33-4 NO.

11 /15
NO.
DAAF360495 e
REV.
otherwise stated
GROUND
This drawing is the property of Wärtsilä Finland Oy and shall not be copied, shown or communicated to a third party without the consent of the owner.
IOM-A1 IOM-A1
STOP LEVER IN STOP POSITION EXHAUST GAS TEMP, CYLINDER A7
GS171 RTFO 3 x 0,5 mm² TE5071A TC type K 2 x 0.5 mm²
Black Green
+ Brown X41-8 X43-2
s Blue X41-2 DI 2 White AI 7
- X41-6 X43-3
PE

EXHAUST GAS TEMP, CYLINDER A8

TE5081A TC type K 2 x 0.5 mm²
Green
X43-6
White AI 8
X43-7

EXHAUST GAS TEMP, CYLINDER A1

TE5011A TC type K 2 x 0.5 mm²
Green
X32-2
White AI 1
X32-3

EXHAUST GAS TEMP, CYLINDER A2

TE5021A TC type K 2 x 0.5 mm²
Green
X32-6
AI 2
White
X32-7

EXHAUST GAS TEMP, CYLINDER A3

TE5031A TC type K 2 x 0.5 mm²
Green
X42-2
White AI 3
X42-3

EXHAUST GAS TEMP, CYLINDER A4

TE5041A TC type K 2 x 0.5 mm²
Green
X42-6
White AI 4
X42-7

EXHAUST GAS TEMP, CYLINDER A5

TE5051A TC type K 2 x 0.5 mm²
Green
X33-2
White AI 5
X33-3

EXHAUST GAS TEMP, CYLINDER A6

TE5061A TC type K 2 x 0.5 mm²
Green
X33-6
White AI 6
X33-7

X31-3
X31-7 MODULE ID=3

GROUND GROUND

All wires black unless

otherwise stated PAGE DRG.
All wires 0.75 mm² unless
otherwise stated
NO.

12 /15
NO.
DAAF360495 e
REV.
This drawing is the property of Wärtsilä Finland Oy and shall not be copied, shown or communicated to a third party without the consent of the owner.
CABINET ENGINE CABLING

STOP SOLENOID 1
ESM CV153-1
2 x 1.5 mm²
1.5 mm² Black
CV153-1 STOP SOLENOID 1 + X22-1 X4-11 Blue 2+
1.5 mm² Blue
- X22-2 X4-12 1-

STOP SOLENOID 2
CV153-2
2 x 1.5 mm²
1.5 mm² Black
+ X22-3 X4-13 2+
CV153-2 STOP SOLENOID 2 1.5 mm² Blue Blue
- X22-4 X4-14 1-

ENGINE SPEED 1
3 x 0.5 mm² ST173
Black
+ X13-1 X4-15 Brown +
ST173 ENGINE SPEED 1 s X13-2 X4-16 Blue s
- X13-3 X4-17 -
PE

ENGINE SPEED 2
3 x 0.5 mm² ST174
Black
+ X14-1 X4-18 +
Brown
ST174 ENGINE SPEED 2 s X14-2 X4-19 s
Blue
- X14-3 X4-20 -
PE

HT WATER TEMP. ENGINE OUTLET A-BANK

3 x 0.75 mm² TEZ402
X13-6 Black
X4-21 Brown 1
TEZ402 HT WATER TEMP, ENGINE OUTLET A-BANK X13-5 X4-22 2
X13-4 Blue
X4-23 3 t

LUBE OIL PRESS. ENGINE INLET

2 x 0.75 mm² PTZ201 ALL CABLE SHIELDS TO BE CONNECTED
Black TO CABLE GLANDS WITH 360 DEGREE CONNECTION
Page 4/5D X4-24 Blue + I
X4-25 -

SLD P

PAGE DRG.
NO.

13 /15
NO.
DAAF360495 e
REV.
This drawing is the property of Wärtsilä Finland Oy and shall not be copied, shown or communicated to a third party without the consent of the owner.
CABINET ENGINE CABLING

MCM START SOLENOID

CV321
RTFO 2 x 1.5 mm²
Black
X35-1 2+
HSD 1 Blue
X35-2 1-

FUEL RACK CONTROL (UGA)

RTFO 2 x 1.5 mm² CV161
W161
Black A
X42-3 A
AO 6
Blue B
X42-4 B
X_CV161
CA06COM-PG14S-7S-44-F183-A176

ENGINE SPEED, PRIMARY

2 x 0.5 mm² ST196P
Brown
FI 1 X23-2 +
Blue f
X23-3 -
n

ENGINE SPEED, SECONDARY

2 x 0.5 mm² ST196S
Brown
FI 2 X22-2 +
Blue f
X22-3 -
n

FUEL RACK POSITION

3 x 0.5 mm² GT165
Black
X4-28 +
Brown
(Page 7/C4) AI 1 X4-29 S
Blue
X4-30 - I

All wires black unless

otherwise stated
PAGE DRG.
All wires 0.75 mm² unless
otherwise stated
NO.

14 /15
NO.
DAAF360495 e
REV.
This drawing is the property of Wärtsilä Finland Oy and shall not be copied, shown or communicated to a third party without the consent of the owner.
GENERATOR IOM10-E1
e
B3A B3B

GENERATOR WINDING TEMP, U

TE7503 d X1a
WGEN-1 IOM-E1-X42-4 AI 3
1R1 1R1 1R1 PT- 0V 1 IOM-E1-X42-3
t 1R1
1R2
1R1 1R1
1R2
PT- 1R 24+ 2
3
IOM-E1-X42-1 b
1R2 PT+ DUT IOM-E1-X42-2

GENERATOR WINDING TEMP, V

TE7504 d IOM-E1-X42-8
2R1 2R1 4 AI 4
2R1 PT- 0V IOM-E1-X42-7
t 2R1 2R1
2R1
2R2 PT- 2R 24+
5 IOM-E1-X42-5 b
2R2 2R2 6 IOM-E1-X42-6
PT+ DUT

GENERATOR WINDING TEMP, W

TE7505 d IOM-E1-X33-4
3R1 3R1 7 AI 5
3R1 PT- 0V IOM-E1-X33-3
t 3R1
3R2
3R1 3R1
3R2
PT- 3R 24+ 8
9
IOM-E1-X33-1 b
3R2 PT+ DUT IOM-E1-X33-2
GENERATOR WINDING TEMP, U
TE7503 C = (35 V, 220 qF, LOW ESR)
4R1 "See instruction DAAF322355
*Spare t 4R1 to correctly install capasitors"
4R2
*Spare sensors
to be connected if primary GENERATOR WINDING TEMP, V
TE7504
sensors are damaged 5R1
*Spare t 5R1
IOM10-E1-X31-3
IOM10-E1-X31-7
5R2 MODULE ID=12
IOM10-E1-X31-4
IOM10-E1-X31-8
GENERATOR WINDING TEMP, W
TE7505
*Spare 6R1
t 6R1
6R2

GENERATOR BEARING TEMP, DE

TE7501
AI 1
30R1 IOM-E1-X32-1
t 10 IOM-E1-X32-2
30R1 11 +
30R2 IOM-E1-X32-3 C
12 -
30R2 IOM-E1-X32-4

GENERATOR BEARING TEMP, NDE

TE7502
AI 2
40R1 IOM-E1-X32-5
t 13 IOM-E1-X32-6
40R1 14 +
40R2 IOM-E1-X32-7 C
15 -
40R2 IOM-E1-X32-8

GENERATOR AIR TEMP, OUTLET

TE7514
AI 11
50R1 IOM-E1-X13-1
t 16 IOM-E1-X13-2
50R1 17 +
50R2 IOM-E1-X13-3 C
18 -
50R2 IOM-E1-X13-4

GENERATOR AIR TEMP, INLET

TE7512
AI 9
60R1 IOM-E1-X23-1
t 19 IOM-E1-X23-2
60R1 20 +
60R2 IOM-E1-X23-3 C
21 -
60R2 IOM-E1-X23-4

GENERATOR COOLING WATER LEAKAGE 1

LS7506
1 22 IOM-E1-X41-7
3S2 DI1
2 23 IOM-E1-X41-1
3S1
3 3S3

GROUND GROUND
PAGE DRG.
All wires black unless
otherwise stated
NO.

15 /15
NO.
DAAF360495 e
REV.
All wires 0.75 mm² unless
otherwise stated
This drawing is the property of Wärtsilä Finland Oy and shall not be copied, shown or communicated to a third party without the consent of the owner.
Modbus communication link
Communication speed: 19200 bits/s
Communication mode: RTU
Data bits: 8
Parity: NONE
Stop bits: 1
Commands in use: 02 (Input status), 03 (Holding register)
Polling delay: 200 ms (recommended)
Physical interface: RS-485 2-wire

Title Explanation
Code Sensor code
Name Signal name
Type Signal type
Range / Unit Signal range and unit
Set point - Alarm Set point for alarm condition
Set point - Stop Set point for stop / shutdown condition
Set point - L.red. Set point for load reduction request condition
Modbus addresses - Anal. On analog addresses (40xxx) integer value multiplied by Scale is shown
Modbus addresses - Alarm On alarm addresses (10xxx) 0 = normal and 1 = alarm ON
Modbus addresses - Stop On stop addresses (11xxx) 0 = normal and 1= stop ON
Modbus addresses - L.red. On load reduction addresses (12xxx) 0 = normal and 1 = load reduction request ON
Alarm cond. Condition for alarm / stop / load reduction activation
Error values -32767 = value not update (not configured) and -32765 = sensor failure
BL Alarm is blocked in stop mode
Delay Activation delay in UNIC software

b 12.5.2017 JKA087 JRE002 Modbus slave, project name, GT165 & WY196_2 scale updated
a 20.3.2017 JHAX66 JRE002 TE7503-5, TE7512-14 and WY196_2 updated. TE600 added. TE601 LR added. TE272 and PT271 added.
Rev Date Made Checked Description

MODBUS SLAVE ID ENGINE NUMBER Wärtsilä Finland OY MODBUS CODE LIST TO W20 UNIC C2
PAAE319083, PAAE319095, PAAE332800,
21 PAAE332806 WIO MARINE MAIN ENGINE DIESEL ELECTRIC
PAAE319084, PAAE319096, PAAE332801,
22 PAAE332807 VARD 848-51
PAAE319090, PAAE319097, PAAE332802,
This drawing is property of Wärtsilä Finland Oy and shall not be copied, shown nor communicated to a third party without the consent of the owner.
23 PAAE332808, PAAE332811
PAAE319091, PAAE319098, PAAE332803,
Made: Kalijärvi 3.11.2016 JKA087 Pages Document No Rev.
24 PAAE332812 Proj.no Product
SP/02770-71, SP/02954-55 W8L20 UNIC C2 Approved: Remsu 3.11.2016 JRE002 1/4 DBAE181661 b

1(5) DBAE181661_b.xlsx Revision b

SP/02770-71, SP/02954-55, VARD 848-51, W8L20 UNIC C2, DBAE181661 rev. b
B Type Range / Set point Alarm Modbus Addresses
Code Name L Unit Alarm Delay L.red. Delay Stop Delay cond Anal. Alarm L.red. Stop Scale Rev.
Fuel oil
PT101 Fuel oil pressure, inlet X 4-20 mA 0-16 bar 5,50 3s low 40001 10001 100
TE101 Fuel oil temp., inlet X Pt100 0-160 °C 8) 5s high 40002 8) 10
LS103A Fuel oil leakage, injection pipes NC-switch 0-1 1 5s equal 10004 1
Lub. oil
PT201 Lub. oil pressure, inlet X 4-20 mA 0-10 bar 3 5s 2,5 5s low 40011 10011 12011 100
TE201 Lub. oil temp., inlet Pt100 0-160 °C 75 5s 80 5s high 40012 10012 12012 10
LS204 Lub. oil level, wet sump NC-switch 0-1 1 20 s equal 10013 1
PDY243 Lub. oil filter differential pressure calculated 0 - 2 bar 1,0 5s high 40014 10014 100
PT271 Lub. oil pressure at turbocharger X 4-20 mA 0-10 bar 1,3 10 s low 40015 10015 100 a
TE272 Lub. oil temp. at turbo charger outlet Pt100 0-160 °C 120 10 s high 40016 10016 10 a
PT241 Lube oil pressure, filter inlet 4-20 mA 0-10 bar 40018 100
PT291A Ctrl oil press, aft. VIC valve A-bank X 4-20 mA 0-10 bar 4) 0,8 5s 3) 0,8 1s 10019 12019 1
Starting air
PT301 Starting air pressure 4-20 mA 0-16 bar 7 15 s low 40022 10022 100
PT311 Control air pressure 4-20 mA 0-40 bar 16 5s low 40023 10023 100
PT312 Instrument air press 4-20 mA 0-10 bar 5 3s low 40024 10024 100
PT301 Starting air pressure 4-20 mA 0-16 bar 15 5s high 10025 100
Cooling water
PT401 HT-water pressure, inlet X 4-20 mA 0-6 bar 5) 2,0 5s 6) 1,6 5s low 40027 10027 12027 100
TE401 HT-water temp., inlet X Pt100 0-160 °C 60 5s low 40028 10028 10
TE402 HT-water temp., outlet X Pt100 0-160 °C 105 5s 108 5s high 40029 10029 12029 10
TE471 LT-water temp., inlet Pt100 0-160 °C 55 30 s high 40032 10032 10
TE482 LT Water temperature, LOC outlet Pt100 0-160 °C 40033 10
Exhaust gas
TE511 Exhaust gas temp. TC inlet 1 NiCr/Ni 0-750 °C 620 10 s 640 20 s high 40038 10038 12038 10
TE517 Exhaust gas temp. TC outlet NiCr/Ni 0-750 °C 450 30 s high 40039 10039 10
TE5011A Exhaust gas temp. cylinder 1 X NiCr/Ni 0-750 °C 510 10 s 530 10 s high 40040 10040 12040 10
TE5021A Exhaust gas temp. cylinder 2 X NiCr/Ni 0-750 °C 510 10 s 530 10 s high 40041 10041 12041 10
TE5031A Exhaust gas temp. cylinder 3 X NiCr/Ni 0-750 °C 510 10 s 530 10 s high 40042 10042 12042 10
TE5041A Exhaust gas temp. cylinder 4 X NiCr/Ni 0-750 °C 510 10 s 530 10 s high 40043 10043 12043 10
TE5051A Exhaust gas temp. cylinder 5 X NiCr/Ni 0-750 °C 510 10 s 530 10 s high 40044 10044 12044 10
TE5061A Exhaust gas temp. cylinder 6 X NiCr/Ni 0-750 °C 510 10 s 530 10 s high 40045 10045 12045 10
TE5071A Exhaust gas temp. cylinder 7 X NiCr/Ni 0-750 °C 530 10 s 570 10 s high 40046 10046 12046 10
TE5081A Exhaust gas temp. cylinder 8 X NiCr/Ni 0-750 °C 510 10 s 530 10 s high 40047 10047 12047 10
TY500 Exhaust gas temperature average calculated 0-750 °C 40049 10
TY5017A Exhaust gas temp. deviation 01A X calculated -200/+200 °C ±90/50 10 s ±110/60 20 s high 40050 10050 12050 10
TY5027A Exhaust gas temp. deviation 02A X calculated -200/+200 °C ±90/50 10 s ±110/60 20 s high 40051 10051 12051 10
TY5037A Exhaust gas temp. deviation 03A X calculated -200/+200 °C ±90/50 10 s ±110/60 20 s high 40052 10052 12052 10
TY5047A Exhaust gas temp. deviation 04A X calculated -200/+200 °C ±90/50 10 s ±110/60 20 s high 40053 10053 12053 10
TY5057A Exhaust gas temp. deviation 05A X calculated -200/+200 °C ±90/50 10 s ±110/60 20 s high 40054 10054 12054 10
TY5067A Exhaust gas temp. deviation 06A X calculated -200/+200 °C ±90/50 10 s ±110/60 20 s high 40055 10055 12055 10
TY5077A Exhaust gas temp. deviation 07A X calculated -200/+200 °C ±100/70 10 s ±120/90 20 s high 40056 10056 12056 10
TY5087A Exhaust gas temp. deviation 08A X calculated -200/+200 °C ±90/50 10 s ±110/60 20 s high 40057 10057 12057 10

2(5) DBAE181661_b.xlsx Revision b

3(5) DBAE181661_b.xlsx Revision b

SP/02770-71, SP/02954-55, VARD 848-51, W8L20 UNIC C2, DBAE181661 rev. b
B Type Range / Set point Alarm Modbus Addresses
Code Name L Unit Alarm Delay L.red. Delay Stop Delay cond Anal. Alarm L.red. Stop Scale Rev.
Status of start blockings
PT201 2) Lub. oil pressure, inlet 4-20 mA 0-10 bar 0,3 0s low 10116 100
GS792 2) Turning gear engaged NC-switch 0-1 1 0s equal 10117 1
GS171 2) Stop lever in stop position NO-switch 0-1 1 0s equal 10118 1
OS7344 2) Local selector in blocked position NO-switch 0-1 1 0s equal 10119 1
OS7312 2) Ext Sb1 from switchboard NO-switch 0-1 1 0s equal 10121 1
Status of shutdowns
STY196 Engine speed sensor failure emergency X 0-1 1 0,1 s equal 11127 1
IS4011 HT water temp shutdown status NO-switch 0-1 1) 1 0,1 s 1 (>110°C) 0,1 s equal 10128 11128 1 a
IS1741/IS1742 Overspeed shutdown status from ESM NO-switch 0-1 1 (>115%) 7) 0,1 s equal 11129 1
IS2011 LO press shutdown status NO-switch 0-1 1) 1 0,1 s 1 (<2 bar) 0,1 s equal 10130 11130 1
IS7310 Ext Sd2 from Switchboard shutdown NO-switch 0-1 1) 1 0,1 s 1 0,1 s equal 10135 11135 1
IS7305 Ext Sd 4 from Emg. Stop PB NO-switch 0-1 1 7) 0,1 s equal 11137 1
NY1604 Engine speed low, run mode switch 0-1 1 1s active 11140 1
NYZ1605 Speed signal missing, start mode switch 0-1 1 0s active 11141 1
Others
NS869 WIP failure SW-function 0-1 1 3s equal 10141 1
NS718 ESM failure SW-function 0-1 1 0,1 s equal 10145 1
NS7799-1 PDM System supply earth fault SW-function 0-1 1 0,1 s equal 10148 1
NS7800-1 PDM System supply failure SW-function 0-1 1 0,1 s equal 10149 1
NB7801 System control supply failure SW-function 0-1 1 0,1 s equal 10150 1
Alternator signals
TE7501 Generator bearing temp, DE Pt100 0-160 °C 90 5s 100 1 s high 40184 10184 11184 10
TE7502 Generator bearing temp, NDE Pt100 0-160 °C 90 5s 100 1 s high 40185 10185 11185 10
TE7503 Generator winding temp L1 Pt1000/4-20mA 0-200 °C 145 5s 155 5s high 40186 10186 12186 10 a
TE7504 Generator winding temp L2 Pt1000/4-20mA 0-200 °C 145 5s 155 5s high 40187 10187 12187 10 a
TE7505 Generator winding temp L3 Pt1000/4-20mA 0-200 °C 145 5s 155 5s high 40188 10188 12188 10 a
LS7506 Generator cooling water leakage 1 switch 0-1 1 5s high 10189 1
TE7512 Generator air temp, cold side, DE Pt100 0-160 °C 55 5s high 40194 10194 10 a
TE7514 Generator air temp, hot side Pt100 0-160 °C 100 5s high 40196 10196 10 a

4(5) DBAE181661_b.xlsx Revision b

Notes:
1) Shutdown prewarning
Exhaust gas temp. deviation diagram (TY50*7A)
2) Status information, not to be treated as an alarm
3) Sp load reduction -> PT291A oil pressure over 0,8 bar and CV381 = OFF
Delay 10 s after CV381 status change 150
4) PT291A oil pressure below 0.8 bar AND CV381 = ON 245 250 500 600
130
5) Variable set point: 2 bar at nominal speed, 1 bar at 50% speed and below. LR low -150 -110 -60 -60
Linear between speeds 50% to 100%. Assumed static pressure 1 bar. 110 LR high 150 110 60 60
6) Variable set point: 1,6 bar at nominal speed, 1 bar at 50% speed and below. 90 Alarm low -150 -90 -50 -50
Linear between speeds 50% to 100%. Assumed static pressure 1 bar. Alarm high 150 90 50 50
7) Shutdown is actuated without shutdown pre-warning (not overridable). 70 Low -150 150 250 250
8) TE101 low and high temp alarms to be generated in alarm system 50 High -150 150 500 500

Temp. deviation [ºC]

LR low A2/A7-150 -120 -90 -90
30 LR high A2/A7150 120 90 90
Alarm low A2/A7
-150 250-100
ºC -70 -70 500 ºC
10
Alarm high A2/A7
150 100 70 70
-10 0 100 200 300 400 500 600
-30

-50
Alarm
-70 Load Reduction
-90 Alarm cyl. 7
-110 Load Reduction cyl. 7

-130 Limit low

-150
Average exh. gas temp. [ºC]

5(5) DBAE181661_b.xlsx Revision b

Wärtsilä 20 Engine O&MM Attachments 2. Vendor manuals

2. Vendor manuals

DBAE529722- 2-1
2. Vendor manuals Wärtsilä 20 Engine O&MM Attachments

This page has intentionally been left blank.

2-2 DBAE529722-
Wärtsilä 20 Engine O&MM Attachments 2. Vendor manuals

2.1 Damper

DBAE529722- 2-3
2. Vendor manuals Wärtsilä 20 Engine O&MM Attachments

This page has intentionally been left blank.

2-4 DBAE529722-
GEISLINGER
DAMPER

LONG
SERVICE LIFE
$77(17,21

35,2572813$&.,1*7+(352'8&75($'$1'
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Manual number: GDM 000688

Added drawings
Assembly
*
Part list
*
Manual for GD4-Damper

1 INTRODUCTION ............................................................................................... 3

2 SAFETY INSTRUCTIONS ................................................................................... 4

3 APPLICATION OF THE PRODUCT ..................................................................... 6

4 TECHNICAL DATA ............................................................................................ 6

5 DAMPER DESCRIPTION .................................................................................... 7

6 TRANSPORT AND LIFTING INSTRUCTIONS ..................................................... 8

6.1 Transport instructions ......................................................................................... 8
6.2 Lifting tackle ...................................................................................................... 9
6.3 Tapped holes for lifting purposes...................................................................... 11
6.4 Lifting instructions ............................................................................................ 12

7 PACKAGING AND STORAGE ......................................................................... 13

8 UNPACKING ................................................................................................... 14

9 DAMPER INSTALLATION INSTRUCTIONS...................................................... 15

10 STARTING UP THE DAMPER .......................................................................... 17

11 REMOVING THE PRODUCT ............................................................................ 18

12 DISMANTLING AND ASSEMBLING THE PRODUCT ....................................... 19

13 SERVICING ...................................................................................................... 20

14 REPAIR INFORMATION .................................................................................. 22

15 OPERATING CONDITIONS.............................................................................. 23
15.1 General ............................................................................................................ 23
15.2 Required oil pressure ........................................................................................ 23
15.3 Required oil viscosity ........................................................................................ 24
15.4 Permissible temperature range for VITON-seals ................................................. 25

16 DISPOSING OF USED PARTS .......................................................................... 26

17 ORDERING REPLACEMENT PARTS ................................................................ 27

18 WARRANTY.................................................................................................... 28

19 APPENDIX....................................................................................................... 28

20 GENERAL MOUNTING INSTRUCTION FOR BOLTS ........................................ 29

20.1 Cleaning the threaded parts ............................................................................. 29
20.2 Use of auxiliary materials for assembly .............................................................. 31
20.2.1 Note on Loctite products .................................................................................. 31
20.2.2 Application on threaded parts .......................................................................... 31
20.2.3 Application on washers .................................................................................... 32
20.3 Assembly ......................................................................................................... 33
20.3.1 Note on washers .............................................................................................. 33
20.3.2 Tightening process ........................................................................................... 33
20.4 After assembly ................................................................................................. 35
20.5 Re-use.............................................................................................................. 35

CONTACT INFORMATION............................................................................................. 36
1 INTRODUCTION

General information on the operating instructions

These operating instructions contain important information on the use of the product.
Carry out these instructions carefully and precisely. This helps to avoid the potential for
damage to the product or personal injury caused by failure to follow correct installation
procedures, downtime and repair costs whilst also increasing the reliability and service life
of the product.

The assembly drawings located in appendix are an important part of these

instructions. Refer to the assembly drawings whenever instructed in this manual.
All numbers in these operating instructions in brackets () refer to item numbers
which are given on the assembly drawing or on figures in this manual.

x These operating instructions are part of the product.

x Keep these instructions in a safe place for the entire life of the product.

x If the product is transferred to a new owner, these instructions and all

associated documents are to be passed on to the new owner.

The meaning and appearance of safety symbols used in these operating instructions are as
follows:

The text after the signal word “WARNING!” contains

important information, which must be followed to avoid
serious personal injury or death.
WARNING!

The text after the signal word “CAUTION!” contains

information, which must be followed to avoid damage to the
product and systems.
CAUTION!
2 SAFETY INSTRUCTIONS

WARNING!

x Ensure that the work area is properly ventilated or appropriate life

supporting breathing apparatus is available.

x Do not smoke or maintain open flames from torches, matches, lighters

etc. in the work area.

x Secure all loose fitting clothing, hair and jewelry before working on
rotating equipment.

x Do not attempt to install, assemble, align, or service a product on

equipment which is rotating or otherwise in operation.

x Do not attempt to install a product component which is damaged.

x Do not attempt to operate a product which has been damaged or contains

damaged components or contains parts obtained from other than
Geislinger.

x Do not heat an oil bath above the flash point of the oil.

Failure to follow these instructions may result in serious personal injury, damage
to the product and system or both.
WARNING!

ANY WORK CARRIED OUT ON AND IN CLOSE PROXIMITY TO THE SYSTEM SHALL
ONLY BE UNDERTAKEN

¾ by trained personnel who are familiar with the product and its use on the
product in which it is installed.

¾ with the system shut down and the supply of power switched off.

¾ in compliance with federal, state and local regulations related to

workplace safety.

¾ in compliance with the safety information and data provided in these

operation instructions.

¾ in compliance with national safety regulations and state of engineering

practice.

Failure to follow these instructions may result in serious personal injury, damage
to the product and system or both.

The following personal protective equipment is to be used for all work on and in the
immediate vicinity of the product.

Safety helmet Safety footwear Protective gloves Protective goggles

3 APPLICATION OF THE PRODUCT

This product is specifically designed for use in a designated system. Make sure that the
system into which the product will be installed is specifically approved.

The product will only function properly if it has been installed in this system according to
the instructions contained in this manual.

Installation of the product in equipment other than the

designated system may cause damage to the system and to
the product.
CAUTION!

4 TECHNICAL DATA

Technical data, dimensions of the components and weights: See attached assembly
drawings and the arrangement drawings (if available).
5 DAMPER DESCRIPTION

Geislinger's vibration damper is a spring-coupled torsional vibration damper with hydraulic

damping. Radially arranged spring blades transmit the elastic torque. Torsional vibrations
are damped by oil displacement from one chamber to the adjoining one.

The spring packs (1) and intermediate pieces (2) are clamped together using a clamping
ring (3). The inner ends of the spring packs (1) reach into the axial grooves of the inner star
(9). The chambers (A, B), which are formed by the intermediate pieces (2) and the spring
packs (1), are filled with oil. If torque is applied to the damper, the outer part (1, 2, 3, 5, 7)
and the inner part (9) of the damper will be twisted against each other. The spring blades
(1) will be deflected during this process. This changes the volume of the oil in chambers A
and B. The oil will be displaced from one chamber into the adjoining one through a narrow
gap. The resultant oil flow resistance delays the relative movement of both parts of the
damper (outer and inner) and dampens the torsional vibrations.

The main bolts (750) connect the middle piece of the damper (1, 2, 3) to the flange (5) and
the side plate (7) by means of friction locking. The two plates (5,7) of the outer part of the
damper and the seals fitted in these hold the oil in the damper so that the required
working pressure can be built up. See Figure 5.1

3
5 7

750

2
A, B Oil chambers

Figure 5.1
6 TRANSPORT AND LIFTING INSTRUCTIONS

Improper transport and lifting of the product may cause it to

fall.

The product may only be lifted and handled by personnel who

have the required licence to
WARNING!
¾ work with cranes
¾ drive industrial trucks

and are also familiar with transport and lifting instructions in

¾ the operating instructions

¾ and the assembly drawing

Supports must always be provided for overhanging

components. Failure to follow these instructions may result in
serious personal injury, property damage or both.

6.1 Transport instructions

¾ Only transport the product with the transport lock (if present) mounted
¾ Only move the product in a horizontal position.
¾ Do not tilt the shipping crate or pallet.
¾ Avoid hard impacts during transportation.
¾ Max. lifting speed 50 m/min.
¾ Do not damage the packaging and preserving agents.
6.2 Lifting tackle

Lifting tackle can break or otherwise fail when lifting the

product, particularly when it is attached to an engine, causing
it to fall.

ONLY USE HIGH-STRENGTH LIFTING TACKLE for lifting.

WARNING!
The nominal carrying capacity of a SINGLE lifting device must
be greater than the total weight of the product or the
component to be carried!

Failure to do so can result in serious personal injury, damage

to the product or both.

LIFTING TACKLE SUPPLIED WITH THE ORDER

These are loadable from all sides and to be mounted and used in accordance with the
instructions in:

x the lifting tackle manufacturer's operating instructions

x the assembly drawing
x and the lifting examples (see Figure 6.4).

LIFTING TACKLE PROVIDED BY THE CUSTOMER

(Lifting tackle not in the scope of delivery)

Geislinger takes no warranty on lifting tackles provided by

the customer.

Lifting tackle can break or otherwise fail when lifting the

product, particularly when it is attached to an engine, causing
WARNING! it to fall.

ONLY HIGH-STRENGTH LIFTING TACKLE is permitted to lift the

product.

The nominal carrying capacity of a SINGLE lifting device must

be greater than the total weight of the product or the
component to be carried!

Failure to do so can result in serious personal injury, damage

to the product or both.
In addition, the following regulations must be observed:

¾ It is only permissible to use lifting tackle approved in the country where it will be
used.
¾ The lifting tackle must comply with the all applicable national and international
safety specifications.
¾ The lifting tackle must not be damaged or corroded.
¾ The lifting tackle must be 100% crack-tested.
¾ The lifting tackle must be completely screwed in the tapped lifting holes on the
product.
¾ The tapped lifting holes on the product must not be damaged during the screwing.
¾ The lifting tackle must be mounted and used in accordance with the instructions in:

x the lifting tackle manufacturer's operating instructions

x the assembly drawing
x and the lifting examples (see Figure 6.4)

For all lifting tackle: Check the lifting tackle is tight before
lifting!

If the lifting tackle is not tightened correctly the product may

WARNING! fall causing serious personal injury, property damage or both.
6.3 Tapped holes for lifting purposes

On the assembly drawing these are indicated with this symbol.

The product should only be lifted using the tapped holes

marked in this way for lifting. Lifting the product without
using the tapped holes may cause the product to fall causing
serious personal injury, property damage or both.
WARNING!

CHECKING THE TAPPED LIFTING HOLES BEFORE ASSEMBLING THE LIFTING TACKLE

Before assembling the lifting tackle check the applicable tapped lifting hole to make sure
that it is suitable to use.

The tapped lifting hole cannot be used if

¾ the thread is damaged, chipped, crossed or distorted

¾ the thread is corroded
¾ if there are signs of reworking such as Helicoil screw
WARNING! thread inserts

If the lifting tackle is used with any of these conditions

present the lifting tackle may fail and the product may fall
causing serious personal injury, property damage or both.

MULTI-PURPOSE TAPPED HOLES

These are tapped holes for screws used for tapped lifting holes and for other purposes.
Use:

¾ Remove bolt from multi-purpose tapped hole

¾ Fit lifting tackle as specified on the assembly drawing in appendix
¾ After the lifting operation has been completed, remove the lifting tackle and
complying with the
x tightening torque
x sealing specifications
x and safety measures
refit bolt as given on the assembly drawing in appendix.
6.4 Lifting instructions

Only lift the product

¾ Using the lifting tackle provided. See Chapter “Lifting tackle”

¾ With suitable carrying straps such as ropes, chains or belts.
¾ After lifting tackle and carrying straps have been fitted in accordance with the
regulations. See Chapter “Lifting tackle”
¾ Using the tapped lifting holes indicated on the assembly drawing. See Chapter
“Tapped holes for lifting purposes”
¾ Attached to at least two lifting points simultaneously.
¾ With the load distributed as equally as possible.

Never lift the product using only one connection point for the
lifting tackle. Using only one connection point can result in
the product breaking loose and falling resulting in property
damage.
CAUTION!

Lifting examples

>30°
max. 30°

Figure 6.4 Emaximum = 45°

STANDING UNDER A SUSPENDED LOAD IS PROHIBITED!

A suspended load may suddenly break loose and fall resulting

WARNING! in serious personal injury, property damage or both.
7 PACKAGING AND STORAGE

STANDARD PACKAGING

The product parts are sealed in polythene film and all metal parts are protected against
corrosion. They are packed in crates made of soft wood or are placed on wooden pallets.
NOTE: Special packaging can also be used for the products in line with the
customer's requirements.

If the packaging is damaged, the product must be

¾ installed in the system within 100 hours

or
¾ the preservatives must be reapplied and the packaging
CAUTION! restored to its original condition.

Failure to do so reduce the service life of the product.

DISPOSAL OF STANDARD PACKAGING

The PE film can be recycled.

NOTE: Contact Geislinger or a Geislinger service location to request for data sheets
on packaging/special packaging. Contact data can be found on
www.geislinger.com.

STORAGE INSTRUCTIONS

x Do not damage the packaging and preserving agents. See “CAUTION” above.
x Do not stack the products or place heavy parts on top of them.
x Store the product in dry conditions: max. permissible relative humidity 85%.
x Avoid variations in temperature of more than 25° Celsius.
x Make sure that the permissible temperature range for seals is adhered to during
storage. See chapter “Operating conditions” for permissible temperature range for
O-rings and seals.

If the temperature rises above or falls below the permissible

temperature range for seals during storage, it may damage
the seals and then subsequently reduce the service life of the
product.
CAUTION!
8 UNPACKING

General

The product, product components and connecting parts may be delivered separately or
packed individually. Each package may contain separately packed tools or small
components (e.g. screws, sealing rings, lifting tackle, etc.). Do not throw these away with
the packaging.

¾ Take the product out of the wooden crate.

¾ Remove the packing film and rust-inhibiting paper (if provided) from the product.
Check the product for possible damage that may have occurred during
transportation.
¾ Fit the lifting tackle (730) (if supplied), as appropriate. Clean the surfaces
underneath prior to mounting.
¾ First bring the product into an upright position.

Before installation, the product may become unbalanced and

fall or roll over. Secure the product to prevent it from moving.
If the product falls or rolls over, it may cause serious personal
injury, damage to the product or both.
WARNING!

NOTE: Bolts which are indicated with this symbol are only hand
tightened by Geislinger or delivered in loose condition. Bolts finally tightened by
customer according to the “Mounting instructions for bolts” given on the
assembly drawing.
9 DAMPER INSTALLATION INSTRUCTIONS

GENERAL

See Chapter “Operating conditions” for information on requirements for problem-free

operation of the damper and information on the permissible operating position of the
damper.

PREPARATION

The damper must be fully assembled.

Check the oil feed and return bores marked in the assembly drawing to make sure that
they are clean and oil can flow through. Remove any masking tape.

Remove the rust inhibitor (e.g. Anticorit) from all flange-mounting surfaces and centring
shoulders.

Do not scratch or damage the surfaces during cleaning.

Scratched or damaged surfaces may result that the damper

does not operate properly and subsequently reduce the
CAUTION! service life.

O-rings on the flanges (for oil supply and venting) must be well greased and undamaged.
INSTALLATION

Install the damper in the system in accordance with the

¾ installation instructions in the assembly drawing and the

¾ safety regulations and transport and lifting instructions contained in Chapters

“Safety instructions” and “Transport and lifting instructions” of this manual.

Do not damage the centring shoulders, seals and sealing

surfaces during the mounting operation.

Damaged centring shoulders, seals and sealing surfaces may

result that the damper does not operate properly and
CAUTION! subsequently reduce the service life.

CHECKS AFTER INSTALLATION

Remove lifting tackle and ancillary installation tools (if

present) from the damper and keep them for use later.

Failure to do so, it may cause serious personal injury, damage

WARNING! to the damper or both.
10 STARTING UP THE DAMPER

INSPECTION BEFORE STARTING UP (If possible)

Supply oil to the damper with the pre-lubrication pump until oil escapes from the oil
circulation bores. (Visual inspection)
See the assembly drawing for the position and number of oil circulation bores.

If no oil escapes from one or several oil circulation bores,

follow the troubleshooting procedures indicated in Chapter
“Repair Information”.

Failure to do so may result that the damper does not operate

CAUTION! properly and subsequently reduce the service life.

An additional thread for connecting a pressure gauge is provided on the majority of

dampers at flange (5) or side plate (7). As a result, the oil pressure in the damper can also
be measured when the engine is not running by connecting a pressure gauge.
11 REMOVING THE PRODUCT

PRODUCT MAY BE HOT! RISK OF BURNING!

Do not switch on the pre-lubrication pump for the engine

when the product is being dismantled! (Danger: sprayed oil!)

Allow the product to cool off to room temperature before

WARNING!
removing it.

¾ Use a suitable container for hot oil to catch the oil remaining in the product.
Dispose of the oil in accordance with state and local regulations where the product
is serviced.
¾ Remove the product from the system, following the “Safety instructions” (see
Chapter 2) as well as “The transport and lifting instructions” (see Chapter 6)
indicated in the operating instructions and the assembly drawing.
¾ Loosen fastening screws (but do not remove).
¾ Attach the lifting device to the product and secure the product with the crane. (*)
¾ Remove the fastening screws.
¾ Fit the ejector screws in the jack threads of the product inner star (9) and push the
product off the crankshaft slowly, exerting even pressure.

*… If it is not possible to mount the lifting devices immediately, mount auxiliary steel rods
to pull out the product from the engine until the lifting devices can be mounted (mount
auxiliary steel rods -> remove fastening screws -> pull out product -> mount lifting devices)

Do not damage the centring shoulders, seals and sealing

surfaces during removal.

Damaged centring shoulders, seals and sealing surfaces may

result that the product does not operate properly and
CAUTION! subsequently reduce the lifetime.

¾ Place the product on the flange plate (5).

The product may become unbalanced and fall or roll over.

Secure the product to prevent it from moving. If the product
falls or rolls over, it may cause serious personal injury,
damage to the product or both.
WARNING!
12 DISMANTLING AND ASSEMBLING THE PRODUCT

¾ Position product on the flange (5)

¾ Contact Geislinger or a Geislinger service location for a service date. See list
www.geislinger.com or appendix.

Do not loosen the main bolts (750) of the product, because

thereby the concentricity setting of the outer part will be lost.

Disassembly of the product requires the use of special

apparatus and the associated knowledge. A further
CAUTION! disassembly and assembly is permitted only by Geislinger or a
Geislinger service location. See list www.geislinger.com or
appendix.

Failure to do so may result that the product does not operate

properly and subsequently reduce the service life.
13 SERVICING
The damper is to be given a comprehensive service in accordance with the stated servicing
frequencies and servicing instructions.

SERVICING INTERVALS AND INSTRUCTIONS

Intervals in hours worked during normal operation

SPEED RANGE OF THE DAMPER

300 – 999 rpm ≥ 1000 rpm
SERVICE TIME SERVICE TIME
SMALL LARGE SMALL LARGE
all all all all
WORK TO BE PERFORMED
15-18,000 30-36,000 10-12,000 20-24,000
Remove the damper from the system X X X X
* Separate the inner part of the damper
from the outer part. Don´t dismantle the X X
damper middle piece 1,2,3.
* Separate the inner part of the damper
from the outer part. Dismantle the damper X X
middle piece 1,2,3.
* Clean all parts, especially the oil supply
X X X X
and oil circulation bores with acetone.
* Replace all rubber seals that can be
X X X X
accessed #
* Replace disc springs and/or lock washers X X X X
* Replace all removed bolts, screws and nuts
X X X X
with thread size up to and including M20
* Check all removed bolts, screws and nuts
X X X X
with thread size larger than M20.
* Check permissible wear. Repair worn parts
X X X X
or replace them, if necessary
* Service or replace all spring packs (1). If
X X
wear is over the limit.
* Service or replace inner star (9). If wear is
X X
over the limit.
* Replace shim (703) (if present). X X
Dispose of worn parts. See Chapter
“Disposing of used parts” X X X X

*... The product may only be dismantled by Geislinger or a Geislinger service location. See list
www.geislinger.com or appendix.
#... NOTE: All rubber seals have to be replaced at least 6 years after the start of operation.
If permissible wear between servicing intervals has been
exceeded by more than 50%, subsequent servicing intervals
are to be shortened accordingly. For this, it is assumed that
wear is at a linear rate.
CAUTION! Servicing frequencies also depend on the specific conditions of
use in each case.

LUBRICATING OIL QUALITY

¾ The quality of the lubricating oil should be checked at regular intervals

If the quality of the lubricating oil does not match the

specification by the engine manufacturer or if it contains too
much water, it may damage the product.
CAUTION!
14 REPAIR INFORMATION

INSPECTED CONDITION CORRECTIVE MEASURE

No oil is escaping from the oil circulation Contact Geislinger or Geislinger service
bores when hydraulic oil is supplied by the location. See list www.geislinger.com or
pre-lubrication pump. appendix.
Seals “sweat” (oil loss less than 0.5 litre of oil
No effect on the function of the damper;
per day) during operation; no repair required.
Seals leaking (oil loss more than 0.5 litre of Damper within crankcase:
oil per day); No effect on the function of as long as
minimum required oil pressure is kept
within the damper
Damper outside crankcase:
Contact Geislinger or Geislinger service
location. See list www.geislinger.com or
appendix.
Traces of oil in a radial position on the flange Contact Geislinger or Geislinger service
or side plate; main bolts (750) leaking. location. See list www.geislinger.com or
appendix.
Bronze particles in oil detected No influence on the function of the
coupling; Bronze particles are generated
due to the wear of bronze shims (700) of
the spring packs (1).
If the quality of the oil does not match the Drain product completely (for products
specification by the engine manufacturer or without permanent oil flushing). Fill
higher water content in the engine oil than product with fresh oil and drain it again;
permitted by the engine manufacturer. repeat flushing process several times.
No damage to engine bearings.
If the quality of the oil does not match the Contact Geislinger or Geislinger service
specification by the engine manufacturer or location. See list www.geislinger.com or
higher water content in the engine oil than appendix.
permitted by the engine manufacturer.
Bearing positions in engine already damaged
as a result of this.

NOTE: If other damage or wear to the product is identified but not described in
this table, contact Geislinger or a Geislinger service location to identify the
appropriate corrective measure. See list www.geislinger.com or appendix.
15 OPERATING CONDITIONS

15.1 General

Everything specified in the operating instructions applies to standard applications. If in

doubt, discuss with Geislinger or Geislinger service location. See list www.geislinger.com
All values given for the damper's oil supply apply to immediately before the oil enters the
damper. (Connection of damper to the customer's unit.)

NOTE: If the operating conditions listed below do not appear in either the
assembly drawing or the operating instructions, please discuss with Geislinger.
See list www.geislinger.com

OPERATING POSITION OR ALIGNMENT OF THE DAMPER

The damper must be installed so that, in its normal operating position, the rotating shaft of
the damper is in a horizontal axis position.

Operation of the damper in a certain tilted position for a

longer period is not permissible. However, short-term
displacements (for example, when transporting by sea or on
account of the movement of a vehicle) are permissible.
CAUTION! Failure to do so may result that the damper does not operate
properly and subsequently reduce the service life.

15.2 Required oil pressure

The stated oil pressure (combined with the oil flow volume) is to be taken to be the
required oil pressure.
If no oil pressure (combined with the oil flow volume) is specified, the damper is to be
supplied with the required oil pressure of min. 2.5 bar gauge pressure (3.5 bar absolute).

If the specified oil pressure required is not obtained, please

contact Geislinger or a Geislinger service location. See list
www.geislinger.com
CAUTION! Failure to do so may affect the performance of the damper.
MAXIMUM PERMISSIBLE OIL PRESSURE

The maximum permissible oil supply pressure is 6 bar absolute. If the supply pressure is
higher than specified, please contact Geislinger. See list www.geislinger.com

OIL FLOW VOLUME

The specified oil flow volume refers to the required oil pressure.

NOTE: If the damper is supplied with oil at a higher pressure than the stated oil
pressure, the oil flow volume increases accordingly.

15.3 Required oil viscosity

The required value applies to the position of the damper oil inlet. For the value required,
see the assembly drawing (technical data field: Ѡo) or obtain it from Geislinger. If
Geislinger has not been provided with any data at the time of design, the calculation is
based on usual figures for the industry.

The permissible oil and ambient temperatures result from the oil viscosity, which was
defined when the product was designed. The limit values can be found in the relevant
assembly drawing or can be obtained from Geislinger. See list www.geislinger.com

If the oil viscosity falls below or raises above the required

value the correct function of the damper is endangered. It
may damage the damper and the system.
CAUTION!
15.4 Permissible temperature range for VITON-seals

Permissible temperature range at standstill,

transport and storage:

from (minimum) to (maximum)

- 20° C (- 4° F) + 120° C (+ 248° F)

Permissible temperature range before start-up and

during operation:

from (minimum) to (maximum)

- 10° C (+ 14° F) + 120° C (+ 248° F)

The exceeding respectively the dropping below of the

permissible temperature ranges may damage the seals and
then subsequently damage the product and the system.
CAUTION!
16 DISPOSING OF USED PARTS

After withdrawing the product from service or after replacing individual components:

x All metal parts can be recycled (scrap metal).

x Oil still in the product or remaining oil must be disposed of as used oil.

x All old seals (O-rings, etc.) must be disposed of as oily consumables (special waste).

NOTE: National and local regulations must always be observed when disposing of
the product or parts thereof.
17 ORDERING REPLACEMENT PARTS

Use only original Geislinger replacement parts.

Failure to do so may cause serious damage of the product and

void the warranty.
CAUTION!

Please provide the following information so that the product can be accurately identified if
enquiries are sent:

x Type designation of product (o See the stamped designation on the outer part or
type plate which is mounted on the product)

x Product serial number (o See type plate)

x Part number of the replacement part (o See assembly drawing/parts list)

x Quantity of the parts required

x Designation of the part

Example

Designation: C 80 / 17.5 / 62H / 10

Serial number: 10106273/2/10

Part number of the replacement part: 850

Quantity of the parts: 2

Designation of the part: O-ring

18 WARRANTY

See:

x Geislinger document GS 442 (AGB) (will be send by Geislinger on request)

x or customer-contract

x or order confirmation

19 APPENDIX

These operating instructions contain the following supplements:

x General assembly instructions for screws and screw/nut connection

x Installation declaration (inside European Union)

x Assembly drawing(s) with parts list

x List of Geislinger service locations

x Code book number coding (optional)

x Operating instructions for bought-in parts (optional)

20 GENERAL MOUNTING INSTRUCTION FOR BOLTS

NOTE: These instructions are intended to supplement the “Mounting instruction

for bolts” given on the assembly drawing.

20.1 Cleaning the threaded parts

Before handling the threaded parts using the assembly tools, the contact surfaces must be
cleaned carefully and thoroughly.

These include the contact surfaces:

x the bolts on the head contact surface and on the thread (see Figure 1.1)
x the nuts (if present) on both contact surfaces and on the thread (see Figure 1.2)
x both sides of the washers (see Figure 1.3)
x the threaded holes (if present) of the counter piece (see Figure 1.4)
x and the contact surfaces on the parts being connected (see Figure 1.5)

Figure 1.1 Figure 1.2 Figure 1.3

Figure 1.4 Figure 1.5

Oxide layers

If the contact surfaces have oxidised, first carefully remove the oxide layers mechanically,
for example using a wire brush.

Dirt and grease

After removing the oxide layers (if present), all contact surfaces must be cleaned and
degreased thoroughly. Isoparaffin or acetone can be used as agents for cleaning and
degreasing.

Do not touch decreased and cleaned contact surfaces

afterwards with bare hands especially if Loctite is be used for
the assembly. If there is new dirt or grease the relevant
contact surfaces must be cleaned again.
CAUTION!
Failure to do so may affect the performance of the product.
20.2 Use of auxiliary materials for assembly

For assembly, the contact surfaces and thread must be treated with seal agents and/or bolt
locking agents or with lubricants. Normally used as bolt locking agents or sealants are
Loctite products and engine oil or Molykote paste as lubricants. The precise types and
application of the auxiliary materials can be found on the relevant assembly drawing in the
table “Mounting instructions for bolts”.

Before applying the auxiliary materials, the contact surfaces

must be dried thoroughly!

Failure to do so may affect the performance of the product.

CAUTION!

20.2.1 Note on Loctite products

Loctite products must always be used within the processing time specified by Loctite. These
processing times can be found in the instructions for the used Loctite products. Do not
exceed the maximum processing times permitted! Try and keep the processing times as
short as possible.

Read first! Relevant Loctite manual!

20.2.2 Application on threaded parts

Before applying the auxiliary materials, the load-bearing thread length "X" (see figure 1.6)
must be calculated for the parts being connected together. This thread length must then
be wetted with the auxiliary material across the entire area. In terms of the quantity, use
only so much that only small quantities of excess auxiliary material overflow after assembly.
A test assembly is recommended to be able to estimate the amount required.

Figure 1.6
With sealing unions in particular, ensure that the threaded gap is completely filled with
sealant. For thread size M16 and over (see Figure 1.7), the threaded hole or the nut thread
must also be coated with the auxiliary material.

up to M14 over M16

X X X
X

+ or

X = load-bearing thread length

Figure 1.7

20.2.3 Application on washers

When using washers, apply to both the front and the back (see green triangles on figures
1.8). In terms of quantity, use only so much that the contact surface is completely covered
and only small quantities of excess auxiliary material overflow after assembly. A test
assembly is recommended to be able to estimate the amount required.

Example of a single-bolt connection

Example of a bolt/nut connection

Figures 1.8
20.3 Assembly

The bolts must be tightened according to the “Mounting instruction for bolts” given on
the assembly drawing.

20.3.1 Note on washers

Disc springs and sometimes wedge lock washers are normally only used as washers for bolt
locking. These must be assembled as follows (see figures 1.9 and 1.10.)

Disc spring usage Wedge lock washer usage

Figure 1.9 Figure 1.10

20.3.2 Tightening process

The bolts must be tightened crosswise, i.e. opposite pairs of bolts must be tightened
immediately after one another. The assembly must always be carried out according to the
same procedure, as described in the example below for a twelve-point division.

The torque values, the tightening of the bolt and the application area for the auxiliary
materials are described in the “Mounting instruction for bolts” on the assembly drawing.
TWELVE DIVISION EXAMPLE

¾ Mark bolts 1-4

¾ Pre-assemble bolts 1-4 without Loctite but apply grease on the threads (as
stated on the assembly drawing) to approx. 30% of the torque value given on the
assembly drawing and in the order given in figure 1.11.

Given torque values on assembly drawing:

Case A: Only tightening torque: Tighten the bolts 1-4 to approx. 30% of the given
tightening torque value.

Case B: Initial tightening torque + twist angle: Tighten the bolts 1-4 with the given
initial tightening torque plus approx. 30% of the given twist angle.

1
12 5
8 9

4 3

10 7
6 11
2

Figure 1.11

¾ Final assembly of bolts 5-12 according to the “Mounting instructions for bolts” on
the assembly drawing and in the order given in figure 1.12.

1
12
2 5
8 9

4 3

10
0 7
6 11
1
2
Figure 1.12
¾ Remove bolts 1-4
¾ Final assembly of bolts 1-4 according to the “Mounting instructions for bolts” on
the assembly drawing and in the order given in figure 1.13.

1
12 5
8 9

4 3

10 7
6 11
2
Figure 1.13

20.4 After assembly

Immediately after the bolt assembly is complete, the excess residue of the auxiliary
materials (especially Loctite residue) must be removed.

20.5 Re-use

If bolt connections secured or sealed using Loctite are unfastened, any old Loctite reside
remaining on the bolts must be completely removed mechanically, for example using a
wire brush. With threaded connections and internal threads (e.g. with nuts), old Loctite
residue must also be removed completely.

All washers from unfastened bolt connections must be

replaced by new washers.

Failure to do so may affect the performance of the product.

CAUTION!

Afterwards, all parts must be prepared for re-assembly (see chapter “General mounting
instruction for bolts”).
CONTACT INFORMATION

Headquarters & Affiliated Companies

Geislinger GmbH, Austria (Headquarters)

Hallwanger Landesstr.3 Tel.: +43/662/66999 0

5300 Hallwang/ Salzburg Fax: +43/662/66999 40
Austria E-mail: info@geislinger.com

Geislinger Corporation, USA

200 Geislinger Drive Tel.: +1/269/4417000

Att.: Mr. Michael Krenn Fax: +1/269/4417001
Battle Creek, MI 49037 E-mail: info@geislinger.us
U.S.A.

Geislinger K.K., Japan

6-8-3, Minatojima Chuo-ku Tel.: +81/78/302 8128

Att.: Mr. Yoshihide Yahata Mobile: +81/80/1503 8010
Kobe, 650-0045 Fax: +81/78/302 8129
Japan E-mail: info@geislinger.jp

Geislinger Ltd., Korea

56, MieumSandan1-ro Tel.: +82/51/970 2000

Gangseo-gu Mobile: +82/10/7567 6543
Att.: Mr. Donggun Byun Fax: +82/51/970 2092
E-mail: info@geislinger.co.kr
Busan, zip 618-260
Republic of Korea

Geislinger (Suzhou) Co., Ltd., China

No. 48 YangPu Road, SIP Tel.: +86/512/6283 7800

Att.: Mr. Ping Zhao Mobile: +86/ 137/ 719 107 57
Suzhou 215021 Fax: +86/512/6283 7900
P.R. China E-mail: info@geislinger.cn
Service Locations

Austria: Geislinger GmbH (Headquarters)

Hallwanger Landesstr.3 Tel.: +43/662/66999 942

Att.: Mr. Andreas Köfler Fax: +43/662/66999 47
5300 Hallwang/ Salzburg E-mail: info@geislinger.com
Austria

Brazil: Romaga Manutencao é Reparos de Motores Diesel Ltda.

Rua Pedro Alvez, Tel.: +55/21/2263 3115

18/20/22/22 fds 01 e 02 Fax: +55/21/2516 3815
Att.: Mr. Leandro Magalhães Mobile: +55/21/9624 9349
Santo Christo E-mail: romaga@romaga.com.br
20220-281 Rio de Janeiro
Brazil

China: Geislinger (Suzhou) Co., Ltd.

No. 48 YangPu Road, SIP Tel.: +86/512/6283 7800

Att.: Mr. Ping Zhao Mobile: +86/1377190757
Suzhou 215021 Fax: +86/512/6283 7900
P.R. China E-mail: info@geislinger.cn

Germany: Blohm + Voss Repair GmbH

Barthels + Lüders Tel.: +49/40/31188 126 (Barenschee)

Division of Blohm + Voss GmbH Tel.: +49/40/31188 712 (Möller)
Norderelbstr. 15 Mobile: +49/163/2592 139 (Barenschee)
Att.:Mr. Rico Barenschee Mobile: +49/172/2726 329 (Möller)
Att.:Mr. Andreas Möller Fax: +49/40/31188 155
20457 Hamburg E-mail: rico.barenschee@blohmvoss.com
Germany E-mail: andreas.moeller.tanas@blohmvoss.com

India: Lubricare Private Ltd.

Registered Office & Factory Tel.: +91/2113/203030

Gat No. 309B, Village Shivare Mobile: +91/955/2034600
Att.: Mr. Prashant Kirloskar E-mail: sales@lubricare.co.in
Tal. Bhor, District Pune – 412206
India

Japan: Geislinger K.K.

6-8-3, Minatojima Chuo-ku Tel.: +81/78/302 8128

Att.: Mr. Yoshihide Yahata Mobile: +81/80/1503 8010
Kobe, 650-0045 Fax: +81/78/302 8129
Japan E-mail: info@geislinger.jp
Korea: Geislinger Ltd.

56, MieumSandan1-ro Tel.: +82/51/970 2000

Gangseo-gu Mobile: +82/10/7567 6543
Att.: Mr. Donggun Byun Fax: +82/51/970 2092
Busan, zip 618-220 E-mail: info@geislinger.co.kr
Republic of Korea

Middle East and Africa: Khaire & Associates

A-1/18, Yashodhan Housing Society Mobile: +91/88883/02929

Chintamainager-II, Bibvewadi E-mail: shyamkhaire@gmail.com
Att.: Mr. Shyam R Khaire
Pune – 411037
India

Netherlands: ADS van Stigt

Avelingen-West 30 Tel.: +31/183/6500/00 or /41 (v.Beest)

Att.: Mr. Pim van Beest 0-24 h: +31/183650028
4202 MS Gorinchem +31/653151164
Netherlands Mobile: +31/651634808 (P. van Beest)
Fax: +31/183/650001
E-mail: info@vanstigt.com

Singapore: GCD Services Pte Ltd

5, Yishun Industrial Street 1 Mobile: +65/96663188

#1-11, North Spring Bizhub
Att.: Mr. Steve Ho W.K. steve.ho@gcd.com.sg
Singapore 768161 sales@gcd.com.sg
Republic of Singapore

UK: Techno Solutions

Techno Solutions Limited Tel.: +44/1252 781616

Unit 8,Manor Farm Business Centre, Mobile: +44/7885 330859
The Street,Tongham Fax: +44/1252 781919
Att: James Mist E-mail: sales@technosolutions.co.uk
Surrey,GU10 1DE
UK

USA, Canada, Central & South America: Geislinger Corporation

200 Geislinger Drive Tel.: +1/269/4417000

Att.: Mr. Michael Krenn Fax: +1/269/4417001
Battle Creek, MI 49037 E-mail: info@geislinger.us
USA
Geislinger Coupling

Geislinger Carbotorq® Geislinger Damper

Geislinger Monitoring

Geislinger Flexlink Geislinger Vdamp®

Geislinger Gesilco®

Geislinger GmbH, Hallwanger Landesstrasse 3, 5300 Hallwang/Salzburg, Austria, Tel. +43 662 669 99-0, Fax +43 662 669 99-40, info@geislinger.com
geislinger.com
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2.2 Turbocharger

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Operating Instructions
ST5 Exhaust Gas Turbocharger

OPERATING and
MOUNTING INSTRUCTIONS
for
EXHAUST GAS
TURBOCHARGER

ST5

Kompressorenbau Bannewitz GmbH

Windbergstraße 45
01728 Bannewitz
Federal Republic of Germany

Phone: +49 351 40 85 603 (Sales)

+49 351 40 85 669 (Service)
+49 172 35 16 045 (24-hour phone)
Fax: +49 351 40 85 648 (Service)

E-Mail: service-24/7@kbb-turbo.de
Website: www.kbb-turbo.de

(A list of service stations is provided in the appendix.)

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Issued: 04/2016 Scholze Checked: S. Käseberg Released: K. Buchmann

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Operating Instructions
ST5 Exhaust Gas Turbocharger

Name plate

Each exhaust gas turbocharger (TC) is characterized by specifying the type, the
specification number and the serial number. This can be taken from the name plate. The
name plate is affixed at the side of the bearing casing of the exhaust gas turbocharger.
For all spare part inquiries, requests and orders the:
· TC type (Type)
· Specification No. (Spec.)
· Serial No. (Serial)

must be specified. Only if these data are known, the request can be handled properly and
promptly.

Exclusion of warranty claims

Any damage which results from
· poor maintenance,
· improper handling and/or the disregard of the operating instructions in this
instruction manual,
· the attachment of additional parts to the exhaust-gas turbocharger by third party or,
· the usage of non-original spare parts is excluded from warranty and liability.

Furthermore, the warranty and liability is excluded in any kind of interventions by

unauthorized persons during the warranty period.
These include particularly:
· the disassembly of any exhaust-gas turbocharger components,
· repair and maintenance work which requires the disassembly of exhaust-gas
turbocharger components,
· the replacement of parts which requires the disassembly of exhaust-gas
turbocharger components.

Exceptions
Exceptions apply to the replacement / removal of the entire exhaust-gas turbocharger, the
speed sensor, silencer filter mats, the entire silencer and the exhaust-gas elbow.
The manufacturer of the exhaust-gas turbocharger may give its consent to other exceptions
on request but these are always subject to the written approval of Kompressorenbau
Bannewitz GmbH.
Authorised persons
Authorised persons are employees of Kompressorenbau Bannewitz GmbH as well as
employees of authorised service workshops (see Appendix / Chapter 9) who have been
trained by Kompressorenbau Bannewitz GmbH.

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Operating Instructions
ST5 Exhaust Gas Turbocharger Contents

Table of Contents
Chapter Title Page

1 TECHNICAL DATA .........................................................................................5

1.1 Operating data ...............................................................................................5

1.2 Alarm values ..................................................................................................6
1.3 Dimensions ....................................................................................................6
1.4 Test connections ...........................................................................................7
1.5 Weights of important components ...............................................................7
1.6 Vibrations .......................................................................................................8
2 SAFETY...........................................................................................................9

2.1 Built-in safety systems ..................................................................................9

2.2 Safety measures (to be taken by user) ........................................................9
2.3 Declaration of incorporation ....................................................................... 10
3 GENERAL INFORMATION ABOUT DANGER ............................................. 11

3.1 Danger zone ................................................................................................. 11

3.2 Operators and maintenance personnel ..................................................... 11
3.3 Installation of spare and wear parts ........................................................... 12
4 DESIGN ......................................................................................................... 13

4.1 Brief description .......................................................................................... 13

4.2 Construction ................................................................................................ 13
4.3 Function........................................................................................................ 13
4.4 Usage to the intended purpose .................................................................. 13
5 OPERATION ................................................................................................. 14

5.1 Commissioning ............................................................................................ 14

5.2 Starting-up.................................................................................................... 14
5.3 Stopping ....................................................................................................... 15
5.4 Failures ......................................................................................................... 15
5.5 Emergency operation of the exhaust gas turbocharger........................... 15
5.6 Measures for extended period without operation ..................................... 16
6 MAINTENANCE ............................................................................................ 17

6.1 General ......................................................................................................... 17

6.2 Maintenance work ........................................................................................ 17
6.3 Cleaning........................................................................................................ 18
6.4 Maintenance schedule................................................................................. 19
6.4.1 Maintenance for operation with Marine Diesel Oil (MDO) .............................. 19
6.4.2 Maintenance for operation with Heavy Fuel Oil (HFO) .................................. 20
6.5 Trouble-shooting table ................................................................................ 22

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Operating Instructions
Contents ST5 Exhaust Gas Turbocharger
7 DISASSEMBLY AND ASSEMBLY .............................................................. 23

7.1 Introduction ................................................................................................. 23

7.2 Checking the components ......................................................................... 23
7.3 Checking the clearances ............................................................................ 24
7.4 Work sheets................................................................................................. 26
7.4.1 Compressor washing .................................................................................... 26
7.4.2 Turbine washing............................................................................................ 27
7.4.3 Cleaning the silencer .................................................................................... 30
7.4.4 Shutting down the exhaust gas turbocharger ................................................ 31
7.4.5 Disassembly of the complete turbocharger ................................................... 32
7.4.6 Assembly of the complete turbocharger ........................................................ 33
7.4.7 Assembly and disassembly of the silencer or air-intake bend ....................... 34
7.4.8 Assembly and disassembly of the compressor casing .................................. 35
7.4.9 Disassembly and assembly of the cartridge .................................................. 36
7.4.10 Disassembly of the exhaust-gas elbow ......................................................... 37
8 SPARE PARTS AND TOOLS ...................................................................... 38

8.1 General......................................................................................................... 38
8.2 Spare parts .................................................................................................. 39
8.2.1 Exhaust gas turbocharger, complete (1000) ................................................. 39
8.2.2 Exhaust gas turbocharger, basic unit (1100)................................................. 40
8.2.3 Turbine casing complete ............................................................................... 41
8.2.4 Compressor casing complete........................................................................ 42
8.2.5 Gaskets and shims (9910) ............................................................................ 43
8.2.6 Connection elements (9921) ......................................................................... 44
8.2.7 Connection elements (9930) ......................................................................... 45
8.2.8 Connection elements (9931) ......................................................................... 46
8.3 Tools ............................................................................................................ 47
8.3.1 Tool Set (9700) ............................................................................................. 47
8.3.2 Optional tools ................................................................................................ 48
9 APPENDIX.................................................................................................... 49

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Operating Instructions
ST5 Exhaust Gas Turbocharger Chapter 1

1 TECHNICAL DATA

1.1 Operating data

Specification 750xxxx
see name
Max. speed plate
Max. exhaust gas temperature upstream of turbine

Lubricating oil
Types of lubricating oil: engine oil with a kinematic viscosity of 110 ... 140 mm²/s
at 40 °C, e.g. SAE30, SAE40
Nominal oil filter fineness upstream of TC max. 25 µm
Lubricating oil pressure upstream of TC 300 + 150 kPa
Admissible lubricating oil pressures for special operating states
at start-up min. 50 kPa
from start-up to idle running min. 50 kPa
at standstill (pre-lubrication or re-lubrication/standby mode) see diagram below
Lubricating oil temperature upstream of TC 40 ... 105 °C
Lubricating oil temperature downstream of TC max. 120 °C
Lubricating oil flow (60°C, 300kPa) max. 45 l/min
Sound pressure level (measured by the silencer/compressor 106 dB(A)
casing, at 1m distance, 92% of max. speed accordingly 100%
engine power)
Counter-pressure downstream of turbine max. 2.5 kPa(g)
Vacuum upstream of compressor max. 1.5 kPa(g)

p oil
(kPa)

t oil (oC)
Admissible lubricating oil pressure for continuous pre- and re-
lubrication (standby operation)

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Operating Instructions
Chapter 1 ST5 Exhaust Gas Turbocharger

1.2 Alarm values

Measurement Alarm value
TC speed 0.97 * n max
Exhaust gas temperature before turbine t max – 15K
Lubricating oil outlet temperature of TC < 120 °C
Lubricating oil pressure before TC > 125 kPa (1.25 bar)

If alarm values are adapted accordingly to the engine data, the values specified above
are not to be exceeded and/or be fallen below in the case of lubricating oil pressure!
The maximum speed and the maximum exhaust gas temperature before turbine are
indicated on the name plate and the test certificate!

1.3 Dimensions

F All dimensions are specified in mm!

Length max. 1320mm

Width (depend on the casing position) max. 610mm
Height (depend on the casing position) max. 690mm

Exhaust gas Inlet single-nozzle casing 1x Ø 153 mm

Inlet double-nozzle casing 2x Ø 100 mm
Inlet three-nozzle casing 3x Ø 85 mm
Outlet Ø 300 mm
Charge air Outlet Ø 175 mm
Cooling compressor * Inlet 2 x M18 x 1.5
Jet Assist * Inlet 2 x M33 x 2
Lubricating oil Inlet at bearing casing Ø 14.5 mm
Outlet at bearing casing Ø 45 mm
Compressor washing Air piping M18 x 1.5
Water piping M16 x 1.5
Turbine washing Water piping M18 x 1.5
Drainage Ø 75 mm

* It might vary depending on turbo specification

F The piping for the pipe connections listed is not included in the scope of supply of
Kompressorenbau Bannewitz GmbH.

Pipes have always to be laid free of stress.

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Operating Instructions
ST5 Exhaust Gas Turbocharger Chapter 1

1.4 Test connections

The turbocharger (TC) is equipped with the following test connections which can be used as
required.
· There are two threads each (M18x1.5) provided at the air intake bend, compressor
casing and turbine-inlet casing and at the exhaust-gas elbow for measuring the
temperature and pressure.
· For measuring the speed, the bearing casing can be equipped with a speed sensor.

1.5 Weights of important components

(The weights shown in this document vary according to the turbocharger variants and serve
as a reference for any installation tools that may be required. The given weights represent
maximum values.)
Designation Part No. Mass
Exhaust gas Turbocharger, complete * (1000) max. 384 kg
(=1100+9100+9010)
Exhaust gas turbocharger, basic unit (1100) max. 297 kg
Cartridge (1200) max. 88 kg
Turbine casing complete max. 91 kg
Turbine casing (5010) max. 71 kg
Insert, turbine casing (5020) max. 16 kg
Containment ring (5220) max. 3 kg
Compressor casing complete max. 79 kg
Compressor casing (6010) max. 57 kg
Insert, compressor casing (6040) max. 20 kg
Turbine nozzle ring (7010) max. 3 kg
Compressor diffuser (8010) max. 5 kg
Exhaust gas elbow (9100) max. 46 kg
Sealing device (9704) max. 26 kg
Silencer (9010) max. 40 kg
Air intake bend (9020) max. 18 kg
Air inlet flange (9025) max. 7 kg
Containment shield (5210) max. 22 kg

* Basic unit including silencer and exhaust-gas elbow (see name plate) without insulation.

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Operating Instructions
Chapter 1 ST5 Exhaust Gas Turbocharger

1.6 Vibrations

Maximum admissible vibration load at engine for 10 ... 250 Hz :

Admissible value at TC (at place LG) at silencer (at place SD)

Velocity V RMS (mm/s) max. 45 mm/s max. 71 mm/s
Amplitude S RMS mm max. 0,7 mm max. 1,1 mm
Acceleration a RMS (m/s²) max. 70 m/s² max. 111 m/s²

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Operating Instructions
ST5 Exhaust Gas Turbocharger Chapter 2

2 SAFETY
The exhaust gas turbocharger is an incomplete machine and has been designed on the
basis of the following standards and regulations:
1. Machinery directive 2006/42/EC
2. Risk assessment and evaluation for ISO 14121-1

2.1 Built-in safety systems

· A safety system for the turbocharger is not necessary as its design and connection
with the engine to which it is attached require an inherent safety.
· For general speed monitoring, i.e. without a turn-off function being included, the
turbocharger can be equipped with a tachometer.
Assembly and disassembly work must not be done during operation.
See chapters 7.4.1 and 7.4.2 for maintenance and cleaning jobs which may be done
while the engine is running.

2.2 Safety measures (to be taken by user)

· These operating instructions are part of the exhaust gas turbocharger and shall be
always accessible for the operators and maintenance personnel.
· The operating instructions should be read before commissioning the turbocharger.
Particular attention should be paid to directions and information relating to dangers.
The user is required:
· to make his operators and maintenance personnel familiar with safe working
methods
· to supervise the observance of the safety regulations.

The individual jobs in these instructions are described such that they can be understood by
skilled workers.
The necessary tools and testing/inspection means must be made available to these
workers.
The user must obtain permission to operate the unit from the local authorities and observe
the following:
1. labour safety
2. cleaning and maintenance of the machines
3. product disposal
4. environmental protection

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Operating Instructions
Chapter 2 ST5 Exhaust Gas Turbocharger

2.3 Declaration of incorporation

In accordance with Directive 2006/42/EC, Annex II, part 1, section B
Manufacturer: Kompressorenbau Bannewitz GmbH
Windbergstraße 45
01728 Bannewitz,
Federal Republic of Germany
Product: Exhaust turbocharger
Type, specification, serial no. see name plate
The head of the engineering department, Klaus Buchmann, Windbergstraße 45, 01728
Bannewitz, is authorized to compile all the special documents in accordance with Annex VII
B.
The exhaust turbocharger is defined as a partly completed machinery in accordance with
article 2g and intended to be assembled to a combustion engine only. The special technical
documents in accordance with Annex II B were compiled and in response to a reasonable
request of a national authority transmitted on an electronic base.
The exhaust turbocharger must not put into service until the final machinery into which is it
to be incorporated has been declared in conformity with the provisions of this Directive.
Ingolf Ulbricht
Corporate Quality

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Operating Instructions
ST5 Exhaust Gas Turbocharger Chapter 3

3 GENERAL INFORMATION ABOUT DANGER

3.1 Danger zone

The danger zone is defined by the engine as the turbocharger is an integral part of the
engine.

F During turbocharger operation, the user must keep the danger zone free of any
objects so to ensure unhindered access to the unit.

Ear muffs should be worn as the sound level is high.

Care should also be taken when approaching the hot casings.

· The exhaust gas turbocharger is mounted on the engine. It may not be interfered
with when the engine is running.
· Make sure the exhaust gas pipes at the turbine side cannot come loose during
operation since exhaust gas might escape at this point.
· As the exhaust gas turbocharger is an integral part of the engine, its operation is
described in connection with the engine. However, its maintenance is described
separately in the operating instructions.

3.2 Operators and maintenance personnel

Operators and maintenance personnel are persons who are responsible for transport,
installation, operation, maintenance, cleaning and troubleshooting.
Make sure to observe the following accident prevention regulations:
· winches, hoisting and drawing gear (BGV D 8)
· load take-up devices for hoisting operations (BGR 500 chapter 2.8)
If these regulations are not observed, your life and limb may be endangered!
1. The turbocharger may only be maintained by duly qualified and authorised persons.
2. In maintaining the turbocharger, the responsibilities shall be clearly defined and
must be adhered to so as to prevent confusing competences with respect to the
safety aspect.
3. The operating instructions shall be followed irrespective of what kind of work
(operation, maintenance, etc.) is concerned.
4. In order to ensure a long service life, the exhaust gas turbocharger has to be
operated in accordance with the technical specification.
5. Operators are not allowed to interfere with the unit in a way that would affect
machine safety.
6. It is also within the responsibility of the operator to see to it that no unauthorized
person works on the turbocharger.
7. The operator must inform the owner without delay of any safety-affecting changes to
the turbocharger.
8. The cleaning, maintenance described in these instructions are easy to understand
by persons skilled in mechanical, cleaning and maintenance work. The necessary
tools and testing/inspection means must be available to these persons.

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Operating Instructions
Chapter 3 ST5 Exhaust Gas Turbocharger
3.3 Installation of spare and wear parts
It is emphasised that spare parts and accessories not supplied by us are not
tested/inspected and approved by us. The installation and use of such products may
negatively affect the performance of your turbocharger. We assume no liability for damage
caused by the use of components and accessories not made by us.
For ordering spare parts and tools, please refer to the
· spare parts list
· tools list.

The spare parts lists attached (see chapter 8.2) contain all spare parts for the turbocharger.
For the maintenance and commissioning of the turbocharger, refer to the respective
chapters in these operating instructions.
Before doing any maintenance, cleaning or repair work, the engine must have come to
a standstill. Therefore turn the engine off and secure it against unintentional
restarting.
See chapters 7.4.1 and 7.4.2 for maintenance jobs which can be done during engine
operation.
Make sure to observe the following accident prevention regulations:
· winches, hoisting and drawing gear (BGV D 8)
· load take-up devices for hoisting operations (BGR 500 chapter 2.8).
If these regulations are not observed, your life and limb may be endangered!

F See the inspection schedule (see chapter 6.4) for the maintenance intervals.

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Operating Instructions
ST5 Exhaust Gas Turbocharger Chapter 4

4 DESIGN

4.1 Brief description

Exhaust gas turbocharger (TC): Type ST5
Specification number: 750xxxx
Mass : 384 kg

4.2 Construction
The exhaust gas turbocharger (TC) ST5 is equipped with a single-stage radial flow turbine
and a single-stage radial flow compressor.
The turbine wheel and the shaft consist of one part, the compressor impeller is mounted on
the shaft. The rotor has a bearing consisting of two plain bearings in a bearing casing. The
compressor casing and the turbine casing are flanged to the bearing casing. You can use a
silencer or alternatively an intake bend (intake elbow) at the entrance of the compressor
casing.
The plain bearings are lubricated by the lubricating oil system of the engine. The lubricating
oil flow depends on the oil temperature, oil pressure and TC speed.

4.3 Function
The rotor is driven by the exhaust-gas energy of the diesel engine. The exhaust gases
reach the turbine wheel via the turbine casing and the turbine nozzle ring.
The compressor impeller mounted on the same shaft takes in the required combustion air
via a silencer, compresses the air to a higher pressure and transports the compressed air to
the engine via a charge air cooler.
The TC is not equipped with a special control device. The TC speed is adjusted depending
on the operating conditions of the engine.

4.4 Usage to the intended purpose

The exhaust gas turbocharger is intended for supercharging combustion engines. Any other
usage is not permitted and has to be cleared up with Kompressorenbau Bannewitz GmbH
(KBB) in advance.
The TC specification attached to the engine is thermodynamically adjusted and is binding
for this engine variant, i.e. if the TC has to be replaced, use the same TC specification
again.
Modifications and additional attachments to the TC are subject to a written consent of
Kompressorenbau Bannewitz GmbH, non-observance of the aforementioned invalidates
any rights of warranty claim.
The usage to the intended purpose also includes that the specified maintenance and
inspection work is carried out regularly and to the full extent (see Chapter 6.4).

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Operating Instructions
Chapter 5 ST5 Exhaust Gas Turbocharger

5 OPERATION

5.1 Commissioning
Prior to commissioning, it is imperative to make sure that the plain bearings of the TC are
supplied with oil. The plain bearings are lubricated by the lubricating oil system of the
engine. The lubricating oil flow depends on the oil temperature, oil pressure and TC speed.
The lubricating oil pressures required for special operating conditions are listed in chapter
1.1.
Ensure and check the free return flow of the lubricating oil.
The following has to be checked :
· lubricating oil pressure upstream of TC,
· lubricating oil temperature upstream of TC.

Ensure the lubricating oil supply of the plain bearings (see chapter 1.1).
Lubrication has to be started prior to start-up processes.
Pay special attention to prevent leakages in the oil supply and return pipes to prevent
oil from flowing onto the hot, gas-carrying casings in order to prevent the formation of
hazardous oil vapours (and fire risk).

5.2 Starting-up
The exhaust gas turbocharger is driven by the exhaust gases of the engine and is started
together with the engine.
The TC speed is adjusted depending on the operating conditions of the engine. The charge
air pressure required for the engine is fixed by adjusting the turbine nozzle ring and the
compressor diffuser during the TC tuning.
If the corresponding meters are available, enter the following measured values into the
engine log during engine operation (at least once every 24 operating hours):
· Speed of exhaust gas turbocharger
· Exhaust gas temperature upstream of turbine or downstream of cylinder
· Charge air temperature downstream of compressor or downstream of charge air
cooler
· Charge air pressure downstream of compressor
· Lubricating oil temperature upstream of TC
· Lubricating oil pressure upstream of TC
The engine has to be stopped immediately when the oil pressure falls below the
minimum value.
Lubrication has to be started prior to start-up processes.
Pay special attention to prevent leakages in the oil supply and return pipes to prevent
oil from flowing onto the hot, gas-carrying casings in order to prevent the formation of
hazardous oil vapours (and fire risk).

Additionally perform the following checks at regular intervals :

· Tightness of the exhaust gas, charge air and oil piping
· Smooth running of the exhaust gas turbocharger

The charge air pressure is utilised as a parameter for the exhaust gas turbocharger speed.

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Operating Instructions
ST5 Exhaust Gas Turbocharger Chapter 5

Unsteady operation (vibration of TC) indicates an increased unbalance of rotating parts

possibly resulting in the rotor or bearing being damaged (see chapter 6.5).

5.3 Stopping
After the engine has been stopped, the exhaust gas turbocharger continues to run for some
time.
The run out period depends on the installation.
If the rotor comes to an immediate standstill, this can be caused by one of the following
reasons:
· damaged bearings
· compressor impeller or turbine blades come in contact with the casing as the
clearance is compensated due to extensive forces caused by thermal distortion
· clamped foreign matters

The turbocharger must be lubricated 15 minutes after the engine is turned off.

F The lubricating time is to be extended in case of engines with a turbine inlet

temperature >580°C (at full load) or oil inlet temperature >80°C.
Pay attention to the operating instructions of the engine manufacturer.

5.4 Failures
Failures can be detected by abnormal measured values (exhaust gas temperature, charge
air pressure, speed), heavy noise or leakages of pipes.
In case of irregularities on the TC, reduce the engine load or stop the engine.
Since even minor failures may cause heavy consequential damage, determine and
immediately eliminate the cause of failure (see chapter 6.5)

5.5 Emergency operation of the exhaust gas turbocharger

If the exhaust gas turbocharger has to be shut down due to a defect and the engine has to
run in emergency operating mode, perform the work according to chapter 7.4.4.
After shutting down the exhaust gas turbocharger, limit the engine output in order to
prevent the exhaust gas temperature from exceeding admissible values downstream
of the outlet cylinders.
Pay attention to the operating instructions of the engine manufacturer.

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Operating Instructions
Chapter 5 ST5 Exhaust Gas Turbocharger

5.6 Measures for extended period without operation

When shutting down an exhaust gas turbocharger, which was operated with an engine
before, for more than twelve month, it has to be dismounted from the engine.
An inspection should be carried by authorized service centres out in accordance with the
maintenance schedule in chapter 6.4.
It is necessary to completely dismantle the exhaust gas turbocharger. All components are to
be cleaned and slightly rubbed with oil. Then the exhaust gas turbocharger can be
reassembled. All machined surfaces and flanges are to be evenly coated with an
anticorrosive agent (such as Tectyl). All openings should be sealed. Additionally, a
hygroscopic drying agent can be put into the interior spaces of the compressor casing and
the turbine inlet.
The preserved exhaust gas turbochargers and spare parts should be kept in a dry room
(humidity of 60 % max.) and protected from moisture, aggressive gases and vapours. At
rest, the exhaust gas turbocharger should be protected against steady vibration which may
damage the bearings.
The state of the preserved parts and exhaust gas turbochargers should be checked every
twelve months.
Before re-operating the exhaust gas turbocharger, it is necessary to clean off the
anticorrosive agent.

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Operating Instructions
ST5 Exhaust Gas Turbocharger Chapter 6

6 MAINTENANCE

6.1 General
Maintenance and monitoring work is summarised in the maintenance schedule in chapter
6.4.
Proper maintenance work enables failures to be detected in time. Maintenance work also
indicates necessary overhauls as well as work to be scheduled during yard or harbour times
or on interruptions.
The operating hours specified in the maintenance schedule are to be considered as
benchmarks. They can be shortened according to existing operating conditions as well as
adjusted to the maintenance intervals of the engine.
It is important to eliminate even minor, apparently insignificant defects immediately and to
determine and eliminate their causes in order to prevent consequential damage at the
engine or exhaust gas turbocharger.
If the engine is not equipped with an automatic monitoring system with data recording,
entries into the engine log are required at least once every 24 operating hours. Thereby,
deviations can be detected in time.

6.2 Maintenance work

In order to keep the exhaust gas turbocharger in a safe condition, perform the inspection
and check of various subassemblies and components according to the maintenance
schedule in chapter 6.4.
The chapter 7.4 includes detailed instructions on the work sequence for assembly and
disassembly work., which may be carried out by the operator. Inspections may be
conducted only by KBB-authorized workshops.
Make sure to observe the following accident prevention regulations:
· winches, hoisting and drawing gear (BGV D 8)
· load take-up devices for hoisting operations (BGR 500 chapter 2.8).

F For a basic overhaul or repairs affecting essential parts of the exhaust gas
turbocharger, it is recommended to document their condition.

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Operating Instructions
Chapter 6 ST5 Exhaust Gas Turbocharger

6.3 Cleaning
Cleaning the silencer
· see chapter 7.4.3

Cleaning the compressor

Cleaning during operation:
· see chapter 7.4.1

Mechanical cleaning:
· Remove the compressor casing and silencer (see chapters 7.4.7 and 7.4.8). (The
compressor impeller remains on the shaft.)
· Remove all deposits with diesel fuel or another admissible liquid cleansing agent.

Make sure to observe the accident prevention regulations!

While washing, make sure to prevent the cleansing agent from entering the charge air
piping or the interior of the turbocharger.
The compressor impeller must not be cleaned with caustic liquids!

Cleaning the turbine

Cleaning the turbine must not affect the dimensions of the functional surfaces. The surfaces
must not be roughened. The blades must not be bent. The following cleaning methods are
allowed:
Cleaning during operation:
· see chapter 7.4.2 (for heavy fuel oil operation only)

Mechanical cleaning:
· Remove the compressor casing and silencer (see chapters 7.4.7 and 7.4.8). (The
compressor impeller remains on the shaft.) The cartridge must be removed from the
turbine casing. The turbine wheel, the turbine nozzle ring and the turbine casing
must be cleaned mechanically.
· Cleaning with an alkaline aqueous detergent solution and subsequent drying
· Cleaning with diesel oil (if lightly soiled)
· In case of heavily soiled, insert the components in diesel or an alkaline aqueous
detergent solution. The parts can be cleaned with a wire brush after that.

Take care not to remove the anti-wear layer from the blades (never use a hammer or
chisel).
Sandblasting is not permitted!
A crack test may show incorrect results after sandblasting!

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Operating Instructions
ST5 Exhaust Gas Turbocharger Chapter 6

6.4 Maintenance schedule

6.4.1 Maintenance for operation with Marine Diesel Oil (MDO)

F The operating hours given in the table are guidelines, which can be reduced for
adjustment to the maintenance intervals of the engine.

The inspections (I to III) must be performed only by authorized service centres!

Item Chapter Maintenance work Recommen- Maintenance interval

ded parts (operating hours)
1. Check for abnormal noise 24
2. 7.4.1 Compressor washing during 24 - 48
operation, actuate compressor
washing system
3. 7.4.3 Replace filter mat at silencer (9012) approx. 500
or on demand
4. Check fastening bolts at the feet, once after
tighten all casing bolts and piping commissioning, then
joints every 1,000 hours
5. Inspection I (9910) max. every 12,500
· disassembly (9921)
· cleaning (9931)
· checking of rotor & bearings
· checking of casings
· assembly
6. Inspection II (9910) max. every 25,000
· like inspection I (9921)
· replacement of the bearings (9931)
7. Inspection III (9910) max. every 50,000
· like inspection II (9921)
· replacement of the rotor (9931)

(9012) Filter mat (9910) Gaskets and shims

(9921) Connecting elements (9931) Connecting elements

F Bearings and rotor are made available by service centre and may be changed only by
these!

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Operating Instructions
Chapter 6 ST5 Exhaust Gas Turbocharger

6.4.2 Maintenance for operation with Heavy Fuel Oil (HFO)

F
The operating hours given in the table are guidelines, which can be reduced for
adjustment to the maintenance intervals of the engine.
The interval of the inspection “0” is depending on the fuel quality.

The inspections (I to III) must be performed only by authorized service centres!

Item Chapter Maintenance work Recommen- Maintenance interval

ded parts (operating hours)
1. Check for abnormal noise 24
2. 7.4.1 Compressor washing during 24 - 48
operation, actuate compressor
washing system
3. Turbine washing during Approx. 300,
operation, actuate turbine according to
7.4.2 washing system requirements
Cleaning with water depending on HFO
quality
4. 7.4.3 Replaced filter mat at silencer (9012) Approx. 500
or on demand
5. Check fastening bolts at the feet, once after
tighten all casing bolts and piping commissioning, then
joints every 1,000 hours
6. 7.4.9 Inspection 0 (9910) approx. every 6000
· disassembly cartridge (9921)
· turbine cleaning (9931)
· assembly
7. Inspection I (9910) max. every 12,500
· disassembly (9921)
· cleaning (9931)
· checking rotor and bearings
· checking casing
· assembly
8. Inspection II (9910) max. every 25,000
· like inspection I (9921)
· replacement of bearings (9931)
9. Inspection III (9910) max. every 50,000
· like inspection II (9921)
· replacement of the rotor (9931)

(9012) Filter mat (9910) Gaskets and shims

(9921) Connecting elements (9931) Connecting elements

F Bearings and rotor are made available by service centre and may be changed only by
these!

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Operating Instructions
ST5 Exhaust Gas Turbocharger Chapter 6

The nozzle ring is subject to an increased wear for heavy fuel oil operation. Therefore it
is a wear part.
The lifetime of the nozzle ring is at least 12,500 hours, but it depends on HFO quality
and operating conditions.
The nozzle ring has to be replaced with appropriate wear and fundamental change of
performance data (as charge air pressure and exhaust temperature).

F However, other factors can also be responsible for a change in the exhaust gas
temperature and charge air pressure!

Irrespective of the foregoing, the exhaust gas temperature limit values (after the cylinder)
specified by the engine manufacturer may not be exceeded.
Wear mostly affects the guide blades and can progress as follows:

“Further use possible Replace

Wear pattern 1 Wear pattern 2 Wear pattern 1

Original
state

Wear pattern 1
· The guide blades display a slot alongside one of the disks.
· The nozzle ring further use possible if the slot length is < 25 mm and the slot width <
6 mm.
Under the above-mentioned conditions the nozzle ring is not considered to be worn to such
an extent that it needs replacement and can thus continue to be used.

Wear pattern 2
· The guide blades display slots alongside both disks.
· The nozzle ring further use possible if the slot length is < 25 mm and the slot width <
4 mm.
Under the above-mentioned conditions the nozzle ring is not considered to be worn to such
an extent that it needs replacement and can thus continue to be used.

Wear pattern 3
· The guide blades show deep slots alongside both disks and the outlet edge of more
than two of the guide blades is completely worn.
The nozzle ring must be replaced.

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Operating Instructions
Chapter 6 ST5 Exhaust Gas Turbocharger

6.5 Trouble-shooting table

Charge air pressure and/or speed too high

Charge air pressure and/or speed too low
Temp. upstream of turbine too high

Lubricating oil pressure too low

Delayed start, short coasting
Fault

Lubricating oil leakage

Turbocharger vibrates
Turbocharger pumps
Heavy noise
Causes Chapter
Silencer or air filter contaminated 7.4.3
Compressor contaminated 7.4.8
Charge air cooler contaminated Engine
Leaking exhaust gas piping Engine
Exhaust gas counter pressure too high
Engine
downstream of turbine
Turbine wheel or compressor impeller Service
damaged (unbalanced) centre
Service
Defective bearing
centre
Service
Rotor in contact with casing
centre
Foreign matter in turbine or compressor Service
(unbalanced) centre
Turbine contaminated 7.4.2
Turbine nozzle ring contaminated 7.4.2
Failure of fuel injection at engine Engine
Leaking charge air piping Engine
High air intake temperature Engine
Inlet or outlet valves of the engine
Engine
contaminated
Low air intake temperature Engine
Lubricating oil filter contaminated Engine
Lubricating oil pressure gauge defective Engine
Lubricating oil inlet temperature too high Engine
Excessive pressure in oil return Engine
Service
Sealing air ineffective
centre
Gaskets damaged, connections leaking Engine
Service
Plain compression rings damaged
centre

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Operating Instructions
ST5 Exhaust Gas Turbocharger Chapter 7

7 DISASSEMBLY AND ASSEMBLY

7.1 Introduction
The chapter 7.4 shall enable the user to perform simple maintenance work by himself.
It is assumed that the staff is familiar with the work and that the tools required are ready at
hand. Furthermore, the exhaust gas turbocharger has to be accessible and corresponding
hoists have to be available.
Make sure to observe the following accident prevention regulations:
· winches, hoisting and drawing gear (BGV D 8)
· load take-up devices for hoisting operations (BGR 500 chapter 2.8).

7.2 Checking the components

The check list shown below can be used as instruction for checking the condition of the
exhaust gas turbocharger and its major components. Damage effecting rigidity, balance and
smooth running of rotating components should be eliminated by the manufacturer or an
authorized workshop. If damaged parts are returned for repair, ensure an appropriate
protection against transportation damage.
After having disassembled the casings, perform the following checks at the cleaned parts.

Rotor, complete
· Are contact traces visible at the casing?
· Are contact traces visible at the rotor?
If re-working is performed or if rotor parts are replaced, rebalancing at KBB
authorized service stations (see appendix "list of service stations") has to be
executed!

Compressor impeller/Turbine wheel

· Can you detect any sliding traces or cracks at the compressor impeller?

Compressor diffusor/Turbine nozzle ring

· Are the guide vanes twisted or worn out?
· Is foreign matter clamped into the ducts?
· Can you detect traces of foreign matter?

Casing
· Are the casings heavily contaminated by oil, dust or soot?
· Is there any leakage at the casing? (Main items: connection flanges, charge air,
exhaust gas and oil connections)
· Are all bolts and nuts tight?

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Operating Instructions
Chapter 7 ST5 Exhaust Gas Turbocharger

7.3 Checking the clearances

The clearances have to be observed to ensure a safe turbocharger operation and achieve
the required efficiency.
The clearances have to be checked if:
· parts have been replaced (turbine casing or turbine casing insert, compressor or
compressor casing insert ,cartridge),
· the engine or turbocharger operating parameters deviate from the norm
· there are score marks on rotor parts or casings
· during overhauls and inspections
· heavy contamination

Checking the clearances:

· Radial clearance S1 (compressor) and S12 (turbine)
· Axial bearing clearance S15

clearance new limit

S1 0.7±0.05 1.0
S12 0.65±0.05 0.95
+0.14
S15 0.21 -

S1 and S12:
The clearance S1 is determined simultaneously at the opposite positions C1 and C2
(horizontal and vertical) between the compressor impeller and the compressor casing insert
using two feeler gauges (measuring range 0.05 to 0.1mm).
The clearance S12 is determined simultaneously at the opposite positions T1 and T2
(horizontal and vertical) between the turbine wheel and the turbine casing insert using two
feeler gauges (measuring range 0.05 to 0.1mm).

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Operating Instructions
ST5 Exhaust Gas Turbocharger Chapter 7

S15:
The clearance S15 is determined on the compressor side of the rotor end. Push the rotor
towards the turbine side and set the dial gauge (measuring range 0 to 1mm, precision min.
±0.001) to "0". Pull the rotor to the compressor side and read out the clearance S15 from
the dial gauge.

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Operating Instructions
Chapter 7 ST5 Exhaust Gas Turbocharger

7.4 Work sheets

7.4.1 Compressor washing
(Every 24 - 48 operating hours)
Legend
1. Ball valve
2. Water tank
3. Water piping
4. Air piping

Work sequence:
1. Operate the engine at 50 - 85 % of nominal output.
2. Open the water tank (2), fill with clean water (no sea water and no additives)
(approx. 0,5 l), close the water tank.
3. Open the ball valve (1), wait for approx. 20 sec., close valve (1). The compressed air
flows through the air piping (4) via the ball valve (1) into the water tank. The water is
pressed through the water piping (3) into the injection pipe, atomised by the air
taken in and hits the compressor blades at high speed.

Perform cleaning only with warm engine at 50 - 85 % of nominal output.

If compressor surging occurs during or after water injection then the engine output
needs to be reduced further.
Continue to operate the engine for at least 10 to 15 min. after cleaning.
Do not wash before a pause of operation. Corrosion risk!
Washing is ineffective in case of hardened deposits, thus perform washing at regular
intervals.
Do not use any chemical additives!

F
If the negative pressure upstream of the compressor is too high, water is already
taken in when the water is filled into the water tank and the cleaning effect is reduced.
In order to avoid this, you can:
· install the water tank at a lower level
(min. 1000 mm below the turbocharger center)
or
· include a second stop valve, which is opened after the water tank has been
closed, into the water piping.

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Operating Instructions
ST5 Exhaust Gas Turbocharger Chapter 7

7.4.2 Turbine washing

(For heavy fuel oil operation only, every 300 operating hours respective depending on HFO
quality)
Heavy fuel oil operation results in contamination and deposits on nozzle ring and

F turbine wheel reducing the efficiency. Due to these deposits the charge air pressure
will be increased.
The washing intervals depend on the fuel quality and operating conditions. That's why
they must be adjusted based on the experience gained during engine operation if
necessary later on.
The increase of charge air pressure by for e.g. more than 0.1 bar (at same engine
power) could be used for adjusting the washing interval.
The recommended washing interval is approx. 300 hours, depending on HFO quality it
could be adjusted within 25 to 600 hours.
Read and take down the charge air pressure and exhaust gas temperatures at a
reference point (at 75 % or 100 % of the output) before and after washing to check the
washing effect.
Hot exhaust gas can escape from the drain - Risk of burning!
Continue to operate the engine for at least 60 minutes after water injection. Do not
wash before a stop of operation. Corrosion risk!
Washing is ineffective in case of hardened deposits, thus perform washing at regular
intervals from the beginning.
In the case of ineffective washing the turbine is to be cleaned mechanically. For this
purpose the turbine casings are to be dismantled.
Pay attention also to instruction of the engine’s operating manual!

Legend
1 Sanitary fresh water 5 3-way valve 9 Valve (optional)
2 Regulating valve 6 Wash-water piping 10 Escape funnel or sight
glass (optional)
3 Fresh-water piping 7 Injector 11 Manometer
4 Removable flexible tube 8 Connection for drain 12 Sealing air (charge air /
(optional) optional)
5010 Turbine casing 9100 Exhaust gas elbow

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Operating Instructions
Chapter 7 ST5 Exhaust Gas Turbocharger

Turbine washing is possible by 2 different procedures as following:

· Interval washing at reduced engine output
· 10 min turbine washing at engine idle

7.4.2.1 Interval washing

Work sequence:

1. Check the injection nozzle/valve (7) for obstruction!

2. Connect the removable flexible tube (4) to the fresh water piping (3).
3. Reduce the engine output until the temperature before the turbine drops to its
specified value (see Table).
4. Wait for approx. 10 minutes!
5. Open valve (9) (if available) for drainage (8).
6. Open valve (2) and set the water pressure (see Table).
7. Open 3-way valve (5) for approx. 30 seconds, if necessary readjust water pressure
by means of valve (2).
8. Close 3-way valve (5).
9. Wait approx. 3 minutes to allow the injected water to evaporate.
10. Repeat steps 7 and 9 twice or three times.
11. Close valve (2) and valve (9) for drainage!
12. Run dry the exhaust-gas turbocharger for approx. 10 minutes and at the same time
increase engine load slowly!
13. Repeat the washing if previously absent vibrations occur at the exhaust-gas
turbocharger.
14. Remove the flexible tube (4).

The effect of the turbine washing could be controlled by changing of charge air

F pressure and exhaust temperature!

Water pressure and washing period could be increased for improvement of washing
effect, if necessary!

Operating values for turbine washing

Exhaust-gas temperature Water pressure Total

before turbine (gauge) washing time
350 – 430 °C 2.5 – 4.5 bar 3-4 x 30 sec

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Operating Instructions
ST5 Exhaust Gas Turbocharger Chapter 7

7.4.2.2 Turbine washing at engine idle

Turbine washing at engine idle is allowed only if a drain is connected!

Drain must be opened, otherwise risk of flooding of turbine!

Work sequence:

1. Check injection nozzle/ valve (7) for free passage!

2. Connect the flexible tube (4) to fresh-water piping (3).
3. Reduce the engine output (see table), run engine at idle.

F Warm up the engine if turbine washing is done after engine start!

4. Wait for approx. 10 minutes!

5. Open the valve (9) of the drain (8).
6. Open 3-way valve (5).
7. Open valve (2) and adjust the water pressure (see table).
8. Check water outlet at the drain.
9. Close the 3-way valve (5) after at least 10 minutes.
10. Close the valve (2) and the valve (9) of the drain.
11. Run dry the exhaust gas turbocharger for approx. 10 minutes and at the same time
increase engine load slowly!
12. Repeat the washing process if the exhaust gas turbocharger is affected by
vibrations which did not occur before.
13. Remove the flexible tube (4).

F
The exhaust temperature before turbine could increase during washing procedure,
but should not exceed max. 350 °C!
The effect of the turbine washing could be controlled by changing of charge air
pressure and exhaust temperature!
Water pressure and washing period could be increased for improvement of washing
effect, if necessary!

Operating values for turbine washing

Engine output Exhaust gas temperature Water pressure Total

before turbine (gauge) washing period

< 10% Max. 350 °C 2.5 – 4.5 bar Min. 10 min

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Operating Instructions
Chapter 7 ST5 Exhaust Gas Turbocharger
7.4.3 Cleaning the silencer

(Every 500 operating hours) Related chapter 7.4.7

General
In most cases merely the filter mat has to be replace. For this purpose the silencer may stay
at the exhaust gas turbocharger.
The given maintenance interval of 500 operating hours is just a mean guide value, since the
accumulation of dirt in the filter mat and the pressure drop resulting there from are largely
dependent on the environment. For operation under extreme conditions, it is recommended
to add a maintenance indicator (water gauge) signalling the right moment for cleaning. This
indicator shall be adjusted so as to give the cleaning signal when a vacuum of app. 100 mm
w.g. is reached at point A intended for mounting (e.g. a MANN maintenance indicator for air
filters, max. 200 mm w.g. = 20 mbar).
Work sequence: Replacing the filter mat
1. Open and remove the tension tapes (9014)
2. Pull the filter mat (9012) from the silencer (9010) .
3. Install the new filter mat (9012) and tension tapes (9014).

Work sequence: Cleaning the silencer

F If the silencer is heavily contaminated or if an inspection is carried out, the silencer

has to be cleaned completely..

1. Dismount the silencer (9010) (see chapter 7.4.7).

2. Clean with a soft brush and let dry.
3. Install the silencer (9010).

To operate the exhaust gas turbocharger without a filter mat is not permitted!
Pay attention to applicable accident prevention regulations (handling of hazardous,
volatile, combustible solvents) and fire protection regulations (DIN 14096). Cleaning
by P3-solution or trichlorethylene is prohibited. If other solvents are used, check the
compatibility with the filter material. In case of ship operation pay attention to the
regulations of the classification societies with regard to washing liquids.

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Operating Instructions
ST5 Exhaust Gas Turbocharger Chapter 7

7.4.4 Shutting down the exhaust gas turbocharger

F
In case of a TC damage especially at the rotor or bearing, it is recommended to shut
down the TC in order to avoid any further damage.
Pay attention to the operating instructions of the engine manufacturer.

When the engine is operated with a defective exhaust gas turbocharger, limit the
engine output in order to prevent the exhaust gas temperature from exceeding
admissible values downstream of the cylinder.

Related chapters
7.5.7, 7.5.9, 7.5.10

Initial condition: The turbocharger is mounted on the engine.

Mass of the silencer approx. 40 kg
Mass of the air intake bend approx. 18 kg
Mass of the compressor casing, compl. approx. 79 kg
Mass of the cartridge (bearing casing with rotor) approx. 88 kg
Mass of the sealing device (9704) approx. 26 kg

Work sequence:
1. Disassemble the silencer (9010) / air intake bend (9020) (see chapter 7.4.7).
2. Loosen all piping at the compressor casing (6010).
3. Disassemble the compressor casing (6010) (see chapter 7.4.8).
4. Remove the cartridge (1200) (bearing casing with rotor) and turbine nozzle ring (7010)
from the turbine casing (5010) (see chapter 7.4.9).

Use a hoist!

F Caution in removing the cartridge in order to avoid damage to the turbine blades.

5. Attach the sealing device (9704) to the turbine casing (5010) and tight with washers
(5100) and hexagon nuts (5090).
6. Screw the sealing device (9704) to the engine console.

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Operating Instructions
Chapter 7 ST5 Exhaust Gas Turbocharger
7.4.5 Disassembly of the complete turbocharger

Mass of complete TC is approx. 384 kg

Make sure to observe the following accident prevention regulations:
· winches, hoisting and drawing gear (BGV D 8)
· load take-up devices for hoisting operations (BGR 500 chapter 2.8)
Pay attention to piping and sheathings!

Work sequence :
1. Remove the sheathings from the turbine casing and loosen the exhaust gas piping if
necessary.
2. Loosen the exhaust gas piping from the turbine casings. Pay attention to gaskets!
3. Loosen the piping at the compressor casing (6010), remove them if necessary.
4. Attach the exhaust gas turbocharger to a hoist. For this purpose
a) Screw the eye screw (3015) into the cartridge (1200) or
b) Put two ropes around the flange between the silencer and the compressor casing
and between the turbine casing and the exhaust-gas elbow.
5. Loosen and remove the foot screws (A) at the sides of the cartridge (1200).
6. Lift and carefully place the exhaust-gas turbocharger on a wooden base, secure
against tilting.
7. Cover the openings of the lubricating oil pipes in the engine console in order to
prevent dirt from entering the lubricating oil system.

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Operating Instructions
ST5 Exhaust Gas Turbocharger Chapter 7

7.4.6 Assembly of the complete turbocharger

Mass of complete TC is approx. 384 kg

Work sequence :
1. Attach the complete TC to a hoist (see chapter 7.4.5) and put it onto the engine
console. Pay attention to the pipe connections!
2. Screw in and tighten the foot screws (A) at the sides of the cartridge (1200).
3. Connect the exhaust gas piping to the turbine casings.
4. Attach the sheathing.
5. Connect the charge air piping.
6. Connect the water and air piping for compressor washing.
7. Tighten the bolts at the connecting pipes.
8. Supply lubricating oil to TC and check all flanged connections for leakages.

After having installed the TC, check that the assembly is free of stresses and forces.
Rework piping, if necessary.

Only use perfect gaskets for the pipe joints. Apply molybdenum sulphide lubricant to

F the connecting bolts of the exhaust gas piping prior to installation.

Replace the O-rings and sealings!
Use the assembly protecting sheet (9712) to protect the O-rings when mounting the
exhaust gas turbocharger on the engine bracket!

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Operating Instructions
Chapter 7 ST5 Exhaust Gas Turbocharger
7.4.7 Assembly and disassembly of the silencer or air-intake bend

Mass of the silencer approx. 40 kg

Mass of the air-intake bend approx. 18 kg
Tightening moment of V-band 35 Nm !

Legend
6010 Compressor casing
6020 V-band, compressor
6190 Hexagon socket screw
9010 Silencer
9020 Air intake bend

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Operating Instructions
ST5 Exhaust Gas Turbocharger Chapter 7

7.4.8 Assembly and disassembly of the compressor casing

Sealing air line go through

Mass of cartridge (bearing casing with rotor) approx. 88 kg.

Mass of compressor casing approx. 79 kg.
Make sure not to damage the compressor impeller during assembly and disassembly
of the compressor casing.

F Replace the O-ring (6030) each assembly and disassembly!

Assembly the shims (8011-8015) that the sealing air line is free!

Legend
1200 Cartridge
5010 Turbine casing
6010 Compressor casing
6030 O-ring, compressor casing
6040 Insert, compressor casing
6041 O-ring
6090 O-ring
6130 Retaining plate
6131 Cylindrical screw
6132 Locking plate
6140 Clamping flange
6150 Stud bolt
6160 Hexagon nut
6170 Washer
8010 Diffuser
8011-8015 Shim
8040 Cylindrical screw

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Operating Instructions
Chapter 7 ST5 Exhaust Gas Turbocharger
7.4.9 Disassembly and assembly of the cartridge

Mass of cartridge (bearing casing and rotor) approx. 88 kg.

Mass of the turbine casing approx. 91 kg.
Caution in disassembling and assembling in order to avoid damage to the turbine
blades.
Use the force screw (9707) to push the cartridge (1200) out of the turbine casing. Use
Diesel oil or rust remover if the connection seized!
Caution in disassembling the turbine casing in order to prevent the turbine nozzle ring
from falling out!
Tightening moment of foot screws (A) 376 Nm
The turbine nozzle ring (7010) fits positively in only one position. If necessary rotate

F the turbine nozzle ring (7010).

Replace O-rings (console) by assembly!
O-Rings are included in the scope of delivery of the engine manufacturer!
Use assembly protecting sheet (9712) to protect the O-rings!
Legend
1200 Cartridge
3015 Eye bolt
5010 Turbine casing
5080 Nut
5100 Ribbed washer
5130 Stud bolt
5140 Hexagon bolt
7010 Nozzle ring
7020 Locating bolts
7040 Metal seal
9707 Force screw
9712 Assembly protecting sheet
A foot screw

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Operating Instructions
ST5 Exhaust Gas Turbocharger Chapter 7

7.4.10 Disassembly of the exhaust-gas elbow

Mass of the exhaust-gas elbow 46 kg

Mass of the turbine casing insert 16 kg
Mass of the Containment ring 3 kg

Legend
5010 Turbine casing
5020 Insert, turbine casing
5090 Nut
5101 Ribbed washer
5220 Containment ring
9100 Exhaust gas elbow

The turbine casing insert (5020) and containment ring (5220) could be fall out if the
exhaust gas elbow (9100) is disassembled!
During transport save the insert turbine casing (5020) with two nuts!

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Operating Instructions
Chapter 8 ST5 Exhaust Gas Turbocharger

8 SPARE PARTS AND TOOLS

8.1 General
The following details are required for an order:
4. Address of orderer
5. Type of turbocharger
6. Serial number of turbocharger (see name plate on page 2)
7. Specification number of turbocharger (see name plate on page 2)
8. Part number, designation and quantity
9. Shipment address

The spare parts box supplied by order contains a selection of the most important wear parts
and a relevant listing.

F The parts contained in the spare parts box are preserved for a storage period of two
years.

A certain selection of tools is also supplied if ordered. These tools are necessary to quickly
restore the operability of the engine after a TC damage by replacing the cartridge and are
not included in the basic equipment of every workshop.

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Operating Instructions
ST5 Exhaust Gas Turbocharger Chapter 8

8.2 Spare parts

8.2.1 Exhaust gas turbocharger, complete (1000)

Part No. Quantity Designation Remarks

1200 1 Cartridge
3140 2 Screw plug
3150 2 Gasket
5010 1 Turbine casing
5210 1 Containment shield
6010 1 Compressor casing
6020 1 V-band
6190 2 Hexagon socket screw
9010 * Silencer
9012 1 Filter mat optional with silencer
9014 2 Tension tape optional with silencer
9020 * Air intake bend
9025 * Air inlet flange
9030 2 Screw plug optional with air intake bend
9040 2 Gasket optional with air intake bend
9050 1 Screw plug
9055 1 Screw plug
9060 1 Gasket
9065 1 Gasket
9070 1 Screw plug
9080 1 Gasket
9100 1 Exhaust gas elbow
9101 3 Flange
9102 12 Hexagon screw
9103 12 Ripped washer
9104 3 Gasket
9110 1 Speed sensor optional, or screw plug (3140) with gasket
(3150)
9120 1 O-Ring only for gas engines
* optional, depending on TC specification

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Operating Instructions
Chapter 8 ST5 Exhaust Gas Turbocharger
8.2.2 Exhaust gas turbocharger, basic unit (1100)

Part No. Quantity Designation Remarks

1200 1 Cartridge
5010 1 Turbine casing
5080 24 Hexagon nut
5100 24 Ripped washer
5130 24 Stud bolt
5140 4 Hexagon-head bolt
5141 4 Gasket
6010 1 Compressor casing
6010 1 Compressor casing
6030 1 O-Ring, compressor casing
6140 8 Clamping flange
6150 24 Stud bolt
6160 24 Hexagon nut
6170 24 Ripped washer
7010 1 Turbine nozzle ring
7020 3 Locating bolt
7040 1 Metal seal
8010 1 Compressor diffuser
8011 *
to Shim *according clearance setting
8015 *
8040 3 Hexagon socket screw

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Operating Instructions
ST5 Exhaust Gas Turbocharger Chapter 8

8.2.3 Turbine casing complete

Part No. Quantity Designation Remarks

5010 1 Turbine casing
5020 1 Insert, turbine casing
5050 3 Screw plug per gas inlet
5060 3 Gasket per gas inlet
5071 2 Stud bolt
5072 2 Locking washer
5080 24 Hexagon nut
5090 12 Hexagon nut
5100 24 Ripped washer
5101 12 Ripped washer
5110 * Stud bolt *number depends on the TC specification
5120 * Stud bolt optional for motor mounting
*number depends on the TC specification
5130 24 Stud bolt
5210 1 Containment shield
5220 1 Containment ring
5230 * Hexagon-head bolt *number depends on the TC specification
5240 * Hexagon-head bolt *number depends on the TC specification
5250 * Ripped washer *number depends on the TC specification

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Operating Instructions
Chapter 8 ST5 Exhaust Gas Turbocharger
8.2.4 Compressor casing complete

Part No. Quantity Designation Remarks

6010 1 Compressor casing
6040 1 Insert, compressor casing
6041 2 O-Ring, compressor casing insert
6050 2 Screw plug
6060 2 Gasket
6090 1 O-Ring, compressor casing insert
6110 2 Screw plug optional: connection for jet assist
6120 2 Gasket optional: connection for jet assist
6130 3 Retaining plate
6131 6 Hexagon socket screw
6132 6 Ripped washer
6140 8 Clamping flange
6150 24 Stud bolt
6160 24 Hexagon nut
6170 24 Ripped washer

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Operating Instructions
ST5 Exhaust Gas Turbocharger Chapter 8

8.2.5 Gaskets and shims (9910)

Part No. Quantity Designation Remarks

9911 1 Gaskets
9912 1 Shims

8.2.5.1 Gaskets (9911)

Part No. Quantity Designation Remarks

2070 1 Compression ring
2090 1 Compression ring
3051 1 O-Ring
6030 1 O-Ring, compressor casing
6041 2 O-Ring, compressor casing insert
6090 1 O-Ring, compressor casing insert
7030 1 Sealing cord
9104 3 Gasket

8.2.5.2 Shims (9912)

Part No. Quantity Designation Remarks

3071 2 Shim (0.1)
3072 2 Shim (0.15)
3081 1 Gasket, bearing cover (0.1)
3082 1 Gasket, bearing cover (0.15)
3083 1 Gasket, bearing cover (0.2)
3084 1 Gasket, bearing cover (0.3)
3085 1 Gasket, bearing cover (0.5)
8011 1 Shim (0.1)
8012 1 Shim (0.15)
8013 1 Shim (0.2)
8014 1 Shim (0.3)
8015 1 Shim (0.5)

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Operating Instructions
Chapter 8 ST5 Exhaust Gas Turbocharger
8.2.6 Connection elements (9921)

F Set (9921) contains all connection elements of compressor side.

Part No. Quantity Designation Remarks

3012 2 Screw plug
3014 2 Gasket
3015 1 Eye bolt
3140 2 Screw plug
3150 2 Gasket
6050 2 Screw plug
6060 2 Gasket
6110 2 Screw plug
6120 2 Gasket
6130 3 Retaining plate
6131 6 Hexagon socket screw
6132 6 Washer
6150 24 Stud bolt
6160 24 Hexagon nut
6170 24 Washer
6190 2 Hexagon socket screw
8040 3 Hexagon socket screw
9030 2 Screw plug
9040 2 Gasket
9070 1 Screw plug
9080 1 Gasket

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Operating Instructions
ST5 Exhaust Gas Turbocharger Chapter 8

8.2.7 Connection elements (9930)

F Set (9930) contains all connection elements of turbine side.

Part No. Quantity Designation Remarks

5050 6 Screw plug per gas inlet
5060 6 Gasket per gas inlet
5071 2 Stud bolt
5072 2 Locking washer
5090 12 Nut
5101 12 Washer
5110 12 Stud bolt
5120 4 Stud bolt optional for motor mounting
5230 8 Hexagon head screw for containment
5240 9 Hexagon head screw for containment
5250 9 Washer for containment
9050 1 Screw plug
9055 1 Screw plug
9055 1 Screw plug
9060 1 Gasket
9065 1 Gasket
9065 1 Gasket
9102 12 Hexagon head screw
9103 12 Washer
9220 20 Hexagon head screw
9221 20 Washer
9931 1 Connection elements

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Operating Instructions
Chapter 8 ST5 Exhaust Gas Turbocharger

8.2.8 Connection elements (9931)

F Set (9931) contains all connection elements for turbine side to replace the
cartridge and is contained in set (9930).

Part No. Quantity Designation Remarks

5080 24 Nut
5100 24 Washer
5130 24 Stud bolt
5140 4 Hexagonal head screw
5141 4 Gasket
7020 3 Locating bolt
9222 22 Hexagonal head screw for sheeting
9223 22 Washer for sheeting

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Operating Instructions
ST5 Exhaust Gas Turbocharger Chapter 8

8.3 Tools

F Tools are an option and therefore should be purchased separately by an official order
from customer.

8.3.1 Tool Set (9700)

F (9700) contains tool for replacement of cartridge.

Part No. Quantity Designation Remarks

9707 4 forcing screw for turbine casing
9711 1 mandrel for locating bolt
9712 1 assembly protecting sheet protected the o-rings on engine console
9714 1 crowfoot wrench for speed sensor
9716 1 extension for 9714
9765 2 hexagonal head screw for air intake bend and exhaust gas
elbow
9782 2 eye bolt for compressor- and turbine casing
9784 1 eye bolt for cartridge
9793 2 eye nut for air intake bend and exhaust gas
elbow
9855 1 mounting sleeve for locking washer 5072

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Operating Instructions
Chapter 8 ST5 Exhaust Gas Turbocharger

8.3.2 Optional tools

Part No. Quantity Designation Remarks

9704 1 Sealing device stoppage of the exhaust gas turbocharger
9722 1 Rack for cartridge (1200)

9722

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Operating Instructions
ST5 Exhaust Gas Turbocharger Chapter 9

9 APPENDIX
Overview Service Stations

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Operating Instructions
Chapter 9 ST5 Exhaust Gas Turbocharger

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Service Stations

Overview Service Stations

Please visit www.kbb-turbo.de for updates.

Argentina Guatemala Norway

Australia Hungary Pakistan
Bangladesh Iceland Poland
Brazil India Russia
Canada Indonesia Singapore
Chile Italy South Africa
China Japan Spain
Denmark Korea Turkey
Ecuador Namibia UAE
Germany Netherlands UK
Greece New Zealand USA

rd
KBB_ServiceStations_en_May2016 page 1 of 10 3 edition (05/2016)

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Service Stations

Argentina
Turbogen de Pascual Mario Ruffa
Lugones 1851 / 55
1430 Buenos Aires
Phone: +54 11 4521 5667/ 1914
Fax: +54 11 4521 8283
Mobile: +54 911 4440 7867
E-mail: turbogenruffa@arnetbiz.com.ar
www.turbogen.com

Australia
MTQ Engine Systems (Aust) Pty Ltd.
1018 - 1022 Canley Vale Road
Laverton
Wetherill Park NSW 2164
Phone: +61 2 8788 2555
Fax: +61 2 8788 2520
Mobile: +61 488 238 393
E-mail: steve.d@mtqes.com.au
www.mtqes.com.au

Bangladesh
Dalwin Marine Bangladesh Ltd.
Fouzderhat Station
CDA Road Bhatiary
Sitakund, Chittagong, 4315
Phone: +880 3 12780222
Fax: +880 3 12780200
Mobile: +880 18193 18410
E-mail: info.bd@dalwin.com
www.dalwin.com

Brazil
American Turbo I.C. Ltda.
Rua Gibraltar Nº 280
Sao Paulo – SP (04755-070)
Phone: +55 11 5641 3600
Fax: +55 11 5641 5550
E-mail: kbb@americanturbo.com.br

Canada
Allied Marine & Industrial Inc.
118 West Street, Port Colborne
Ontario, L3K 4C9
Phone: +1 905 834 8275
Fax: +1 905 834 5645
E-mail: sales@allmind.com
www.allmind.com

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Service Stations

Dynamic Engineering Inc.

1270 Frances Street
Vancouver, B.C. V6A 1Z5
Phone: +1 604 253 4427
Fax: +1 604 253 3553
E-mail: turbo@dynamicengineering.com
www.dynamicengineering.com

Chile
Maestranza Diesel Ltda.
Santa Elena 1433
Santiago
Phone: +56 2 5502000
Fax: +56 2 5550938
E-mail: susconsultas@md.cl
www.md.cl

China
Tru-Marine Machinery
Engineering Shanghai Co., Ltd.
No. 318 Cheng Yin Road
Baoshan Urban Industrial Park
Baoshan, Shanghai 200444
Phone: +86 21 65204 220
Fax: +86 21 6520 6639
E-mail: turbo@trumarineshanghai.cn
www.trumarine.com

Tru-Marine Cosco (Tianjin) Engineering Co., Ltd.

No. 26 Lu Shan Road
Tgeda Tanggu
Tianjin P.C. 300451
Phone: +86 22 2521 2086
Fax: +86 22 2521 2300
E-mail: turbo@trumarinetianjin.cn
www.trumarine.com

Tru-Marine Machinery Engineering Guangzhou Co. Ltd.

No. 1168 Kangnan Road
Yunpu Industrial Park
Huangpu District, Guangzhou
P.R. China, P.C. 510760
Phone: +86 20 8222 7678
Fax: +86 20 8222 7578
E-mail: turbo@trumarineguangzhou.cn

Kemklen Technical Services Ltd.

Shop No. 8, G/F., Block B, Vigor Industrial Bldg.,
14-20 Cheung Tat Road, Tsing Yi, N.T. Hong Kong.
Phone: +852 2861 2812
Fax: +852 2861 1168
E-mail: service@turbokts.com
www.turbokts.com

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Service Stations

K&C Global Ltd.

Block M, Yiu Lian Dockyards
No 1-7, Sai Tso Wan Road
Tsing Yi Island, New Territories
Hong Kong
24 Hours: +852 9449 4281
Phone: +852 2435 7880
Fax: +852 2432 1001
E-mail: service@kc-global.com
www.kc-global.com

Denmark
PJ Diesel Engineering A/S
Skudehavnsvej 14
DK-2150 Nordhavn Copenhagen
Phone: +45 3929 1553
Fax: +45 3927 1054
E-mail: sales@pjdiesel.dk
www.pjdiesel.com

Ecuador
Turbomotores Ecuatorianos S.A.
Grupo TME
Av. Maldonado 10324 – Quito
Phone: +593 2 267 5605
Fax: +593 2 268 2097
E-mail: turbokralj@grupotme.com
www.grupotme.com

Germany
Barthels & Lüders a Division of Blohm + Voss GmbH
Norderelbstraße 15
20457 Hamburg
Phone: +49 40 311 88 126
Fax: +49 40 311 88 155
E-mail: service@barthels-lueders.com
www.barthels-lueders.com

Scan Turbo Handels- und Service GmbH

Kleiner Westring 15
27568 Bremerhaven
Phone: +49 471 969 165 0
Fax: +49 471 969 165 20
E-mail: info@scan-turbo.com
www.scan-turbo.com

Turbinen & Motoren – Service GmbH

Kleiner Westring 7
27572 Bremerhaven
Phone: +49 471 97 202 0
Fax: +49 471 97 202 39
E-mail: info@turbinen-motoren.de
www.turbinen-motoren.de

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Service Stations

Treckel Schiffsservice GmbH & Co. KG

Reusenweg 1
18069 Rostock
Phone: +49 381 20260 – 420
Fax: +49 381 20260 – 423
E-mail: mail@treckel.com

Greece
Turbomed Yiannis Paraskevopoulos S.A.
Schisto Industrial Park (VIPAS), Block 2 Str. 1 & 2
18863 Perama, Piraeus
Phone: +30 210 4000111
Fax: +30 210 4000225
Helpline: +30 6932210060
E-mail: turbomed@otenet.gr
www.turbomed.gr

Guatemala
Elliott Turbocharger Guatemala, S.A.
4 Av. 4-44 Z.8 San Cristobal, Sector A-5
Mixco
Phone: +502 2427 9696
Fax: +502 2427 9608
E-mail: ventas@elliott-guatemala.com
www.elliott-guatemala.com

Hungary
Ferryker Turbo Kft.
Janos Apostol u. 186799 hrsz.
1239 Budapest
Phone: +361 2870 256
Fax: +361 2870 514
E-mail: ferrykerturbo@t-online.hu
www.ferrykerturbo.hu

Iceland
Framtak Blossi EHF
Dvergshöfda 27
110 Reykjavik
Phone: +354 535 5850
Fax: +354 535 5851
E-mail: elli@blossi.is
www.blossi.is

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Service Stations

India
Dalwin Marine Turbo Engg Pvt Ltd.
R-307, Rabale
TTC Industrial Area
Navi Mumbai, Maharashtra
India – 400701
Phone: +91-22-27602239
Fax: +91-22-27602931
E-mail: power@dalwin.com
www.dalwin.com

Dalwin Marine Turbo Engg Pvt Ltd.

Plot-50A, AIE
Pedagantyada Road No. 10
Visakhapatnam, Andhra Pradesh
India – 530044
Phone: +91-891-2707053
Fax: +91-891-2707053
Mobile: +91 932 4265196
E-mail: power@dalwin.com
www.dalwin.com

Indonesia
PT. Trimanunggal Perkasindo
Bizpark Commercial Estate Block A7#21.
Jalan Raya Bekasi Km.21.5, Jakarta 13920.
Phone: +62 21 2936 8722
Fax: +62 21 2936 8724
E-mail: tpturbo@cbn.net.id

Italy
La Meccanica Turbo Diesel srl
Calata Gadda
Ship repair area
16128 Genova Porto
Phone: +39 010 246 7499
Fax: +39 010 246 1144
E-mail: mtd@mtd.it
www.mtd.it

Japan
Kobayashi Industries, Ltd.
1025-176, Hamano-Cho, Chuo-Ku,
Chiba 260 0824
Phone: +81 43 208 0511
Fax: +81 43 208 1511
E-mail: kobayashi-ind@kbysh-ind.co.jp

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Service Stations

Sanyo Marine Industry Co., Ltd.

Nishinakamachi 2-44
Hyogo-ku, Kobe
652-0835
Phone: +81 78 681 3491
Fax: +81 78 681 0780
E-mail: sanyomrn@ac.auone-net.jp

Korea
Jonghap Maritime Inc.
27, Haeyang-ro 23 beon-gil,
Yeongdo-gu, Busan (zip code: 606-822)
Phone: +82 51 413 4277 (24hrs on duty)
Fax: +82 51 413 7442
E-mail: infoturbo@jonghap.co.kr
www.jonghap.co.kr

Namibia
Namib Diesel CC
28, 2nd Street East
P.O. Box 2449
Walvis Bay
Phone: +264 64 203971
Fax: +264 64 203255
Mobile: +264 81 1283987
E-mail: info@namibdiesel.com.na
www.namibdiesel.com.na

Netherlands
Tru-Marine Rotterdam
Nieuwe Waterwegstraat 17
3115 HE Schiedam
Phone: +31 10 426 7383
Fax: +31 10 473 3050
E-mail: turbo@trumarine.nl
www.trumarine.com

New Zealand
NZ Marine Turbochargers Ltd.
136 Vanguard Street
Nelson
Phone: +64 3 546 6188
Fax: +64 3 548 0974
E-mail: service@turbocharger.co.nz
www.turbocharger.co.nz
Further branch in Auckland

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Service Stations

Norway
Frydenbo Industri AS, avd. Ost
Lurudveien 5
2020 Skedsmokorset
Phone: +47 6387 1635
Fax: +47 6387 1667
E-mail: post.fino@frydenbo.no
www.frydenbo-industri.no
For emergency 24/7
Phone: +47 913 90 916

Pakistan
Orient Energy Systems (Private) Ltd.
Plot No 09
Sector 24
Korangi Industrial Area
Karachi
Phone: +92 21 111507 507
Fax: +92 21 3507 2095
E-mail: nouman.siddiqui@orient-power.com
www.orient-power.com

Poland
Cassiopeia Ltd.
5A, Uczniowska Str.
70-893 Szczecin, Poland
Phone: +48 504 926 696
Fax: +48 91 469 3064
E-mail: marketing@cassiopeia-service.com
www.cassiopeia-service.com

Russia
Baltic Turbo Ltd.
Serdobolskaya str. 7, office 412
197343, St. Petersburg
Phone: +7 812 4960512
Fax: +7 812 4960540
E-mail: info@balticturbo.ru
www.balticturbo.ru

Singapore
Tru-Marine Pte Ltd.
35 Tuas Basin Link
Singapore 638769
Phone: +65 6861 8398
Fax: +65 6861 8396
E-mail: turbo@trumarine.com
www.trumarine.com

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Service Stations

South Africa
Majestic Engineering cc t/a Turbocharger Services
48 Karim Lane, Rossburgh
4094 Durban
Phone: +27 31 459 0749
Fax: +27 31 459 0748
E-Mail: turbocharger@telkomsa.net

Sturrock Grindrod Marine Tech

8 Ludel Park, Koeberg Road, Montaque Gardens,
7441 Cape Town
PO Box 349, Paarden Eiland,
7420 Cape Town
Phone: +27 21 831 7600
Fax: +27 21 511 1770
E-Mail: Fransvdm@sturrockgrindrod.com
www.sturrockgrindrod.com

Spain
Turbo 10, S.L.
Muelle de Reparaciones de Bouzas, s/n
36208 – Vigo
Phone: +34 986 213669
Fax: +34 986 214077
E-mail: info@turbovigo10.com

Turbo Cadiz S.L.

Poligono Industrial PELAGATOS
C/ Del Progreso 17A – 20A
11130 – Chiclana de la Frontera – Cadiz
Phone: +34 956 407 949 / 950
Fax: +34 956 407 951
E-mail: tc@turbocadiz.com
www.turbocadiz.com

Turbo Cadiz S.L. - Las Palmas

Puerto de Las Palmas
Av Pantalan de Cory - Esq. Compañia Navegacion Paquet
35008 – Las Palmas de Gran Canaria
E-mail: tc@turbocadiz.com
www.turbocadiz.com

Turkey
Istanbul Marine Turbine Service Ind. & Trd. Co. Ltd.
Istanbul Deri Organize Sanayi Sitesi
1. Yol X5-A Parsel Aydinli-Orhanli Mevkii
34953 Tuzla / Istanbul
Phone: +90 216 394 04 73
Fax: +90 216 394 04 75
E-mail: sales@istmarin.com
www.istmarin.com

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Service Stations

UAE
Tru-Marine PTE LTD SHJ. BR.
Plot No. 2, Sharjah Industrial Area 17,
P.O. Box 37529, Sharjah
Phone: +971 6 5349 357
Fax: +971 6 5349 356
E-mail: turbo@trumarine.ae
www.trumarine.com

UK
Marine Turbo Engineering Ltd.
Abbey House
Priory Trading Estate
Birkenhead, Merseyside
CH 415 JU
Phone: +44 151 647 8141
Fax: +44 151 666 2143
E-mail: info@marineturbo.co.uk
www.marineturbo.co.uk

USA
Motor-Services Hugo Stamp Inc.
3190 S.W. 4th Avenue
Ft. Lauderdale, Florida 33315
Phone: +1 954 763 3660
Fax: +1 954 713 0440
E-mail: turbo@mshs.com
www.mshs.com

Motor-Services Hugo Stamp Inc.

1509 Sams Avenue
Harahan, Louisiana 70123
Phone: +1 504 265 8800
Fax: +1 504 265 8838
E-mail: turbo@mshs.com
www.mshs.com

L.A. Maritime
327 Lecouvreur Avenue
Los Angeles, CA 90744, USA
Phone: +1 310 518 1718
Fax: +1 310 549 1122
E-mail: info@la-maritime.com
www.la-maritime.com

Tru-Marine Houston
808 West 13th Str. Deer Park
Houston, Texas 77536, USA
Phone: +1 281 930 7680
Fax: +1 281 930 7681
E-mail: turbo@trumarinehouston.us
www.trumarine.com

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Operating instructions
BKF0004EN

Transfer Gear Pumps KF 4...112

BKF0004EN_D0024710002-07
Englisch

2011-03-24

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Table of Content

1 General points 5

1.1 About the documentation 5

1.2 Manufacturer´s address 5
1.3 Intended use 5
2 Safety 7

2.1 Safety instructions and symbols 7

2.2 Staff qualification and training 7
2.3 General safety instructions 7
2.4 Hazard statements 8
3 Device description 13

3.1 General points 13

3.2 Basic construction 14
3.2.1 KF 4...112 R/L/B (with cover) 14
3.2.2 KF 4...112 R/L - D (with pressure relief valve) 16
3.2.3 KF 4...25 U (with universal valve) 18
3.2.4 KF 32...80 U (with universal valve) 20
3.3 Types of seals 22
3.4 Type key 23
3.5 Important special numbers 24
4 Technical data 25

4.1 General characteristics 25

4.2 Overview of nominal sizes 26
4.3 Permissible speed 26
4.4 Overview materials 27
4.5 Operating pressure and fluid temperature 28
4.6 Dimensions 29
5 Transport and storage 30

5.1 Transport damage 30

5.2 Transport 30
5.3 Corrosion protection 32
6 Installation 33

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6.1 General points 33

6.2 Noise reduction 34
6.3 Definition of the direction of rotation and pumping 34
flow
6.3.1 KF 4...112 (with end cover or pressure relief valve) 35
6.3.2 KF 4...25 U (with universal valve) 36
6.3.3 KF 32...80 U (with universal valve) 36
6.4 Change of the direction of rotation 37
6.5 Design of suction and pressure line 39
6.5.1 Suction line 39
6.5.2 Pressure line 42
6.6 Mounting the clutch 44
6.7 Mechanical installation 47
6.8 Assembly with further components and devices 50
6.9 Electrical connection 50
7 Operation start-up 51

7.1 Preparation 51
7.2 Pumps with liquid seal (quenching connection) 53
7.2.1 General points 53
7.2.2 Seal variants with liquid seal 54
7.3 Setting the pressure relief valve 55
7.4 Further operation start-up 57
8 Removal 58

8.1 General points 58

8.2 Disassembling the pump 58
9 Maintenance 60

9.1 General points 60

9.2 Unusual noise 62
9.3 Cleaning 63
9.4 Static seals 63
9.5 Confining fluid level 63
9.6 Rotary shaft lip seal 63

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9.7 Mechanical seal 64

9.8 Clutch 64
9.9 Screw joints 64
9.10 Damage 64
9.11 Surface temperature 64
9.12 Bearing, gear, wheel chamber housing 65
10 Repairs 66

10.1 General points 66

10.2 Troubleshooting 66
10.3 Elimination of damage 66
10.4 Return 66
10.5 Disposal 67
10.6 Detecting and eliminating problems 67

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Transfer Gear Pumps KF 4...112

1 General points

1.1 About the documentation

These operating instructions describe the installation, operation and mainte-

nance of the transfer gear pumps KF 4...112, also referred to below as the
device.
The device is manufactured in different versions. Information about the ver-
sion concerned in the individual case can be found on the device's type plate.
The structure of the type designation and a more detailed description of the
individual series and nominal sizes can be found in the chapter 3 “Device
description” and in the chapter 4 “Technical data”.
If you have any questions about this operating manual, please contact the
manufacturer.

1.2 Manufacturer´s address

Kracht GmbH
Gewerbestraße 20
DE 58791 Werdohl
phone: +49 (0) 23 92 / 935-0
fax: +49 (0) 23 92 / 935-209
email: info@kracht.eu
web: www.kracht.eu

1.3 Intended use

The device is a pump for continuous delivery of liquids. The various seal var-
iants and materials enable use with different media.
The device has been designed for operation with fluids. Dry operation is not
permitted. The medium must guarantee a minimum lubrication.
The medium must not contain any abrasive constituents.
Petrols, solvents, etc. are not permissible.
Use in explosive areas is not permissible.
The operator must guarantee that the medium to be conveyed is compatible
with the materials used in the device (see "Overview materials" in the chapter
4 “Technical data”). Chemical expertise is required for that.

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The maximum permissible operating data listed in the chapter 4 “Technical

data” must always be observed.
Deviations from the above-mentioned data and operating conditions require
express approval by the manufacturer and/or are specified on the type plate.
Type plates or other references on the device must not be removed nor made
illegible or irrecognisable.
In cases of noncompliance, all warranty claims and manufacturer responsi-
bility shall be void.

6 2011-03-24 BKF0004EN_D0024710002-07

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Transfer Gear Pumps KF 4...112

2 Safety

2.1 Safety instructions and symbols

The safety notices in these operating instructions are marked with caution
symbols.
Non-compliance can lead to hazards for people and the device.
In addition, the safety instructions are marked with signal words. They have
the meanings as explained below:
Caution: Identification of a low risk hazard, which could lead to minor or
medium bodily injury if not avoided.
Warning: Identification of a potential medium risk hazard, which would lead
to death or severe bodily injury if not avoided.
Danger: Identification of an immediate hazard, which would result in death
or severe bodily injury if not avoided.

Notice: Flagging of notices to prevent property damage.

Flagging of special user tips and other especially useful or important infor-
mation.

2.2 Staff qualification and training

The staff designated to install, operate and maintenance the device must be
properly qualified. This can be through training or specific instruction. Staff
must be familiar with the contents of this operating manual.

2.3 General safety instructions

The operational safety of the device delivered is only guaranteed when it is

Transfer Gear Pumps KF 4...112

3 Device description

3.1 General points

KF series pumps are external gear pump types that work according to the
positive displacement principle.
When rotated, two gears being engaged with each other cause volume ex-
pansion by opening the tooth gaps in the pump inlet (suction side) so that the
medium can enter while a corresponding volume is being displaced in the
pump outlet (pressure side) through engagement of the teeth into the filled
tooth gap. Fluid transport takes place through entrainment in the tooth gaps
along the wall of the wheel chamber. The so-called geometric flow rate Vg is
being displaced per wheel rotation. A value that is stated in technical docu-
ments as rated volume Vgn to specify the pump size.
The actually delivered amount of liquid does not correspond with the theo-
retical value, it is being reduced through losses due to the necessary toler-
ances. The losses are less the lower the operating pressure and the higher
the viscosity.
Gear pumps are self-priming within wide limits. The displacement cycle de-
scribe initially takes place without exhibiting appreciable pressure build-up.
Only after setting external loads, for example, through delivery head, outlet
resistances, line elements, etc. the required working pressure will arise to
overcome these resistances.
As usual with so-called rigid pumps, i.e. non-axial play compensated pumps,
the lateral clearance between gear and front face has been set in such a way
that the maximum allowable operating pressure is managed in an adequate
and secure way.
The medium lubricates the pump's friction bearings and shaft seal. The
pump's operating life will be reduced if the medium contains abrasive ingre-
dients.
The shaft sealing pocket is connected to the pump's suction side. Therefore,
the max. permissible suction-side pressure is dependent on the type of seal.

Tab. 3.1: Functional principle external gear pumps

pe = Suction side
pb = Pressure side

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Tab. 3.12: Explanation of type key KF 4...112

Explanation of type key KF 4...112

1. Product name
2. Nominal size
Vg Size 1: 4, 5, 6, 8, 10, 12, 16, 20, 25 cm3
Size 2: 32, 40, 50, 63, 80 cm3
Size 3: 100, 112 cm3
3. Direction of rotation
R Right B Right and left
L Left U Universal (Direction of rotation right and
left, direction of discharge consistent)
4. Mounting
F DIN flange without outboard bear- W Mounting angle without outboard bearing
ing
G DIN flange with outboard bearing X Mounting angle with outboard bearing
5. Seal type
1 Single rotary shaft lip seal BABSL 18 Single rotary shaft lip seal BAUMX7 FKM
NBR
2 Single rotary shaft lip seal BABSL 19 Double rotary shaft lip seal BABSL NBR
FKM
3 Single rotary shaft lip seal PTFE 20 Mechanical seal with EPDM secondary
seal (not resistant to mineral oil)
4 Double rotary shaft lip seal PTFE 23 Singel rotary shaft lip seal MSS-1 FKM
(low temperature)
5 Mechanical seal with FKM secon- 30 Without shaft seal, O-Ring FKM
dary seal (external leak oil discharge)
6 Mechanical seal with PTFE secon- 31 Single rotary shaft lip seal BABSL FKM
dary seal (low temperature)
7 Double rotary shaft lip seal BABSL 32 Double rotary shaft lip seal EPDM
FKM (not resistant to mineral oil)
9 Single rotary shaft lip seal EPDM
(not resistant to mineral oil)
6. Special number for specific types
See section 3.5 “Important special numbers”

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Transfer Gear Pumps KF 4...112

Explanation of type key KF 4...112

7. Pressure relief valve (only for direction of rotation R or L)
D 15 Adjustable from 0 - 15 bar D 25 Adjustable from 15 - 25 bar
8. Housing and cover material
Not specified: EN-GJL-250 (GG-25)
GJS EN-GJS-400-15 (GGG-40)

3.5 Important special numbers

Tab. 3.13: Important special numbers KF 4...112

Special Description
num-
bers
74 Pump with double rotary shaft lip seal for vacuum operation and connection for liquid
seal (quench), inner rotary shaft lip seal mounted with sealing lip towards shaft end
158 SAE ¾ connections for KF 4...12, SAE 1 connections for KF 16...25
197 Noise-optimized version for aerated oils and vacuum
198 Mechanical seal with connection for liquid seal (quench)
232 SAE 2 connections for KF 50...80, SAE 2 1/2 connections for KF 100...112
304 Bearing bushings Iglidur® X, Δpmax = 10 bar
317 Noise-optimized version for aerated oils and vacuum, bearing bushings Iglidur® X,
Δpmax = 10 bar
332 Version for low-viscous media (only in connection with material GJS), bearing bushings
Iglidur® X, νmin = 4 mm²/s at Δpmax = 10 bar
353 Noise-optimized version for aerated oils and vacuum, bearing bushings DP4 (leadfree)
355 Bearing bushings Iglidur® X, SAE ¾ connections for KF 4...12, SAE 1 connections for
KF 16...25, Δpmax = 10 bar
363 Version for low-viscous media (only in connection with material GJS), bearing bushings
Iglidur® X, νmin = 4 mm²/s at Δpmax = 10 bar, SAE ¾ connections for KF 4...12, SAE 1
connections for KF 16...25
391 Noise-optimized version for aerated oils and vacuum, SAE 2 connections for KF 50...80,
SAE 2 1/2 connections for KF 100...112

Particularities in noise-optimized pumps

● Air trapped in the medium or too high negative pressure can result in
delivery rate reduction for pumps in noise-optimized version.
● Measures for noise optimisation are only feasible for one rotational di-
rection and only effective for aerated oils or vacuum.

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4 Technical data

4.1 General characteristics

Tab. 4.1: General characteristics KF 4...112

General characteristics KF 4...112

Construction External gear pump
Materials See section 4.4 “Overview materials”
Fixing type Flange DIN ISO 3019
End of drive shaft ISO R 775 short-cylindrical
Pipe connection KF 4...12 Whitworth pipe thread G 3/4
KF 4...12/158 Flange connection SAE 3/4
KF 16...25 Whitworth pipe thread G 1
KF 16...25/158 Flange connection SAE 1
KF 32...80 Flange connection SAE 1 1/2
KF 50...80/232
Flange connection SAE 2
KF 100...112
KF 100...112/232 Flange connection SAE 2 1/2
Installation position KF ...R/L/B... ohne Quench Arbitrary*
KF ...R/L/B... mit Quench Horizontal, quenching connec-
tion on top
KF ...U... Horizontal, perssure connection
on top
Viscosity νmin 12 mm2/s**
νmax 20000 mm2/s
Ambient tempera- ϑu min -20 °C
ture ϑu max 60 °C
Speed n See section 4.2 “Overview of nominal sizes”
Fluid temperature ϑ
Operating pressure pe and See section 4.5 “Operating pressure and fluid temperature”
pb
Filtering Filter porosity ≤ 60 µm
Permissible media Fluids without abrasive components which are compatible with the
pump materials used. The fluids must guarantee minimum lubrica-
tion. Media-specific characteristics must be taken into account.
Petrols, solvents, etc. are not permissible.
* A reduced service life must be expected for the shaft seal when vertically installed.
** Lower viscosities only in connection with GJS housings and reduced pressures (consult manu-
facturer).

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4.2 Overview of nominal sizes

Tab. 4.2: Nominal sizes KF 4...112

Nominal Geom. Speed Permissi- Sound lev- Weights

size* delivery ble radial el***** kg
volume nmin nmax force** LpA with cover with D- with
Vg Fradial db(A) valve univer-
rpm rpm
cm3 N sal de-
(n=1500 vice
rpm)
4 4,03
5 5,05
6 6,38 2,9*** 3,7***
6,9
8 8,05 4,2**** 5,0****
10 10,11 200 3000 700 ≤ 67
12 12,58
16 16,09
3,5*** 4,3***
20 20,10 7,5
4,8**** 5,6****
25 25,10
32 32,12
40 40,21 7,7 9,5 27,5
50 50,20 200 3000 1500 ≤ 68
63 63,18
9,4 11,2 29,5
80 80,50
100 101,5
200 3000 1500 ≤ 69 15,9 19,0 -
112 113,5
* See type key and type designation at pump: KF ...
** Radial forces only at version with outboard bearing. Fradial on central shaft end.
*** Valid for pump KF 4...25 with Whitworth pipe thread.
**** Valid for pump KF 4...25 with flange connection SAE.
***** n= 1500 rpm; v= 34 mm2/s ; p= 5...25 bar

4.3 Permissible speed

Tab. 4.3: Permissible speed depending on the viscosity

Kinematic viscosity ν in mm2/s

< 300 300 500 1000 2000 3000 6000 10000 20000 30000
≥ 1450 1250 1000 750 600 500 400 300 200 100
Speed nmax in rpm

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4.4 Overview materials

Tab. 4.4: Materials KF 4...112

Seal Housing / cover Gear Bearing Shaft seal O-Rings

type*
1 NBR NBR
2 FKM FKM
3 PTFE FEP
4 PTFE FEP
5 CrMo-casting/ FKM
Carbon in syn-
thetic resin,
FKM, 1.4571,
1.4401
6 SiC-Si/SiC-Si FEP
(KF 4...25), SiC-
DU, P10 Si/Carbon in
synthetic resin
(Steel,
(KF 32...80),
sintered bronze,
EN-GJL-250 FFKM, 1.4571
PTFE, Pb)
7 (GG-25) Carburising steel FKM FKM
Iglidur® X
EN-GJS-400-15** (1.7139)
9 DP4 EPDM EPDM
(GGG-40)
18 (Steel, FKM FKM
sintered bronze,
19 NBR NBR
PTFE)
20 SiC-Si/Carbon, EPDM
CrNi-steel,
CrNiMo-steel
23 FKM (low tem- FKM (low
perature) tempera-
ture)
30 Without shaft FKM
seal
31 FKM (low tem- FKM (low
perature) tempera-
ture)
32 EPDM EPDM
* See type key and type designation at pump: KF ...
** For version in EN-GJS-400-15 type designation: KF ... - GJS

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4.5 Operating pressure and fluid temperature

Tab. 4.5: Operating pressure and fluid temperature KF 4...112

Type of Operating pressure Fluid temperature

seal* Suction side Pressure side
pe min bar abs.** pe max bar pb bar pb max bar ϑmin °C ϑmax °C
(perm. conti- (pressure
nous pressure) peaks)
1 90
...6****
2 150
3
2 200
4
5 150
10
6 - 10 200
7 ...6**** 150
9 0,6 *** 120
0,5
18 150
19 ...6**** 25***** 40 90
20 10 120
23 0,5 -30
30 25 -10 150
31 1 -30
32 0,5 120
4/74 200
7/74 -10 150
0,1 0,2
19/74 90
32/74 120
* See type key and type designation at pump: KF ...
** Heed restrictions of pe min = -0,65 bar absolute for universal design (KF .. U).
*** Temporary during starting state: 0,4 bar absolute
**** See table 4.6 for permissible pressures
***** Type of seal 31: pb = 20 bar

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Tab. 4.6: Permissible operating pressures pe max for seal types 1, 2, 7 and 19

Max. speed nmax in rpm KF 4...80 KF 100...112

Permissible pressure pe max in bar Permissible pressure pe max in bar
750 6 6
1000 5 5
1500 4 3,5
2000 3 2,5
3000 2 1,5

NOTICE
Danger of property damage due to overload
Overloads in pumps with Iglidur® X bearings can cause the bearings to
wear prematurely.
● Never exceed the max. permissible Δp = 10 bar.

NOTICE
Danger of property damage when simultaneously utilizing multiple
operating limits
When simultaneously utilizing multiple operating limits (see chapter 4
“Technical data”), the pump could become damaged or prematurely wear.
● Do not use minimum and maximum parameters at the same time.
For example, maximum operating pressure ist not permissible in con-
nection with low speed and/or low viscosity.

NOTICE
Danger of property damage when pumping aqueous fluids
When pumping aqueous dispersions or solvents, low pressure on the inlet
port can lead to cavitation damage on the pump.
● Comply with the media-specific attributes.
● When designing the inlet line, make sure the inlet port pressure on the
pump inlet during operation is always higher than the steam pressure
of the pumping fluid. While doing so, also take the altitude of the site of
the device over mean sea level into consideration.
● For aqueous dispersions and solvents, limit the operating temperature
to max. 50 °C, install the pump underneath the liquid level and limit the
rotational speed to maximal 1500 rpm.

4.6 Dimensions

Dimensions of the device can be found in the relevant technical data sheets.

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5 Transport and storage

5.1 Transport damage

Inspect the device for shipping damage as soon as the delivery has been
received.
If shipping damage is discovered, inform the shipping company.
If proper operation of the device is impaired by the damage, the device must
be replaced or repaired. In that case, contact the manufacturer.

5.2 Transport

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Handling aid
● When transporting individuals devices, the eyebolts can be screwed into
the connectiing flange as a handling aid.

Tab. 5.1: Example for safe transport of pumps

WARNING
Hazard from falling and tipping loads
Due to the size and weight of the device, accidents can occur resulting in
severe injuries or death during transport and shipping.
● For pump devices: do not use eyelets on the motor to transport the
pump devices. They can only support the weight of the motor.

Tab. 5.2: Examples for safe transport of pump units

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5.3 Corrosion protection

The device's function is tested in the plant with mineral hydraulic oil. Then all
connections are closed. The remaining residual oil protects the interior parts
for about 6 months.
Clean bare outer metal parts have also been protected by anti-corrosive oil
or protective metal paint for a period of 6 months against corrosion.
The device must not be exposed in the influence of the weather and major
fluctuations in temperature during transport and storage and must be stored
in a dry place.
If the device is stored over a longer period, it must be treated on the inside
and outside with a suitable corrosion protecting oil. In addition, it must be
protected from humidity by a humidity-absorbing agent.
If high air humidity or aggressive atmosphere is to be expected during trans-
port, suitable corrosion prevention measures must be carried out.

NOTICE
Corrosion damage on units with EPDM seals
The functionality of units with EPDM seals is not tested. There is no pres-
ervation of the interior parts. If the unit is not put into operation immediately,
corrosion damage can occur.
● Protect the unit by using suitable corrosion-preventing measures.

NOTICE
Chemical impact on the device and the sealing materials
Incompatibility between the preservation agents and the materials and
elastomers used in the device can lead to damage of the device and the
seals being used.
● Check to make sure the preservation agent is compatible with the ma-
terials and elastomers used in the device.
● Check to make sure the preservation agent is compatible with the media
to be pumped.

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6 Installation

6.1 General points

NOTICE
Danger of property damage due to insufficiently qualified personnel
Improper work can lead to damages and malfunctions in the device and in
the plant.
● Permit only expert and technically qualified personnel to work on the
device.

NOTICE
Danger of property damage due to a lack of cleanliness
During installation, foreign bodies can get into the interior of the device or
the plant due to a lack of cleanliness and cause malfunctions there.
● Pay attention to cleanliness during all work.

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6.2 Noise reduction

Measures for sound optimizing

● In view of optimising noise protection, it is advisable to mount a bell-
housing with vibration damper between pump and motor as well as
vibration damper between motor and mounting surface. Suction and
pressure piping must be able to move freely or it needs to be elastically
suspended.
● Installation of suction and pressure hoses diminishes the noise level of
hydraulic systems. Some hose manufacturers offer special, highly flex-
ible suciton hoses for this purpose.
● Installation of the pump above the liquid level diminished the noise level
of hydraulic systems. The pressure pe on the pump's intake should be
approx. 0.8...0.9 bar absolute.

6.3 Definition of the direction of rotation and pumping flow

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6.3.1 KF 4...112 (with end cover or pressure relief valve)

Tab. 6.1: Rotation and delivery direction KF 4...112

The following definition shall apply with respect to the rotation and delivery
direction of external gear pumps in case of pump connections being posi-
tioned below the drive shaft:
Looking at the pump shaft end, the Looking at the pump shaft end, the
pumping flow is from left to right pumping flow is from right to left
when the shaft is moving clock- when the shaft is moving anticlock-
wise. wise.
Without pressure relief valve

ps = Suction side pd = Pressure side

With pressure relief valve

ps = Suction side pd = Pressure side

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6.3.2 KF 4...25 U (with universal valve)

Tab. 6.2: Rotating and delivery direction KF 4...25 U

With regard to the direction of rotation and pumping flow of pumps with
universal device KF 4...25 the following definition shall apply when looking
at the pump shaft end:
Direction of rotation right Direction of discharge consistent
and left

ps = Suction side pd = Pressure side

6.3.3 KF 32...80 U (with universal valve)

Tab. 6.3: Rotating and delivery direction KF 32...80 U

With regard to the direction of rotation and pumping flow of pumps with
universal valve KF 32...80...U2 the following definition shall apply when
looking at the pump shaft end:
Direction of rotation right and left Direction of discharge consistent

ps = Suction side pd = Pressure side

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6.4 Change of the direction of rotation

Change of the direction of rotation in the case of KF...R... and KF...L... pump
types, i.e. pure clockwise or anticlockwise rotating pumps, is only possible by
converting the pump.
The manufacturer normally carries out the conversion work and the customer
should do this only in case of an emergency.
Pumps in noise-optimized version cannot be converted.

Guarantee and manufacturer responsibility

● All warranty claims and manufacturer responsibility shall be void when
improper conversation work takes place.

NOTICE
Danger of property damage due to incorrect installation
Improper retrofitting can lead to damages and malfunctions in the unit and
in the plant.
● Permit only expert and technically qualified personnel to work on the
device.

NOTICE
Danger of leaks on the unit
When altering the unit, seals that are removed, damaged or jammed can
lead to leaks during operation.
● Do not remove, damage or jam seals.

NOTICE
Danger of damage on the device
The cover or pressure relief valve and housing are fixed to each other with
adapter sleeves or dwowel pins. If the bearings are damaged when as-
sembling or dismantling the cover or pressrue relief valve, e.g. by bending
out of line, there could be malfunctions and a decrease of the service life.
Furthermore, the seal faces on the cover or pressure relief valve could be
damaged. That can lead to leaks during operation.
● When mounting and dismantling the cover or pressure relief valve, do
not damage the bearings, e.g. by bending out of line.
● When dismantling the cover or pressure relief valve, do not lever in the
joint with a screwdiver or similar tools.

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Tab. 6.4: Change of the direction of rotation KF ...R... und KF ...L...

ps = Suction side * Fastening screws

pd = Pressure side ** Leak oil hole

In case of a pump's change of the direction of rotation the cover and/or pres-
sure relief valve must be rotated through 180°.
● Loose fastening screws.
● Remove the cover or the pressure relief valve respectively from the pump
housing and put it back on rotated by 180°.
● Tighten all fastening screws applying the below mentioned tightening
torques (see table 6.5).
When checking, pay attention to the following points:
● Pumps without pressure relief valve must have their leak oil hole on the
interior cover side at the pump's suction side.
● Pumps with pressure relief valve must have their pressure relief valve
adjusting screw point toward the pump's pressure side.

Tab. 6.5: Tightening torques for fastening screws

Nominal size* 4 ... 25 32 ... 80 100 ... 112

Tightening torque 25 Nm 49 Nm 79 Nm
* See type key and type designation at pump: KF ...

In the case of pumps having seal type 6, the mechanical seal must be re-
placed in addition. During this process, the spring coiling direction must be
observed. Heed the assembly instructions of the respective manufacturer
when replacing the mechanical seal.

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6.5 Design of suction and pressure line

NOTICE
Danger of property damage due to distortion
The load on the device due to impermissible external loads can lead to
malfunctions or to breakage of the flange or housing.
● Pipelines must be fitted absolutely tension-free to the device connec-
tions.
● Pipelines must be designed in such a way that no tension e.g. caused
by changes in length due to fluctuations in temperature can be trans-
ferred to the device.

NOTICE
Danger of property damage caused by foreign bodies in the device
During installation, when using unsuitable sealing materials foreign bodies
can get into the interior of the device or the plant due to a lack of cleanliness
and cause malfunctions there.
● During installation, do not use any hemp or filler as sealing material.

Suction and pressure hoses

● Installation of suction and pressure hoses diminishes the noise level of
hydraulic systems. Some hose manufacturer offer special, highly flexi-
ble suction hoses for this purpose.
● Lay pressure hoses in sufficiently large radii.

6.5.1 Suction line

NOTICE
Malfunction due to incorrectly designed inlet line
Due to excessive underpressure, an incorrectly designed inlet line can lead
to a reduction of the delivery rate, increased noise emissions and cavitation.
● Design the inlet line with extreme care since it will strongly influence the
pump's performance.

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The suction line must be piped as short as possible and in a straight line.
Avoid large suction heights.
Additional line resistance such as formed parts, fittings and closed meshed
suction filters increase the pipe resistance of the suction line and must be
avoided.
The negative pressure in the suction line is calculated from the sum of all
suction-side resistances and the suction height considering the media-spe-
cific data.

Check the underpressure

● The negative pressure can be controlled by fitting a vacuum gauge to
the pump suction line connector.

Ensure proper suction when piping the suction line and the distances to the
floor and to the bulkhead partitions must be sufficiently large.
The inlet port must have a sufficient distance to the lowest fluid level.

Nominal width of the suction line

● The nominal width of the suction line may actually be selected to be
larger than the pump connection.

Expansion of the suction cross section

● Funnel-shaped formation of the suction port at the pump suction side or
obliquely cutting the suction pipe end is recommended of enlargement
of the suction cross section.

When hose lines are used on the pump suction side, care must be taken to
ensure that the hoses are sufficient stability so that they will not be constricted
through the sucking action.
The media-specific data need to be observed, for example, the device must
be arranged below the fluid level in case of aqueous dispersions and solu-
tions.

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The recommended flow velocity in the suction line is max. 1,5 m/s.

Tab. 6.6: Piping the suction line as siphon

If there is a possibility that the suction line

can run dry if the pump stops, piping the
suction line as siphon is an option to avoid
suction problems. This way, the pump will
remain permanently filled after initial com-
missioning.
The air in the pressure line can be conduc-
ted directly into the tank via a nozzel (see
section 6.5.2 “Pressure line”).
It is appropriate to employ a foot valve or a
non-return valve in case of longer suction
lines that can run dry while the pump is at
rest. These must have been designed for
use in suction lines and should offer as low
a flow resistance as possible.

Tab. 6.7: Suction line at vacuum operation

If the pump is to intake from a tank under

vacuum, the pump must be arranged ap-
prox. 0.8 m below the tank. The suction line
must run in a straight line and without any
resistances.
The tank may be subjected to vacuum only
then when the pipework and the pump have
been filled with liquid.
For this application, only pumps designed
as a vacuum system may be employed.

* = Vacuum

6.6 Mounting the clutch

NOTICE
Danger of property damage due to falsely dimensioned coupling.
An incorrect design can lead to premature failure of the coupling due to
breakage or wear.
● When dimensioning the coupling, pay attention to safe dimensioning to
be able to transfer the expected maximum torque reliably and perma-
nently.
● Take the vibrations, peak torques and temperatures into consideration.
The permissible values from the coupling manufacturer must not be ex-
ceeded.
● Comply with the coupling manufacturer's installation rules.

When mounting the clutch, keeping the "E" measure exactly is of the essence
so that the clutch will remain axially movable when used. In order to avoid
any frontal pressure against the elastic gear rim, measure "E" should each
be considered as minimum in the case of an axial displacement.
If the shaft clearance is less than clutch clearance "E", one of the shaft ends
can easily extend into the gear rim. Size "dW" corresponds to the max. shaft
diameter that may extend with the parallel key into the gear rim, size "dH". If
there is the chance to offset the parallel key, i.e. only the shaft extends into
the gear rim, the size of the shaft may be increased up to 2 mm below the
specified "dH" size in order not to obstruct the gear rim in its axial movability.
The permissible displacement values of the elastic clutches stated represent
general guide values taking a clutch loading up the the clutch nominal torque
and an operating speed n = 1500 rpm as well as an occurring ambient tem-
perature of +30 °C into account. Consultation with the manufacturer is
necessary for deviating operating conditions.
The displacement data may only be used individually in each case and in case
of simultaneous appearance in proportion only.

Increasing the service life of the coupling

● Careful and exact shaft alignment inreases clutch life.

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Fig. 6.1: Displacements - aligning the clutch

* Clutch clearance "E"

** Shaft with parallel key extends into the gear rim (dw)

Tab. 6.9: Types of coupling

19 24 28 38 42 48 55 65 75
Type of coupling*
19/24 24/28 28/38 38/45 42/55 48/60 55/70 65/75 75/90
Clutch clearance** E 16 18 20 24 26 28 30 35 40
Dimension** s 2 2 2,5 3 3 3,5 4 4,5 5
Dimension** dH 18 27 30 38 46 51 60 68 80
Dimension** dW 12 20 22 28 36 40 48 55 65
Max. axial displace- ΔKa 1,2 1,4 1,5 1,8 2,0 2,1 2,2 2,6 3,0
ment**
Max. radial displace- ΔKr 0,20 0,22 0,25 0,28 0,32 0,36 0,38 0,42 0,48
ment**
n=1500 1/min
Max. angular dis- ΔKw 1,2° 0,9° 0,9° 1,0° 1,0° 1,1° 1,1° 1,2° 1,2°
placement
n=1500 rpm
* Example: RA19-Z25/14-Z25/19 or RA19/24-Z25/14-Z25/24
** Dimensions in mm

NOTICE
Danger of property damage when mounting other types of couplings
If other coupling types are used, when mounting the coupling the instruc-
tions from the respective manufacturer is binding.
● The respective manufacturer's installation instructions must be com-
plied with when using other coupling types.

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NOTICE
Danger of property damage if installation is not correct
Do not strike the shaft when installing the respective coupling half on the
motor and pump shaft. There is a danger that the built-in bearing could be
damaged.
● Do not knock onto the shafts during installation of the clutch halves!

Easing coupling installation

● The hubs should be heated for mounting the clutch and slid onto the
shaft while hot.
Using a pinion gear drive, it must also be heated and slid onto the shaft
end while hot.

NOTICE
Danger of property damage due to displacement of the coupling
halves
When the coupling hub is not secured against axial displacement on each
shaft, there is a danger that the coupling hub will shift during operation. That
can lead to a failure of the coupling.
● Prevent axial displacement on every coupling hub on cylindrical shafts
with a threaded pin that presses against the fitting key or the shaft.

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6.7 Mechanical installation

NOTICE
Malfunctions due to leaking lines and connections
Leaks can occur and air can be sucked in if lines or connections are not
tight. Suctioned air leads to a decrease of the delivery rate and foams up
the medium.
● Make sure all lines and connections are tight.

● Before installation, the device must be checked for transport damage and
soiling.
● Any preserving agents must be removed before installation using ben-
zine or solvent.
● Clean the pipework of dirt, scale, sand, swarf, etc. prior to installation.
Welded pipes in particularly must be pickled or flushed. Cotton waste
must not be used for cleaning.
● Mount clutch and clutch halves respectively to pump and drive (see sec-
tion 6.6 “Mounting the clutch”").

● Mount pump to bellhousing, foot or housing and pay attention to careful

Transfer Gear Pumps KF 4...112

7.2 Pumps with liquid seal (quenching connection)

7.2.1 General points

NOTICE
Danger of the failure of the seal due to a lack of sealing fluid
A lack of sealing fluid can lead to a failure of the shaft seal and to increased
temperatures and increased wear.
● Fill the pump's sealing cavity with a suitable sealing medium. The seal-
ing fluid must be compatible with the seals and materials used as well
as with the pumping medium.
● The confining fluid's minimum and maximum filling level must be en-
sured using appropriate technical and/or organisational measures.
● The liquid seal in the quenching connection must not be subjected to
pressure or vacuum.

If fluids are delivered,

● that cure in air,
● crystallise in contact with air humidity,
● the leakage of which must not be released into the environment,
● are under vacuum and their seal shall be gastight,
than the employment of a double seal with liquid seal is necessary.
● A tank for the liquid seal is to be connected to the quenching connection.
Suitable tanks are available from the manufacturer.
● The tank for the liquid seal must be placed above the pump.
● The installation position is restricted and the quenching connection shall
be directed upward..
● Check of the fluid level in the tank must be possible at any time.

Flushing connection sealing cavity

● A second port on the device enables purging of the sealing cavity and
draining of the seal liquid.

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7.2.2 Seal variants with liquid seal

Tab. 7.1: KF 4...112 with liquid seal (Quench)

Types of seals: Types of seals: Triple rotary shaft lip Type of seal: 5
4, 7, 19, 32 4, 7, 19, 32 seal Special number 198
Special number 74 (on request)

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7.3 Setting the pressure relief valve

Applies for pumps with built-on pressure relief valve

(Type designation: KF ... - D15 or KF ... - D25)

Fig. 7.1: Pressure setting KF 4...112 - D..

- response pressure lower

+ response pressure higher

NOTICE
Danger of the pump overheating
The series D.. pressure relief valves are exclusively used to protect the
pump. The valves must only respond for short durations. Permanent drain-
ing of the volumetric flow through the valve will destroy the pump through
overheating.
● Make sure the valve responds only briefly.

For pressure setting on the pressure relief valve see figure 7.1:
● loosen the hexagon nut (1)
● adjust set screw (2)
clockwise = response pressure higher
anticlockwise = response pressure lower
● secure the set screw (2) using hexagon nut (1) once the desired pressure
has been adjusted.

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DANGER
Danger due to breakage or squirting fluids!
When securing screw (3) is loose, set screw (2) can be screwed into the
valve until the valve is completely shut. That can result in inadmissibly high
pressures in the system if there is no other pressure relief device. Breakage
can lead to parts flying around uncontrolled or to fluids squirting out which
can lead to accidents and severe injuries or even result in death.
Fluid can spurt out from the valve if set screw (2) is completely screwed
out. That can lead to accidents with severe injuries or result in death.
● Never operate the unit with securing screw (3) loosened.
● Never completely screw set screw (2) into the valve.
● Never completely unscrew set screw (2) out of the valve.

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7.4 Further operation start-up

● The pumps may only start without or with low pressure load. For this
purpose, open the existing shut-off elements and adjust the pressure
relief valve incorporated in the pressure pipe to the lowest opening pres-
sure.
● Start-up takes place by repeated quick on-off switching of the driving
motor (jog mode) without reaching full speed until proper operation of the
device is evident. This applies particularly when a cold pump is to start
with already heated medium. The reason for this is to achieve slow heat-
ing of the pump and prevent the pump seizing through thermal shock.
● Proper function indicated by noise generation or on the pressure gage
should be reached after max. 30 seconds.
● First of all, run the pump at zero pressure or low pressure for a couple
of minutes after switching on the motor.
● Bleed the plant on the distribution pipes, preferably at the highest point.
● Pressure loading can be gradually increased up to the desired operating
pressure (max. permissible pressures, see chapter 4 “Technical data”)
● Check the temperature of the medium and that of the pump after the
intended operating characteristics have been reached. Checkpoints on
the pump are the bearing locations, the housing and the shaft seal. The
temperatures observed on the pump surface may be approx. 10 °C
above medium temperature.
● Check the fluid level of the plant once more and top up if necessary.
● Check the final operating temperature after several hours running time
(see chapter 4 “Technical data” for max. permissible temperatures).
● Check the static seals on the suction and pressure connections and the
pump's joints for leakages.
● Check the threaded connections for leakages. Such leakages can be
easily eliminated by simply retightening the threaded connections.
● Also check all motor and pump fastening screws after a few hours of
operation.

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8 Removal

8.1 General points

NOTICE
Danger of property damage due to a lack of cleanliness
A lack of cleanliness can lead to damages and malfunctions in the device
and in the plant.
● Pay attention to cleanliness during all work.
● Close all openings with protective caps to prevent dirt from penetrating
into the system.

8.2 Disassembling the pump

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● Remove the depressurised pipelines from the pump.

● Seal the pump connections and pipelines to prevent dirt penetration.
● Disassemble the pump
● Pull off clutch hub resp. the driving pinion from shaft end using an ex-
tractor.

NOTICE
Danger of malfunction due to curing liquids
Curing liquids can engage the device mechanically and make it unusable.
● Immediately clean the pump or store it in such a way that curing is def-
initely prevented in cases where the pump was operated with curing
liquids.

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9 Maintenance

9.1 General points

NOTICE
Danger of damages and malfunctions due to a lack of maintenance
If the device is not regularly maintained, damage that is not discovered or
not repaired can lead to malfunctions and to the failure of the device.
● Maintain the device regularly.
● Check the device initially right after commissioning.
● Adapt the scope and time between maintenance intervals to the de-
mands posed by the location.
● During visual inspections, look purposefully for possible damages.
● The device must not be used if visible damages are found.
● Document the type and extent of the maintenance work. That allows the
fastest possible detection of a change in operating performance.

When designed to the conditions of use and fitted correctly, the devices are
able to be used for long and problem-free operation. They only require a little
maintenance. This is absolutely essential for problem-free operation, howev-
er. Experience shows that a high percentage of the problems and damage
that occur can be traced back to dirt and lack of maintenance.
The scope and time intervals for inspections and maintenance are generally
specified by the operator in a respective plan.

Barriers and instructions

● All removed barrieres and warning signs must be put back to their orig-
inal position on completing maintenance and/or repair.

Checking the operating data

● Regular checking of all operating data such as pressure, temperature,
current consumption, degree of filter soiling etc. contributes to early
problem detection.

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9.2 Unusual noise

Some damage is indicated by unusual noises. If there is a change in the dec-

ive's operating noise, a thorough examination of the cause must always take
place.

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9.3 Cleaning

The pump shaft as well as the associated hardware must not run in dust ac-
cumulations.
Regular cleaning of the pump and its environment is therefore necessary.
Cleaning the pump using a steam jet cleaner is not permissible.

9.4 Static seals

The static seals on the device's separation joints and the connection lines
must be periodically checked for leakproofness.
If there are any visible leaks, immediately stop plant operation.
If the leaks cannot be stopped by simply retightening the connection, replace
all affected seals.

9.5 Confining fluid level

Checking the confining fluid filling level is mandatory for safe pump operation.
Top up the confining fluid as required.
If there is no automatic monitoring, the filling level must be checked at least
befor each shift begins.
The outer but also the inner shaft seal could be leaking if the filling level should
dorp unusually fast within a short period of time. The confining fluid will then
leak into the coupling space or it will be sucked into the pump thereby mixing
with the medium.
If the filling level should rise, the inner shaft seal may probably be leaking and
the confining fluid is begin mixed with the pressurised medium.
Stop plant operation immediately in both cases.

9.6 Rotary shaft lip seal

Rotary shaft lip seals are particulary prone to wear for functional reasons and
must accordingly be carfully checked. Excessicely high supply pressure or
negative suction pressure, wrong rotational direction or pollution leads to in-
creased wear, increased and impermissible temperature rises.
Small amounts of leakage, however, are indispensable for function. The per-
missible amount of leakage, though, is highly dependet on the operational
conditions and cannot be quantified.
If there are excessive amounts of leakage, stop pump operation immediately.
Replace the rotary shaft lip seal.

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Increased wear on the rotary shaft lip seal should be taken into account in the
case of vertical pump installation.

9.7 Mechanical seal

Mechanical seals are particularly prone to wear for functional reasins and
must accordingly be carfully checked. Too high admission pressure, wrong
rotational direction, frequent star-ups, gas or air portions in the oil or contam-
ination lead to increased wear, increased leckage and impermissible tem-
perature rises.
Small amounts of leckages, however, are indispensable for mechanical seal
function. The permissible amount of leackage, though, is highly dependent
on the operational conditions and cannot be quantified.
If there are excessive amounts of leakage, stop pump operation immediately.
Replace the mechanical seal. In so doing, heed the assembly instructions of
the mechanical seal manufacturer.
Increased wear on the mechanical seal should be taken into account in the
case of vertical pump installation.

9.8 Clutch

Clutches must be maintained according to the specifications of the respective

manufacturer.

9.9 Screw joints

All the screw joints must be checked at regular intervals to make sure they
are tight fit. Loose screw joints must be tightened and, if necessary, secured
against loosening by e.g. Loctite (medium stregth).

9.10 Damage

Check the pump as well as its environment regularly for damage such as
dents in the clutch guard.

9.11 Surface temperature

For identifying premature wear or pump overload, it is useful to check the

temperatures on the pump surface at regular intervals.

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This temperatures should never be much higher (max. 10 °C) than the media
temperature at the pump inlet. Checkpoints on the pump are the bearing lo-
cations, the housing and the shaft seal.
If the measured temperatures are higher than the permissible values, this is
an indication of wear or bearing damages. The pump must be replaced in this
case.

9.12 Bearing, gear, wheel chamber housing

Like shaft seals, bearings, gear and wheel chamber housings are wear items.
Wear largely depends on the occurring loads, life cycle as well as type and
proportion of solids in the medium. Wear cannot be identified from the outside.
The condition of a pump, however, can be analysed by the volumetric effi-
ciency factor. Decrease of the efficiency factor would normally indicate wear.
Therefore, a check on all operating data such as delivery, pressure, temper-
ature, drive data, degree of filter contamination should also be carried out
during maintenance work.
Further investigations into the cause are necessary in the event of major de-
viations (> 10 %) to the reference values. This helps detecting premature
pump failure in time. The pump must immediately be taken out of service at
a drop of delivery or pressure to 80 % of the original values. The achieved
values at initial commissioning serve as reference in this case.

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10 Repairs

10.1 General points

The term repairs covers:

● Troubleshooting, in other words establishing damage, determining and
localising the reason for the damage.
● Elimination of the damage, in other words eliminating the primary cau-
ses and replacing or repairing faulty components.

10.2 Troubleshooting

Leaks are the most frequent problem. If these occure on the pipelines, they
can be eliminated by straightforward tightening of the screw joints.
If the device itself is leaking, the respective seals have to be replaced.

10.3 Elimination of damage

Repair damage onsite, predominantly by replacing the defective device. The

device itself is generally repaired by the manufacturer.
If corresponding expertise and sufficient equipment is available, the consum-
er or OEM can also make the repairs. For support, spare parts lists and
sectional drawings are available. They can be requested from the manu-
facturer.

NOTICE
Danger of property damage due to incorrect work and use of non-
original spare parts
Improper work can lead to damages and malfunctions in the device and in
the plant. That also applies to the use of non-original spare parts.
● Permit only expert and technically qualified personnel to work on the
device.
● Use only genuine original spare parts.

10.4 Return

If the device has to be repaired or checked over the manufacturer's premises,

it must be packed suitably for transport. In addition, a safety data sheet for
the medium used must be enclosed with the device. In case of well-known
mineral oils, at least the exact type description is required.

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If harding or agglutinative media are involved, the device must be cleaned

befor it is returned.
Cleaning is also necessary if the device has been operated with hazardous
fluids.
Any openings must be closed.

10.5 Disposal

Disposal of the packaging and used parts must be garried out according to
the regualtions valid in the country where the device is installed.

10.6 Detecting and eliminating problems

2.4 Engine air starter

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Publication T5-703, Rev. 2

Dated: July 31, 2009

SERVICE MANUAL

T50-P
TURBOTWIN Engine Air Starter

AN 99-447 From Tech Development

6800 Poe Ave. xDayton OH 45414
Tel: (937) 898-9600 xFax: (937) 898-8431

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TDI TURBOTWIN
FROM TECH DEVELOPMENT

TABLE OF CONTENTS
Section Subject Page

1.0 Introduction……………………………. 1
2.0 Description of Basic Groups…………. 3
3.0 Disassembly………………………… … 5
4.0 Cleaning and Inspection…………… … 7
5.0 Assembly………………………………. 10
6.0 Parts List……………………………. … 13

LIST OF TABLES

Table No. Title Page

1 T50 Series Service Tool Kits………… 5

2 Cleaning Materials & Compounds.. … 7
3 Parts Inspection Check Req………. … 8
4 Parts Wear Limits………………….. … 9
5 Torque Values…………………………. 9
6 Materials for Assembly……………….. 10

LIST OF ILLUSTRATIONS

Figure Title Page

1 TDI Turbotwin Nameplate……………. 2

2 T50 Series Part Number Coding…….. 2
3 Turbine Housing Assembly…………… 3
4 Gearbox Housing Assembly…..……… 4
5 Drive Assembly………………………… 4
6 Bendix Drive Removal………………… 5
7 Turbine Rotor Removal.………………. 6
8 Turbine Shaft Removal……………….. 6
9 Nozzle 2 Removal…………………….. 6
10 Gear Teeth Wear Allowance…………. 9
11 Turbine Bearing/Shaft Removal.….. … 10
12 T50 Illustrated Parts List……………… 15
13 T50 IPB (S/N: 0610-0994 & After)……..16

Publication T5-703, Rev. 2

Issued July 31, 2009
Page: i

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FROM TECH DEVELOPMENT

SECTION 1.0 INTRODUCTION

NOTE - use to point out special interest
information.
1.1 GENERAL INFORMATION
This manual provides information for servicing,
1.3 DESCRIPTION OF OPERATION
disassembly, and re-assembly of the TDI Turbotwin
T50-P air starter. If there are questions not answered The Turbotwin T50-P air starter is powered by a two
by this manual, please contact your local TDI stage axial flow turbine coupled to a simple planetary
distributor or dealer for assistance. Illustrations and gear reduction set. The T50-P air starter incorporates
exploded views are provided to aid in disassembly and a pre-engaged drive coupled to the starter gearbox
re-assembly. drive train to provide a means of disengaging the pinion
from the engine’s ring gear.
The TDI Turbotwin T50-P engine air starter is specially
designed for starting today’s automated, low-emission The high horsepower of the turbine air motor combined
engines. The Turbotwin uses aerodynamic speed with the planetary gear speed reducer results in a very
control, allowing for cranking torque throughout the efficient and compact unit. The Turbotwin T50-P air
start cycle. starters can be used over a wide range of drive
pressures from 40 psig (2.7 BAR) to 120 psig (8 BAR)
The Turbotwin T50-P air starter is suited to operate and are suitable for operation on compressed air and
within a wide range of inlet pressures and ambient natural gas.
temperatures. This starter is designed for operation on
compressed air and natural gas. The T50-P weighs approximately 34 pounds (15 KG)
and is capable of delivering over 45 HP (33.6 kW) of
The robust turbine motor design in the Turbotwin T50-P cranking power at the maximum pressure of 120 psig
air starter has no rubbing parts and, therefore, is (8 BAR).
tolerant of hard and liquid contamination in the supply
to the starter. 1.4 INSTALLATION AND SERVICE

As with all TDI air starter products, there are no rubbing It is important to properly install and operate the TDI
parts so there is no lubrication required. This T50-P air starter to receive the full benefits of the
eliminates failures due to lubricator problems, the turbine drive advantages. It must be installed in
expense of installing and maintaining the system, and accordance with the instructions provided by Tech
the messy and hazardous oil film around the starter Development (TDI).
exhaust. The starter is factory grease packed for the
life of the starter so it requires no maintenance. WARNING
Failure to properly install the starter or failure to
Please review the rest of this manual before attempting operate it according to instructions provided by
to service the TDI Turbotwin T50-P air starter. TDI may result in damage to the starter or engine,
or cause personal injury. DO NOT OPERATE
1.2 WARNINGS, CAUTIONS, & NOTES THIS STARTER UNLESS IT IS PROPERLY
ATTACHED TO AN ENGINE.
Throughout this manual, certain types of information
will be highlighted for your attention: Repair technicians or service organizations without
turbine starter experience should not attempt to repair
WARNING - used where injury to personnel or this starter until they receive factory approved training
damage to equipment is possible. from TDI, or its representatives. Proper operation and
repair of your TDI Turbotwin will assure continuous
CAUTION - used where there is the possibility reliability and superior performance for many years.
of damage to equipment.

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1.5 NAMEPLATE INFORMATION

TURBOTWIN
The nameplate located on the turbine housing provides PNUEMATIC STARTER
TECH DEVELOPMENT INC.
important information regarding the construction of your
6800 POE AVE.,DAYTON
T50-P air starter, refer to Figure 1. The part number OH
coding explanation, refer to Figure 2, can help you MODEL NO. SERIAL NO. CW(RH) (CCW)LH)
when talking to your distributor. T510 9910-112 X .
PART NUMBER
NOTE T510-60048-01R-4 .
You should always have the starter’s Part Number, HOUSING PROOF PRESSURE IS 600 PSIG
Serial Number, Operating Pressure, and Direction of MAX OPERATING INLET PRESS. 120 PSIG
Rotation information before calling your TDI distributor WARNING DO NOT OPERATE UNLOADED, WITHOUT EXHAST
or dealer. GUARD OR WITHOUT EXHAUST FITTING

Figure 1. TDI TURBOTWIN Nameplate

T5 10 - 60048 - 01R - 0 - 00
MODEL T50 PRODUCT
ORIENTATION OF INLET/CONTROL PORTS
NUMBER OF NOZZLES 00= 0 DEGREES (STD) 07= 210 DEGREES
08= 8 NOZZLES 01= 30 DEGREES 08= 240 DEGREES
10= 10 NOZZLES 02= 60 DEGREES 09= 270 DEGREES
14= 14 NOZZLES 03= 90 DEGREES 10= 300 DEGREES
04= 120 DEGREES 11= 330 DEGREES
05= 150 DEGREES
DRAWING NUMBER FOR T50 MODEL TYPE
06= 180 DEGREES
60048= T50P (PRE-ENGAGED, OUTBOARD NOSE, 11.2:1 RATIO, SAE 3 MOUNT)
60051= T50Y (PRE-ENGAGED, OVERHUNG PINION, 11.2:1 RATIO, SAE 3 MOUNT)
60052= T50Y (PRE-ENGAGED, OVERHUNG PINION, 11.2:1 RATIO, SAE 1 MOUNT) EXHAUST OPTIONS
0= EXHAUST SCREEN
PINION CODES 1= (NOT AVAILABLE)
2= 2" NPT STRAIGHT
01= 6/8 DP, 11T ON 12T BLANK, 2.00 PD, 20° PA
3= (NOT AVAILABLE)
02= 8/10 DP, 12T ON 13T BLANK, 1.625 PD, 20° PA
03= 8/10P, 10T ON 11T BLANK, 1.375 PD, 20° PA 4= EXHAUST CLOSURE PLATE (ECP)
04= 3 MOD, 9T ON 9.567T BLANK, 1.063 PD, 14.5° PA 5= (NOT AVAILABLE)
05= 3 MOD, 11T ON 11.7 BLANK, 1.299 PD, 14.5° PA 6= (NOT AVAILABLE)
06= 3.5 MOD, 11T ON 11.64T BLANK, 1.516 PD, 14.5° PA 7= (NOT AVAILABLE)
07= 3.5 MOD, 13T ON 13.7T BLANK, 1.791 PD, 14.5° PA 8= (NOT AVAILABLE)
08= 8/10P, 13T ON 14T BLANK, 1.750 PD, 20° PA
09= 3.5 MOD, 15T ON 15.66T BLANK, 1.772 PD, 14.5° PA ROTATION
10= USE CODE #03 (THIS IS A LH VERSION) R= RH (CW)
11= 3.5 MOD, 17T ON 17.67T BLANK, 2.343 PD, 14.5° PA L= LH (CCW)
12= USE CODE #02 (THIS IS A LH VERSION)
13= 3.5 MOD, 14T ON 14.7T BLANK, 1.929 PD, 14.5° PA
14= 8/10DP, 12T ON 12T BLANK, 1.500 PD, 20° PA
15= 4.25 MOD, 11T ON 11T BLANK, 1.840 PD, 20° PA
16= 6/8DP, 12T ON 12.7T BLANK, 2.126 PD, 20° PA
17= USE CODE #01 (THIS IS A LH VERSION)
18= USE CODE #07 (THIS IS A LH VERSION)
19= 8/10 DP, 12T ON 13T BLANK, 1.625 PD, 20° PA
20= 3.5 MOD, 14T ON 14.7T BLANK, 2.026 PD, 20° PA
21= 4 MOD, 15T ON 15.65T BLANK, 2.465 PD, 0.325 CORRECTION FACTOR, 14.5° PA
22= 3.5 MOD, 14T ON 14.68T BLANK, 2.023 PD, 0.34 CORRECTION FACTOR, 14.5° PA
23= 3.5 MOD, 14T, 2.023 PD, 0.34 CORRECTION FACTOR, 20° PA

Figure 2. T50 Series Nameplate Identification

Page 2
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FROM TECH DEVELOPMENT

SECTION 2.0 DESCRIPTION OF 2.2 TURBINE HOUSING ASSEMBLY

BASIC GROUPS
The Turbine housing assembly, refer to figure 3,
2.1 GENERAL consists of a stage one (23) and a stage two (13)
turbine rotor mounted on sungear shaft (29). The front
The TDI Turbotwin T50-P air starter is a lightweight, bearing (15) is secured by a retainer plate (27) and the
compact unit driven by a two stage turbine air motor. aft bearing is pre-load by a spring washer (16).
The starter is composed of three basic assembly
groups: Turbine Housing Assembly, Gearbox Housing The ring gear (31) is installed between the turbine
Assembly, and Bendix Drive Assembly. assembly (26) and the gearbox housing (41) and
secured by four screws (42).

Figure 3. Turbine Housing Assembly

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2.3 GEARBOX HOUSING ASSEMBLY The carrier shaft (32) is mounted on a single bearing
(38) in the gearbox housing (41). The retainer ring (48)
secures the carrier shaft in the gearbox housing. The
The gearbox housing assembly, refer to figure 4,
bearing housing (44) and pre-engaged piston (50) are
consists of a planet gear carrier and output shaft (32),
installed in the gearbox housing (31).
three planet gears (36), needle bearings (37), spacers
(35), and planet shafts (34).

Figure 4. Gearbox Housing Assembly

2.4 DRIVE ASSEMBLY The front end of the carrier shaft (32) is mounted in a
needle bearing (58), which is installed in the nose of
The drive assembly, refer to figure 5, consists of a pre- the drive housing.
engagement drive (53) and drive housing (56). Twelve
screws (57) secure the drive housing to the gearbox Split rings (52) and a return spring (54) aid in the
housing. disengagement of the pinion from the engine’s ring
gear.

Figure 5. Drive Assembly

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SECTION 3.0 DISASSEMBLY
3.3 GEARBOX HOUSING
3.1 GENERAL
3.3.1 Removal of Gearbox Housing
Always mark adjacent parts on the starter; Nozzle 2/ Remove the four screws (42) and separate the gearbox
Containment Ring (21), Turbine Housing (26), Gearbox assembly from the turbine assembly. If the gearbox is
Housing (41), and Drive Housing (56) so these parts too tight, tap it with a mallet to loosen.
can be located in the same relative position when the
starter is reassembled. 3.3.2 Gearbox Disassembly

Do not disassemble the starter any further than Remove snap ring (48) and two thrust washers (47)
necessary to replace a worn or damaged part from carrier shaft (32).

Always have a complete overhaul kit on hand before Apply pressure to the carrier shaft to remove it from the
starting any overall of a Turbotwin T50-Pair starter. gearbox housing.
Never use old screws, seals, and o-rings.
Remove four screws (39) and press the bearing
The tools listed in Table 1 are suggested for use by housing/pre-engaged piston assembly (44,50) from the
technicians servicing the Turbotwin T50-P air starter. gearbox housing.
The best results can be expected when these tools are
used. Hand press bearing housing (44) out of pre-engaged
piston (50).
TOOL DESCRIPTION TDI/PN
Spanner Wrench 2-27272 3.3.3 Carrier Shaft/Planet Gear Disassembly
Stage 2 Rotor Puller Tool 52-20076
Remove snap ring (33) from planet shaft (34) and push
Tool, Turbine Bearing 45-25294
shaft through holes in assembly. Refer to figure 6.
Tool, Bearing/Seal 2-26943
Tool, Seal Positioning 45-25316 Slide the planet gear (36) out from the carrier shaft and
Table 1. T50 Series Service Tools (P/N: T50-28570)
remove the two spacers (35).

3.2 DRIVE HOUSING Press the needle bearing (37) from the planet gear (36)
to remove it.
3.2.1 Removal of Drive Housing

Mark position of drive pinion opening relative to

gearbox housing for reference during re-assembly.

Remove the 12 screws (57) and pull drive housing (56)

from gearbox housing (41). If drive housing is too tight,
tap it with a mallet to loosen.

3.2.2 Removal of Drive CARRIER SHAFT

ASSEMBLY (32)
PLANET
Remove return spring (54) and pull drive (53) from GEAR (36) PLANET GEAR
SPACER (35)
carrier shaft assembly (32).

Remove split rings (52) from drive assembly.

PLANET
BEARING (37)
PLANET
3.2.3 Drive Bearing Removal SHAFT (34)
RETAINING
RING (33)

Press needle bearing (58) from drive housing (56)

using press tool. Figure 6. Carrier Shaft Disassembly

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3.4 TURBINE HOUSING Remove the aft bearing (15), wavy washers (16), and
labyrinth (17) from nozzle 2.
3.4.1 Stage 2 Rotor Removal
Install three screws (42) removed from the gearbox
housing into the jack holes on the turbine housing (26)
Remove four screws (4), ECP assembly (5), exhaust
as shown in figure 9.
support (9), and exhaust guard (10). Units with an
exhaust screen (no ECP) will utilize 8 screws.
Turn the screws in sequence until the turbine housing
(26) is completely removed from the nozzle 2 (21).
Hold the stage 2 rotor (13) and remove the turbine
screw (11) and washer (12).
Remove the stage 1 rotor (23) and square key (14).

NOTE Press turbine shaft (29) through forward bearing (15) to

Secure the sun gear (29) in a soft jaw vise when remove bearing from shaft.
removing turbine screw.
ARBOR
PRESS
PRESSING TOOL
Install rotor puller tool P/N 52-20076 and remove the
stage 2 rotor as shown in figure 7. ROTOR, STG 1 (23)

SQUARE KEY (14)

PULLER TOOL
52-20076 ROTOR 2
(13)

TURBINE SHAFT (29)

NOZZLE, STAGE 1 (26)

NOZZLE 2/CONTAINMENT
RING (21)

Figure 8. Turbine Shaft Removal

NOZZLE, STAGE 1 (26)

1/4 - 20 UNC SCREW

Figure 7. Turbine Rotor Removal

Remove the square key (14)) from turbine shaft (29).

3.4.2 Turbine Housing Disassembly

Place the turbine on a firm surface with the sun gear

end facing up.
NOZZLE 2/CONTAINMENT
RING (21)
Remove three screws (28) and bearing retainer plate
(27) from turbine housing (26). Units with S/N: 0610-
0994 and after will utilize four screws.
Figure 9. Nozzle 2 Removal
With the exhaust end facing up, press turbine shaft (29)
through turbine housing (26) as shown in figure 8.
Remove labyrinth (24) from turbine shaft.
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ITEM NUMBER * TORQUE

In-lbs Nm
4 (Screw) 190 21
11 (Screw) 220 25
18 (Screw) 75 8
28 (Screw) 113 13
39 (Screw) 81 9
42 (Screw) 190 21
57 (Screw) 190 21
* Refer to section 6 for part number
identification.
Table 5. Torque Values

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SECTION 5.0 ASSEMBLY

5.1 GENERAL INFORMATION ARBOR

PRESS

PRESSING
The tools listed in Table 1 are suggested for use by TOOL 2-26943
technicians servicing the Turbotwin T50-P air starter.
The best results can be expected when these tools are
used.

CAUTION
Replace all screws, o-rings, lip seals, and bearings.
These parts are included in the overhaul kit shown in
the Parts List, Section 6.0.

NOTE
Always press the inner race of a ball bearing when
installing a bearing onto a shaft. Always press the Figure 11. Turbine Bearing / Shaft Installation
outer race of a ball bearing when installing into a
housing. DO NOT LOAD BEARING BALLS.
5.2.2 ROTOR 1 INSTALLATION
Lubricate all o-rings with petroleum jelly or Parker O-
ring Lube before assembly. Refer to Table 5 for a list Turn the turbine nozzle over (exhaust end up) and
of materials to be used during assembly. install the labyrinth (18) onto the shaft. For units with
0610-0994 and after press lip seal P/N: 2-26179 onto
MATERIALS SOURCE spacer P/N: 9-93114 and press lip seal with lips facing
Petroleum Jelly Commercially Available up into aft end of nozzle 1.
Parker-O-Ring Lube Commercially Available
Press the square key (14) into the keyway of turbine
Aeroshell #6 Grease Commercially Available
shaft (29) until seated.
Loctite RC290 Commercially Available
Grease, gearbox TDI P/N 9-94121-001 Install stage 1 rotor (23) by sliding over turbine shaft
Table 6. Materials for Assembly (29), while simultaneously aligning the key with the
keyway in the rotor.
5.2 TURBINE HOUSING
5.2.3 STAGE 2 NOZLE INSTALLATION
5.2.1 TURBINE BEARING INSTALLATION
Install turbine housing (26) into nozzle 2 containment
Press the turbine bearing (15) onto the turbine shaft housing (21).
(29) until seated.

Press the turbine bearing/shaft assembly (15,29) into NOTE

the turbine housing (26). Use press tool P/N 2-26943 if The air inlet port on nozzle 2 must be aligned with the
required per figure 11. Do not press on the end of the casting indentation on the turbine housing.
shaft because the load could damage the bearing balls.
5.2.4 ROTOR 2 INSTALLATION
Install the bearing retainer (27) into the turbine housing
(26) and secure with three screws (28) Torque to 75 Turn the turbine nozzle over (exhaust end up) and
in-lbs. Units with S/N: 0610-0994 and after will utilize install the labyrinth (17) onto the shaft.
four screws.
Install pre-load springs (16) into bearing bore of nozzle
Install o-ring (25) onto turbine housing (20). 2 containment housing (21).

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Install o-ring (43) into the groove on the bearing
housing (44).
Apply a light coating of oil to the bearing bore in the
Nozzle Containment Assembly and press the turbine
bearing (15) over the turbine shaft and into the bearing
bore using press tool P/N. 2-26943
NOTE
Apply a small amount of Aeroshell grease to the outer
Insert key (14) into turbine shaft keyway and install wall of the bearing hub and the inside wall of the
stage 2 rotor (13) onto shaft while simultaneously gearbox housing to allow for easier housing installation.
aligning the key with the keyway in the rotor.
Install the bearing housing assembly (38,44,46) in the
Secure stage 2 rotor with rotor washer (12) and rotor forward side of the gearbox housing (41) and secure
screw (11). Torque to 220 in-lb. with four screws (39). Torque to 81 In-Lbs.

Turn turbine housing over and install o-ring (30) into Install two o-rings (49,51) into the grooves on the pre-
the o-ring groove on the turbine housing (26). engaged piston (50).

Install plug (22) into Nozzle Containment Assembly.

NOTE
Install the ring gear (31) onto turbine housing with the Apply a small amount of Aeroshell # 6 grease to the
dowel pin hole facing up. inner and inner walls of the pre-engaged piston to allow
for easier installation.
Install dowel pin (40) into dowel pin hole in ring rear
(31). Press pre-engaged piston into the forward side of the
gearbox housing and remove any excess grease from
5.3 GEAR BOX ASSEMBLY gearbox housing.

5.3.1 PLANETARY GEAR CARRIER ASSEMBLY Install lip seal tool PN: 45-25316 into forward side of
gearbox housing (41) placing tapered end of tool into
Press needle bearings (37) into planet gears (36) using lip seal (46).
arbor press. The bearing ID stamping must be against
pressing tool. The bearing should be centered Install gearbox housing onto carrier shaft and place two
between gear faces. thrust washers (47) on carrier shaft (32). Secure with
snap ring (48) using snap ring pliers.
Place thrust washer (35) on each side of planet gear
(36) and install into carrier shaft (32) slot. 5.3.3 DRIVE INSTALLATION

Install planet shaft (34) into the carrier and secure with Apply a small amount of Aeroshell # 6 grease to split
snap ring (33). Be sure the anti-rotation pin is inserted rings (52) and install split rings onto drive assembly
into the slot on the carrier shaft. (53).

5.3.2 CARRIER SHAFT INSTALLATION Install o-ring (55) onto drive housing (56)

Install o-ring (43) into forward side of gearbox housing Install the drive assembly (53) onto carrier shaft and
(41). place return spring (54) over drive assembly.

If removed, press gearbox bushing (38) into bearing 5.3.4 NOSE BEARING INSTALLATION
housing (44).
Place the drive housing onto arbor press with the nose
Press the lip seal (46) into the forward side of the of drive facing down.
bearing housing (44) until seated using press tool P/N:
2-26943. Press needle bearing (58) into drive housing (56) using
arbor press. The bearing ID stamping must be against
pressing tool. Do not press bearing tight against the

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drive housing shoulder. In addition, be sure stamped
end is beneath shoulder of bearing bore.

Align gearbox assembly with turbine assembly and

fasten together with four screws (42).
5.4 FINAL ASSEMBLY
Install drive housing (56) onto gearbox housing (41)
and secure with twelve screws (57). Torque to 150 in-
Apply o-ring grease to o-ring (30) and install onto
lb.
gearbox housing.
Install exhaust closure plate assembly using four
Apply liberal amounts of grease (100 grams) to planet
screws (4). Torque to 150 in-lb.
gears (36), turbine shaft sun gear (29) and ring gear
(31).

Temporarily install one screw (42) into ring gear (31) to

prevent it from rotating while applying grease.

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SECTION 6.0 PARTS LIST

The components illustrated and/or described in this section are for the Turbotwin T50-P air starter. When rebuilding
a T50-P air starter, it is recommended to purchase and completely install the appropriate service kit(s).

T50-P ILLUSTRATED PARTS LIST

Overhaul Kit
ITEM # DESCRIPTION PART NUMBER QTY. T50P-28533-001
1 Nut, Hex 9-92155-06 1 9
2 Washer, Flat 9-93018-011 2
3 Plate, Baffle 2-20192 1
4 Screw 14F-25020-014 8 9
5 Housing, Exhaust Cover 2-28369 1
6 Bushing 9-91436 1
7 Spring, Compression 9-90408-016 1
8 Post 2-27223 1
9 Exhaust Support 2-27475 1
10 Exhaust Guard 2-28380 1
11 Screw, Rotor Attachment 14F-25028-012 1 9
12 Rotor Washer 9-93047 1
13 Stage 2 Rotor 2-28410 1
14 Square Key (1/8") 9-90220-050 2 9
15 Turbine Bearing 9-91224 2 9
16 Bearing Pre-Load Spring 9-90439 2 9
17 Spacer / Labyrinth 2-28445 1 9
18 Screw 71F-31218-020 4
19 Inlet Flange 2-28360 1
20 O-Ring 9-90001-031 1 9
21 Containment, Nozzle 2, RH 2-28359-00R 1
21 Containment, Nozzle 2, LH 2-28359-00L 1
22 Hollow Hex Plug 9-93501-002 1
23 Stage 1 Rotor 2-27225 1
24 Spacer/Labyrinth 2-28444 1 9
25 O-Ring 9-90001-047 1 9
26 Turbine Hsg. / Stage 1 (10 Noz. RH) 2-28354-10R 1
26 Turbine Hsg. / Stage 1 (10 Noz. LH) 2-28354-10L 1
26 Turbine Hsg. / Stage 1 (14 Noz. RH) 2-28354-14R 1
26 Turbine Hsg. / Stage 1 (14 Noz. LH) 2-28354-14L 1
27 Bearing Retainer 2-28446 1
28 Screw 71F-25020-012 3 9
29 Turbine Shaft 11.2:1) 2-28339 1
30 O-Ring 9-90001-047 2 9

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Overhaul Kit
ITEM # DESCRIPTION PART NUMBER QTY. T50P-28533-001
31 Ring Gear 2-28430 1
32 Carrier Shaft Assembly 2-28358 1
33 Retaining Ring 9-92001-001 3
34 Planet Shaft 2P-20182 3
35 Planet Gear Spacer 9-93004 6 9
36 Planet Gear (11.2:1) 2-28316 3
37 Planet Bearing 9-91004-001 3 9
38 Bushing 9-91405 1 9
39 Screw 14F-19024-012 4 9
40 Dowel Pin 9-91502-007-0-10 1
41 Gearbox Housing 2-28352 1
42 Screw 14F-25020-044 4 9
43 O-Ring 9-90001-035 1 9
44 Bearing Housing 2-24114 1
45 O-Ring 9-90002-331 1 9
46 Lip Seal 2-23810 1 9
47 Thrust Washers 9-93085 2 9
48 Retaining Ring 9-92001-025 1 9
49 O-Ring 9-90002-336 1 9
50 Pre-engage Piston 2-24644-001 1
51 O-Ring 9-90002-234 1 9
52 Split Rings 2-23419 2 9
53 Drive, 6/8P, 11T, RH 2-22954 1
53 Drive, 6/8P, 11T, LH 2-22956 1
53 Drive, 3.5MOD, 14T, RH 2-26816 1
53 Drive, 3.5MOD, 14T, LH 2-25933 1
53 Drive, 6/8P, 12T, RH 2-26143-001 1
54 Return Spring 9-90422 1
55 O-Ring 9-90001-041 1 9
56 Drive Housing (6/8P) 2-24127-007 1
57 Screw 14F-25020-012 12 9
58 Nose Bearing (6/8P) 9-91408 1 9

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Figure 12. T50-P Illustrated Parts List

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T50-P TURBINE ASSEMBLY (effective serial #: 0610-0994)

Overhaul Kit
ITEM # DESCRIPTION PART NUMBER QTY T50P-28533-001
24 Bearing Spacer 9-93114 1
24A Lip Seal 2-26719 1
26 Turbine Hsg. / Stage 1 (8 Noz. RH) 2-28354-08R 1
26 Turbine Hsg. / Stage 1 (8 Noz. LH) 2-28354-08L 1
26 Turbine Hsg. / Stage 1 (10 Noz. RH) 2-28354-10R 1
26 Turbine Hsg. / Stage 1 (10 Noz. LH) 2-28354-10L 1
26 Turbine Hsg. / Stage 1 (14 Noz. RH) 2-28354-14R 1
26 Turbine Hsg. / Stage 1 (14 Noz. LH) 2-28354-14L 1
27 Bearing Retainer 2-27406 1
28 Screw 71F-25020-012 4

Figure 13. Model T50 Series Turbine Assembly Configured for Air & Natural Gas
(Effective serial #: 0610-0994)

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2.5 Speed Control Devices

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2.5.1 UG A

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Product Manual 37512

(Revision H)
Original Instructions

UG-Actuator

Installation and Operation Manual

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This is the safety alert symbol. It is used to alert you to potential personal
injury hazards. Obey all safety messages that follow this symbol to avoid
possible injury or death.
x DANGER—Indicates a hazardous situation which, if not avoided, will result in death
or serious injury.
DEFINITIONS x WARNING—Indicates a hazardous situation which, if not avoided, could result in
death or serious injury.
x CAUTION—Indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury.
x NOTICE—Indicates a hazard that could result in property damage only (including
damage to the control).
x IMPORTANT—Designates an operating tip or maintenance suggestion.

The engine, turbine, or other type of prime mover should be equipped with an
overspeed shutdown device to protect against runaway or damage to the prime
mover with possible personal injury, loss of life, or property damage.
The overspeed shutdown device must be totally independent of the prime mover
control system. An overtemperature or overpressure shutdown device may also
be needed for safety, as appropriate.

Read this entire manual and all other publications pertaining to the work to be performed before
installing, operating, or servicing this equipment. Practice all plant and safety instructions and
precautions. Failure to follow instructions can cause personal injury and/or property damage.

This publication may have been revised or updated since this copy was produced. To verify that
you have the latest revision, be sure to check the Woodward website:
www.woodward.com/pubs/current.pdf
The revision level is shown at the bottom of the front cover after the publication number. The latest
version of most publications is available at:
www.woodward.com/publications
If your publication is not there, please contact your customer service representative to get the
latest copy.

Any unauthorized modifications to or use of this equipment outside its specified mechanical,
electrical, or other operating limits may cause personal injury and/or property damage, including
damage to the equipment. Any such unauthorized modifications: (i) constitute "misuse" and/or
"negligence" within the meaning of the product warranty thereby excluding warranty coverage
for any resulting damage, and (ii) invalidate product certifications or listings.

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

device, make sure the charging device is turned off before disconnecting the battery
from the system.

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

and observe the precautions in Woodward manual 82715, Guide for Handling and
Protection of Electronic Controls, Printed Circuit Boards, and Modules.

Revisions—Text changes are indicated by a black line alongside the text.

Woodward Governor Company reserves the right to update any portion of this publication at any time. Information
provided by Woodward Governor Company is believed to be correct and reliable. However, no responsibility is assumed
by Woodward Governor Company unless otherwise expressly undertaken.
© Woodward 1992
All Rights Reserved

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Manual 37512 UG-Actuator

Contents

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

CHAPTER 1. GENERAL INFORMATION ........................................................... 1
Introduction .............................................................................................................1
Description ..............................................................................................................1
Available Terminal Shafts and Drive Shafts ...........................................................2
UG Governor Similarities ........................................................................................3
Hydraulic Pump ......................................................................................................3
References .............................................................................................................3
CHAPTER 2. INSTALLATION.......................................................................... 8
Introduction .............................................................................................................8
Receiving ................................................................................................................8
Storage ...................................................................................................................8
Drive Shaft Rotation ...............................................................................................8
Attitude....................................................................................................................9
Mounting Dimension ...............................................................................................9
Drive Connection ....................................................................................................9
Remote Actuator Oil Connection ..........................................................................10
Control Linkage ....................................................................................................10
Oil Supply .............................................................................................................12
Electrical Connection ............................................................................................14
Heat Exchanger Selection ....................................................................................15
CHAPTER 3. INITIAL OPERATION ................................................................ 17
CHAPTER 4. PRINCIPLES OF OPERATION ................................................... 18
Introduction ...........................................................................................................18
Increase in Load or Speed Setting .......................................................................18
Decrease in Load or Speed Setting .....................................................................19
Loss of Control Voltage ........................................................................................19
CHAPTER 5. SERVICE OPTIONS ................................................................. 20
Product Service Options .......................................................................................20
Woodward Factory Servicing Options ..................................................................21
Returning Equipment for Repair ...........................................................................21
Replacement Parts ...............................................................................................22
Engineering Services............................................................................................22
How to Contact Woodward ...................................................................................23
Technical Assistance ............................................................................................23
UG-ACTUATOR CONTROL SPECIFICATIONS ............................................... 25

Woodward i

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UG-Actuator Manual 37512

Illustrations and Tables

Figure 1-1. The UG-Actuator ..................................................................................1

Figure 1-2. Outline Drawing of UG-Actuator ..........................................................4
Figure 1-3. Remote Mounted Actuator ...................................................................5
Figure 1-4. Drive Shaft and Terminal Shaft Configurations ...................................6
Figure 1-5. Schematic of UG-Actuator ...................................................................7
Figure 2-1. Alignment of Reference Notch and Arrow............................................9
Figure 2-2. Terminal Shaft Travel .........................................................................11
Figure 2-3. Linear Linkage....................................................................................11
Figure 2-4. Nonlinear Linkage ..............................................................................11
Figure 2-5. Oil Chart .............................................................................................13
Figure 2-6. Viscosity Comparisons .......................................................................14
Figure 2-7a. Wiring for a UG-Actuator ..................................................................15
Figure 2-7b. Wiring for a UG-Actuator with LVDT ................................................16
Figure 2-8. UG-Actuator Heat Exchanger ............................................................16

ii Woodward

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Regulatory Compliance
The UG Actuator is suitable for use in Class I, Division 2, Groups A, B, C, and D
per CSA for Canada or non-hazardous locations only.

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

methods as applicable, and in accordance with the authority having jurisdiction.

These listings are limited only to those units bearing the CSA agency
identification.

EXPLOSION HAZARD—Do not remove covers or connect/disconnect

electrical connectors unless power has been switched off or the area
is known to be non-hazardous.

Substitution of components may impair suitability for Class I,

Division 2.

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

raccorder / débrancher les prises électriques, sans vous en
assurez auparavant que le système a bien été mis hors
tension; ou que vous vous situez bien dans une zone non
explosive.

La substitution de composants peut rendre ce matériel

inacceptable pour les emplacements de Classe I, Division 2.

Woodward iii

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Manual 37512 UG-Actuator

Chapter 1.
General Information

Introduction
This manual describes the installation and operation of the UG-Actuator.

Figure 1-1. The UG-Actuator

Description
The UG-Actuator is a proportional electro-hydraulic actuator which can be used
with electronic controls which provide a 20 to 160 mA position signal. The
actuator is designed for use with Woodward 2301, 400, 43027, 500-series, and
700-series controls.

The actuator converts a given electrical signal to an output shaft position through
the action of a torque motor and follower-type pilot valve. The rotary output
actuator has 42 degrees of terminal (output) shaft travel. Recommended travel
from the no-load to the full-load position is 2/3 of full actuator travel.

The UG-Actuator is used on diesel, gas, and gasoline engines (also steam and
industrial gas turbines) to replace UG-8 type governors, providing the
advantages of electronic control and load sharing systems with the convenience
of the existing UG-8 type drive and linkage.

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The standard UG-Actuator provides a maximum work capacity of 19.4 J (14.3
ft-lb) in the increase direction, and 23.3 J (17.2 ft-lb) in the decrease direction. A
special actuator is available which provides 27.1 J (20.0 ft-lb) of work in both
directions. Another special actuator is the remote actuator which does not have a
drive shaft. Pressurized oil (758–2758 kPa/110–400 psi) must be supplied to the
actuator. The remote actuator has 27.1 J (20.0 ft-lb) when supplied with 2758
kPa/400 psi. Work capacity is based on the full 42 degree travel of the terminal
(output) shaft. Rated work capacity is 2/3 of maximum work capacity.

The actuator can be built with a low speed pump for speed ranges of 375 to 1100
rpm, or with a high speed pump for 600 to 1500 rpm.

The UG-Actuator is available with an LVDT for position feedback. The LVDT is
not available with the MPU option. With the LVDT, the actuator has a 10-pin
connector on the cover.

The actuator may be equipped with a special gear and magnetic pickup, using
the governor drive to sense engine speed. This permits an added convenience
when converting from a UG hydraulic-mechanical governor to an electronic
control system. Low cranking speeds may require override of the electronic
failsafe. The MPU option is not available with the 27.1 J (20.0 ft-lb) work capacity
UG-Actuator.

The MPU will sense the speed of the governor drive, which is not
necessarily the same rpm as the engine. The frequency sensed by
the MPU must match the frequency range of the electronic control.

The UG-Actuator output is directly proportional to a 20 to 160 mA signal from an

electronic control system.

This manual provides outline drawings to show the base and drive
configurations. The outline drawings include information on electrical wiring,
installation dimensions, drive requirements, oil requirements, and output shaft
dimensions. The drawings are provided for reference only. Do not use the
drawings for construction.

Available Terminal Shafts and Drive Shafts

The following terminal shafts and drive shafts are available:

Standard—
0.500–36 serrated terminal shaft (0.625–36 serrated for the 20 ft-lb model)
0.625–36 serrated drive shaft

Available (for special applications at additional cost)—

Terminal Shafts—
0.562 / 0.625 D-shaped terminal shaft
0.500–36 serrated terminal shaft with one missing serration
0.500–36 serrated terminal shaft on RH or LH side only

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Keyed Drive Shafts—
0.750–6 splined drive shaft
1.125–48 serrated drive shaft [with PG-style base adapter]
French standard BNA 227 NF-E22-151 0.16-31 drive shaft
RHD6 drive shaft
0.625 keyed drive shaft with 0.625-18 thread
Extended 0.625 keyed drive shaft

UG Governor Similarities
The UG-Actuator uses the same cast-iron case as the UG governor. The
standard UG output shaft, power lever, power piston, and piston link are used in
the actuator. The base is designed to fit any drive designed for a UG governor.

Hydraulic Pump
The UG-Actuator is equipped with a Gerotor pump (3161 governor type). High
speed and low speed pumps are available, depending on the drive speed from
the engine. The pump uses oil from the self-contained UG-Actuator sump to
provide 1172 kPa (170 psi) internal operating pressure.

The direction of rotation is selected by pump housing alignment. The pump

operates in one direction only. The drive uses a maximum of 375 W (0.5 hp). In
some cases the actuator may require an oil cooler to operate at the high end of
the drive speed range.

References
The following publications provide additional information about installation,
operation, and storage of Woodward products. All are available on the
Woodward website (www.woodward.com).

Publication
25071 Oils for Hydraulic Controls
25075 Commercial Preservation Packaging for Storage of Mechanical-
Hydraulic Controls
50516 Governor Linkage for Butterfly Control Valve
37511 UG-Actuator Product Specification

This manual does not attempt to provide information about the electronic control
which determines the position of the UG-Actuator output. This information must
be obtained from the appropriate manual for the electronic control. Contact your
nearest Woodward Distributor or Authorized Independent Service Facility about
repairs.

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Figure 1-2. Outline Drawing of UG-Actuator

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Figure 1-3. Remote Mounted Actuator

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Figure 1-4. Drive Shaft and Terminal Shaft Configurations

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Figure 1-5. Schematic of UG-Actuator

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Chapter 2.
Installation

Introduction
This chapter describes receiving, storage, and installation requirements for the
UG-Actuator.

Use care while handling and installing the UG-Actuator. Be particularly careful to
avoid striking the drive shaft, terminal shaft, or the electrical connector. Abuse
can damage seals, internal parts, and factory adjustments. Do not set the
actuator on its drive shaft.

Receiving
After factory testing and calibration, the UG-Actuator is drained of oil. This leaves
a light film of oil on internal parts to prevent rust. External parts are painted or
coated with a spray lubricant/rust inhibitor.

No internal cleaning or flushing is necessary before installation and operation.

The little oil left in the actuator is clean, multi-viscosity engine oil which will not
contaminate the oil selected to operate the actuator.

Fill the actuator with 1.4 liters (1.5 quarts) of oil selected to match the expected
operating conditions. (If the actuator is a direct replacement for a UG governor,
you may use the same grade and weight of oil that was being used in the
governor.) Use only new, clean oil in the actuator. Do not allow dirt or
contamination to enter the actuator while filling with operating oil. Do not use oil
drained from the UG governor.

Storage
The UG-Actuator may be stored for short periods of time (less than a year) as
received from the factory. For long-term storage (more than a year), storage in an
environment with large temperature changes, humid or corrosive atmosphere, etc.,
or if the actuator is installed on the engine for storage, fill the actuator with oil and
follow preservation packaging instructions in Woodward manual 25075,
Commercial Preservation Packaging for Storage of Mechanical-Hydraulic Controls.

Drive Shaft Rotation

The actuator drive-shaft rotation is one direction only. Rotation, as viewed from
the top of the actuator, must be the same as that of the engine drive when
looking down on the mounting pad.

If the actuator oil pump is rotated in the wrong direction, oil pressure will not be
generated in the actuator.

Be sure engine mounting-pad drive and actuator-drive rotation are

the same. Incorrect drive rotation will cause the actuator to become
inoperative, and may cause actuator damage.

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Figure 2-1. Alignment of Reference Notch and Arrow

Use the following procedure to change the direction of rotation:

1. Remove the four pump-housing screws.

2. Index the pump plate 180 degrees to align the arrow corresponding to the
direction of rotation selected with the reference notch in the base.

3. Replace the four screws, and torque the screws to 16.4–17.5 N·m (145–155
lb-in).

4. Make sure that the actuator drive shaft rotates freely.

Attitude
The UG-Actuator can be installed in a vertical or near vertical position without
affecting its calibration. Do not install more than 45 degrees from vertical. See
the outline drawing for installation instructions and dimensions.

Mounting Dimension
When using the o-ring supplied with the actuator to seal between the actuator
and actuator mounting pad on the engine, the mounting hole should have
dimensions of 82.7–83.2 mm (3.255–3.275 inches) in order to provide the correct
amount of squeeze on the o-ring. The mounting hole must be concentric with the
drive in order to avoid side-loading the actuator drive shaft.

Drive Connection
Make sure the actuator drive shaft turns freely before installing the actuator. The
drive gear or coupling must slip freely into the governor drive of the engine. Do
not apply external force. The drive must be free of binding, side load, or excess
end-play. Improper alignment or fit between the parts can result in excessive
wear or actuator-drive seizure.

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Mount the actuator squarely on the mounting pad. Torque the mounting bolts
evenly. There can be no movement or rocking of the actuator on the engine-
mounting pad.

Remote Actuator Oil Connection

If the UG-Actuator is remotely installed, oil supply is through the side of the base
mounting plate (Figure 1-3). Connect the external pressure supply to one of the
two .250–18 NPTF ports in the base mounting plate. The oil supply line should
be fitted with a 20–25 μm filter. The oil supply pressure must be at least 758 kPa
(110 psi). A pressure of 2758 kPa (400 psi) will be required for 27 J (20 ft-lb) of
output. The remote unit will require 1.9 L/min (0.5 US gal/min) at steady state
and 9.5 L/min (2.5 US gal/min) transient response supply flow.

Connect the return line to the .250–18 NPTF port in the top cover. Do not use the
.125–27 connection in the base during operation. The actuator should be kept
filled with oil for corrosion protection of internal parts.

Control Linkage
The terminal shaft rotates 42 degrees. Use 2/3 of the total rotation between no
load and full load. The additional “overtravel” should be split and used at both
ends to provide maximum fuel when required and to assure shutdown at
minimum-fuel actuator position (see Figure 2-2).

To prevent possible serious injury or loss of life, or damage to the

engine, be sure to allow sufficient overtravel at each end of the
terminal shaft so the actuator can shut down the engine, and also
give maximum fuel when required. Misadjusted linkage could prevent
the actuator from shutting down the engine.

Many control problems are related to the linkage between the actuator and the
engine. Use only first-quality rod ends for the linkage, rod ends that will last
under the nearly constant motion associated with precise speed control. The
linkage must be stiff, not subject to engine-caused vibration. The linkage must be
as light as possible and still maintain the attributes of stiffness. Linkage which is
too heavy can damage the actuator as well as make it difficult to achieve steady
control.

Installed linkages must operate smoothly, be free of binding, and free of lost
motion due to worn parts. If there is a collapsible member in the linkage, be sure
it does not yield each time the actuator moves the linkage rapidly.

Use a linear linkage for most diesel applications. Most gasoline and gas fueled
engines will require a non-linear linkage. See Figures 2-3 and 2-4 for information
on the arrangements of linear and nonlinear connections. Linear linkage moves
the fuel setting shaft in direct proportion to the movement of the actuator output.
Nonlinear fuel arrangement lets the actuator open the fuel setting more at
maximum settings than it does at minimum settings. Woodward application note
50516, Governor Linkage for Butterfly Throttle Valves, provides more information
about non-linear linkage.

Design the linkage so the power output of the engine is proportional to the
position of the actuator output shaft.

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Figure 2-2. Terminal Shaft Travel

Follow the engine manufacturer's instructions on linkage selection, installation,

and adjustment. In almost all cases, the linkage designed for a UG-8 governor
will work with the UG-Actuator. In the case of a direct exchange, make sure that
the linkage is in good condition and the installation of the lever on the actuator is
in the same position as it was on the governor.

Figure 2-3. Linear Linkage Figure 2-4. Nonlinear Linkage

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Oil Supply
Use the information given in Figures 2-5 and 2-6 as a guide in the selection of a
suitable oil. Oil grade selection is based on the operating temperature range of
the actuator. Also use this information to aid in recognizing and correcting
common problems associated with oil used in the actuator. Many operation and
maintenance problems associated with UG-Actuators are directly related to the
selection and condition of the oil in the actuator. Use care in the selection and
make sure that the oil in the actuator is not contaminated.

The oil in the UG-Actuator is both a lubricating and hydraulic oil. It must have a
viscosity index that allows it to perform over the operating temperature range and
it must have the proper blending of additives that cause it to remain stable and
predictable over this range.

The UG-Actuator is designed to give stable operation with most oils, if the fluid
viscosity at the operating temperature is within a 50 to 3000 SUS (Saybolt
Universal Seconds) range (see Figure 2-6). Poor actuator response or instability
is an indication that the oil is too thick or too thin.

Actuator oil must be compatible with seal material, that is, nitrile, polyacrylic, and
fluorocarbon. Many automotive and gas engine oils, industrial lubricating oils,
and other oils of mineral or synthetic origin meet these requirements.

Fill the actuator with about 1.4 liters (1.5 quarts) of oil, to the mark on the oil sight
glass. After the engine is started and the actuator is at operating temperature,
add oil if necessary. Oil must be visible in the glass under all operating
conditions.

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

1. Insufficient lubrication caused by:

an oil that flows slowly when it is cold, especially during start-up;
no oil in the actuator.
2. Contaminated oil caused by:
dirty oil containers;
an actuator exposed to heating and cooling cycles, which created
condensation of water in the oil.
3. Oil not suitable for the operating conditions caused by:
changes in ambient temperature;
an improper oil level which creates foamy, aerated oil.

Operating an actuator continuously beyond the high limit temperature of the oil
will result in oil oxidation. This is identified by varnish or sludge deposits on the
actuator parts. To reduce oil oxidation, lower the actuator operating temperature
with a heat exchanger or other means, or change to an oil more oxidation-
resistant at the operating temperature.

To prevent possible serious injury or loss of life, or damage to the

engine, resulting from engine overspeed or a runaway engine, be
sure to use only oil that falls within the 50 to 3000 SUS range. Using
oils outside this range could cause the actuator to be unable to
prevent a runaway engine.

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Oil Maintenance
Replace the actuator oil if it is contaminated, and change it if it is suspected of
contributing to instability. Drain the oil while it is still hot. Flush the actuator with a
clean solvent having some lubricating quality (fuel oil or kerosene) before refilling
with new oil. If drain time is insufficient for the solvent to completely drain or
evaporate, flush the actuator with the same oil it is being refilled with to avoid
dilution and possible contamination of the new oil.

Oil that has been carefully selected to match the operating conditions and is
compatible with actuator components should give long service between oil
changes. Check oil conditions regularly and change oil if any deterioration or
contamination is suspected.

Regularly scheduled oil changes will extend the life of the actuator and improve
actuator operation. Properly selected oil should permit annual oil changes, but
more frequent changes are recommended.

Figure 2-5. Oil Chart

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Figure 2-6. Viscosity Comparisons

EXPLOSION HAZARD—Do not remove covers or connect/disconnect

electrical connectors unless power has been switched off or the area
is known to be non-hazardous.

Substitution of components may impair suitability for Class I,

Division 2.

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

raccorder / débrancher les prises électriques, sans vous en
assurez auparavant que le système a bien été mis hors
tension; ou que vous vous situez bien dans une zone non
explosive.

La substitution de composants peut rendre ce matériel

inacceptable pour les emplacements de Classe I, Division 2.

Due to the hazardous location listings associated with this product,

proper wire type and wiring practices are critical to operation.

Do not connect any cable grounds to “instrument ground”, “control

ground”, or any non-earth ground system. Make all required
electrical connections based on the wiring diagrams (Figures 2-7a
and 2-7b).

Electrical Connection
The electrical connector on the UG-Actuator is a 3-pin (MS-3102E-14S-7P) plug
connector. The LVDT version has a 10-pin connector (MS-3102E-18-1P or
MS-3102R-18-1P).

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Heat Exchanger Selection

A heat exchanger is available for the UG-Actuator. It consists of a plate mounted
on the front of the actuator. Passages are cut in the plate that allow cooling fluid
to pass through the plate and remove energy from the actuator. The guidelines
for when to use the heat exchanger are not straightforward, and some knowledge
of the installation is required.

The pump on the UG-Actuator generates energy which must be dissipated from
the actuator. Most of the energy is dissipated through the bottom mounting
surface of the actuator . Therefore, the more direct mounting (no gasket) and the
better heat-dissipating mounting surface (wide) will allow the actuator to run at
the lowest temperatures.

Because of the variability of mounting surfaces, it is difficult to quantify the

maximum drive speed to maintain the actuator oil at a safe temperature to not
break down the oil. Analysis predicts a 0.65 degree C increase in oil temperature
relative to the mounting surface for each increase of 100 rpm on the low speed
pump, and 0.45 degree C per 100 rpm for the high speed pump. Lab tests show
as much as 0.6 degree C per 100 rpm for the high speed pump. This is
complicated by the fact that the mounting temperature will also rise, so the rise in
oil temperature per 100 rpm is actually greater than this. The rise in the mounting
surface temperature depends greatly on the geometry of the mounting surface
itself.

Refer to Figure 2-8 for selection of heat exchanger parameters. The temperature
reduction achieved with the heat exchanger depends on the difference between
the heat exchanger inlet temperature and the temperature of the actuator oil
without the heat exchanger. It also depends on the specific heat of the coolant.
The chart is based upon petroleum oil. It does not depend heavily on supply
pressure of the coolant. Testing at Woodward was done at 138 and 345 kPa (20
and 50 psi), as a guideline.

Overall, to maintain the lowest actuator temperature at a given rpm, use the
thinnest gasket or none at all (seal with an o-ring around pump housing) and
provide the lowest possible coolant temperature to the heat exchanger.

Figure 2-7a. Wiring for a UG-Actuator

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Figure 2-7b. Wiring for a UG-Actuator with LVDT

Figure 2-8. UG-Actuator Heat Exchanger

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Chapter 3.
Initial Operation

Before initial operation of the engine equipped with a UG-Actuator, read all of
Chapter 2, Installation Procedures. Make sure that all installation steps have
been correctly accomplished and all linkages are secured and properly attached.

Carefully review the direction of rotation for the actuator oil pump.

Follow this procedure when putting a new or repaired UG-Actuator into service.

1. Check that the actuator is full of the proper type and grade of clean oil.

2. Properly adjust the linkage.

To prevent possible serious injury or loss of life, or damage to the

3. Select a LOW SPEED setting on the Woodward electronic control to give

low engine speed at initial start up.

Be prepared to make an emergency shutdown when starting the

engine, turbine, or other type of prime mover, to protect against
runaway or overspeed with possible personal injury, loss of life, or
property damage.

4. Follow the engine manufacturer's instructions, and start the engine.

5. Adjust the selected speed setting on the Woodward electronic control as

necessary to bring the engine to rated speed.

6. Obtain system stability as outlined in the electronic control instruction

manual. (If less than the recommended actuator output stroke is used, it
may cause for less than optimum engine stability or response.)

All operating adjustments of the UG-Actuator are made during factory calibration.
Additional adjustment should not be needed.

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Chapter 4.
Principles of Operation

Introduction
This chapter describes the operation of the UG-Actuator. The schematic drawing
in Figure 1-5 illustrates the working relationship of the various parts.

Connecting oil passages between components are simplified for ease in

visualizing the system.

The UG-Actuator contains its own sump.

The UG-Actuator consists of the following basic components:

1. Oil Pump
Gerotor pump. Pump is driven by the actuator drive shaft.

2. Relief Valve
Set to maintain internal operating pressure at 1172 kPa (170 psi).

3. Oil Filter
Filters oil to the pilot valve to prevent contamination of the orifice and
nozzle. Bypass oil flows through the filter, providing a filter-cleaning function.

4. Torque Motor, Torque Motor Beam, Feedback Spring, and Loading Spring
Used to establish a mechanical position of the pilot valve flapper in
response to the dc current being sent to the actuator.

5. Pilot Valve Plunger

A follower-type valve, which duplicates the movement of the torque-motor
beam, but at a much higher force level, controls flow of oil to and from the
servo. The pressure regulator is used to minimize calibration shifts due to
speed-induced pump pressure changes.

6. Power Piston, Terminal Lever, and Terminal Shaft

The terminal lever converts the linear motion of the differential-type servo
piston to rotary motion of the terminal shaft, which in turn moves the fuel
linkage. The terminal-shaft position is fed back to the torque-motor beam to
provide the proportional control.

Increase in Load or Speed Setting

An increase in load, or speed setting, causes an increase in control current from
the electronic control to the torque motor. This, in turn, causes an increase in the
torque-motor force, tending to lower the centering adjustment end of the torque
motor beam. The flow of oil through the nozzle is decreased, which increases
pressure on the top side of the differential power land. Pressure above the
differential power land then moves the pilot-valve plunger down, or allows the
plunger to follow the torque-motor beam as if they were one piece. Pressure oil is
now directed to the underside of the servo piston, causing it to move upward,
which rotates the terminal lever and terminal shaft in the increase-fuel direction.

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As the terminal shaft rotates, the range adjustment and feedback linkage
increases the feedback spring force, and cause the torque-motor beam to move
away from the nozzle. As flow through the nozzle is less restricted, pressure
decreases on the top side of the differential power land to start moving the pilot-
valve plunger up. The terminal shaft and pilot-valve plunger movement continues
until the increase in feedback-spring force equals the increase in force seen in
the torque motor. When the pilot-valve control land is centered, all movement
stops at the new position required to run the engine at the increased load or
speed setting.

Decrease in Load or Speed Setting

A decrease in load or speed setting causes a decrease in control current from
the electronic control to the torque motor. This, in turn, causes a decrease in
torque motor force, and raises the centering adjustment of the torque motor
beam. The pilot valve follows the beam and uncovers the control port. Oil trapped
under the servo piston escapes to drain, causing the servo piston to move
downward and the terminal shaft to rotate in the decrease-fuel direction.

As the terminal shaft rotates, the range adjustment and feedback linkage decrease
the feedback-spring force. The terminal shaft rotates until the decrease in spring
force equals the decrease in force in the torque motor, and the pilot-valve plunger
is centered. This stops the servo piston and the actuator shaft in the new position
needed to run the engine at the decreased load or speed setting.

Loss of Control Voltage

Upon loss of control voltage, the actuator terminal shaft goes to minimum fuel,
thus offering a safety feature.

With loss of control voltage, there is no current sent to the torque motor and no
magnetic force generated. The torque motor and attached beam and the force of
the loading spring causes the center adjustment to raise. The pilot valve follows,
keeping the control port uncovered. Trapped oil escapes to drain, and the servo
piston moves down until it reaches minimum fuel position.

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Chapter 5.
Service Options

Product Service Options

If you are experiencing problems with the installation, or unsatisfactory
performance of a Woodward product, the following options are available:
x Consult the troubleshooting guide in the manual.
x Contact the manufacturer or packager of your system.
x Contact the Woodward Full Service Distributor serving your area.
x Contact Woodward technical assistance (see “How to Contact Woodward”
later in this chapter) and discuss your problem. In many cases, your
problem can be resolved over the phone. If not, you can select which course
of action to pursue based on the available services listed in this chapter.

OEM and Packager Support: Many Woodward controls and control devices are
installed into the equipment system and programmed by an Original Equipment
Manufacturer (OEM) or Equipment Packager at their factory. In some cases, the
programming is password-protected by the OEM or packager, and they are the best
source for product service and support. Warranty service for Woodward products
shipped with an equipment system should also be handled through the OEM or
Packager. Please review your equipment system documentation for details.

Woodward Business Partner Support: Woodward works with and supports a

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

A current list of Woodward Business Partners is available at

www.woodward.com/support/directory.cfm.

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Woodward Factory Servicing Options

The following factory options for servicing Woodward products are available
through your local Full-Service Distributor or the OEM or Packager of the
equipment system, based on the standard Woodward Product and Service
Warranty (5-01-1205) that is in effect at the time the product is originally shipped
from Woodward or a service is performed:
x Replacement/Exchange (24-hour service)
x Flat Rate Repair
x Flat Rate Remanufacture

Replacement/Exchange: Replacement/Exchange is a premium program

designed for the user who is in need of immediate service. It allows you to
request and receive a like-new replacement unit in minimum time (usually within
24 hours of the request), providing a suitable unit is available at the time of the
request, thereby minimizing costly downtime. This is a flat-rate program and
includes the full standard Woodward product warranty (Woodward Product and
Service Warranty 5-01-1205).

This option allows you to call your Full-Service Distributor in the event of an
unexpected outage, or in advance of a scheduled outage, to request a
replacement control unit. If the unit is available at the time of the call, it can
usually be shipped out within 24 hours. You replace your field control unit with
the like-new replacement and return the field unit to the Full-Service Distributor.

Charges for the Replacement/Exchange service are based on a flat rate plus
shipping expenses. You are invoiced the flat rate replacement/exchange charge
plus a core charge at the time the replacement unit is shipped. If the core (field
unit) is returned within 60 days, a credit for the core charge will be issued.

Flat Rate Repair: Flat Rate Repair is available for the majority of standard
products in the field. This program offers you repair service for your products with
the advantage of knowing in advance what the cost will be. All repair work carries
the standard Woodward service warranty (Woodward Product and Service
Warranty 5-01-1205) on replaced parts and labor.

Flat Rate Remanufacture: Flat Rate Remanufacture is very similar to the Flat
Rate Repair option with the exception that the unit will be returned to you in “like-
new” condition and carry with it the full standard Woodward product warranty
(Woodward Product and Service Warranty 5-01-1205). This option is applicable
to mechanical products only.

Returning Equipment for Repair

If a control (or any part of an electronic control) is to be returned for repair,
please contact your Full-Service Distributor in advance to obtain Return
Authorization and shipping instructions.

When shipping the item(s), attach a tag with the following information:
x return authorization number;
x name and location where the control is installed;
x name and phone number of contact person;
x complete Woodward part number(s) and serial number(s);
x description of the problem;
x instructions describing the desired type of repair.

Woodward 21

DBAE529722- 2-189
2. Vendor manuals Wärtsilä 20 Engine O&MM Attachments

UG-Actuator Manual 37512

Packing a Control
Use the following materials when returning a complete control:
x protective caps on any connectors;
x antistatic protective bags on all electronic modules;
x packing materials that will not damage the surface of the unit;
x at least 100 mm (4 inches) of tightly packed, industry-approved packing
material;
x a packing carton with double walls;
x a strong tape around the outside of the carton for increased strength.

To prevent damage to electronic components caused by improper

handling, read and observe the precautions in Woodward manual
82715, Guide for Handling and Protection of Electronic Controls,
Printed Circuit Boards, and Modules.

Replacement Parts
When ordering replacement parts for controls, include the following information:
x the part number(s) (XXXX-XXXX) that is on the enclosure nameplate;
x the unit serial number, which is also on the nameplate.

Engineering Services
Woodward offers various Engineering Services for our products. For these services,
you can contact us by telephone, by email, or through the Woodward website.
x Technical Support
x Product Training
x Field Service

Technical Support is available from your equipment system supplier, your local Full-
Service Distributor, or from many of Woodward’s worldwide locations, depending
upon the product and application. This service can assist you with technical
questions or problem solving during the normal business hours of the Woodward
location you contact. Emergency assistance is also available during non-business
hours by phoning Woodward and stating the urgency of your problem.

Product Training is available as standard classes at many of our worldwide

locations. We also offer customized classes, which can be tailored to your needs
and can be held at one of our locations or at your site. This training, conducted
by experienced personnel, will assure that you will be able to maintain system
reliability and availability.

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

and location, from many of our worldwide locations or from one of our Full-
Service Distributors. The field engineers are experienced both on Woodward
products as well as on much of the non-Woodward equipment with which our
products interface.

For information on these services, please contact us via telephone, email us, or
use our website: www.woodward.com/support.

22 Woodward

2-190 DBAE529722-
Wärtsilä 20 Engine O&MM Attachments 2. Vendor manuals

Manual 37512 UG-Actuator

How to Contact Woodward

For assistance, call one of the following Woodward facilities to obtain the address
and phone number of the facility nearest your location where you will be able to
get information and service.

Electrical Power Systems Engine Systems Turbine Systems

Facility---------------- Phone Number Facility---------------- Phone Number Facility---------------- Phone Number
Brazil ------------- +55 (19) 3708 4800 Brazil ------------- +55 (19) 3708 4800 Brazil ------------- +55 (19) 3708 4800
China ----------- +86 (512) 6762 6727 China ----------- +86 (512) 6762 6727 China ----------- +86 (512) 6762 6727
Germany: Germany: India --------------- +91 (129) 4097100
Kempen ---- +49 (0) 21 52 14 51 Stuttgart----- +49 (711) 78954-0 Japan -------------- +81 (43) 213-2191
Stuttgart----- +49 (711) 78954-0 India --------------- +91 (129) 4097100 Korea -------------- +82 (51) 636-7080
India --------------- +91 (129) 4097100 Japan -------------- +81 (43) 213-2191 The Netherlands - +31 (23) 5661111
Japan -------------- +81 (43) 213-2191 Korea -------------- +82 (51) 636-7080 Poland--------------- +48 12 295 13 00
Korea -------------- +82 (51) 636-7080 The Netherlands - +31 (23) 5661111 United States ---- +1 (970) 482-5811
Poland--------------- +48 12 295 13 00 United States ---- +1 (970) 482-5811
United States ---- +1 (970) 482-5811

You can also contact the Woodward Customer Service Department or consult our
worldwide directory (www.woodward.com/support/directory.cfm) for the name
of your nearest Woodward distributor or service facility.

Technical Assistance
If you need to telephone for technical assistance, you will need to provide the following information.
Please write it down here before phoning:

Your Name
Site Location
Phone Number
Fax Number
Engine/Turbine Model Number
Manufacturer
Number of Cylinders (if applicable)
Type of Fuel (gas, gaseous, steam, etc)
Rating
Application
Control/Governor #1
Woodward Part Number & Rev. Letter
Control Description or Governor Type
Serial Number
Control/Governor #2
Woodward Part Number & Rev. Letter
Control Description or Governor Type
Serial Number
Control/Governor #3
Woodward Part Number & Rev. Letter
Control Description or Governor Type
Serial Number

If you have an electronic or programmable control, please have the adjustment setting positions or
the menu settings written down and with you at the time of the call.

Woodward 23

DBAE529722- 2-191
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UG-Actuator Manual 37512

24 Woodward

2-192 DBAE529722-
Wärtsilä 20 Engine O&MM Attachments 2. Vendor manuals

UG-Actuator Control Specifications

Control Qualities
Hysteresis Within 3% of maximum travel when measured over full 42 degree travel.
Within 0.5% of maximum travel when measured over 4% of full travel at
1 Hz.
Temperature Drift Nominally ±1 degree per 42 ºC (108 ºF)
Time Constant 70 to 90 ms for 50 mA step with 1172 kPa (170 psi) actuator oil pressure
Linearity Within 2.5% of full 42 degree output travel
Work Output 27.7 Nxm (20.4 lb-ft) stalled torque; 20 J (15 ft-lb) of work over 42 degrees.
The UG-Actuator operates with 1172 kPa (170 psi) internal hydraulic
pressure.
Pump Gerotor (3161 pump). Relief valve set at 1172 kPa (170 psi).
Output Shaft 0.500-36 inch serrated standard. In same location relative to drive as UG
governor. (See Chapter 1 for additional optional shafts.)
Drive Shaft 0.625-36 serration standard. (See Chapter 1 for additional optional shafts.)
Weight 16 kg (36 lb), dry weight
Vibration Resistance Vibration tested to US MIL-STD 810C, Curve D (10 G to 2000 Hz; in Y-axis,
parallel to drive shaft, 8 G maximum)

Drive/Hydraulic Specifications
Drive Speed and Rotation Actuator available with either high or low speed pump. High speed pump:
600 to 1500 rpm. Low speed pump: 375 to 1100 rpm. Drive operates in one
direction only.
Drive Power Requirement Drive will use a maximum of 375 W (0.5 hp)
Hydraulic Supply Self contained sump, 1.4 liter (1.5 quart) capacity. See Woodward manual
25071, Oils for Hydraulic Controls, for specific recommendations. In most
cases, the same type and weight of oils used in the engine can be used in
the governor.
Ambient Temperature Range +29 to +93 °C (+20 to +200 °F)
Operating Temperature +29 to +93 °C (+20 to +200 °F), within the limits of the oil being used in the
governor

Electrical Specifications
Electrical Connector 3 pin, US MIL-STD 3102E-14S-7P, located in cover
LVDT: 10-pin, US MIL-STD 3102E-18-1P or MS 3102R-18-1P
Coil Resistance 23–26 1 at 20 °C
Calibration 1–2 degrees at 20 mA, 37 ±2 degrees additional travel from 20 mA to 160
mA. Reaches maximum fuel at less than 200 mA.

Regulatory Compliance
These listings are limited only to those units bearing the CSA agency identification.

CSA: CSA Certified for Class I, Division 2, Groups A, B, C, & D, T4 at

122 °C ambient, for use in Canada
Certificate: 160584-1365765

DBAE529722- 2-193
2. Vendor manuals Wärtsilä 20 Engine O&MM Attachments

We appreciate your comments about the content of our publications.

Send comments to: icinfo@woodward.com

Please reference publication 37512H.

PO Box 1519, Fort Collins CO 80522-1519, USA

1000 East Drake Road, Fort Collins CO 80525, USA
Phone +1 (970) 482-5811 x Fax +1 (970) 498-3058

Email and Website—www.woodward.com

Woodward has company-owned plants, subsidiaries, and branches,

as well as authorized distributors and other authorized service and sales facilities throughout the world.
Complete address / phone / fax / email information for all locations is available on our website.

2011/1/Colorado

2-194 DBAE529722-
This page has intentionally been left blank.
Wärtsilä is a global leader in complete lifecycle power solutions for the marine and energy markets.
By emphasising technological innovation and total efficiency, Wärtsilä maximises the environmental
and economic performance of the vessels and power plants of its customers. Wärtsilä is listed on the
NASDAQ OMX Helsinki, Finland.

Wärtsilä Services Main Office Vaasa, Finland

Switchboard +358 10 709 0000
Find local offices at www.wartsila.com/contact

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