Control/Regulation C0

M32

Control/Regulation

16 M 32 C

Engine No.: 34247 Record No.: 262151

34264
34265

en / 20.09.2010 AA047729 1
 Total Index C0.01

Control/Regulation C0
Total Index C0.01
Introduction Electrical Equipment C0.02
Table of contents C5.01

en / 20.09.2010 AA047685 1/1

 Introduction C0.02
Electrical Equipment

M20-M601C

The structure of the contents ensures that you will find the required spares very quickly

Example: Electrical Equipment

Electrical engine equipment

C5.05.05 10.17.93

Book C Chapter Engine Regulation

External Documentation

- These documents reflect your actual engine equipment and are, therefore, not compatible with other or
similar engine plants.

- Possible modifications or additions to the catalogue due to conversions will be carried out on request by
our customer service.

Ordering Spare Parts:

Please observe the following when ordering spare parts:

1. All spare parts orders must be placed with your dealer.

2. In case of multi-engine plants please do not place a collective order.

3. Each engine must be treated separately stating its respective engine No.
Please find attached the required enquiry/order sheets.

4. For reasons of order handling each order must contain the following data:

• P.O. number/Customer ref. No.

• Order date
• Forwarding address (telephone/fax number and person in charge)
• Date of delivery
• Required date of arrival (ETA)
• Marks, special instructions, e.g. complete delivery
• Ship’s name/plant
• Engine type
• Engine No.
• Shipping instruction, unless otherwise specified we will choose the cheapest method of
shipment, not prepaid ex works
• Drawing No. and sheet
• Part No.
• Catalogue sheet No.
• Description and measuring point No.
• Quantity
• Address on invoice, i.e. the complete address to which the invoice is to be made out

en / 28.11.2006 AA035841 1/7

 Introduction C0.02
Electrical Equipment

M20-M601C

Procedure

Variant A

The damaged component with identification of measuring point must be identified on the engine or cable.

Exhaust thermocouple cylinder 1

Next to the plug a metal plate with identification of the measuring point is fitted. Additionally, the measu-
ring point number is identified on the cable of the plug-in connection.

Measuring point No. 8211.1

In the chapter Electrical Equipment Engine C5.05.05.10.nn the component with stock
No. 273 450 450 is easily found by means of the measuring point No. 8211.1 .

en / 28.11.2006 AA035841 2/7

 Introduction C0.02
Electrical Equipment

M20-M601C

Variant B

By means of the drawings Sensor - Actuators - Arrangement / Engine General View

Here as well measuring point 8211.1 can be found. Procedure as described above.

Example B1

8211.1 Thermocouple type K 273 450 450

...
8211.6

en / 28.11.2006 AA035841 3/7

 Introduction C0.02
Electrical Equipment

M20-M601C

A relay can be clearly identified by means of the drawing Junction Box 1. In this example K9

In the chapter Electrical Equipment Engine C5.05.05.10.nn the component with stock No. 213 480 770 is
easily found by means of component identification K9.

Example B2

K9 Attaching type relay 213 480 770

en / 28.11.2006 AA035841 4/7

 Introduction C0.02
Electrical Equipment

M20-M601C

Variant C

With the electric documents Sensoric Level Sensor Junction Box 1 / Alarm System
Level probe B7301 Water min. Measuring point No. 7301.

In the chapter Electrical Equipment Engine C5.05.05.10.nn the component with stock No. 213 483 072 is
easily found by means of the measuring point No.7301.

Example C

7301 Level probe 213 483 016

en / 28.11.2006 AA035841 5/7

 Introduction C0.02
Electrical Equipment

M20-M601C

Variant D

Ordering a cable

If a cable has to be replaced, at least a measuring point or plug designation is to be safely identified.

By stating the engine number the part "cable loom" can be ordered.

en / 28.11.2006 AA035841 6/7

cvb2 Caterpillar Motoren GmbH & Co. KG

Anfrage/Ersatzteilbestellschein / Spare Parts Inquiry or Order Sheet

Auftrags-Nr,/Kunden-Referenz-Nr. Auftragsdatum
P.O. Number/Customer Ref. No. Order date

Käufer/Buyer Empfänger/Consignee
(postalisch einwandfreie Anschrift) (genaue Warenempfänger-Anschrift) Liefertermin Erforderlicher Ankunftstermin
exact postal address exact addressee of consignee Date of Delivery (voraussichtliche Ankunftszeit)
Date of required arrival (eta)

Markierung, spezielle Anweisungen, z. B. vollständige Lieferung

Marks, special instructions, e. g. complete delivery

Schiffsname/Anlage/Ship's name/Plant Motor-Typ/Engine Type Motor-Nr./Engine No. *) Versandart/Shipping Instructions

Bitte stets angeben Nur von Caterpillar auszufüllen

Pl i d O l b l db C ill
Pos. Sach-Nr. Zeichnungs-/Teile-Nr. Sach-Nr. Zeichnungs-/Teile-Nr. Benennung und Messstellennummer Menge
Item Stock No. Drawing/Part No. Stock No. Drawing/Part No. Description and Measuring Point No. Quantity
Beispiel für Bestellung Beispiel für Bestellung
As an illustration for ordering As an illustration for ordering
213 480 770 9-A-1081-83, Page 5 Attaching type relay 4
1
2
3
4
5
6
7
8
9
10
*) Pro Einzelbestellschein nur eine Motor-Nr. angeben!
Please state only one engine no. on each spare parts order sheet! Rechtsverbindliche Unterschrift und Stempeldruck des Bestellers
Stamp and signed by buyer
Fordern Sie bitte rechtzeitig kostenlos neue Vordrucke zur Bestellung von Ersatzteilen an
44.17/11.06 Please forward your requirement of free-of-charge new order sheets in due time to us ..................................................................................................................................
 Table of contents C5.01

Table of contents C5.01

Engine, measuring points C5.05.02

A List of Measuring Point C5.05.02.01.51.53

Engine, control C5.05.04

B UG40 Actuator C5.05.04.20.20.34
C Booster Servomotor C5.05.04.20.22.01
D Oil - Regulations
(Woodward) C5.05.04.20.27.01
E Adjustment "MaK-Genset 723+"
(Woodward) C5.05.04.20.29.50

Engine, regulation C5.05.05

F Circuit diagram Motor C5.05.05.10.31.67
G Equipment List Engine C5.05.05.10.61.47
H Maintenance Unit
Control Stand C5.05.05.45.23.03
I Electrical Equipment
RPM Switch Unit C5.05.05.70.06.45
J Electrical Equipment
Engine Monitoring Devices Terminal Box C5.05.05.70.16.63
K RPM Switch Unit
Description C5.05.05.75.11.45

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 List of Measuring Points C5.05.02.01.51.53
-

VM32

List of Measuring Points

en / 14.11.2006 FD032469 1/5

 List of Measuring Points Engine 16M32C
c Unit Description
Sensors and Actuators
Sensor range Trigger Remarks
Signal range Normal

1105 Pressure transmitter 0 – 600 kPa

Lub. oil pressure low – pre alarm shutdown 4-20mA 1105 350 kPa
500 kPa
1106 Pressure switch 0 – 600 kPa 290 kPa
Lub. oil pressure low – shutdown binary 500 kPa
1202 Resistance thermometer -40-160° C 70° C
Lub. oil temp. at engine inlet high – alarm PT 100 60-65° C
1203 NTC/switch unit -40-120° C 75° C
Lub. oil temp. at engine inlet high – shutdown binary 60-65° C
1251/1253 Oil mist detector VN115/87 1 evaluation unit for
9631 1251 Oil mist concentration in crankcase high – 1251 : 0,5...25% 1251 2% 1251 , 1253 , 9631
alarm binary < 2%
1253 Oil mist concentration in crankcase high – 1253 : 0,5...25% 1253 2%
shutdown binary <2%
9631 Oil mist detector failure – alarm 9631 -
binary
2102 Pressure transmitter 0 – 600 kPa * * 40 kPa below
Cooling water pressure HT at engine inlet low – 4-20mA > 250 kPa operating pressure
alarm
2103 Pressure switch 0 – 600 kPa * * 60 kPa below
Cooling water pressure HT at engine inlet low – binary > 250 kPa operating pressure
shutdown stop delay : 20s
2112 Pressure transmitter 0 – 600 kPa * * 40 kPa below
Cooling water pressure LT at engine outlet low – 4-20mA > 200 kPa operating pressure
alarm
2201 Resistance thermometer -40-160° C -
Cooling water temp. HT at engine inlet - Dicare PT 100 > 75° C
2211 Resistance thermometer -40-160° C 93° C
Cooling water temp. HT at engine outlet high- PT 100 80-90° C
alarm
2213 NTC/switch unit -40-120° C 98° C
Cooling water temp. HT at engine outlet high- binary 80-90° C
shutdown
2229 Resistance thermometer -40-160° C -
Cooling water temp. LT at engine inlet – PT 100 < 40° C
indication
5102 Pressure transmitter 0 – 1000 kPa 100 kPa
Fuel oil pressure at engine inlet low - alarm 4-20mA 400 kPa
5111 Differential pressure switch 0 – 80 kPa 80 kPa
Differential pressure fuel oil filter high – alarm binary < 60 kPa

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 List of Measuring Points Engine 16M32C
c Unit Description
Sensors and Actuators
Sensor range Trigger Remarks
Signal range Normal

5201/5202* Resistance thermometer

5201 Fuel oil temp. at engine inlet low – alarm -40-160° C 5201 : 35° C
PT 100 40-50° C 1 sensor for 5201 + 5202*
5202 Fuel oil temp. at engine inlet high – alarm 5202 : 60° C * not in use with HFO
40-50° C
5301 Level probe/switch unit - 2 sensors 5301A + 5301B
Leakage oil niveau at engine high - alarm binary for 5301
6101 Pressure transmitter 0 – 6000 kPa 1250 kPa
Starting air at engine inlet low - alarm 4-20mA 1200-3000 kPa
6105 Pressure switch 100-1200 kPa 600 kPa Alarm delay : 2s
Stopping air pressure at engine low - alarm binary 750 kPa
6181 Absolute pressure transmitter 80 – 120 kPa
Intake air pressure in engine room - Dicare 4-20mA
7109 Pressure transmitter 0 – 400 kPa
Charge air pressure at engine inlet - Dicare 4-20mA
7201 Resistance thermometer -40-160° C 65° C
Charge air temp. at engine inlet high - alarm PT 100 45-60° C
7206 Resistance thermometer -40-160° C
Intake air temp. at turbocharger inlet - Dicare PT 100
7301 Level probe/switch unit -
Condense water in charge air canal - alarm binary
7307 Differential pressure transmitter 0 – 10 kPa
Charge air diff. pressure at charge air cooler - 4-20mA
Dicare
7309A Thermocouple type K -200-1300° C -
Charge air temp. at charge air cooler inlet A - NiCr-Ni < 200° C
Dicare (mV)
7309B Thermocouple type K -200-1300° C -
Charge air temp. at charge air cooler inlet B - NiCr-Ni < 200° C
Dicare (mV)
8211.1A Thermocouple type K -200-1300° C * * Load dependend with
……. Exhaust gas temp. after cylinder 1A.....8A – NiCr-Ni < 440° C alarm delay : 16s
8211.8A shutdown (mV)
8211.1B Thermocouple type K -200-1300° C * * Load dependend with
……. Exhaust gas temp. after cylinder 1B.....8B – NiCr-Ni < 440° C alarm delay : 16s
8211.8B shutdown (mV)
8221A Thermocouple type K -200-1300° C * 350° C * Load dependend with
Exhaust gas temp. at turbocharger outlet A - NiCr-Ni < 400° C alarm delay : 16s
shutdown (mV)
8221B Thermocouple type K -200-1300° C * 350° C * Load dependend with
Exhaust gas temp. at turbocharger outlet B - NiCr-Ni < 400° C alarm delay : 16s
shutdown (mV)

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 List of Measuring Points Engine 16M32C
c Unit Description
Sensors and Actuators
Sensor range Trigger Remarks
Signal range Normal

8231A Thermocouple type K -200-1300° C -

Exhaust gas temp. at turbocharger inlet A - NiCr-Ni < 580° C
Dicare (mV)
8231B Thermocouple type K -200-1300° C -
Exhaust gas temp. at turbocharger inlet B - NiCr-Ni < 580° C
Dicare (mV)
R1A Resistance thermometer -40-160° C
Temperature compensation thermocouples PT 100
Bank A
R1B Resistance thermometer -40-160° C
Temperature compensation thermocouples PT 100
Bank B
R16 Resistance thermometer -40-160° C
Electr. charge air temp. control PT 100
9419.1 Pick up 0-1200 upm -
RPM switching equipment 0-15 KHz < 1 KHz
9419.2 Pick up 0-1200 upm -
RPM switching equipment 0-15 KHz < 1 KHz
9419.3 Pick up 0-1200 upm -
Electronic governor 0-15 KHz < 1 KHz
9419.4 Pick up 0-1200 upm -
Electronic governor 0-15 KHz < 1 KHz
9429A Pick up /transmitter 0-30000 upm -
Turbine speed A – Dicare 4-20mA < 31000 upm
Turbine speed A – Indication 0-10V
9429B Pick up /transmitter 0-30000 upm -
Turbine speed A – Dicare 4-20mA < 31000 upm
Turbine speed A – Indication 0-10V
9503 Limit switch -
Control lever at fuel rack – 100% fuel binary
9509 Distance sensor / switching device 125% Load -
Fuel setting 4-20mA < 100% Load
9561 Limit switch -
Turning gear engaged - starting interlock binary
9601 Relay contact -
Voltage failure at terminal X1 - alarm binary
9717 Relay contact -
Voltage failure at terminal X3 - alarm binary
S1 Limit switch -
Turning gear engaged binary
Contactor reverser ON
Y1.1 Solenoid valve -
shutdown 24V DC/ 6W

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 List of Measuring Points Engine 16M32C
c Unit Description
Sensors and Actuators
Sensor range Trigger Remarks
Signal range Normal

Y1.2 Solenoid valve -

Start 24V DC/ 6W
Y1.6 Solenoid valve -
Starting interlock for manual emergency start 24V DC/ 18,5W
M1 Actuator -
0 - 200mA

CD6_Mischke Page: 4
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 UG40 Actuator C5.05.04.20.20.34
-

UG40 Actuator

en / 18.02.2002 FD022663 1/27

We appreciate your comments about the content of our publications.
Please send comments to:
Woodward Governor Company
Attention: Technical Publications
PO Box 1519
Fort Collins CO 80522-1519, USA
Please include the manual number from the front cover of this publication.

Woodward Governor Company/Industrial Controls

PO Box 1519, Fort Collins CO 80522-1519, USA
1000 East Drake Road, Fort Collins CO 80525, USA
Phone (1)(970) 482-5811 • Fax (1)(970) 498-3058
E-mail and World Wide Web Home Page—http://www.woodward.com

Registered Firm
ISO 9001:1994/Q9001-1994
Certificate QSR-36

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/e-mail information for all locations is available on our website.

00/12/F
 Booster Servomotor C5.05.04.20.22.01
-

Booster Servomotor

en / 20.10.2003 FD022607 1/37

36684M

Booster
Servomotor

Single Cylinder (8901-037, -043, -051)

Tandem (8901-065, -067)
Two-Stage (8901-091, -103)

Installation and Operation Manual

Manual 36684M
 WARNING
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.

The engine, turbine, or other type of prime mover should be equipped with an
overspeed (overtemperature, or overpressure, where applicable) shutdown
device(s), that operates totally independently of the prime mover control device(s)
to protect against runaway or damage to the engine, turbine, or other type of prime
mover with possible personal injury or loss of life should the mechanical-hydraulic
governor(s) or electric control(s), the actuator(s), fuel control(s), the driving
mechanism(s), the linkage(s), or the controlled device(s) fail.

IMPORTANT DEFINITIONS
WARNING—indicates a potentially hazardous situation which, if not avoided, could
result in death or serious injury.

CAUTION—indicates a potentially hazardous situation which, if not avoided, could

result in damage to equipment.

NOTE—provides other helpful information that does not fall under the warning or
caution categories.

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.
© 1974, 1998 by Woodward Governor Company
All Rights Reserved
Manual 36684 Booster Servomotor

Contents

CHAPTER 1. GENERAL INFORMATION ........................................................... 1

Introduction.............................................................................................................1
Description..............................................................................................................1
Types of Boosters...................................................................................................1
Regulatory Compliance ..........................................................................................2
CHAPTER 2. INSTALLING AND ADJUSTING A BOOSTER SERVOMOTOR ........... 7
General Rules.........................................................................................................7
Installing and Adjusting a Single Cylinder Booster.................................................7
Installing and Adjusting a Tandem Booster............................................................8
Installing and Adjusting a Two-Stage Booster .......................................................9
CHAPTER 3. PRINCIPLES OF OPERATION ................................................... 15
How Single-Cylinder and Tandem Boosters Operate ..........................................15
How a Two-Stage Booster Operates ...................................................................16
CHAPTER 4. REPLACEMENT PARTS ........................................................... 19
Ordering Replacement Parts................................................................................19
Parts List for Figure 4-1........................................................................................20
Parts List for Figure 4-2........................................................................................22
Parts List for Figure 4-3........................................................................................24
CHAPTER 5. SERVICE OPTIONS ................................................................. 27
Product Service Options.......................................................................................27
Returning Equipment for Repair...........................................................................28
Replacement Parts ...............................................................................................29
How to Contact Woodward...................................................................................29
Engineering Services ...........................................................................................30
Technical Assistance............................................................................................31

Illustrations and Tables

Figure 1-1. Schematic of Single Booster Connections to PG-Type Governor.......3

Figure 1-2. Schematic of Tandem Booster Connections to PG-Type Governor....3
Figure 1-3. Outline Drawing of Single Booster.......................................................4
Figure 1-4. Outline Drawing of Tandem Booster....................................................5
Figure 1-5. Outline Drawing of Two-Stage Booster ...............................................6
Figure 2-1. Governors Used with Single-Cylinder Boosters ................................11
Figure 2-2. Governors Used with Single-Cylinder Boosters ................................12
Figure 2-3. Governors Used with Tandem Boosters............................................13
Figure 2-4. Governors Used with Two-Stage Boosters .......................................14
Figure 3-1. Single Booster, Phase 1 ....................................................................15
Figure 3-2. Single Booster, Phase 2 ....................................................................15
Figure 3-3. Two-Stage Booster, Phase 1.............................................................16
Figure 3-4. Two-Stage Booster, Phase 2.............................................................16
Figure 3-5. Two-Stage Booster, Phase 3.............................................................17
Figure 4-1. Exploded View of Single Boosters.....................................................21
Figure 4-2. Exploded View of Tandem Boosters..................................................23
Figure 4-3. Exploded View of Two-Stage Boosters .............................................25

Woodward i
Booster Servomotor Manual 36684

ii Woodward
Manual 36684 Booster Servomotor

Chapter 1.
General Information

Introduction
This manual covers the three types of Woodward booster servomotor:
x Low-volume, single-cylinder booster
x Medium-volume, double-cylinder (tandem) booster
x High-volume, two-stage booster

Description
A booster servomotor supplies pressurized oil to mechanical-hydraulic governors
and electro-hydraulic actuators at the instant starting air reaches the engine. This
instant oil pressure eliminates the time required for the rotary gear pump in the
governor to build up enough oil pressure to move the linkage. This produces a
faster start, which conserves starting air, and in vessels with direct reversible
engines, improves maneuverability.

When the booster is inactive, a piston is held at one end of a cylinder by a spring.
The cylinder is full of oil supplied from a line from the governor's sump.

Compressed air applied to the side of the piston opposite this oil forces the
piston against the oil, which flows through ports at the other end of the cylinder to
the governor.

When air is removed from the piston, the spring returns the piston to its rest
position. Reduced pressure in the cylinder causes oil to flow into it from the
sump.

Check valves at all oil ports allow oil to flow in only one direction. This prevents
oil in the booster from flowing back to the governor's sump when the booster
operates, and prevents oil in the booster outlet lines from flowing back into the
booster when it is inactive.

Types of Boosters
Boosters are available with different air-to-oil pressure ratios, making them
suitable for both high and low air pressure applications:
Model Type Pressure Ratio
(Oil Out to Air In)
8901-037, -043 single-cylinder 1:1
8901-051 single-cylinder 2:1
8901-065 tandem 1:1
8901-067 tandem 2:1
8901-091 two-stage 2:1
8901-103 two-stage 3:1

Single-cylinder boosters supply enough oil for governors with small and medium
work outputs, such as UG-8/-40, EGB-10/-13, 3161, and PG governors with
outputs of 16 and 23 J (12 and 17 ft-lbs).

Woodward 1
Booster Servomotor Manual 36684
Tandem boosters, with larger volumes of oil and three oil outlets, are appropriate
for PG-29/-58, EG-29/-58, and PG-TM 58 governors (39/79 J; 29/58 ft-lb).

Two-stage, high-volume boosters meet the boost oil requirements for PG, EGB,
and PG-TM governors with 271, 407, and 678 J (200, 300, and 500 ft-lb) power
cases.

Single-Cylinder Booster (Figures 1-1 and 1-3)

Single-cylinder boosters have two oil outlets: one is unrestricted, and one has a
built-in orifice-type restriction. Outlet #1 (unrestricted) is connected directly to the
governor's oil pressure system. Outlet #2 (restricted) can be used to pressurize
the speed setting servo, which compresses the speeder spring of PGA, PGPL,
and PGG governors equipped with any shutdown feature.

A single-cylinder booster has two air inlets, one restricted and one unrestricted.
Using the restricted air inlet results in slower movement of the fuel rack.

Tandem Booster (Figures 1-2 and 1-4)

Tandem boosters have two cylinders and three oil outlets. Outlet #1 is
unrestricted. The other two outlets are restricted by an adjustable needle valve.

Oil outlet #1 is connected to the governor's accumulator. Outlet #2 is connected

to the speed setting servo (of PGA, PGPL, and PGG governors equipped with
any shutdown feature). Outlet #3 is connected to a point directly under the power
piston.

If outlet #2 is used, its needle valve determines the rate at which the speeder
spring is compressed. The needle valve in outlet #3 controls the rate at which the
power piston moves.

Two-Stage Booster (Figures 1-5, 2-4, and 3-3)

Two-stage boosters have three oil outlets, but a two-stage feature allows oil to
flow through outlet #2 before it flows through the other two outlets.

In most applications, outlet #1 supplies oil to the power piston in the governor.
Outlet #2 supplies oil to the speed setting servo (of PGA, PGPL, and PGG
governors equipped with any shutdown feature). Outlet #3 supplies oil to the
relay piston.

Regulatory Compliance
Compliance with the following European Directives or standards does not qualify
this product for application of the CE Marking:

Machinery Directive: Compliance as a component with 98/37/EC

COUNCIL DIRECTIVE of 23 July 1998 on the
approximation of the laws of the Member States
relating to machinery.
Pressure Equipment Compliant as “SEP” per Article 3.3 to Pressure
Directive: Equipment Directive 97/23/EC of 29 May 1997 on
the approximation of the laws of the Member States
concerning pressure equipment.

2 Woodward
Manual 36684 Booster Servomotor

Figure 1-1. Schematic of Single Booster Connections to PG-Type Governor

Figure 1-2. Schematic of Tandem Booster Connections to PG-Type Governor

Woodward 3
Booster Servomotor Manual 36684

Figure 1-3. Outline Drawing of Single Booster

4 Woodward
Manual 36684 Booster Servomotor

Figure 1-4. Outline Drawing of Tandem Booster

Woodward 5
Booster Servomotor Manual 36684

Figure 1-5. Outline Drawing of Two-Stage Booster

6 Woodward
Manual 36684 Booster Servomotor

Chapter 2.
Installing and Adjusting a Booster
Servomotor

General Rules
Observe the following rules when you install a Woodward booster servomotor.

Location
Install the booster servomotor at a lower level than the governor to prevent air
from being trapped in the booster and oil lines.

Oil Lines
Oil lines must slope up from the booster to the governor with a minimum of loops
and bends.

Oil Leakage
It is not unusual for small oil particles (from assembly oil) to come out of the vent
hole at initial use of the booster and after several starts in a row, due to oil
particles in the bleed air.

Starting-Air Valve
A starting-air valve (supplied by the customer) must be installed in the air line to
the booster. This valve must admit compressed air to the booster at the same
time that starting air is supplied to the engine, and it must vent the air cylinder of
the booster to atmosphere when starting air is removed from the engine. Air
pressure at the booster air inlet must not exceed 3500 kPa (500 psi).

CAUTION
Purge air from the booster's oil chamber, the tubing, and the governor
before starting the engine, by cycling the booster piston with start-air or air
from a separate source. Failure to purge air completely may result in
sluggish governor response.

Installing and Adjusting a Single Cylinder Booster

Models 8901-037, -043, and -051 (Figures 1-3, 2-1, and 2-2)

Refer to the general rules at the beginning of this section.

Figures 2-1 and 2-2 show locations of inlet and outlet ports on Woodward
governors with which a single-cylinder booster can be used. Figure 1-3 shows
locations of ports and the stroke limit screw on a single-cylinder booster.

Install 10 mm (3/8 inch) steel tubing from the sump of the governor to the oil inlet
on the booster.

Install 6 mm (1/4 inch) steel tubing from oil outlet #1 on the booster to the power
piston (the inlet marked “OUTLET #1”) of the governor.

Woodward 7
Booster Servomotor Manual 36684
If the governor is a PGA, PGPL, or PGG equipped with any shutdown feature,
install 6 mm (1/4 inch) steel tubing from oil outlet #2 on the booster to the speed
setting servo (the inlet marked “OUTLET #2”) of the governor. Otherwise, plug
outlet #2 (this plug is delivered with the booster).

Connect a line containing an air-starting valve from the starting-air supply to the
appropriate air inlet on the booster. Use the inlet with the built-in orifice if you
want to move the fuel racks at a slower rate. The other air inlet needs to be
plugged.

Fill the governor with oil to the proper level (refer to the installation manual for the
governor).

When all air and oil connections are secure, purge air from the booster and oil
lines by cycling air to the booster from a remote source without cranking the
engine. Add oil to the governor as needed.

When there is no more air in the booster and oil lines, set the initial opening of
the fuel racks by adjusting the stroke of the booster piston. Turn the stroke limit
screw counterclockwise to increase starting fuel, and clockwise to decrease it.
This screw limits the intake stroke of the booster and the volume of oil supplied
to the governor in one stroke of the booster servomotor.

Installing and Adjusting a Tandem Booster

Models 8901-065 and 8901-067 (Figures 1-4 and 2-3)

On PGA governors, decals indicating where to connect lines from the booster do
NOT apply to tandem boosters. Refer to Figure 2-3 when connecting a tandem
booster to a PGA governor.

Refer to the general rules at the beginning of this section.

Figure 2-3 shows locations of outlet and inlet ports on governors with which a
tandem booster can be used. Figure 1-4 shows locations of stroke limit screws
and ports on a tandem booster.

Connect 10 mm (3/8 inch) steel tubing from the sump of the governor to the oil
inlet on the booster; and from oil outlet #1 of the booster to the accumulator of
the governor.

On PGA, PGPL, and PGG governors equipped with any shutdown feature,
connect 6 mm (1/4 inch) steel tubing from oil outlet #2 on the booster to the
speed setting servo of the governor.

On PGA, PGPL, and PGG governors, connect 6 mm (1/4 inch) steel tubing from
oil outlet #3 on the booster to the power piston of the governor.

Connect a line with an air-starting valve from the starting-air supply to the air inlet
on the booster.

Plug the unused oil outlet(s) and air inlet (these plugs are delivered with the
booster).

Fill the governor with oil to the correct level (refer to the installation manual for
the governor).

8 Woodward
Manual 36684 Booster Servomotor
When all oil and air connections are secure, purge air from the booster and oil
lines by cycling air to the booster from a remote source without cranking the
engine. Add more oil to the governor as needed.

When there is no more air in the booster and oil lines, limit the volume of oil
going to the governor by adjusting the two stroke limit screws. The positions of
these screws determine the maximum volume of oil supplied by the booster.
This, in turn, determines the maximum travel of the fuel racks. Turn the screws
clockwise to reduce the travel of the racks, and counterclockwise to increase the
travel.

Adjust the needle valves in oil outlets #2 and #3. If outlet #2 is used, its needle
valve controls the rate of oil flow to the speeder spring servo, which determines
how fast the speeder spring servo moves. The needle valve in outlet #3 controls
the rate at which the power piston moves. Turn the needle valve clockwise to
restrict oil flow, and counterclockwise to increase flow.

NOTE
Outlets #2 and #3 are connected to separate cylinders. Outlet #1 is
connected to both cylinders, with check valves preventing flow between the
cylinders. Unequal amounts of oil will flow through the two outlets if the
stroke limit screws are adjusted unequally. It is usually best to adjust both of
these screws the same distance, and regulate the rate of oil flow through
outlets #2 and #3 with their respective needle valves.

Installing and Adjusting a Two-Stage Booster

Models 8901-091 and 8901-103 (Figures 1-5 and 2-4)

On PGA, PGPL, and PGG governors, decals indicating where to connect lines
from the booster do NOT apply to two-stage boosters. Refer to Figure 2-4 when
connecting a two-stage booster to a PGA, PGPL, or PGG governor.
Refer to the general rules at the beginning of this section.

Connect 12 mm (1/2 inch) steel tubing from the sump of the governor to the oil
inlet port on the booster, and from oil outlet #1 on the booster to the power piston
of the governor.

On PGA, PGPL, and PGG governors equipped with any shutdown feature,
connect 8 mm (5/16 inch) steel tubing from oil outlet #2 on the booster to the
speed setting servo of the governor.

Connect 8 mm (5/16 inch) steel tubing from oil outlet #3 on the booster to the
relay piston of the governor.

If you have an EGB-200, -300, or -500 actuator, leave oil outlet #3 of the booster
plugged and loosen the plug in outlet #2. Turn the shuttle piston adjusting screw
fully clockwise, thereby opening up the passage to outlet #1 (otherwise, the
booster servomotor remains inactive). Tighten the plug in outlet #2.

Connect a line with an air-starting valve from the starting-air supply to the air inlet
on the booster.

Fill the governor with oil to the correct level (refer to the installation manual of the
governor).

Woodward 9
Booster Servomotor Manual 36684
When all air and oil connections are secure, purge air from the booster and oil
lines by cycling air from a remote source to the booster without cranking the
engine. Add oil to the governor as needed.

When there is no more air in the booster and oil lines, regulate the volume of oil
going to the governor by adjusting the stroke limit screw. If you are not using an
EGB-200, -300, or -500 actuator, adjust the shuttle piston adjusting screw and
the needle valve in oil outlet #3.

Remember that:
x The stroke limit screw limits the volume of oil going to the governor through
oil outlets #1 and #3. This controls the maximum amount of fuel output
during a booster-assisted start.
x If you use outlet #2, the shuttle piston adjusting screw limits the volume of
oil going to the speed setting servo through oil outlet #2.
x The needle valve limits the rate of flow of oil through oil outlet #3; this
controls the rate at which the output shaft of the governor moves. The
needle valve setting also limits the stroke of the power piston in the
governor.

Turn the stroke limit screw clockwise to reduce the volume of oil to the governor
and fuel to the engine, and counterclockwise to increase volume.

Turn the needle valve clockwise to reduce the rate and volume of oil flow, and
counterclockwise to increase the rate and volume.

10 Woodward
Manual 36684 Booster Servomotor

Figure 2-1. Governors Used with Single-Cylinder Boosters

Woodward 11
Booster Servomotor Manual 36684

Figure 2-2. Governors Used with Single-Cylinder Boosters

12 Woodward
Manual 36684 Booster Servomotor

Figure 2-3. Governors Used with Tandem Boosters

Woodward 13
Booster Servomotor Manual 36684

Figure 2-4. Governors Used with Two-Stage Boosters

14 Woodward
Manual 36684 Booster Servomotor

Chapter 3.
Principles of Operation

How Single-Cylinder and Tandem Boosters Operate

First Phase of Operation
Refer to Figure 311 (which represents a
single-cylinder booster; a tandem booster
has two pistons and three oil outlets, but its
principle of operation is the same).

When compressed air enters the booster,

the piston(s) moves up, forcing oil through
the outlets to the governor's pressurized oil
system. The governor's power piston moves
to increase fuel.

A check valve in the oil inlet prevents oil

from flowing from the booster back to the
sump in the governor.

Figure 3-1. Single Booster, Phase 1

Second Phase of Operation

Refer to Figure 3-2 (which represents a
single cylinder booster; a tandem booster
has two pistons and three oil outlets, but
its principle of operation is the same).

When starting air is removed, the booster

is vented to atmosphere through the
starting-air valve (customer supplied) in
the booster's air line. Spring force returns
the booster's piston(s) to the original
position. Oil stops flowing out of the
booster. Reduced pressure in the
booster causes sump oil to flow back into
the booster. The booster is ready to start
again.

Check valves in the oil outlets prevent oil

from flowing back through the oil outlets
into the booster.

Figure 3-2. Single Booster, Phase 2

Woodward 15
Booster Servomotor Manual 36684

How a Two-Stage Booster Operates

First Phase of Operation

Figure 3-3. Two-Stage Booster, Phase 1

When compressed air enters the booster, the main piston moves to the right,
forcing oil to the shuttle piston cavity and moving the shuttle piston up. The
shuttle piston forces oil through oil outlet #2 and blocks oil outlets #1 and #3.

The shuttle piston adjusting screw limits the stroke of the shuttle piston, which
limits the amount of oil supplied through oil outlet #2.

Second Phase of Operation

When the shuttle piston reaches the end of its stroke, it uncovers the passages
to outlets #1 and #3, and oil flow through outlet #2 ceases. Oil remaining in the
booster flows through outlets #1 and #3 to the relay and power pistons in the
governor, moving them to increase fuel.

Figure 3-4. Two-Stage Booster, Phase 2

The needle valve in outlet #3 limits the amount of oil that goes through this outlet
and its rate of flow. This, in turn, limits the stroke of the power piston in the
governor and the rate at which fuel is supplied to the engine.

The stroke limit screw limits the stroke of the main booster piston, which limits
the total amount of oil supplied to the governor by the booster.

Check valves prevent oil from flowing from the booster into the governor's sump.

16 Woodward
Manual 36684 Booster Servomotor
Third Phase of Operation

Figure 3-5. Two-Stage Booster, Phase 3

The air side of the main piston is vented to atmosphere through the starting-air
valve. Spring forces return the main booster piston and shuttle piston to their
original positions. Reduced pressure in the booster causes sump oil to flow back
into the booster.

Check valves prevent oil from flowing into the booster from the oil outlet lines.

Woodward 17
Booster Servomotor Manual 36684

18 Woodward
Manual 36684 Booster Servomotor

Chapter 4.
Replacement Parts

Ordering Replacement Parts

When ordering replacement parts, include the following information:
1. The booster servomotor part number shown on the nameplate.
2. The manual number printed on the cover of the manual (this is manual
36684).
3. The part reference number in the parts list, and the description of the part or
part name.

Figures 4-1, 4-2, and 4-3 and their associated parts lists illustrate and name all
the replaceable parts of the various booster servomotors. The numbers assigned
are used as reference numbers and are not specific Woodward part numbers.
Woodward will determine the exact part number for your particular booster.

Woodward 19
Booster Servomotor Manual 36684

Parts List for Figure 4-1

Part No. Name................................................ No. Req'd
36684-6 0-ring ...............................................................1
36684-7 Glide Ring........................................................1
36684-15 5/16"-24 Nut.....................................................4
36684-16 0-ring ........................................................ 1 or2
36684-18 1/8"-27 Steel Plug ............................................2
36684-23 Glide Ring................................................ 1 or 2
36684-24 0-ring ....................................................... 1 or 2
36684-25 Check Valve Assembly ....................................3
36684-31 Cylinder Head ..................................................1
36684-32 Booster Spring .................................................1
36684-33 Accumulator Cylinder.......................................1
36684-34 Piston...............................................................1
36684-35 End Cap...........................................................1
36684-36 5/16"-24 Screw ................................................4
36684-37 Flat Washer .....................................................8
36684-38 5/16" Shakeproof Washer................................4
36684-39 1/4" Thread Seal..............................................1
36684-40 Flat Washer .....................................................1
36684-41 1/4"-28 Nut.......................................................1
36684-42 1/4''-28 Stroke Limit Screw ..............................1
36684-44 Cylinder Head ..................................................1
36684-45 0-ring ...............................................................1
36684-46 Reducing Bushing............................................1
36684-47 Booster Spring .................................................1
36684-48 Accumulator Cylinder.......................................1
36684-49 Piston...............................................................1

20 Woodward
Manual 36684 Booster Servomotor

Figure 4-1. Exploded View of Single Boosters

Woodward 21
Booster Servomotor Manual 36684

Parts List for Figure 4-2

Part No. Name................................................ No. Req'd
36684- 6 0-ring ...............................................................2
36684- 7 Glide Ring........................................................2
36684-15 5/16"-24 Nut.....................................................6
36684-18 1/8"-27 Steel Plug ............................................4
36684-23 Glide Ring................................................ 2 or 4
36684-24 0-ring ....................................................... 2 or 4
36684-25 Check Valve Assembly ....................................6
36684-32 Booster Spring .................................................2
36684-34 Piston...............................................................2
36684-36 5/16"-24 Screw ................................................6
36684-37 Flat Washer .....................................................6
36684-38 5/16" Shakeproof Washer................................6
36684-39 1 /4" Threadseal ..............................................2
36684-40 Flat Washer .....................................................2
36684-41 1/4"-28 Nut.......................................................2
36684-47 Booster Spring .................................................2
36684-49 Piston...............................................................2
36684-52 Needle Valve ...................................................2
36684-53 0-ring ...............................................................2
36684-55 1 /4"-28 Stroke Limit Screw .............................2
36684-56 End Cap...........................................................1
36684-57 Accumulator Cylinder.......................................2
36684-58 Gasket .............................................................4
36684-59 Servo Head......................................................1
36684-61 Accumulator Cylinder.......................................2
36684-62 Reducing Bushing............................................2

22 Woodward
Manual 36684 Booster Servomotor

Figure 4-2. Exploded View of Tandem Boosters

Woodward 23
Booster Servomotor Manual 36684

Parts List for Figure 4-3

Part No. Name................................................ No. Req'd
36684-25 Check Valve Assembly ....................................4
36684-63 Booster Servo Piston .......................................1
36684-64 Seal .................................................................1
36684-65 Block Vee Seal ................................................2
36684-66 Backup Ring ....................................................1
36684-67 Seal Retainer ...................................................1
36684-68 .500 Springlock Washer...................................9
36684-69 .500-13 Cap Screw ..........................................1
36684-70 2:1 Ratio Spring ...............................................1
36684-71 Reducing Bushing............................................1
36684-72 Booster Servo Sleeve ......................................1
36684-73 Booster Servo End Cap ...................................1
36684-74 4.234 ID O-ring ................................................1
36684-75 .500 Thread Seal .............................................1
36684-76 .500 Flat Washer .............................................1
36684-77 .500-13 Hex Nut...............................................1
36684-78 .500-13 Stroke Limit Screw..............................1
36684-79 3.484 ID O-ring ................................................1
36684-80 Servo Head Assembly .....................................1
36684-81 Steel Ball .........................................................1
36684-82 Ball Check Spring ............................................1
36684-83 Int. Retaining Ring ...........................................1
36684-84 Oil Failure Piston .............................................1
36684-85 Spring ..............................................................1
36684-86 .864 ID O-ring ..................................................1
36684-87 Booster Servo Plug..........................................1
36684-88 Int. Retaining Ring ...........................................1
26684-89 Needle Valve ...................................................1
36684-90 .301 IDO-ring ...................................................1
36684-91 Stop Screw ......................................................1
36684-92 .312 UNF Steel Plug ........................................1
36684-93 .562 UNF Steel Plug ........................................1
36684-94 .486 ID O-ring ..................................................3
36684-95 Breather Filter Cap ..........................................1
36684-96 .239 ID O-ring ..................................................2
36684-97 Threaded Rod..................................................4
36684-98 .500-20 Hex Nut...............................................8
36684-104 .351 ID O-ring ..................................................1
36684-105 .438 UNF Steel Plug ........................................1

24 Woodward
Manual 36684 Booster Servomotor

Figure 4-3. Exploded View of Two-Stage Boosters

Woodward 25
Booster Servomotor Manual 36684

26 Woodward
Manual 36684 Booster Servomotor

Chapter 5.
Service Options

Product Service Options

The following factory options are available for servicing Woodward equipment,
based on the standard Woodward Product and Service Warranty (5-01-1205)
that is in effect at the time the product is purchased from Woodward or the
service is performed:
x Replacement/Exchange (24-hour service)
x Flat Rate Repair
x Flat Rate Remanufacture

If you are experiencing problems with installation or unsatisfactory performance

of an installed system, the following options are available:
x Consult the troubleshooting guide in the manual.
x Contact Woodward technical assistance (see “How to Contact Woodward”
later in this chapter) and discuss your problem. In most cases, your problem
can be resolved over the phone. If not, you can select which course of
action you wish to pursue based on the available services listed in this
section.

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 also a flat rate structured program and
includes the full standard Woodward product warranty (Woodward Product and
Service Warranty 5-01-1205).

This option allows you to call 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 Woodward facility as explained below (see “Returning Equipment
for Repair” later in this chapter).

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 to Woodward within 60 days, Woodward will issue a credit for
the core charge. [The core charge is the average difference between the flat rate
replacement/exchange charge and the current list price of a new unit.]

Return Shipment Authorization Label. To ensure prompt receipt of the core,

and avoid additional charges, the package must be properly marked. A return
authorization label is included with every Replacement/Exchange unit that leaves
Woodward. The core should be repackaged and the return authorization label
affixed to the outside of the package. Without the authorization label, receipt of
the returned core could be delayed and cause additional charges to be applied.

Woodward 27
Booster Servomotor Manual 36684

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 to Woodward for
repair, please contact Woodward in advance to obtain a Return Authorization
Number. When shipping the item(s), attach a tag with the following information:
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.

CAUTION
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.

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.

28 Woodward
Manual 36684 Booster Servomotor

Return Authorization Number

When returning equipment to Woodward, please telephone and ask for the
Customer Service Department [1 (800) 523-2831 in North America or
+1 (970) 482-5811]. They will help expedite the processing of your order through
our distributors or local service facility. To expedite the repair process, contact
Woodward in advance to obtain a Return Authorization Number, and arrange for
issue of a purchase order for the item(s) to be repaired. No work can be started
until a purchase order is received.

NOTE
We highly recommend that you make arrangement in advance for return
shipments. Contact a Woodward customer service representative at 1 (800)
523-2831 in North America or
+1 (970) 482-5811 for instructions and for a Return Authorization Number.

Replacement Parts
When ordering replacement parts for controls, include the following information:
x the part number(s) (XXXX-XXX) that is on the enclosure nameplate;
x the unit serial number, which is also on the nameplate.

How to Contact Woodward

In North America use the following address when shipping or corresponding:
Woodward Governor Company
PO Box 1519
1000 East Drake Rd
Fort Collins CO 80522-1519, USA

Telephone—+1 (970) 482-5811 (24 hours a day)

Toll-free Phone (in North America)—1 (800) 523-2831
Fax—+1 (970) 498-3058

For assistance outside North America, call one of the following international
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.

Facility Phone Number

Australia +61 (2) 9758 2322
Brazil +55 (19) 3708 4800
India +91 (129) 523 0419
Japan +81 (476) 93-4661
The Netherlands +31 (23) 5661111

You can also contact the Woodward Customer Service Department or consult
our worldwide directory on Woodward’s website (www.woodward.com) for the
name of your nearest Woodward distributor or service facility. [For worldwide
directory information, go to www.woodward.com/ic/locations.]

Woodward 29
Booster Servomotor Manual 36684

Engineering Services
Woodward Industrial Controls Engineering Services offers the following after-
sales support for Woodward 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

Contact information:
Telephone—+1 (970) 482-5811
Toll-free Phone (in North America)—1 (800) 523-2831
Email—icinfo@woodward.com
Website—www.woodward.com/ic

Technical Support is available through our many worldwide locations or our

authorized distributors, depending upon the product. This service can assist you
with technical questions or problem solving during normal business hours.
Emergency assistance is also available during non-business hours by phoning
our toll-free number and stating the urgency of your problem. For technical
support, please contact us via telephone, email us, or use our website and
reference Customer Services and then Technical Support.

Product Training is available at many of our worldwide locations (standard

classes). 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. For information concerning training, please contact us
via telephone, email us, or use our website and reference Customer Services
and then Product Training.

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

and location, from one of our many worldwide locations or from one of our
authorized 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 field service engineering assistance, please contact us
via telephone, email us, or use our website and reference Customer Services
and then Technical Support.

30 Woodward
 Manual 36684 Booster Servomotor

Technical Assistance
If you need to telephone for technical assistance, you will need to provide the following information.
Please write it down here before phoning:

General
Your Name
Site Location
Phone Number
Fax Number

Prime Mover Information

Engine/Turbine Model Number
Manufacturer
Number of Cylinders (if applicable)
Type of Fuel (gas, gaseous, steam, etc)
Rating
Application

Control/Governor Information
Please list all Woodward governors, actuators, and electronic controls in your system:

Woodward Part Number and Revision Letter

Control Description or Governor Type

Serial Number

Woodward Part Number and Revision Letter

Control Description or Governor Type

Serial Number

Woodward Part Number and Revision 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 31
 We appreciate your comments about the content of our publications.
Send comments to: icinfo@woodward.com
Please include the manual number from the front cover of this publication.

Woodward / Industrial Controls

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

FM 57982
BS EN ISO 9001:1994
6 March 2001

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.

02/5/F
 Oil - Regulations C5.05.04.20.27.01
(Woodward)

Oil - Regulations

(Woodward)

en / 06.06.2006 FD032293 1/25

25071J

Oils for Hydraulic Controls

Manual 25071J
 Contents

CHAPTER 1. GENERAL INFORMATION ...................................................................................... 1

Introduction ...................................................................................................................................... 1
Oil Characteristics ............................................................................................................................ 1
Oil Lubrication Properties................................................................................................................. 2
Performance Additives ..................................................................................................................... 3
Lubrication Protective Additives....................................................................................................... 4

CHAPTER 2. HOW TO SELECT AN OIL ....................................................................................... 7

General Information ......................................................................................................................... 7
Proper Oil Selection ......................................................................................................................... 9
Automatic Transmission Fluids ...................................................................................................... 12
Synthetic Oils ................................................................................................................................. 12
Remarks......................................................................................................................................... 13

CHAPTER 3. OIL MAINTENANCE ............................................................................................... 15

General Information ....................................................................................................................... 15
Oil Change Intervals....................................................................................................................... 16
When to Change Governor Oil....................................................................................................... 17
Contaminated Governor Oil ........................................................................................................... 18
Oil Filters ........................................................................................................................................ 18
Oil Lacquering ................................................................................................................................ 20

Illustrations and Tables

2-1. Oil Chart ....................................................................................................................... 11

2-2. Viscosity Comparisons ................................................................................................. 11

IMPORTANT DEFINITIONS
WARNING—indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury.

CAUTION—indicates a potentially hazardous situation which, if not

avoided, could result in damage to equipment.

NOTE—provides other helpful information that does not fall under the
warning or caution categories.

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.
© 1986 by Woodward Governor Company
All Rights Reserved
Manual 25071 Oils for Hydraulic Controls

Chapter 1
General Information

Introduction
This manual serves as a general guide for anyone involved in the selection of oils
for use in Woodward governors or actuators.

One of the primary functions required of an oil is to stand up to high loadings

and high temperatures, while remaining a good lubricant. Oil, as it emerges from
the refinery process, is a slippery liquid, but it lacks additives vital to its intended
functions.

These additives turn a liquid into a lubricant that fights heat, cold, contamination,
corrosion, rust, wear, and other environmental and mechanical hazards. Lubricant
additives are grouped into three general categories according to the functions
they perform:
x protect the lubricated surface
x improve lubricant performance
x protect the lubricant

Surface protective additives include anti-wear agents, corrosion and rust

inhibitors, and detergents and dispersants. Performance additives include pour
point depressants, seal swell agents, and viscosity index improvers. Lubricant
protective additives cover anti-foamants, anti-oxidants, and metal deactivators.

Oil Characteristics
There are four important characteristics to be considered in an oil: viscosity, pour
point, shear stability, and thermal stability.

Viscosity
All natural lubricants thin as they warm, and thicken as they cool. The magnitude
of this change is measured by the Viscosity Index (VI). The higher the VI
number, the less effect temperature has on viscosity change. An oil with a VI of
200 is very good in this respect.

Pour Point
The pour point of an oil is a measure of its low temperature suitability. Chemical
compounds, called pour point depressants, are used to allow the oil to flow even
at low operating temperature when the oil has thickened.

Woodward 1
Oils for Hydraulic Controls Manual 25071
Shear Stability
Oil viscosity can also change due to shear. Actual mechanical shearing of long
chain polymers in oil will act to lower both the actual viscosity at any given
temperature and the Viscosity Index.

Thermal Stability
Oil viscosity changes will also occur with long-term operation at high
temperatures. In this case, the oil will thicken due to oxidation and evaporation of
the lighter molecules.

Multi-viscosity oils extend the operating temperature range while still

maintaining proper viscosity. However, they have relatively poor thermal and
shear stability resulting in shorter useful life. A good alternative is synthetic oils,
since they have good temperature viscosity characteristics. Synthetic oils are
covered in Chapter 2.

Oil Lubrication Properties

Oil lubrication properties are greatly improved by the addition of a variety of
chemical compounds such as anti-wear agents, corrosion and rust inhibitors, and
detergents and dispersants.

If information is needed about the additive contents of an oil, it may be advisable

to check with an oil company representative.

Anti-wear Agents
Mechanical wear from metal-on-metal rubbing or abrasives is normally
prevented by hydrodynamic lubrication with an oil film thick enough to keep the
parts separated. But under certain conditions such as high load, low speed, and
low lubricant viscosity, the lubricant film may rupture and allow metal-to-metal
contact. This condition may exist between thrust bearing surfaces or between
closefitting pump gears and gear pockets.

To prevent wear due to metal-to-metal contact, anti-wear additives found in most

lubricants form a coating which will yield under the shear stress imposed by
minimum lubrication. However, heat from friction between mating surfaces
provides energy for a chemical reaction between the additive and metal surfaces
that result in a protective coating.

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Manual 25071 Oils for Hydraulic Controls
Corrosion And Rust Inhibitors
Another important lubrication property of an oil is that it must be able to resist
rust and corrosion and be compatible with seal material.

If a lubricating oil becomes contaminated with moisture, corrosion can develop.

In the case of governors using engine oil, the oil may become contaminated with
the acidic products of combustion.

Detergents And Dispersants

Detergents are compounds used to control deposits at high temperature, while
dispersants are used to control the formation of sludge at low temperature.
Dispersants absorb contaminant particles and keep them in suspension so they
cannot agglomerate and form sludge.

Performance Additives
Oil performance characteristics also can be greatly improved with additional
compounds such as pour point depressants, seal swell agents, and Viscosity
Index improvers.

If information is needed about the additive contents of an oil, it may be advisable

to check with an oil company representative.

Pour Point Depressants

Pour point depressants are compounds which allow the oil to flow even at low
operating temperature when the oil has thickened. These natural properties of oil
are determined by the crude itself and by the refinery process.

Seal Swell Agents

A number of seals are used throughout a governor to keep the dirt out and the oil
in. Seals are made of many compounds including nitrile and silicon. Currently,
the trend in seal material is to Viton which can withstand prolonged temperatures
to 204 °C (400 °F).

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Oils for Hydraulic Controls Manual 25071
Viscosity Index Improvers
The rate at which mineral oils thin out is described by a mathematical
relationship between their viscosities at 100 °F (38 °C) and 210 °F (99 °C),
which is referred to as Viscosity Index (VI).

Oils with a high VI exhibit less viscosity change with temperature than oils with
a low VI. A lubricant that is expected to perform over a wide temperature range
must usually have a high VI. The VI of oils has received much attention because
ease in starting the engine requires low viscosity at low temperatures, and normal
operation requires an adequate oil film at normal operating temperature.

Wide temperature-range viscosity requirements of oils has been met by treating

the oil with an additive known as a VI improver. VI improvers also improve
shear stability.

Polymeric VI improvers are more likely, however, to be broken apart by shear

forces between moving surfaces. Once this type of permanent shear has occurred,
the polymer contributes less to high-temperature thickening. Therefore, high VI
oils using polymeric VI improvers require a polymer that will continue to provide
adequate thickening at high temperature.

Lubrication Protective Additives

Special additives also are used to increase the lubrication protection given by
oils. Such additives include anti-foamants, anti-oxidants, and metal deactivators.

If information is needed about the additive contents of an oil, it may be advisable

to check with an oil company representative.

Anti-Foamants
When subjected to sufficient agitation, all oils will entrap air and produce foam.
This, in turn, causes more problems. Oil reaction increases exposure of the oil to
oxygen, which increases the rate of oxidation.

Air and foam also reduce lubricant efficiency as a coolant and as a hydraulic
fluid. Retained air changes oil to a compressible fluid and may cause operational
problems. To eliminate foaming, additives with a lower surface tension than the
oil, and low solubility in the lubricants are used. This weakens and ruptures the
oil film surrounding the bubbles.

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Manual 25071 Oils for Hydraulic Controls
Anti-Oxidants
The oxidation process is complex and is highly undesirable. Often, additives that
reduce oil oxidation also reduce corrosion.

Decomposition of the oil may also occur, forming a variety of compounds such
as aldehydes, alcohols, and acids. These compounds may further oxidize and
react with each other to form more compounds. Some of these compounds may
be soluble in oil, resulting in a viscosity increase; others may be insoluble and
form varnish or sludge.

Oxidation is affected by many factors: temperature, lubricated materials, crude

source, and refining process. The choice of the anti-oxidant agent used is based
on tests of a particular oil.

Metal Deactivators
Additives that are used as corrosion and rust inhibitors form coatings on metal
surfaces which also act as metal deactivators. Metal deactivators also inhibit
oxidation by coating metals such as lead, copper, and iron, which could act as
oxidation catalysts.

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Oils for Hydraulic Controls Manual 25071

6 Woodward
Manual 25071 Oils for Hydraulic Controls

Chapter 2
How to Select an Oil

General Information
There are several important factors to consider in the selection of an oil for
proper governor operation. Following is a list of those factors and how they
affect governor operation.

Viscosity
In governor applications, a change in viscosity can seriously affect performance.
If the oil is too thin, the governor can become unstable. If the oil is too thick, the
governor will become sluggish and unresponsive.

The higher the VI (Viscosity Index) number, the less effect temperature has on
viscosity change. Our recommended range of viscosities for proper governor
operation is from 50 to 3000 SUS with a nominal 150 SUS being ideal. With this
in mind, proper oil selection would be that with 150 SUS at operating
temperature and a high VI

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

Pour Point
We recommend an oil with a pour point 8 to 11 Celsius degrees (15 to 20
Fahrenheit degrees) below the lowest starting temperature anticipated. This
avoids possible pump cavitation and slow response. In arctic conditions, it may
be necessary to install an oil heater. Contact Woodward for information
concerning the specific requirements of your installation.

Shear Stability
In applications where severe service is expected or long spans between oil
changes are required, an oil with a high shear stability should be selected. Check
with an oil company representative for information regarding the shear stability
of a particular oil.

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Oils for Hydraulic Controls Manual 25071
Thermal Stability
For service conditions expecting long-term high-temperature operation, an oil
with high thermal stability should be selected. Multi-viscosity oils extend the
operating temperature range while still maintaining proper viscosity. However,
they have relatively poor thermal and shear stability, resulting in shorter useful
life. A good alternative is synthetic oils. These products have good temperature
viscosity characteristics and good thermal and shear stability.

A heat exchanger can be used to lower the operating temperature of a governor.

Corrosion And Rust Inhibitors

Another important factor in the selection of an oil for proper governor or actuator
operation is that it must be able to resist rust and corrosion.

Corrosion is a particular problem in governors because the oil may become

contaminated with moisture. In the case of governors using engine oil, the oil
may become contaminated with the acidic products of combustion.

Sludge Dispersion
Dispersants are especially useful in protecting engines that rarely reach normal
operating temperature. This type of service leads to the formation of sludge,
which coats parts and can block internal oil passages in the governor.

Seal Compatibility
Oils used in governors must be compatible with these materials. While
significant shrinkage or softening of seals cannot be tolerated, a slight swelling is
often desirable. If the base oil cannot cause sufficient swelling, a seal swell agent
may be used.

Oil Oxidation
When subjected to sufficient agitation, all engine/governor oils will entrap air
and produce foam. This, in turn, causes more problems. Oil reaction increases
exposure of the oil to oxygen, which increases the rate of oxidation. Air and
foam also reduce lubricant efficiency as a coolant and as a hydraulic fluid.
Retained air changes oil to a compressible fluid and may cause a perfectly
adjusted governor to become unstable. To eliminate foaming, additives with a
lower surface tension than the oil and low solubility are added to the lubricant
used. The additives weaken and rupture the oil film surrounding the bubbles.

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Anti-wear Additives
Oils containing anti-wear additive packages provide more protection during
periods of boundary lubrication, when true hydrodynamic lubrication is not
possible, due to high loads, low speed, excessive temperatures, etc. This
additional lubrication is possible due to the formation of protective films on
metal surfaces.

Zinc dialkyldithiophosphates (ZDPs) are often used as anti-wear additives and

are found in many common hydraulic and engine oils. Governors do not
normally require anti-wear additives, but under certain marginal lubrication
conditions may benefit from their use.

CAUTION
ZDP is corrosive to silver and tends to attack it. Oils with a ZDP anti-
wear additive are not recommended for use in the PGEV governor
with an oil-filled side plate. The PGEV governor contains a load-
control resistor with silver contacts. Increased silver contamination
of the oil and wear of the load-control resistor contacts may result
from using an oil with a ZDP anti-wear additive. PGE governors and
PGEV governors without an oil-filled side plate may continue to use
oils with a ZDP anti-wear additive, as the oil does not come into
contact with the silver contacts.

Proper Oil Selection

There are two essential factors that need to be considered in the selection of an
oil for proper governor operation. The first one is the SUS viscosity range of the
oil, and the second one is the operating temperature of the governor in its
ambient environment.

Oil Viscosity Range

The recommended range of viscosities for governor operation is from 50 to 3000
SUS at normal governor operating temperature.

This range is shown in the “Legend” (at the bottom of the Oil Chart) and in the
Oil Chart as the “Acceptable Operating Range”. The higher the viscosity number,
the less effect temperature has on viscosity change.

Woodward governors are designed to give stable operation with most oils if oil
viscosity at the operating temperature span is within a range of 50 to 3000 SUS.
The ideal range of viscosities for governor operation is from 100 to 300 SUS at
normal governor operating temperatures. The governor oil operating
temperatures are shown on a scale from –40 to +116 °C (–40 to +240 °F) on top
of the Oil Chart. This range is represented by the white sections in the legend and
in the Oil Table as the “Ideal Operating Range”.

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Oils for Hydraulic Controls Manual 25071
Governor Operating Temperature
The recommended oil temperature for continuous governor operation is 60 to 93
°C (140 to 200 °F). Measure the temperature of the governor or actuator on the
outside lower pan of the case. The actual oil temperature will be slightly warmer,
about 6 Celsius degrees higher (10 Fahrenheit degrees higher). The ambient
temperature range is –29 to +93 °C (–20 to +200 °F).

WARNING
Governor operation must not be attempted below the pour point of
the oil as the governor can become sluggish and unresponsive.
Seizure of governor internal parts can also result, causing loss of
governor control with resulting damage to equipment and/or personal
injury.

How to Read the Oil Chart

(Figure 2-1)

The cross-hatched sections to the left of the white section in the legend and in the
Oil Chart designate the low temperature limits acceptable for operation for
limited periods of time only.

The hatched sections designated “Pour Point” in the legend and in the Oil Chart
indicate the temperature range where oil gets progressively thicker to reach its
pout point. The approximate pour point is represented by the low temperature
end of the hatched section (left-hand end).

If the oil is too thick, the governor can become sluggish and unresponsive. An oil
with a pour point 8 to 11 Celsius degrees (15 to 20 Fahrenheit degrees) below the
lowest starting temperature anticipated is recommended.

The cross-hatched sections to the right of the white sections in the legend and in
the Oil Chart designate the high temperature limits acceptable for operation for
limited periods of time only. The right-hand end of these sections represents the
approximate degradation temperature of the oil.

Prolonged use at temperatures above this point, without frequent oil change, may
result in governor failure. To avoid governor operation close to the point of oil
degradation, change to an oil more temperature resistant or lower the governor
operating temperature with a heat exchanger, or both.

Under extreme ambient operating temperatures, such as tropical or arctic

operating conditions, it may be necessary to install a heat exchanger or an oil
heater. Contact Woodward for information concerning the specific requirements
of your installation.

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Manual 25071 Oils for Hydraulic Controls

Figure 2-1. Oil Chart

Figure 2-2. Viscosity Comparisons

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Oils for Hydraulic Controls Manual 25071
Automatic Transmission Fluids
Automatic transmission fluids, such as AT FLUID TYPE F, AT FLUID TYPE
A, OR DEXRON II, are suitable for governor use. Automatic transmission fluid
can be used at temperatures lower than most petroleum oils and at temperatures
to 149 °C (300 °F) for short periods. However, at elevated temperatures, internal
governor leakage may develop. Any transmission fluid approved by a
transmission manufacturer should be suitable in a governor, providing viscosity
requirements are met.

Synthetic Oils
Most synthetic lubricants are excellent for governor use, provided they meet
viscosity requirements. Synthetics provide better lubrication than conventional
oils under severe demands, particularly at high speeds or broad temperature
ranges. They are not generally recommended as an alternative to straight mineral
oil in standard applications.

The major advantages of the synthetic family of oils over straight petroleum oils
in governor applications are a wider temperature range, a high resistance to
oxidation, and a very low volatility. The disadvantages are cost and more limited
availability in some areas. As with any oil, it is not recommended that these be
mixed with each other or with petroleum oils.

CAUTION
Some classes of synthetic oils may not be compatible with
diaphragms, gaskets, and seals. Serious damage to diaphragms,
gaskets, and seals can result, requiring replacement of parts. If in
doubt, contact Woodward for specific recommendations.

Synthetic lubricants are classed according to chemical source: for example, the
silicones, the polyglycols, the synthesized hydrocarbons, and the organic esters.

Silicone Lubricants
The name "silicones" has been broadly applied to several different base fluids,
and they are available in a wide range of viscosities.

The main advantage over petroleum oils comes from the formulations that
provide very high viscosity index (usually in the 200 to 300 range), high
resistance to oxidation, and very low volatility.

Polysulfide additives have greatly improved the load-carrying capacity and anti-
wear properties of silicone lubricants. Silicone oils have little effect on most
rubbers, but this is not the case with other oils. Systems previously lubricated
with other oils should be cleaned and flushed.

Silicone oils are used in high temperature, high pressure hydraulic systems, air
compressors, and gear boxes. The cost of these oils is competitive with other
synthetic oils.

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Manual 25071 Oils for Hydraulic Controls
Polyglycol Lubricants
Examples of polyglycol lubricants are the glycols, polyethers, and polyalkylene
glycols. These are the least expensive of the synthetics.

They have excellent viscosity-temperature characteristics, have a low volatility

comparable with silicones, and have a good lubricating quality. They are also
compatible with other synthetic lubricants, and they readily accept additives for
further improvement of their properties.

Polyglycols are not compatible with petroleum oils and are not acceptable for
governor use in that they attack paint and other non-metallic materials, although
they have little effect on rubber.

Synthesized Hydrocarbons
Synthesized hydrocarbons are high performance oils that are made from a
petroleum-derived raw material and not from the refining of petroleum.

Several types of synthesized hydrocarbons (SHC) are now available. SHC oils
are compatible with petroleum oils and the systems for which petroleum oils are
designed. These oils do not deteriorate rapidly at high temperatures and do not
congeal readily at low temperatures. SHC base fluids are free of aromatics,
sulfur, and wax normally present in conventional mineral oils.

Organic Esters
Organic esters are formed by reacting of alcohol and certain types of acids. The
two categories of esters used mostly for synthetic oils are dibasic acid ester and
polyol esters. Characteristics of organic esters are much the same as the
synthesized hydrocarbons.

Remarks
In applications where the Woodward governor or actuator shares the oil supply
with the engine, use the oil recommended by the engine manufacturer. Protect
governors or actuators using engine oil with a suitable filter. Refer to the
appropriate governor manual for filter size requirements.

Governors with a self-contained oil supply, or using a self-contained oil sump, do

not require an oil containing detergents or dispersants since they do not have the
“hot spots” found in internal combustion engines, and do not have the
contaminants resulting from the internal combustion. As a result, oil that has
been carefully selected to match the operating conditions, and is compatible with
governor seals, is suitable for governor operation.

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Oils for Hydraulic Controls Manual 25071
Providing all other necessary characteristics are met, most detergent oils are
satisfactory for use in governors and actuators. The oil that meets the
requirements and is locally available should be selected.

In addition to oils listed in the Oil Chart, oils which meet the API (American
Petroleum Institute) engine service classification in either the “S” group or the
“C” group (starting with “SA” and “CA” through the current API standard) are
suitable for governor service. Oils meeting performance requirements of the
following US military specifications are also suitable:
x MIL-L-2104A
x MIL-L-2104B
x MIL-L-2104C
x MIL-L-46152
x MIL-L-46152A
x MIL-L46152B
x MIL-L-45199B

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Manual 25071 Oils for Hydraulic Controls

Chapter 3
Oil Maintenance

General Information
Oil maintenance is essential to long and reliable governor operation. Regular oil
changes must be maintained, but there are also other important factors to
consider.

Once a class of oil is selected, continue using that oil. Adding or changing oil of
one class to another class without thoroughly cleaning a hydraulic system may
cause operational problems such as foaming, filter plugging, and sludge
formation. Some classes of oil may not be compatible with diaphragms, gaskets,
or seals.

Any water, regardless of the quantity, in a governor should immediately be

removed and the oil changed. Water, even in trace amounts, contributes
significantly to early bearing failure as well as forming oxides that also
contribute to failures.

Clean oil is a necessity, whether filling the governor for the first time or whether
adding make-up oil. Clean oil cannot remain clean if the container or pouring
spout is not clean. Partially used cans of oil should not be used unless kept
covered in a clean area. Cleanliness of oil and container cannot be overstressed.

Most governors with self-contained sumps do not have filters or screens, and this
makes it essential that contaminants are not introduced into the governor through
the oil. Make sure to protect governors using engine oil with a suitable filter.
Refer to the appropriate governor manual for filter size requirements.

The effects of oil on governors using engine oil are determined by filter changes
and engine oil condition. If engine manufacturer's oil recommendations are
closely followed, satisfactory service should result.

Oil Change Intervals

Self-Contained Oil Sump

The “best time” to change oil is difficult to determine. The best time, of course,
to change the oil is just before the oil is worn out, but before any damage to the
machine has occurred.

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Oils for Hydraulic Controls Manual 25071
This condition is best determined by oil analysis, but because the cost of doing
this exceeds the cost of a quart or two of governor oil, it is not a practical
solution on a continual basis. Analysis can be used to set up a maintenance
schedule which should remain in effect as long as the original conditions do not
change. Experience with other hydraulic equipment similar to governors can also
be used as a guideline. Conditions such as operating temperature, atmospheric
conditions which include dirt, moisture, etc., or anything that may change the
composition of the oil, or shorten its useful life, should be taken into account
when determining the frequency of oil changes.

Anytime a known contaminant gets into the governor, the governor should be
drained, flushed, and refilled with clean oil as soon as possible.

Particles of dirt and water in the oil are the greatest causes of governor or
actuator failures. Particular care should be taken to keep dirt and moisture out of
opened or stored governors and opened control lines.

Breakdown of oil or depletion of additives is another frequent cause of governor

failure. The presence of sludge, varnish, sediment, or a dirty filter is a good
indication that an oil change is required. It is also an indication that perhaps a
different oil should be used, especially if it has only been a short time since the
last oil change.

A varnish buildup is an indication that governor operating temperatures are

exceeding the capability of the oil. This problem can usually be solved by going
to an oil with good high temperature characteristics or by installing a heat
exchanger. Low operating temperatures may lead to the formation of sludge.
Sludge is a complex mixture of products from sources such as fuel combustion,
water, carbon, and oxidized oil that has agglomerated and is no longer soluble in
oil.

Sludging may be controlled by raising the governor operating temperature,

increasing the frequency of oil changes, or by changing to a different type of oil.
Fluids, such as automatic transmission fluids, may prove to be more resistant to
sludge than some engine oils.

Oil that has been carefully selected to match the operating conditions and is
compatible with governor seals should give long service between oil changes.
For governors operating under ideal conditions (minimum exposure to dust and
water, within the temperature limits of the oil), oil changes can be extended to
two or more years. If available, a regularly scheduled oil analysis is helpful in
determining the frequency of oil changes.

Engine Oil Governors

Oil change intervals are dependent upon the various operating conditions of the
engines and the sulfur content of the diesel fuel used.

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Manual 25071 Oils for Hydraulic Controls
Oil change intervals are normally recommended by the engine manufacturer for
the engine. However, if governor problems develop due to oil breakdown or
contaminated oil, the frequency of oil changes should be increased for a specific
lubricant.

A conservative recommendation of high temperature degradation threshold for a

variety of lubricant types is listed below.

Degradation Begins
Fluid Family °C °F
Natural petroleum 93 200
Polyglycols 107 225
Diesters 121 250
Synthetic hydrocarbons 121 250
Polyol esters 135 275
Methyl silicons 149 300
Phenyl silicons 204 400
Halogenated silicons 218 425
Polyphenyl ethers 246 475
Fluoroethers 288 550

When to Change Governor Oil

Oil should be changed if:
x Appearance is different than when new.
x Oil feels gritty when rubbed between fingers.
x Oil smells different than when new. (NOTE: some oil may smell burned and
still be acceptable. Check with oil company representatives.) If in doubt,
change oil.
x Any water, antifreeze, or other incompatible material contaminates the oil.
x Viscosity has changed; increased or decreased.
x Excessive wear of parts occurs.
x If governor has been run at temperatures exceeding the recommended limit
for the type of oil use.
x If governor operating temperatures have changed, bringing fluid viscosity
outside of ideal operating condition.

Contaminated Governor Oil

Replace the governor oil if it is contaminated. Also change it if it is suspected of
contributing to governor instability. Drain the oil while it is still hot and agitated.
Flush the governor with a lighter weight of the same oil or with a solvent having
some lubricating quality before refilling with new oil.

CAUTION
Be sure the solvent is compatible with seals. Serious damage to
diaphragms, gaskets, and seals can result, requiring replacement of
parts. If in doubt, contact Woodward for specific recommendations.

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Oils for Hydraulic Controls Manual 25071
If the drain time is insufficient for the solvent to completely drain or evaporate,
flush the governor with a lighter weight of the same oil it is being refilled with to
avoid dilution and possible contamination of the new oil. To avoid
recontamination, the replacement oil should be free of dirt, water, and other
foreign material. Use clean containers to store and transfer oil.

WARNING
Observe manufacturer's instructions or restrictions regarding the use
of solvents. If no instructions are available, handle with care. Use the
cleaning solvent in a well ventilated area away from fires or sparks.

Failure to follow above safety instructions can result in dangerous

fires, extensive damage to equipment, personal injury and/or loss of
life.

Oil Filters
Industrial surveys show that 80% of all governor problems are caused by dirty or
contaminated oil. Although particles of dirt are always present, good properly-
maintained filtration controls dirt particles effectively.

Proper use of filtration not only pays for itself, but it also reduces the overall cost
of operation and maintenance. Compared to the cost of downtime, proper
filtration is a good investment.

Selection Of Filter Element

It is relatively easy to under-filter or to over-filter because of the wide range of
contaminants and the wide range of filter materials available to control them.

Filter material which is too coarse allows dangerous contamination. Filter

material which is too fine requires replacement too often, or if not changed,
filters operate in the bypass mode and all protection is gone.

Filter Element Specifications

Beta Ratio
The Beta Ratio is a numerical representation of the efficiency of a filter. It is the
number of particles of a given size found upstream of a filter divided by the
number of same-size particles found downstream, as described by the multi-pass
test method recognized by ANSI, NFPA, and ISO (ANSI/B93.31-1973).

ȕx = __N(up)__, where x = particle size (in µm)

N(down)

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Manual 25071 Oils for Hydraulic Controls
Thus ȕ10 = 2 means that the filter will remove 1 particle greater than 10 µm for
every 2 particles greater than 10 µm entering the filter.

In the above example, assume 10 000 particles greater than 10 µm were counted
upstream, and 5000 particles greater than 10 µm were counted downstream.
Then,

ȕ10 = __10 000__ = 2

5000

Some filter literature may show a rating as:

ȕx = 2/20/75, x = 6/11/15
which means: ȕ6 = 2, ȕ11 = 20, ȕ15 = 75.

The first three numbers (2/20/75) are the Beta ratings at the particle size of the
second three numbers (6, 11, and 15 µm respectively).

Efficiency
The efficiency of a filter at a given particle size can be derived by the formula:

Efficiency = (1–1/ȕ) x 100%

So, if ȕ10 = 2
Efficiency at 10 µm = (1–1/2) x 100% = 50%

Following below is an efficiency table for “x” size particles:

ȕx = 1.01 is 1% efficient
ȕx = 1.1 is 9% efficient
ȕx = 1.5 is 33% efficient
ȕx = 2.0 is 50% efficient (nominal)*
ȕx = 5.0 is 80% efficient
ȕx = 10.0 is 90% efficient
ȕx = 20.0 is 95% efficient
ȕx = 75.0 is 98.7% efficient (absolute)*
ȕx = 1000.0 is 99.9% efficient
ȕx = 3000.0 is 99.97% efficient
*—The filtration industry is coming to accept a nominal rating as 50% efficient at
removing a given particle size, and an absolute rating as at least 98.6% efficient
at removing a given particle size.

Filter Capacity
Filter capacity is the amount of contaminant (measured in grams) that a filter
element will hold before reaching a specified differential pressure. Everything
else being equal, the capacity indicates the service life of the element. The greater
the capacity, the longer the life.

Oil Compatibility
Filtering elements are compatible with petroleum base lubricating oils. When
using synthetic fluids, it is advisable to check with a filter company
representative regarding compatibility of specific elements.

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Oils for Hydraulic Controls Manual 25071
Oil Lacquering
Hydro-mechanical governors can be affected by a condition known as oil
“lacquering”. If not prevented, lacquering can lead to various possible failure
modes, with the potential for the governor to stick in the max fuel or min fuel
position.

WARNING
Lacquering can lead to governor failure, with the potential for engine
overspeed. In a marine application, a vessel could be unable to
maintain headway. Preventing lacquering, and having a backup
governing/safety system, are essential for safety.

Lacquering is defined as the condition in which the governor is coated internally

by a residue from the oil (often referred to as varnish or sludge). The deposits
form a hard layer which is difficult and time-consuming to remove (the cost of
cleaning a lacquered governor can be as high as 40% of the new price of such a
unit.). Lacquering is generally accompanied by a smell similar to burnt oil.

The results can range from sticking pilot valves to plugged oil passages and
orifices.

Lacquering is generally caused by the oil breaking down, which can be caused
by:
x too high an oil temperature;
x too long an interval between oil changes;
x water condensing inside the governor during cooldown periods (water in oil
can cause hydrolysis which is a known failure mode for oils).

Oil selection is important, as some oils are less prone to lacquering than others. It
is up to the plant operator/vessel owner and the oil supplier to establish the
correct oils and change intervals for each application. Such a selection should
consider operating temperature, oil change interval, and other operating
conditions known to the plant operator/vessel owner. A proper selection can
achieve suitable economies of cost and change interval while also preventing
lacquering.

Any governor can be affected, depending on oil change interval, operating

temperature, and oil type. Some governor types work their oils harder than
others.

Since Woodward is cannot be aware of the operating conditions of each

application, here are some general recommendations:
x Oil Temperature—Woodward recommends that the oil temperature for
continuous operation be between 60 and 93 °C (140 and 200 °F).
x Oil Change Interval—Because oil change interval must take into
consideration all operating conditions, the correct oil change interval must
be established between the plant operator/vessel owner and the oil supplier.

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Manual 25071 Oils for Hydraulic Controls
x Oil Selection—Woodward specifies two essential factors that need to be
considered in the selection of an oil for proper governor operation:
f viscosity range—allowed is 7.5 cSt (50 SUS) to 650 cSt (3000 SUS);
ideal is 20 cSt (100 SUS) to 65 cSt (300 SUS).
f operating temperature—recommended is an oil temperature for
continuous operation between 60 and 93 °C (140 and 200 °F).

NOTE
Failure to avoid lacquering of oil inside a governor is considered to
be a misuse outside Woodward control. Such misuse is not covered
by Woodward warranty.

WARNING
If a governor has become lacquered, it is imperative that this
situation be diagnosed and corrected as soon as possible. A
lacquered governor should not be used, since this can have serious
consequences.

Carefully consider the choice of governor oil with your oil supplier. When
choosing an oil interval, start with shorter than expected intervals and slowly try
longer intervals. Monitor the condition of the oil, especially the build-up of
deposits, to ensure that the oil remains within the operating conditions defined by
the oil supplier.

Woodward 21
 We appreciate your comments about the content of our publications.
Send comments to: icinfo@woodward.com
Please include the manual number from the front cover of this publication.

Woodward/Industrial Controls
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
E-mail and Home Page—www.woodward.com

FM 57982
BS EN ISO 9001:1994
6 March 2001

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/e-mail information for all locations is available on our website.

02/3/F
 Adjustment "MaK-Genset 723+" C5.05.04.20.29.50
(Woodward)

VM32

Adjustment "MaK-Genset 723+"

(Woodward)

en / 18.08.2010 FD044182 1/7

 Kostenträger-Nr./Record No.
Programmierung "MaK-Genset 723+"
262151
Motortype/Engine Type
Adjustment "MaK-Genset 723+"
Software ABLS Version 4.00 / P/N 9926-660 rev. J 16 CM32 C

Einstellwerte/Adjustment
Menu - Alarmlog Voreinstellung/Preadjust Betrieb/Service

1. First Alarm 1 -
2. 1/Spd Probe #1 Fault 2 -
3. 2/Spd Probe #2 Fault 3 -
4. 3/Both Probes Fault 4 -
5. 4/Torsional Alarm 5 -
6. 5/Rem Spd Inp Flt 6 -
7. 6/Rem Bsld Inp Flt 7 -
8. 7/Load Sensor Fault 8 -
9. 8/Synch Fault 9 -
10. 9/No Baseload 10 -
11. 10/Overspeed 11 -
12. 11/Act Wirebreak ? 12 -
13. Reset First Alarm ? 13 -

Datum/Date Abteilung/Departm. Name/Name Zeichnungs-Nr./Drawing No.

Seite/Sheet: 1
von/of: 6
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Caterpillar : Confidential Green
 Kostenträger-Nr./Record No.
Programmierung "MaK-Genset 723+"
262151

Motortype/Engine Type
Adjustment "MaK-Genset 723+"
Software ABLS Version 4.00 / P/N 9926-660 rev. J 16 CM32 C

Einstellwerte/Adjustment
Menu - Monitor Analog Voreinstellung/Preadjust Betrieb/Service
1. Engine Speed 1 -
2. Speed Reference 2 -
3. Spd Ref Before Bias 3 -
4. Generator Load KW 4 -
5. Load Reference KW 5 -
6. PID % 6 -
7. Actuator LSS (%) 7 -
8. Actuator output (%) 8 -
9. Torsionals Rpm 9 -
10. Gain 10 -
11. Stop Mode 11 -
12. Failsafe Mode 12 -
13. Isoch Mode 13 -
14. Baseload Mode 14 -
15. Droop Mode 15 -
16. Unload Mode 16 -
17. Fuel Lim Mode 17 -
18. Shutdown Mode 18 -

Menu - Monitor Inputs

1. Speed #1 (rpm) 1 -
2. Speed #2 (rpm) 2 -
3. Syn Inp (+/- V DC) 3 -
4. Bs Ld Ref Inp (mA) 4 -
5. Rmt Ref Input (mA) 5 -
6. Loadsensor Inp (mA) 6 -
7. LS Input 7 -
8. 29/Run Stop 8 -
9. 30/Reset 9 -
10. 31/Lower 10 -
11. 32/Raise 11 -
12. 33/Droop Isoch 12 -
13. 34/Unload 13 -
14. 35/Base Load 14 -
15. 36/Gen Breaker 15 -

Menu - Monitor Outputs

1. Alarm RLY 1 -
2. Jet/Mjr Alm RLY 2 -
3. CB Open RLY 3 -
4. LS Relay (K4) 4 -
5. Analog Out #1 5 -
6. Analog Out #2 6 -
7. Analog Out #3 7 -
8. LS Output 8 -

Datum/Date Abteilung/Departm. Name/Name Zeichnungs-Nr./Drawing No.

Seite/Sheet: 2
von/of: 6
17.08.2010 CA 63 Steiner 4-SK-16608-262151
Caterpillar : Confidential Green
 Kostenträger-Nr./Record No.
Programmierung "MaK-Genset 723+"
262151
Motortype/Engine Type
Adjustment "MaK-Genset 723+"
Software ABLS Version 4.00 / P/N 9926-660 rev. J 16 CM32 C
Einstellwerte/Adjustment
Menu - Speed Setting Voreinstellung/Preadjust Betrieb/Service
1. Idle Speed 1 450
2. Rated Speed 2 720
3. Raise Speed Limit 3 756
4. Wait Min Spd Time 4 1
5. Accel Rate (rpm/sec) 5 5
6. Decel Rate (rpm/sec) 6 10
7. Synchroniser Rate 7 1
8. Speed Raise Rate 8 1
9. Speed Lower Rate 9 1
10. 4 mA Remote Ref 10 450
11. 20 mA Remote Ref 11 756
12. Spd Flt Ovrd Time 12 5
13. Hunt Alarm RPM 13 100
14. Hunt Alm Delay (sec) 14 1
15. Spd Fil MPU #1 (Hz) 15 6
16. Spd Fil MPU #2 (Hz) 16 6
17. Lower Pulse (RPM) 17 1
18. Raise Pulse (RPM) 18 1

Menu - kW Load
1. Maximum Load (kW) 1 7450
2. Unload Offset (kW) 2 50
3. Minimum Load (kW) 3 150
4. Raise Rate (kW/sec) 4 100
5. Lower Rate (kW/sec) 5 100
6. Load Ref at 4 mA 6 0
7. Load Ref at 20 mA 7 7450
8. Load Sens at 4 mA 8 0
9. Load Sens at 20 mA 9 * Depending on load sensor signal 8096 *
10. Load Input Filter 10 0.2

Menu - Droop
1. No Load Act (%) 1 20
2. Full Load Act (%) 2 80
3. Droop (%) 3 5

Menu - Fuel Limits

1. Start Lmt Dis Time 1 3
2. Maximum Limit 2 101
3. Start Lmt P1 (%/LSS) 3 44
4. Start Lmt P2 (%/LSS) 4 44
5. Start Lmt Rte units/s 5 2.5

Menu - Dynamics 1
1. Gain 1 1 0.3
2. Integrator Rate 1 2 0.7
3. Derivative Ratio 1 3 40
4. Fast Gain 1 4 0.6
5. Fast Gain Window 1 5 5
Datum/Date Abteilung/Departm. Name/Name Zeichnungs-Nr./Drawing No.
Seite/Sheet: 3
von/of: 6
17.08.2010 CA 63 Steiner 4-SK-16608-262151
Caterpillar : Confidential Green
 Kostenträger-Nr./Record No.
Programmierung "MaK-Genset 723+"
262151
Motortype/Engine Type
Adjustment "MaK-Genset 723+"
Software ABLS Version 4.00 / P/N 9926-660 rev. J 16 CM32 C

Einstellwerte/Adjustment
Menu - Dynamics 2 Voreinstellung/Preadjust Betrieb/Service
1. Gain 2 1 0.3
2. Integrator Rate 2 2 0.7
3. Derivative Ratio 2 3 40
4. Fast Gain 2 4 0.6
5. Fast Gain Window 2 5 15

Menu - Tune Aux Output

1. 1/PID% at 4 mA 1 not used 0
2. 1/PID% at 20 mA 2 - 100
3. 2/MPU #1 rpm at 4 mA 3 - 0
4. 2/MPU #1 rpm at 20 mA 4 - 100
5. 3/MPU #2 rpm at 4 mA 5 - 0
6. 3/MPU #2 rpm at 20 mA 6 - 100
7. 4/Load% at 4 mA 7 - 0
8. 4/Load% at 20 mA 8 - 100
9. 5/Act% at 4 mA 9 - 0
10. 5/Act% at 20 mA 10 - 100
11. 6/Tors RPM at 4 mA 11 - 0
12. 6/Tors RPM at 20 mA 12 - 100
13. 7/Jmp Lim% at 4 mA 13 - 0
14. 7/Jmp Lim% at 20 mA 14 - 100

Menu - Torsionals
1. No Tors above % Load 1 not used 20
2. Max Hunt RPM 2 - 2.5
3. Min Hunt RPM 3 - 0.5
4. Gain Factor 4 - 0.5
5. Integrator Factor 5 - 2.5
6. Change Rate 6 - 0.05

Menu - JMP Rate Limit

1. Jump 1 %/Act 1 not used 35
2. Rate Jump 1 %/sec 2 - 0.5
3. Enbl Jmp 2 at % Load 3 - 60
4. Jump 2 %/Act 4 - 40
5. Rate Jump 2 %/sec 5 - 2

Menu - Jet Assist

1. Loadstep 1 % Load 1 not used 25
2. Breakpoint % Load 2 - 50
3. Loadstep 2 % Load 3 - 30
4. Relay Pulse (sec) 4 - 50

Menu - Auto Isoch

1. Allowed Spd Error 1 not used 15
2. Spd Error Delay 2 - 1

Datum/Date Abteilung/Departm. Name/Name Zeichnungs-Nr./Drawing No.

Seite/Sheet: 4
von/of: 6
17.08.2010 CA 63 Steiner 4-SK-16608-262151
Caterpillar : Confidential Green
 Kostenträger-Nr./Record No.
Programmierung "MaK-Genset 723+"
262151
Motortype/Engine Type
Adjustment "MaK-Genset 723+"
Software ABLS Version 4.00 / P/N 9926-660 rev. J 16 CM32 C

Einstellwerte/Adjustment
Menu - Calibration Voreinstellung/Preadjust Betrieb/Service
1. Bs Ld Ref Inp Offs 1 not used 0
2. Bs Ld Ref Inp Gain 2 - 1
3. Rmt Ref Input Offs 3 - 0
4. Rmt Ref Input Gain 4 - 1
5. Loadsensor Inp Offs 5 - 0
6. Loadsensor Inp Gain 6 - 1
7. Offset Aux #1 7 - 0
8. Gain Aux #1 8 - 1
9. Offset Aux #2 9 - 0
10. Gain Aux #2 10 - 1
11. Offset Aux #3 11 - 0
12. Gain Aux #3 12 - 1

Menu - BSLD Fine Tune

1. Base Fine Max Spd 1 not used 730
2. Base Fine Min Spd 2 - 710

Menu – Load Sharing

1. Load Share Offset 1 0
2. Load Share Gain 2 1

Menu – CB Open Pulse

1. Pulse Used ? 1 TRUE
2. Active above KW (%) 2 60
3. Active above ACT (%) 3 40
4. Pulse Time (sec) 4 0.5
5. Deactivate Delay (sec) 5 0.2

Menu - Port Setting

1. Set Download Mode 1 1

Datum/Date Abteilung/Departm. Name/Name Zeichnungs-Nr./Drawing No.

Seite/Sheet: 5
von/of: 6
17.08.2010 CA 63 Steiner 4-SK-16608-262151
 Caterpillar : Confidential green
Kostenträger-Nr./Record No.
Programmierung "MaK-Genset 723+"
262151
Motortype/Engine Type
Adjustment "MaK-Genset 723+"
Software ABLS Version 4.00 / P/N 9926-660 rev. J 16 CM32 C

Einstellwerte/Adjustment
Menu - Configuration Voreinstellung/Preadjust Betrieb/Service
1. Gear #1 Teeth 1 44
2. Gear #2 Teeth 2 44
3. Act Forward Act 3 TRUE
4. Enable Synchronizer 4 FALSE
5. Cont Open Stop 5 TRUE
6. Overspeed 6 863
7. Use Torsionals ? 7 FALSE
8. Use Jmp Rte Lim ? 8 FALSE
9. Use Jet Assist ? 9 FALSE
10. Use Auto Iso ? 10 FALSE
11. Use Rs/Lo in Iso ? 11 FALSE
12. Block Rs/Lo in Iso ? 12 FALSE
13. CB Open on Stop ? 13 TRUE
14. BSLD Fine Tune Enbl ? 14 FALSE
15. Use Act Wirebreak ? 15 FALSE
16. Act mA_0 16 10
17. Act mA_100 17 180

Menu - Set Alarms

1. Loadsensor Used ? 1 TRUE
2. Loadsens Alarm ? ( 2 2
3. MPU #1 Failed Alarm ? ( 3 2
4. MPU #2 Failed Alarm ? ( 4 2
5. Torsional Alarm ? * ( 5 1
6. Bs Ld input Alarm ? ( 6 1
7. Rem Spd input Alarm ? ( 7 1
8. Spm input Alarm ? ( 8 1
9. Stop on Major Alm ? 9 TRUE
10. Brkr Open Rly NC ? 10 FALSE
11. Jet (F) / Mjr (T) Alm Rly ? 11 FALSE
12. Jet/Mjr Alm Rly NC ? 12 FALSE
13. Alarm Relay NC ? 13 FALSE
14. Act WB Major ALM ? 14 FALSE

Menu - Set Outputs

1. Select Aux 1 ( 1 not used 6
2. Select Aux 2 ** ( 2 - 2
3. Select Aux 3 ( 3 - 3

Menu - LON COM

1. LON Adres 1 -

*) 1 = No Alarm **) 1 = PID %

2 = Minor Alarm 2 = Speed MPU #1 RPM
3 = Major Alarm 3 = Speed MPU #2 RPM
4 = Load %
5 = Limit %
6 = Torsional Level RPM
7 = Jump Rate Limit %
Datum/Date Abteilung/Departm. Name/Name Zeichnungs-Nr./Drawing No.
Seite/Sheet: 6
von/of: 6
17.08.2010 CA 63 Steiner 4-SK-16608-262151
Caterpillar : Confidential Green
 Circuit diagram Motor C5.05.05.10.31.67
-

VM32

Circuit diagram Motor

en / 21.07.2006 FD032474 1/34

 Equipment List Engine C5.05.05.10.61.47
-

VM32

Equipment List Engine

en / 04.12.2006 FD033371 1/6

 Equipment List Engine 16M32C
c Unit
Devices, Sensors and Actuators
Description Sensor range Stock – No. Drawing – No.
Signal range

1105 Pressure transmitter

1105 Lub. oil pressure low- prealarm shutdown 0 – 600 kPa 283 460 008 0.00.6-93.25.00-25
4-20mA
1106 Pressure switch 0 – 600 kPa 283 460 280 0.00.6-71.35.00-52
Lub. oil pressure low – shutdown binary
1202 Resistance thermometer -40-160° C 263 481 016 0.00.6-93.17.00-31
Lub. oil pressare at engine inlet high – alarm PT 100
1203 NTC -40-120° C 213 464 022 0.00.6-93.17.00-20
Lub. Oil pressare at engine inlet high – NTC
shutdown
X1/A1 Attaching type switching device 233 463 034 0.00.6-93.17.02-11
1251/1253 Oil mist detector VN115/87
9631 1251 Oil mist concentration in crankcase high – 1251 : 0,5...25% 263 450 185 0.00.6-71.30.00-40
alarm binary
1253 Oil mist concentration in crankcase high – 1253 : 0,5...25%
shutdown binary
9631 Oil mist detector failure – alarm 9631 -
binary
2102 Pressure transmitter 0 – 600 kPa 283 460 007 0.00.6-93.25.00-24
Cooling water pressure HT at engine inlet low – 4-20mA
alarm
2103 Pressure switch 0 – 600 kPa 283 460 280 0.00.6-71.35.00-52
Cooling water pressure HT at engine inlet low – binary
shutdown
2112 Pressure transmitter 0 – 600 kPa 283 460 007 0.00.6-93.25.00-24
Cooling water pressure LT at engine outlet low - 4-20mA
alarm
2201 Resistance thermometer -40-160° C 263 481 016 0.00.6-93.17.00-31
Cooling water temp. HT at engine inlet - Dicare PT 100
2211 Resistance thermometer -40-160° C 263 481 017 0.00.6-93.17.00-32
Cooling water temp. HT at engine outlet high - PT 100
alarm
2213 NTC -40-120° C 213 464 023 0.00.6-93.17.00-21
Cooling water temp. HT at engine outlet high - NTC
Shutdown
X1/A2 Attaching type switching device 233 463 034 0.00.6-93.17.02-11
2229 Resistance thermometer -40-160° C 263 481 016 0.00.6-93.17.00-31
Cooling water temp. LT at engine inlet - PT 100
indication
5102 Pressure transmitter 0 – 1000 kPa 283 460 008 0.00.6-93.25.00-25
Fuel oil pressure at engine inlet low - alarm 4-20mA

5111 Differential pressure switch 0 – 80 kPa 193 094 468 0.00.6-71.35.00-31

Differential pressure fuel oil filter high – alarm binary

CD42_Mischke Page: 1
Status: 11.09.2006 EG 1.98.7-46.92.00-06_ni_en
Caterpillar : Confidential Green
 Equipment List Engine 16M32C
c Unit
Devices, Sensors and Actuators
Description Sensor range Stock – No. Drawing – No.
Signal range

5201/5202 Resistance thermometer 263 481 016 0.00.6-93.17.00-31

5201 Fuel oil temp. at engine inlet low – alarm -40-160° C
5202 Fuel oil temp. at engine inlet high – Alarm PT 100
(not in use with HFO)
5301A Level probe - 213 483 074 0.00.6-91.31.00-24
Leakage oil niveau at engine high - alarm ground switching
Plug 977 032 805 VG95234-E-10SL-3SN
X1/K2 Attaching type relay 213 480 770 9.01.7-91.08.00-06
5301B Level probe - 213 483 074 0.00.6-91.31.00-24
Leakage oil niveau at engine high - alarm ground switching
Plug 977 032 805 VG95234-E-10SL-3SN
X1/K5 Attaching type relay 213 480 770 9.01.7-91.08.00-06
6101 Pressure transmitter 0 – 6000 kPa 283 460 009 0.00.6-93.25.00-26
Starting air pressure low - alarm 4-20mA
6105 Pressure switch 100-1200 kPa 253 460 012 0.00.6-71.35.00-50
Stopping air pressure low - alarm binary
6181 Absolute Pressure transmitter 80 – 120 kPa 283 460 011 0.00.6-93.25.00-28
Intake air pressure in engine room – Dicare 4-20mA
7109 Pressure transmitter 0 – 400 kPa 283 460 006 0.00.6-93.25.00-23
Charge air pressure at engine inlet– Dicare 4-20mA
7201 Resistance thermometer -40-160° C 263 481 017 0.00.6-93.17.00-32
Charge air temp. at engine inlet high– alarm PT 100
7206 Resistance thermometer -40-160° C 263 481 016 0.00.6-93.17.00-31
Intake air temp. at turbocharger inlet – Dicare PT 100
7301 Level probe - 213 483 072 0.00.6-91.31.00-22
Condense water in charge air canal – alarm ground switching
Plug 977 032 805 VG95234-E-10SL-3SN
X1/K3 Attaching type relay 213 480 770 9.01.7-91.08.00-06
7307 Differential pressure transmitter 0 – 10 kPa 263 460 006 0.00.6-93.25.00-27
Charge air diff. pressure at charge air cooler – 4-20mA
Dicare
7309A Thermocouple type K -200-1300° C 223 482 350 1.00.7-48.99.00-51
Charge air temp. at charge air cooler inlet A – NiCr-Ni
Dicare (mV)
7309B Thermocouple type K -200-1300° C 223 482 350 1.00.7-48.99.00-51
Charge air temp. at charge air cooler inlet B – NiCr-Ni
Dicare (mV)
8211.1A Thermocouple type K -200-1300° C 223 482 350 1.00.7-48.99.00-51
..... Exhaust gas temp. after cylinder 1A.....8A – NiCr-Ni
8211.8A shutdown (mV)
8211.1B Thermocouple type K -200-1300° C 223 482 350 1.00.7-48.99.00-51
..... Exhaust gas temp. after cylinder 1B....8B – NiCr-Ni
8211.8B shutdown (mV)
8221A Thermocouple type K -200-1300° C 223 482 350 1.00.7-48.99.00-51
Exhaust gas temp. at turbocharger outlet A – NiCr-Ni
shutdown (mV)

CD42_Mischke Page: 2
Status: 11.09.2006 EG 1.98.7-46.92.00-06_ni_en
Caterpillar : Confidential Green
 Equipment List Engine 16M32C
c Unit
Devices, Sensors and Actuators
Description Sensor range Stock – No. Drawing – No.
Signal range

8221B Thermocouple type K -200-1300° C 223 482 350 1.00.7-48.99.00-51

Exhaust gas temp. at turbocharger outlet B – NiCr-Ni
shutdown (mV)
8231A Thermocouple type K -200-1300° C 223 482 350 1.00.7-48.99.00-51
Exhaust gas temp. at turbocharger inlet A – NiCr-Ni
Dicare (mV)
8231B Thermocouple type K -200-1300° C 223 482 350 1.00.7-48.99.00-51
Exhaust gas temp. at turbocharger inlet B – NiCr-Ni
Dicare (mV)
R16 Resistance thermometer -40-160° C 263 481 018 0.00.6-93.17.00-34
Electr. – charge air temp. control PT 100
9419.1 Pick up 0-1200 upm 263 450 224 0.00.6-93.21.00-74
9419.2 RPM switching equipment 0-15 KHz
Plug angle 977 032 801 CA3108-E-14S-5S-B-F80
9419.3 Pick up 0-1200 upm 263 450 224 0.00.6-93.21.00-74
9419.4 Electronic governor 0-15 KHz
Plug angle 977 032 801 CA3108-E-14S-5S-B-F80
9429A Pick up 0-30000 upm TPL65FE (HZTL-XXXX)
Turbine speed A 0-1 KHz
Plug 263 450 019 0.00.6-94.63.00-07
X8/A10 Frequency-current transformer 0-1KHz/4-20mA 193 466 125 FTW113-S10
X8/A11 Transformer 4-20mA/4-20mA 977 180 090 8787140000
X8/A12 Transformer 4-20mA/0-10V 977 180 089 8787130000
9429B Pick up 0-30000 upm TPL65FE (HZTL-XXXX)
Turbine speed B 0-1 KHz
Plug 263 450 019 0.00.6-94.63.00-07
X8/A13 Frequency-current transformer 0-1KHz/4-20mA 193 466 125 FTW113-S10
X8/A14 Transformer 4-20mA/4-20mA 977 180 090 8787140000
X8/A15 Transformer 4-20mA/0-10V 977 180 089 8787130000
9503 Limit switch - 260 480 950 1.00.7-48.98.00-69
Control lever at fuel rack – 100% fuel binary
9509 Distance sensor 125% load 260 480 070 1.00.7-48.98.00-53
Fuel setting 0-20mA
X1/A10 Attaching type fuel setting 0-20mA/4-20mA 243 910 260 9.01.7-91.08.00-13
X1/A11 Transformer 4-20mA/4-20mA 977 180 090 8787140000
Plug 213 480 101 CA06EW-14S-5S-B-03A
9561 Limit switch - DTE7-2RN-PG
Turning gear engaged – starting interlock binary
X3/k3 Attaching type relay 233 480 820 9.01.7-91.08.00-02
S1 Limit switch - BZE7-2RN-PG
Turning gear engaged – contactor reverser ON binary
S2 Pressure switch 1 – 1600 kPa 283 460 020 0.00.6-71.35.00-51
Starting air pressure at main starting valve binary
Y1.1 Solenoid valve - 213 413 018 0.00.6-41.26.00-32
Shutdown 24V DC / 6W

CD42_Mischke Page: 3
Status: 11.09.2006 EG 1.98.7-46.92.00-06_ni_en
Caterpillar : Confidential Green
 Equipment List Engine 16M32C
c Unit
Devices, Sensors and Actuators
Description Sensor range Stock – No. Drawing – No.
Signal range

Plug 253 460 054 49020200(GDM3011)

Y1.2 Solenoid valve - 263 410 124 0.00.6-41.21.00-88
Start 24V DC / 6W
Plug 253 460 054 49020200(GDM3011)
Y1.6 Solenoid valve -
Starting interlock for manual emergency start 24V DC / 18,5W
Plug 253 460 054 49020200(GDM3011)
M1 Actuator -
0 - 200mA
left-handed 263 410 113 0.00.6-72.11.00-96
right-handed 263 410 114 0.00.6-72.11.00-97
Plug connector (14) 253 460 058 CA3106E-20-27S-F80-DN
X1/K4 Attaching type relay 213 480 770 9.01.7-91.08.00-06
X3/K9 Attaching type relay 213 480 770 9.01.7-91.08.00-06
S11/H9 Start push button
Luminous key 977 037 060
Frame 977 037 062
Push button cap 977 037 066
Bulb 223 480 054
S12/H10 Stopp push button
Luminous key 977 037 060
Frame 977 037 062
Push button cap 977 037 065
Bulb 223 480 054
S13 Change over switch –engine/remote
Locking key 977 037 085
Key base 977 037 071
S14 Lamp-test push button
Luminous key 977 037 060
Frame 977 037 062
Push button cap 977 037 063
H11 Lamp false start
Luminous key 977 037 061
Frame 977 037 062
Push button cap 977 037 064
Bulb 223 480 054
H12 Lamp starting interlock
Luminous key 977 037 061
Frame 977 037 062
Push button cap 977 037 064
Bulb 223 480 054
H13 Lamp remote control
Luminous key 977 037 061
Frame 977 037 062
Push button cap 977 037 063

CD42_Mischke Page: 4
Status: 11.09.2006 EG 1.98.7-46.92.00-06_ni_en
Caterpillar : Confidential Green
 Equipment List Engine 16M32C
c Unit
Devices, Sensors and Actuators
Description Sensor range Stock – No. Drawing – No.
Signal range

Bulb 223 480 054

P1 Engine speed indication 0-10V 263 480 305 NRQ96-10
Scale 0-1200 253 480 033 SS82-12
P01A Turbocharger speed indication 0-10V 263 480 305 NRQ96-10
Scale 0-30000 263 480 309 SS87-17
P01B Turbocharger speed indication 0-10V 263 480 305 NRQ96-10
Scale 0-30000 263 480 309 SS87-18
P02 Exhaust gas temp. measuring instrument NiCr-Ni 263 450 194 0.00.6-93.40.00-46
Busboard (XC1A/XC1B) 283 360 070 9.01.7-91.11.00-14
X1.1 Plug connector (40)
X1.3 Housing (Female) 977 062 817
X1.4 Housing insert 977 062 818
X1.5 Contact socket 977 062 812
X3.3 Washer 977 062 822
X3.4 Plug box (Male) 977 062 819
X2.1A/B Housing insert 977 062 815
X2.2A/B Contact pin 977 062 814
X3.1 Plug connector (19)
X3.2 Male 263 480 303 CA3102E-20A-48P-B-04
X3.5 Female 977 032 812 VG95234-G-20A-48SN
X8/A16 Limit value switch 283 480 043 AD-MK330GS320-253
X1/1-70 Terminal 977 062 506 047826(AST)
X6/1-50 Terminal 977 062 506 047826(AST)
X3/1-50 Terminal 977 062 506 047826(AST)
X8/20-35 Terminal 977 062 506 047826(AST)
X2A/1-40 Terminal 977 062 506 047826(AST)
X2A/R1A Terminal / PT100 213 481 075 801473(DK4/32PT100)
X2B/1-40 Terminal 977 062 506 047826(AST)
X2B/R1B Terminal / PT100 213 481 075 801473(DK4/32PT100)
Manometer charge air 263 450 101 0.00.6-71.33.00-79.1
Manometer cooling water HT 263 450 103 0.00.6-71.33.00-80.1
Manometer cooling water LT 263 450 103 0.00.6-71.33.00-80.1
Manometer fuel oil 263 450 107 0.00.6-71.33.00-82.1
Manometer lub. oil 263 450 103 0.00.6-71.33.00-80.1
Manometer starting air 263 450 111 0.00.6-71.33.00-83.1
Service unit 263 410 060 0.00.6-41.25.00-37
Compressed air filter 223 860 024 0.00.6-41.54.00-11
Safety valve 223 860 023 0.00.6-41.20.00-96
3/2 way valve NW40 283 410 065 0.00.6-41.21.00-91
Cylinder 263 260 008 0.00.6-26.51.00-18

CD42_Mischke Page: 5
Status: 11.09.2006 EG 1.98.7-46.92.00-06_ni_en
Caterpillar : Confidential Green
 Maintenance Unit C5.05.05.45.23.03
Control Stand

M20/M25/M32/M43

Maintenance Unit

Control Stand

en / 23.03.2007 FD034174 1/25

Pressure reducing station R417000844
R417000845
R417000888

Operating instructions
Imprint:
The copyright of this user´s manual remains the property of Bosch-Rexroth AG.

Included are instructions and technical drawings, which may not be reproduced or copied
either in part of whole, nor may they be used for evaluation or distributed for competition pur-
poses.

The diagrams and drawings used in this manual are for guidelines only and are not to be used for
the actual design.

This edition supersedes all previous ones.

No part of this edition may be reproduced whithout our prior permission.

Order Number: 883 890 035 3 – BDL – 001 – AC

Table of contents

Safety information 28
Explanation of symbols 28
GB Occupational safety 29

Design and mode of operation 30

General 30
Block diagram 32
Versions 33

Startup 34
Ports and Installation, Assembly position, 34

Maintenance and care 35

General 35
Replacing the sealing elements, dismantling 36
Dismantling the filters and the drain valves 36
Dismantling the pressure switch 38
and the adjusting screw
Dismantling the pressure control valves 38
Dismantling the three/two-way valve 40
Replacing the sealing elements, assembly 42
Setup and Tests 43
Spare parts package 44

Storage and transportation 45

General 45

Technical specifications 46
General 46
Circuit diagram 46
Dimensional drawing 47

After sales service and adresses 48

Any questions? 48

883 890 035 3 – BDL – 001 –AC (10/06) 27

Safety information

Danger!
This symbol is to be found with all
information and warnings in these
Explanation operating instructions regarding work
of symbols safety, where there is potential danger
to humans.
Take notice of such warnings and act
with particular caution in these cases.

Warning!
This symbol is to be found in these
operating conditions wherever it is
Warning! necessary to ensure that guidelines,
regulations and warnings are adhered
to and that the work processes are
carried out correctly, without damage
to or destruction of the servo-actuator.

This way up!

This symbol is found wherever
components have to be transported,
stored or mounted in a particular
position. (to DIN 30 600)

Grease!
This symbol is to be found wherever
components, areas etc. need to be
Fett lubricated.
Grease

Secure by glue!
This symbol is marking parts which
must be secured by means of a liquid
adhesive (according to DIN 30 600).

883 890 035 3 – BDL – 001 –AC (10/06) 28

Safety information

Warning
Do only pressurise the pressure-reducing station, if it has been
Occupational mounted properly.
safety Do not handle the pressure-reducing station, if it is pressurised.
Always cut off the air supply before starting work.

Technical State
The pressure-reducing station has been designed according to the
latest state of the technology and safety standards for operation.

Proper Use
The pressure-reducing station has the following purpose:
Reduction of a high inlet pressure to a low outlet pressure.

The ambient conditions as well as the operating pressure range

specified in the technical data have to be observed. The compressed
air supplied must be clean, dry and free of lubricant.

Air quality:
PNEUROP-
Quality class acc. to : recommendation ISO 8573-1
6611 / 1984
Solid matters 4 7
Oil rate 3 3
Pressure dew point 2 3

Applications other than those stated are regarded as not appropriate.

Improper use is at the customer's risk. The manufacturer is not liable
for any resulting damage.

This device may cause danger if it is used improperly, under

inappropriate conditions or by unqualified personnel.

Using the device appropriately does, of course, also mean observing

the assembly, dismantling and maintenance instructions.

Guarantee
The pressure-reducing station must by maintained and repaired by
authorised, skilled personnel only.

The user must only operate the pressure-reducing station in perfect

condition.

The user is obliged to report any changes of the device's condition that
might reduce its safety.

Unauthorised modifications and changes that might reduce the safety

of the pressure-reducing station are not permitted.

Before commissioning please read the operating instructions

carefully.

883 890 035 3 – BDL – 001 –AC (10/06) 29

Design and mode of operation

Purpose
The pressure-reducing station has the following purposes:
General x Filtering the pressurized air and condensing
x Reduction of a high inlet pressure to a low outlet pressure
x Monitoring of the reduces outlet pressure via pressure gauge and
safety valve
x Ventilation of the compressed air tab “A”.

Design
The pressure-reducing station consists of a housing that contains the
following components (fig. 1) :

compressed air filter with drain valve (1), pressure control valves (2),
safety valve (3), pressure gauge (4), 3/2-way valve, operated electro-
magnetically (5) and pressure switch (6) with testing tab (7).

Mode of operation
The pressurized air entering at point “P” (pmax = 30 bar) flows through
the compressed air filter (1) and is cleaned from solid impurities. The
resulting condensate is collected in the lower part of the housing and
may be drained via the drain valve.

The cleaned, pressurized air then reaches the pressure control valve
(2). Here the reduction from the inlet pressure to a lower outlet
pressure (3 bar...8,5 bar) takes place. The outlet pressure set at the
pressure control valve is indicated at the pressure gauge (4). The
safety valve (3) has to limit the operating pressure in the pressure-
reducing station to a maximum of 8,5 bar in order to prevent damages
to the connected devices.

The compressed air continues to flow from the pressure control valve
(2) to the electro-magnetically operated 3/2-way valve (5). This valve
can supply the tab “A” with compressed air. In addition to tab “A” tab
“P1” also furnishes a constant compressed air supply.

The pressure switch (6) is used for monitoring of the reduced outlet
pressure. In case a lower threshold limit of the pressure value has
been exceeded, an electrical contact is closed.
The compressed air tab “14” can be used to supply compressed air to
the testing tab (7) for the pressure switch, thus ensuring that the
function of the pressure switch (6) can be continuously monitored
during operations. In order to enable this feature, the adjusting screw
of the testing tab has to be turned into the housing until it stops.

883 890 035 3 – BDL – 001 –AC (10/06) 30

Design and mode of operation

If the compressed air supply at tab “P” is interrupted, the pressure-

reducing station is vented by force; thus ensuring that no pressure is
present at any of the subsequent devices.
General
(cf. block diagram on page 32 and circuit diagram on page 46)

Versions
Fig. 2a - 2c show three versions of the pressure reducing station,
which basically differ in the arrangement of the pressure switch and
the pressure gauge.

883 890 035 3 – BDL – 001 –AC (10/06) 31

Design and mode of operation

Block-

4
diagram
fig. 1

5
A
P1

6
7

14
2

3
P

883 890 035 3 – BDL – 001 –AC (10/06) 32

Design and mode of operation

fig. 2a : R417000888 (replacement for 335 320 200 0)

Versions

pressure gauge

drain valve

3/2-way-valve
safety valve pressure switch

fig. 2b : R417000845 (replacement for 335 320 201 0)

pressure gauge

drain valve
3/2-way-valve

safety valve pressure switch

883 890 035 3 – BDL – 001 –AC (10/06) 33

Startup

fig. 2c : R417000844 (replacement for 335 320 202 0)

Versions

drain valve

3/2-way-valve

safety valve pressure switch

Ports and Ports and Installation

Installation The pressure-reducing station is fixed with 3 screws M10. The boring
pattern can be taken from the dimensional drawing.

Pneumatic connections are materialised by traded ports M14x1.5.

Assembly
position
Assembly position
For assembly purposes it has to be taken into account that the drain
valve points downwards.

Warning! Warning!
When disassembled dirt, humidity or foreign matter must not enter the
compressed air ports. For this reason the ports must be closed by
means of suitable transportation protecting plugs.
The disassembled pressure-reducing station must be protected from
environmental influences. Before assembly the transportation
protecting plugs must be removed. In addition the device must be
visually inspected for damages of any kind.

883 890 035 3 – BDL – 001 –AC (10/06) 34

Maintenance and care

Maintenance intervals
In order to guarantee a safe operation of the pressure-reducing
General station, all sealing elements must be replaced after 3 years at the
latest provided that the required compressed-air quality and the
permissible ambient conditions are observed. We recommend to
return the pressure reducing station to Bosch Rexroth AG for
repairs. For the replacement of sealing elements at own
responsibility a spare part kit 335 320 003 2 is available.

The following maintenance and care instructions have to be adhered

to:

Drain valve
The filters should be drained daily using the drain valve. In order to do
so, the handles of the drain valve should be slightly moved sideways.

Warning!
Warning! If the valves are under pressure, the condensate is very powerfully
ejected. Do not move the handles with your hands but use suitable
tools to move the handles sideways.

Cleaning of the filter cartridge

The filter cartridges have to be cleaned regularly according to the state
of contamination of the compressed air. For cleaning purposes
cleaner's naphtha or dissolvents can be used. Dry the filter cartridge
before returning it to its position.
Follow fig.3 for the removal and reinsertion of the cartridges.

Danger!
Conduct all works on the pressure-reducing station only in an un-
pressurized state.

Warning! Warning!
Check the seals at the fastening screw.
Ensure that the cartridge is not installed at an angle.

Replacing the filter cartridges

Extremely dirty filter cartridges should be replaced by new ones.
The required parts are contained in the spare parts package
335 320 003 2.

Fett Greasing the sealing elements

Grease The sealing elements of the pressure-reducing station have to be
greased lightly using the lubricant contained in the repair set before
assembly, except if they are subject to special maintenance and care
instructions.

Before assembly, all sealing seats, faces etc. have to be cleaned.

883 890 035 3 – BDL – 001 –AC (10/06) 35

Maintenance and care

Replacing the sealing elements, dismantling

Dismantling
The following section describes the dismantling and assembly of a
pressure-reducing station for the replacement of the sealing elements.

All elements necessary for a complete scheduled overhaul are

contained in the spare parts package 335 320 003 2.

In case of such an overhaul, the following instructions for the

dismantling/mounting have to be adhered to.

Warning! Warning!
Conduct all works in a de-pressurized state.
Shut off the compressed air supply and vent the device !
Interrupt the electric power supply.

Dismantling the filters and the drain valves (fig. 3)

x Loosen fastening screw T1 and remove sealing ring 1, filter 2 and
O-ring 3
x Remove valve screw T2 and sealing ring 4
x Remove circlip 7 and spring 6 as well as valve 5 from the valve
screw T2.

883 890 035 3 – BDL – 001 –AC (10/06) 36

Maintenance and care

fig.3 B A

1
2
3

T1
MA = 150Nm

Y
X

C B A

T26 T25

T11

7 26

5
4
view Y
T2
MA = 60Nm

view X

883 890 035 3 – BDL – 001 –AC (10/06) 37

Maintenance and care

Dismantling the pressure switch (fig. 4a)

(Version R417000888 , R417000844 , 3353202000 and
Dismantling 3353202020)

x Disassemble pressure switch T3. Loosen screw T4 (2x)

x Remove O-ring 36

Dismantling the pressure switch (fig. 4b)

(Version R417000845 and 3353202010)

x Disassemble pressure switch T3. Loosen screw T4 (2x)

x Disassemble adapter T12 and screw T24 (2x)
x Remove O-ring 11 and 36

Dismantling the pressure control valves (fig. 5)

x Loosen grub screw T7 and remove cap T8 from the housing

x Remove spring T9 and piston 35 with O-ring 14
x Disassemble circlip 15 and pull valve 16 together with valve nut
17, bushing 18, valve ring 19, O-ring 21 and O-ring 34 from the
drill hole. Remove spring 20
x Dismantle circlips 22, 24 and filters 23, 25
x Remove banjo bolt T11 from the housing and remove piston cup
26
(cf. fig. 3).

Dismantling the adjusting screw (fig. 4a)

x Disassemble circlip 12 and remove washer T5

x Remove adjusting screw T6 from the housing. Remove O-rings 8,
9 and 10
x Remove ventilation 13.

883 890 035 3 – BDL – 001 –AC (10/06) 38

Maintenance and care

fig.4a

13
fig.4b

T5
8
12 9
T6
10
36

T3
T4
11
T12
T24
fig.5 T3 T4 36

T8
T7
T9 24 Ø 9.8

35 37
14 25 17
13.6 +0.2

X
16
23 15
18
22 34
B-B Y
20
21
19
Take care of view X
mounting position !
view Y

883 890 035 3 – BDL – 001 –AC (10/06) 39

Maintenance and care

Dismantling the 3/2-way valve (fig. 6)

Dismantling
x Loosen screw T25 and remove holding plate T26 (fig. 3)
x Dismantle servo valve 33. In order to do so, remove ventilation
T13, the coil T14 and loosen the screw T15 (2x)
x Remove gasket 27
x Loosen screw T16 (2x) and remove the base plate T17
Warning! Warning!
compression spring T18 is pre-stressed

x Disassemble the following parts: compression spring T18,

bushing T19, piston T20, sleeve T21, ram T22, washer T23 (6x),
washers 32, spacer T24 (2x), sealing ring 28 (4x) as well as
grooved ring 29
x Disassemble circlips 24, 30 and filters 25, 31.

883 890 035 3 – BDL – 001 –AC (10/06) 40

Maintenance and care
fig.6
C-C T16
T17

X 25
24
Y 30
31

D D

T15

33

T14

T13 MA = 1.2 +0.2 Nm

T18

T19

32

28
T23 D-D
T24 27
28
X
T22
28
T24
T23
28

32
T21
T20
29
Y
883 890 035 3 – BDL – 001 –AC (10/06) 41
Maintenance and care

Replacing the sealing elements, assembly

Assembly Reassemble the device in reverse sequence.
Take care not to damage the sealing elements during assembling.

Fett All sealing elements must prior to assembling be slightly lubricated

Grease with the grease from the spare parts kit. Before this all sealing
surfaces are to be cleaned.

Assembly of the filter and the drain valve (fig. 3)

x Replace sealing ring1, filter 2 and O-ring 3. Tightening torque for
fastening screw T1: MA = 150 Nm
x Replace sealing ring 4, valve 5, spring 6 and circlip 7. Tightening
torque for valve screw T2: MA = 60 Nm
x Replace piston cup 26.

Assembly of the pressure switch and the adjusting screw

(fig. 4)
x Replace O-rings 8, 9, 10, 11, 36, circlip 12 and ventilation 13.

Assembly of pressure control valve (fig. 5)

x Replace circlip 15, valve 16, valve nut 17, bushing 18, valve ring
19, spring 20, O-rings 14, 21, 34 and piston 35.

Warning! Warning!
Keep clearance 13.6 +- 0.2 mm for valve nut 17. For checking use
adjusting sleeve 37.
Secure valve nut 17 with substance for locking screws (e. g. Loctite
241).

Warning! Warning!
Ensure correct assembly position of valve ring 19!
x Replace circlips 22, 24 and filters 23, 25.

883 890 035 3 – BDL – 001 –AC (10/06) 42

Maintenance and care

Assembly of the 3/2-way valve (fig. 6)

Assembly x Replace gasket 27, sealing ring 28 (4x) and grooved ring 29
x Replace circlips 24, 30 and filters 25, 31.

Warning! Warning!
Bushing T19 and sleeve T21 must overhang the upper housing edge
by 0.4 r0.1mm. Attach washers 32 accordingly.
x Replace servo valve 33

Warning! Warning!
In case of pressure reducing stations with holding plate T26 (new
version) during assembly the srew T25 must be fixed by a screw
securing means (e.g. Loctite 241).

In case of pressure reducing stations without holding plate T26 (old

version) the exhaust T13 must be tightened with a torque of MA =
1.2+0.2 Nm and a screw securing means (e.g. Loctite 241) must be
applied.

Secure screw T15 (2x) and screw T16 (2x) with substance for
locking screws (e. g. Loctite 241).

Setup and
Test Setup and Tests of the pressure-reducing station
After the dismantling/mounting of the pressure-reducing station, it is
required to set up the operating pressure of the pressure control
valves again. In order to do so, the grub screw T7 has to be loosened
and the cap T8 has to be screwed from the housing with the exception
of the last five turns.
Set tab P to a pressure of 30 bar. By turning the cap T8 the operating
pressure at the pressure control valve can be adjusted, then tighten
the grub screw T7.

Warning! Warning!
Turn cap T8 only in pressureless state.

Check the 3/2-way valve for correct performance by working it.

Finally the complete pressure-reducing station has to be tested for
tightness.

883 890 035 3 – BDL – 001 –AC (10/06) 43

Maintenance and care

Spare parts package:

Order number 335 320 003 2
Spare parts
package
Item Description Dimension Qty.
335 320 003 2 1 sealing ring 36 x 42 x 2 1
2 filter 1
3 O-ring 23,3 x 2,4 1
4 sealing ring 22 x 27 x 1,5 1
5 valve 1
6 conical spring 0,8 x 12,7 x 26,5 1
7 circlip 15 x 1 1
8 O-ring 6 x 1,5 1
9 O-ring 5 x 1,2 1
10 O-ring 4 x 1,2 1
11 O-ring 6,75 x 1,78 1
12 circlip 20 x 1 1
13 ventilation M14 x 1,5 1
14 O-ring 32,9 x 3,5 1
15 circlip 14 x 1 1
16 valve 1
17 valve nut 1
18 bushing 8x9x4 1
19 valve ring 1
20 conical spring 1 x 11,2 x 18,1 1
21 O-ring 5,28 x 1,78 1
22 circlip 20 x 1,5 1
23 filter 20 x 2,3 1
24 circlip 8,3 x 0,5 2
25 filter 8x2 2
26 piston cup 3x8x4 1
27 gasket 18 x 3 1
28 sealing ring 4
29 grooved ring 12,8 x 21,2 x 4 1
30 circlip 30 x 1,2 1
31 filter 30 x 2 1
32 washer 13 x 0,2 6
33 servo valve 1
34 O-ring 10 x 1,3 1
35 piston 1
36 O-ring 6x2 1
37 adjusting sleeve 1
38 lubricant 20g

883 890 035 3 – BDL – 001 –AC (10/06) 44

Storage and transportation

During storage and transportation the pressure-reducing station must

in principle be protected against mechanical damage and weather
influences.
General
Contacts with aggressive media must be avoided.

Compressed air ports must be closed in a way to prevent entry of dirt,

humidity and foreign matter.

The ambient temperature during storage and transportation must

neither drop below -35qC nor exceed +80qC.

Storage

Warning! Warning!
Consider that sealing elements are subjected to ageing also during
storage. The storage period must be taken into account for deter-
mining the replacement intervals appropriately.

Transportation

Danger!
In principle the provisions for the prevention of accidents must be
observed. Above all the device must during transportation be secured
against getting out of place resp. falling down.

883 890 035 3 – BDL – 001 –AC (10/06) 45

Technical specifications

General

Technical Data
Permissible medium compressed air

inlet pressure max. 30 bar

outlet pressure min. 3 bar / max. 8,5 bar

pressure reducing valve adjusted to 7,5 bar

safety valve adjusted to 8,5 bar

pressure switch adjusted to 6,0 bar , decreasing

threaded tabs M14 x 1,5

thermal application range 273 K … 343 K

Circuit diagram
fig. 7
A

4
2

P P1

14

883 890 035 3 – BDL – 001 –AC (10/06) 46

Technical specifications

Dimensional drawing / Version R417000888

fig. 8

threaded tabs: M14 x 1.5; 12 deep

883 890 035 3 – BDL – 001 –AC (10/06) 47

After sales service and adresses

Are there any questions left?

If anything is still not clear after reading these operating instructions,
any please let us know. Your suggestions for improvements are always
welcome.
Questions?
If you require any further information, please contact the sales staff in
our Marine Technique Division directly or the address below.

Bosch Rexroth AG
„The Drive & Control Company“
Marine Technique

Ulmerstraße 4
D – 30880 Laatzen

Tel.: +49 (0) 511 2136 251

Fax.: +49 (0) 511 2136 165

e-mail: marinesales@boschrexroth.de
Internet: http://www.boschrexroth.de

48
 Electrical Equipment C5.05.05.70.06.45
RPM Switch Unit

Electrical Equipment

RPM Switch Unit

en / 03.03.2008 FD021336 1/2

c RPM–SWITCH–UNIT
Equipment list

Unit Description CAT- No. Stock- No. Drawing - No.

A1 Plug in card (without presetting) 263 360 140 9.01.7-91.21.00-16

Plug in card (presetting for engine M20) 193 300 029 9.01.7-91.21.00-16

Plug in card (presetting for engine M25) 193 375 001 9.01.7-91.21.00-16

Plug in card (presetting for engine M32) 193 466 036 9.01.7-91.21.00-16

Plug in card (presetting for engine VM32) 193 466 037 9.01.7-91.21.00-16

Plug in card (presetting for engine M43) 193 376 030 9.01.7-91.21.00-16

Plug in card (presetting for engine VM43) 193 376 030 9.01.7-91.21.00-16

A2 Plug in card 263 360 150 9.01.7-91.21.00-17

CD6 / Mischke Seite: 1

Status: 28.10.2004 EG 1.00.7-36.29.00-45_en
Caterpillar : Confidential Green
 Electrical Equipment C5.05.05.70.16.63
Engine Monitoring Devices Terminal Box

Electrical Equipment

Engine Monitoring Devices Ter-

minal Box

en / 21.07.2006 FD032471 1/18

 Equipment List Engine 16M32C
c Unit
Devices, Sensors and Actuators
Description Sensor range Stock – No. Drawing – No.
Signal range

1105 Pressure transmitter

1105 Lub. oil pressure low- prealarm shutdown 0 – 600 kPa 283 460 008 0.00.6-93.25.00-25
4-20mA
1106 Pressure switch 0 – 600 kPa 283 460 280 0.00.6-71.35.00-52
Lub. oil pressure low – shutdown binary
1202 Resistance thermometer -40-160° C 263 481 016 0.00.6-93.17.00-31
Lub. oil pressare at engine inlet high – alarm PT 100
1203 NTC -40-120° C 213 464 022 0.00.6-93.17.00-20
Lub. Oil pressare at engine inlet high – NTC
shutdown
X1/A1 Attaching type switching device 233 463 034 0.00.6-93.17.02-11
1251/1253 Oil mist detector VN115/87
9631 1251 Oil mist concentration in crankcase high – 1251 : 0,5...25% 263 450 185 0.00.6-71.30.00-40
alarm binary
1253 Oil mist concentration in crankcase high – 1253 : 0,5...25%
shutdown binary
9631 Oil mist detector failure – alarm 9631 -
binary
2102 Pressure transmitter 0 – 600 kPa 283 460 007 0.00.6-93.25.00-24
Cooling water pressure HT at engine inlet low – 4-20mA
alarm
2103 Pressure switch 0 – 600 kPa 283 460 280 0.00.6-71.35.00-52
Cooling water pressure HT at engine inlet low – binary
shutdown
2112 Pressure transmitter 0 – 600 kPa 283 460 007 0.00.6-93.25.00-24
Cooling water pressure LT at engine outlet low - 4-20mA
alarm
2201 Resistance thermometer -40-160° C 263 481 016 0.00.6-93.17.00-31
Cooling water temp. HT at engine inlet - Dicare PT 100
2211 Resistance thermometer -40-160° C 263 481 017 0.00.6-93.17.00-32
Cooling water temp. HT at engine outlet high - PT 100
alarm
2213 NTC -40-120° C 213 464 023 0.00.6-93.17.00-21
Cooling water temp. HT at engine outlet high - NTC
Shutdown
X1/A2 Attaching type switching device 233 463 034 0.00.6-93.17.02-11
2229 Resistance thermometer -40-160° C 263 481 016 0.00.6-93.17.00-31
Cooling water temp. LT at engine inlet - PT 100
indication
5102 Pressure transmitter 0 – 1000 kPa 283 460 008 0.00.6-93.25.00-25
Fuel oil pressure at engine inlet low - alarm 4-20mA

5111 Differential pressure switch 0 – 80 kPa 193 094 468 0.00.6-71.35.00-31

Differential pressure fuel oil filter high – alarm binary

CD42_Mischke Page: 1
Status: 28.06.2004 EG 1.98.7-46.92.00-06_ni_en
Caterpillar : Confidential Green
 Equipment List Engine 16M32C
c Unit
Devices, Sensors and Actuators
Description Sensor range Stock – No. Drawing – No.
Signal range

5201/5202 Resistance thermometer 263 481 016 0.00.6-93.17.00-31

5201 Fuel oil temp. at engine inlet low – alarm -40-160° C
5202 Fuel oil temp. at engine inlet high – Alarm PT 100
(not in use with HFO)
5301A Level probe - 213 483 074 0.00.6-91.31.00-24
Leakage oil niveau at engine high - alarm ground switching
Plug 977 032 805 VG95234-E-10SL-3SN
X1/K2 Attaching type relay 213 480 770 9.01.7-91.08.00-06
5301B Level probe - 213 483 074 0.00.6-91.31.00-24
Leakage oil niveau at engine high - alarm ground switching
Plug 977 032 805 VG95234-E-10SL-3SN
X1/K5 Attaching type relay 213 480 770 9.01.7-91.08.00-06
6101 Pressure transmitter 0 – 6000 kPa 283 460 009 0.00.6-93.25.00-26
Starting air pressure low - alarm 4-20mA
6105 Pressure switch 100-1200 kPa 253 460 012 0.00.6-71.35.00-50
Stopping air pressure low - alarm binary
6181 Absolute Pressure transmitter 80 – 120 kPa 283 460 011 0.00.6-93.25.00-28
Intake air pressure in engine room – Dicare 4-20mA
7109 Pressure transmitter 0 – 400 kPa 283 460 006 0.00.6-93.25.00-23
Charge air pressure at engine inlet– Dicare 4-20mA
7201 Resistance thermometer -40-160° C 263 481 017 0.00.6-93.17.00-32
Charge air temp. at engine inlet high– alarm PT 100
7206 Resistance thermometer -40-160° C 263 481 016 0.00.6-93.17.00-31
Intake air temp. at turbocharger inlet – Dicare PT 100
7301 Level probe - 213 483 072 0.00.6-91.31.00-22
Condense water in charge air canal – alarm ground switching
Plug 977 032 805 VG95234-E-10SL-3SN
X1/K3 Attaching type relay 213 480 770 9.01.7-91.08.00-06
7307 Differential pressure transmitter 0 – 10 kPa 263 460 006 0.00.6-93.25.00-27
Charge air diff. pressure at charge air cooler – 4-20mA
Dicare
7309A Thermocouple type K -200-1300° C 223 482 350 1.00.7-48.99.00-51
Charge air temp. at charge air cooler inlet A – NiCr-Ni
Dicare (mV)
7309B Thermocouple type K -200-1300° C 223 482 350 1.00.7-48.99.00-51
Charge air temp. at charge air cooler inlet B – NiCr-Ni
Dicare (mV)
8211.1A Thermocouple type K -200-1300° C 223 482 350 1.00.7-48.99.00-51
..... Exhaust gas temp. after cylinder 1A.....8A – NiCr-Ni
8211.8A shutdown (mV)
8211.1B Thermocouple type K -200-1300° C 223 482 350 1.00.7-48.99.00-51
..... Exhaust gas temp. after cylinder 1B....8B – NiCr-Ni
8211.8B shutdown (mV)
8221A Thermocouple type K -200-1300° C 223 482 350 1.00.7-48.99.00-51
Exhaust gas temp. at turbocharger outlet A – NiCr-Ni
shutdown (mV)

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Caterpillar : Confidential Green
 Equipment List Engine 16M32C
c Unit
Devices, Sensors and Actuators
Description Sensor range Stock – No. Drawing – No.
Signal range

8221B Thermocouple type K -200-1300° C 223 482 350 1.00.7-48.99.00-51

Exhaust gas temp. at turbocharger outlet B – NiCr-Ni
shutdown (mV)
8231A Thermocouple type K -200-1300° C 223 482 350 1.00.7-48.99.00-51
Exhaust gas temp. at turbocharger inlet A – NiCr-Ni
Dicare (mV)
8231B Thermocouple type K -200-1300° C 223 482 350 1.00.7-48.99.00-51
Exhaust gas temp. at turbocharger inlet B – NiCr-Ni
Dicare (mV)
R16 Resistance thermometer -40-160° C 263 481 018 0.00.6-93.17.00-34
Electr. – charge air temp. control PT 100
9419.1 Pick up 0-1200 upm 263 450 224 0.00.6-93.21.00-74
9419.2 RPM switching equipment 0-15 KHz
Plug angle 977 032 801 CA3108-E-14S-5S-B-F80
9419.3 Pick up 0-1200 upm 263 450 224 0.00.6-93.21.00-74
9419.4 Electronic governor 0-15 KHz
Plug angle 977 032 801 CA3108-E-14S-5S-B-F80
9429A Pick up 0-30000 upm TPL65FE (HZTL-XXXX)
Turbine speed A 0-1 KHz
Plug 263 450 019 0.00.6-94.63.00-07
X8/A10 Frequency-current transformer 0-1KHz/4-20mA 193 466 125 FTW113-S10
X8/A11 Transformer 4-20mA/4-20mA 977 180 090 8787140000
X8/A12 Transformer 4-20mA/0-10V 977 180 089 8787130000
9429B Pick up 0-30000 upm TPL65FE (HZTL-XXXX)
Turbine speed B 0-1 KHz
Plug 263 450 019 0.00.6-94.63.00-07
X8/A13 Frequency-current transformer 0-1KHz/4-20mA 193 466 125 FTW113-S10
X8/A14 Transformer 4-20mA/4-20mA 977 180 090 8787140000
X8/A15 Transformer 4-20mA/0-10V 977 180 089 8787130000
9503 Limit switch - 260 480 950 1.00.7-48.99.00-69
Control lever at fuel rack – 100% fuel binary
9509 Distance sensor 125% load 260 480 070 1.00.7-48.99.00-53
Fuel setting 0-20mA
X1/A10 Attaching type fuel setting 0-20mA/4-20mA 243 910 260 9.01.7-91.08.00-13
X1/A11 Transformer 4-20mA/4-20mA 977 180 090 8787140000
Plug 213 480 101 CA06EW-14S-5S-B-03A
9561 Limit switch - DTE7-2RN-PG
Turning gear engaged – starting interlock binary
X3/k3 Attaching type relay 233 480 820 9.01.7-91.08.00-02
S1 Limit switch - BZE7-2RN-PG
Turning gear engaged – contactor reverser ON binary
S2 Pressure switch 1 – 1600 kPa 283 460 020 0.00.6-71.35.00-51
Starting air pressure at main starting valve binary
Y1.1 Solenoid valve - 213 413 018 0.00.6-41.26.00-32
Shutdown 24V DC / 6W
Plug 253 460 054 49020200(GDM3011)

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Caterpillar : Confidential Green
 Equipment List Engine 16M32C
c Unit
Devices, Sensors and Actuators
Description Sensor range Stock – No. Drawing – No.
Signal range

Y1.2 Solenoid valve - 263 410 124 0.00.6-41.21.00-88

Start 24V DC / 6W
Plug 253 460 054 49020200(GDM3011)
Y1.6 Solenoid valve -
Starting interlock for manual emergency start 24V DC / 18,5W
Plug 253 460 054 49020200(GDM3011)
M1 Actuator -
0 - 200mA
left-handed 263 410 113 0.00.6-72.11.00-96
right-handed 263 410 114 0.00.6-72.11.00-97
Plug connector (14) 253 460 058 CA3106E-20-27S-F80-DN
X1/K4 Attaching type relay 213 480 770 9.01.7-91.08.00-06
X3/K9 Attaching type relay 213 480 770 9.01.7-91.08.00-06
S11/H9 Start push button
Luminous key 977 037 060
Frame 977 037 062
Push button cap 977 037 066
Bulb 223 480 054
S12/H10 Stopp push button
Luminous key 977 037 060
Frame 977 037 062
Push button cap 977 037 065
Bulb 223 480 054
S13 Change over switch –engine/remote
Locking key 977 037 085
Key base 977 037 071
S14 Lamp-test push button
Luminous key 977 037 060
Frame 977 037 062
Push button cap 977 037 063
H11 Lamp false start
Luminous key 977 037 061
Frame 977 037 062
Push button cap 977 037 064
Bulb 223 480 054
H12 Lamp starting interlock
Luminous key 977 037 061
Frame 977 037 062
Push button cap 977 037 064
Bulb 223 480 054
H13 Lamp remote control
Luminous key 977 037 061
Frame 977 037 062
Push button cap 977 037 063
Bulb 223 480 054

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Caterpillar : Confidential Green
 Equipment List Engine 16M32C
c Unit
Devices, Sensors and Actuators
Description Sensor range Stock – No. Drawing – No.
Signal range

P1 Engine speed indication 0-10V 263 480 305 NRQ96-10

Scale 0-1200 253 480 033 SS82-12
P01A Turbocharger speed indication 0-10V 263 480 305 NRQ96-10
Scale 0-30000 263 480 309 SS87-17
P01B Turbocharger speed indication 0-10V 263 480 305 NRQ96-10
Scale 0-30000 263 480 309 SS87-18
P02 Exhaust gas temp. measuring instrument NiCr-Ni 263 450 194 0.00.6-93.40.00-46
Busboard (XC1A/XC1B) 283 360 070 9.01.7-91.11.00-14
X1.1 Plug connector (40)
X1.3 Housing (Female) 977 062 817
X1.4 Housing insert 977 062 818
X1.5 Contact socket 977 062 812
X3.3 Washer 977 062 822
X3.4 Plug box (Male) 977 062 819
X2.1A/B Housing insert 977 062 815
X2.2A/B Contact pin 977 062 814
X3.1 Plug connector (19)
X3.2 Male 263 480 303 CA3102E-20A-48P-B-04
X3.5 Female 977 032 812 VG95234-G-20A-48SN
X8/A16 Limit value switch 283 480 043 AD-MK330GS320-253
X1/1-70 Terminal 977 062 506 047826(AST)
X6/1-50 Terminal 977 062 506 047826(AST)
X3/1-50 Terminal 977 062 506 047826(AST)
X8/20-35 Terminal 977 062 506 047826(AST)
X2A/1-40 Terminal 977 062 506 047826(AST)
X2A/R1A Terminal / PT100 213 481 075 801473(DK4/32PT100)
X2B/1-40 Terminal 977 062 506 047826(AST)
X2B/R1B Terminal / PT100 213 481 075 801473(DK4/32PT100)
Manometer charge air 263 450 101 0.00.6-71.33.00-79.1
Manometer cooling water HT 263 450 103 0.00.6-71.33.00-80.1
Manometer cooling water LT 263 450 103 0.00.6-71.33.00-80.1
Manometer fuel oil 263 450 107 0.00.6-71.33.00-82.1
Manometer lub. oil 263 450 103 0.00.6-71.33.00-80.1
Manometer starting air 263 450 111 0.00.6-71.33.00-83.1
Service unit 263 410 060 0.00.6-41.25.00-37
Compressed air filter 223 860 024 0.00.6-41.54.00-11
Safety valve 223 860 023 0.00.6-41.20.00-96
3/2 way valve NW40 283 410 065 0.00.6-41.21.00-91
Cylinder 263 260 008 0.00.6-26.51.00-18

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Caterpillar : Confidential Green
 c Description of the Engine Monitoring Devices
16M32C

1. Relay Page 2
9.01.7-91.08.00-02/06

2. Temperature Monitoring Page 3

Switching Device RH41M

3. Engine Speed Pick-up Page 4

FA2-H-3C-XX

4. Turbocharger Speed Acquisition Page 5

FTW113

5. Electro-Pneumatic Control for Generator Drive Page 7

6. Standard Signal Measuring Contact Page 9

AD-MK 330 GS

7. Fuel Rack Position Transmitter Page 11

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 c Description of the Engine Monitoring Devices
16M32C

Relay: 9.01.7-91.08.00-02/06

Principle

The MaK relay is a wired monostable printed-board relay in a modular housing. It is used for electric con-
trol functions, especially for switching of voltages up to 48V. The relay is protected against false polarity
and over-voltages such as may be expected on board.

Technical Data:

Rated voltage: 24V DC+30% / -25%

Power draw: 200mW
Relay contacts: 1 change-over contact, 1 change-over type normally
closed or open contact
Switching voltage: max. 48V
Constant current: 1A
Breaking capacity: 50W / 24V DC
6
Service life: approx. 2x10 at 50W
Response time: 3ms
Releasing time: 2ms
Type of protection: IP20, connections IP00
Protection against false polarity: provided
Transient protection: acc. to GL-rules (IEC801-4-5-6)
Ambient temperature: 0...70°C

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 c Description of the Engine Monitoring Devices
16M32C
Switching Device for Temperature Monitoring: RH41M

The switching device RH41M is used in conjunction with an NTCresistor as temperature probe for tempera-
ture monitoring working in an open-circuit system with break monitoring.

Function

Contact I is for wire break monitoring of the line from the switching device to the temperature probe. If
voltage is applied and the probe line is intact, this contact is closed. The measuring current from the safety
and monitoring system passes via this closed contact, contact II which is in its normal position when the
temperature is not excessive, and the resistor.

In the event of wire break in the probe line or voltage failure, contact I will open and interrupt the measuring
current of the wire break monitoring. A wire break alarm will be activated in the safety system.

If the temperature at the probe rises above the alarm value set at the switching device, contact II will
change over and signal the excessive temperature to the safety system via the output terminals 4/6. Contact
I will not change its position in this situation.

Terminals

Terminal 9 and 8: Probe connection (NTCresistor)

Terminal 7 and 3: Resistor (value to be chosen according to the safety system used)

Terminal 6 and 4: Output contact for the safety system

Wiring diagram R1/E1

9 8 2- 1+
RH41M

6 7 3 4

3K3

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 c Description of the Engine Monitoring Devices
16M32C
Adjustment Instructions for Engine Speed Pick-up FA2H-3C-XX

1. Alignment of the speed pick-up for axial mounting position

Red mark, parallel to the direction of movement (counterboring)

2. Alignment of the speed pick-up for radial mounting position

Permissible deviation

Red mark, at right angle to the angle of skew

(counterboring)

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 c Description of the Engine Monitoring Devices
16M32C
Turbocharger Speed Monitoring FTW113

The frequency/analogue converter is a micro-processor controlled measuring device which converts the im-
pulse frequency supplied by a contactless magnetic inductive speed pick-up into a current signal which is
proportional to the speed. The assignment of the frequency/speed to the desired output value of the user is
easily possible by corresponding parameterising (RS232). The frequency/analogue converter has been pre-
cisely calibrated by supplier (Caterpillar).

Technical Data

Measurement range: 1Hz ... 35kHz

Input level: 50mVeff ... 80Veff
Sensor voltage: +12V / 25mA
Sensor monitoring: built-in, signalisation by LED and zero mA on the current output
Output: 0/4 ... 20mA max. load 500V
Voltage: 18 ... 33V DC
Operating temperature: 0 ... 60°C
Impulse sensor: magnetic inductive, ferrostat. HF-& speed pick-up with or without
amplifier
Configuration: special interface cable via PC

UPAC-Converter

The UPACconverter is providing a 4 … 20mA and a 0 … 10V signal for the turbocharger speed monitoring.

The UPAC converter has been precisely calibrated according to the indicated signal range. However, if an
adaption of the signal range to your application be necessary, zero and span can be adjusted by trimmers
accessible from the front of the module.

Technical data

Input
Voltage input: selectable from 0 ... 20mV to 0 ... 100V DC
Current input: selectable from 0 ... 1mA to 0 ... 100mA DC
unipolar or bipolar configurable
Maximum over-voltage: 60V DC
Maximum over-current: 170mAeff
Range of zero adjustment: 0 ... 50% of input range using potentiometer on the front
Range of span adjustment: 100 ... 50% of input range using potentiometer on the front

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 c Description of the Engine Monitoring Devices
16M32C
Output
Current output: 0 ... 20mA, 4 ... 20mA max. load 600V
0 ... 1mA max. load < 7,5kV
Voltage output: unipolar Out: 0 ... 5V, 0 ... 10V
bipolar Out: -10 ... 10V, -5 ... 5V, min load > 1kV

Status indication
LED INPUT: green, power ON
input > 110%, 8Hz blinking
input < -10%, 4Hz blinking

General
Voltage supply: 9 ... 30V DC, 1,5W typ. 2,5W max.
Current consumption: < 65mA permanent at 24V DC

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 c Description of the Engine Monitoring Devices
16M32C
Electro-Pneumatic Control for Generator Drive

Function of the Installation

Preparing the installation for operation:

After opening the air bottle air at 30bar flows to the starting valve and to the maintenance unit at the con-
trol stand. The pressure switch cancels the alarm “Low stopping air pressure” in the alarm system. Put the
emergency stop lever on the control stand into operating position, so that the governor increase fuel supply
during starting.

Electric Starting-Stopping from Operating Panel Engine

Engine Starting

The following conditions must be met to carry out an engine start via the operating key START in the operat-
ing panel of the engine:

- no starting interlock
- no false start
- selector switch in the engine operating panel in position ENGINE
- engine speed below nzünd (firing speed)

Upon actuation of the push button START, the starting procedure is initiated by excitation of the starting
valve. The starting air flows to the starting system of the cylinders. At the injection moment the fuel pump
releases the control air for the starting valve. Starting air is admitted to the booster. This unit provides the
oil pressure required for starting in order to pull the pumps via the injection linkage to fuel supply position.
The starting valve remains locked-in electrically as long as either the firing speed is reached or the time tstart
has expired.

False Start

If the engine does not reach the firing speed within the starting time, the starting procedure will be termi-
nated and the visual message FALSESTART will be displayed. By actuating the push button STOPthe mes-
sage FALSESTART can be cancelled, so that it is possible to restart the engine.

Engine Stop

By actuating the push button STOP the stopping valve will by energized and the engine stops. The stop sig-
nal remains locked-in electrically until the engine is started. In case of a mechanical start directly on the
starting valve the stop signal is cancelled via the pressure switch for starting air after the main starting
valve.

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 c Description of the Engine Monitoring Devices
16M32C
Electric Start-Stop from the Remote Control Stands

The electric start-stop by remote control is only possible if the selector switch on the operating panel engine
is in position REMOTE CONTROL and additional operating elements such as start-stop keys, false start and
starting interlock indicator lamps are installed.

Starting Interlock

A starting interlock is provided for safety both the personnel and the engine. If there are any hazardous cir-
cumstances, e.g. in case of an emergency stop or engaged barring gear, the safety system sends a message
to the DIESEL start/stop logic. This prevents an engine start and releases the visual message STARTING
INTERLOCK. In order to prevent a manual start via the emergency start push button, the solenoid is ener-
gized electrically and the emergency start button is blocked.

Automatic Stop

In case of over-speed or other criteria, which might endanger the engine (e.g. lubricating oil pressure below
danger level) or if an emergency stop push button is actuated, the stop solenoid is energized electrically by
the safety system. The stop cylinders on the injection pumps press the pumps to STOP.

The stop signal goes into a lock electrically and can only be cancelled after elimination of the fault and ac-
knowledgement. The stop signal is also sent to the governor in parallel.

Emergency Control

Engine Start

A manual start via the emergency start button is only possible if there is no starting interlock. The stop sig-
nal is cancelled via the pressure switch for starting air after main starting valve and the governor can in-
crease fuel supply.

Engine Stop

By means of the emergency stop lever on the control stand the engine can stopped manually.

Crankcase Oil Mist Detector

The crankcase oil mist detector is provided by the maintenance unit with control air (7.5bar)

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 c Description of the Engine Monitoring Devices
16M32C
Standard Signal Measuring Contact AD-MK 330 GS

The measuring contacts purpose is to montior the engine speed. Based on a 1% threshold of rated speed,
the measuring contact is signalising “Engine Running” respectively “Engine Stop” to the electronic control-
ler via a relay contact.

Description

The measuring contact AD-MK 330 GS compares the measuring value applied at the input with the measur-
ing value set at the pushbutton encoder switch. If the measuring signal exceeds or falls below the set value,
the appropriate output relay reacts to pre-set function. As analogue input value all three standard signals
(0 … 20mA, 4 … 20mA, 0 … 10V) are possible without additional commutation. The critical value are to be
set at 0 … 99% at the front via encoder switch. The output function 2 max, 2 min ore 1 max/min as well as
the rest or working principle of the output relay is also adjustable at the front. Input, output and the supply
voltage are galvanically separated from each other. A highly efficient, integrated electronic wide-range
power pack (ALLPOWER) enables operation with 20 … 253V ACor DC. There is no possibility of cross polar-
ity connection voltage. A high packing density is achieved due to its narrow build.

Technical data

Power supply: ALLPOWER24 ... 230V ACor DC

internal galvanically isolated
Power consumption: ca. 2.3VA resp. 1.5W
Input: selectable 0 ... 20mA, 4 ... 20mA, 0 ... 10V
Input-resistance: in 0 ... 20mA: 50V
or 4 ... 20mA: 50V
in 0 ... 10V: 400kV
Output: 2 relay (changer), selectable in rest- or working principle
Breaking voltage: max. 250V, 50Hz
R.m.s. current: max. 2A
Breaking capacity: max. 100VA
Selectable functions: 2 max, 2 min, 1 max/min
Precision: 1% resp. 1 digit
EMC-certification: CE-Konformität
IEC801-5 SURGEclass 3
IEC801-4 BURST class 3
Radio interference suppression: EN 55011, limit graph B
Protective systems: input/power supply: against over-voltage, confusing the poles,
over-current, over-temperature
Ambient temperature: 0 ... 50°C

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 c Description of the Engine Monitoring Devices
16M32C
Connections and factory default values

4 5 6
Switches on the front side
Relay B
not in use

1 2 3 attract relay A drop out relay A

Relay A
= 02 => 1% RPM attract relay B drop out relay B

2x contact (A+B) 1x hysteresis

Chassis (-)
0 ... 10V (+) 0 ... 10V
0 ... 20mA (+)

7 8 9

4 ... 20mA (+)

10 11 12
Power supply
(ALLPOWER) 24V DC
20 ... 253V AC/DC

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 c Description of the Engine Monitoring Devices
16M32C
Fuel Rack Position Transmitter

Adjustment fuel signal (mechanical)

Zero position

Distance sensor
3 – 8mm = 0 – 20mA
Fuel

Attention:

Before adjusting the cam the speed governor should be disconnected from the fuel rack. The cams are ad-
justed in such a manner that in stop position the centre of the level gauge aligns with the punched centre
mark.

Adjustment fuel signal (electrical)

Measurement Governor control shaft at full fuel position – about po-

converter tentiometer “A” current output adjust at 20mA.
A
Installation place: (Clamp) Governor control shaft at zero position – about poten-
Terminal box X1 on tiometer “B” current output adjust at 4mA.
diesel engine
B Repeat adjusting 1 or 2 times.
(Zero point)

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 c Description of the Engine Monitoring Devices
16M32C

Technical data

Voltage input: selectable 0 ... 6mA

Current output: selectable 12 ... 20mA
Voltage supply: 24V DC–25% / +30%

UPAC-Converter

The UPACconverter is providing potential free signal (4 ... 20mA) for the fuel rack position monitoring.

Technical data

Input
Current input: selectable from 0 ... 1mA to 0 ... 100mA DC
unipolar or bipolar configurable
Maximum over-voltage: 60V DC
Maximum over-current: 170mAeff
Range of zero adjustment: 0 ... 50% of input range using potentiometer on the front
Range of span adjustment: 100 ... 50% of input range using potentiometer on the front

Output
Current output: 4 ... 20mA max. load 600V

Status indication
LED INPUT: green, power ON
input > 110%, 8Hz blinking
input < -10%, 4Hz blinking

General
Voltage supply: 9 ... 30V DC, 1.5W typ. 2.5W max.
Current consumption: < 65mA permanent at 24V DC

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 RPM Switch Unit C5.05.05.75.11.45
Description

RPM Switch Unit

Description

en / 07.04.2008 FD020042 1/10

 c Description of the RPM Switch Unit

1. Technical Data
Operating voltage: 24V DC+30% / -25%

Power draw: 20W

Type of protection: switchboard housing with enclosure from

the front IP54 acc. to DIN 40050

Protection against false polarity: provided

Transient protection: provided

Ambient temperature: 0 ... 70 °C

Contact load of output relays:

Plug-in cards A1 and A2 breaking capacity: 50W / 24V DC

continous current: 1A

Plug-in card A2 relay K3 breaking capacity: 50W / 24V DC

100VA / 220V AC
continous current: 1A

Analog outputs for engine

speed range: 0 ... *** rpm

Current output: 4 ... 20mA

Load resistor: - 500V

Voltage output: 0 ... 10V / max. 10mA

Setting range for the speed

switching points: 0 ... 1300rpm
Hysteresis: 20rpm ± 10%
Input for engine start signal
from the START-stop system 24V DC± 20%

*** adjusted in dependence on the engine type

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 c Description of the RPM Switch Unit

2. Function of the RPM Swich Unit

The RPM switch unit consists of electronic and electro-mechanical control units which control the
monitoring of the speed limit values depending on sensors with frequency output. Furthermore the
control of the engine speed indicators is carried out via this unit and the engine start –stop device
is suppressed until the engine is at a complete standstill.

2.1 Overspeed Protection System

The task of the electric MaK overspeed protection system is to monitor the diesel engine with
regard to its permissible technical maximum speed and to stop the engine immediately if this
speed is exceeded. The complete system for each engine consists of the following input devices:
sensor with frequency output, RPM switch, safety system, alarm system and shutdown solenoid
with pneumatic miniature cylinders on the fuel pumps. Of this equipment the two sensors, the
shutdown solenoid and the miniature cylinders are fitted to the engine.

2.2 Principle

An RPM switch monitors both sensors and if the set speed value is exceeded emits an immedi-
ate shutdown signal to the safety system via a potential-free contact. The safety system stores
the shutdown signal and immediately actuates the shutdown device on the engine. Furthermore
a closed current loop is formed via a potential-free contact which serves for triggering the alarm
system. Both circuits are externally monitored for wire break. The system is self- monitoring and
automatically indicates possible faults to the alarm system. The following faults are recorded
and indicated autonomously.

Failure of 24V DCoperating voltage

Failure of sensor *
Sensor cable broken

* In case of failure of one sensor the overspeed protection system continues to be

operative via the second sensor.

2.3 Functional Check

A functional check of the electronic can be carried out via the test pushbutton of the RPM switch
both with engine stopped or running. There will be no automatic engine shutdown.

A functional check of the mechanical shutdown devices can be carried out by actuating the emer-
gency stop pushbuttons. There will be an automatic engine shutdown.

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 c Description of the RPM Switch Unit

3. Plug-in Cards
All of the plug-in cards of the RPM switch unit are of Euro-format 100 x 160mm. The use of code
strips ensures that the individual plug-in cards types cannot be mixed up.

3.1 Plug-in Card A1: 9.01.7-91.21.00-16

Two speed switching points to be set at option.

1. switching point n = 1.15 nominal speed – OVERSPEED – with 2 potential-free contacts for trig-
gering of the safety and alarm systems.

2. switching point n = nzünd (firing speed) in connection with plug-in card A2, relay K3 (2 change-
over contacts) for switching off the electric motor driven prelubrication pump and the cooling
water preheating unit.

2. switching point n = nzünd (firing speed) in connection with plug-in card A2, relay K4 (1 change-
over contact) for triggering of the externally installed service hour counter.

3.2 Plug-in Card A2: 9.01.7-91.21.00-17

One speed switching point to be set at nmin (1 change-over contact) for alarm suppression at en-
gine stop.

RPM Switch Setting of Switching Point

Via the potentiometer RPM the speed switching point can be set
to any desired value
RPM
Let the engine run at switching speed and then set the switching
point.

Engine Stand Still Monitoring (M20 only)

In order to avoid mechanical damages to the engine starting unit, the engine start signal from the
start-stop unit is released only after the engine has come to a complete standstill. A starting inter-
lock is indicated via LED on plug-in card A2.

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 c Description of the RPM Switch Unit

4. Balancing of RPM Switch and Adjustment of Switching Point

Via potentiometer R28 and R39 the speed switching points can be adjusted V20
R28
to any desired value
R23

- SCALERANGE0 – 1300rpm – CHANNEL I

CHANNEL II
R34
After the adjustment has been carried out, the indicating dials are to be ar- V24
rested via lock. The RPM switch is already balanced at MaK’s works. How-
R39
ever, if a readjustment should become necessary nevertheless, balancing is
to be carried out as follows.

4.1 Balancing of Switching Point Range

Adjust the speed potentiometers R28 an 39 precisely to a current engine speed as high as possi-
ble. Then adjust the trimming potentiometers R23 and R34 in clockwise direction until both light
emitting diodes V20 and V24 cease to light. Balance CHANNALS I and II by carefully turning left
on R23 or R34 respectively. In doing so, the light emitting diodes V20 or V24 resp. will light up.

Check the switching point adjustment by changing the engine speed and in case of deviations
repeat the procedure.

Attention:
The switching hysteresis is to be taken into account for adjustment.

4.2 Balancing of the Analogue Outputs 4-20mA and 0-10V

Adjust the output current to 12mA via R63 at engine speed ** or the
output voltage to 5V via R67 respectively.
R67
R63

Attention:

When rebalancing, the scale ranges of the indicators for engine

speed are to be taken into acount.

Scale range of
Engine type engine speed indication Engine speed **

M20 / VM32 0 ... 1200rpm 600rpm

M32 / M453 0 ... 800rpm 400rpm
M43 / VM43 0 ... 600rpm 300rpm
M25 0 ... 1000rpm 500rpm

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c RPM–SWITCH–UNIT
Equipment list

Unit Description CAT- No. Stock- No. Drawing - No.

A1 Plug in card (without presetting) 263 360 140 9.01.7-91.21.00-16

Plug in card (presetting for engine M20) 193 300 029 9.01.7-91.21.00-16

Plug in card (presetting for engine M25) 193 375 001 9.01.7-91.21.00-16

Plug in card (presetting for engine M32) 193 466 036 9.01.7-91.21.00-16

Plug in card (presetting for engine VM32) 193 466 037 9.01.7-91.21.00-16

Plug in card (presetting for engine M43) 193 376 030 9.01.7-91.21.00-16

Plug in card (presetting for engine VM43) 193 376 030 9.01.7-91.21.00-16

A2 Plug in card 263 360 150 9.01.7-91.21.00-17

CD6 / Mischke Seite: 1

Status: 28.10.2004 EG 1.00.7-36.29.00-45_en
Caterpillar : Confidential Green
 Ambiguous Document References X0

en / 20.09.2010 QV020011 1/1